JP6328646B2 - グラフェン補強ポリマーマトリクス複合体を製造するためのinsitu剥離方法 - Google Patents
グラフェン補強ポリマーマトリクス複合体を製造するためのinsitu剥離方法 Download PDFInfo
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims description 257
- 229910021389 graphene Inorganic materials 0.000 title claims description 127
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- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 2
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- AWJWCTOOIBYHON-UHFFFAOYSA-N furo[3,4-b]pyrazine-5,7-dione Chemical compound C1=CN=C2C(=O)OC(=O)C2=N1 AWJWCTOOIBYHON-UHFFFAOYSA-N 0.000 description 1
- 239000011881 graphite nanoparticle Substances 0.000 description 1
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- 238000010348 incorporation Methods 0.000 description 1
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- 150000002739 metals Chemical class 0.000 description 1
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- 229910052760 oxygen Inorganic materials 0.000 description 1
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- 229910052763 palladium Inorganic materials 0.000 description 1
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- 125000001997 phenyl group Chemical group [H]C1=C([H])C([H])=C(*)C([H])=C1[H] 0.000 description 1
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- QAOWNCQODCNURD-UHFFFAOYSA-N sulfuric acid Substances OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/505—Screws
- B29C48/67—Screws having incorporated mixing devices not provided for in groups B29C48/52 - B29C48/66
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/15—Nano-sized carbon materials
- C01B32/182—Graphene
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
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- C08J3/201—Pre-melted polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/005—Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
- B29K2105/162—Nanoparticles
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2381/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2381/06—Polysulfones; Polyethersulfones
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- Chemical Kinetics & Catalysis (AREA)
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- Polymers & Plastics (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Nanotechnology (AREA)
- Manufacturing & Machinery (AREA)
- Inorganic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Carbon And Carbon Compounds (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
Description
本願は、35 U.S.C. セクション 119(e)に基づき、2012年10月19日に提出された米国仮特許出願第61/716461号に対して優先権を主張するものであり、その全体が参照として本明細書に組み込まれる。
本発明は、良結晶化グラファイト粒子を含有するポリマー複合体を、種々の商業的応用を有する、ナノ分散された単層または多層グラフェン粒子へと変換するための高効率混合方法に関するものである。
本開示は、記載された特定の系、方法または手順に制限されず、これらは変更されていてもよい。本文中で用いられる専門用語は、単に特定のバージョンまたは実施形態を説明することを目的として用いられるもので、その範囲を限定することは意図しない。
用語「グラフェン」は、ベンゼン環構造中に高密充填された、炭素原子の単層に与えられる名称を述べる。
2.抽出したグラファイト粒子のポリマーマトリクス相中へ混入、および高効率混合/剥離処理による、グラファイト含有ポリマーのグラフェン補強ポリマーマトリクス複合体(G−PMC)への変換;
3.機械的剥離ならびに多層グラフェンおよびグラフェンナノ粒子の分布の程度を決定するためのモルフォロジー分析;および、
4.機械的剥離の関数としての多層グラフェンまたはグラフェン結晶サイズを決定するためのX線回折分析。
複合体構造の継続した精製を確保するために、押出パラメータは調整されて複合体のより高い粘度を補償する。
Oxford EDSと共に、Zeiss Sigma 電界放射走査電子顕微鏡(FESEM)が、グラファイトの多層グラフェンまたはグラフェンナノ粒子への機械的剥離の程度およびこれらの粒子の厚さを決定するために用いられた。観察の間、3kVの加速電圧および約8.5mmの作動距離が用いられた。観察の前に、3G−PMC、30G−PMCおよび90G−PMCの各サンプルからの試料に切り込みが入れられ、低温で平坦な破断面を形成するよう破断され、少なくとも24時間真空下に配置され、金でコートされ、および真空下で保管された。
3G−PMC、30G−PMCおよび90G−PMCの各サンプルにおけるXRD分析は、4つの段階を含む:(1)試料の調製、(2)解説パターンの取得、(3)形状のフィッティング、および(4)デバイ−シェラー(Debye‐Scherrer)式に従った面外(D)結晶サイズの算出。
3つの異なるスケール(倍率)における、3G−PMC、30G−PMCおよび90G−PMCの各サンプルのモルフォロジーは図3に示される。
デバイ−シェラー(Debye‐Scherrer)式が、FWHMおよびX線回折パターンから得られた間隔dの結果へと適用され、3G−PMC、30G−PMC、および90G−PMCに対する多層グラフェンまたはグラフェンナノ粒子の結晶厚(D)を提供した。XRD結果および結晶厚を表1に表す。3G−PMC、30G−PMC、および90G−PMCサンプルに対して、それぞれ、結晶厚は40nm、31nm、および23nm、FWHMは0.202°、0.257°、および0.353°、ならびに間隔dは3.361nm、3.353nm、および3.387nmである。FWHMは混合時間と共に増加し、結晶厚は混合時間と共に減少し(図5)、これはグラファイトの多層グラフェンまたはグラフェンへの機械的剥離が生じており、混合時間が長くなるに従って増進されたことを示している。図6はFWHMの関数としての結晶サイズの減少を示す。
ポリマー処理装置中における、繰り返しせん断ひずみ動作の結果としての、グラファイトの多層グラフェンまたはグラフェンへの機械的剥離は、種々の化学反応を生じさせる機会を提供するダングリング1次および2次ボンドを発生させ、これはG−PMCの特性強化を得るために有効活用することができる。これは、グラフェンオキサイドを形成する先行技術である従来の方法に対しての利点を表し、ここで、ダングリング1次および2次ボンドは酸素と共有結合し、これはグラフェンオキサイドが減少された後に置いてもなお、これらの位置に一般的にとどまる、
たとえば、これらの多層グラフェンまたはグラフェンナノ粒子からポリマーマトリクスへのダングリングボンドを共有結合的に取り付ける化学反応は、G−PMCの優れた機械的特性を提供しうる。あるいは、グラフェンナノ粒子の端部に適切なバンドギャップ材料の化学的に結合することによって、または、たとえば金、銀、動などの導電性金属を配位させることによって、電気伝導性を高めてもよい。グラフェン補強ポリマーは、その後、ポリマーまたは他の組成物へ添加されて、電気伝導性を提供または改善してもよい。グラフェン補強ポリマーを触媒担体として提供して、結合はまた、金属、たとえばプラチナおよびパラジウムのような金属に配位されて、触媒を提供してもよい。機能性グラフェンの他の形は、米国特許第8,096,353号明細書に開示されており、この開示は参照として本願に組み入れられている。
他の用途は、複合艇体、航空機、航空宇宙システム、運搬用車両、兵隊用の装甲(personnel armor)、圧力容器、反応器チャンバー、スプレーコート、3Dプリント用のポリマー粉末、電子デバイスタッチスクリーン用の透明電極などが含まれる。1−2wt%のグラフェンのポリマーマトリクスへの添加は、電気伝導性を与える一方、光学的透明性は維持され、それ故、ソーラーパネル、フラットパネルディスプレイ、および病院における静電放電の制御のための応用を可能とする。
現在の小さなバッチミキサーの設計を変形してより高いせん断速度を提供してもよく、これはポリマーマトリクス内における優れたグラファイトの機械的剥離を順に提供する。
ランドキャッスル(Randcastle)は、G−PMCを製造するために、ポリマーマトリクス中におけるグラファイトの多層グラフェンまたはグラフェンへの機械的剥離をより可能としうる押出機スクリューへの改良がなされた。
Claims (12)
- (a)グラファイト微粒子を溶融熱可塑性ポリマー相中に分散させること、ここで、前記グラファイト微粒子中のグラファイトの少なくとも50%が、c軸方向に沿って1.0ミクロンと1000ミクロンとの間の範囲の厚さである多層グラファイト結晶から成り、および、
(b)一連のせん断応力イベントを溶融ポリマー相へ供給して、前記溶融ポリマー相中におけるせん断応力は前記グラファイト微粒子の層間せん断強度(ISS)と同等であるか、またはより大きく、前記グラファイトが少なくとも部分的に剥離され、前記c軸方向に沿って10nm未満の厚さの単層および多層グラフェンナノ粒子の前記溶融ポリマー相中への分布を形成するまで、前記溶融ポリマー相が各イベントによって前記グラファイトを連続的に剥離すること、
を含む、グラフェン補強ポリマーマトリクス複合体の製造方法。 - 前記グラファイト微粒子が、軸状の溝が掘られた伸長混合要素またはらせん状の溝が掘られた伸長混合要素を有する一軸押出機を用いて、ポリマーマトリクス中へと組み込まれうる、請求項1に記載の方法。
- グラファイト含有ポリマーマトリクスが、繰り返し押出しにさらされることでグラファイト材料の剥離が誘起された結果として、前記ポリマーマトリクス中にグラフェンナノ粒子の均一な分布を形成する、請求項2に記載の方法。
- ポリマーが、ポリエーテル−エーテルケトン、ポリエーテルケトン、ポリフェニレンサルファイド、ポリエチレンサルファイド、ポリエーテルイミド、ポリフッ化ビニリデン、ポリスルホン、ポリカーボネート、ポリフェニレンエーテル/オキサイド、ナイロン、芳香族熱可塑性ポリエステル、芳香族ポリスルホン、熱可塑性ポリイミド、液晶ポリマー、熱可塑性エラストマー、ポリエチレン、ポリプロピレン、ポリスチレン、ポリメチルメタクリレート、ポリアクリロニトリル、超高分子量ポリエチレン、ポリテトラフルオロエチレン、アクリロニトリルブタジエンスチレン、ポリアミド、ポリフェニレンオキサイド、ポリオキシメチレンプラスチック、ポリイミド、ポリアリールエーテルケトン、ポリ塩化ビニル、アクリル、およびこれらの混合物からなる群から選択される、請求項1〜3のいずれか1項に記載の方法。
- 少なくとも90%の前記グラファイトが剥離されて、前記c軸方向に沿って10nm未満の厚さの単層および多層グラフェンナノ粒子の前記溶融ポリマー相中への分布を形成するまで、前記一連のせん断応力イベントが供給されうる、請求項1〜4のいずれか1項に記載の方法。
- 少なくとも50%の前記グラファイトが剥離されて、前記c軸方向に沿って10nm未満の厚さの単層および多層グラフェンナノ粒子の前記溶融ポリマー相中への分布を形成するまで、前記一連のせん断応力イベントが供給されうる、請求項1〜4のいずれか1項に記載の方法。
- 少なくとも75%の前記グラファイトが剥離されて、前記c軸方向に沿って10nm未満の厚さの単層および多層グラフェンナノ粒子の前記溶融ポリマー相中への分布を形成するまで、前記一連のせん断応力イベントが供給されうる、請求項1〜4のいずれか1項に記載の方法。
- 前記グラファイトが、膨張グラファイトである、請求項1〜7のいずれか1項に記載の方法。
- 前記グラファイト微粒子は、前記溶融熱可塑性ポリマー相中において、前記グラファイト微粒子および溶融熱可塑性ポリマーの総重量に対して2重量%以上50重量%以下の量で分散される、請求項1〜8のいずれか1項に記載の方法。
- 前記グラファイト微粒子は、前記溶融熱可塑性ポリマー相中において、前記グラファイト微粒子および溶融熱可塑性ポリマーの総重量に対して2重量%以上30重量%以下の量で分散される、請求項1〜8のいずれか1項に記載の方法。
- 前記グラファイト微粒子は、前記溶融熱可塑性ポリマー相中において、前記グラファイト微粒子および溶融熱可塑性ポリマーの総重量に対して2重量%以上10重量%以下の量で分散される、請求項1〜8のいずれか1項に記載の方法。
- 前記グラフェン補強ポリマーマトリクス複合体は、残留グラファイト微粒子を含む、請求項1〜8のいずれか1項に記載の方法。
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