JP2019535909A - 伝導性高分子構造体の外部にコーティングされた金属薄膜層を含む耐酸化性ハイブリッド構造体及びその製造方法 - Google Patents
伝導性高分子構造体の外部にコーティングされた金属薄膜層を含む耐酸化性ハイブリッド構造体及びその製造方法 Download PDFInfo
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- JP2019535909A JP2019535909A JP2019545221A JP2019545221A JP2019535909A JP 2019535909 A JP2019535909 A JP 2019535909A JP 2019545221 A JP2019545221 A JP 2019545221A JP 2019545221 A JP2019545221 A JP 2019545221A JP 2019535909 A JP2019535909 A JP 2019535909A
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- conductive polymer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
- C23C18/1601—Process or apparatus
- C23C18/1633—Process of electroless plating
- C23C18/1646—Characteristics of the product obtained
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/06—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances
- H01B1/12—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances organic substances
- H01B1/124—Intrinsically conductive polymers
- H01B1/128—Intrinsically conductive polymers comprising six-membered aromatic rings in the main chain, e.g. polyanilines, polyphenylenes
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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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D11/00—Inks
- C09D11/52—Electrically conductive inks
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
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- C23C18/2086—Multistep pretreatment with use of organic or inorganic compounds other than metals, first
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
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Abstract
Description
(a)伝導性高分子構造体を形成し、
(b)前記伝導性高分子構造体、金属塩前駆体、還元剤、及び分散溶媒を含有する溶液を用いて前記金属塩前駆体を還元させることで無電解めっき法により前記伝導性高分子構造体の表面に金属をコーティングすることによって、前記伝導性高分子構造体の表面にコーティングされた金属薄膜層を含むハイブリッド構造体を収得する。
(a)伝導性高分子構造体を形成し、
(b)前記伝導性高分子構造体、金属塩前駆体、還元剤、及び分散溶媒を含有する溶液を用いて前記金属塩前駆体を還元させることで無電解めっき法により前記伝導性高分子構造体の表面に金属をコーティングすることによって、前記伝導性高分子構造体の表面にコーティングされた金属薄膜層を含むハイブリッド構造体を収得する。
クロロホルム、トルエン、キシレン、核酸などの疎水性有機溶媒を重合反応槽に入れ、アニリンとその誘導体単位体とドーパントをこれらの溶媒に溶かし、反応誘導槽には開始剤とドーパントを含む新水性の酸性水溶液を入れることで反応媒質を構成する。滴下漏斗(dropping funnel)を用いて反応誘導槽の溶液を重合反応槽に滴下し、反応終了後、濾過洗浄して伝導性高分子を得る。
重合反応槽には、有機溶媒にアニリンとその誘導体単位体を溶かした溶液とドーパントを溶かした酸性水溶液とを適当な割合で混合し、不均一相を作る。反応誘導槽には、開始剤とドーパントを含む水溶液で反応媒質を構成する。漏斗(dropping funnel)を用いて重合反応槽に反応誘導槽の溶液を滴下し、反応終了後、濾過洗浄して伝導性高分子を得る。反応槽に生成されたポリアニリン粒子の形態と大きさには、界面を構成する親水性層−疎水性層の相対的な体積比が影響を与える。先ず、球形(何れか1つの相の体積比が15%未満)、棒状(何れか1つの相の体積比が25%〜40%)、並びに板状(何れか1つの相の体積比が40%〜60%)を形成するように界面の形状を作り、これらの界面で重合反応が起こるようにする。このとき、単位体と開始剤との相対的なモル比とpH、撹拌速度とインペラの形状、並びに反応温度が粒子の縦横比に影響を与える。単位体の濃度比が高いほど、そしてpHが低いほど形態の調整が容易であり、撹拌速度を調整して二次成長(secondary growth)を阻むことが好ましい。
実施例1:ポリアニリンEBとESの製造
1Lのダブルジャケット反応器に冷却循環器を設け、ここに1Mの塩酸溶液60mLを反応器に入れてアニリンモノマー0.025モル(4mL)を加えた後、10℃で1時間良くかき混ぜる。ここにクロロホルム300mLを添加し、分散させる。このとき、アニリンモノマー‐塩酸塩が界面活性剤の役割をし、安定した第1の溶液が製造される。第2の溶液は、1Mの塩酸溶液125mLに開始剤として過硫酸アンモニウム(ammonium persulfate、APS)5.7g(0.025モル)を溶かし、1時間かき混ぜる。これを第1の溶液に1時間滴下しながら300rpmでかき混ぜる。第2の溶液を全て入れてからさらに1時間反応を進行させた後、反応を終了し、2μmの濾紙で濾過する。生成されたES状のポリアニリン粒子を1Mの塩酸溶液で3回洗浄した後、メタノールと水で色が出なくなるまで洗浄し、これを1Mのアンモニア水150mL水溶液に24時間撹拌してEB状に切り換える。濾過して50℃の真空オーブンに24時間以上乾燥させることでアニリンポリマーEBを得る。
実施例1と同じ手法で実施しながら、塩酸溶液60mLの代わりにAMPSA水溶液150mLを使用して重合する。反応初期段階で重合体の二次成長を抑制するために、控え目に反応速度を調整しながら界面重合を誘導する。合成された沈殿物を濾過し、数回にわたってメタノールと水で洗浄した後、濾過して直接ES粒子を得る。図3に示す走査型電子顕微鏡写真(SEM)を見ると、アスペクト比(aspect ratio)5〜10の棒状粒子が合成されたことが分かる。図4は、ES状の粒子をトリフルオロエタノール(trifluoroethanol)に溶かした後、分光分析を実施することで得たUv−visスペクトルである。ピーク420nm付近と近赤外線(near IR)領域での吸収は、それぞれポーラロン(polaron)ピークと自由キャリアテール(free−carrier tail)に起因したものと知られている。合成されたポリアニリンエメラルジン塩は、バンドギャップ(band gap)が4.0eVで、イオン化エネルギーは5.1eVと相対的に低く、酸によってドーピングされれば、電子が離脱して伝導帯へ移動しながら電気が通るようになる。図4において近赤外線分野の吸収度が波長によって増加し続けるのは、ドーピングが上手くできて電子の移動性が活発な微細構造が形成されたことを意味する。従って、本発明で製造したESは、腐食防止の効果も高いだけでなく、もしこれらの粒子の表面に金属膜が部分的にコーティングされれば、金属による電磁波の反射と共に電磁波の吸収も同時に起こり、効果的な電磁波の遮断も可能になる。
エチレングリコール(ethylene glycol)溶媒にジルコニアボール(1mm、1kg)とEBパウダー10gを入れて24時間回転させる。ジルコニアボールをフィルタリングした後、遠心分離機を用いて7000rpmで10分間分離してから沈殿物を集め、50℃の真空オーブンに24時間以上乾燥させることでEBパウダーを得た。これをSEMで測定して粒子の形状と大きさを確認した。図5には、30nm〜70nmのサイズの球形ナノ粒子が示されている。
めっき前の伝導性高分子粒子の前処理が重要である。クロム酸、ポリエチレングリコール(polyethylene glycol)、SnCl2、PdCl2、グリシンのような着火剤(complexing agent)で前処理すれば、より均一で、且つ厚さの調整が容易なめっきが可能である。めっき反応前の超音波撹拌(100Wセッティングで40KHz〜60KHz)によって粒子の表面に金属塩溶液が万遍なく濡らされるように誘導し、内部の気孔に空気が残らないよう十分にかき混ぜる。分散媒質として蒸溜水を選んでポリエチレングリコール(PEG−1000)0.1g/mlを溶かし、ここにEB又はES粒子を入れて5分間超音波で洗浄し、撹拌しながら遠心分離により回収し、これを3回繰り返した後、伝導性高分子1g当たりにSnCl2を0.1g/100mlの濃度で3分間、そしてPdCl2を30分間前処理を実施する。
実施例4で製造されたEB粒子0.50gをエチレングリコール(ethylene glycol)200gに投入した後、超音波を用いて1時間分散させる。金属塩として二酢酸銅(copper diacetate)5mmolをエチレングリコール(ethylene glycol)200gに10分間溶解させ、この溶液をエチレングリコール(ethylene glycol)に分散されたEB溶液に滴下した後、160℃で1時間撹拌する。反応終了後、2μmの濾紙でフィルタリングし、濾過物を50℃の真空オーブンに24時間以上乾燥して銅−PANI(copper−PANI)ハイブリッド複合体を得た。これらの粒子の透過型電子顕微鏡(TEM)形状(図6)とX−ray回折図を示す(図7)。大きさが500nm未満の銅でコーティングされた球形粒子がぶどうの房のように示されている。X−ray回折図からもこれらの複合ピークの存在を確認することができる。2シータ(two theta)の20度付近の無定形の広いピークはEB、そして43度付近の強いピークは銅原子の結晶面(111)反射を示す。
強い還元剤は、アンモニア水、水酸化ナトリウム、ホスフィン酸ナトリウム(NaH2PO2)、水素化ホウ素ナトリウム(NaBH4)、ヒドラジン(hydrazine(N2H4H2O))、ブローム化カリウム(potassium bromide)、NaCl、及びこれらの組み合わせから選択する。これらの還元剤は、伝導性高分子粒子の脱ドーピングを誘発しながら水溶液における混和性(compatibility)を上げ、分散性を良好にすると同時に粒子の耐熱性を向上させる。先ず、実施例1で合成したES粒子0.30gをアンモニア水100mLと共にビーカに入れて良く濡らす。この溶液と硝酸銅(copper nitrate)0.56gを水100mLに溶かした溶液を反応器に入れて1時間撹拌した後、ここに水素化ホウ素ナトリウム0.91gをさらに入れて1時間撹拌する。反応溶液の色が暗褐色から黒に変化し、反応が終了すると、これを濾過して乾燥することでハイブリッド複合体を得る。
腐食防止のために、従来の方式として知られている伝導性高分子で金属粒子を覆う比較実験を実施した。ポリアニリンを溶解することのできる有機溶媒は、N−メチルピロリドン(NMP、N−methylpyrrolidone)、クロロホルム(cnloroform)、トリフルオロエタノール、N,N−ジメチルホルムアミド(DMF、N,N−dimethylformamide)などを使用することができる。実施例2で合成された試料をトリフルオロエタノール(trifluoroethanol)溶媒に溶かし、直径20nmの銅粒子を入れて撹拌した後、これを遠心分離、濾過して乾燥した後、X−ray回折テストを実施した。図9に示すX−ray回折図を見ると、酸化されていない銅原子(2シータ、43.2度)よりも酸化された銅(Cu2O、36.4度と38度)のピークの方が遥かに強く示されている。重合過程においてin−situで又は伝導性高分子合成の後、溶液状態に製造してからナノサイズ金属粒子をコーティングすることで腐食を抑制する方法は有効ではないことが分かる。
実施例5で製造された本発明のハイブリッド粒子は、300℃でも安定しているため、ホットプレス(hot press)を用いて300℃で1時間焼結を実施した。図10及び図11は、これらの試験片の形状及びFE−SEMを示している。銅色が見える焼結された部分の試験片の形状の写真は、表面層の銅が酸化されず純粋な銅として存在していることを示し、電子顕微鏡の写真を見ると、表面銅層の融着(necking)が起こり、金属粒子薄膜が互いに連結されて繋がっていることが分かる。
Claims (26)
- 伝導性高分子構造体の表面にコーティングされた金属薄膜層を含み、金属の耐酸化性及び/又は耐腐食性を向上させるための、ハイブリッド構造体。
- 前記伝導性高分子は、ポリアニリン、ポリピロール、ポリチオフェン、ポリ(3,4−エチレンジオキシチオフェン)、ポリアセチレン、及びこれらの組み合わせからなる群より選択される伝導性高分子を含む、請求項1に記載のハイブリッド構造体。
- 前記伝導性高分子構造体は、縦横比が1〜1,000である構造を有する、請求項1に記載のハイブリッド構造体。
- 前記伝導性高分子は、ポリアニリンエメラルジン塩基(Emeraldine Base、EB)、エメラルジン塩(Emeraldine Salts、ES)、及びこれらの組み合わせからなる群より選択される伝導性高分子を含む、請求項1に記載のハイブリッド構造体。
- 前記金属は、銅、ニッケル、パラジウム、ルテニウム、スズ、鉛、鉄、ステンレス鋼、金、銀、及びこれらの組み合わせからなる群より選択される金属を含む、請求項1に記載のハイブリッド構造体。
- 前記金属は、銅を含む、請求項1に記載のハイブリッド構造体。
- 前記金属薄膜層の厚さは、1nm〜300nmである、請求項1に記載のハイブリッド構造体。
- 前記金属薄膜層は、前記伝導性高分子構造体の表面の一部分又は全体にコーティングされたものである、請求項1に記載のハイブリッド構造体。
- 前記金属薄膜層は、100℃以上の高温でも耐酸化性を有する、請求項1に記載のハイブリッド構造体。
- 請求項1乃至9のいずれか一項による、伝導性高分子構造体の表面にコーティングされた金属薄膜層を含み、金属の耐酸化性及び/又は耐腐食性を向上させるためのハイブリッド構造体を含む、導電性インク充填剤。
- 請求項1乃至9のいずれか一項による、伝導性高分子構造体の表面にコーティングされた金属薄膜層を含み、金属の耐酸化性及び/又は耐腐食性を向上させるためのハイブリッド構造体を導電性フィラーとして含むプラスチック基材を含む、導電性プラスチック複合材。
- 請求項11による前記導電性プラスチック複合材を含む、燃料電池分離膜。
- 請求項1乃至9のいずれか一項による、伝導性高分子構造体の表面にコーティングされた金属薄膜層を含み、金属の耐酸化性及び/又は耐腐食性を向上させるためのハイブリッド構造体を含む、電極。
- 請求項1乃至9のいずれか一項による、伝導性高分子構造体の表面にコーティングされた金属薄膜層を含み、金属の耐酸化性及び/又は耐腐食性を向上させるためのハイブリッド構造体を含む、電磁波遮蔽材。
- (a)伝導性高分子構造体を形成し、
(b)前記伝導性高分子構造体、金属塩前駆体、還元剤、及び分散溶媒を含有する溶液を用いて前記金属塩前駆体を還元させることで無電解めっき法により前記伝導性高分子構造体の表面に金属をコーティングすることによって、前記伝導性高分子構造体の表面にコーティングされた金属薄膜層を含むハイブリッド構造体を収得することを含む、ハイブリッド構造体の製造方法。 - 前記ステップ(b)の前に、前記伝導性高分子構造体を前処理することをさらに含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記伝導性高分子構造体の前処理のために使用される物質は、ポリエチレングリコール(polyethylene glycol)、ポリアクリル酸ナトリウム(sodium polyacrylate)、ポリビニルピロリドン(polyvinylpyrrolidone)、ポリ(ビニルカプロラクタム)(poly(vinyl caprolactam))、ポリ(4−スチレンスルホン酸ナトリウム)(poly(sodium 4−styrenesulfonate))、SnCl2、PdCl2、及びこれらの組み合わせからなる群より選択されるものを含む、請求項16に記載のハイブリッド構造体の製造方法。
- 前記ステップ(b)で使用される還元剤は、弱い還元剤であって均一な金属薄膜層の形成を助ける、エチレングリコール、ジエチレングリコール、プロピレングリコール、ブタンジオール、ペンタンジオールを含む多価アルコール、アスコルビン酸、グリシン(glycine)、ジマル酸(di−malic acid)、酒石酸ナトリウム(sodium tartrate)、酢酸アンモニウム(ammonium acetate)、及びこれらの組み合わせからなる群より選択されるものを含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記ステップ(b)で使用される還元剤は、強い還元剤であって前記伝導性高分子の脱ドーパント(dedoping agents)として用いられるアンモニア水、水酸化ナトリウム、ホスフィン酸ナトリウム(NaH2PO2)、水素化ホウ素ナトリウム、ヒドラジン、及びこれらの組み合わせからなる群より選択されるものを含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記ステップ(b)において、超音波処理が間欠的に行われる、請求項15に記載のハイブリッド構造体の製造方法。
- 前記伝導性高分子は、ポリアニリン、ポリピロール、ポリチオフェン、ポリ(3,4−エチレンジオキシチオフェン)、ポリアセチレン、及びこれらの組み合わせからなる群より選択される伝導性高分子を含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記金属は、銅、ニッケル、パラジウム、ルテニウム、スズ、鉛、鉄、ステンレス鋼、金、銀、及びこれらの組み合わせからなる群より選択される金属を含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記金属塩前駆体は、銅、ニッケル、スズ、鉛、あるいは鉄の硫酸塩、塩化塩、硝酸塩、酢酸塩、シアン化塩、ヨウ化銅、及びこれらの組み合わせからなる群より選択されるものを含む、請求項15に記載のハイブリッド構造体の製造方法。
- 前記金属薄膜層の厚さは、1nm〜300nmである、請求項15に記載のハイブリッド構造体の製造方法。
- 前記金属薄膜層は、前記伝導性高分子構造体の表面の一部分又は全体にコーティングされたものである、請求項15に記載のハイブリッド構造体の製造方法。
- 前記伝導性高分子構造体は、縦横比が1〜1,000である構造を有する、請求項15に記載のハイブリッド構造体の製造方法。
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