WO2020077365A1 - Particule revêtue de graphène - Google Patents
Particule revêtue de graphène Download PDFInfo
- Publication number
- WO2020077365A1 WO2020077365A1 PCT/US2019/056342 US2019056342W WO2020077365A1 WO 2020077365 A1 WO2020077365 A1 WO 2020077365A1 US 2019056342 W US2019056342 W US 2019056342W WO 2020077365 A1 WO2020077365 A1 WO 2020077365A1
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- WO
- WIPO (PCT)
- Prior art keywords
- graphene
- particle
- composite
- coating layer
- composite particle
- Prior art date
Links
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title claims abstract description 105
- 229910021389 graphene Inorganic materials 0.000 title claims abstract description 103
- 239000002245 particle Substances 0.000 claims abstract description 77
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims abstract description 62
- 239000000945 filler Substances 0.000 claims abstract description 61
- 239000002131 composite material Substances 0.000 claims abstract description 56
- 239000011246 composite particle Substances 0.000 claims abstract description 41
- 229910000019 calcium carbonate Inorganic materials 0.000 claims abstract description 30
- 239000011247 coating layer Substances 0.000 claims abstract description 27
- 239000002064 nanoplatelet Substances 0.000 claims abstract description 22
- 239000002861 polymer material Substances 0.000 claims abstract description 12
- 239000011230 binding agent Substances 0.000 claims abstract description 9
- 229920001169 thermoplastic Polymers 0.000 claims abstract description 6
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 6
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract description 5
- 229920001971 elastomer Polymers 0.000 claims abstract description 4
- 239000000806 elastomer Substances 0.000 claims abstract description 4
- 239000007787 solid Substances 0.000 claims description 50
- 229920000642 polymer Polymers 0.000 claims description 19
- 239000004743 Polypropylene Substances 0.000 claims description 13
- 229920001155 polypropylene Polymers 0.000 claims description 13
- 239000011159 matrix material Substances 0.000 claims description 6
- -1 polypropylene Polymers 0.000 claims description 5
- 230000001788 irregular Effects 0.000 claims description 3
- 238000000576 coating method Methods 0.000 abstract description 17
- 239000011248 coating agent Substances 0.000 abstract description 16
- 239000000126 substance Substances 0.000 abstract description 15
- 239000000463 material Substances 0.000 abstract description 12
- 230000004888 barrier function Effects 0.000 abstract description 7
- 238000000034 method Methods 0.000 description 14
- 239000000454 talc Substances 0.000 description 12
- 229910052623 talc Inorganic materials 0.000 description 12
- 239000010410 layer Substances 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 5
- 238000000227 grinding Methods 0.000 description 5
- 239000000292 calcium oxide Substances 0.000 description 4
- 235000012255 calcium oxide Nutrition 0.000 description 4
- 239000011256 inorganic filler Substances 0.000 description 4
- 229910003475 inorganic filler Inorganic materials 0.000 description 4
- 238000011068 loading method Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000011324 bead Substances 0.000 description 3
- 239000000920 calcium hydroxide Substances 0.000 description 3
- 235000011116 calcium hydroxide Nutrition 0.000 description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 3
- 239000004927 clay Substances 0.000 description 3
- 229910052570 clay Inorganic materials 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 description 3
- 239000010445 mica Substances 0.000 description 3
- 229910052618 mica group Inorganic materials 0.000 description 3
- 239000011707 mineral Substances 0.000 description 3
- 235000010755 mineral Nutrition 0.000 description 3
- 239000012764 mineral filler Substances 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000010456 wollastonite Substances 0.000 description 3
- 229910052882 wollastonite Inorganic materials 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 235000019738 Limestone Nutrition 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 2
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 239000006028 limestone Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000010128 melt processing Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 229920002647 polyamide Polymers 0.000 description 2
- 229920001721 polyimide Polymers 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 229920002725 thermoplastic elastomer Polymers 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 241000237519 Bivalvia Species 0.000 description 1
- 229910021532 Calcite Inorganic materials 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 241000237502 Ostreidae Species 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- 229920002396 Polyurea Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229920000180 alkyd Polymers 0.000 description 1
- NKWPZUCBCARRDP-UHFFFAOYSA-L calcium bicarbonate Chemical compound [Ca+2].OC([O-])=O.OC([O-])=O NKWPZUCBCARRDP-UHFFFAOYSA-L 0.000 description 1
- 229910000020 calcium bicarbonate Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 235000020639 clam Nutrition 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 210000003278 egg shell Anatomy 0.000 description 1
- 238000001493 electron microscopy Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical class O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 150000007522 mineralic acids Chemical class 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 231100000252 nontoxic Toxicity 0.000 description 1
- 230000003000 nontoxic effect Effects 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000020636 oyster Nutrition 0.000 description 1
- 239000011049 pearl Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 239000003209 petroleum derivative Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000747 poly(lactic acid) Polymers 0.000 description 1
- 229920001610 polycaprolactone Polymers 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920006324 polyoxymethylene Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920001021 polysulfide Polymers 0.000 description 1
- 239000005077 polysulfide Substances 0.000 description 1
- 150000008117 polysulfides Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 238000005549 size reduction Methods 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K9/00—Use of pretreated ingredients
- C08K9/02—Ingredients treated with inorganic substances
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/02—Compounds of alkaline earth metals or magnesium
- C09C1/021—Calcium carbonates
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/02—Compounds of alkaline earth metals or magnesium
- C09C1/021—Calcium carbonates
- C09C1/022—Treatment with inorganic compounds
- C09C1/024—Coating
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/12—Surface area
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/20—Oxides; Hydroxides
- C08K3/22—Oxides; Hydroxides of metals
- C08K2003/2227—Oxides; Hydroxides of metals of aluminium
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
- C08K3/26—Carbonates; Bicarbonates
- C08K2003/265—Calcium, strontium or barium carbonate
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K2201/00—Specific properties of additives
- C08K2201/002—Physical properties
- C08K2201/006—Additives being defined by their surface area
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
- C08K3/042—Graphene or derivatives, e.g. graphene oxides
Definitions
- the present invention relates in general to an inorganic filler for composite materials and in particular to binder free graphene coated calcium carbonate and talc filler particulate to improve properties of a polymeric composite containing the same, with such properties including at least one of mechanical, chemical, or barrier.
- a composite material is a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure, differentiating composites from mixtures and solid solutions. Composite materials may be preferred for many reasons including being stronger, lighter, or less expensive when compared to traditional materials.
- Polymer composites are formed of a thermoset, thermoplastic, or elastomer-based polymer and a filler material, which together build up the structure of the composite.
- Polymer composites are extensively used in the manufacture of strong, rigid, lightweight, flame retardant and abrasion resistant components for the automotive, aeronautical industries, other transportation, sporting goods, electronics, construction, and household goods.
- the physical properties are strongly dependent on the chemical structure and ratio of the polymer and the fillers employed.
- Mineral fillers are widely used in polymer composites.
- the typical mineral fillers used in this application are calcium carbonate, talc, mica, silica, glass beads, clay, wollastonite, calcium sulfate, and alumina.
- calcium carbonate and talc are by far the most widely used fillers, which occupy a majority of the market. This is mainly because of the cost effectiveness of calcium carbonate and talc.
- These fillers are typically cheaper than polymers, thus, adding these fillers reduces the cost of the final composites. However, these fillers usually reduce the strength and impact strength of the resulting matrix polymer.
- Calcium carbonate is one of the most widely used inorganic fillers for polymer composite applications.
- Calcium carbonate is a common substance found in rocks as the minerals calcite and aragonite and is the main component of pearls, eggshells, and the shells of marine organisms such as clams and oysters, making calcium carbonate widely available, environmentally friendly, easy to process, non-toxic, and inexpensive.
- Given the low cost of calcium carbonate it can be used in high loadings in polymer composites to adjust the overall cost of the final products. It is used in thermoset, thermoplastic, and elastomer- based composites primarily because of the low cost of the filler.
- calcium carbonate is relatively brittle and tends to crack under impact or compressive forces.
- calcium carbonate tends to dissolve in many organic and inorganic acids. Accordingly, composite materials having calcium carbonate fillers have lower impact strength, lower compressive strength, reduced elongation, and lower resistance to acids as compared to some other advanced fillers. Additionally, calcium carbonate fillers tend to increase abrasive wear on melt processing equipment used in forming composite materials, especially at high loadings.
- Talc is another mineral filler widely used in polymer composite. It is a clay mineral caused by the metamorphic reaction of magnesium silicate minerals. Talc is widely available at low cost in many areas in the world such as China, Brazil, India, US, France, Finland, Italy, Russia, and Canada. Talc has layered structure in which octahedral magnesium oxide layer is sandwiched between tetrahedral silicate layers. Because of the structure, talc has plate-like morphology. Once mixed in a polymer matrix at 20 to 40 total weight percent loading, talc can improve the stiffness and the heat deflection temperature of the resulted composite. Also, the thermal conductivity could be improved to certain extent. However, the impact strength and toughness are reduced at the same talc loading levels.
- the present invention provides a composite particle for use as a filler in a composite material.
- the composite particle includes a solid filler particle such as calcium carbonate, talc, mica, silica, glass beads, clay, wollastonite, calcium sulfate, and alumina and similar particles and a graphene coating layer formed on at least a portion of the outer surface of the solid filler particle applied by a dry process and independent of the presence of a binder.
- the graphene coating is formed of graphene particles, graphene nanoplatelets, graphene sheet, few-layer graphene, single-layer graphene, double-layer graphene, graphene oxide, reduced graphene or a combination thereof.
- the present invention further provides a composite material formed of a thermoplastic, thermoset, or elastomer-based polymer material and a plurality of graphene coated solid filler particles compounded in the polymer material.
- the resulting composite material has improved impact and compressive strength as well as improved chemical resistance due to the mechanical strength and flexibility, barrier properties, and chemical resistance of the graphene coated mineral solid filler material.
- FIG. 1 is a cross sectional view of an inventive composite particle with a solid particle core and a graphene coating layer.
- the present invention relates to a graphene coated solid particle filler and has utility as a low-cost inorganic filler having improved mechanical strength and flexibility and improved barrier and chemical resistance properties for use in composite materials having improved impact and compressive strength as well as improved chemical resistance.
- the present invention also has utility as a low-cost solid filler with reduced wear on composite material processing equipment.
- a range of values are provided herein, that the range is intended to encompass not only the end point values of the range, but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range.
- a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.
- a composite particle for use as a filler in a composite material is described herein.
- the composite particle includes a solid filler particle such as calcium carbonate, talc, mica, silica, glass beads, clay, wollastonite, calcium sulfate, and alumina and a graphene coating layer formed on at least a portion of the outer surface of the solid particle applied by a dry process and independent of the presence of a binder.
- the solid particle is directly coated with the graphene coating layer.
- directly coated it is meant that the graphene forms a direct contact with the solid particle. The contact is sufficiently direct to allow the formation of a strong, robust interaction between the graphene coating layer and the solid particle surface. Similarly, there is no intermediary material disposed between the graphene coating layer and the solid particle.
- the present disclosure provides graphene coated solid particle to improve the mechanical, chemical, and barrier properties of polymer composite materials loaded with hybrid solid particle fillers.
- the composite particle is spherical, cylindrical, ovoidal, polyhedronal, flake-like, plate-like, or irregular non-poly hedronal.
- the composite particle has the mean domain size between 0.1 and 100 microns.
- at least 50 percent of the surface area of the solid filler particle is coated by the graphene coating layer.
- the outer surface of the solid particle is entirely coated by the graphene coating layer. The surface area coverage is measured by electron microscopy imaging.
- the starting solid filler particles can be any product produced by a known method.
- the present invention allows for the use of both natural and synthetic solid filler particles.
- both the natural calcium carbonate particulate (heavy calcium bicarbonate particles) and synthetic calcium carbonate particles (light calcium carbonate particles and colloidal calcium carbonate particles) can be used.
- Natural solid filler particles can be processed by mechanically crushing and grading natural ore to obtain particles adjusted to the desired size.
- Synthetic solid filler particles can be formulated in various process conditions.
- synthetic calcium carbonate particles are manufactured by first preparing a calcium oxide (quick lime) by subjecting limestone to calcination by burning a fuel, such as coke, a petroleum fuel (such as heavy or light oil), natural gas, petroleum gas (LPG) or the like, and then reacting the calcium oxide with water to produce a calcium hydroxide slurry (milk of lime), and reacting the calcium hydroxide slurry with the carbon dioxide discharged from a calcination furnace for obtaining the calcium oxide from limestone to obtain the desired particle size and shape.
- a fuel such as coke, a petroleum fuel (such as heavy or light oil), natural gas, petroleum gas (LPG) or the like
- LPG petroleum gas
- Graphene is a 1 to 10 atom-thick layer of sp 2 hybridized carbon atoms in a honeycomb-like hexagonal, 2-dimensional sheet.
- Graphene is known to have excellent mechanical strength and flexibility, thermal and electric conductivities, and good chemical resistance and barrier properties compared to calcium carbonate.
- graphene nanoplatelets and graphene sheets having a thickness of 3 to 100 nm, and a lateral size of 200 nm to 100 microns are operative in the present invention.
- An inventive graphene coating on the surface of solid filler particulate helps deflect impacting force applied thereto and as a result protect the solid filler particle due to the excellent mechanical strength of graphene.
- the graphene coating protects the solid filler particles from being in contact with the environment, thereby improving the overall chemical resistance of the particles. Furthermore, the graphene coating on the solid filler particles also help reduce the wear of the composite processing equipment such as extruders and moldings. According to the present invention, the graphene coating is applied without resort to an intermediate binder thereby improving the manufacture and properties of the resulting graphene coated solid filler particulate.
- the graphene coating is formed of graphene particles, graphene nanoplatelets, graphene sheet, few-layer graphene, single-layer graphene, double-layer graphene, graphene oxide, reduced graphene or a combination thereof.
- the graphene has a size between 200 nanometers and 100 microns and a Brunauer-Emmett-Teller (BET) measured surface area of greater than about 100 m 2 /g.
- BET Brunauer-Emmett-Teller
- the graphene has an aspect ratio between about 25 and 100,000 which is the ratio of the maximum linear extent and the minimum linear extent, synonymously referred to herein as thickness.
- the graphene coating layer is formed of multiple graphene particles that have a maximal lateral dimension of greater than 200 nm.
- the graphene coating layer is formed of multiple graphene nanoplatelets having a thickness of 3 nm to 100 nm.
- the graphene nanoplatelets having a maximal lateral dimension of less than 5 microns and some inventive embodiments the graphene nanoplatelets having a maximal lateral dimension in the range from 500 nm to 10 microns.
- the graphene layer includes multiple layers of graphene particles of graphene nanoplatelets.
- the graphene particles or graphene nanoplatelets stack or overlap in the coating and form multi-layer coatings that are discontinuous in regions or everywhere, continuous in regions or everywhere, or a combination thereof.
- the graphene coating layer forms a coating from 0.1 to 20 total weight percent of an inventive coated calcium carbonate particulate.
- Typical composite particles of the present invention have a mean domain size that ranges from 0.2 microns to 100 microns.
- the mean domain size ranges from 0.5 microns to 30 microns, while in still other inventive embodiments, the mean domain size ranges from 0.8 microns to 10 microns.
- the composite particles are typically spherical owing to the formation process, but other shapes such as cylindrical, ovoidal, polyhedronal, flake-like, plate-like, or irregular non-polyhedronal are operative herein. When non-spherical shapes are used, the domain size refers to the longest linear extent of the particle.
- the grinding techniques have been used to process ores for a long time. However, it was found that grinding under dry conditions often did not give good results in the end in terms particles size reduction as well as the particle size distribution. Thus, liquids and/or grinding agents are added to improve the efficiency of the grinding efficiency. These techniques are exemplified in US4126277A, US4136830A, and US4793985A.
- the grinding techniques have also been used to functionalize solids particles or fabricate composite materials based on solid particles, however, liquids and/or binder materials have also been added to those processes (e.g. US5116561A, etc.)
- Graphite or graphene coated solid particles have also been proposed, however, addition of binders was proposed to make such materials. These techniques are exemplified in US7402338B2.
- the present invention provides graphene coated solid filler particles which are made by dry milling techniques without any binders and/or solvents and that can be mass- produced at low cost and easy to handle by conventional powder filler handling equipment yet showed significant improvement on impact strength in polymer composites.
- the present invention can provide a cost-effective solution to improve the impact strength of polymer composite materials based on cost-effective graphene coated solid filler materials which can be handled easily by widely available process equipment to produce polymer composite materials based on those graphene-coated solid fillers.
- the polymer material can be a thermoset polymer illustratively including epoxy, vinyl ester, unsaturated polyester, phenolic resin, polyurethane, polyurea, silicone resin, polysiloxane, alkyds, and polyimide where polymer curing involves coupling or crosslinking reactions.
- the polymer material can alternatively be a thermoplastic polymer illustratively including polyolefins, polyamides, polyesters, polyethers, polyurethanes, phenol- formaldehydes, urea-formaldehydes, melamine-formaldehydes, polysulfides, polyacetals, polyethylene oxides, polycaprolactams, polycaprolactones, polylactides, polyimides, thermoplastic elastomers, copolymer thereof, and a mixture thereof.
- polyolefins, polyamides, thermoplastic elastomers, and polycarbonates illustratively including polyolefins, polyamides, polyesters, polyethers, polyurethanes, phenol- formaldehydes, urea-formaldehydes, melamine-formaldehydes, polysulfides, polyacetals, polyethylene oxides, polycaprolactams, polycaprolactones, polylactides
- the resulting composite material has a high impact strength and a high compressive strength compared to like materials containing normalized amounts of like-dimensioned conventional calcium carbonate particulate.
- the inventive composite material also has a high resistance to acids that would otherwise degrade solid filler particles.
- the amount of inventive graphene coated solid filler particle in the polymer matrix material may be varied depending on the desired characteristics of the resulting composite material and the presence (or absence) of other fillers.
- the amount of inventive graphene coated calcium carbonate particulate filler varies from a low level (e.g., less than 5 percent by weight) if other fillers are present and heavily relied upon, to high level (e.g., 20 percent by weight and more).
- the graphene coated solid filler particles are present in an amount of at least 1 total weight percent of the composite material.
- FIG. 1 shows an inventive composite particle generally at 10.
- the composite particle 10 includes a solid filler particle 12 and a graphene coating layer 14.
- the solid filler particle has a domain size and a surface defined by radius r; although it is appreciated that oblong pellets are also envisioned with the scope of the present invention.
- the coating 14 has a thickness, t and shown in partial cutaway. In certain embodiments, the linear ratio r:t is between 1:0.001-0.2
- Composite particles having the form depicted in FIG. 1 are formed by coating mean diameter 5 um spherical calcium carbonate (CaCCri) particles with xGnPTM graphene nanoplatelets.
- the calcium carbonate particle has a typical surface area of 1.2 m 2 /g while the graphene nanoplatelets have a typical surface area of 200 m 2 /g.
- the xGnPTM graphene nanoplatelets used in this example has the average particle diameters in between 0.5 to 5 pm.
- the coating coverage being 100 percent of the surface area with an average thickness of about
- Composite particles having the form depicted in FIG. 1 are formed by coating mean diameter 39 um spherical alumina particles with xGnPTM graphene nanoplatelets.
- the alumina particle has a typical surface area of 0.2 m 2 /g while the graphene nanoplatelets have a typical surface area of 200 m 2 /g.
- the xGnPTM graphene nanoplatelets used in this example has the average particle diameters in between 0.5 to 5 microns.
- the coating coverage being 100 percent of the surface area with an average thickness of about 0.1 microns.
- a composite material is formed using the composite particles of Example 1.
- the xGnPTM coated calcium carbonate particles are compounded in polypropylene (PP) with an extruder and injection molding machine
- the composite material includes 2.5 weight percent xGnP-coated CaCCb in the PP.
- the resulting composite material shows 67 percent improved Notched Izod Impact Strength over a control PP sample, while 2.5 weight percent conventional CaCCb (no coating) in PP showed 5 percent worse Notched Izod Impact Strength compared to the control PP sample.
- a composite material is formed using the composite particles of Example 2.
- the xGnPTM coated alumina particles are compounded in polypropylene (PP) with an extruder and injection molder.
- the composite material includes 2.5 weight percent xGnP-coated Alumina in the PP.
- the resulting composite material shows 2lpercent improved Notched Izod Impact Strength over a control PP sample, while 2.5 weight percent conventional Alumina (no coating) in PP showed only 7 percent improved Notched Izod Impact Strength over the control PP sample.
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Abstract
La présente invention concerne une particule composite pour utilisation en tant que charge dans un matériau composite. La particule composite comprend une particule de carbonate de calcium et une couche de revêtement en graphène formée sur au moins une partie de la surface externe de la particule de carbonate de calcium, et ce, en l'absence de tout liant. Le revêtement en graphène est formé de particules de graphène, de nanoplaquettes de graphène ou d'une combinaison de celles-ci. L'invention concerne également un matériau composite formé d'un matériau polymère thermoplastique, thermodurci ou à base d'élastomère et de telles particules de charge à base de carbonate de calcium revêtues de graphène dispersées dans celui-ci. Le matériau composite résultant présente une résistance à l'impact et à la compression améliorée ainsi qu'une résistance chimique améliorée qui tient à sa résistance mécanique et à sa flexibilité, à ses propriétés de barrière et à la résistance chimique du matériau formant la charge à base de carbonate de calcium revêtu de graphène.
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