TWI461347B - 微結構材料及其製造方法 - Google Patents

微結構材料及其製造方法 Download PDF

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TWI461347B
TWI461347B TW097149977A TW97149977A TWI461347B TW I461347 B TWI461347 B TW I461347B TW 097149977 A TW097149977 A TW 097149977A TW 97149977 A TW97149977 A TW 97149977A TW I461347 B TWI461347 B TW I461347B
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mesh
substrate
article
coating
emulsion
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TW200946441A (en
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Arkady Garbar
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Cima Nanotech Israel Ltd
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Description

微結構材料及其製造方法
本發明係關於微結構材料及製造微結構材料之方法的領域。
本發明根據35 USC §119(e)規定主張2008年6月16日申請之美國臨時申請案案號61/061,890及2007年12月20日申請之美國臨時申請案案號61/015,483之優先權，其全文以引用方式併入本文。
具有控制微結構之材料具有廣大消費性及工業用途。特別地，具有經控制孔隙率之經選擇材料的薄相鄰片係用於各種應用中。該薄片及該等孔可供多種目的使用。例如，織物及紡織品可由編織材料產生以供機械載體、化學分離、絕熱或裝飾用途使用。多種材料可用於界定材料網狀物，例如自然有機材料係用於傳統服飾中。或者，無機材料，諸如金屬可用於多種多孔消費性應用中，諸如插入窗或門中之傳統屏風中的金屬網。此外，金屬網存在各式各樣的工業用途，包括作為尺寸-分離過濾器、電磁干擾過濾器、基材、電極等等之用途。
控制網狀物結構，包括網眼尺寸及尺寸分佈(寬度、厚度)、網眼材料、網眼連通性、網眼孔徑及孔徑分佈之手段係各式各樣的並且經常係非常昂貴的。高度複雜的製造技術，諸如光刻法，或印刷及電鑄法可精確形成幾何結構，但需極大成本。成本較低之製造技術係存在的，諸如交織或衝壓，但受限於幾何形狀控制及精密度或材料性質。
因此對經簡化之經改良微結構材料以及更經濟之製造方法存在著需要。
此處揭示一種微結構物件及其製造方法。物件包括圍繞不規則形網格之互連跡線的獨立式網狀物，其中互連跡線包括至少部分連接之奈米顆粒。基於奈米顆粒之薄圖案化結構宏觀上具有一互連二維網狀圖案並且微觀上具有界定網狀物圖案之一連串連接之奈米顆粒。該圖案化結構在此為簡化亦將稱為「網眼」，即使圖案係不規則形的並且不是藉由互連垂直和水平部件所形成的。該網眼可被稱為「獨立式」或「自持」或「無基材」，所有皆提及無單石基材(諸如均勻薄片網)被整合至物件中之事實。
微結構材料之另一態樣係關於形成網眼或圖案化結構的金屬奈米顆粒。當顆粒具有小於約100奈米之平均粒徑時係較佳的，具有高達約3微米之平均粒徑的較大顆粒可用於一些場合中。不論尺寸，用於形成本發明之圖案化結構之所有顆粒在此將被稱為「奈米顆粒」。奈米顆粒可被燒結成彼此緊密接觸以界定一牢固互連的網狀物。此等金屬網狀物可另外以低薄片電阻(例如，<10,000Ohms/sq)、對可見光之高透明度(例如，>50%)、低區域質量密度(小至1g/m2 )、經控制之小孔(在1um2 及1mm2 之間)以及小網狀跡線(<100um寬度，<100um厚度)為特徵。典型網狀物的結構將係無規的，其具有尺寸類似，通常呈圓形或多角形之不規則形網格。
在一些情況中，可能希望網眼之網格內包含填充材料，諸如與此同一日期申請之共同申請案中所述般，其揭示內容以引用的方式併入本文中。
另一實施例係一種網眼，其中奈米顆粒具有附加塗層或材料塗層，諸如可藉由電鍍一第二金屬(與奈米顆粒材料類似或不同)層在奈米顆粒網狀物上或完全圍繞奈米顆粒網狀物實現。或者，可使用鈍化材料層，諸如氧化物或有機塗層。此外，可使用黏著劑。
另一實施例係由二維網狀網眼所構成，其中二維網狀網眼之兩表面具有不對稱性質。例如，一側表面可具有高度平面性以及高鏡面光反射，並且第二側具有比其外形更高無規度，以及較低鏡面光反射但更高之漫反射。而且，兩面可係不同顏色。
本發明之另一態樣係關於一種製造微結構材料之方法。US20050214480及WO2006/135735描述一種乳液乾燥方法以在基材上形成包含奈米顆粒的透明傳導性塗料。遵循該方法或相關方法後，可執行其他步驟以製造一獨立式微結構材料。
該方法之一實施例係藉由化學移除或鈍化將網眼黏合至基材之黏著元素而自基材釋出先前存在之網眼。例如，酸或鹼可用於移除將金屬網眼固定在基材上之有機黏著劑。或者，可藉由熱力方法或光激發使黏著元素惰性或者被破壞。
另一實施例係藉由化學移除基材而自基材釋出先前存在之網眼。例如，酸或鹼可用於自金屬網眼移除有機基材。
另一實施例係藉由將先前存在之網眼自一基材轉移至第二或另一基材，然後釋出第二或另一基材而自基材處釋出先前存在之網眼。例如，具有平坦表面以及用於圖案形成之最佳性質的基材或具有高通量處理能力之基材最初可用於形成網狀圖案或網眼，然後將網眼轉移至經塗覆，例如，經黏著劑塗覆之第二基材以隨後轉移網眼，諸如藉由黏著劑之釋出轉移網眼。
另一實施例係以機械方式有或無如上所述之額外處理地將網眼拉離初始基材。為促進藉由方法，諸如刮、剝除、用刀分離及類似方法而將網眼機械移除，所形成之網眼可藉由化學處理而部分釋出或減弱其對基材之黏著力，或者網眼可在對其黏著力較低之初始基材上形成並且隨後藉由自基材處「剝除」之而完全移除。
另一實施例係在網眼中引起機械應力以協助或強迫移除，諸如藉由網眼在由網眼與基材間之熱膨脹係數的差異所驅動的燒結或分層期間收縮進行。
另一實施例係利用化學環境以連續或同時塗覆以及移除網眼。例如，酸性電鍍槽可用於同時塗覆網狀網眼以及降低將網狀物固定至基材之黏著力。
在從基材移除之後，網眼可經拉長或變形以便改變網格之形狀。例如，伸長可定向並且增加網眼中網格的縱橫比。此可有效增強沿一軸之傳導，以及可能有效增加電各向異性。
獨立式微結構材料具有許多產品應用。材料可用作透明導體，特別係作為下列中之一或多種：電極、EMI過濾器、天線、導電接地面、散熱器、加熱器、電子材料過濾器或熱交換器。
材料可用作機械濾波器(例如)以分離材料或保持材料或者具有不同有效尺寸或性質之燒灼材料之不同區域分離。該過濾器可用於多種操作介質中，包括真空、空氣、水、溶劑及一般流體。
該材料可用作加熱器或熱交換器，其具有高有效表面積以用於網眼與開放介質，諸如真空、空氣、水、溶劑及一般流體間之熱傳遞。
該材料科同時用作EMI過濾器及空氣或流體通風孔，諸如在金屬網眼用於完成一圍繞目標之法拉第籠以防止EMI傳輸越過壁障，但同時容許空氣或流體流動而使熱量輸送穿越相同區域之情況。
藉由對其施加恒定或隨時間變化之電壓以控制材料流向或通過過濾器，該材料可用作電子濾波器。
上述概述不意圖描述本發明之各揭示實施例或每個執行。隨後之圖式及詳細說明係更詳細地例證說明性實施例。
本發明之微結構材料係基於奈米顆粒之細小網眼，其宏觀上具有在跡線間形成不規則形網格之互連跡線之二維網狀圖案，並且微觀上具有界定網狀物之跡線之一連串連接奈米顆粒。該網眼可被稱為「獨立式」或「自持」或「無基材」，所有皆提及無單石基材(諸如均勻薄片網)被整合至物件中之事實。
該材料可藉由US20050214480及WO2006/135735(其揭示內容以引用的方式併入本文中)中所描述在基材上形成透明傳導性塗層之方法的改良及擴充形成。如上述專利申請案中所描寫般，可利用一具有添加劑諸如奈米顆粒之乳液的方法以在控制條件下基材上製造一網狀網眼。在較佳構型中，該網狀物可由金屬奈米顆粒組成，隨後以熱力或化學方式燒結之以互連奈米顆粒而形成一互連網眼並且可視需要經電鍍以提高導電性。
根據本發明方法之一實施例，隨後處理該網眼，諸如藉由電鍍處理之以添加類似或非類似材料至網眼中，並且將其暴露於酸中以釋出適當固定基材之黏合劑而產生獨立式網眼。如上所述，獨立式網眼對禁止或限制結合基材之網眼的應用而言將具有許多好處。
額外好處亦可包括移除未連接至剩餘網眼之材料，諸如在別的開放/透明網格中間中乳液塗覆處理中所形成之分離奈米顆粒。該等奈米顆粒增加薄膜光霧度並且降低透明度，但無顯著增加薄片之電或熱傳導性質。依此方式產生獨立式網眼降低最終物件中此類缺陷量。同樣，沿網狀跡線邊緣之結合性不佳的材料將被移除，並且可改良透明度/光霧度而無顯著降低電導。此外，完整並且完好，但無達到另一網狀「網點」(僅一端連接至網狀物之網狀支柱)的平滑網狀跡線可優先以此種方式自網狀物移除。
所得薄膜亦將係重量較輕，消耗較少體積，以及允許自網狀物之相對側緊密電、熱力或者化學連接。該方法亦可再次使用基材，所以在網眼本身之製造中消耗較少材料，並且允許基材用於塗覆之可針對塗覆最適化之用途，並且隨後，可使用具有針對最終使用應用最適化之性質的分離基材(或獨立式薄膜)。
現參考圖式，圖1a及1b係具有84%可見光透明度、3%光霧度及0.04Ohms/sq薄片電阻之微結構網眼的實施例之光學影像。
如可在圖2中所見般，以傳輸模式取得之光學顯微照片(微結構網眼以網眼之網格中可見之透射光在在成像系統上投射影子)，本發明之一實施例在網狀網眼中以大致20um寬的網路線或大致20um厚之跡線產生大致100um大小、不規則形之網格。
在如圖3及4中所顯示般於較高放大率下，以反射模式(微結構網眼將鏡面反射光反射回至成像系統)取得之影像顯示相同網眼之兩相對表面之反射影像在鏡面反射中具有很大差異。
用於製造獨立微結構網眼之方法之一實施例係逐步描述於圖5中。
微結構網眼可在連續捲繞方法中使用如圖6中所示之慣用設備製成。處理線之不同站係如下所描述般：
站1係用於軋輥之退繞元件。
站2係底漆塗層站。
站3係底漆乾燥站。
站4係乳液塗覆站。
站5係乳液乾燥站。
站6係電鍍槽站。
站7係酸暴露站。
站8係乾燥站。
站9係自載體分離網眼之分離站。
站10係一對用於收集網眼及載體之繞組元件。
現參考圖7，圖7係用於製造本發明之微結構物件並且隨後將其轉移至與其原來形成於上之不同基材之方法之另一實施例之簡圖。如圖7中所示般，提供基材組合或複數個基材組合702。
基材組合702可係撓性或剛性的，諸如玻璃、紙、陶瓷及織物。該基材可包含聚合物諸如聚酯、聚醯胺、聚醯亞胺、聚碳酸酯、聚烯烴、聚丙烯酸酯、聚甲基丙烯酸甲酯(PMMA)、共聚物或其混合物。基材702可具有平坦表面或曲面，並且表面可係光滑或者粗糙的。
為改良某些性質，基材可經預處理及/或可具有在塗覆乳液調配物之前施加預備的塗層。例如，基材可具有底漆層以控制網眼塗覆黏附，或者基材可具有所施加之硬塗覆層以便對刮傷及損壞提供機械抗力。底漆亦可影響網眼中之網格尺寸，因此允許針對某些產品應用最適化網眼。
可執行預處理，例如藉由物理手段或化學手段清潔表面或改變之。該手段包括(但不限於)：電暈、電漿、UV曝光、雷射、輝光放電、微波、火焰處理、化學蝕刻、機械蝕刻或印刷。該處理可施用於乾淨之基材或者施用於薄膜供應商已放置底漆、預備塗層或預先處理基材表面的基材上。
預處理步驟可在隨後塗覆、印刷及沉積步驟之前立即離線或線上執行。基材之該物理處理可藉由批次處理設備或連續塗覆設備以小型實驗室規模或較大工業規模，包括捲繞方法執行。
基材組合702係經提供至乳液塗覆站。在乳液塗覆站處，將乳液施用至基材組合702之表面710上。
乳液較佳係如上所述具有分散於乳液之有機相中之奈米顆粒的油包水型乳液。顆粒與期望之溶劑混合以形成分散，該分散可藉由機械攪拌、球磨混合及利用均質器或超音波混合而達到。
奈米顆粒較佳係由導電性金屬或金屬之混合物組成，其中金屬之混合物包含選自(但不限於)銀、金、鉑、鈀、鎳、鈷、銅或任何該等之組合之群的金屬合金。適合之金屬奈米顆粒包含銀、銀銅合金、銀鈀或其他銀合金、或由已知為冶金化學方法(MCP)生產之金屬或金屬合金，而冶金化學方法(MCP)係描述於美國專利第5,476,535號(「生產高 純度特細金屬粉末之方法」)及PCT申請案WO2004/000491 A2(「用於生產極高純度之金屬奈米粉末之方法以及藉此生產之奈米粉末」)。奈米顆粒可係經塗覆或未經塗覆，並且可係成團或非成團的。
乳液可在乳液塗覆站藉由任何適合之技術，諸如壓模塗覆、線棒塗覆、絲網印刷、噴墨印刷、旋轉塗覆、浸塗、噴霧塗覆、凹板印刷、滾筒塗覆及刮刀塗覆施加。實驗室規模或工業方法可在乳液塗覆站處利用單程或多程塗覆設備應用。應將乳液施用至基材組合702之表面710以提供1至200微米之濕乳液厚度，並且更佳係5至200微米。
將乳液施加至表面710後，有或無施加熱地自乳液蒸發溶劑，如參考數字712處所所示般。較佳地，如參考數字714處所示般，在約室溫至約850℃範圍內之溫度下燒結剩餘塗層，藉此提供網眼層於表面710上。燒結較佳係發生在環境大氣壓下。
或者或者額外地，全部或部分參考數字714處所顯示之燒結處理可在引起燒結處理的化學品的存在下進行。適合之化學品實例包括甲醛或酸類，諸如甲酸、乙酸及鹽酸。化學品可呈蒸汽或流體形式，而沉積之顆粒係暴露於其中。或者，該等化學品可在沉積之前摻入包含奈米顆粒之組合物中，或可在將顆粒沉積在基材上後沉積在奈米顆粒上。
該方法亦可包括後-燒結處理步驟，如參考數字716處所 顯示般，其中可如上所述般更進一步燒結、退火、電鍍網眼層或者利用熱、雷射、紫外線、酸或其他處理後-處理網眼層及/或將其暴露於化學品諸如金屬鹽、鹼或離子液體中。經處理之網眼層可使用水或其他化學洗液諸如酸性溶液、丙酮或其他適合液體洗滌。塗層之後處理可藉由批次處理設備或連續塗覆設備以小型實驗室規模或較大工業規模，包括捲繞方法執行。
較佳網眼層的特徵在於燒結後之薄片電阻係在0.005Ω/square至5kΩ/square之間，較佳係小於50ohm/sq，更佳係小於20ohm/sq，並且最佳係小於或等於10ohm/sq。當電鍍網眼層時，薄片電阻進一步降低。
網眼層之形成可在最多約350℃之溫度下使用低溫沉積及處理方法亦係本方法之特點。低溫液相處理可以相對較低之成本執行，尤其當網眼層形成於大規模表面上並且允許使用熱敏基材諸如某些聚合體基材時。
可控制網眼層之形成以獲得不同網格尺寸並且調整之以獲得特殊器件之最佳性能亦係本方法之特點。例如，在形成網眼之前，基材上底漆之使用可改變網格尺寸。
在網眼移除站，網眼層係與基材組合702分離而形成分離或獨立式網眼層。網眼層與基材組合702之分離可藉由物理方法諸如刮、剝除、用刀分離及類似方法實現。隔離劑或脫模層之存在，或者無黏著劑存在可促進網眼層之移除。
該方法亦可包含變形步驟，其中網眼層係經伸長或變形 以便改變網眼內之網格形狀。例如，如以網眼圖案所說明般，伸長可定向並且增加之網格的縱橫比。
具有圖案之分離網眼層可被收集於一軋輥上，或者轉移至另一基材上以用於後續處理。附加處理步驟可如上所述結合參考數字716的方式執行。
本發明可更進一步藉由下列非限制性實例說明。在此等實例中，網眼係根據US20050214480及WO2006/135735中所描述之方法以及如描述之後續處理先形成於基材上。
實例1
使用4mil厚之聚對苯二甲酸乙二酯(Toray Lumirror U46)之基材。
在基材上沉澱一底漆層。底漆係由0.28wt%聚[二甲基矽氧烷-共-[3-(2-(2-羥基乙氧基)乙氧基)丙基]甲基矽氧烷](Aldrich Cat.No.480320)及0.60wt%溶於丙酮溶液中之Synperonic NP30(Fluka Cat.No 86209)所構成。材料係藉由手搖動而混合。大約3ml之材料係沉積在8.5"×11"之基材材料樣品一邊緣上，並且利用繞線桿向下流過薄膜以產生名義上12微米厚(濕)之塗層。允許樣品在室溫以及室內濕度條件中乾燥大約1分鐘。
在上表中水相系統本身係由BYK 348於水中之0.02%溶液(重量比)組成。
如上所述般大約3ml材料係沉積在8.5"×11"已塗覆有底漆之基底材料樣品之一邊緣上，並且使用繞線桿向下流過該薄膜以產生名義上30微米厚(濕)之塗層。允許樣品在室溫以及室內濕度條件中乾燥大約90秒。隨後將其放置在烘箱中150℃下2分鐘。
隨後將樣品浸入丙酮槽中30秒，在空氣中乾燥大約1分鐘，並且浸入水槽中之1M HCl裏1分鐘，在水槽中溫和清洗/攪拌10秒，並且另外在烘箱中150℃下乾燥2分鐘。
在此步驟中，金屬薄膜之網狀網眼係在PET基材上產生。隨後步驟允許產生獨立式網眼。
電解槽係藉由製造下列以質量百分比列出之溶液製得：7.00% CuSO4 *5H2 O，0.029%聚乙二醇，0.010%十二烷基硫酸鈉，9.61% H2 SO4 ，0.021% HCl，及83.33%去離子水。
此溶液係在直徑為10英吋以及高度為12英吋之12夸脫Prolon桶中混合。
將Mastech HY1803D電源緊鄰該槽放置，其中陰極係連接至5英吋寬1英吋長之扁平銅電極，並且陽極係連接至大約4英吋寬5英吋高用作尺寸大約相同之微孔樣品之相對電極之扁平銅板。
基材上之微結構網眼樣品係沿頂部邊緣以夾具連接陰極銅電極並且幾乎整個浸入電解質溶液地下降至一深度而使電極夾緊物(5"×1"銅)正好不及與電鍍槽接觸處(大約5mms網眼在電鍍槽外)。接著將正電極板浸入電解質溶液中。
在浸沒兩個電極後，取決期望之電阻，於1.01安培之穩定電流下持續10或15分鐘啟動電源。在電鍍第一個五分鐘之後，從槽中取出電鍍10分鐘之樣品，使其脫離夾具，並且倒置(從上至下)，再夾緊，並且再次電鍍以提供更佳電鍍厚度均勻性，同時在7.5分鐘後倒置電鍍15分鐘之樣品。接著自槽中移除經塗覆基材，以流動自來水洗滌樣品不到1分鐘，並且另其在空氣中乾燥。
為自基材移除電鍍塗層，將樣品置於10%硫酸溶液中整夜。接著用手緩慢剝除該層。在電鍍前，微結構網眼薄片之電阻係大約5ohms/square，而10及15分鐘電鍍樣品在電鍍後之電阻範圍分別為0.1-0.2及0.06-0.1ohms/square。
實例2
網眼係在玻璃基材上產生。在室溫下將網眼及基材浸入5%氫氟酸於水中之槽中達1分鐘，自槽中取出，使用自來水洗滌不到1分鐘。用手自基材剝除金屬網眼。
702‧‧‧基材組合
710‧‧‧表面
圖1a係本發明微結構物件之一實施例的照片。
圖1b係以較高放大率顯示微結構物件圖案之圖1a之實施例。
圖2係微結構物件之一實施例以背光取得之顯微鏡影像。
圖3係微結構物件之一實施例以擷取反射影像所取得的顯微鏡影像。
圖4係微結構物件之一實施例之由第二表面擷取反射影像所取得的顯微鏡影像。
圖5說明用於製造微結構物件之本發明一實施例之步驟。
圖6係圖解用於製造微結構物件之本發明實施例之示意圖。
圖7係圖解用於製造微結構物件之本發明另一實施例之示意圖。
(無元件符號說明)

Claims (14)

  1. 一種微結構物件，其包含一環繞不規則形網格的互連金屬跡線之獨立式網狀物，其中該互連跡線包括至少部分連接之奈米顆粒。
  2. 如請求項1之物件，其中該網狀物具有小於10,000ohms/sq之薄片電阻。
  3. 如請求項1之物件，其中該網狀物具有在一平方微米及一平方毫米之間之網格尺寸。
  4. 如請求項1之物件，其中該跡線係小於100微米寬及小於100微米厚。
  5. 如請求項1之物件，其中該跡線於其上包括一塗層。
  6. 如請求項5之物件，其中該塗層係藉由電鍍形成。
  7. 如請求項5之物件，其中該塗層包含一鈍化材料。
  8. 如請求項7之物件，其中該鈍化材料係一氧化物或一有機塗層。
  9. 如請求項1之物件，其中該物件包含至少兩個主要表面，並且一主要表面具有比另一主要表面更平滑之形貌。
  10. 如請求項1之物件，其中該物件包含至少兩個主要表面，並且一主要表面係與另一主要表面不同顏色。
  11. 一種用於製造如請求項1之微結構物件之方法，其包括：a)藉由源自一乳液之該等奈米顆粒之自組合形成一互連跡線之網狀物，該網狀物包含一基材表面上圍繞不規 則形網格之奈米顆粒；b)電鍍該網狀物；c)將該網狀物暴露於酸以將該網狀物自該基材處釋出；及d)自該基材處移除該網狀物。
  12. 如請求項11之方法，其中該乳液包括一油包水型乳液且該油相包括一具有奈米顆粒分散於其中之有機溶劑。
  13. 如請求項11之方法，其中該網狀物係在自其形成於上之基材移除後轉移至一第二基材。
  14. 一種用於製造如請求項1之微結構物件之方法，其包括：a)藉由源自一乳液之該等奈米顆粒之自組合形成一互連跡線之網狀物，該網狀物包含一基材表面上圍繞不規則形網格之奈米顆粒；b)藉由機械手段自該基材分離該網狀物；及c)將經分離之網狀物收集於一捲軸上。
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