WO2020153352A1 - 層状化合物の剥離層分散液及びそれを用いた透明基板 - Google Patents
層状化合物の剥離層分散液及びそれを用いた透明基板 Download PDFInfo
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Definitions
- the present invention relates to a dispersion liquid of plate-like particles formed from a release layer substance by delamination of a layered compound, a coating film and a transparent substrate using the dispersion liquid.
- a layered compound has a crystal structure in which constituent atoms are laterally linked to form a plate-shaped molecule (layer), and the remaining molecules are stacked in one direction.
- the presence of metal ions that play a role of connecting the layers between the layers forms a strong bond between the layers and the metal ions, thereby forming a layered compound having layers and layers. It is formed.
- Examples of such layered compounds include clay minerals, manganates, titanates, niobates and the like.
- the layered compound has the property of intercalation in which various ions and molecules are reversibly incorporated between layers.
- a mechanical shearing force and/or an impact force is applied to a mixture of an aggregate of an organically modified clay mineral having a layered structure in which a quaternary ammonium compound is intercalated between layers and a silicone oil, to obtain the organically modified clay.
- An oily sol in which a layered substance (organic modified clay mineral having a plate-like particle structure) is dispersed in silicone oil by subjecting mineral aggregates to a peeling treatment is disclosed (see Patent Document 1).
- an antifouling antireflection film comprising a silica-based porous film and an antifouling layer coating the surface of the silica-based porous film, wherein the antifouling layer has a plurality of nanosheets derived from an inorganic layered compound.
- Patent Document 2 a resin composition comprising a vinyl alcohol polymer and a swelling layered silicate having quaternary ammonium ions introduced between the layers, and a gas barrier film using the same are disclosed (see Patent Document 3). ..
- a layered compound prepared by intercalating didecyldimethylammonium ion as a quaternary ammonium ion or hexadecyltrimethylammonium ion between layers is subjected to delamination under ultrasonic irradiation in a pentane solvent, Preparation of a release layer dispersion liquid is disclosed (see Non-Patent Document 1). Also, the layers are intercalated with hexadecyltrimethylammonium ion, and then the layers are silanized with (1-butyl-3-(3-triethoxysilylpropyl)-4,5-dihydroimidazolium chloride.
- Non-Patent Document 2 It has been disclosed that a delamination liquid having been delaminated and prepared is prepared (see Non-Patent Document 2). Further, the synthesis of ialite, which is a kind of layered compound, and the X-ray diffraction pattern of the synthesized ialite are disclosed (see Non-Patent Document 3).
- the present invention is intended to obtain a stable dispersion of a release layer substance by coating a release layer substance obtained by heating an aqueous medium of a layered compound containing a release agent with a specific anionic surfactant. It is what
- a dispersion liquid in which the plate-like particles (C) are dispersed in a liquid medium, and the average particle size of the plate-like particles (C) in the dispersion liquid by a dynamic light scattering method is 10 to 600 nm.
- the dispersion according to the first aspect wherein the plate-like particles (C) are a release layer substance obtained by delamination of the layered compound (D).
- the dispersion according to the second aspect wherein the layered compound (D) is ilaite.
- the dispersion according to any one of the first to fourth aspects wherein the Na ion concentration in the dispersion is 100 ppm or less.
- the dispersion according to any one of the first to fifth aspects wherein the concentration of the quaternary ammonium ion (A) in the dispersion is 10% by mass or less.
- the dispersion according to any one of the first to sixth aspects wherein the concentration of the anionic surfactant (B) having ammonium ions in the dispersion is 0.01 to 1% by mass.
- a coating composition containing the dispersion according to any one of the first to tenth aspects As a twelfth aspect, a coating film containing the plate-like particles (C) in the dispersion according to any one of the first to tenth aspects, As a thirteenth aspect, a transparent substrate having a coating film according to the twelfth aspect on a substrate and having a total light transmittance of 80% or more when the thickness of the coating film is 500 nm, As a fourteenth aspect, the following steps (a) to (e): Step (a): a step of producing an aqueous dispersion of the layered compound (D), Step (b): The total amount of carbon atoms in the aqueous dispersion obtained in Step (a) is 15 to 45, which is equal to to 3 times the ion exchange capacity of the layered compound (D).
- a method for producing a dispersion of a layered compound (D) according to the fourteenth aspect which is a step (a1) of performing an heat treatment to produce an aqueous dispersion having a concentration of the fine layered compound (D2) of 30% by mass or less.
- the fine layered compound (D2) has an average major axis of 250 to 750 nm, an average minor axis of 200 to 550 nm, and a ratio of the average minor axis to the average major axis of 1.0 to 2.0.
- the method for producing a dispersion liquid according to the fifteenth aspect wherein the pulverization of the layered compound (D) in the step (a1) is carried out by a dry method using a planetary ball mill.
- the dispersion according to any one of the fourteenth aspect to the eighteenth aspect which further comprises a step (f): a step of solvent-displacing the dispersion liquid obtained after the step (e) with an organic solvent.
- the dispersion according to any one of the first to tenth aspects is applied to a substrate and heated at 40 to 300° C. It is a method of manufacturing a substrate.
- a release agent (specific quaternary ammonium ion) is intercalated between layers of a layered compound so that the layers are expanded and swollen, and a release layer substance generated by delamination of the layered compound is treated with a specific anion.
- a surface treatment with a surfactant prevents the formation of layered compounds due to recombination of the release layer substance, and the release layer substance is sufficiently dispersed in the liquid medium without applying mechanical shearing force or impact force. Can be obtained.
- the shape change of the release layer substance hardly occurs, and the shape of the plate crystal is maintained.
- the dispersion can be obtained in this state. Then, without using a large device such as a shearing device, it is possible to produce a dispersion liquid with simple equipment by adding a stripping agent or an anionic surfactant and performing heat treatment.
- the dispersion liquid since it is possible to form a dispersion liquid having high dispersibility while maintaining the shape of the minute plate-like particles, the dispersion liquid is applied as a nanosheet liquid onto the substrate to form a coating film. By forming it, a transparent substrate having high transparency and low surface irregularities can be obtained. Further, in the present invention, since the plate-like particles are in the state where the minute plate-like particles maintain their shape, the particles are highly adherent to each other on the substrate coated with the dispersion liquid of the present invention, and the airtightness is It is possible to obtain a coating film with high quality. Therefore, when the dispersion of the present invention is applied onto a plastic or glass substrate to form a coating film, a gas barrier film having a high effect of blocking water vapor and gas can be formed.
- the present invention has a quaternary ammonium ion (A) having 15 to 45 total carbon atoms and 1 to 2 alkyl groups having 10 to 20 carbon atoms, and an anionic surfactant having ammonium ion ( B) and having an average thickness of 0.7 to 40 nm, or 0.7 to 20 nm, an average major axis of 100 to 600 nm, an average minor axis of 50 to 300 nm, and a ratio of the average minor axis to the average major axis of 1.0 to 10.
- A quaternary ammonium ion
- B anionic surfactant having ammonium ion
- the plate-like particles (C) are dispersed in a dispersion medium containing a liquid medium and a quaternary ammonium ion (A) and an anionic surfactant (B) having an ammonium ion, the above-mentioned (A). ) And (B) at least partly covered or adsorbed by one or both of them, or one or both of (A) and (B) are present between the plate-like particles (C). It may be any of the following states.
- the plate-like particles (C) are preferably particles having a Na ion concentration of 0.2% by mass or less.
- concentration of the plate-like particles (C) in the dispersion may be 30% by mass or less, or 0.01 to 30% by mass, 0.1 to 30% by mass.
- the average major axis and the average minor axis of the plate-like particles (C) can be measured by observation with a transmission electron microscope.
- the average thickness of the plate-like particles (C) can be measured by observing the coated surface when the dispersion liquid is coated on the substrate with an AFM (atomic force microscope).
- AFM atomic force microscope
- a sample in which a dispersion liquid having a plate-like particle concentration of 1% by mass or less is dropped on a mica substrate and dried can be used.
- the sample is preferably dried naturally, but may be heated.
- a sample applied to the substrate by the Langmuir-Blodgett method can be used for AFM measurement.
- the average particle size of the plate-like particles (C) can be measured as the average particle size of the plate-like particles (C) in the dispersion liquid by the dynamic light scattering method.
- the concentration of the dispersion liquid (concentration of plate-like particles) at the time of measurement can be 30% by mass or less.
- a release layer substance obtained by delamination of the layered compound (D) can be used.
- the layered compound (D) include layered polysilicate, clay mineral, manganate, titanate and niobate.
- clay minerals include smectite and vermiculite.
- the layered polysilicate include kanemite, macatite, kenyaite, islayite (Ilerite is also referred to as illite, illite, and illerite).
- islayite can be preferably used.
- Iarite has the chemical formula Na 2 O.8SiO 2 .nH 2 O, has a silicic acid skeleton on a plane, and has silanol groups between layers. Iraite does not exist in nature, so it is artificially synthesized.
- Islayite can be obtained by, for example, placing an aqueous solution (SiO 2 /Na 2 O molar ratio of 4.0, for example) in which colloidal silica and sodium hydroxide are mixed in a sealed container and performing a hydrothermal reaction at about 90 to 150° C. Can be synthesized.
- the layered compound (D) can be usually produced in a concentration range of 30% by mass or less.
- the Na ions in the dispersion liquid are Na ions released from the layered compound (interlayer) when the Na ions existing between layers of the layered compound (layered silicate) are ion-exchanged with the quaternary ammonium ion (A).
- a low concentration of Na ions is desirable in the dispersion to prevent re-layering of the release layer material.
- the Na ion concentration in the dispersion liquid can be 100 ppm or less, for example, 0.1 to 100 ppm, or 1 to 100 ppm.
- dimethyldioctadecyl ammonium can be preferably used.
- the counter ion of the ammonium ion include chlorine ion and bromine ion.
- the concentration of the quaternary ammonium ion (A) in the dispersion may be 10% by mass or less, or 0.001 to 10% by mass, or 0.01 to 1.00% by mass.
- the anionic surfactant (B) having an ammonium ion is a compound in which a hydrophilic group portion is composed of a pair of anion and ammonium ion among surfactants composed of a hydrophobic group and a hydrophilic group, and It is preferable to use a compound containing neither sodium ion nor potassium ion.
- the above-mentioned anionic surfactant (B) having an ammonium ion is preferably a compound containing a relatively long chain alkyl group having about 8 to 12 carbon atoms as a hydrophobic group, and also containing an aromatic ring. It is preferable that the compound is not present.
- anionic surfactant (B) having an ammonium ion examples include ammonium octanoate, ammonium decanoate, ammonium laurate, ammonium stearate, ammonium hexanesulfonate, ammonium octanesulfonate, ammonium decanesulfonate, and dodecanesulfone.
- examples thereof include ammonium acid salt, ammonium lauryl sulfate (ammonium dodecyl sulfate), ammonium myristyl sulfate, ammonium lauryl phosphate and ammonium tripolyphosphate.
- ammonium lauryl sulfate (ammonium dodecyl sulfate) can be preferably used.
- concentration of the ammonium ion-containing anionic surfactant (B) in the dispersion may be 0.01 to 1% by mass.
- the anionic surfactant (B) having an ammonium ion is essential.
- the anionic surfactant (B) having an ammonium ion is not added, or when an anionic surfactant having a sodium ion or an anionic surfactant having a potassium ion is used instead of the ammonium ion, A situation may occur in which the delamination does not proceed, or the delaminated release layer material easily forms a layered structure again, and thus the transparency of the dispersion liquid decreases (that is, the absorbance of the dispersion liquid does not decrease). ..
- organic solvent methanol, ethanol, isopropanol, butanol, diacetone alcohol, methyl cellosolve acetate, ethyl cellosolve acetate, propylene glycol, propylene glycol monomethyl ether, propylene glycol monoethyl ether, methyl isobutyl carbinol, propylene glycol monobutyl ether, propylene Glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, propylene glycol monopropyl ether acetate, propylene glycol monobutyl ether acetate, toluene, xylene, methyl ethyl ketone, cyclopentanone, cyclohexanone, ethyl 2-hydroxypropionate, 2-hydroxy-2- Ethyl methylpropionate, Ethyl ethoxyacetate, Ethyl hydroxyacetate, Methyl 2-hydroxy-3-
- R 1 is an acryloxy group, a methacryloxy group, an aryl group, an alkyl group, an alkenyl group, a glycidoxy group, or an alkyl group having 1 to 10 carbon atoms containing a functional group thereof, or an epoxy group, an acryloyl group, It contains an organic group having a methacryloyl group, a mercapto group, and a cyano group, and is bonded to a Si atom by a Si—C bond, and a represents an integer of 1 to 3.
- R 2 is a hydrolyzable group consisting of an alkoxy group, an aryloxy group, an acyloxy group, or a halogen group.
- At least one R 2 (hydrolyzable group) forms a MO—Si bond on the surface of the plate-like particle (C), and when the plate-like particle is derived from ialite, M is Si in the ilaite. Indicates an atom.
- the alkyl group is a linear or branched alkyl group having 1 to 10 carbon atoms, and examples thereof include methyl group, ethyl group, n-propyl group, i-propyl group, n-butyl group, i-butyl group, s-Butyl group, t-butyl group, n-pentyl group, 1-methyl-n-butyl group, 2-methyl-n-butyl group, 3-methyl-n-butyl group, 1,1-dimethyl-n- Propyl group, 1,2-dimethyl-n-propyl group, 2,2-dimethyl-n-propyl group, 1-ethyl-n-propyl group, n-hexyl group, 1-methyl-n-pentyl group, 2- Methyl-n-pentyl group, 3-methyl-n-pentyl group, 4-methyl-n-pentyl group, 1,1-dimethyl-n-butyl group, 1,2-d
- alkylene group examples include alkylene groups derived from the above alkyl groups.
- a methyl group is a methylene group
- an ethyl group is an ethylene group
- a propyl group is a propylene group.
- alkenyl group examples include alkenyl groups having 2 to 10 carbon atoms, such as an ethenyl group (vinyl group), 1-propenyl group, 2-propenyl group, 1-methyl-1-ethenyl group, 1-butenyl group, 2- Butenyl group, 3-butenyl group, 2-methyl-1-propenyl group, 2-methyl-2-propenyl group, 1-ethylethenyl group, 1-methyl-1-propenyl group, 1-methyl-2-propenyl group, 1 -Pentenyl group, 2-pentenyl group, 3-pentenyl group, 4-pentenyl group, 1-n-propylethenyl group, 1-methyl-1-butenyl group, 1-methyl-2-butenyl group, 1-methyl- 3-butenyl group, 2-ethyl-2-propenyl group, 2-methyl-1-butenyl group, 2-methyl-2-butenyl group, 2-methyl-3-butenyl group, 3-methyl-1-buten
- aryl group examples include aryl groups having 6 to 20 carbon atoms, such as phenyl group, o-methylphenyl group, m-methylphenyl group, p-methylphenyl group, o-chlorophenyl group, m-chlorophenyl group, p -Chlorophenyl group, o-fluorophenyl group, p-mercaptophenyl group, o-methoxyphenyl group, p-methoxyphenyl group, p-aminophenyl group, p-cyanophenyl group, ⁇ -naphthyl group, ⁇ -naphthyl group, o-biphenylyl group, m-biphenylyl group, p-biphenylyl group, 1-anthryl group, 2-anthryl group, 9-anthryl group, 1-phenanthryl group, 2-phenanthryl group, 3-phenanthryl group, 4-phenan
- Examples of the organic group having an epoxy group include a glycidoxymethyl group, a glycidoxyethyl group, a glycidoxypropyl group, a glycidoxybutyl group, and an epoxycyclohexyl group.
- Examples of the organic group having an acryloyl group include an acryloylmethyl group, an acryloylethyl group, and an acryloylpropyl group.
- Examples of the organic group having a methacryloyl group include a methacryloylmethyl group, a methacryloylethyl group, and a methacryloylpropyl group.
- Examples of the organic group having a mercapto group include an ethylmercapto group, a butylmercapto group, a hexylmercapto group and an octylmercapto group.
- Examples of the organic group having a cyano group include a cyanoethyl group and a cyanopropyl group.
- alkoxy group examples include an alkoxy group having 1 to 10 carbon atoms, that is, an alkoxy group having a linear, branched, or cyclic alkyl moiety having 1 to 10 carbon atoms, such as a methoxy group, an ethoxy group, and n-propoxy group.
- Examples of the aryloxy group include a phenoxy group, a benzyloxy group, a phenethyloxy group and the like.
- Examples of the acyloxy group include an acyloxy group having 2 to 20 carbon atoms, and examples thereof include a methylcarbonyloxy group (acetoxy group), an ethylcarbonyloxy group, an n-propylcarbonyloxy group, an i-propylcarbonyloxy group, n-butyl.
- Fluorine, chlorine, bromine, iodine and the like can be mentioned as the halogen group.
- the silicon-containing compound represented by the formula (1) is, for example, tetramethoxysilane, tetrachlorosilane, tetraacetoxysilane, tetraethoxysilane, tetra n-propoxysilane, tetraisopropoxysilane, tetra n-butoxysilane, tetraacetoxysilane.
- Methoxysilane phenylenebistrimethoxysilane, phenylenebistriethoxysilane, phenylenebismethyldiethoxysilane, phenylenebismethyldimethoxysilane, naphthylenebistrimethoxysilane, bistrimethoxydisilane, bistriethoxydisilane, bisethyldiethoxydisilane, bismethyldimethoxydisilane , Hexamethyldisilane, hexamethyldisilazane, hexamethyldisiloxane, and the like.
- a metal chelate compound In addition to nitric acid, a metal chelate compound, an organic acid, an inorganic acid, an organic base, or an inorganic base can be used in combination.
- the hydrolysis catalyst can be used in an amount of 0.001 to 10 mol, preferably 0.001 to 1 mol, per 1 mol of the hydrolyzable group.
- the reaction temperature during the hydrolysis and condensation is usually 20 to 80°C.
- the hydrolysis may be complete hydrolysis or partial hydrolysis. That is, the silane compound, which is a hydrolyzate or a monomer, may remain in the hydrolyzed condensate.
- a substrate which is usually used is exemplified, and examples thereof include plastic, glass, ceramics, silicon wafer, wood, paper and the like.
- the ratio of the solid content in the coating composition can be in the range of, for example, 0.1 to 30% by mass.
- the solid content refers to all components of the coating composition excluding the liquid medium (water, organic solvent, etc.).
- the coating composition can be applied to the substrate by a spin coating method, a dipping method, a screen coating method, or a roll coating method.
- the rotation speed is set to, for example, 700 to 2000 rpm, and the coating is performed for 5 to 50 seconds.
- the solvent can be removed under normal pressure or reduced pressure. At that time, it is possible to heat according to the material of the base material if necessary. It is possible to heat plastic, wood, paper, etc. within the range of 40 to 100°C.
- the solvent can be optionally removed by heating in the range of 40 to 300°C.
- the viscosity of the coating composition can be set in the range of 1 to 1,000 mPa ⁇ s, or 1 to 100 mPa ⁇ s.
- the coating film formed on the substrate by the coating composition containing the dispersoid (plate-like particles (C)) in the dispersion has a film thickness of 1 nm to 10 ⁇ m, or 5 nm to 1000 nm, or 5 nm to 600 nm, or 5 It can be set in the range of up to 500 nm.
- the coating film formed on the substrate has high transparency, and for example, a transparent substrate having a total light transmittance of 80% or more, usually 90% or more when the coating film has a film thickness of 500 nm can be obtained.
- a transparent substrate having a total light transmittance of 80% or more, usually 90% or more when the coating film has a film thickness of 500 nm can be obtained.
- the coating composition of the present invention for example, when the total light transmittance of the substrate before forming the coating film is 100, the reduction rate of the total light transmittance of the substrate after forming the coating film is less than 20%. , And even less than 10%.
- the above coating film can be used as a gas barrier film. That is, it is possible to provide a gas barrier film including the coating film.
- the gas barrier film is a film capable of blocking harmful gas to the substrate, such as water vapor, active oxygen, sulfur-containing gas and the like.
- a gas barrier film in which the barrier gas is water vapor can be formed.
- the present invention is also directed to a method for producing the above-mentioned dispersion liquid, which includes the following steps (a) to (e).
- Step (a) a step of producing an aqueous dispersion of the layered compound (D)
- Step (b) The total amount of carbon atoms in the aqueous dispersion obtained in Step (a) is 15 to 45, which is equal to to 3 times the ion exchange capacity of the layered compound (D).
- the above step (a) will be described by exemplifying islaite as the layered compound (D) used here.
- Iraite is a layered compound that does not exist in nature, and can be synthesized, for example, by subjecting a silicic acid compound aqueous solution to a hydrothermal reaction at 90 to 150°C.
- the silicic acid compound include silicates such as sodium silicate and potassium silicate.
- the above-mentioned aqueous solution of silicic acid is sodium silicate having a SiO 2 /M 2 O molar ratio of 3.5 to 4.0 (where M is Na and K) and a silicic acid compound concentration of about 10 to 30 mass %.
- Aqueous solutions are preferred.
- the hydrothermal conditions are preferably 90 to 150° C., particularly preferably 90 to 130° C., and the isolaite can be synthesized by static heating for 1 day to 24 days, or 1 day to 12 days.
- the layered compound (D1) pulverized by pulverization of the layered compound (D) is added as seed particles to the silicate aqueous solution, and hydrothermal treatment is performed at 90 to 130° C. for 6 to 72 hours.
- the step (a1) of producing an aqueous dispersion having a concentration of the fine layered compound (D2) of 30% by mass or less can be performed.
- step (a1) unreacted sodium silicate is removed from the hydrothermal reaction medium, and the fine layered compound (D2) powder dried at 40° C. is dissolved in a concentration of 30% by mass or less. Can be used as an aqueous dispersion of the layered compound (D) in step (a).
- the particle size of the (fine) layered compound (particularly ilaite) (D2) obtained by adding a seed crystal (seed particles) to a hydrothermal reaction has an average major axis of 250 to 750 nm, an average minor axis of 200 to 550 nm, and an average minor axis. And the ratio of the average major axis is 1.0 to 2.0.
- the average major axis and the average minor axis can be measured by observation with a transmission electron microscope.
- the average particle diameter by the dynamic light scattering method (D2) can be 100 nm to 600 nm, and preferably 200 to 400 nm.
- the layered compound (D) (particularly islaite) used for seed crystals (seed particles) is obtained by seeding the layered compound (D), which is an unpulverized or pulverized layer, in the silicate aqueous solution or the silicate aqueous solution. It can be obtained by a hydrothermal reaction by allowing the suspension added as particles) to stand at 90 to 150° C., particularly 90 to 130° C. for 1 day to 24 days, and particularly 110° C. for 1 day to 12 days.
- the seed crystal added to the silicate aqueous solution when the layered compound (D) used for the seed crystal (seed particles) is not limited in particle size, and is 0.1 to 10% by mass with respect to the silicate. Alternatively, it is preferably added in the range of 0.1 to 5% by mass, or 0.1 to 2% by mass.
- Pulverization is performed using, for example, a planetary ball mill pulverizer.
- the planetary ball mill can grind a container containing hard balls (for example, zirconia balls) and islayite by rotating and revolving.
- This planetary ball mill crushing can be carried out in two stages, and by performing preliminary crushing first and then further finely crushing, it is possible to obtain an ilaite (D1) as a seed crystal.
- the pulverization may be wet or dry, but dry pulverization is preferred.
- an Iraite obtained separately can be used, or a part of the previous batch can be added, or batches can be continuously produced by using the one remaining in the reaction vessel.
- the total amount of carbon is added to the aqueous dispersion of the layered compound (D) obtained in the step (a) in an amount of 1 to 3 times the ion exchange capacity of the layered compound (D).
- the anionic surfactant (B) having ammonium ion can be applied under ultrasonic irradiation in order to sufficiently coat the ilaite surface.
- Step (e) is a step of heating the liquid obtained in step (d) at 40 to 90° C. for 12 to 48 hours.
- step (f) a step of solvent-displacing the aqueous dispersion obtained after the step (e) with an organic solvent can be included.
- a dispersion liquid (sol) in which the plate-like particles delaminated from the ilaite are dispersed in the organic solvent is obtained.
- the thus-obtained dispersion liquid of the present invention has high dispersibility, and for example, has dispersion stability such that precipitation does not occur even after 6 months at room temperature.
- the above dispersion liquid can be used in a coating composition.
- the pH of the composition can be adjusted to 7 to 12, or 7 to 11, or 9 to 12, or 9 to 11.
- the coated article to which the coating composition of the present invention is applied includes a display, an LCD surface, an optical lens, a spectacle lens, a solar cell surface base material, a mobile phone, an organic EL issuing member, an illumination lamp, a building window glass, and the like.
- Examples thereof include agricultural films and transparent members for vehicles.
- Average minor axis, average major axis Transmission electron microscope JEM-1010 manufactured by JEOL Ltd. was used to measure 200 particles with an image analyzer.
- Substrate transmittance The total light transmittance of the substrate was measured using a haze meter NDH 5000 manufactured by Nippon Denshoku Industries Co., Ltd.
- Average thickness AFM (atomic force microscope), manufactured by Shimadzu Corporation, trade name SPM-9500J3 was used to measure in contact mode.
- the particle diameter by the light scattering method was 41 nm, and the crystallinity was 10.6%).
- 0.32 g of the obtained crushed particles of Iraite were added to 50 ml of No. 4 water glass as seed crystals (seed particles), which was enclosed in a closed container made of SUS304 and heated at 110° C. for 12 hours for static heating.
- Iraite nanoparticles having a number-based median diameter of light scattering diameter of 250 nm were obtained.
- the obtained Iraite had a long diameter of 456 nm, a short diameter of 396 nm, and a ratio of the short diameter to the long diameter of 1.2.
- a transmission electron micrograph of the obtained Iraite is shown in FIG. 1 (magnification: 100,000 times). It was confirmed by XRD that the product was ilaite (PDF card No. 00-048-0655).
- Example 1 Production of nanosheet dispersion and production of transparent substrate
- 0.3 g of the ilaitoite nanoparticles obtained in Synthesis Example 1 and 0.73 g of dimethyldioctadecyl ammonium chloride were added to 30 g of water, and the mixture was allowed to stand at 80° C. for 20 hours to heat the silicate layers between the ilaito silicate layers.
- the sodium ions were replaced with dimethyldioctadecyl ammonium ions (dimethyl dioctadecyl ammonium ion concentration 2.2 mass%).
- ion-exchanged ilaite powder was obtained (Na ion concentration in the ion-exchanged ilaite powder was 605 ppm). Ion-exchanged Iraite powder 0.03 g was added to 0.5% by mass of dodecyl ammonium sulfate solution to make 30 g (the absorbance of the solution at this time was 0.1% by mass of ion-exchanged Iraite, optical path length 1 cm, It was 2.334 at a wavelength of 620 nm).
- Aqueous ammonia was added thereto to adjust the pH to 9 or more (the absorbance of the solution at this time was 0.120 at a concentration of ion-exchanged ilaite of 0.1% by mass, an optical path length of 1 cm, and a wavelength of 620 nm).
- the solution obtained here was statically heated at 60° C. for 24 hours to obtain a colloidal solution of nanosheets (plate-like particles) in which isolaite nanoparticles were delaminated (Na concentration in the dispersion at this time).
- the obtained plate-like particles have an average major axis of 302 nm, an average minor axis of 233 nm, a ratio of the average minor axis to the average major axis of 1.3, an average particle diameter by dynamic light scattering method of 34.3 nm, and an average thickness of 1.
- the absorbance of the obtained dispersion was 0.007 at a concentration of ion-exchanged ilaite of 0.1% by mass, an optical path length of 1 cm, and a wavelength of 620 nm.
- FIG. 2 A transmission electron micrograph of the obtained plate-like particles is shown in FIG. 2 (magnification: 100,000 times).
- the dispersion liquid was applied onto a PET (polyethylene terephthalate) substrate and dried at 100° C. to form a coating film, thereby forming a transparent substrate.
- the thickness of the obtained transparent substrate was 600 nm, and the total light transmittance was 92.8%.
- Example 1 The same operation as in Example 1 was carried out except that ammonium dodecyl sulfate was not added.
- the absorbance of the finally obtained dispersion was 1.602 at a concentration of ion-exchanged islayite of 0.1% by mass, an optical path length of 1 cm, and a wavelength of 620 nm.
- Example 2 The same operation as in Example 1 was performed except that the same amount of sodium dodecyl sulfate was added in place of ammonium dodecyl sulfate in Example 1.
- the absorbance of the finally obtained dispersion liquid was 0.020 at a concentration of ion-exchanged islayite of 0.1% by mass, an optical path length of 1 cm, and a wavelength of 620 nm.
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Abstract
Description
例えば、層間に第4級アンモニウム化合物をインターカレーションした層状構造を有する有機変性粘土鉱物の凝集体とシリコーンオイルとの混合物に、機械的せん断力及び/又は衝撃力を加えて、前記有機変性粘土鉱物の凝集体を剥離処理し、層状物質(板状粒子構造を有する有機変性粘土鉱物)がシリコーンオイルに分散させた油性ゾルが開示されている(特許文献1参照)。
またシリカ系多孔質膜と、シリカ系多孔質膜の表面を被覆する防汚層とを備え、防汚層が無機層状化合物に由来する複数のナノシートを有する防汚性反射防止膜が開示されている(特許文献2参照)。
さらに、ビニルアルコール系重合体と、層間に第4級アンモニウムイオンが導入された膨潤性層状珪酸塩からなる樹脂組成物、及びそれらを用いたガスバリア性フィルムが開示されている(特許文献3参照)。
また、層間に、第4級アンモニウムイオンとしてジデシルジメチルアンモニウムイオンや、ヘキサデシルトリメチルアンモニウムイオンでインターカレーションを行って作成した層状化合物を、ペンタン溶剤中で超音波照射下に層間剥離を行う、剥離層分散液の作成が開示されている(非特許文献1参照)。
また、層間を、ヘキサデシルトリメチルアンモニウムイオンでインターカレーションを行って、その後に層間を(1-ブチル-3-(3-トリエトキシシリルプロピル)-4、5-ジヒドロイミダゾリウムクロライドでシラン処理を行い、層間剥離した剥離層分散液の作成が開示されている(非特許文献2参照)。
また、層状化合物の一種であるアイアライトの合成と、合成されたアイアライトのX線回折パターンについて開示されている(非特許文献3参照)。
第2観点として、板状粒子(C)が、層状化合物(D)の層間剥離による剥離層物質である、第1観点に記載の分散液、
第3観点として、層状化合物(D)が、アイラアイトである第2観点に記載の分散液、
第4観点として、板状粒子(C)が、0.2質量%以下のNaイオン濃度を有する、第1観点乃至第3観点のいずれか一つに記載の分散液、
第5観点として、分散液中のNaイオン濃度が100ppm以下である、第1観点乃至第4観点のいずれか一つに記載の分散液、
第6観点として、分散液中の第4級アンモニウムイオン(A)の濃度が、10質量%以下である、第1観点乃至第5観点のいずれか一つに記載の分散液、
第7観点として、分散液中のアンモニウムイオンを有する陰イオン界面活性剤(B)の濃度が0.01~1質量%である、第1観点乃至第6観点のいずれか一つに記載の分散液、
第8観点として、アンモニウムイオンを有する陰イオン界面活性剤(B)が、ドデシル硫酸アンモニウムである、第1観点乃至第7観点のいずれか一つに記載の分散液、
第9観点として、分散液中の板状粒子(C)の濃度が30質量%以下である、第1観点乃至第8観点のいずれか一つに記載の分散液、
第10観点として、分散液が、板状粒子(C)の濃度が0.1質量%、光路長1cm、波長620nmにおいて、0.015以下の吸光度を有する、第1観点乃至第9観点のいずれか一つに記載の分散液、
第11観点として、第1観点乃至第10観点のいずれか一つに記載の分散液を含む塗布用組成物、
第12観点として、第1観点乃至第10観点のいずれか一つに記載の分散液中の板状粒子(C)を含む塗布膜、
第13観点として、基板上に第12観点に記載の塗布膜を有し、該塗布膜の膜厚が500nmである時の全光線透過率が80%以上である、透明基板、
第14観点として、下記(a)工程乃至(e)工程:
(a)工程:層状化合物(D)の水性分散液を製造する工程、
(b)工程:(a)工程で得られた水性分散液に、層状化合物(D)のイオン交換容量の等倍~三倍量となる、総炭素原子数15~45であり、且つ、炭素原子数10~20のアルキル基を1~2個有する第4級アンモニウムイオン(A)を添加し、40~90℃で、12~48時間の加熱をする工程、
(c)工程:(b)工程で得られた液に純水を加え、液中のナトリウムイオン濃度が100ppm以下になるように、ナトリウムイオン含有液を系外に取り除く工程、
(d)工程:(c)工程で得られた液を乾燥させた乾燥粉を、濃度が0.01~1質量%のアンモニウムイオンを有する陰イオン界面活性剤(B)水溶液中に分散させた後、さらに、アンモニアを添加して液中のpHを9.0~12.0に調整する工程、
(e)工程:(d)工程で得られた液を、40~90℃で、12~48時間の加熱を行い、分散液を得る工程、を含む第1観点乃至第10観点のいずれか一つに記載の分散液の製造方法、
第15観点として、(a)工程が、層状化合物(D)の粉砕によって粉砕された層状化合物(D1)を種粒子として珪酸塩水溶液に添加し、90~130℃で、6~72時間の水熱処理を行い、微細な層状化合物(D2)の濃度30質量%以下の水性分散液を製造する(a1)工程である、第14観点に記載の層状化合物(D)の分散液の製造方法、
第16観点として、粉砕された層状化合物(D1)が、30~60nmの動的光散乱法による粒子径を有し、〔(2θ=6.9~8.4°までの回折ピークの積分強度の総和)/(2θ=5~40°までの回折ピークの積分強度の総和)〕×100で示される粉末X線回折による結晶化度が5~15%である、第15観点に記載の製造方法、
第17観点として、微細な層状化合物(D2)が、平均長径250~750nm、平均短径200~550nm、平均短径と平均長径の比が1.0~2.0である、第15観点に記載の製造方法、
第18観点として、(a1)工程の層状化合物(D)の粉砕が遊星ボールミルを用い、乾式で行われる、第15観点に記載の分散液の製造方法、
第19観点として、(f)工程:(e)工程の後に得られた分散液を有機溶媒で溶媒置換する工程をさらに含む、第14観点乃至第18観点のうちいずれか一つに記載の分散液の製造方法、及び
第20観点として、第1観点乃至第10観点のいずれか一つに記載の分散液を、基板に塗布し、40~300℃で加熱する、第13観点に記載の透明基板の製造方法である。
また本発明にあっては、層状化合物の層間剥離時に機械的せん断力や超音波照射による衝撃力等の外力が加わらないため、剥離層物質の形状変化が生じ難く、板状結晶の形状を維持した状態で分散液を得ることができる。
そして、せん断装置などの大きな装置を用いずとも、剥離剤や陰イオン界面活性剤を加えて加熱処理することで、簡単な設備で分散液を製造することが可能である。
本発明の分散液は微小な板状粒子が分散質となった分散液であり、高い分散性を維持しているため、分散液の透明性が高い。
また本発明において、上記板状粒子は、微小な板状粒子がその形状を維持した状態であるため、本発明の分散液を塗布した基材上において該粒子同士の密着性が高く、気密性の高い塗布膜が得られる。従って、本発明の分散液をプラスチックやガラス基板上に塗布し塗布膜を形成した場合に、水蒸気やガスを遮断する効果が高いガスバリア膜を形成することができる。
上記分散液において、板状粒子(C)は、液状媒体と第4級アンモニウムイオン(A)とアンモニウムイオンを有する陰イオン界面活性剤(B)を含有する分散媒に分散した状態、前記(A)及び(B)の一方又は双方により少なくともその一部が被覆された或いは吸着してなる状態、板状粒子(C)同士の間に前記(A)及び(B)の一方又は双方が介在してなる状態のいずれの状態であってよい。
また前記分散液中での板状粒子(C)の濃度は、30質量%以下、又は0.01~30質量%、0.1~30質量%とすることができる。
また前記板状粒子(C)の平均厚さは、分散液を基板上に塗布した時の塗布面をAFM(原子間力顕微鏡)で観察することにより測定できる。AFMでの観察には、板状粒子の濃度が1質量%以下の分散液をマイカ基板上に滴下し乾燥させた試料を用いることができる。試料の乾燥は自然乾燥が好ましいが、加熱してもよい。その他、ラングミュア・ブロジェット法を用いて基板に塗布した試料をAFMの測定に用いることもできる。
さらに板状粒子(C)の平均粒子径は、分散液中の板状粒子(C)の動的光散乱法による平均粒子径として測定することができる。このとき、測定する際の分散液の濃度(板状粒子の濃度)は、30質量%以下とすることができる。
これら層状化合物(D)の中でも、アイラアイトを好ましく用いることができる。アイアライトは化学式Na2O・8SiO2・nH2Oを有し、平面上ケイ酸骨格を持ち、層間にシラノール基を有する。アイラアイトは天然には存在しないため、人工的に合成する。アイラアイトは、例えばコロイダルシリカと水酸化ナトリウムとを混合した水溶液(SiO2/Na2Oモル比は例えば4.0)を密封容器に入れ、90~150℃程度の水熱反応を行うことにより、合成することができる。
層状化合物(D)は通常、濃度30質量%以下の濃度範囲で製造することができる。
このような第4級アンモニウムイオン(A)としては、例えば、ヘキサデシルトリメチルアンモニウムイオン、ジデシルジメチルアンモニウムイオン、ジメチルジオクタデシルアンモニウム等が挙げられる。特に、ジメチルジオクタデシルアンモニウムを好適に用いることができる。該アンモニウムイオンの対イオンとしては、塩素イオンや臭素イオンが挙げられる。
上記第4級アンモニウムイオン(A)の分散液中の濃度は、10質量%以下、又は0.001~10質量%、又は0.01~1.00質量%とすることができる。
上記アンモニウムイオンを有する陰イオン界面活性剤(B)としては、例えばオクタン酸アンモニウム、デカン酸アンモニウム、ラウリン酸アンモニウム、ステアリン酸アンモニウム、ヘキサンスルホン酸アンモニウム、オクタンスルホン酸アンモニウム、デカンスルホン酸アンモニウム、ドデカンスルホン酸アンモニウム、ラウリル硫酸アンモニウム(ドデシル硫酸アンモニウム)、ミリスチル硫酸アンモニウム、ラウリルリン酸アンモニウム、トリポリリン酸アンモニウム等が挙げられる。中でもラウリル硫酸アンモニウム(ドデシル硫酸アンモニウム)を好ましく用いることができる。
上記アンモニウムイオンを有する陰イオン界面活性剤(B)の分散液中の濃度は、0.01~1質量%とすることができる。
上記有機溶媒としてはメタノール、エタノール、イソプロパノール、ブタノール、ジアセトンアルコール、メチルセロソルブアセテート、エチルセロソルブアセテート、プロピレングリコール、プロピレングリコールモノメチルエーテル、プロピレングリコールモノエチルエーテル、メチルイソブチルカルビノール、プロピレングリコールモノブチルエーテル、プロピレングリコールモノメチルエーテルアセテート、プロピレングリコールモノエチルエーテルアセテート、プロピレングリコールモノプロピルエーテルアセテート、プロピレングリコールモノブチルエーテルアセテート、トルエン、キシレン、メチルエチルケトン、シクロペンタノン、シクロヘキサノン、2-ヒドロキシプロピオン酸エチル、2-ヒドロキシ-2-メチルプロピオン酸エチル、エトキシ酢酸エチル、ヒドロキシ酢酸エチル、2-ヒドロキシ-3-メチルブタン酸メチル、3-メトキシプロピオン酸メチル、3-メトキシプロピオン酸エチル、3-エトキシプロピオン酸エチル、3-エトキシプロピオン酸メチル、ピルビン酸メチル、ピルビン酸エチル、エチレングリコールモノメチルエーテル、エチレングリコールモノエチルエーテル、エチレングリコールモノプロピルエーテル、エチレングリコールモノブチルエーテル、エチレングリコールモノメチルエーテルアセテート、エチレングリコールモノエチルエーテルアセテート、エチレングリコールモノプロピルエーテルアセテート、エチレングリコールモノブチルエーテルアセテート、ジエチレングリコールジメチルエーテル、ジエチレングリコールジエチルエーテル、ジエチレングリコールジプロピルエーテル、ジエチレングリコールジブチルエーテルプロピレングリコールモノメチルエーテル、プロピレングリコールジメチルエーテル、プロピレングリコールジエチルエーテル、プロピレングリコールジプロピルエーテル、プロピレングリコールジブチルエーテル、乳酸エチル、乳酸プロピル、乳酸イソプロピル、乳酸ブチル、乳酸イソブチル、ギ酸メチル、ギ酸エチル、ギ酸プロピル、ギ酸イソプロピル、ギ酸ブチル、ギ酸イソブチル、ギ酸アミル、ギ酸イソアミル、酢酸メチル、酢酸エチル、酢酸アミル、酢酸イソアミル、酢酸ヘキシル、プロピオン酸メチル、プロピオン酸エチル、プロピオン酸プロピル、プロピオン酸イソプロピル、プロピオン酸ブチル、プロピオン酸イソブチル、酪酸メチル、酪酸エチル、酪酸プロピル、酪酸イソプロピル、酪酸ブチル、酪酸イソブチル、3-メトキシ-2-メチルプロピオン酸メチル、2-ヒドロキシ-3-メチル酪酸メチル、メトキシ酢酸エチル、3-メトキシブチルアセテート、3-メトキシプロピルアセテート、3-メチル-3-メトキシブチルアセテート、3-メチル-3-メトキシブチルプロピオネート、3-メチル-3-メトキシブチルブチレート、アセト酢酸メチル、メチルプロピルケトン、メチルブチルケトン、2-ヘプタノン、3-ヘプタノン、4-ヘプタノン、N、N-ジメチルホルムアミド、N-メチルアセトアミド、N,N-ジメチルアセトアミド、N-メチル-2-ピロリドン、4-メチル-2-ペンタノール、及びγ-ブチロラクトン等を挙げることができる。これらの溶媒は単独で、または二種以上の組み合わせで使用することができる。
R2はアルコキシ基、アリールオキシ基、アシルオキシ基、又はハロゲン基からなる加水分解性基である。少なくとも1つのR2(加水分解性基)は、板状粒子(C)の表面でM-O-Siの結合を形成し、板状粒子がアイアライト由来である場合、Mはアイラアイト中のSi原子を示す。
アリーレン基としては、上記アリール基に由来するアリーレン基を挙げることができる。
アシルオキシ基としては例えば炭素原子数2~20のアシルオキシ基が挙げられ、例えばメチルカルボニルオキシ基(アセトキシ基)、エチルカルボニルオキシ基、n-プロピルカルボニルオキシ基、i-プロピルカルボニルオキシ基、n-ブチルカルボニルオキシ基、i-ブチルカルボニルオキシ基、s-ブチルカルボニルオキシ基、t-ブチルカルボニルオキシ基、n-ペンチルカルボニルオキシ基、1-メチル-n-ブチルカルボニルオキシ基、2-メチル-n-ブチルカルボニルオキシ基、3-メチル-n-ブチルカルボニルオキシ基、1,1-ジメチル-n-プロピルカルボニルオキシ基、1,2-ジメチル-n-プロピルカルボニルオキシ基、2,2-ジメチル-n-プロピルカルボニルオキシ基、1-エチル-n-プロピルカルボニルオキシ基、n-ヘキシルカルボニルオキシ基、1-メチル-n-ペンチルカルボニルオキシ基、2-メチル-n-ペンチルカルボニルオキシ基、3-メチル-n-ペンチルカルボニルオキシ基、4-メチル-n-ペンチルカルボニルオキシ基、1,1-ジメチル-n-ブチルカルボニルオキシ基、1,2-ジメチル-n-ブチルカルボニルオキシ基、1,3-ジメチル-n-ブチルカルボニルオキシ基、2,2-ジメチル-n-ブチルカルボニルオキシ基、2,3-ジメチル-n-ブチルカルボニルオキシ基、3,3-ジメチル-n-ブチルカルボニルオキシ基、1-エチル-n-ブチルカルボニルオキシ基、2-エチル-n-ブチルカルボニルオキシ基、1,1,2-トリメチル-n-プロピルカルボニルオキシ基、1,2,2-トリメチル-n-プロピルカルボニルオキシ基、1-エチル-1-メチル-n-プロピルカルボニルオキシ基、1-エチル-2-メチル-n-プロピルカルボニルオキシ基、フェニルカルボニルオキシ基、及びトシルカルボニルオキシ基等が挙げられる。
また、加水分解し縮合させる際に触媒を用いることができ、こうした加水分解触媒としては硝酸が用いられる。また硝酸に加えて金属キレート化合物、有機酸、無機酸、有機塩基、又は無機塩基を併用することができる。加水分解触媒は、加水分解性基の1モル当たり、0.001~10モル、好ましくは0.001~1モルの量にて用いることができる。
加水分解と縮合を行う際の反応温度は、通常20~80℃である。
加水分解は完全に加水分解を行うことも、部分加水分解することでもよい。即ち、加水分解縮合物中に加水分解物やモノマーである上記シラン化合物が残存していてもよい。
前記塗布用組成物はスピンコート法、ディッピング法、スクリーンコート法、ロールコート法により基材に塗布することが可能である。スピンコートする場合、回転数を例えば700~2000rpmに設定し、5~50秒間行われる。
前記塗布用組成物を基材に塗布後、常圧下、又は減圧下に溶媒を除去することができる。その時、必要に応じて基材の材質に合わせて加熱することが可能である。プラスチック、木材、紙等であれば、40~100℃の範囲で加熱することが可能であり。ガラス、セラミックス、シリコンウエハ等であれば、40~300℃の範囲で加熱し、任意に溶媒を除去することができる。
本発明の塗布用組成物を用いることで、例えば塗布膜を形成する前の基板の全光透過率が100としたとき、塗布膜形成後の基板の全光透過率の低下率を20%未満、さらには10%未満とすることができる。
(a)工程:層状化合物(D)の水性分散液を製造する工程、
(b)工程:(a)工程で得られた水性分散液に、層状化合物(D)のイオン交換容量の等倍~三倍量となる、総炭素原子数15~45であり、且つ、炭素原子数10~20のアルキル基を1~2個有する第4級アンモニウムイオン(A)を添加し、40~90℃で、12~48時間の加熱をする工程、
(c)工程:(b)工程で得られた液に純水を加え、液中のナトリウムイオン濃度が100ppm以下になるように、ナトリウムイオン含有液を系外に取り除く工程、
(d)工程:(c)工程で得られた液を乾燥させた乾燥粉を、濃度が0.01~1質量%のアンモニウムイオンを有する陰イオン界面活性剤(B)水溶液中に分散させた後、さらに、アンモニアを添加して液中のpHを9.0~12.0に調整する工程、
(e)工程:(d)工程で得られた液を、40~90℃で、12~48時間の加熱を行い、分散液を得る工程。
微細なアイラアイトは、アイラアイト自体を微細な種晶(種粒子)として、ケイ酸ナトリウム水溶液中に添加することによって合成することができる。
また上記(D2)の動的光散乱法による平均粒子径は、100nm~600nmとすることができ、好ましくは200~400nmとすることができる。
動的光散乱法:スペクトリス株式会社製 商品名ゼータサイザーナノSで測定した。
結晶化度:株式会社島津製作所製 粉末X線回折装置 XRD-6100で測定した値を用い、(2θ=6.9~8.4°までの回折ピークの積分強度の総和)/(2θ=5~40°までの回折ピークの積分強度の総和)〕×100より結晶化度を算出した。
吸光度:株式会社島津製作所製 紫外可視近赤外分光光度計 商品名UV-3600Plusで測定した。
透過型電子顕微鏡:日本電子株式会社製 商品名JEM-1010を使用した。
平均短径、平均長径:透過型電子顕微鏡 日本電子株式会社製 JEM-1010を用い、粒子200個を画像解析装置で測定した。
基板の透過率:日本電色工業株式会社製 ヘーズメーター 商品名NDH 5000を用い基板の全光線透過率を測定した。
平均厚さ:AFM(原子間力顕微鏡)、(株)島津製作所製、商品名SPM-9500J3を使用してコンタクトモードで測定した。カンチレバー(探針)はオリンパス(株)製の窒化シリコン(商品名:OMCL-TR800PSA-1)を使用した。
4号水ガラス(日本化学工業(株)製、SiO2:Na2O:H2Oモル比は3.9:1:39.0、SiO2濃度は23.44質量%、Na2O濃度は6.29質量%)50mlをステンレス鋼(SUS304)製密閉容器に封入し、110℃で12日間静置加熱してアイラアイトを水熱合成した。尚、生成物がアイラアイトであることはXRDにて確認した(PDFカードNo.00-048-0655)。
得られたアイラアイト2gを、遊星ボールミル(フリッチュ社製、商品名P-7型)の窒化ケイ素製容器(容量45ml)に直径5mmのジルコニア製粉砕ボール73gとともに装入し、回転速度220rpmで1時間の乾式粉砕を空気雰囲気で行った。続いて、直径5mmの粉砕ボールを直径3mmのジルコニア製粉砕ボール73gと入れ替えた後、回転速度を300rpmに変更して1時間の乾式粉砕を空気雰囲気で行った(このときの粉砕粒子の動的光散乱法による粒子径は41nm、結晶化度は10.6%であった)。
得られたアイラアイトの粉砕粒子0.32gを種晶(種粒子)として4号水ガラス50mlに添加し、これをSUS304製の密閉容器に封入して110℃で12時間静置加熱し、動的光散乱径の個数基準中位径が250nmのアイラアイトのナノ粒子が得られた。得られたアイラアイトは長径が456nm、短径が396nm、短径と長径の比が1.2であった。得られたアイラアイトの透過型電子顕微鏡写真を図1に示す(倍率10万倍)。尚、生成物がアイラアイトであることはXRDにて確認した(PDFカードNo.00-048-0655)。
合成例1で得られたアイラアイトナノ粒子0.3gと、ジメチルジオクタデシルアンモニウムクロリド0.73gを水30gに添加し、80℃で20時間の静置加熱をすることで、アイラアイトのシリケート層間のナトリウムイオンをジメチルジオクタデシルアンモニウムイオンで置換した(ジメチルジオクタデシルアンモニウムイオン濃度2.2質量%)。Naイオンを限外濾過により系外に除いた後、80℃で乾燥させることで、イオン交換したアイラアイト粉末を得た(イオン交換したアイラアイト粉末中のNaイオン濃度は605ppmであった)。
イオン交換したアイラアイト粉末0.03gを0.5質量%のドデシル硫酸アンモニウム溶液に加え30gとした(なお、このときの液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、2.334であった)。これにアンモニア水を加えてpHを9以上とした(このときの液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、0.120であった)。ここで得られた溶液を60℃で24時間の静置加熱することで、アイラアイトのナノ粒子が層剥離したナノシート(板状粒子)のコロイド溶液を得た(このときの分散液中のNa濃度は0.6ppm、ドデシル硫酸アンモニウムの濃度は0.5質量%、ジメチルジオクタデシルアンモニウムイオン濃度は0.06質量%であった。)
得られた板状粒子は平均長径が302nm、平均短径が233nm、平均短径と平均長径の比が1.3、動的光散乱法による平均粒子径が34.3nm、平均厚さ1.1nmであり、得られた分散液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、0.007であった。得られた板状粒子の透過型電子顕微鏡写真を図2に示す(倍率10万倍)。
分散液をPET(ポリエチレンテレフタレート)基板上に塗布し100℃で乾燥して塗布膜を形成し、透明基板を作成した。得られた透明基板の膜厚は600nmであり、全光線透過率は92.8%であった。
実施例1において、ドデシル硫酸アンモニウムを添加しなかった以外は実施例1と同様に操作した。
最終的に得られた分散液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、1.602であった。
実施例1において、ドデシル硫酸アンモニウムの代わりに、ドデシル硫酸ナトリウムを同量添加した以外は実施例1と同様に操作した。
最終的に得られた分散液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、0.020であった。
実施例1において、ドデシル硫酸アンモニウムの代わりに、ラウリン酸カリウムを同量添加した以外は実施例1と同様に操作した。
最終的に得られた分散液の吸光度は、イオン交換したアイラアイトの濃度0.1質量%、光路長1cm、波長620nmで、2.703であった。
一方、アンモニウムイオンを有する陰イオン界面活性剤(B)を添加しなかった比較例1、アンモニウムイオンに代えてナトリウムイオンを有する陰イオン界面活性剤を使用した比較例2、或いはカリウムイオンを有する陰イオン界面活性剤を使用した比較例3にあっては、分散液の透明性が低下した。これら比較例の結果は、系内において層状化合物の層間剥離が進行していない、或いは、層間剥離した剥離層物質が再び層状構造を形成したことを示唆するものであった。
Claims (20)
- 総炭素原子数15~45であり、且つ、炭素原子数10~20のアルキル基を1~2個有する第4級アンモニウムイオン(A)と、アンモニウムイオンを有する陰イオン界面活性剤(B)とを含み、平均厚さ0.7~40nm、平均長径100~600nm、平均短径50~300nm、及び平均短径と平均長径の比が1.0~10.0である板状粒子(C)が液状媒体に分散した分散液であって、該分散液中の該板状粒子(C)の動的光散乱法による平均粒子径が10~600nmである分散液。
- 板状粒子(C)が、層状化合物(D)の層間剥離による剥離層物質である、請求項1に記載の分散液。
- 層状化合物(D)が、アイラアイトである、請求項2に記載の分散液。
- 板状粒子(C)が、0.2質量%以下のNaイオン濃度を有する、請求項1乃至請求項3のいずれか1項に記載の分散液。
- 分散液中のNaイオン濃度が100ppm以下である、請求項1乃至請求項4のいずれか1項に記載の分散液。
- 分散液中の第4級アンモニウムイオン(A)の濃度が、10質量%以下である、請求項1乃至請求項5のいずれか1項に記載の分散液。
- 分散液中のアンモニウムイオンを有する陰イオン界面活性剤(B)の濃度が0.01~1質量%である、請求項1乃至請求項6のいずれか1項に記載の分散液。
- アンモニウムイオンを有する陰イオン界面活性剤(B)が、ドデシル硫酸アンモニウムである、請求項1乃至請求項7のいずれか1項に記載の分散液。
- 分散液中の板状粒子(C)の濃度が30質量%以下である、請求項1乃至請求項8のいずれか1項に記載の分散液。
- 分散液が、板状粒子(C)の濃度が0.1質量%、光路長1cm、波長620nmにおいて、0.015以下の吸光度を有する、請求項1乃至請求項9のいずれか1項に記載の分散液。
- 請求項1乃至請求項10のいずれか1項に記載の分散液を含む塗布用組成物。
- 請求項1乃至請求項10のいずれか1項に記載の分散液中の板状粒子(C)を含む塗布膜。
- 基板上に請求項12に記載の塗布膜を有し、該塗布膜の膜厚が500nmである時の全光線透過率が80%以上である、透明基板。
- 下記(a)工程乃至(e)工程:
(a)工程:層状化合物(D)の水性分散液を製造する工程、
(b)工程:(a)工程で得られた水性分散液に、層状化合物(D)のイオン交換容量の等倍~三倍量となる、総炭素原子数15~45であり、且つ、炭素原子数10~20のアルキル基を1~2個有する第4級アンモニウムイオン(A)を添加し、40~90℃で、12~48時間の加熱をする工程、
(c)工程:(b)工程で得られた液に純水を加え、液中のナトリウムイオン濃度が100ppm以下になるように、ナトリウムイオン含有液を系外に取り除く工程、
(d)工程:(c)工程で得られた液を乾燥させた乾燥粉を、濃度が0.01~1質量%のアンモニウムイオンを有する陰イオン界面活性剤(B)水溶液中に分散させた後、さらに、アンモニアを添加して液中のpHを9.0~12.0に調整する工程、
(e)工程:(d)工程で得られた液を、40~90℃で、12~48時間の加熱を行い、分散液を得る工程、を含む
請求項1乃至請求項10のいずれか1項に記載の分散液の製造方法。 - (a)工程が、層状化合物(D)の粉砕によって粉砕された層状化合物(D1)を種粒子として珪酸塩水溶液に添加し、90~130℃で、6~72時間の水熱処理を行い、微細な層状化合物(D2)の濃度30質量%以下の水性分散液を製造する(a1)工程である、請求項14に記載の層状化合物(D)の分散液の製造方法。
- 粉砕された層状化合物(D1)が、30~60nmの動的光散乱法による粒子径を有し、〔(2θ=6.9~8.4°までの回折ピークの積分強度の総和)/(2θ=5~40°までの回折ピークの積分強度の総和)〕×100で示される粉末X線回折による結晶化度が5~15%である、請求項15に記載の製造方法。
- 微細な層状化合物(D2)が、平均長径250~750nm、平均短径200~550nm、平均短径と平均長径の比が1.0~2.0である、請求項15に記載の製造方法。
- (a1)工程の層状化合物(D)の粉砕が遊星ボールミルを用い、乾式で行われる、請求項15に記載の分散液の製造方法。
- (f)工程:(e)工程の後に、得られた分散液を有機溶媒で溶媒置換する工程をさらに含む、請求項14乃至請求項18のうちいずれか1項に記載の分散液の製造方法。
- 請求項1乃至請求項10のいずれか1項に記載の分散液を、基板に塗布し、40~300℃で加熱する、請求項13に記載の透明基板の製造方法。
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