Electrically Conductive Textile Materials and Method for Making Same

In the drawings,

FIG. 1-A is a photomicrograph, magnification 210.times., taken by a light microscope, of the polypyrrole film, remaining after dissolution of the basic dyeable polyester fiber, produced in Example 2;

FIG. 1-B is similar to FIG. 1-A but at a magnification of 430.times.;

FIG. 2-A is a photomicrograph, magnification 500.times., taken with an electron scanning microscope (ESM) of the coated fibers of the nylon 6,6 fabric of Example 9;

FIG. 2-B is similar to FIG. 2-A but at a magnification of 2,000.times.;

FIG. 3 is a photomicrograph, magnification 210.times., taken by light microscope of a cross-section of the spun nylon fibers produced in Example 9;

FIG. 4-A is a photomicrograph, magnification 70.times., taken by light microscope, showing the polypyrrole film, remaining after dissolution of the nylon 6,6 fibers;

FIG. 4-B is similar to FIG. 4-A but at a magnification of 210.times.;

FIG. 4-C is similar to FIG. 4-A but at a magnification of 430.times.;

FIG. 5-A is a photomicrograph, magnification 210.times., taken by light microscope, of the polypyrrole film, remaining after dissolution of the polyester fiber produced in Example 19, Run B;

FIG. 5-B is similar to FIG. 5-A, but at a magnification of 430.times.;

FIG. 6 is a photomicrograph, taken by light microscope, magnification 210.times., of the cross-section of the coated polyester fibers from Example 19, Run B;

FIG. 7 is a photomicrograph, magnification 1,000.times., taken by an ESM, of the coated polyester fibers produced in Example 19, Run G; and

FIG. 8 is a photomicrograph, magnification 210.times., taken by light microscope, of the polypyrrole film, remaining after dissolution of the polyester fiber produced in Example 19, Run G.

Various procedures can be used to perform the method of preparation of a conductive fabric as it applies to the invention by operating within the parameters as described above. Typical methods are described below:

Approximately 50 g of fabric is placed in a dyeing machine having a rotating basket insert and the port of the machine is closed. Depending upon the desirable liquid ratio, usually about 500 cc, water is then added to the reaction chamber. The basket is turned to assure that the fabric is properly wetted out before any other ingredients are added. Then the desired amount and type of oxidizing agent is dissolved in approximately 500 cc of water and is added to the machine while the basket is rotating. Finally, the monomer and if necessary the doping agent in approximately 500 cc of water is added through the addition tank to the rotating mixture. In order to eliminate any heat build-up during the rotation, cooling water is turned on so that the temperature of the bath is kept at the temperature of the cooling water, usually between 20.degree. and 30.degree. C. After the fabric has been exposed for the appropriate length of time, the bath is dropped and replaced with water; in this way the fabric is rinsed twice. The fabric is then withdrawn and air dried.

An 8 ounce jar is charged with five to ten grams of the fabric to be treated. Generally, approximately 150 cc of total liquor are used in the following manner: First, approximately 50 cc of water is added to the jar and the jar is closed and the fabric is properly wetted out with the initial water charge. The oxidizing agent is then added in approximately 50 cc of water, the jar is closed and shaken again to obtain an appropriate mixture. Then the monomer and if necessary the doping agent in 50 cc of water is added at once to the jar. The jar is first shaken by hand for a short period of time and then is put in a rotating clamp and rotated at approximately 60 RPM for the appropriate length of time. The fabric is withdrawn, rinsed and air dried as described for Method A. Conveniently this method can be used to conduct the reaction at room temperature or if preferred at lower temperatures. If lower temperatures are used the mixture including the fabric and oxidizing agent is first immersed into a constant temperature bath such as a mixture of ice and water and rotated in such a bath until the temperature of the mixture has assumed the temperature of the bath. Concurrently the monomer and if necessary the doping agent in water is also precooled to the temperature at which the experiment is to be conducted. The two mixtures are then combined and the experiment is continued, rotating the reaction mixture in the constant temperature bath.

A one-half gallon jar is charged with 50-100 g of fabric to which usually a total of 1.5 liter of reaction mixture is added in the following manner: First, 500 cc of water are added to the jar and the fabric is properly wetted out by shaking. Then the oxidizing agent dissolved in approximately 500 cc of water is added and mixed with the original charge of water. Subsequently, the monomer and if necessary the doping agent in 500 cc of water is added at once to the jar. The jar is closed and set in a shaking machine for the appropriate length of time. The fabric is withdrawn from the jar and washed with water and air dried.

A glass tube approximately 3 cm in diameter and 25 cm long equipped with a removable top and bottom connection is charged with approximately 5 to 10 g of fabric which has been carefully rolled up to fill approximately 20 cm of the length of the tube. A mixture containing approximately 150 cc of reaction mixture is prepared by dissolving the oxidizing agent in approximately 100 cc of water and then adding at once to the solution a mixture of the monomer and if necessary the doping agent in approximately 50 cc of water. The resulting mixture of oxidizing agent and monomer is pumped into the glass tube through the bottom inlet by the use of a peristaltic pump, e.g. from Cole Palmer. As soon as the entire amount is inside the glass tube, the pump is momentarily stopped and the hose through which the liquor has been sucked out of the container is connected to the top outlet of the reaction chamber. The flow is then reversed and the pumping action continues for the desired amount of time. After this, the tube is emptied and the fabric is withdrawn from the tube and rinsed in tap water.

In Method D the glass tube can be jacketed and the reaction can be run at temperatures which can be varied according to the temperature of the circulating mixture in the jacket.

These methods describe a number of possible modes by which this reaction can be carried out but does not limit the invention to the use of these particular methods.

The invention may be further understood by reference to the following examples but the invention is not to be construed as being limited thereby. Unless otherwise indicated, all parts and percentages are by weight.

Following the procedure described for Method A, 50 grams of a polyester fabric consisting of a 2.times.2 right hand twill, weighing approximately 6.6 oz. per square yard and being constructed from a 2/150/34 textured polyester yarn from Celanese Type 667 (fabric construction is such that approximately 70 ends are in the warp direction and 55 picks are in the fill direction), is placed in a Werner Mathis JF dyeing machine using 16.7 g ferric chloride hexahydrate, 2 g of pyrrole, 1.5 g of 37% hydrochloric acid in a total of 1.5 liters of water. The treatment is conducted at room temperature conditions for two hours. The resulting fabric has a dark gray, metallic color and a resistivity of 3,000 and 4,000 ohms per square in the warp and fill directions, respectively.

Example 1 is repeated except that the fabric is made from basic dyeable polyester made from DuPont's Dacron 92T is used in the same construction as described in Example 1. The resistivity on the fabric measures 2,000 ohms per square in the warp direction and 2,700 ohms per square in the fill direction. This example demonstrates that the presence of anionic sulfonic acid groups, as they are present in the basic dyeable polyester fabric, apparently enhances the adsorption of the polymerizing species to the fabric, resulting in a higher conductivity.

The uniformity of the polypyrrole film can be seen from the photomicrographs in FIGS. 1-A and 1-B. These photomicrographs are obtained by cutting the treated fabric into short lengths of about 1 millimeter and collecting a few milligrams of individual coated fibers. The fiber samples are placed into a beaker with a solvent for the fiber, in this case m-cresol at about 130.degree. C. After the fibers are dissolved the remaining black material is placed on a microscopic slide and covered with a glass for examination. In these photographs, the darker shaded areas correspond to overlapping thicknesses of the polypyrrole film.

Example 1 is repeated except that 50 g of nylon fabric, constructed from an untextured continuous filament of Nylon 6 is used. The black appearing fabric showed a resistivity of 7,000 and 12,000 ohms per square in the warp and fill direction, respectively.

Seven grams of textured Nylon 6,6 fabric is treated according to the procedure of Method B using a total of 150 cc of liquor, using 1 g of ferric chloride anhydride, 0.15 g of concentrated hydrochloric acid and 0.2 g of pyrrole. After spinning the flask for two hours, a uniformly treated fabric is obtained showing a resistivity of 1,500 and 2,000 ohms per square in the two directions of the fabric.

Fifty grams of a bleached, mercerized cotton fabric is treated according to Method A using 10 g of ferric chloride anhydride, 1.5 g of concentrated hydrochloric acid, and 2 g of pyrrole. A uniformly treated fabric of dark black color is obtained with resistivities of 71,000 ohms and 86,000 ohms per square, respectively, in the two directions of fabric.

Fifty grams of a spun Orlon sweater knit fabric is treated according to

Method C, using 10 g of ferric chloride anhydride, 1.5 g of concentrated hydrochloric acid and 2 g of pyrrole. After two hours of shaking, the fabric is withdrawn, washed and dried and shows a resistivity of 7,000 and 86,000 ohms per square in the two directions of the fabric.

Approximately 50 g of a wool flannel fabric is treated according to Method C using the same chemicals in the same amounts as described in Example 6. After washing and drying, the so prepared wool fabric shows a uniform black color and has a resistivity of 22,000 and 18,000 ohms per square in the two directions of the fabric.

Approximately 50 g of a fabric produced from a spun viscose yarn, Style #266, from Test Fabrics, Inc. was treated by Method C in the same manner as described in Example 6. After drying, the fabric shows a uniform black color and has a resistivity of 130,000 and 82,000 ohms per square in the two directions of the fabric.

Approximately 50 g of a fabric produced from a spun Nylon 6,6 yarn was treated according to Method A, using the same chemicals and amounts as described in Example 6. After reacting the fabric for two hours and washing and drying, the spun nylon fabric shows a uniform black color and has a resistivity of 2,400 and 6,000 ohms per square, respectively, in the two directions of the fabric. The absence of any surface deposits is seen from FIGS. 2-A and 2-B, showing the coated nylon fibers at 500.times. and 2,000.times. magnifications, respectively. The uniformity of the polypyrrole film can be seen from the photomicrograph of the cross-section of the fibers of a single yarn at 210.times.. FIGS. 4-A, 4-B and 4-C show similarly produced polypyrrole films on nylon fabric, at magnifications of 70.times., 210.times. and 430.times., respectively, after dissolution of the nylon fibers (as described in Example 2) using concentrated formic acid at room temperature as the solvent for Nylon 6,6.

Fifty grams of a fabric produced from a spun polypropylene yarn is treated according to Method A, using the same chemicals and amounts as described in Example 6. After treatment and drying, the so produced polypropylene fabric has a metallic gray color and shows a resistivity of 35,000 and 65,000 ohms per square, respectively, in the two directions of the fabric.

Approximately 50 g of a fabric produced from a spun polyester yarn is treated according to Method A, using identical chemicals and amounts as described in Example 1. After drying, a uniformly appearing grayish fabric is obtained showing a resistivity of 11,000 and 20,000 ohms per square in the two directions of the fabric.

Approximately 5 g of an untextured Dacron taffeta fabric is treated according to Method B, as described in Example 4. After treatment, a uniformly grayish looking fabric having resistivity of 920 and 960 ohms per square in the two directions of the fabric is obtained.

Approximately 5 g of a weft insertion fabric, consisting of a Kevlar warp and a polyester filling, is treated according to Method B, using the same conditions as described in Example 4. The resulting fabric has a resistivity of approximately 1,000 ohms per square in the direction of the Kevlar yarns and 3,500 ohms per square in the direction of the polyester yarns.

Approximately 5 g of a filament acetate sand crepe fabric is treated according to Method B, under the same conditions as described in Example 4. The resulting fabric has a resistivity of approximately 7,200 and 9,200 ohms per square in the two directions of the fabric.

Approximately 5 g of a filament acetate Taffeta fabric is treated according to Method B, using the same conditions as described in Example 4. The resulting fabric has a resistivity of approximately 47,000 and 17,000 ohms per square in the two directions of the fabric.

Approximately 5 g of a filament Rayon Taffeta fabric is treated according to Method B, using the same conditions as described in Example 4. The resulting fabric has a resistivity of approximately 420,000 and 215,000 ohms per square in the two directions of fabric.

Approximately 5 g of a filament Arnel fabric is treated according to Method B, using the same conditions as described in Example 4. The resulting fabric has a resistivity of approximately 6,000 and 10,500 ohms per square in the two directions of the fabric.

The previous examples show the applicability of the process of this invention to a wide range of synthetic and natural fabrics under a broad range of conditions, including reactant concentrations and contacting methods. The following examples serve to further demonstrate some of the useful parameters for carrying out the present invention.

This example demonstrates the influence of various types of surface active agents in the process of this invention.

The procedures described for Example 1 are repeated except that an anionic, nonionic or cationic surfactant of the type and in the amount shown in the following Table 1 is used. The results of the resistivity measurements are also shown in Table 1.

From the results reported in Table 1 it is seen that the incorporation of the anionic surfactant promotes the formation of the electrically conductive polypyrrole film, whereas the incorporation of the nonionic or cationic surfactant inhibits formation of conductive polypyrrole.

When the procedure of Runs B-D is repeated, using N-methylpyrrole in place of pyrrole, similar results are obtained.

When Run B is repeated but using 4 grams of sodium octyl sulfate the resistivity is increased to more than 40.times.10.sup.6 ohms. In other words, high amounts of anionic surfactant, for example, from about 2-5 or more grams per liter, interfere with the deposition/polymerization reaction in the same way as the use of cationic or nonionic surfactants.

Although the precise mechanism by which the surfactant interferes with the deposition of a conductive polymer film is not completely understood, it is presumed that the surfactant competes with the in status nascendi forming polymer species for available deposition sites on the textile substrate.

This example demonstrates the influence of reactant concentration on the conductive polypyrrole films produced according to this invention.

Following the procedure of Method A, using 50 grams of the same polyester fabric as described in Example 1, the reactant concentrations are varied as shown in Table 2. The resistivity of the resulting fabric is measured after the treatment is conducted a room temperature conditions for two hours, followed by rinsing and drying as described in Method A.

In Run G, although the quantity of polymer pick-up is as high as about 9% and the resistivity is very low, the appearance of the treated fabric is very non-uniform. Substantial surface deposits on the relatively thick polypyrrole film are seen from FIG. 7, which is a photomicrograph, magnification 1,000.times., of individual fibers.

FIGS. 5-A and 8, each at 210.times. magnification, show the polypyrrole film, after dissolution of the polyester fibers with m-cresol (at 130.degree. C.), from Run B (10 g FeCl.sub.3, 1.5 g HCl, 2 g pyrrole) and Run G (40 g FeCl.sub.3, 6 g HCl and 8 g pyrrole), respectively. These photographs reveal the difference between the treatment conditions with respect to the uniformity of the polypyrrole film, and the possibility of avoiding depositing polymer particles by selection of appropriate concentrations of reactants. FIG. 5-B (polypyrrole film at 430.times.) and FIG. 6 (fiber cross-section at 210.times.) further illustrate the uniformity of the polypyrrole film coatings which can be obtained by the present invention.

Following the procedure of Method A, 50 grams of a polyester fabric, as described in Example 1, is treated at room temperature for two hours in a Werner Mathis JF dyeing machine, using 3.75 g of sodium persulfate, 2 g of pyrrole in a total of 1.5 liter water. The resulting fabric has a resistivity of 39,800 and 57,000 ohms per square in the warp and fill directions, respectively.

When this example is repeated, except that 20 g NaCl is used in the treatment, the resistivity values are decreased to 11,600 ohms and 19,800 ohms per square in the warp and fill directions, respectively.

If in place of 20 g NaCl, 10 g CaCl.sub.2 is used and the total amount of water is decreased in 1.0 liter, the resistivity is further lowered to 3,200 ohms per square and 4,600 ohms per square, respectively. These results are comparable to the results obtained in Example 1 using 16.7 g FeCl.sub.3.6H.sub.2 O and 1.5 g of 37% HCl.

This example shows that the conductive polypyrrole films are highly substantive to the fabrics treated according to this invention. The procedure of Example 1 is repeated, except that in place of 16.7 g of FeCl.sub.3.6H.sub.2 O, 10 g of anhydrous FeCl.sub.3 is used. The resulting fabric is washed in a home washing machine and the pyrrole polymer film is not removed, as there is no substantial color change after 5 repeated washings.

This example shows the influence of the treatment time on the conductivity of the deposited pyrrole polymer film.

Following the procedure of Method B, 4 sheets, each weighting 5 g, of the same polyester fabric as used in Example 1 are prepared. Each sheet is treated in 150 cc of water with 1 g anhydrous ferric chloride, 0.15 g HCl and 0.2 g pyrrole. The jar is rotated 15 minutes. 30 minutes, 60 minutes or 120 minutes, to form a conduction polypyrrole film on each of the four sheets after which the fabric is withdrawn from the jar, rinsed and air-dried. The resistivities of the dried fabrics are measured in the warp and fill directions. The resutlts are shown in Table 3.

In order to demonstrate the stability of the conductive polypyrrole composite fabrics of this invention, two different types of polyester fabrics (from Examples 1 and 2, respectively) are treated under the same conditions as used in Examples 1 and 2. The composite fabrics are placed in a preheated oven at 380.degree. F. for 60 seconds. The results are shown in Table 4.

This example demonstrates that the process of this invention does not work with ordinary organic solvents In each case 5 grams of polyester fabric is treated by Method B, using 150 cc of solvent and 1.0 g anhydrous FeCl.sub.3, 0.2 g pyrrole and 0.15 g conc. HCl. The following solvents are used: methylene chloride, acetonitrile, nitrobenzene, methanol, ethanol, isopropanol, tetrahydrofuran, ethyl acetate. The treatment is continued at room temperature for 2 hours. None of these solvents provides a polypyrrole film deposited on the polyester fabric. Similar negative results are obtained using N-methyl-pyrrole in place of pyrrole. Similar negative results are also obtained using other oxidizing agents.

This example is designed to confirm that it is not the polypyrrole polymer, per se, that is being adsorbed by the textile substrate.

A. Following the procedure for Method C except that no fabric is used, 16.7 g FeCl.sub.3.6H.sub.2 O, 2 g pyrrole, 1.5 g HCl and 1.5 liters H.sub.2 O are added to the jar and, with agitation, the reaction proceeds at room temperature for 2 hours. A black powder is formed and is filtered, washed with water and dried. Approximately 300 mg of black powder (polypyrrole) is recovered.

This black powder (300 mg) is then added to the jar containing 1.5 liters H.sub.2 O, 1.5 g HCl and 50 g of polyester fabric (as described in Example 1 is used) and shaken for 2 hours. The fabric is withdrawn, washed with water and dried. The fabric has a dirty, uneven appearance and no improvement in conductivity. Thus, a conductive film of pyrrole polymer is not deposited on the fabric simply by immersing the fabric in a suspension or dispersion of polypyrrole black powder.

B. When the above procedure is repeated except that the oxidative polymerization reaction is allowed to proceed for 20 hours (rather than 2 hours) approximately 1 g (approximately 50% yield) of black powder is formed. If 50 grams of the polyester fabric is immersed in a suspension of the black powdery polypyrrole (1 g) in 1.5 liters water containing 1.5 g HCl, similar results are obtained, namely a dirty appearing fabric with no readable improvement in resistivity up to 40.times.10.sup.6 ohms, the highest readable value for the meter used to measure resistivity.

C. Example 25A is repeated except that the black powder formed after reaction for 2 hours is not separated and 50 grams of the polyester fabric is inserted into the reaction mixture and shaking is continued for another 2 hours after which the fabric is withdrawn, rinsed and dried. Approximately 1 gram (approximately 2% o.w.f pick-up) of conductive polypyrrole film is deposited on the fabric. All of the remaining liquor is collected, and filtered from the remaining black powder, washed and dried. Approximately 0.24 g of polypyrrole is recovered which is about the same amount as described in Example 25A. Nevertheless, the remaining liquid is capable of producing another gram of polypyrrole on the surface of the fabric after only 2 additional hours.

Therefore, this example shows that the pyrrole is polymerized slowly in the absence of the textile material, but in the presence of the textile material the polymerization proceeds faster and on the surface of the fabric In other words, it appears that the fabric surface functions to catalyze the reaction and to adsorb the in status nascendi forming polymer.

To show that neither the monomer nor the oxidizing agent is adsorbed or absorbed onto or into the fibers of the textiles the following experiments were conducted:

(1.) 0.8 g of pyrrole was dissolved in 600 cc of water and 150 cc each were dispensed into four 8 oz. jars.

(2.) A solution of 11 g FeCl.sub.3.6H.sub.2 O in 1,000 ml of water containing 1 g of concentrated hydrochloric acid was prepared and filtered and 150 g of this solution was added to four 8 oz. jars.

Three 7.times.7" fabrics were used, (a) polyester (as in Example 1 weighing approx. 5 g), (b) basic dyeable polyester (as in Example 2 weighing approx. 9 g) and (c) textured nylon (as in Example 4 weighing approx. 7 g) and placed into the monomer or oxidant solution respectively. One jar served as reference. All 8 containers were closed and tumbled for 4 hours and the concentration of the reactant was measured at this time.

The concentration of pyrrole was determined by U.V. spectroscopy and ferric chloride was determined by atomic adsorption.

As can be seen from Table 5 no adsorption of either agent is taking place

This example is carried out following the procedure of Example 12 (Method B--polyester fabric 5 g) using 1.7 g FeCl.sub.3.6H.sub.2 O, 0.2 g pyrrole and 0.5 of various different counter ions (doping agents) in 150 cc of H.sub.2 O. The resistivities of the resulting composite fabrics are shown in Table 6.

The following example demonstrates the importance of temperature in the epitaxial polymerization of pyrrole. Following the procedure for low temperature reaction given in Method B, 5 grams of polyester fabric as defined in Example 1 was treated using 1.7 gram of ferric chloride hexahydrate, 0.2 grams of pyrrole, 0.5 grams of 2,6-naphthalenedisulfonic acid, disodium salt in 150 cc of water at 0.degree. C. After tumbling the sample for 4 hours the textile material was withdrawn and washed with water. After drying a resistivity of 100 ohms and 140 ohms was obtained in the two directions of the fabric.

The same experiment was repeated but instead of the polyester fabric, 7 grams of a knitted, textured nylon fabric was used. After rinsing and drying resistivities of 130 and 180 ohms respectively were obtained in the two directions of the fabric.

Following the procedure given for low temperature experiments under Method B, 5 grams of polyester fabric as defined in Example 1 was treated with 0.7 grams sodium persulfate, 0.2 grams pyrrole and 0.5 grams of 2.6-naphthalenedisulfonic acid, disodium salt in 150 cc of water. After tumbling the mixture for 2 hours at 0.degree. C. the textile material was withdrawn, washed with water and air dried. The fabric showed a resistivity of 150 and 220 ohms in the two directions of the fabric.

The same example was repeated but 7 grams of a textured nylon fabric was used. The resistivity was determined to be 180 and 250 ohms in the two directions of the fabric. These samples clearly demonstrate the improvements in conductivity which can be obtained by conducting the epitaxial polymerization at lower temperatures. As the polymerization rate is considerably lowered at 0.degree. C., it is now possible to also use higher concentrations of pyrrole or lower liquor ratios which yields even better conductivities.

This example shows the effect of another oxidant, ammonium persulfate, alone and with various sulfur compound doping agents. The same procedure as used in Example 27 is followed except that 0.375 g ammonium persulfate [(NH.sub.4).sub.2 S.sub.2 O.sub.8 ] is used in place of 1.7 g. FeCl.sub.3.6H.sub.2 O. Table 7 shows the doping agent, and results of the treatment which is carried out for 2 hours at room temperature.

Sample C was retested for its resistivity after aging under ambient conditions for four months. The measurements obtained were 800 and 1300 ohms in the two directions of the fabric. This illustrates the excellent stability of products obtained by this invention. In contrast, stabilities of composite structures reported by Bjorklund, et al., Journal of Electronic Materials, Vol. 13, No. 1 1984 p. 221, show decreases of conductivity by a factor of 10 or 20 over a 4 month period.

This example illustrates a modification of the procedure of Method A described above using ammonium persulfate (APS) as the oxidant wherein the total amount of oxidant is introduced incrementally to the reaction system over the course of the reaction.

Fifty two grams of polyester fabric, as described in Example 1, is placed in the rotating basket insert of a Werner Mathis JF dyeing machine and, with the port of the machine closed, 500 cc of water is added to the reaction chamber to wet out the fabric. Then 1.7 g APS and 5 g of 1,5-naphthalenedisulfonic acid, disodium salt, dissolved in 500 cc of water is introduced to the reaction chamber while the basket is rotating. Finally, 2 g pyrrole in 500 cc water is added to the rotating mixture and the reaction is allowed to proceed at about 20.degree. C. for 30 minutes, at which time an additional 1.7 g APS (in 50 cc H.sub.2 O) is introduced to the rotating reaction mixture. After 60 minutes and 90 minutes from the initiation of the reaction (i.e. from the introduction of the pyrrole monomer) an additional 1.7 g APS in 50 cc water is introduced to the reactor, such that a total of 6.8 g APS (1.7.times.4) is used. The reaction is halted at the end of two hours (30 minutes after last introduction of APS) by dropping the bath and rinsing twice with water. The fabric is withdrawn from the reactor and is air dried. The pH of the liquid phase at the end of the reaction is 2.5. The resistivity of the fabric is 1,000 ohms per square and 1,200 ohms per square in the warp and fill directions, respectively. Visual observation of the liquid phase at the end of the reaction shows that no polymer particles are present.

This example demonstrates the influence of the concentration of APS oxidant in the reaction system. The procedure of Method B is followed using 5 g polyester fabric as described in Example 1 with 0.2 g pyrrole, 0.5 g 1,5-naphthalenedisulfonic acid, disodium salt as doping agent and 150 cc of water. APS is used at concentrations of 0.09 g, 0.19 g, 0.375 g and 0.75 g. The results are shown in Table 8.

In each of Runs A-D the liquid phase remains clear throughout the reaction, confirming that the in status nascendi forming polymer is adsorbed by the textile fabric where polymerization of the conductive polymer is completed, namely that the conductive polymer is not formed in the liquid phase.

Example 34 is repeated, except that different amounts of ammonium persulfate are used and 2,6-naphthalene disulfonic acid disodium salt was used instead of the 1,5 substituted derivative. The results are shown in Table 9.

This example demonstrates that the conductivity of the polypyrrole film can be reversed by sequential neutralization and replacement of the counter ion doping agent.

The composite fabrics prepared in Example 27, Runs A (toluene sulfonic acid) and C (1,5-naphthalenedisulfonic acid, disodium salt) are used. In order to neutralize the sulfonic acid counter ion, each composite fabric sample is individually immersed in 200 cc water solution of ammonia (8 grams) and tumbled for 2 hours. The treated fabric is rinsed with fresh water and then dried. The resistivity of each fabric before the washing treatment, after the washing treatment, and after redoping is measured and the results are shown in Table 10. Redoping is carried out after immersing the ammonia treated fabric in water, and reimmersing the wet fabric in (a) 0.5 g toluene sulfonic acid in 200 cc water or (b) 0.5 g 1,5-naphthalene disulfonic acid, disodium salt, in 200 cc water, plus 3 drops H.sub.2 SO.sub.4 (conc.) The results are reported in Table 10.

As seen from this example it is possible to undope (reduced state) and redope (oxidized state) the polypyrrole film. This ability can be utilized to reversibly alter the conductivity of the composite fabric between highly conductive and weakly conductive or non-conductive states. Furthermore, in view of the extreme thinness of the conductive films, i.e. generally less than 1 micron, e.g. about 0.2 micron, the rates of diffusion of the doping agent into and out of the film are very high. Therefore, the composite fabrics can be used, for example, as a redox electrode in electrochemical cells, fuel cells and batteries.

This example demonstrates the application of the process of this invention to the production of electrically conductive composite yarn. The process is carried out using conventional package dyeing equipment.

A. 2376 g of a texturized Dacron Polyester yarn, type 54, 1/150/34, is wound on a bobbin and placed in a Gaston County package dyeing machine where it is scoured with water (3 times each with 14 liters of water). The machine is then filled with 12 kg water to which is added consecutively 50 g of 1,5-naphthalenedisulfonic acid, disodium salt in 500 cc water; 25 g pyrrole in 500 cc water and 37.5 g potassium persulfate in 500 cc water. Additional water is then added to fill the machine to capacity. The machine is then run at room temperature for 60 minutes with the direction of flow of liquid through the yarn being changed every 3 minutes, i.e. after each 3 minute cycle, the direction of flow is reversed from inside-out to outside-in or vice versa.

By "outside-in" is meant that the liquid is forced from the outside of the yarn package into the perforated spindle and through a recirculating system back to the outside of the yarn package In the inside-out flow pattern this procedure is reversed.

At the end of 60 minutes the liquid is removed and the yarn is rinsed. The polyester yarn is uniformly coated throughout the yarn package and is electrically conductive.

B. The procedure of Example 34A is repeated using 1112 grams of polyester yarn 1/150//68, Type 54 treated with 167 g FeCl.sub.3 in 1000 cc H.sub.2 O and 20 g HCl and 25 g pyrrole in 500 cc H.sub.2 O. After twenty 3 minute cycles (60 minutes in total) an evenly coated conductive yarn is obtained.

Following the procedure in Method B, 7 g of textured nylon fabric, test fabric style 314 is inserted into an 8 oz. jar containing 150 cc of water, 0.4 g of aniline hydrochloride, 1 g conc. HCl, 1 g of 2,6-naphthalenedisulfonic acid, disodium salt and 0.7 g of ammonium persulfate. After rotating the flask for 2 hours at room temperature a uniformly treated fabric having the typical green color of the emeraldine version of poly-aniline is obtained showing a resistivity of 4200 ohms and 5200 ohms in the two directions of the knitted fabric.

The above experiment is repeated except that the reaction vessel is immersed in an ice water mixture to conduct the reaction at 0.degree. C. A green colored fabric is obtained showing a resistivity of 6400 ohms and 9000 ohms in the two directions of the fabric.

Example 38 was repeated using 5 g of polyester fabric as defined in example #1. A resistivity of 75000 and 96600 ohms was measured in the two directions of the fabric.

The same experiment as in Example 38 was repeated but 9 g of basic dyeable polyester, as defined in example #2, was used. A resistivity of 15800 and 11800 ohms was measured in the two directions of the fabric.

Following the procedure in Method B, 7 grams of textured nylon fabric is inserted into an 8 ounce jar containing 75 cc of water, 0.4 gram of aniline hydrochloride, 5 grams of concentrated HCl, 1 gram of 1,3-benzenedisulfonic acid disodium salt and 0.7 gram of ammonium persulfate. After rotating the flask for 4 hours at room temperature, a uniformly treated fabric having a green color was obtained, showing a resistivity of 1500 ohms and 2000 ohms in the two directions of the knitted fabric. This example demonstrates how variations in concentration and acidity can lead to improved and higher conductive fabrics.

Following the procedure of Example 1 of U.S. Pat. No. 4,521,450 (Bjorklund, et al.) 5 different fabric materials (100% polyethylene terephthalate; 100% cotton; basic dyeable polyester; wool; acrylic knit; nylon taffeta) are treated with a solution of 10 g FeCl.sub.3.6H.sub.2 O in 100 ml 0.01 M HCl. Each fabric is dipped in the FeCl.sub.3 solution until thoroughly wet-out and is then placed in a container and covered with pyrrole liquid where it remains at room temperature. The samples are then withdrawn and rinsed with water. In each case the fabric is extremely non-uniformly coated with the pyrrole polymer and many thick deposits are observed on all the substrates. Furthermore, the fabrics are stiff, indicating polymerization in the interstices as described in the patent. Polymerization is also observed in the pyrrole liquid and powdery polymer particles precipitate onto the fabric and onto the glass container.

XPS spectra were run on polypyrrole coated quartz fabrics according to the method described in the present application, the method described in Maus, U.S. Pat. No. 4,696,835, and Bjorklund, U.S. Pat. No. 4,521,450. These fabrics were compared and contrasted in order to determine polymer order on the coated fabric. A sample is also prepared containing no fabric where the pyrrole was solution polymerized using the same concentrations as described in the above-identified application. This polymerized pyrrole is studied in the form of a pressed pellet.

All XPS analyses were performed in the scanning mode on quartz coated fabric so that there would be no contribution from underlying carbons as there would be on typical synthetic fabrics such as polyester and nylon which, of course, contain carbon. The instrumental resolution was 2 eV using a 300u diameter X-ray spot. Twenty eight scans were taken on sample A prepared according to the Kuhn method and 30 scans on sample B prepared according to the Kuhn method, and 50 scans were taken of each carbon 1s peak for the other samples. A 20 eV wide window was used in all cases and approximately centered on each peak. Peak fitting was performed for each carbon 1s peak by constraining the full width half height of the alpha and beta carbons to their literature values (see P. Pfluger and G. B. Street, J. Chem Phys. 80 (1), 544. Gaussian components were used for the deconvolutions The procedure used to prepare the samples made as described above according to the present application is the general procedure set forth in Example 1 above except that the hydrochloric acid was deleted. The aqueous solution consisted of 200 ml of water, 1.7g of FeCl.sub.3.H.sub.2 O and 0.2g of pyrrole. The quartz fabric was a 5.5 g Stevens Astro Quartz fabric and the reaction was run at ambient temperature. The samples were washed in distilled water prior to submission for XPS study.

The polypyrrole pellet sample was prepared out of an aqueous solution containing the identical concentration of components.

The XPS results are reported in FIGS. 9 and 10 according to accepted methods of spectra interpretation developed by Pfluger and Street (J. Chem. Phys. 80 (1), 544) the difference in polymer order is clearly demonstrated. The spectra of the polypyrrole quartz fabric made according to the present application shows considerably more order than that of the surface absent free formed polypyrrole shown in FIG. 10. This is due to a higher degree of alpha-alpha bonding which is consistent with a higher degree of order. The alpha-alpha bonding peak is the large peak at 284.40 eV with the disorder peaks being at 285.83 eV. This disorder is due it is believed to saturated pyrrole moieties in the chain, alpha-beta coupling, and crosslinking.

As indicated above a separate sample of quartz fabric was coated with polypyrrole according to the method described by Maus, U.S. Pat. No. 4,696,835. The procedure followed was as follows: a 4.times.4" piece of quartz fabric (the same sample as used above) was dipped into a solution of 10 g of ferric chloride and 100 ml of acetonitrile. After drying the fabric was suspended 1 inch above the surface of a plate containing pyrrole monomer. Two samples were taken after polymerization had taken place. Sample C was submitted as is for XPS study and sample D was washed in distilled water prior to submission for XPS study. As can be seen in FIGS. 11 and 12, there is substantial asymmetry to the XPS spectral peaks. In both of these figures the deconvoluted alpha-alpha bonding peaks occur at 284.47 eV, the same energy as the Kuhn sample alpha-alpha bonds, but have a considerably less contribution to the general peak shape indicating less polymer order. The growth of additional disorder peaks at higher energies is also indicative of greater disorder in the polymer chain.

A separate sample of quartz fabric of the same type employed above was treated according to the procedure described in the Bjorklund, et al., U.S. Pat. No. 4,521,450. The following procedure was employed. A 4.times.4" piece of quartz fabric was dipped into a solution of ferric chloride (10 g) in 0.01 molar hydrochloric acid. While still wet the fabric was placed in liquid pyrrole at ambient temperature. Sample E was placed in the pyrrole solution for 15 minutes, removed, dried and prepared for XPS studies. Sample F was soaked in the pyrrole for 25 minutes and then washed in distilled water prior to drying and preparation for XPS study. The XPS study of the Bjorklund samples is shown in FIGS. 13 and 14. Again, there is considerable disorder of the polymer structure as shown in these figures. The alpha-alpha bonded carbons appear around 284.5 eV and there is considerable contribution to peak asymmetry from higher energy disorder carbons.

Based upon the above XPS spectra analysis, it is clear that the polypyrrole formed by the process of the present invention on the fabrics is much more ordered in its structure than are the fabrics of either Maus or Bjorklund. This is further demonstrated by comparison of the Maus and Bjorklund samples with that of the sample prepared according to the present invention shown in FIG. 9 where no surface is involved and the degree of asymmetry to polymers disorder is clearly seen. It is interesting to note that the Bjorklund sample shown in FIG. 14 showed less asymmetry than the previous Bjorklund sample shown in FIG. 13. Since the Bjorklund sample of FIG. 14 was exposed to the pyrrole solution for a longer period of time, ordering of the top layers of polymer may increase as the coating gets thicker. If, indeed, this is the case then the samples prepared according to the present invention must have a higher degree of order of the initial layers and this order is propagated through the polymer structure.