Patent Application
20170152386
The present invention relates to a copper powder to be used as a material for an electrically conductive paste and the like, and more particularly, to a copper powder having a novel shape capable of improving electric conductivity and a copper paste using the same.
A paste such as a resin type paste or a calcined type paste using a metal filler such as a silver powder or a copper powder is frequently used in the formation of a wiring layer, an electrode, and the like in an electronic device.
A metal filler paste of silver or copper is applied or printed on various kinds of substrates of an electronic device and subjected to a treatment of heat curing or heat calcination to form an electrically conductive film to be a wiring layer or an electrode.
For example, a resin type electrically conductive paste is composed of a metal filler, a resin, a curing agent, a solvent, and the like, and it is formed into an electrically conductive film by being printed on an electric conductor circuit pattern or a terminal and cured by heating at from 100° C. to 200° C. so as to form a wire and an electrode. In a resin type electrically conductive paste, the thermosetting resin is cured and shrunk by heat, and metal fillers are thus joined by pressure and brought into contact with one another so that the metal fillers overlap each other, and as a result, an electrically connected current path is formed. This resin type electrically conductive paste is treated at a curing temperature of 200° C. or lower so that it is often used in a substrate using a material susceptible to heat such as a printed wiring board.
On the other hand, a calcination type electrically conductive paste is composed of a metal filler, glass, a solvent, and the like, and it is formed into an electrically conductive film by being printed on an electric conductor circuit pattern or a terminal and calcined by heating at from 600° C. to 800° C. so as to form a wire and an electrode. The calcination type electrically conductive paste is treated at a high temperature so that electrical continuity is secured as the metal fillers are sintered together. This calcination type electrically conductive paste cannot be used in a printed wiring board using a resin material since it is treated at a high temperature for calcination in this manner, but it has a feature that low resistance is easily obtained since the metal fillers are connected by sintering. Such a calcination type electrically conductive paste is used, for example, in an external electrode of a multilayer ceramic capacitor or the like.
Meanwhile, a silver powder has been so far used as a metal filler to be used in these resin type electrically conductive paste and calcination type electrically conductive paste. However, in recent years, the price of precious metals has soared and the use of a copper powder that is less expensive than the silver powder has been preferred for cost reduction as well.
Here, shapes such as a granular shape, a dendritic shape, and a flat plate shape have been often used as the powder of copper or silver to be used as a metal filler since electricity is conducted as the particles are connected to one another.
Particularly, in the case of evaluating the particles by the sizes in three directions, longitudinal, lateral, and thickness, a flat plate shape having a thin thickness has an advantage that it is possible to secure a larger contact area in which the particles are in contact with one another than cubic or spherical particles having a certain thickness so that low resistance, namely, high electric conductivity can be accordingly achieved as well as the flat plate shape contributes to thinning of the wiring material due to a decrease in thickness. Hence, it is particularly suitable for an application as an electrically conductive coating material or an electrically conductive paste for which electric conductivity is desired to be maintained.
In addition, the influence of impurities contained in the copper powder is not ignored in the case of using the electrically conductive paste by thinly applying it.
In order to fabricate such a flat plate-shaped copper powder, for example, a method for obtaining a flake-shaped copper powder suitable for a filler of an electrically conductive paste is disclosed in Patent Document 1. Specifically, a spherical copper powder having an average particle diameter of from 0.5 to 10 μm as a raw material is mechanically processed into a flat plate-shaped copper powder by mechanical energy of the medium loaded in the mill by using a ball mill or a vibration mill.
In addition, for example, a technique related to a copper powder for electrically conductive paste, in particular, a discoid copper powder capable of obtaining high performance as a copper paste for a through hole and an external electrode and a method for producing the same are disclosed in Patent Document 2. Specifically, a granular atomized copper powder is put in a medium stirring mill, from 0.5 to 1 mass % fatty acid is added thereto with respect to the copper powder, and the copper powder is ground in the air or an inert atmosphere by using a steel ball having a diameter of from ⅛ to ¼ inch as a grinding medium so as to be processed into a flat plate shape.
Furthermore, for example, a method for obtaining an electrolytic copper powder of which the moldability is improved as compared to an electrolytic copper powder of the prior art without developing the dendrite of the electrolytic copper powder more than necessary so that it can be molded to have high strength is disclosed in Patent Document 3. Specifically, one kind or two or more kinds selected from a tungstate, a molybdate, and a sulfur-containing organic compound are added to an aqueous solution of copper sulfate of an electrolytic solution to precipitate an electrolytic copper powder for the purpose of miniaturizing the size of the crystallites constituting the electrolytic copper powder so as to precipitate an electrolytic copper powder which can be molded to have high strength through an increase in strength of the electrolytic copper powder itself.
In any of the methods disclosed in these Patent Documents, the granular copper powder obtained is formed into a flat plate shape by being mechanically deformed (processed) by using a medium such as a ball, and regarding the size of the flat plate-shaped copper powder formed through the processing, the average particle diameter is from 1 to 30 μm in the technique of Patent Document 1, and the average particle diameter is set to a size of from 7 to 12 μm in the technique of Patent Document 3.
Meanwhile, an electrolytic copper powder precipitated in a dendritic shape called a dendritic shape is known. The dendritic electrolytic copper powder is formed through a process in which copper grows while branching so that copper grows in a needle shape by branching in the secondary direction from copper that has first grown in a needle shape, then further grows in a needle shape from the secondary direction to the tertiary direction, and the like, furthermore, each branch also has a shape so that tree leaves grow on the branches as the width of each branch spreads and the like. Such a dendritic electrolytic copper powder has a dendritic shape, and thus it has a large surface area, exhibits excellent moldability and sinterability, and is used as a raw material for an oil-retaining bearing, a mechanical part, or the like as a powder metallurgy application. In particular, the miniaturization of an oil-retaining bearing and the like has progressed, and the oil-retaining bearing and the like are required to be porous, thinned, and complicatedly shaped along with this. In order to meet these requirements, for example, a copper powder for metal powder injection molding which has a complicated three-dimensional shape and a high dimensional accuracy and a method for manufacturing an injection molded article using the same are disclosed in Patent Document 4. Specifically, it has been indicated that the copper powder can be molded to have a high strength since the dendrites of the adjacent electrolytic copper powders are intertwined with one another at the time of the compression molding so as to be firmly connected to one another by further developing the dendritic shape. Furthermore, it is described that it is possible to utilize the fact that a larger number of contact points are formed as compared to a spherical shape since the copper powder has a dendritic shape in the case of being utilized as a metal filler of an electrically conductive paste or an electromagnetic wave shield.
However, in the case of utilizing a dendritic copper powder as described above as a metal filler of an electrically conductive paste, an electromagnetic wave shielding resin, or the like, the dendritic copper powders are intertwined with one another to cause aggregation when the metal filler in the resin has a dendritically developed shape, and thus a problem that the dendritic copper powders are not uniformly dispersed in the resin and the viscosity of the paste increases due to aggregation to cause a problem in the wiring formation by printing. Such a problem is also pointed out, for example, in Patent Document 3.
In this manner, it is not easy to use a dendritic copper powder as a metal filler of an electrically conductive paste or the like, and the dendritic copper powder is also a cause of poor progress in the improvement in electric conductivity of the paste. Incidentally, it is easier for a dendritic shape to secure the contact points than a granular shape in order to secure electric conductivity, and it is thus possible to secure high electric conductivity as an electrically conductive paste or an electromagnetic wave shield.
Patent Document 1: Japanese Unexamined Patent Application, Publication No. 2005-200734
Patent Document 2: Japanese Unexamined Patent Application, Publication No. 2002-15622
Patent Document 3: Japanese Unexamined Patent Application, Publication No. 2011-58027
Patent Document 4: Japanese Unexamined Patent Application, Publication No. H09-3510
The present invention has been proposed in view of the circumstances as described above, and an object thereof is to provide a copper powder capable of being suitably utilized in an application such as an electrically conductive paste or an electromagnetic wave shield while securing excellent electric conductivity by increasing the number of contact points among the copper powders.
The present inventors have found out that a copper powder can be uniformly mixed, for example, with a resin while securing excellent electric conductivity and can be thus suitably used in an application such as an electrically conductive paste as the copper powder has a dendritic shape having a linearly grown main stem and a plurality of branches separated from the main stem, the main stem and branches thereof are composed of flat plate-shaped copper particles having a predetermined cross sectional average thickness, and the copper powder has an average particle diameter in a specific range, thereby completing the present invention. In other words, the present invention provides the following.
(1) A first aspect of the present invention is a copper powder having a dendritic shape having a linearly grown main stem and a plurality of branches separated from the main stem, in which the main stem and the branches include flat plate-shaped copper particles having a cross sectional average thickness of from 0.2 μm to 1.0 μm and an average particle diameter (D50) of the copper powder is from 5.0 μm to 30 μm.
(2) A second aspect of the present invention is the copper powder according to the first aspect, in which a ratio obtained by dividing a cross sectional average thickness of the flat plate-shaped copper particles by an average particle diameter (D50) of the copper powder is in a range of from 0.01 to 0.1 and a bulk density of the copper powder is in a range of from 0.3 g/cm3 to 5.0 g/cm3.
(3) A third aspect of the present invention is the copper powder according to the first or second aspect, in which a crystallite diameter in the Miller index of a (111) plane by X-ray diffraction is in a range of from 800 Å to 2000 Å.
(4) A fourth aspect of the present invention is a metal filler including the copper powder according to any one of the first to third aspects at a proportion of 20% by mass or more to the entire metal filler.
(5) A fifth aspect of the present invention is a copper paste including the metal filler according to the fourth aspect mixed with a resin.
(6) A sixth aspect of the present invention is an electrically conductive coating material for electromagnetic wave shielding including the metal filler according to the fourth aspect.
(7) A seventh aspect of the present invention is an electrically conductive sheet for electromagnetic wave shielding including the metal filler according to the fourth aspect.
The copper powder according to the present invention is a dendritic copper powder having a linearly grown main stem and a plurality of branches separated from the main stem, and the main stem and branches thereof are composed of flat plate-shaped copper particles having a predetermined cross sectional average thickness. This makes it possible to have a large contact area as well as to secure a large number of contact points, to secure excellent electric conductivity, and to prevent aggregation, and the copper powder can be thus suitably utilized in an application such as an electrically conductive paste or an electromagnetic wave shield.
Hereinafter, specific embodiments (hereinafter, referred to as the “present embodiment”) of the copper powder according to the present invention will be described in detail with reference to the drawings. Incidentally, the present invention is not limited to the following embodiments, and various modifications are possible without changing the essence of the present invention.
This dendritic copper powder 1 can be obtained, for example, by immersing an anode and a cathode in an electrolytic solution which exhibits acidity by sulfuric acid and contains a copper ion and allowing a direct current to flow through the electrolytic solution for electrolysis so as to precipitate copper on the cathode although the production method will be described in detail later.
As illustrated in the observation image of
Here, the flat plate-shaped copper particles constituting the main stem 2 and the branch 3 have a cross sectional average thickness of from 0.2 μm to 1.0 μm. The effect as a flat plate is further exerted as the cross sectional average thickness of the flat plate-shaped copper particles is thinner. In other words, it is possible to secure a large contact area between the copper particles and between the dendritic copper powders 1 as the main stem 2 and the branch 3 are constituted by flat plate-shaped copper particles having a cross sectional average thickness of 1.0 μm or less, and it is possible to realize low resistance, namely, high electric conductivity as the contact area increases. This makes it possible for the copper powder to exhibit superior electric conductivity, to maintain electric conductivity, and to be suitably used in an application of an electrically conductive coating material or an electrically conductive paste. In addition, the dendritic copper powder 1 can contribute to thinning of a wiring material and the like as it is constituted by the flat plate-shaped fine copper particles 2.
Incidentally, the concaves and convexes decrease when the size of the flat plate is too small even if the cross sectional average thickness of the flat plate-shaped copper particles is as thin as 1.0 μm or less, and the number of contact points decreases when the dendritic copper powders 1 come in contact with one another. Hence, the lower limit value of the cross sectional average thickness of the copper particles 2 is preferably 0.2 μm or more as described above, and this makes it possible to increase the number of contact points.
In addition, the average particle diameter (D50) of the dendritic copper powder 1 is from 5.0 μm to 30 μm. Incidentally, the average particle diameter (D50) can be measured, for example, by a method for laser diffraction and scattering type particle size distribution measurement.
Here, for example, as pointed out in Patent Document 1, a problem of a dendritic copper powder is that the dendritic copper powders are intertwined with one another to cause aggregation and are not uniformly dispersed in the resin in some cases when the metal filler in the resin has a developed dendritic shape in the case of utilizing the dendritic copper powder as a metal filler of an electrically conductive paste, a resin for electromagnetic wave shielding, or the like. In addition, the viscosity of the paste increases due to the aggregation so as to cause a problem in wiring formation by printing. This is caused by a large shape of the dendritic copper powder, and the size of the shape of the dendritic copper powder is required to be decreased in order to solve this problem while taking advantage of the dendritic shape. However, it is impossible to secure the dendritic shape when the dendritic copper powder is too small. Hence, the dendritic copper powder is required to have a size larger than a predetermined size in order to secure the effect of being a dendritic shape, namely, the effect that the dendritic copper powder has a large surface area, exhibits excellent moldability and sinterability, and can be molded to have a high strength by being strongly connected to one another via a branch-shaped place as it has a three-dimensional shape.
In this regard, the surface area increases and favorable moldability and sinterability can be secured as the average particle diameter of the dendritic copper powder 1 is from 5.0 μm to 30 μm. Moreover, the dendritic copper powder 1 according to the present embodiment has a dendritic shape as well as the main stem 2 and branch 3 thereof are composed of flat plate-shaped copper particles in this manner, and it is thus possible to secure more contact points among the copper powders 1 by the three-dimensional effect of being dendritic and the effect that the copper particles constituting the dendritic shape have a flat plate shape.
In addition, the dendritic copper powder 1 is not particularly limited, but it is preferable that the ratio (cross sectional average thickness/average particle diameter) obtained by dividing the cross sectional average thickness of the flat plate-shaped copper particles by the average particle diameter (D50) of the dendritic copper powder 1 is in a range of from 0.01 to 0.1. The ratio (aspect ratio) represented by “cross sectional average thickness/average particle diameter” is an indicator, for example, of an aggregation degree and dispersibility when the dendritic copper powder is processed as an electrically conductive copper paste and the retainability of the appearance shape at the time of coating the copper paste. When this aspect ratio is less than 0.01, the dendritic copper powder is close to a copper powder composed of spherical copper particles, aggregation thereof is likely to occur, and it is difficult to uniformly disperse the dendritic copper powder in the resin at the time of being formed into a paste. On the other hand, when the aspect ratio exceeds 0.1, the viscosity increases at the time of forming the dendritic copper powder into a paste and the retainability of the appearance shape and the surface smoothness of the copper paste at the time of being applied deteriorate in some cases.
In addition, the bulk density of the dendritic copper powder 1 is not particularly limited, but it is preferably in a range of from 0.3 g/cm3 to 5.0 g/cm3. There is a possibility that the contact points among the copper powders cannot be sufficiently secured when the bulk density is less than 0.3 g/cm3. On the other hand, when the bulk density exceeds 5.0 g/cm3, the average particle diameter of the dendritic copper powder 1 also increases, the surface area decreases, and the moldability and the sinterability thus deteriorate in some cases.
In addition, the dendritic copper powder 1 is not particularly limited, but it is preferable that the crystallite diameter thereof is in a range of from 800 Å (angstrom) to 2000 Å. When the crystallite diameter is less than 800 Å, the copper particles constituting the main stem 2 and branch 3 tend to have a spherical shape rather than a flat plate shape, it is difficult to secure a sufficiently large contact area, and there is a possibility that electric conductivity decreases. On the other hand, when the crystallite diameter exceeds 2,000 Å, the average particle diameter of the dendritic copper powder 1 also increases, the surface area decreases, and the moldability and sinterability thus deteriorate in some cases.
Here, the crystallite diameter is determined from the diffraction pattern obtained by using an X-ray diffraction measuring apparatus on the basis of the Scherrer equation expressed by the following Equation (1), and it is a crystallite diameter in Miller index of the (111) plane by X-ray diffraction.
D=0.9λ/βcos θ. . . Equation (1)
(Incidentally, D: crystallite diameter (Å), β: diffraction peak spread (rad) depending on crystallite size, λ: wavelength of X-ray [Cuκα] (Å), and θ: diffraction angle (°) .)
Incidentally, it is possible to obtain the same effect as the copper powder composed only of the dendritic copper powder when the dendritic copper powder having the shape as described above accounts for a predetermined proportion in the obtained copper powder when observed through an electron microscope although copper powders having shapes other than the shape are mixed therein. Specifically, copper powders having shapes other than the shape described above may be contained in the obtained copper powder as long as the dendritic copper powder having the shape described above accounts for 50% by number or more, preferably 80% by number or more, and more preferably 90% by number or more in the entire copper powders when observed through an electron microscope (for example, 500-times to 20,000-times).
The dendritic copper powder 1 according to the present embodiment can be produced by a predetermined electrolytic method using, for example, a solution which exhibits acidity by sulfuric acid and contains a copper ion as an electrolytic solution.
Upon electrolysis, for example, the solution which exhibits acidity by sulfuric acid and contains a copper ion described above is accommodated in an electrolytic cell in which metallic copper is installed as the anode and a stainless steel plate, a titanium plate, or the like is installed as the cathode and an electrolytic treatment is conducted by applying a direct current to the electrolytic solution at a predetermined current density. This makes it possible to precipitate (electrodeposit) the dendritic copper powder 1 on the cathode along with energization. Particularly, in the present embodiment, it is possible to precipitate the dendritic copper powder 1 in which the flat plate-shaped fine copper particles 2 gather to form a dendritic shape on the surface of the cathode by only the electrolysis without subjecting the copper powder which is obtained by electrolysis and has a granular shape or the like to mechanical deformation processing or the like using a medium such as a ball.
More specifically, as the electrolytic solution, for example, one that contains a water-soluble copper salt, sulfuric acid, an additive such as an amine compound, and a chloride ion can be used.
The water-soluble copper salt is a copper ion source for supplying a copper ion, and examples thereof may include copper sulfate such as copper sulfate pentahydrate, copper chloride, and copper nitrate, but the water-soluble copper salt is not limited thereto. In addition, the concentration of the copper ion in the electrolytic solution can be set to about from 1 g/L to 20 g/L and preferably about from 5 g/L to 10 g/L.
Sulfuric acid is an acid that is used to prepare an electrolytic solution exhibiting acidity from sulfuric acid. The concentration of sulfuric acid in the electrolytic solution may be set to about from 20 g/L to 300 g/L and preferably about from 50 g/L to 150 g/L as the concentration of free sulfuric acid. This concentration of sulfuric acid affects the electric conductivity of the electrolytic solution and it thus affects the uniformity of the copper powder obtained on the cathode.
As an additive, for example, an amine compound can be used. This amine compound contributes to the shape control of the copper powder to be precipitated together with the chloride ion to be described later, and it is thus possible to form the copper powder to be precipitated on the surface of the cathode into a dendritic copper powder having a main stem and branches branched from the main stem which are composed of flat plate-shaped copper particles having a predetermined cross sectional average thickness.
The amine compound is not particularly limited but, for example, safranine or the like can be used. Incidentally, as the amine compound, one kind may be added singly or two or more kinds may be added concurrently. In addition, the amount of the amine compound added is preferably set to an amount so that the concentration of the amine compound in the electrolytic solution is in a range of about from 0.1 mg/L to 500 mg/L.
The chloride ion can be contained in the electrolytic solution by adding a compound (chloride ion source) for supplying a chloride ion such as hydrochloric acid and sodium chloride thereto. The chloride ion contributes to the shape control of the copper powder to be precipitated together with the additive such as the amine compound described above. The concentration of the chloride ion in the electrolytic solution can be set to about from 30 mg/L to 1000 mg/L, preferably about from 50 mg/L to 800 mg/L, and more preferably about from 100 mg/L to 300 mg/L.
In the method for producing the dendritic copper powder according to the present embodiment, for example, the dendritic copper powder is produced by precipitating and generating a copper powder on the cathode through electrolysis using the electrolytic solution having the composition as described above. A known method can be used as the electrolysis method. For example, the current density is preferably set to a range of from 5 A/dm2 to 30 A/dm2 upon electrolysis using an electrolytic solution exhibiting acidity by sulfuric acid, and the electrolytic solution is energized while being stirred. In addition, the liquid temperature (bath temperature) of the electrolytic solution can be set, for example, to about from 20° C. to 60° C. In addition, the time for electrolysis may be appropriately set depending on the concentration of the copper ion in the electrolytic solution and the like, and it can be set, for example, to about from 6 hours to 15 hours.
<<3. Application such as Electrically Conductive Paste and Electrically Conductive Coating Material>>
The dendritic copper powder 1 according to the present embodiment is a dendritic copper powder having a linearly grown main stem and a plurality of branches branched from the main stem, the main stem and branches thereof are composed of flat plate-shaped copper particles having a cross sectional average thickness of from 0.2 μm to 1.0 82 m, and the average particle diameter (D 50) of the copper powder is from 5.0 82 m to 30 μm as described above. Such a dendritic copper powder 1 has a large surface area and exhibits excellent moldability and sinterability as it has a dendritic shape, and the dendritic copper powder 1 can secure a large number of contact points and exhibits excellent electric conductivity as the main stem and branch thereof are composed of predetermined flat plate-shaped copper particles.
In addition, according to the dendritic copper powder 1 having such a predetermined structure, it is possible to suppress aggregation of the dendritic copper powder and to uniformly disperse the dendritic copper powder in the resin even in the case of forming the dendritic copper powder into a copper paste or the like, and it is also possible to suppress occurrence of defective printing and the like due to an increase in viscosity of the paste or the like. Hence, the dendritic copper powder 1 can be suitably used in applications such as an electrically conductive paste and an electrically conductive coating material.
For example, as an electrically conductive paste (copper paste), the dendritic copper powder 1 is not limited to use under particularly limited conditions, but the electrically conductive paste can be fabricated by kneading the dendritic copper powder 1 according to the present embodiment as a metal filler with a binder resin, a solvent, and further an additive such as an antioxidant or a coupling agent if necessary.
The dendritic copper powder 1 according to the present embodiment can be used by being mixed with a copper powder having another shape in the case of being utilized as a metal filler of an electrically conductive paste or the like. At this time, the proportion of the dendritic copper powder 1 in the total amount of the copper powders is preferably 20% by mass or more, more preferably 50% by mass or more, and even more preferably 75% by mass or more. In this manner, in the case of using the dendritic copper powder 1 as a metal filler, the gap of the dendritic copper powder 1 is filled with a copper powder having another shape by mixing the copper powder having another shape together with the dendritic copper powder 1 as the copper powder, and this makes it possible to secure more contact points for securing electric conductivity. In addition, as a result, it is also possible to decrease the total input amount of the dendritic copper powder 1 and a copper powder having another shape. When the dendritic copper powder 1 is less than 20% by mass in the total amount of the copper powders to be used as the metal filler, the contact points among the dendritic copper powders 1 decrease and electric conductivity as a metal filler decreases even if an increase in the number of contact points due to mixing of the dendritic copper powder 1 with a copper powder having another shape is taken into consideration. Incidentally, as a copper paste, for example, a spherical copper powder of about from 1 μm to 10 μm may be mixed in the copper paste as the rest as long as the dendritic copper powder 1 is contained therein at a proportion to be an amount of 20% by mass or more as described above.
Specifically, the binder resin is not particularly limited, but an epoxy resin, a phenol resin, or the like can be used. In addition, organic solvents such as ethylene glycol, diethylene glycol, triethylene glycol, glycerin, and terpineol can be used as the solvent. In addition, the amount of the organic solvent added is not particularly limited, but the added amount can be adjusted in consideration of the particle size of the dendritic copper powder 1 so as to obtain a viscosity suitable for an electrically conductive film forming method such as screen printing or a dispenser.
Furthermore, it is also possible to add another resin component for adjustment of viscosity. Examples thereof may include a cellulose-based resin typified by ethyl cellulose, and it is added as an organic vehicle prepared by dissolving the resin component in an organic solvent such as terpineol. Incidentally, the amount of the resin component added is required to be suppressed to an extent to which the sinterability is not inhibited, and it is preferably set to 5% by mass or less with respect to the total amount.
In addition, an antioxidant or the like can be added as an additive for improving electric conductivity after calcination. The antioxidant is not particularly limited, but examples thereof may include a hydroxycarboxylic acid. More specifically, a hydroxycarboxylic acid such as citric acid, malic acid, tartaric acid, or lactic acid is preferable, and citric acid or malic acid having a high adsorptive power to copper is even more preferable. The amount of the antioxidant added can be set, for example, to about from 1 to 15% by mass in consideration of the antioxidation effect, the viscosity of the paste, and the like.
In addition, the metal filler described above is not limited to utilization under particularly limited conditions in the case of being used as the material for electromagnetic wave shielding as well, and it is possible to use the metal filler by a general method, for example, by mixing it with a resin.
For example, in the case of forming an electrically conductive coating material for electromagnetic wave shielding by utilizing the metal filler described above, it is possible to utilize the metal filler as an electrically conductive coating material by a general method, for example, by mixing it with a resin and a solvent and further with an antioxidant, a thickener, an anti-settling agent, and the like if necessary and kneading the mixture. The binder resin and solvent to be used at this time are not particularly limited, and those that have been used in the prior art can be used. For example, a vinyl chloride resin, a vinyl acetate resin, an acrylic resin, a polyester resin, a fluorocarbon resin, a silicone resin, a phenol resin, and the like can be used. In addition, with regard to the solvent as well, it is possible to use an alcohol such as isopropanol, an aromatic hydrocarbon such as toluene, an ester such as methyl acetate, a ketone such as methyl ethyl ketone, and the like which have been used in the prior art. In addition, with regard to the antioxidant as well, it is possible to use a fatty acid amide, a higher fatty acid amine, a phenylenediamine derivative, a titanate-based coupling agent, and the like, which have been used in the prior art.
In addition, in the case of forming an electrically conductive sheet for electromagnetic wave shielding by utilizing the metal filler described above as well, the resin to be used for forming the electromagnetic wave shielding layer of the electrically conductive sheet for electromagnetic wave shielding is not particularly limited, and those that have been used in the prior art can be used. For example, it is possible to appropriately use a thermoplastic resin, a thermosetting resin, a radiation-curing resin, and the like that are composed of various kinds of polymers and copolymers such as a vinyl chloride resin, a vinyl acetate resin, a vinylidene chloride resin, an acrylic resin, a polyurethane resin, a polyester resin, an olefin resin, a chlorinated olefin resin, a polyvinyl alcohol-based resin, an alkyd resin, and a phenol resin.
The method for producing the electromagnetic wave shielding material is not particularly limited, but for example, the electromagnetic wave shielding material can be produced by applying or printing a coating material in which a metal filler and a resin are dispersed or dissolved in a solvent on a substrate to form an electromagnetic wave shielding layer and drying the coating material to an extent to which the surface is solidified. In addition, it is possible to utilize a metal filler containing the dendritic silver coated copper powder 1 according to the present embodiment in the electrically conductive adhesive layer of an electrically conductive sheet.
Hereinafter, the present invention will be described more specifically with reference to Examples together with Comparative Examples, but the present invention is not limited to the following Examples at all.
The copper powders obtained in the following Examples and Comparative Examples are subjected to the observation of shape, the measurement of average particle diameter, and the measurement of crystallite diameter by the following methods.
20 arbitrary fields of vision were observed in a field of vision at 1,000-times magnification through a scanning electron microscope (model: JSM-7100F manufactured by JEOL Ltd.), and the copper powder contained in the field of vision was observed.
(Measurement of average particle diameter)
The average particle diameter (D50) of the obtained copper powder was measured by using a laser diffraction/scattering method particle size distribution measuring instrument (HRA9320×-100 manufactured by NIKKISO CO., LTD.).
The crystallite diameter was calculated from the diffraction pattern obtained with an X-ray diffraction measuring apparatus (X′Pert PRO manufactured by PANanalytical B. V.) by a method generally known as the Scherrer equation. (Measurement of aspect ratio)
The obtained copper powder was embedded in an epoxy resin to fabricate a sample for measurement, and the sample was cut and polished, and observed through a scanning electron microscope to observe the cross section of the copper powder. First, 20 copper powders were observed and the average thickness (cross sectional average thickness) of the copper powders was determined. Next, the aspect ratio (average thickness/D50) was determined from the ratio of the average thickness value to the average particle diameter (D50) determined by using a laser diffraction/scattering method particle size distribution measuring instrument.
The specific resistance value of the coating film was determined by measuring the sheet resistance value with a four-terminal method using a low resistivity meter (Loresta-GP MCP-T600 manufactured by Mitsubishi Chemical Corporation) and the film thickness of the coating film using a surface roughness and shape measuring instrument (SURFCO M130A manufactured by TOKYO SEIMITSU CO., LTD.) and dividing the sheet resistance value by the film thickness.
The evaluation of the electromagnetic wave shielding property was carried out by measuring the attenuation factor of the samples obtained in the respective Examples and Comparative Examples by using an electromagnetic wave having a frequency of 1 GHz. Specifically, the level in the case of Comparative Example 4 in which the dendritic copper powder was not used was evaluated as “Δ”, a case in which the attenuation factor was worse than the level of Comparative Example 4 was evaluated as “×”, a case in which the attenuation factor was more favorable than the level of Comparative Example 4 was evaluated as “◯”, and a case in which the attenuation factor was superior to the level of Comparative Example 4 was evaluated as “573 ”.
In addition, it was confirmed whether the electromagnetic wave shielding property changed or not by bending the fabricated electromagnetic wave shield in order to evaluate the flexibility of the electromagnetic wave shield.
A titanium electrode plate having an electrode area of 200 mm ×200 mm and a copper plate having an electrode area of 200 mm ×200 mm were installed in an electrolytic cell having a capacity of 100 L as the cathode and the anode, respectively, an electrolytic solution was put in the electrolytic cell, and a direct current was applied to this, thereby precipitating a copper powder on the cathode plate.
At this time, a solution having a composition in which the concentration of copper ion was 10 g/L and the concentration of sulfuric acid was 100 g/L was used as the electrolytic solution. In addition, Basic Red 2 (manufactured by KANTO CHEMICAL CO., INC.) as an additive was added to this electrolytic solution so as to have a concentration of 75 mg/L in the electrolytic solution, and a hydrochloric acid solution (manufactured by Wako Pure Chemical Industries, Ltd.) was further added thereto so that the concentration of chloride ion (chlorine ion) in the electrolytic solution was 30 mg/L.
Thereafter, the temperature of the electrolytic solution adjusted to the concentration described above was maintained at 25° C. while circulating the electrolytic solution with a metering pump at a flow rate of 15 L/min, and an electric current was applied thereto so that the current density of the cathode was 25 A/dm2, thereby precipitating a copper powder on the cathode plate.
The electrolytic copper powder precipitated on the cathode plate was mechanically scraped off to the cell bottom of the electrolytic cell by using a scraper and recovered, and the copper powder thus recovered was washed with pure water, then placed in a vacuum dryer, and dried.
The shape of the electrolytic copper powder thus obtained was observed by the method using a scanning electron microscope (SEM) described above, and as a result, the copper powder thus precipitated was a copper powder having a two-dimensional or three-dimensional dendritic shape, and it was a copper powder having a dendritic shape having a linearly grown main stem, a plurality of branches linearly branched from the main stem, and branches further branched from the branches. In addition, the copper particles constituting the main stem and the branches had a flat plate shape having a cross sectional thickness (cross sectional average thickness) of 0.42 μm. In addition, the average particle diameter (D50) of the dendritic copper powder was 25.1 μm. Moreover, the aspect ratio calculated from the cross sectional average thickness of the copper particles and the average particle diameter of the dendritic copper powder was 0.016. In addition, the crystallite diameter of the dendritic copper powder was 1752 Å. Incidentally, it was confirmed that such a dendritic copper powder is present in the entire copper powders thus obtained at least at a proportion of 65% by number or more. In addition, the bulk density of the copper powder thus obtained was 0.43 g/cm3.
A copper powder was precipitated on the cathode plate under the same conditions as in Example 1 except that a solution having a composition in which the concentration of copper ion was 5 g/L and the concentration of sulfuric acid was 100 g/L was used as the electrolytic solution, Basic Red 2 as an additive was added to the electrolytic solution so as to have a concentration of 100 mg/L in the electrolytic solution, and a hydrochloric acid solution was further added thereto so that the concentration of chlorine ion in the electrolytic solution was 50 mg/L.
The shape of the electrolytic copper powder thus obtained was observed by the method using a scanning electron microscope (SEM) described above, and as a result, the copper powder thus precipitated was a copper powder having a two-dimensional or three-dimensional dendritic shape, and it was a copper powder having a dendritic shape having a linearly grown main stem, a plurality of branches linearly branched from the main stem, and branches further branched from the branches. In addition, the copper particles constituting the main stem and the branches had a flat plate shape having a cross sectional thickness (cross sectional average thickness) of 0.38 μm. In addition, the average particle diameter (D50) of the dendritic copper powder was 8.5 μm. Moreover, the aspect ratio calculated from the cross sectional average thickness of the copper particles and the average particle diameter of the dendritic copper powder was 0.045. In addition, the crystallite diameter of the dendritic copper powder was 922 Å. Incidentally, it was confirmed that such a dendritic copper powder is present in the entire copper powders thus obtained at least at a proportion of 75% by number or more. In addition, the bulk density of the copper powder thus obtained was 0.76 g/cm3.
A copper powder was precipitated on the cathode plate under the same conditions as in Example 1 except that a solution having a composition in which the concentration of copper ion was 5 g/L and the concentration of sulfuric acid was 100 g/L was used as the electrolytic solution, Basic Red 2 as an additive was added to the electrolytic solution so as to have a concentration of 150 mg/L in the electrolytic solution, and a hydrochloric acid solution was further added thereto so that the concentration of chlorine ion in the electrolytic solution was 75 mg/L.
The shape of the electrolytic copper powder thus obtained was observed by the method using a scanning electron microscope (SEM) described above, and as a result, the copper powder thus precipitated was a copper powder having a two-dimensional or three-dimensional dendritic shape, and it was a copper powder having a dendritic shape having a linearly grown main stem, a plurality of branches linearly branched from the main stem, and branches further branched from the branches. In addition, the copper particles constituting the main stem and the branches had a flat plate shape having a cross sectional thickness (cross sectional average thickness) of 0.88 μm. In addition, the average particle diameter (D50) of the dendritic copper powder was 15.5 μm. Moreover, the aspect ratio calculated from the cross sectional average thickness of the copper particles and the average particle diameter of the dendritic copper powder was 0.057. In addition, the crystallite diameter of the dendritic copper powder was 1272 Å. Incidentally, it was confirmed that such a dendritic copper powder is present in the entire copper powders thus obtained at least at a proportion of 75% by number or more. In addition, the bulk density of the copper powder thus obtained was 0.58 g/cm3.
A copper powder was precipitated on the cathode plate under the same conditions as in Example 1 except a condition in which Basic Red 2 as an additive and a chlorine ion were not added to the electrolytic solution.
The shape of the electrolytic copper powder thus obtained was observed by the method using a scanning electron microscope (SEM) described above, and as a result, although the copper powder thus obtained had a dendritic shape, the granular copper particles gathered. Incidentally,
A solution having a composition in which the concentration of copper ion was 10 g/L and the concentration of sulfuric acid was 150 g/L was used as the electrolytic solution. In addition, Basic Red 2 (manufactured by KANTO CHEMICAL CO., INC.) as an additive was added to this electrolytic solution so as to have a concentration of 50 mg/L in the electrolytic solution, and a hydrochloric acid solution (manufactured by Wako Pure Chemical Industries, Ltd.) was further added thereto so that the concentration of chloride ion (chlorine ion) in the electrolytic solution was 10 mg/L. Thereafter, the temperature of the electrolytic solution adjusted to the concentration described above was maintained at 45° C. while circulating it with a metering pump at a flow rate of 15 L/min, and an electric current was applied thereto so that the current density of the cathode was 20 A/dm2, thereby precipitating a copper powder on the cathode plate. Incidentally, an electrolytic copper powder was fabricated under the same conditions as in Example 1 except these conditions.
The shape of the electrolytic copper powder thus obtained was observed by the method using a scanning electron microscope (SEM) described above and the results thereof are illustrated in
The evaluation results of the dendritic copper powders obtained in Examples and Comparative Examples described above are summarized in the following Table 1. Incidentally, with regard to the results observed through an SEM, a case when the dendritic copper powder was a dendritic copper powder of which the main stem and the branch extending from the main stem were constituted by flat plate-shaped copper particles was denoted by “◯”, and a case when the dendritic copper powder was not a dendritic copper powder of which the main stem and the branch extending from the main stem were constituted by flat plate-shaped copper particles was denoted by “×”.
With 70 parts by mass of the electrolytic copper powder obtained in Example 1, 15 parts by mass of a phenol resin (PL-2211 manufactured by Gunei Chemical Industry Co., Ltd.) and 10 parts by mass of butyl cellosolve (KANTO CHEMICAL CO., INC. Cica Special Grade) were mixed, and the mixture was repeatedly kneaded by using a small kneader (Non-bubbling Kneader NBK-1 manufactured by NIHONSEIKI KAISHA LTD.) for 3 minutes at 1200 rpm three times to be formed into a paste. Upon pasting, the copper powder was uniformly dispersed in the resin without aggregating with one another. The copper paste thus obtained was printed on glass by using a metal squeegee and cured for 30 minutes at temperatures of 150° C. and 200° C. in the air atmosphere.
The specific resistance value of the coating film obtained by curing was measured, as a result, it was 8.9×10−5 Ω·cm (curing temperature: 150° C.) and 2.4×10−5 Ω·cm (curing temperature: 200° C.), respectively, and it has been found that excellent electric conductivity is exhibited.
With 70 parts by mass of the electrolytic copper powder obtained in Example 2, 15 parts by mass of a phenol resin (PL-2211 manufactured by Gunei Chemical Industry Co., Ltd.) and 10 parts by mass of butyl cellosolve (KANTO CHEMICAL CO., INC. Cica Special Grade) were mixed, and the mixture was repeatedly kneaded by using a small kneader (Non-bubbling Kneader NBK-1 manufactured by NIHONSEIKI KAISHA LTD.) for 3 minutes at 1200 rpm three times to be formed into a paste. Upon pasting, the copper powder was uniformly dispersed in the resin without aggregating with one another. The copper paste thus obtained was printed on glass by using a metal squeegee and cured for 30 minutes at temperatures of 150° C. and 200° C. in the air atmosphere.
The specific resistance value of the coating film obtained by curing was measured, as a result, it was 9.2×10−5 Ω·cm (curing temperature: 150° C.) and 2.8×10−5 Ω·cm (curing temperature: 200° C.), respectively, and it has been found that excellent electric conductivity is exhibited.
In order to compare the dendritic copper powder to a flat plate-shaped copper powder of the prior art, comparison of the dendritic copper powder to a flat plate-shaped copper powder fabricated by mechanically flattening a granular electrolytic copper powder was carried out. Specifically, for the fabrication of the flat plate-shaped copper powder, 5 g of stearic acid was added to 500 g of a granular atomized copper powder (manufactured by MAKIN METAL POWDERS LTD.) having an average particle diameter of 7.9 μm, and the mixture was subjected to a flattening treatment by a ball mill. The flattening treatment was conducted by putting 5 kg of 3 mm zirconia beads in the ball mill and rotating the mixture for 90 minutes at a rotation speed of 500 rpm. The average particle diameter of the flat plate-shaped copper powder fabricated in this manner was measured by a laser diffraction/scattering method particle size distribution measuring instrument, and as a result, it was 20.1 μm. The flat plate-shaped copper powder was observed through a scanning electron microscope, and as a result, the thickness thereof was 0.4 μm.
Next, the flat plate-shaped copper powder thus obtained was formed into a paste in the same manner as in Example 4, 15 parts by mass of a phenol resin (PL-2211 manufactured by Gunei Chemical Industry Co., Ltd.) and 10 parts by mass of butyl cellosolve (KANTO CHEMICAL CO., INC. Cica Special Grade) were mixed with 70 parts by mass of the flat plate-shaped copper powder, and the mixture was repeatedly kneaded by using a small kneader (Non-bubbling Kneader NBK-1 manufactured by NIHONSEIKI KAISHA LTD.) for 3 minutes at 1200 rpm three times to be formed into a paste. The copper paste thus obtained was printed on glass by using a metal squeegee and cured for 30 minutes at temperatures of 150° C. and 200° C. in the air atmosphere.
The specific resistance value of the coating film obtained by curing was measured, as a result, it was 2.1×10−4 Ω·cm (curing temperature: 150° C.) and 5.6×10−5 Ω·cm (curing temperature: 200° C.), respectively, and the copper paste thus obtained had a higher specific resistance value and exhibited poorer electric conductivity as compared to the copper pastes obtained in Examples 4 and 5.
The dendritic copper powder fabricated in Example 1 was dispersed in a resin to produce an electromagnetic wave shielding material.
In other words, 40 g of the dendritic copper powder obtained in Example 1 was mixed with 100 g of a vinyl chloride resin and 200 g of methyl ethyl ketone, respectively, and the mixture was repeatedly kneaded by using a small kneader for 3 minutes at 1200 rpm three times to be formed into a paste. Upon pasting, the copper powder was uniformly dispersed in the resin without aggregating with one another. This was applied on a substrate formed of a transparent polyethylene terephthalate sheet having a thickness of 100 μm by using a Mayer bar and dried to form an electromagnetic wave shielding layer having a thickness of 25 μm.
The electromagnetic wave shielding property was evaluated by measuring the attenuation factor by using an electromagnetic wave having a frequency of 1 GHz. The evaluation results on the property are presented in Table 2.
The dendritic copper powder fabricated in Example 2 was dispersed in a resin to produce an electromagnetic wave shielding material.
In other words, 40 g of the dendritic copper powder obtained in Example 2 was mixed with 100 g of a vinyl chloride resin and 200 g of methyl ethyl ketone, respectively, and the mixture was repeatedly kneaded by using a small kneader for 3 minutes at 1200 rpm three times to be formed into a paste. Upon pasting, the copper powder was uniformly dispersed in the resin without aggregating with one another. This was applied on a substrate formed of a transparent polyethylene terephthalate sheet having a thickness of 100 μm by using a Mayer bar and dried to form an electromagnetic wave shielding layer having a thickness of 25 μm.
The electromagnetic wave shielding property was evaluated by measuring the attenuation factor by using an electromagnetic wave having a frequency of 1 GHz. The evaluation results on the property are presented in Table 2.
The flat plate-shaped copper powder fabricated in Comparative Example 3 by mechanically flattening a granular electrolytic copper powder was dispersed in a resin to produce an electromagnetic wave shielding material.
In other words, 40 g of the flat plate-shaped copper powder obtained in Comparative Example 3 was mixed with 100 g of a vinyl chloride resin and 200 g of methyl ethyl ketone, respectively, and the mixture was repeatedly kneaded by using a small kneader for 3 minutes at 1200 rpm three times to be formed into a paste. Upon pasting, the copper powder was uniformly dispersed in the resin without aggregating with one another. This was applied on a substrate formed of a transparent polyethylene terephthalate sheet having a thickness of 100 μm by using a Mayer bar and dried to form an electromagnetic wave shielding layer having a thickness of 25 μm.
The electromagnetic wave shielding property was evaluated by measuring the attenuation factor by using an electromagnetic wave having a frequency of 1 GHz. The evaluation results on the property are presented in Table 2.
1 Copper powder (dendritic copper powder)
2 Stem
3, 3a, and 3b Branch
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-130456 | Jun 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/059483 | 3/26/2015 | WO | 00 |
