Patent Application
20100136327
The present invention provides modified carbon nanotube (CNT), and a CNT/Polymer composite having electromagnetic interference shielding effectiveness, and preparation methods thereof.
USP 2007/012900 A1 discloses a particulate conductive filler which comprises a conductive metal coating formed over a coarse carbon-based core such as graphite between 350 and 1000 microns in size. The conductive filler is used in conjunction with a polymer matrix such as an elastomer typified by silicone elastomer to form composite materials for conductive and electromagnetic interference shielding applications.
WO 2007/010517 A1 discloses modified polymers which are prepared by providing a nanotube or nanoparticle suspension, adding a preformed polymer, swelling the preformed polymer in the suspension, and isolating the modified polymer from the suspension. The polymer may be a swellable polymer in the form of polymeric yarns, fibres, fabrics, ribbons or films. The swelling may be carried out using ultrasonic treatment. Carbon nanotubes, magnetic (Fe3O4) and fluorescent (CdTe) nanoparticles suspensions have been utilized to demonstrate the fabrication of new polymer composites. The magnetic polymer composites are useful in electromagnetic interference (EMI) shielding of medical equipment in hospitals, computers and consumer electronics.
USP 2005/127329 A1 discloses a method of reinforcing a polymeric material with nanosize materials, in which materials such as vapor grown carbon nanofibers, carbon nanotubes, layered silicates, nanosize sphered silica, or graphite nanoparticles are combined with a polymer and a solvent to form a substantially homogeneous mixture, followed by removal of the solvent by evaporation or coagulation. Depending on the nanosize materials used, the resulting polymeric nanocomposite material exhibits high electrical and thermal conductivity, enhanced mechanical strength, abrasion resistance, reduced gas permeation, and/or dimensional stability. The polymeric nanocomposite material may be used in electromagnetic interference shielding. The polymer used in this prior art invention is preferably selected from the group consisting of polyurethanes, polyolefins, polyamides, polyimides, epoxy resins, silicone resins, polycarbonate resins, acrylic resins, and aromatic-heterocyclic rigid-rod and ladder polymers.
WO 2004/097853 A1 discloses a conductive carbon nanotube-polymer composite comprising carbon nanotubes and a polymer, wherein the carbon nanotubes primarily reside between coalesced particles of the polymer. The composite is prepared with a suspension of carbon nanotubes that can be stabilized with a stabilizer, such as a water-soluble polymer or surfactant. The nanotube suspension is mixed with a polymer suspension of polymer particles that substantially exclude the nanotubes. The polymer suspension can be stabilized with a stabilizer, such as a water-soluble polymer or surfactant. After mixing the two suspensions, water and any solvent are removed to form a nanotube-polymer composite. As liquid is removed from the nanotube-polymer suspension, the polymer particles coalesce and the nanotubes become trapped and aggregate primarily between the polymer particles, wherein the nanotubes form a conductive network in the polymer composite. Electrical percolation was realized with less than 0.04 wt % single-wall carbon nanotubes in poly(vinyl acetate).
The inventors of the present invention disclose in U.S. patent application Ser. No. 12/081,517 (publication No. US 2009-0104361 A1) a method of preparing carbon nanotube/polymer composite having electromagnetic interference (EMI) shielding effectiveness, which comprises dispersing multi-walled carbon nanotubes (MWCNT) in an organic solvent such as N,N-Dimethylacetamide (DMAc); dissolving monomers such as methyl methacrylate (MMA) and an initiator such as 2,2-azobisisobutyronitrile (AIBN) in the MWCNT dispersion; and polymerizing the monomers in the resulting mixture at an elevated temperature such as 120° C. to form a MWCNT/PMMA composite. The composite is coated onto a PET film, and the coated PET film alone or a stack of multiple coated PET films can be applied as an EMI shielding material.
Friedel-Crafts acylation is a well known reaction, details of which can be found on http://en.wikipedia.org/wiki/Friedel-Crafts_reaction.
An objective of the present invention is to provide a modified CNT.
Another objective of the present invention is to provide a modified CNT/polymer composite having electromagnetic interference (EMI) shielding effectiveness.
A further objective of the present invention is to provide a method of preparing a modified CNT.
Another further objective of the present invention is to provide a method of preparing modified CNT/polymer composite having electromagnetic interference (EMI) shielding effectiveness.
In order to accomplish the aforesaid objective a modified carbon nanotube (CNT) prepared in accordance of the present invention comprises a CNT and —C(O)—R′ or —C(O)—R—COOH covalently bounded to a surface of said CNT, wherein R′ is C1-C26 alkyl or C2-C26 alkenyl, and R is C1-C26 alkylene or C2-C26 alkenylene.
Preferably, the modified CNT has —C(O)—R—COOH covalently bounded to the surface thereof. More preferably, R is is —C═C—.
The present invention also discloses a method for preparing a modified carbon nanotube (CNT) comprising undergoing Friedel-Crafts acylation of a CNT and an acid anhydride or acyl chloride in a solvent, in the presence of a catalyst, in an inert atmosphere and under refluxing.
Preferably, said method comprises undergoing Friedel-Crafts acylation of the CNT and the acid anhydride acid. More preferably, said acid anhydride is (RCO)2O, and R is C1-C26 alkylene or C2-C26 alkenylene. Most preferably, R is —C═C—.
The present invention further discloses a modified CNT/polymer composite having electromagnetic interference shielding effectiveness, which comprises a polymer and 0.1-10% of the modified CNT of the present invention dispersed therein, based on the weight of the polymer.
Preferably, the composite is a layer having a thickness of 0.05 mm to 1.0 mm formed on a substrate.
Preferably, said CNT is a single-walled or multi-walled CNT (MWCNT).
Preferably, said CNT is a bamboo-type or a spiral-type CNT.
Preferably, said polymer is a homopolymer of monomers selected from the group consisting of acrylic acid, methacrylic acid, methyl acrylate, methyl methacrylate, and styrene; or a copolymer of acrylonitrile, butadiene and styrene. More preferably, said polymer is poly(methyl methacrylate).
Preferably, said polymer is poly(acrylic acid), poly(methacrylic acid), poly(methyl acrylate), poly(methyl methacrylate), polystyrene, soluble polyamide, soluble polyamideimide, polyamide, soluble polyurethane, unsaturated polyester, acrylonitrile-butadiene-styrene copolymer, poly-ether-sulfone (PES), soluble poly-ether-imide (PEI), poly(vinyl ester), thermoplastic polyurethane, silicone or epoxy resin.
The present invention further discloses a method for preparing a modified CNT/polymer composite having electromagnetic interference (EMI) shielding effectiveness, comprising the following steps:
a) preparing a polymer solution containing 0.1-10 wt % of the modified carbon nanotubes of the present invention dispersed therein, based on the weight of the polymer; and b) coating the polymer solution containing the modified carbon nanotubes dispersed therein on a substrate and drying the resulting layer coated on the substrate.
Preferably, the method of the present invention further comprises the following step: c) stacking a plurality of the substrates prepared from step b), each of which has the dried layer. More preferably, step c) further comprises applying an adhesive on the substrates prior to said stacking so that the stacked substrates are bonded.
Preferably, the dried layer on the substrate prepared in step b) has a thickness of 0.05 mm to 1.0 mm. More preferably, 2 to 100 sheets of the substrates are stacked in step c).
Preferably, said preparing in step a) comprises dispersing the modified carbon nanotubes in an organic solvent; dissolving monomers and an initiator in the carbon nanotubes dispersion; and polymerizing the monomers in the resulting mixture to form said polymer solution containing the modified carbon nanotubes dispersed therein. Said monomers preferably are selected from the group consisting of acrylic acid, methacrylic acid, methyl acrylate, methyl methacrylate, and styrene; or said monomers are a mixture of acrylonitrile, butadiene and styrene. Among them, methyl methacrylate (MMA) is more preferable. Said organic solvent preferably is N,N-Dimethylacetamide (DMAc), said initiator preferably is 2,2-azobisisobutyronitrile (AIBN), and said monomers preferably are polymerized at 120° C.
Alternatively, said preparing in step a) comprises dissolving a polymer in an organic solvent and dispersing the modified carbon nanotubes in the resulting polymer solution to form said polymer solution containing carbon nanotubes dispersed therein. Said polymer preferably is selected from the group consisting of poly(acrylic acid), poly(methacrylic acid), poly(methyl acrylate), poly(methyl methacrylate), soluble polyimide, soluble poly(amide imide), polyamide, polystyrene, soluble polyurethane, unsaturated polyester, poly(ether sulfone), soluble poly(ether imide), poly(vinyl ester), thermoplastic polyurethane, silicone, and epoxy resin. Among them poly(methyl methacrylate) (PMMA) is more preferable. Said PMMA is preferably prepared by polymerizing methyl methacrylate in a solvent of N,N-Dimethylacetamide and in the presence of an initiator of 2,2-azobisisobutyronitrile at 120° C.
Preferably, said substrate in step b) is a film of poly(ethylene terephthalate), polyimide, polyethylene, polypropylene, or poly(vinyl chloride). More preferably, said substrate in step b) is a poly(ethylene terephthalate) (PET) film.
Preferably, said substrate in step b) is an insulation layer enclosing an electric wire.
A carbon nanotube/polymer composite having electromagnetic interference (EMI) shielding effectiveness prepared by a method according to one of the preferred embodiments of the present invention comprises the following steps:
A carbon nanotube/polymer composite having electromagnetic interference (EMI) shielding effectiveness prepared by a method according to another preferred embodiment of the present invention comprises the following steps:
The present invention will be better understood through the following Examples, which are merely for illustration and not for limiting the scope of the present invention. Materials used in the following Examples and Control Examples were:
5 g of pristine multi-walled carbon nanotubes (P-MWCNTs), 500 mL of nitro-methane and 50 g of anhydrous maleic acid anhydride were introduced into a three-neck flask, where a ultrasonication was carried out for one hour and half to dissolve the anhydrous maleic acid anhydride in nitor-methane completely and well disperse P-MWCNTs in the solution. 140 g of AlCl3 was added to the dispersion, and the flask was vacuumed and nitrogen was then introduced. In nitrogen atmosphere the mixture was reacted at 60° C. under refluxing for 60 hours.
500 mL of distilled water was added to the reaction mixture after the reaction, which was then subjected to a ultrasonication for one hour, so that unreacted AlCl3 was dissolved in the distilled water. The resulting mixture was then filtered with suction to obtain powder, which was then added to 500 mL HCl, and ultrasonicated for one hour to neutralize the unreacted maleic acid anhydride on the powder, followed by filtration with suction. The resulting powder was washed with distilled water, and dried in vacuo to obtain a final product of carbon nanotubes modified by Friedel-Crafts acylation (Mah-g-MWCNT), which were identified by XPS and Raman spectra.
Raman spectra were recorded with LabRam I confocal Raman spectrometer (Dilor, France). The excitation wavelength was 632.8 nm from a He—Ne laser with a laser power of ca. 15 mW at the sample surface. A holographic notch filter reflected the exciting line into an Olympus BX40 microscope (Tokyo, Japan). X-Ray photoelectron spectra (XPS) measurements were performed using a VG Scientific ESCALAB 220 iXL spectrometer equipped with a hemispherical electron analyzer and an Mg Ka (hν=1487.7 eV) X-ray source. A small spot lens system allowed analysis of a sample that was less than 1 mm2 in area.
Raman spectroscopy is a powerful tool to investigate the extent of disorder in the functionalized MWCNT.
The content of organic molecules in the modified MWCNT (Mah-g-MWCNT), was determined as the weight loss at 500° C. by TGA. The results show that the modified MWCNT (Mah-g-MWCNT) has 5.05 wt % content of organic molecules.
2.62 g of P-MWCNT were dispersed in 97.5 g of DMAc; 52.5 g of MMA and 0.11 g of AIBN initiator were added into the resulting dispersion; next, the mixture was allowed to undergo polymerization at 120° C. under refluxing for four hours, so that a solution of MWCNT/PMMA composite having 4.76 wt % of MWCNT was formed. The MWCNT/PMMA composite solution was coated on a PET film, and the resulting coating layer was dried by evaporating the organic solvent therefrom to form a MWCNT/PMMA composite layer having a thickness of 0.1 cm on the PET film. The coating area was 20 cm×20 cm. 10 sheets of the coated PET films were prepared as above. A single sheet of the coated PET film was used as an EMI shielding material, or multiple sheets of the coated PET films were stacked and the resulting stack was used as an EMI shielding material.
52.5 g of MMA and 0.11 g of AIBN initiator were dissolved in 97.5 g of DMAc, and the solution was allowed to undergo polymerization at 120° C. under refluxing for four hours to form a PMMA solution. 2.62 g of P-MWCNT was dispersed in the PMMA solution under ultrasonication. The MWCNT/PMMA composite solution was coated on a PET film, and the resulting coating layer was dried by evaporating the organic solvent therefrom to form a MWCNT/PMMA composite layer having a thickness of 0.1 cm on the PET film. The coating area was 20 cm×20 cm. 10 sheets of the coated PET films were prepared as above. A single sheet of the coated PET film was used as an EMI shielding material, or multiple sheets of the coated PET films were stacked and the resulting stack was used as an EMI shielding material.
The procedures in Control Example 1 were repeated except that the pristine MWCNT (P-MWCNT) was replaced by the modified MWCNT (Mah-g-MWCNT) prepared in Preparative Example 1.
The procedures in Control Example 2 were repeated except that the pristine MWCNT (P-MWCNT) was replaced by the modified MWCNT (Mah-g-MWCNT) prepared in Preparative Example 1.
EMI shielding effectiveness (2-18 GHz) was measured by using a HP 8722ES Vector Network Analyzer manufactured by Damaskos, Inc., Concordville, Pa., USA.
The pristine MWCNT/PMMA coated PET film or the stacks of multiple films prepared in Control Examples 1 and 2 of the present invention have better EMI shielding effectiveness in comparison with the PET film(s) coated with the modified Mah-g-MWCNT/PMMA composite having the same MWCNT contents prepared in Examples 1 and 2, as shown in
The P-MWCNT/PMMA composite prepared in Control Example 1 was poured into a PET mold to prepare a sheet of 20 cm×20 cm having a thickness of 1 mm (the P-MWCNT content of 4.76 wt %). A circular specimen for wear endurance test having a diameter of 18 cm and a central hole of 8 mm was cut from the sheet.
The procedures in Control Example 1 were repeated by varying the amount of P-MWCNT used to prepare P-MWCNT/PMMA composites having 0.25, 0.50, 0.74, 0.99 and 2.44 wt % of P-MWCNT, which were then used to prepare circular specimens for wear endurance test as above.
The P-MWCNT/PMMA composite prepared in Control Example 2 was poured into a PET mold to prepare a sheet of 20 cm×20 cm having a thickness of 1 mm (the P-MWCNT content of 4.76 wt %). A circular specimen for wear endurance test having a diameter of 18 cm and a central hole of 8 mm was cut from the sheet.
The procedures in Control Example 2 were repeated by varying the amount of P-MWCNT used to prepare P-MWCNT/PMMA composites having 0.25, 0.50, 0.74, 0.99 and 2.44 wt % of P-MWCNT, which were then used to prepare circular specimens for wear endurance test as above.
The Mah-g-MWCNT/PMMA composite prepared in Example 1 was poured into a PET mold to prepare a sheet of 20 cm×20 cm having a thickness of 1 mm (the P-MWCNT content of 4.76 wt %). A circular specimen for wear endurance test having a diameter of 18 cm and a central hole of 8 mm was cut from the sheet.
The procedures in Example 1 were repeated by varying the amount of Mah-g-MWCNT used to prepare Mah-g-MWCNT/PMMA composites having 0.25, 0.50, 0.74, 0.99 and 2.44 wt % of Mah-g-MWCNT, which were then used to prepare circular specimens for wear endurance test as above.
The Mah-g-MWCNT/PMMA composite prepared in Example 2 was poured into a PET mold to prepare a sheet of 20 cm×20 cm having a thickness of 1 mm (the P-MWCNT content of 4.76 wt %). A circular specimen for wear endurance test having a diameter of 18 cm and a central hole of 8 mm was cut from the sheet.
The procedures in Example 2 were repeated by varying the amount of Mah-g-MWCNT used to prepare Mah-g-MWCNT/PMMA composites having 0.25, 0.50, 0.74, 0.99 and 2.44 wt % of Mah-g-MWCNT, which were then used to prepare circular specimens for wear endurance test as above.
An objective of the present invention is to prepare a coating for EMI shielding, and thus it makes the surface wear endurance of the composite of the present invention become am important property. Wear endurance test for the composite specimens was conducted by using TABER QC-619T, Silitech Technology Co., Taiwan, with a weight load of 500 g and a speed of 60 rpm for 10 minutes. The results are shown in
It can be observed from
The specimens after wear endurance tests were observed with SEM, and the surface roughness thereof observed shows that the composites prepared by in-situ polymerization have a more smoother surface and a less degree of destruction than the composites prepared by ex-situ polymerization. This observation is consistent with the results of the above wear endurance test.
| Number | Date | Country | Kind |
|---|---|---|---|
| 98107777 | Mar 2009 | TW | national |
The present application is a continuation-in-part application of U.S. patent application Ser. No. 12/081,517, filed Apr. 17, 2008. The above-listed application is commonly assigned with the present invention and the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12081517 | Apr 2008 | US |
| Child | 12654331 | US |
