Application note

Conductive silicones in elevated temperatures

As the level of sophistication increases for applications, the ability –– Low modulus
of the material supplier to aid the manufacturer in choosing an –– Versatile - Can be filled with various conductive fillers
appropriate material remains more crucial than ever. Whether
FROM INSULATIVE TO CONDUCTIVE1
an application requires a conductive or merely static dissipative
material, the operating temperature of the application can Before deciding which product or filler to choose, it is important
greatly affect conductivity. With silicone’s insulative nature to understand the degree of conductivity a particular application
and large Coefficient of Thermal Expansion (CTE), sustaining requires. Although naturally insulative, silicone can be optimized to
conductivity as temperatures rise requires a special understanding achieve varied conductivity.
of silicone chemistry and filler technology. Conductivity can be
maintained by adjusting the type, amount, and the particle size –– Insulative (Insulator)
and distribution of filler in the silicone matrix. This Application –– >1011 ohm·cm
Note discusses the trade-offs one should expect when customizing –– Prevents or limits the flow of electrons across its surface or
silicone to remain conductive in elevated temperatures and help through its volume
explain why changes occur. –– Static Dissipative
–– (104-1011) ohm·cm
–– Electrons flow across or through the material and are
WHY CHOOSE A SILICONE?
controlled by the volume or surface resistance. The transfer of
A legacy derived from decades of use in aerospace and other charge will typically take longer than a conductive material
harsh environments that commonly experience temperature –– Conductive
extremes is why most choose silicone for many applications. –– <104 ohm·cm
Siloxane-based polymeric systems are unique polymers, as –– Low electrical resistance, and electrons flow easily across its
compared to standard, organic-based materials. Cured silicones surface or volume
are typically low modulus, which absorb stresses during thermal
CONDUCTIVE FILLERS
cycling and do not degrade at continuous operating temperatures
up to 250°C. Other attributes of silicones are: Due to silicone’s large free volume and “polar nature” compared
to carbon-based polymers, various fillers can be used to optimize
–– Typical dielectric strength > 500 V/mil silicone’s conductivity. Filler technology is also a rapidly growing
–– Volume resistivity > 1011 ohm·cm enterprise in which fillers with various particle sizes and shapes
–– Biologically inert can be added to silicones to impart key properties such as
–– Low moisture absorption < 0.4% ( 85°C/85 RH/168 Hrs ) maintaining conductivity at elevated temperatures. Caution

APPLICATION NOTE
should be used when considering filler for a specific conductive
property. While some only impart one type of conductivity - such
Filler
as Boron Nitride to increase thermal conductivity — others,
like silver, increase thermal conductivity, as well as electric
conductivity concurrently. In general, there are three main types
of filler: electrically insulative ceramic filler that contributes Tensile Elongation Viscosity Durometer
thermal conductivity only; carbon filler that contributes electric
conductivity and, to some degree, thermal conductivity; and,
finally, metal filler that contributes greatly to both electric and
thermal conductivity. The following are examples of fillers, what Effects of CTE on Conductivity
property they target and a description of filler shapes to consider:
Silicone is naturally insulative; therefore point-to-point contact
of the filler is crucial to maintain conductivity. This requirement
Filler Shapes Attributes
becomes a challenge; however, when you consider the large CTE
Amorphous Solid structures that form aggregates of various shapes
Spherical Good Point-Point Contact
that silicone exhibits (120-1000 ppm/°C) and the CTE mismatch
Flake Better Aspect Ratio between the filler and silicone. The main considerations when
Fibers Best Aspect Ratio maintaining the point-topoint contact as silicone expands are
particle size and distribution. Along with what type of filler is
being used, the size and shape of the filler is going to dramatically
dictate how conductive a silicone is and at what temperature it
ceases to conduct.
Aluminum
Silver
Oxide
Electrically & Only
Thermally Thermally
Conductive Carbon Conductive
Black

Boron
Gold
Nitride

Physical Affects on Silicone with the Addition of Filler

Filler shape and size significantly affect a material’s rheology,

Room Temperature Heated
mechanical properties and conductivity. Physically, the amount
of filler that can be added is governed by the interaction between
the polymer and the filler. It is also important to understand that,
COMPARISON OF FILLERS
while maximum loading gives the best conductivity, changes to
the silicone’s physical properties - durometer, elongation, etc. - In an effort to evaluate the performance of different fillers, a study
are common. As a general rule, the following changes should be was performed comparing their conductivity at various elevated
expected in the physical properties of a material: temperatures: 28°C, 80°C, 100°C, 125°C, 150°C, 175°C and 200°C.
In the study, traditional fillers, such as carbon black and silver
spheres, were evaluated.

2 | Choosing a Silicone Primer/Adhesive System

Testing Method Material ECS1 ECS2 ECS3
Filler Amorphous Carbon Black Fibers Siler Coated
–– Volume Resistivity, ASTM D 257 (ASTM D 4495) Carbon Black Metal Spheres
–– Cured per the Design Specification onto coupon, open face Specialization Tough Wide Operating Low VR at RT
Temperatures and Flowable
–– 4 wire
Cure System Addition (Platinum) Addition (Platinum) Addition (Platinum)
–– Agilent 34401A digital Multimeter
–– Blue M Convection Oven ~% Filler 4 30 80

–– Measured VR at 28 °C, 80 °C, 100 °C, 125 °C, 150 °C, and 250 °C Specific Gravity 1.04 1.2 3.41
Durometer "A" 30 75 80
Tensile (psi) 414 450 440
W(T2 = T1) Elongation (%) 329 83 81
VR = R Volume Resistivity 750 1.7 0.002
L (25C)

Where VR = Volume resistivity in ohm.cm 1000000

100000
R = resistance reading from multimeter in ohms
10000 ECS1 Amorphous Carbon
W = Average width of sample in cm
T2 = Average thickness of sample and coupon in cm 1000
T1 = Average thickness of coupon in cm
Volume Resistivity (ohm.cm)

100 ECS2 Carbon Fibers

L = Distance between inner copper strips on coupon in cm
10

Examples of Traditional Conductive Materials 1 ECS3 silver coated

metal spheres
28 80 100 125 150 175 200
0.1
Below are examples of current NuSil materials with three different
Temperature ˚C
types of traditional fillers: Amorphous Carbon Black (ECS12), 0.01
Carbon Black Fibers (ECS23) and Silver-Coated Metal Spheres
0.001
(ECS34). When reviewing the data, one should notice three
important facts. First, as expected, the material containing the
most conductive filler, ECS3, produces a silicone material with the Novel Fillers for Increased Performance
highest conductivity at room temperature. As the temperature
increases, however, at 80°C, the second fact is observed; the For some applications, the performance shown above is sufficient,
material with fibers, having a better aspect ratio, changed the and standard technology is able to accommodate their needs.
least as temperature increased. This is explained by its ability However, some applications are exposed to harsh environments,
to maintain its point-to-point contact as the silicone material and thermal or electrical conductivity must be maintained. To
expanded with heat. While the silver spheres are more conductive, accommodate this need, NuSil has developed products using
the shape of that filler isn’t as forgiving as they are separated from novel fillers described below. ECS45 and ECS67 both utilize a
each other as the silicone expands. The third fact — at a certain dynamic filler package making them viable at higher temps. In
temperature, shown here around 150°C — traditional fillers all fall fact, while ECS6, an addition-cure silicone, is certified to maintain
to static dissipative and, as the silicone continues to expand with conductivity at 10-2 ohm·cm in 80°C, ECS4, a condensation-cure
temperature, it will eventually become insulative. silicone, is certified to maintain conductivity at 10-3 ohm·cm in

3 | Choosing a Silicone Primer/Adhesive System

200°C. Also, to compensate for the added mass that high levels The Balancing Act
of filler contribute to a conductive material and an application,
NuSil has developed a material with a much lower specific Determining the best product to choose involves a thorough
gravity, ECS56. By incorporating lighter spheres coated in silver, understanding of applications’ requirements. At times, a balance
we have been able to offer a material a third as dense as similar needs to be achieved between changes in physical properties
traditional material. and necessary conductivity. Along with physical changes to
the material, one must consider their ability to process the
material. NuSil Technology has several standard products, such
Material ECS4 ECS5 ECS6
as ECS1-ECS3, that are designed to work well in many different
Filler Silver Coated Fibers Silver Coated Spheres Silver Coated Fibers
applications; however, as limits are pushed and applications
Specialization 0.008 ohm*cm Lower Density 0.020 ohm*cm
at 200 C at 80 C experience harsher environments, novel solutions must be
Cure System Condensation (Tin) Addition (Platinum) Addition (Platinum) generated. Steps to solve these challenges have already begun,
~% Filler 80 55 80 and a few examples are seen with ECS4-ECS6. NuSil Technology
Specific Gravity 3.21 1.18 3 will continue to explore advanced fillers to improve our materials.
Durometer "A" 80 91 85
Tensile (psi) 400 311 440 References
Elongation (%) 56 55 64
Volume Resistivity 0.003 0.002 0.004 1. Electrostatic Discharge Association, “ESD Fundamentals Part 1”.
(25C)
2011. 29 June 2011 www.esda.org/fundamentalsP1.html.
2. Nusil CV-2640 (ECS1)
3. Nusil CV2-2640 (ECS2)
4. NuSil CV-2644 (ECS3)
5. NuSil CV2-2646 (ECS4)
6. Developmental Material (ECS5)
7. NuSil CV2-2644 (ECS6)

It is the sole responsibility of each purchaser to ensure that any use of these materials is safe and complies with all applicable laws and
24523-GM-KK

regulations. It is the user’s responsibility to adequately test and determine the safety and suitability for their applications, and NuSil Technology
LLC makes no warranty concerning fitness for any use or purpose.
©2020 Avantor, Inc. All rights reserved. Trademarks are owned by Avantor, Inc., or its affiliates unless otherwise noted.
0320 Lit. No. 931042W