Patent Application
20170373249
The invention generally concerns a process for making materials that can be used in a wide-array of applications and electronic devices. In particular, the invention concerns a one-pot synthesis process for attaching a reducible nanomaterial (e.g., graphene oxide) to an organic polymer (e.g., polypropylene, polyethylene terephthalate, etc.) in the presence of a reducing agent (e.g., amine containing reducing agents).
Nanomaterials have become attractive materials because of their properties of large specific surface area, number of surface atoms, surface energy and surface tension and small size effect, surface effect, quantum scale effect and macroscopic quantum tunnel effect, etc. Thus, nanomaterials have wide application in photology, non-linear photology, electrology, magnetology, energy fields, and chemistry fields. Examples of nanomaterials include graphene, graphene oxide, reduced graphene oxide, metal particles, metal oxides and the like.
Many nanomaterials can be fixed in a polymer based material, attached to the surface of a polymeric substrate, or dispersed and/or aligned in a polymer based material. Current methods for preparing such materials require multiple steps. By way of example, nanomaterials can be deposited on polymers using transfer processes, roll-to roll processes, chemical vapor deposition or physical vapor deposition. One problem associated with depositing nanomaterials on the surface of polymeric materials is that the nanomaterials do not sufficiently adhere or attach to the polymers. The attachment issues are currently addressed by using multiple processing steps, where a first step is to activate the polymer or polymeric surface with a functional group. Subsequently, a second step introduces a nanomaterial to the functionalized polymer to create the desired attachment. Each of the functionalizing and attachment steps require their own set of reaction conditions and processing materials, thereby adding to the complexity and costs associated with attaching nanomaterials to polymeric materials. Current methods to disperse and align graphene fillers in polymers include sonication, solution or melt mixing, in-situ mechanical exfoliation, in-situ polymerization, and physical impregnation. To obtain alignment or film-type of dispersion of graphene, within polymers, electric and/or magnetic field have to be applied to the composites. This can also lead to heating of components and requires additional processing steps to obtain a robust interface between the polymer and graphene. Apart from these challenges, some composite fabrication methods involve tedious and multi-step covalent functionalization of graphene.
A solution to the problems associated with attaching nanomaterials to polymeric substrates has been discovered and/or dispersing nanomaterials in a polymeric substrate (e.g., a polymeric matrix). The solution resides in the ability to (1) reduce a reducible nanomaterial, (2) activate an organic polymer, and (3) attach the reduced nanomaterial to the activated organic polymer under a “one-pot” synthesis scheme in which steps (1)-(3) can be performed in the same reactor under the same processing conditions. Such a one-pot process leads to in situ activation of the reducible moiety of the nanomaterial (for example, oxygen moieties) which can bind the nanomaterial to the activated moiety (for example, a carbon or heteroatom) of the polymer surface. Without wishing to be bound by theory, it is believed that the reduction and activation reactions can occur simultaneously or substantially simultaneously when a reducing agent is added to a mixture of the reducible nanomaterial and the organic polymer. By way of example, a polymeric material (e.g., an organic polymer), a reducible nanomaterial (e.g., graphene oxide), and a reducing agent (e.g., an amine containing reducing agent—e.g., hydrazine) can be used in a one-pot reaction synthesis under a given set of reaction conditions (e.g., aqueous conditions at 75 to 85° C.) to simultaneously or substantially simultaneously reduce the graphene oxide, activate the organic polymer, and attach the reduced graphene oxide to the activated organic polymer. The resulting material can be used in a wide array of applications, non-limiting examples of which include energy devices, pollution control devices, gas separation devices, electrodes, interconnects in flexible electronic devices, etc.
In one aspect of the present invention, there is disclosed a method for attaching a reducible nanomaterial to an organic polymer. The method includes subjecting a reaction mixture that includes the reducible nanomaterial and the organic polymer to a reducing agent under reaction conditions sufficient to reduce the nanomaterial, activate the organic polymer, and attach the reduced nanomaterial to the organic polymer during the reaction. In some aspects of the invention, the reaction conditions are sufficient to simultaneously or substantially simultaneously reduce the nanomaterial, activate the organic polymer and attach the reduced nanomaterial to the surface of the organic polymer. The reduced nanomaterial can be covalently bonded to the surface of the organic polymer after the reduction and activation reactions. In other instances, the reduced material can be attached to the organic polymer via hydrogen bonds. In still further instances, a combination of covalent bonds and hydrogen bonds can attach the reduced material to the organic polymer. In a particular aspect, the reaction mixture can be obtained by depositing the reducible nanomaterial on the organic polymer. In a preferred aspect, the reducible material is deposited on the surface of the organic polymer. The reaction mixture can be treated with the reducing agent after or during deposition of the reducible nanomaterial on the organic polymer. The reducible nanomaterial can be any nanomaterial that includes one or more atoms or metals that can be reduced or removed such that the oxidation state of the nanomaterial is lowered. In a particular aspect of the invention, the nanomaterial has not previously been reduced and/or the organic polymer has not previously been activated. In some instances, the reducible material can include additional nanostructures (for example, nanorods, nanowires, nanoparticles, quantum dots, or any combination thereof). The nanostructures can be on the surface of the reducible nanomaterial. In a particular instance, graphene oxide is decorated with the additional nanostructures. The additional nanostructures can include metal oxide, metal, bi-metallic compounds, tri-metallic compounds, metal alloys, carbon-based compounds, carbides, chalcogenides, or any combination thereof. In one embodiment, the organic polymer is in the form of an organic polymer substrate such as a film, sheet, or fiber mesh, and the reduced nanomaterial is attached to the surface of the polymeric substrate after the reaction. A non-limiting example of a reducible nanomaterial includes an oxygen-containing carbon nanostructure, a defect-containing carbon nanotube, a transition metal compound, or a transition metal oxide. In a preferred aspect, the oxygen-containing carbon nanostructure is graphene oxide. In some aspects, the transition metal compound or transition metal oxide nanomaterial includes vanadium. The organic polymer can be any organic polymer. In a preferred aspect, the organic polymer is a thermoplastic polymer or a blend of thermoplastic polymers. Thermoplastic polymers include polyethylene terephthalate (PET), a polycarbonate (PC) family of polymers, polybutylene terephthalate (PBT), poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate) (PCCD), glycol modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine (PEI) and its derivatives, polyetherimide and its derivatives, thermoplastic elastomer (TPE), terephthalic acid (TPA) elastomers, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), polyamide (PA), polystyrene sulfonate (PSS), sulfonated polysulfone family of polymers, polyether ether ketone (PEEK), or combinations or blends thereof. In some embodiments, the organic polymer is polypropylene, polyethylene terephthalate, polyetherimide, or polyethylene, or blends thereof. In certain embodiments, the organic polymer is polypropylene or polyethylene terephthalate. In some aspects, the polypropylene polymer is biaxially oriented polypropylene. The reducing agent can be any substance capable of reducing the functional groups of the nanomaterial and activating the organic polymer. In a preferred aspect, the reducing agent is a nitrogen containing compound. Nitrogen containing compounds include mono-amines, di-amines, polyamines, hydrazines, hydrazine monohydrate, di-imides, or mixtures thereof. In a preferred embodiment, the reducing agent is hydrazine monohydrate. In a particular embodiment, the reaction mixture includes graphene oxide and an organic polymer, and the reducing agent is hydrazine monohydrate. In embodiments, when the polymer is biaxially oriented polypropylene (BOPP), the BOPP is flame or corona plasma treated. Suitable reaction conditions include temperatures from 25 to 500° C., 50 to 250° C., or 75 to 100° C. at pressures of 1 atmosphere. In particular instances, when flame treatment is used, the conditions can include the use of a mixture of air at 138-345 kPA and a fuel (e.g., gas such as butane, propane, methane, coal gas, etc.) at lower pressure such as less than 10 kPa, less than 5 kPa, or from 1 to 3 kPa. For corona plasma treatment, non-limiting corona energy levels (kJ/m2) of at least 5, 10, 20, 50, 70, 100 or more can be used or a range of 5 to 100 kJ/m2 can be used. Air-corona or corona treatment under a chemical atmosphere can be used. In some aspects the reaction mixture is subject to plasma discharge under a reducing agent atmosphere, for example, a hydrazine, atmosphere.
In another aspect of the invention, a polymeric material having reduced graphene oxide attached to the surface of the material is described. The polymeric material is prepared by the processes described throughout the specification. The polymeric material can be used in optoelectronics, catalysis, batteries, super capacitors, ultrasensitive sensors for pressure changes, gas storage or gas separation, lubricants, energy storage devices, a coating (e.g., optical fiber protection coatings, functional coatings, masks for printed electronics), lightening protection system, smart textile, sensors, high-strength structural material, light-weight structural material and the like. In a particular aspect, the polymeric material is conductive. The polymeric material can be included in an electronic device, a printed circuit board, or an integrated circuit. The electronic device can be a transistor, a resistor, a logic device, a sensor, an antenna, an integrated circuit, an electroluminescence device or a field effect device. In some embodiments, the electronic device is an optoelectronic device. The optoelectronic device can be a touch panel, a liquid crystal display, a solar cell, a sensor, a memory element, an antenna, or a light emitting diode. In some embodiments, the polymeric material is an electrode such as a transparent electrode, flexible electrode, or a transparent flexible electrode. The electrode can be used as an anode, a cathode or both in a photovoltaic device, or an energy storage device. In some embodiments, the polymeric material is used as a transparent top electrode in a photovoltaic device and an opaque or reflective material is used as a bottom electrode in the photovoltaic device. The electrode of the present invention can also be used as circuitry in flexible electronic circuits. In other aspects of the invention, the polymeric material of the present invention can be used at a pollution control and mitigation platform by catalyzing the destruction of undesired gases such as SOx and NOx. In some aspects of the invention, the polymeric material is used in a gas separation surface where two gases can be separated based on differential absorption rate to the surface. In some embodiments, the polymeric material is included in a polymeric laminate (sheet or film) that includes the polymeric material and an additional polymeric material, where the reduced nanomaterial is between the polymer of the polymeric material and the additional polymeric material.
In the context of the present invention 50 embodiments are described. Embodiment 1 describes a method for attaching a reducible nanomaterial to an organic polymer. The method can include subjecting a reaction mixture that includes the reducible nanomaterial and the organic polymer to a reducing agent under reaction conditions sufficient to reduce the nanomaterial, activate the organic polymer, and attach the reduced nanomaterial to the organic polymer during the reaction. Embodiment 2 is the method of embodiment 1, further including obtaining the reaction mixture by depositing the reducible nanomaterial on the organic polymer. Embodiment 3 is the method of embodiment 2, wherein the reaction mixture is treated with the reducing agent after the reducible nanomaterial has been deposited on the organic polymer. Embodiment 4 is the method of embodiment 2, wherein the reaction mixture is treated with the reducing agent during deposition of the reducible nanomaterial on the organic polymer. Embodiment 5 is the method of any one of embodiments 1 to 4, wherein the reducible nanomaterial is an oxygen-containing carbon nanostructure, a defect-containing carbon nanotube, a transition metal compound, or a transition metal oxide. Embodiment 6 is the method of embodiment 5, wherein the reducible material includes additional nanostructures. Embodiment 7 is the method of embodiment 6, wherein the additional nanostructures are nanorods, nanowires, nanoparticles, quantum dots, or any combination thereof. Embodiment 8 is the method of any one of embodiments 7 to 8, wherein the nanostructures include a metal oxide, a metal, a bi-metallic compound, a tri-metallic compound, an alloy, a carbon-based compound, a carbide, a chalcogenide, or any combination thereof. Embodiment 9 is the method of any one of embodiments 5 to 8, wherein the oxygen-containing carbon nanostructure is graphene oxide. Embodiment 10 is the method of embodiment 5, wherein the transition metal compound or the transition metal oxide includes vanadium. Embodiment 11 is the method of any one of embodiments 1 to 10, wherein the organic polymer is a thermoplastic polymer or blend thereof. Embodiment 12 is the method of embodiment 11, wherein the thermoplastic polymer is polyethylene terephthalate (PET), a polycarbonate (PC) family of polymers, polybutylene terephthalate (PBT), poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate) (PCCD), glycol modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine or polyetherimide (PEI) and their derivatives, thermoplastic elastomer (TPE), terephthalic acid (TPA) elastomers, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), polyamide (PA), polysulfone sulfonate (PSS), sulfonates of polysulfones, polyether ether ketone (PEEK) or combinations or blends thereof. Embodiment 13 is the method of embodiment 12, wherein the thermoplastic polymer is polypropylene, polyethylene terephthalate, polyethyleneimine, polyetherimide, or polyethylene, or blends thereof. Embodiment 14 is the method of embodiment 13, wherein the organic polymer is polypropylene or polyethylene terephthalate. Embodiment 15 is the method of embodiment 14, wherein the polypropylene is biaxially oriented polypropylene. Embodiment 16 is the method of embodiment 15, wherein the biaxially oriented polypropylene is flame or Corona treated. Embodiment 17 is the method of any one of embodiments 1 to 16, wherein the reducing agent is a nitrogen containing compound. Embodiment 18 is the method of embodiment 17, wherein the reducing agent is a mono-amine, a di-amine, a polyamine, a hydrazine, a hydrazine monohydrate, a di-imide, or mixtures thereof. Embodiment 19 is the method of embodiment 18, wherein the reducing agent is a hydrazine monohydrate. Embodiment 20 is the method of any one of embodiments 1 to 19, wherein the nanomaterial has not previously been reduced. Embodiment 21 is the method of any one of embodiments 1 to 20, wherein the polymer has not previously been activated. Embodiment 22 is the method of any one of embodiments 1 to 22, wherein the organic polymer is in the form of an organic polymeric substrate and the reduced nanomaterial is attached to the surface of the substrate after the reaction. Embodiment 23 is the method of embodiment 22, wherein the substrate is in the form of a film, sheet, or a fiber mesh. Embodiment 24 is the method of any one of embodiments 1 to 23, wherein the reduced nanomaterial is covalently attached to the organic polymer after the reaction. Embodiment 25 is the method of any one of embodiments 1 to 23, wherein the reduced material is attached to the organic polymer via hydrogen bonds or via a combination of hydrogen bonds and covalent bonds. Embodiment 26 is the method of any one of embodiments 1 to 25, wherein the reaction conditions include a temperature from 25 to 500° C. Embodiment 27 is the method of any one of embodiments 1 to 26, wherein the reaction mixture is an aqueous mixture.
Embodiment 28 is a polymeric material having reduced graphene oxide attached to the surface of an organic polymer, wherein the polymeric material is prepared by the process of any one of embodiments 1 to 27. Embodiment 29 is the polymeric material of embodiment 28, wherein the polymeric material is included in an electronic device. Embodiment 30 is the polymeric material of embodiment 28, wherein the electronic device is a transistor, a resistor, a logic device, a sensor, an antenna, an integrated circuit, an electroluminescence device, a field effect device, or lightening protection system. Embodiment 31 is the polymeric material of embodiment 30, wherein the electronic device is an optoelectronic device. Embodiment 32 is the polymeric material of embodiment 30, wherein the optoelectronic device is a touch panel, a liquid crystal display, a solar cell, a sensor, a memory element, an antenna, or a light emitting diode. Embodiment 33 is the polymeric material of embodiment 28, wherein the polymeric material is an electrode. Embodiment 34 is the polymeric material of embodiment 33, wherein the electrode is used as an anode or cathode in an energy storage device. Embodiment 35 is the polymeric material of embodiment 34, wherein the energy storage device is a capacitor. Embodiment 36 is the polymeric material of embodiment 32, wherein the electrode is a transparent electrode. Embodiment 37 is the polymeric material of embodiment 36, wherein the transparent electrode is used as an anode, a cathode, or both in a photovoltaic device or an energy storage device. Embodiment 38 is the polymeric material of embodiment 37, wherein the transparent electrode is used as the top electrode in the photovoltaic device, wherein the bottom electrode is opaque or reflective. Embodiment 39 is the polymeric material of embodiment 38, wherein the electrode is an opaque electrode. Embodiment 40 is the polymeric material of any one of embodiments 32 to 39, wherein the electrode is a flexible electrode. Embodiment 41 is the polymeric material of embodiment 39, wherein the electrode is used as circuitry in flexible electronic circuits. Embodiment 42 is the polymeric material of embodiment 24, wherein the polymeric material is included in a printed circuit board or an integrated circuit. Embodiment 43 is the polymeric material of embodiment 28, wherein the polymeric material is used as a catalyst for destruction of SOx or NOx gases. Embodiment 44 is the polymeric material of embodiment 42, wherein the catalyst is used at a pollution control and mitigating platform. Embodiment 45 is the polymeric material of embodiment 28, wherein the polymeric material is used as to separate two gases from each other. Embodiment 46 is the polymeric material of embodiment 45, wherein the separation takes place on the surface of the polymeric material, and wherein the separation is based on differential absorption rate to the surface. Embodiment 47 is the polymeric material of embodiment 28, wherein the polymeric material is included in a coating, light protection system, a smart textile, high-strength material, and light-weight structural material. Embodiment 48 is the polymer material of embodiment 47, wherein the coating is an optical fiber coating, a mask, or a functional coating. Embodiment 49 is the polymeric material of any one of embodiments 28 to 48, wherein the polymeric material is conductive. Embodiment 50 is the polymeric material of any one of embodiments 28 to 49, wherein the polymeric material is included in a polymeric sheet or film that includes the polymeric material and an additional polymeric, wherein the reduced nanomaterial is between the polymer of the polymeric material and the additional polymeric.
The following includes definitions of various terms and phrases used throughout this specification.
“Attach” or “attached” refers to the attachment or adhesion between the nanomaterial and the polymer or polymeric surface of a material. In certain aspects, and after employing the process of the present invention, the nanomaterial can be covalently bonded to the surface of the polymer or can be bonded through hydrogen bonds or a combination of covalent and hydrogen bonds.
“Activated” when used to modify the terms or phrases “polymer”, “organic polymer,” or “polymeric surface” means that the polymer, organic polymer, or polymeric surface has been functionalized with a functional group, oxidized, or reduced, or any combination thereof, to aid in the attachment of a nanomaterial to said polymer. Therefore, a polymer that has not previously been activated prior to using a process of the present invention is a polymer or organic polymer or polymeric material that has not previously been subjected to a functionalization, oxidation, or reduction reaction that would aid in the attachment of a nanomaterial to said polymer.
“Nanomaterial” refers to an object or material in which at least one dimension of the object or material is equal to or less than 1000 nm (e.g., one dimension is 1 to 1000 nm in size). In a particular aspect, the nanomaterial includes at least two dimensions that are equal to or less than 1000 nm (e.g., a first dimension is 1 to 1000 nm in size and a second dimension is 1 to 1000 nm in size). In another aspect, the nanomaterial includes three dimensions that are equal to or less than 1000 nm (e.g., a first dimension is 1 to 1000 nm in size, a second dimension is 1 to 1000 nm in size, and a third dimension is 1 to 1000 nm in size). The shape of the nanomaterial can be of a wire, a particle, a sphere, a rod, a tetrapod, a hyper-branched structure, a tube, multiple tubes, or mixtures thereof.
“Reduction” refers to a decrease in the oxidation state of an element of the Periodic Table.
“Reducing agent” refers to any compound that can donate electrons or hydrogen to another compound. Non-limiting examples of reducing agents include amines and di-amines such as hydrazine.
“Reducible nanomaterial” refers to a nanomaterial that has the capacity to gain electrons or hydrogen.
“Oxidation” refers to an increase in the oxidation state of an element of the Periodic Table.
“Substrate” refers to a material onto which the nanomaterial or polymeric material is attached. In certain instances, the substrate can be a polymeric material. The substrate can be rigid or flexible. The substrate can be transparent, translucent, or opaque, or any degree of transparency, translucency, or opacity as desired. Non-limiting examples of rigid substrates include, for example, glass, polycarbonates, acrylics, etc. Non-limiting examples of flexible substrates include polyesters (e.g., polyethylene terephthalate, polyester naphthalate, and polycarbonate), polyolefins (e.g., linear, branched, and cyclic polyolefins), polyvinyls (e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetals, polystyrene, polyacrylates, etc.), cellulose ester bases (e.g., cellulose triacetate, cellulose acetate), polysulfones such as polyethersulfone, polyimides, silicones and other conventional polymeric films. Additional examples of suitable substrates can be found in, e.g., U.S. Pat. No. 6,975,067, which are incorporated herein by reference.
The term “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.
The term “substantially” and its variations are defined as being largely but not necessarily wholly what is specified as understood by one of ordinary skill in the art, and in one non-limiting embodiment substantially refers to ranges or time periods within 10%, within 5%, within 1%, or within 0.5% of a referenced range or time period.
The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and/or the specification includes any measurable decrease or complete inhibition to achieve a desired result.
The term “effective,” as that term is used in the specification and/or claims, means adequate to accomplish a desired, expected, or intended result.
The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”
The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
The methods for making polymeric materials of the present invention can “comprise,” “consist essentially of,” or “consist of” particular ingredients, components, compositions, etc. disclosed throughout the specification. With respect to the transitional phase “consisting essentially of,” in one non-limiting aspect, a basic and novel characteristic of the process of the present invention is the ability to reduce a reducible nanomaterial and activate an organic polymer in “one-pot” such that the reduced nanomaterial attaches to the organic polymer.
Other objects, features and advantages of the present invention will become apparent from the following figures, detailed description, and examples. It should be understood, however, that the figures, detailed description, and examples, while indicating specific embodiments of the invention, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. The drawings may not be to scale.
The use of nanomaterials attached to polymers or polymeric surfaces has far-reaching implications in today's society. Some non-limiting uses of such composite materials include energy devices, pollution control devices, gas separation devices, electrodes, interconnects in flexible electronic devices, etc.
As discussed above, the previous processes used to make such materials can be complicated and inefficient. For instance, such processes typically require at least two separate steps that require their own reaction conditions. The first step is typically activation of the polymer or polymeric surface with a functional group. The second step introduces a nanomaterial to the functionalized polymer to create the desired attachment.
By comparison, the one-pot synthesis processes of the present invention provide distinct advantages when compared to the aforementioned multi-step processes. In the one-pot processes, a mixture of a reducible nanomaterial and an organic polymer can be contacted with a reducing agent. The reducing agent is capable of reducing the nanomaterial and activating the organic polymer such that the reduced nanomaterial attaches to the surface of the organic polymer, while preserving the properties of the reduced nanomaterial. Without wishing to be bound by theory, it is believed that the reduction and activation reactions can occur simultaneously or substantially simultaneously. Notably, it allows reduction of nanomaterials (for example, graphene oxide (GO) to reduced graphene oxide (rGO)) and produces activated moieties on the polymer site that can bond to the reduced nanomaterial in situ.
These and other non-limiting aspects of the present invention are discussed in further detail in the following sections with reference to the Figures.
1. Reducible Nanomaterials
Reducible nanomaterials are nanomaterials that have the capacity to gain electrons or hydrogen. Non-limiting examples of such materials include oxygen-carbon nanostructures, defect-containing carbon nanotube structures, transition metals compounds, metal oxides, or combinations thereof.
A non-limiting oxygen-carbon nanostructure includes graphene oxide. Graphene oxide can be prepared by treating graphite using the Hummer or Hummer modified processes (see Chen et. al., “An improved Hummers method for eco-friendly synthesis of graphene oxide”, Carbon, vol. 64, pp. 225-229 (2013), which is incorporated into the present application by reference). Graphene oxide includes many forms of oxidized or substituted carbon, for example, carbonyls, epoxides, alcohols, and carboxylic acids. The actual chemical composition of oxidized graphene varies due to the processing conditions to obtain. A non-limiting structure of graphene oxide is shown as
Defect-containing carbon nanotube structures include single cylindrical wall and multi-walled nanotubes that contain atomic vacancies or a rearrangement of the carbon bonds. A rearrangement of the carbon bonds can be referred to as a Stone-Wales (SW) defect. Defect-containing carbon nanotube structures can have larger absorption energies and charge transfer energies than those of pristine carbon nanotubes. Non-limiting examples of defects include vacancy in the lattice (mono- or di-vacancy), result of a knock-on damage, originated by chemisorbant or physiosorbent adduct, or defects that are caused by mechanical processes (see P. G. Collins, Defects and Disorder in Carbon Nanotubes, University of California at Irvine, Irvine, USA; see also P. G. Collins, Defects and Disorder in Carbon Nanotubes in Oxford Handbook of Nanoscience and Technology: Frontiers and Advances, Narlikar, A. V. & Fu, Y. Y.Eds. (Oxford Univ. Press, Oxford, 2009), both of which are incorporated by reference). Defects in carbon nanotubes are typically characterized by a combination of electrochemical (such as conductance), spectroscopic (such as Raman), and microscopic (such as scanning tunneling microscopy, optical light microscopy and transmission electron microscopy) techniques (P. G. Collins (2009)). Commercial sources of such carbon nanotubes include Nanocyl SA (Sambreville, Belgium), Cnano Technology Limited (San Francisco, Calif., USA), and Hyperion Catalysis International Inc. (Cambridge, Mass., USA).
Transition metals compounds and transition metal oxides include compounds containing metals from Groups IIIB, IVB, VB, VIB, VIIIB, VIII, IB and IIB (Columns 3-12) of the Periodic Table, preferably metals from Group V (Column 5), most preferably, vanadium. Non-limiting examples of metal oxides include vanadium pentoxide (V2O5), ammonium metavanadate (NH4VO3), molybdenum trioxide, ammonium molybdate (VI), tungsten trioxide, ammonium tungstate. Transition metal compounds or transition metal oxides are available from commercial sources. A non-limiting example of a source of transition metal compounds or transition metal oxides is Sigma-Aldrich® (Milwaukee, Wis., USA).
The reducible material can include nanostructures deposited on the surface of the reducible material. The nanostructures can be any shape or size (e.g., nanowires, nanoparticles, nanorods, or quantum dots). A non-limiting example is graphene oxide decorated on one or both surfaces with nanoparticles. In some embodiments, the reducible material can be decorated with nanostructures. Such nanostructures can include metal oxide, metal, bi-metallic compounds, tri-metallic compounds, metal alloys, carbon-based compounds, carbides, chalcogenides, or any combination thereof. Non-limiting examples of additional nanostructures include ZnO nanoparticles, Au nanorods, Pt nanoparticles, and CdSe/ZnS core/shell quantum dots. Nanostructures are commercially available from commercial sources. Non-limiting examples of sources of nanostructures are Sigma-Aldrich® (Milwaukee, Wis., USA) and Nanosys® (Milpitas, Calif., USA).
2. Organic Polymers
The organic polymer can be any organic polymer, copolymer, terpolymer, cross-linked polymers, or a polymer blend comprising a polymer, copolymer, terpolymer, cross-linked polymers, or combinations thereof. In a particular aspect, the polymers have not gone any treatments to functionalize, oxidize, or reduce the carbon, oxygen, or nitrogen moieties in the polymers. In a preferred aspect, the organic polymers are a thermoplastic polymer or a blend of thermoplastic polymers. Thermoplastic polymers include polyethylene terephthalate (PET), a polycarbonate (PC) family of polymers, polybutylene terephthalate (PBT), poly(1,4-cyclohexylidene cyclohexane-1,4-dicarboxylate) (PCCD), glycol modified polycyclohexyl terephthalate (PCTG), poly(phenylene oxide) (PPO), polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polymethyl methacrylate (PMMA), polyethyleneimine (PEI) and its derivatives, polyetherimide and its derivatives, thermoplastic elastomer (TPE), terephthalic acid (TPA) elastomers, poly(cyclohexanedimethylene terephthalate) (PCT), polyethylene naphthalate (PEN), polyamide (PA), polystyrene sulfonate (PSS), sulfonated polysulfone family of polymers, polyether ether ketone (PEEK), or combinations or blends thereof. In some embodiments, the organic polymer is polypropylene, polyethylene terephthalate, polyethyleneimine, or polyethylene, or blends thereof. In certain embodiments, the organic polymer is polypropylene or polyethylene terephthalate. In some aspects, the polypropylene polymer is biaxially oriented polypropylene (BOPP). In some embodiments, the polymer can be a polymeric substrate in which its surface is patterned. The nanomaterial can then be attached to the pattern in the surface area via the processes of the present invention. The polymer can be functionalized with functional groups either in the polymer back bone or pendant such as esters, carbonates, amides, etherimides, acids, hydroxyl, etc. that can react with amine such as amino silanes, hydrazine, halogenated amines, etc. The polymers that do not have such chemistry can be pre-conditioned. For example, such as flame-treated polyolefins (e.g., polyethylene).
3. Reducing Agents
The reducing agent can be any substance capable of reducing the functional groups of the nanomaterial and activating the organic polymer. In a preferred aspect, the reducing agent is a nitrogen containing compound. Nitrogen containing compounds include mono-amines, di-amines, polyamines, hydrazines, hydrazine monohydrate, di-imides, or mixtures thereof. In a preferred embodiment, the reducing agent is hydrazine monohydrate. Mono-amines include compounds having one nitrogen atom, for example, primary amines and secondary amines, with primary amines being preferred. Non-limiting examples of mono-amines include alkyl amines, ethylamine, propylamine, 2-(N,N-dimethylamino)ethyl methacrylate (DMAEMA), aralkyl amines, benzyl amine, aromatic amines, aniline, naphthylamine. toluidines, N,N-dimethyl-p-toluidine. Diamines include compounds that have two (2) nitrogen atoms. Examples of diamines include alkyl amines, ethylenediamine, aryl amines, phenyl diamine, and hydrazines. Examples of hydrazine compounds include hydrazine monohydrate. Amines and diamines are commercially available from numerous suppliers. A non-limiting example of a commercial supplier is Sigma-Aldrich® (Milwaukee, Wis., USA).
In some embodiments, attaching a reducible nanomaterial to an organic polymer includes subjecting a reaction mixture that includes the reducible nanomaterial and the organic polymer to a reducing agent under reaction conditions sufficient to reduce the nanomaterial, activate the organic polymer, and attach the reduced nanomaterial to the organic polymer during the reaction. An organic polymer can be obtained and mixed with the reducible nanomaterial in a suitable solvent in a single reaction vessel (“one-pot”). The organic polymer can be patterned prior to mixing the organic polymer with the nanomaterial. In some embodiments, the reducible material can be decorated with nanostructures. In embodiments, when the organic polymer is BOPP, the polymer can be treated with flame or corona plasma discharge. In a non-limiting embodiment, the organic polymer and nanomaterial are mixed in the absence of solvent. A suitable solvent can include water, alcohols, ethanol, glycol, tetrahydrofuran (THF), dimethyl sulfoxide (DMSO) or mixtures thereof. In some embodiments, the reducing agent is the solvent, for example, the organic polymer and the nanomaterial are mixed in hydrazine monohydrate. The mixture can be heated to a temperature suitable to allow the reducing agent to react with the organic polymer and the nanomaterial. The temperature can be from 25 to 500° C., 50 to 250° C., or 75 to 100° C., or the refluxing temperature of the solvent.
1. Deposition of the Reducible Nanomaterial on the Surface of a Polymer
2. Spray Coating of Reducible Nanomaterial
3. Reducible Nanomaterial With Deposited Nanostructures on the Surface of a Polymer
In some instances, the polymeric material can be made by coating a polymeric substrate with a reducing agent and the reducible nanomaterials with deposited nanostructures. The coating of the reducing agent and/or reducible nanomaterials as described above in Section B(2) or using other known coating methods (e.g., dip coating).
Without wishing to be bound by theory, it is believed that one or more pathways can produce the polymeric material. A first pathway can include stepwise reactions of the reducing agent with the organic polymer material and/or the nanomaterials to form intermediates that react to form the polymeric material. A first pathway can include the reducing agent reacting with the organic polymer to form a polymer-reducing agent intermediate. The polymer reducing agent intermediate can react with the reducible nanomaterial and form the polymeric material 214. A second pathway can include the reducing agent reacting with the nanomaterial to form a reducible nanomaterial-reducing agent intermediate. The reducible nanomaterial-reducing agent intermediate can react with the polymer to form the polymeric material 214. A third pathway can include the formation of the two intermediates which then react or form the polymeric material 214.
The reducible nanomaterial can undergo 1 to 100%, 10%, 20%, 50%, 75%, 80%, 90%, or 100% reduction. In some embodiments, the reduced nanomaterial includes a mixture of reduced and unreduced sites, however, the amount of reduction of the nanomaterial is sufficient to allow attachment of the reduced nanomaterial to the surface of the polymer. A ratio of reduced and unreduced sites in the reduced nanomaterial 216 can range from 0.0001:100 to 1:99, or 10:90, 20:80, or 50:50. In a non-limiting example, polymeric material 214 includes reduced graphene oxide as the reduced nanomaterial. The reduced graphene oxide can have a mixture of reduced and unreduced sites.
The nanocomposites of such polymer structures with graphene, or graphene heterostructures, wrapped around the polymer can be treated to remove the encapsulated polymer (e.g., heat treated in an oxidizing atmosphere) to result in hollow graphene-based architectures. This approach provides a significantly less complicated method for hollow graphene architectures preparation as compared to conventional methods, which typically require multiple templating and acid/base etching steps. Such architectures will be useful for catalysis, sensors, plasmonics, electrodes, and energy storage.
The produced polymeric materials of the present invention can be used in a wide range of applications and electronic devices.
By way of example, the process of the present invention can be used to create either or both of the upper and lower electrodes for a single device or can be used to create cathodes and anodes for a single device. By way of example only, the materials of the present invention can be incorporated into a wide variety of devices, including any device that currently makes use of transparent conductors (such as metal oxide films) or reflective conductors or both. For instance, the following devices are contemplated: (i) Electronic display devices including an electroluminescent (EL) device (e.g., an organic light emitting display (OLED)), an electrophoretic display (e-paper), an electrochromic device, a liquid crystal display device (e.g., transflective liquid crystal display (LCD) devices) or an electrowetting display device; (ii) Photovoltaic cells, for instance amorphous silicon (a-Si) cells; (iii) Light irradiation devices and decorative illumination devices, for instance, devices containing light-emitting elements such as light-emitting diodes and semiconductor lasers; (iv) Electromagnetic radiation shield devices; (v) Any device which requires a reflective electrode; and (vi) Electronic device e.g., a transistor, a resistor, a logic device, sensors, antennas, integrated circuits, electroluminescence devices, memory elements or a field effect device.
In some embodiments, the polymeric material can be a fiber mesh integrated with graphene. The reducing agent (e.g., hydrazine) based one-step treatment can be utilized to coat graphene and link the flakes to the surface of fibers, bridge fibers, and uniformly disperse and integrate flakes within the fiber mesh. This method can overcome problems associated with high temperature in-situ growth of graphene using copper-coated mesh structures. Apart from that, the physically-mixed graphene flakes (in fiber mesh) due to less z-direction strength impart low shear strength to such composites. This shear strength can be significantly improved by utilizing the methods as described in this application. Being a single-step and water-based functionalization process, the challenges of multi-step and non-specific functionalization approaches can be overcome. For example, polymer fiber mesh integrated with reduced graphene oxide made using the methods described herein can be useful for optical fiber protection coatings, functional coatings, masking for printed electronics, lightening protection system, smart textile, sensors, and high-strength and light-weight structural material. Coatings can include optical fiber protection coatings, functional coatings, and masks for printed electronics. Functional coating can include coatings with a capability to send chemical and biological agents, humidity, brine, stress; gas barrier coatings and thermally or electronically conductive coatings.
In other aspects of the invention, the polymeric material of the present invention can be used as a pollution control and mitigation platform by catalyzing the destruction of undesired gases such as SOx and NOx. In some aspects of the invention, the polymeric material is used in a gas separation surface where two gases can be separated based on differential absorption rate to the surface.
The polymeric material can be used in a roll-to roll process to produce polymer sheets, membranes, films or the like.
The present invention will be described in greater detail by way of prophetic examples. The following examples are offered for illustrative purposes only, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.
Graphene oxide nanocolloids (2 mg of graphene oxide nanocolloids/1 mL of water) were purchased from Sigma-Aldrich® (USA). Hydrazine hydrate (55% diluted) was purchased from Acros Organics (USA), and PET was bought in the form of transparency slides. A slide of PET was cleaned with water and dried. The dried sheet was coated with a diluted hydrazine hydrate (1 ml, 60 mM of hydrazine in water) at room temperature to produce a hydrazine coated PET substrate. The hydrazine coated PET substrate was further coated with a drop of the aqueous graphene oxide nanocolloid solution (2 mg/ml). The hydrazine/graphene oxide coated PET substrate was dried in an oven at 80° C. for overnight. The samples were characterized by Fourier Transform Infrared (FTIR) spectroscopy and optical microscopy. The procedure was repeated 3 times to produce 3 samples. FTIR was conducted on the 3 different samples and for each sample more than 5 points were generated for analysis.
In order to evaluate the deoxygenation or reduction of graphene oxide during the process of coating on PET substrate, a comparative experiment was conducted. A slide of PET was cleaned with water and dried. The dried sheet was coated with a diluted hydrazine hydrate (1 ml, 60 mM of hydrazine in water) at room temperature to produce a hydrazine coated PET substrate. The hydrazine coated PET substrate was dried in an oven at 80° C. for overnight. The samples were characterized by Fourier Transform Infrared (FTIR) spectroscopy and optical microscopy.
Table 1 lists the FTIR peaks of: a untreated PET slide, standard PET stretches, Comparative Example 1 (hydrazine-treated PET) stretches, standard terathalic dihydrazide stretches, Example 1 (PET with reduced graphene oxide), standard graphene oxide stretches, standard reduce graphene oxide stretches, and standard hydrazine hydrated stretches.
1Chen et al., European Polymer Journal, 2012, 48, 1586-1610.
2Soni et al., Journal of Applied Polymer Science, 2009, 113, 1090-1096.
3Choi et al., Journal of Materials Chemistry, 2010, 20, 1907-1912.
4http://www.hanhonggroup.com/ir/ir_en/RB01060076.html
5Basirun et al., Nanoscale Research Letters, 2013; 8, 397.
6Tripathi et al., Synthesis of High-Quality Graphene through Electrochemical Exfoliation of Graphite in Alkaline Electrolyte, arXiv: 1310.7371
It was observed that a twin peak present in graphene oxide (˜1710 cm−1,
A clear or semi-transparent coating on the surface of PET of Example 1 was observed under 500× magnification optical microscope.
Two blank PET sheets were coated with 1 ml of 60 mM hydrazine hydrate. 0.01 wt % graphene oxide was coated on one of the hydrazine-coated PET sheet. The second hydrazine-coated PET sheet was flipped on top of first sheet (with hydrazine and graphene oxide). The sandwiched samples were dried for 24 hours at 80° C. A control PET-graphene oxide-PET sandwich sample was prepared, but without any hydrazine. The dried samples were manually peeled. The sandwich sample with hydrazine treatment (
A small (0.5 cm×0.5 cm) sample from Example 1 was placed on the SEM stub and inserted in the microscope for analysis. Reduced GO nanoplatelets can be seen as dots in the SEM images.
As shown in the Examples, the methods of the present invention resulted in reduced graphene oxide strongly attached (bonded) to the surface of PET. The experiments with graphene sandwiched between two PET sheets also resulted in strong binding between the sheets.
This application claims benefit to U.S. Provisional Patent Application No. 62/104,126 titled “ONE-POT ORGANIC POLYMERIC SURFACE ACTIVATION AND NANOPARTICLE REDUCTION”, filed Jan. 16, 2015 and U.S. Provisional Patent Application No. 62/275,835 titled “ONE-POT ORGANIC POLYMERIC SURFACE ACTIVATION AND NANOPARTICLE REDUCTION”, filed Jan. 7, 2016. The contents of both referenced applications are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/012563 | 1/8/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62104126 | Jan 2015 | US | |
| 62275835 | Jan 2016 | US |
