Polymers are intrinsically poor thermal conductors, which are ideal for thermoelectrics, but low electrical conductivity and thermopower have excluded them as feasible candidates as thermoelectric materials in the past. However, recent progress in polymer technology, particularly nanomaterial-polymer composites, can bring them into degenerate semiconductor or metallic regimes by incorporating a small amount of conductive filler. I demonstrate that such polymer nanocomposites can be viable for light-weight and economical thermoelectrics by using a segregated network approach for the nanocomposite synthesis. The thermoelectric properties were further improved by a change of stabilizer and drying conditions. The thermoelectric properties of the segregated network nanocomposites were measured for carbon nanotubes and the thermoelectric figure of merit, ZT, was calculated at room temperature. The influence on thermoelectric properties from filler concentration, stabilizer materials and drying condition are also discussed.

Health monitoring is an important field as small failures can build up and cause a catastrophic failure. Monitoring the health of a structure can be done by measuring the motion of the structure through the use of strain sensors. The limitations of current strain sensing technology; cost, size, form could be improved. This research intends to improve current strain sensing technology by creating a conductive polymer composite that can be used monitor health in structures. Conductive polymer composites are a viable candidate due to the low costs of manufacturing, tailorable mechanical and electrical properties, and uniform microstructure. This work will focus on determining if a all-polymer composite can be used as a strain sensor, and investigating the effects of filler, doping and latex effect the electrical and strain sensing properties. Strain sensors were prepared from polyaniline (PANI)-latex composites, the morphology, mechanical, electrical and strain sensing properties were evaluated. These strain sensors were capable of repeatable measuring strain to 1% and able to measure strain until the substrates failure at 5% strain, with a sensitivity (measured by gauge factor) of between 6-8 (metal foil strain sensors have a gauge factor of 2). The best performing strain sensor consisted of 4 wt.% polyaniline. This composition had the best combination of gauge factor, linearity, and signal stability. Further experiments were conducting to see if improvements could be made by changing the polymer used for the matrix material, the molecular weight and the level of doping of the polyaniline. Results indicate through differences in strain sensing response; lower hysteresis and unrecoverable conductivity, that polyaniline latex composites can be adjusted to further improve their performance. The polyaniline-latex composites were able to repeatable measure strain to 1%, as well as strain until failure and with gauge factor between 6-8, and a 70% increase in signal at failure. These properties make these composites viable candidates to monitor health in structures, buildings, bridges, and damns.

A set of experiments was designed and performed to gain a fundamental understanding of various aspects of the segregated network concept. The electrical and mechanical properties of composites made from commercial latex and carbon black are compared with another composite made from a polymer solution. The percolation threshold of the emulsion-based composite is nearly one order of magnitude lower than that of the solution-based composite. The segregated network composite also shows significant improvement in both electrical and mechanical properties with low carbon black loading, while the solution-based composite achieves its maximum enhancement at higher carbon black loading (~25wt%). The effect of the particle size ratio between the polymer particle and the filler was also studied. In order to create a composite with an extremely large particle size ratio (> 80,000), layer-by-layer assembly was used to coat large polyethylene particles with the carbon black. Hyper-branched polyethylenimine was covalently grafted to the surface of polyethylene to promote the film growth. The resulting composite has a percolation threshold below 0.1 wt%, which is the lowest percolation threshold ever reported for a carbon-filled composite. Theoretical predictions suggest that the actual percolation threshold may be lower than 0.002 wt%. Finally, the effect of the emulsion polymer modulus on the segregated network was studied. Monodispersed emulsions with the different glass transition temperature were used as the matrix. The composites made using the emulsion with higher modulus show lower percolation threshold and higher conductivity. Higher modulus causes tighter packing of carbon black between the polymer particles. When the drying temperature was increased to 80°C, the percolation thresholds became closer between some systems because their moduli were very close. This work suggests modulus is a variable that can be used to tailor percolation threshold and electrical conductivity, along with polymer particle size.