We review experimental and theoretical work on electrical percolation of carbon nanotubes (CNT) in polymer composites. We give a comprehensive survey of published data together with an attempt of systematization. Parameters like CNT type, synthesis method, treatment and dimensionality as well as polymer type and dispersion method are evaluated with respect to their impact on percolation threshold, scaling law exponent and maximum conductivity of the composite. Validity as well as limitations of commonly used statistical percolation theories are discussed, in particular with respect to the recently reported existence of a lower kinetic (allowing for re-aggregation) and a higher statistical percolation threshold.

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The ability to examine conducting filler particles in an insulating polymer matrix by scanning electron microscopy (SEM) was investigated. The detection of selected secondary electrons is necessary to resolve sub-micron scale filler particles, but not every SEM detector seems to be able to monitor the small changes introduced by the conducting filler particles. The influence of SEM parameters and the challenge of image interpretation in view of the apparent lack of appropriate information in literature are discussed. In accordance with other experiments on light element samples, all monitored electrons seem to be emitted within approximately 50 nm of the sample depth and no information is accessible from deeper regions even by increasing the acceleration voltage.

We analyse statistical and kinetic percolation thresholds and maximum electrical conductivities of carbon nanotube epoxy composites as a function of shear forces, processing conditions, nanotube type and dimensions. Entangled and non-entangled nanotubes of different lengths (15-100 microm) and thicknesses (12-80 nm) have been obtained with three different synthesis methods based on catalytic or plasma enhanced chemical vapour deposition. The dispersions were processed either solely with a dissolver disk or additionally with a three roll calender. Care was taken to prevent unintentional shearing (e.g. through convection) in all samples that were not subject to deliberate shearing. It was found that shear forces have a similar influence on kinetic percolation thresholds and composite conductivities independent of nanotube types and dimensions.

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