CN100363436C - 特别地包含铝的铜基金属片及其制备方法 - Google Patents

特别地包含铝的铜基金属片及其制备方法 Download PDF

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CN100363436C
CN100363436C CNB03819743XA CN03819743A CN100363436C CN 100363436 C CN100363436 C CN 100363436C CN B03819743X A CNB03819743X A CN B03819743XA CN 03819743 A CN03819743 A CN 03819743A CN 100363436 C CN100363436 C CN 100363436C
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Abstract

本发明涉及高光泽的金色金属效果颜料,其包含铜基合金和附加的金属合金组分,优选为铝,并且其通过剥离和粉碎在真空中沉积的金属膜而制得。

Description

特别地包含铝的铜基金属片及其制备方法
金属效果颜料是可以在平整取向的颗粒上呈现出镜面反射的颜料(DIN 55944)。有光泽的金色效果颜料倍受关注,特别是在印刷、漆类、涂料、塑料着色、化妆品和玻璃着色应用领域中,这是因为金状制品具有高度的美学品质,并且使得这种经涂覆的、经压印的或经着色的材料具有豪华的外表。很早以前在装饰领域就开始用成本更经济的替代品来代替昂贵的真金片。
最知名的真金片替代颜料是所谓的金色青铜粉,其主要由铜/锌合金组成,并且根据其组成可以具有从红金到青金范围的不同色调(PigmentHandbook,第1卷,第二版,第805页及其后,Wiley)。金色青铜颜料是通过将熔融的铜/锌合金雾化和随后碾碎雾化生成的颗粒而制备的。在碾碎过程中,使合金颗粒变形呈片状并进行粉碎。实际上,主要对金色青铜颜料进行干燥碾碎。为了防止冷粘结,向所用的颗粒中添加润滑剂例如硬脂酸。在专用球磨机中通过刷擦或轻度研磨对碾碎的制品进行的后处理可以提高金属颜料的光泽,并且被称为抛光。金属片表面的不规则性会具有降低光泽的作用。由于在碾碎过程中无法避免产生金属片表面结构的不规则性和不同的金属片厚度,因此这种方式制备的金色青铜颜料不会呈现出根据合金的反射率计算得到的光泽。此外,几乎所有通过碾碎工艺制备的金色青铜颜料都会表现出悬浮特性,即它们漂浮在介质中,这可以归因于碾碎工艺中添加的润滑剂。制备非悬浮的金色青铜颜料需要以昂贵的方式除去润滑剂。
用铁-氧化物涂覆的云母颜料(G.Pfaff和R.Maisch,Farbe+Lack,第2卷,1955,第89-93页)或用铁-氧化物涂覆的铝颜料(W.Ostertag,N,Mronga和P.Hauser,Farbe+Lack,第12卷,1987,第973-976页)代替真金片的尝试没有达到其关于所需亮度方面的目标。虽然可以通过干涉作用生产所希望的从红金到绿金范围的色调,但是已表明通过氧化反射面无法达到高光泽决定的金属反射值。
从US4,321,087已知将金属沉积到载片上,并在剥除和粉碎后得到颜料。
至于制备金属化层的方法,可以使用常规的气相沉积方法(电子束技术,电阻辐射加热工艺),例如在G.Kienel(编辑)“Vakuumbeschichtung第1-5卷”,VDI-Verlag 1995中作了详细描述。
对于由两种或更多种组分组成的合金来说,由于不同的蒸气压力因而会出现分级。存在不同的蒸发方法(闪蒸、同时法或跳跃光束法(jumpingbeam method)),由此可以制备具有任何所需组成的均匀合金层(G.Kienel)。
本发明的目的是提供一种有光泽的高亮度金色金属效果颜料,其不存在上述真金替代品的缺点。
一个特殊的目的是获得具有平面平行的表面且均匀颗粒厚度低的有光泽的金色金属效果颜料,使得所述颜料可应用于图形工业的所有领域中,特别地用于胶印领域中。
本发明的另一目的是获得可出现从红金到绿金的不同色调的有光泽的金色金属效果颜料。
本发明的另一目的是获得腐蚀稳定形式的有光泽的金色金属效果颜料,使得在常规应用领域中不会损坏制品的光泽和色调。
此外,其应当可以以经济上可接受的成本制备。
具有平面平行的反射面的单层片状金属颜料可以实现这些目的,所述颜料由通过气相冷凝而沉积的铜基合金组成。优选合适的合金伴侣是铝,还有金属银、钯和硅,其可单独使用或组合使用。该新型的有光泽的金色颜料的色彩主要由铜与非彩色的合金组分的比值决定。本发明的有光泽的铜基金属片包含至少51%的铜。铜的百分比越高,该片体更多地呈现红金色。硅可以提高所述片体的颜色深度。具有红金到黄金或绿金光泽的片体的典型组成除了铜之外还包含1~49%铝和非必要的0.1~6%硅。所述片体的厚度为10~100nm,优选为20~60nm,并且可以轻易地改变。非常薄的所述片体是部分透明的。
所述有光泽的金色颜料的一个特殊特征是它们完美的平面平行的表面、其未受干扰的结构组成和其均匀的片厚度,这使得具有可能的最高反射值。
所述制备方法的最重要的步骤是在载体上施加脱模涂层,冷凝所述合金在脱模涂层上成膜,剥离金属膜,粉碎该膜和可选择地对该颜料颗粒筛分。根据已知的方法使用易制得的合金或单独的金属在真空中蒸发金属。
本发明的颜料呈现出最高的亮度,并且在许多应用领域中具有充分的腐蚀稳定性。如果要求特殊的腐蚀稳定性,那么可以通过表面涂层来提高高光泽颜料的稳定性。所述表面涂层一般足够薄,并且对金属片的光泽性能基本不会产生影响。在金属膜沉积的过程中可以于真空室中施涂用以提高所述腐蚀性能的表面涂层,例如通过在金属膜的两侧面上真空沉积SiOx进行施涂,或在粉碎膜的过程中或者之后通过湿化学方法进行施涂。根据需要,已证实Si02、Al203、磷酸盐、磷酸酯、次膦酸、硅烷或这些化合物组合的保护涂层是有效的。
有光泽的金色金属片可用于漆类、涂料、染料、打印机油墨、塑料着色、化妆品、玻璃和陶瓷。
下面是详细的解释:
本发明涉及一种由合金组成的新型效果颜料。本文中合金是指两种或更多种金属的固态溶液。令人惊讶的是可以在真空中由气相沉积出色彩合适的合金。迄今为止尚未已知由合金组成的并且通过同时冷凝金属蒸气制得的颜料。
用于通过PVD工艺形成鲜亮的真金替代颜料的合适合金是以铜为基础的并且包含例如铝和/或银、钯和硅作为附加合金组分。在这些所列的金属中,铝是铜的优选合金伴侣,这不仅仅是因为它优异的反射率和低比重。银和钯在沉积合金中的百分比可以提高有光泽金色金属片的腐蚀稳定性,硅可以影响色彩效果。这些金属可以单独蒸发或以预先熔融的合金蒸发。
通过沉积合金的组成可以产生处于红金色、浅金色和绿金色之间的宽色彩范围。在本发明中提供颜色的铜起到了重要的作用。例如具有90wt%铜的颜料表面具有红金色光泽,而仅具有60wt%铜的颜料表面显示浅黄色。硅具有降低亮度的作用,并且在有光泽的金色片体的较大色彩深度下变得视觉上显而易见。色彩上令人感兴趣的组成例如是90~99%铜、10~1%铝。如果存在非常薄的片体,那么它们可以表现出部分透明。干涉作用对上述色彩的影响较小。
通过金属的蒸发速率和皮带速度可以容易地调节和控制有光泽的金色金属片的厚度。出于经济上考虑,一般选择皮带速度为2~5m/sec。根据需要,在该方法中可以选择金属膜厚度为10~100nm。至于制备有光泽的金色金属片,20~60nm的厚度特别受关注。在从载片上剥离金属膜之后,通过机械粉碎膜片段来调节颗粒尺寸。这种粉碎可以用合适的搅拌器、泵或借助悬浮于溶剂中的膜片段的超声装置进行。一般地,3~150μm、优选5~50μm的颗粒尺寸值得关注。至于所有效果颜料,可以通过筛分(即设定具有不同平均直径的窄颗粒尺寸分布)改变光学外观。可以在例如沉降器中进行筛分。
所述金色金属片的特性是其高反射性和颜料在应用中非常高的着色力。高反射性是以镜面平滑的未受干扰的表面和片体的均匀厚度为基础的。最大限度地减少潜在的散射中心。所述颜料的高着色力是以单个颗粒的低厚度为基础的,从而使得以相对少量的颜料就可以达到足够的覆盖程度。
制备本发明的颜料使得载片可选择地涂覆有脱模涂层,例如PET膜或连续金属带。通过浸涂或压印方法可以用可溶性树脂或蜡对载片进行涂布。
然后例如在一个或更多个蒸发器内于高真空下单独地或者以预先熔融的合金蒸发合适的金属,并使其冷凝在载片上。
随后在适于应用的溶剂(例如异丙醇、乙酸异丙酯、乙酸乙酯或乙二醇醚)中通过合适的搅拌器或施加高剪切力的泵剥离金属膜并将其粉碎至颜料颗粒尺寸。可以附加地或作为选择地使用超声粉碎。可选择地,另外对颜料颗粒进行筛分。
为了保护本发明颜料的金属表面免受腐蚀,可以在附加步骤中为其提供抗腐蚀层。由于这些层薄并且折射作用低,因此它们对所述颜料的光学行为几乎没有影响。原则上,两种施加抗腐蚀层的方法均可行:一方面通过在蒸发工艺中气相沉积双面保护层,另一方面通过在粉碎膜片段的工艺中或者之后沉淀钝化层。在蒸发工艺中气相沉积保护层是按保护层、合金膜、保护层的顺序进行的,就保护层而言一般选择低溶解性但是易蒸发的材料,例如SiOx或MgF2。沉淀钝化层是以湿化学反应进行的。已证实合适的是通过硅烷的水解和随后硅烷醇处理的方式方便地经由溶胶-凝胶法来沉淀薄的SiO2层,还可以沉淀氧化铝、氧化硅、磷酸盐、磷酸、磷酸酯、次膦酸、硅烷、有机改性的硅酸盐、钛酸盐、锆酸盐或基于甲基丙烯酸酯的聚合物层或这些化合物的组合。
在本发明中施加所述金属膜的步骤通过电子束、电阻加热或辐射加热、闪蒸、同时蒸发或跳跃光束蒸发而进行。
下面根据优选的实施方案更详细地说明本发明。
实施例1
在Leybold Heraeus公司的辊涂机中,在高真空下用铜/铝合金涂覆涂有脱模涂层的48μm厚的PET载体膜。该脱模涂层由可溶于丙酮的甲基丙烯酸甲酯树脂组成,并将其预先在单独的加工步骤中印于载体膜上。调节真空度至5.10-4毫巴。
展开载体膜的速度是4m/s。通过电阻加热在蒸发皿中蒸发铜含量为92%的铜/铝合金,其蒸发速率使得位于运动的载片上的金属膜厚度为40nm。完成涂覆后,使辊涂机充满氮气,移走金属化的PET卷并在剥离状态下用丙酮处理。通过溶解脱模涂层,将该金属膜与载体膜分离。在离心机中聚集金属膜片段,并使其与含有丙酮溶液的脱模涂层分离。接着,使滤饼进入异丙醇溶液中,在那里粉碎该膜20分钟。其中存在金属片的悬浮液是12%的悬浮液。
所得的颜料悬浮液呈现出具有最高亮度的有光泽的金色颜料颗粒。这些片体的平均粒度为10μm(Cilas)。化学分析表明该颜料含有92%铜和8%铝。X射线分析显示这些元素以均匀的合金形式存在。
实施例2
a)在实施例1所述的装置中,沉积铜-铝-硅膜。按照类似实施例1的方式进行该操作,不同之处在于除了铜/铝的蒸发源之外,还设置了另一个硅蒸发源。可用于蒸发的铜/铝合金含有94%的铜。由气相沉淀得到的膜的厚设定为45nm。按照实施例1的方式剥离该膜并将膜片段粉碎至颜料尺寸。
在悬浮液中得到的颜料具有深红金色光泽。它含有2%硅。根据Cilas测量,平均颗粒尺寸是11μm。
b)稳定化:
将1000g上述制备的异丙醇中12%颜料悬浮液加热至沸点,并加入11g四乙氧基硅烷和10g水。随后用Dosimat加入10%DMEA水溶液,直至pH值达到8。在保持该pH值的同时,搅拌该混合物2小时。然后在搅拌的同时,于4小时内均匀地投入溶解在12g异丙醇中的1.4g二苯基二甲氧基硅烷。随后,加入0.5g 3-氨基丙基三甲氧基硅烷(DynasilanAMMO),并在搅拌的同时于10小时内冷却该混合物。
然后,所述金属颜料以腐蚀稳定的形式存在。

Claims (13)

1.有光泽的铜基金属片,其除了至少51%的铜之外还包含1~49%的铝并且通过如下方式制备:在载片上真空沉积金属膜,从所述载片上剥离该膜和随后粉碎该膜。
2.根据权利要求1所述的有光泽的铜基金属片,其特征在于所述有光泽的铜基金属片包含选自银、钯和硅的一种或多种附加合金组分。
3.根据权利要求1所述的有光泽的铜基金属片,其特征在于所述有光泽的铜基金属片具有平面平行的表面并且厚度为10~100nm。
4.根据权利要求3所述的有光泽的铜基金属片,其特征在于所述有光泽的铜基金属片的厚度为20~60nm。
5.根据权利要求1-4中任一项所述的有光泽的铜基金属片,其特征在于所述有光泽的铜基金属片的表面涂有抗腐蚀层。
6.根据权利要求5所述的有光泽的铜基金属片,其特征在于所述抗腐蚀层包含氧化铝、氧化硅、磷酸盐、磷酸、磷酸酯、次膦酸、硅烷、有机改性硅酸盐、钛酸盐、锆酸盐或基于甲基丙烯酸酯的聚合物层或这些化合物的组合。
7.一种制备根据权利要求1-4中任一项所述的有光泽的铜基金属片的方法,其包括以下的工艺步骤:
a)可选择地在载片上施加脱模涂层
b)经真空沉积在所述脱模涂层或所述载片上施加金属膜
c)剥离所述金属膜
d)粉碎成颜料颗粒。
8.根据权利要求7所述的制备有光泽的铜基金属片的方法,还包括在所述有光泽的铜基金属片的表面施涂抗腐蚀层。
9.根据权利要求7所述的方法,其特征在于施加所述金属膜的步骤通过蒸发合金进行。
10.根据权利要求7所述的方法,其特征在于施加所述金属膜的步骤通过单独地蒸发合金组分进行。
11.根据权利要求7-10中任一项所述的方法,其特征在于施加所述金属膜的步骤通过电子束、电阻加热或辐射加热而进行。
12.根据权利要求7-10中任一项所述的方法,其特征在于施加所述金属膜的步骤通过闪蒸、同时蒸发或跳跃光束蒸发而进行。
13.根据权利要求11所述的方法,其特征在于施加所述金属膜的步骤通过闪蒸、同时蒸发或跳跃光束蒸发而进行。
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