JP6788013B2 - 接着剤と1つ又は複数のナノファイバーシートとを備える複数層複合材 - Google Patents
接着剤と1つ又は複数のナノファイバーシートとを備える複数層複合材 Download PDFInfo
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- JP6788013B2 JP6788013B2 JP2018532541A JP2018532541A JP6788013B2 JP 6788013 B2 JP6788013 B2 JP 6788013B2 JP 2018532541 A JP2018532541 A JP 2018532541A JP 2018532541 A JP2018532541 A JP 2018532541A JP 6788013 B2 JP6788013 B2 JP 6788013B2
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Description
1つ又は複数のナノファイバーシートと接着剤とを含む多層化複合材が本明細書で開示される。開示されている「接着性ナノファイバー複合材」は一部の実施形態では、高度に導電性であり、金属化されてもよい。開示されている複合材に存在する接着剤はナノファイバーシート(複数可)の部分すべてを完全に覆う必要があるわけではなく、シート(複数可)の導電性部分を他の導電性の機能にアクセス可能のままにしておいてもよい。一部の実施形態例では、接着性ナノファイバー複合材はまた所望の構成に応じて伸縮可能であってもよい。
本明細書で使用されるとき、用語「ナノファイバー」は1μm未満の直径を有する繊維を意味する。本明細書の実施形態がカーボンナノチューブから製造されるとして主に記載されている一方で、グラフェン、ミクロンもしくはナノ尺度の黒鉛の繊維及び/又は板であろうとなかろうと他の炭素同素体、及び窒化ホウ素のようなナノ尺度繊維のさらに他の組成物が以下で記載されている技法を用いてナノファイバーシートを製造するのに使用されてもよいことが十分に理解されるであろう。本明細書で使用されるとき、用語「ナノファイバー」及び「カーボンナノチューブ」は単一壁のカーボンナノチューブ及び/又は炭素原子が一緒につなげられて円筒状の構造を形成する多重壁のカーボンナノチューブの双方を包含する。多重壁のナノチューブは2以上の壁を有する。一部の実施形態では、本明細書で参照されるカーボンナノチューブは4〜10の間の壁を有する。本明細書で使用されるとき、「ナノファイバーシート」または単に「シート」は、シートのナノファイバーの縦軸がシートの主要面に垂直ではなくシートの主要面に平行であるように(すなわち、シートの堆積させたような形態で、「フォレスト」とも呼ばれることが多い)引き抜き加工(国際公開第2007/015710号にて記載され、その全体はここに引用することによって本明細書の記載の一部をなすものとする)を介して並べられたナノファイバーのシートを指す。
主題の開示の種々の実施形態によれば、ナノファイバー(カーボンナノチューブを含むが、これらに限定されない)は、本明細書では「フォレスト」と呼ばれる構成を含む種々の構成で配置することができる。本明細書で使用されるとき、ナノファイバーまたはカーボンナノチューブの「フォレスト」は、基材上で互いに実質的に平行に配置されるほぼ同等の寸法を有するナノファイバーの配列を指す。図1は基材上のナノファイバーのフォレスト例を示す。基材は任意の形状であってもよいが、一部の実施形態では、基材は、その上にフォレストが集合させられる平面を有し、一部の実施形態では、平面は柔軟性であってもよい。図1で分かるように、フォレストにおけるナノファイバーは高さ及び/又は直径でほぼ同等であってもよい。
種々の方法を使用して主題の開示に係るナノファイバーフォレストを製造することができる。たとえば、一部の実施形態では、高温の加熱炉でナノファイバーを成長させてもよい。一部のそのような実施形態では、触媒を基材の上に堆積させ、反応器に入れ、次いで反応器に供給される燃料化合物にさらしてもよい。基材は、800℃〜1000℃を超える温度に耐えることができ、不活性物質であってもよい。シリコン(Si)ウエハーの代わりに他のセラミック基材(たとえば、アルミナ、ジルコニア、SiO2及びガラスのセラミック)が使用されてもよいが、基材は下にあるシリコン(Si)ウエハー上に配置されるステンレス鋼またはアルミニウムを含んでもよい。フォレストのナノファイバーがカーボンナノチューブである例では、たとえば、アセチレン、メタン及びエタン等の脂肪族炭化水素を含む炭素系化合物が炭素原子の供給源として使用されてもよい。反応器に導入された後、次いで炭素源(複数可)が分解してもよく、得られる炭素原子が触媒上に蓄積し、基材から上方に成長することによってナノチューブを集合させ始め、ナノファイバーのフォレストを形成することができる。
フォレストの構成における配置に加えて、主題の出願のナノファイバーはシートの構成においても配置されてもよい。本明細書で使用されるとき、用語「ナノファイバーシート」、「ナノチューブシート」または単に「シート」は、ナノファイバーが平面にて実質的に端から端まで並べられるナノファイバーの配置を指す。一部の実施形態では、ナノファイバーシートはシートの厚さの100倍を超えて大きい長さ及び/又は幅を有する。一部の実施形態では、ナノファイバー整列の方向はナノファイバーシート全体にわたって連続性であってもよい。一部の実施形態では、長さ、幅またはその双方はシートの平均厚さより103、106または109倍大きい。ナノファイバーシートは、たとえば、約5nm〜20μmの間、10nm〜10μmの間、20nm〜100nmの間、30nm〜80nmの間、または40nm〜60nmの間の厚さを有することができる。ナノファイバーシートは意図される適用に好適である任意の長さ及び幅を有してもよい。一部の実施形態では、ナノファイバーシートは1cm〜10メートルの間の長さ及び1cm〜1メートルの間の幅を有してもよい。これらの長さは単に説明のために提供される。ナノファイバーシートの長さ及び幅は、ナノチューブ、フォレストまたはナノファイバーシートのいずれかの物理的または化学的な特性によってではなく、製造機器の構成によって制約される。たとえば、連続法は任意の長さのシートを製造することができる。これらのシートはそれらが製造されるにつれてロールに巻き上げることができ、一部の実施形態では、離型シートをナノファイバーシートと共に巻くことができる。
本明細書で開示されているような接着性ナノファイバー複合材は1つ又は複数のナノファイバーシートとポリマーとで形成されてもよい。一部の実施形態では、ポリマーは接着剤を含む、または接着剤である。1つのナノファイバーシート102を含む接着性ナノファイバー複合材例100の上面斜視図を図5にて示す。図5は1つのナノファイバーシートを含んでいるが、接着性ナノファイバー複合材100には、たとえば、1、1を超える、5を超える、10を超える、15を超える、または20を超える任意の数のナノファイバーシートが含まれてもよい。一部の実施形態では、接着性ナノファイバー複合材は1〜20の間または5〜25の間のナノファイバーシートを含む。複数のナノファイバーシート102は互いに並べられてもよく、または整列の似ていない方向を有してもよい。たとえば、一部の実施形態では、ナノファイバーシート102はナノファイバーの平行な整列方向を有するように位置づけられてもよい。しかしながら、他の実施形態では、ナノファイバーシート102は、ある角度で向けられたナノファイバーの整列方向で位置づけられてよい。たとえば、隣接するナノファイバーシートは、互いから少なくとも1°、少なくとも5°、少なくとも10°、少なくとも15°、少なくとも20°、少なくとも25°、少なくとも45°、少なくとも60°、または少なくとも85°の角度でのナノファイバーの整列方向で位置づけられてもよい。
接着性ナノファイバー複合材100は、本明細書に記載されている技法によることを含む任意の好適な技法によって製造されてもよい。図11は、接着性ナノファイバー複合材100を形成するのに使用されてもよい方法例200を説明している。図11で示されるように、方法200は、ナノファイバーシート(複数可)を提供すること202と任意でナノファイバーシート(複数可)を金属化すること204とを含む。ナノファイバーシートは、化学蒸着(CVD)、圧力補助化学蒸着(PCVD)、電子ビーム(eBeam)堆積、スパッタリング、原子層堆積(ALD)、及び/又は電気めっきを含むが、これらに限定されない既知の技法によって金属化されてもよい。ナノファイバーシートは一部の実施形態では、1を超えるナノファイバーシートの積み重ね配置にて個々にまたは全体として金属化されてもよい。ナノファイバーシートの積み重ね配置が金属化される一部のそのような実施形態では、金属は、最上部のナノファイバーシートだけでなく下にある1つ又は複数のナノファイバーシートにも堆積させてもよい。一部の実施形態では、1を超える金属層をナノファイバーシート(複数可)に堆積させてもよい。接着性ナノファイバー複合材が金属化される実施形態では、金属の堆積に先立って緩衝層をナノファイバーシート(複数可)上に堆積させてもよい。一部のそのような実施形態では、CVD、PCVD、eBeam堆積、スパッタリング、ALD及び/又は電気めっきを含む、ナノファイバーシートを金属化するのに使用される技法を用いて緩衝層を堆積させてもよい。種々の実施形態では、緩衝層は接着、摩耗、電気伝導性及び/又は反射性を改善することができる。緩衝層110に関して本明細書に記載されている任意の物質を用いて緩衝層を形成してもよい。
多数の方法を用いて主題の開示に係る接着性ナノファイバー複合材を製造してもよい。一部の特定の実施例が本明細書に詳細に記載されている。
20枚のナノファイバーシートと、ポリアクリル酸系の接着剤と、約150nmの厚さを有する銀金属層とを含む接着性ナノファイバー複合材例を形成した。この接着性ナノファイバー複合材例は測定された0.7Ω/スクエアの電気抵抗を有した。
Claims (17)
- カーボンナノチューブを含む少なくとも1つのナノファイバーシートと、
前記カーボンナノチューブ上に共形に堆積されてなる金属層と、
前記カーボンナノチューブと前記金属層との間に緩衝層と、
前記少なくとも1つのナノファイバーシート上の接着剤であって、前記接着剤と前記少なくとも1つのナノファイバーシートとで、10Ω/スクエア未満の電気抵抗を有する接着性ナノファイバー複合材を形成する、接着剤と、
前記少なくとも1つのナノファイバーシートとは反対側の前記接着剤に付着する除去可能な基材と
を備える接着性ナノファイバー複合材。 - 前記接着剤が感圧接着剤である請求項1に記載の接着性ナノファイバー複合材。
- 前記接着剤が、アクリル、ポリウレタン、ラテックス、ブチルゴム、天然ゴム、スチレンブロックコポリマー、ポリエステル、シリコーン、ポリビニルエステル及びそれらの組み合わせから成る群から選択される請求項1に記載の接着性ナノファイバー複合材。
- 前記接着剤がステンレス鋼基材上で2〜30N/25mmの間の接着強度を有する請求項1に記載の接着性ナノファイバー複合材。
- 少なくとも2つのナノファイバーシートを備える請求項1に記載の接着性ナノファイバー複合材。
- 前記金属層の金属が、金、銀、銅、及びアルミニウムを少なくとも1つ含む請求項1に記載の接着性ナノファイバー複合材。
- 前記緩衝層が炭化物形成金属を含む請求項1に記載の接着性ナノファイバー複合材。
- 前記炭化物形成金属がチタンである請求項7に記載の接着性ナノファイバー複合材。
- 前記緩衝層が30nm未満の膜厚を有する請求項1に記載の接着性ナノファイバー複合材。
- 前記除去可能な基材が変形可能である請求項1に記載の接着性ナノファイバー複合材。
- 前記接着性ナノファイバー複合材が伸縮可能である請求項1に記載の接着性ナノファイバー複合材。
- 前記接着性ナノファイバー複合材が5ミクロン未満の総厚を有する請求項1に記載の接着性ナノファイバー複合材。
- 前記少なくとも1つのナノファイバーシートが10nm未満の厚さを有する請求項1に記載の接着性ナノファイバー複合材。
- カーボンナノチューブを含む少なくとも1つのナノファイバーシートと
前記少なくとも1つのナノファイバーシートの前記カーボンナノチューブと電気的に接触する金属層であって、前記カーボンナノチューブ上に共形に堆積されてなる金属層と、
前記少なくとも1つのナノファイバーシートの前記カーボンナノチューブと前記金属層との間に緩衝層と、
前記少なくとも1つのナノファイバーシート上の接着剤と
を備えた金属化された接着性ナノファイバー複合材。 - 前記接着剤が、アクリル、ポリウレタン、ブチルゴム、天然ゴム、スチレンブロックコポリマー、ポリエステル、シリコーン、ポリビニルエステル及びそれらの組み合わせから成る群から選択される請求項14に記載の金属化された接着性ナノファイバー複合材。
- 前記金属層の金属が、金、銀、銅、白金、ニッケル、スズ、亜鉛、リチウム、タングステン、アルミニウム、及びパラジウムの少なくとも1つを含む請求項14に記載の金属化された接着性ナノファイバー複合材。
- 前記緩衝層がチタンを含む請求項14に記載の金属化された接着性ナノファイバー複合材。
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