CN100386370C - 新颖勃姆石颗粒及掺入这种颗粒的聚合物材料 - Google Patents
新颖勃姆石颗粒及掺入这种颗粒的聚合物材料 Download PDFInfo
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Abstract
揭示了一种改性聚合物材料,其包括聚合物基料和在聚合物基料内的勃姆石颗粒。所述勃姆石颗粒主要由各向异性形状的颗粒构成。
Description
发明背景
发明领域
本发明涉及勃姆石颗粒,具体涉及特别适用作热塑树脂填料的。
相关领域的叙述
由于勃姆石粒度细及其分散在聚合物中相对惰性使得它长期以来被认为是热塑树脂的合适填料。它能充分地提高模量和热性能,甚至在美国专利6,143,816提出用它作阻燃剂。
一些美国专利如USP5,360,680和5,401,703所述的较佳方式是认为较佳的细小薄片状,因为早期经研磨法产生的细粒状勃姆石粉会呈球形作为填料效果稍差。用其它方法制造细颗粒勃姆石会引起其它问题。例如热解会产生一系列勃姆石产品的污染物,且常规的水热处理会形成结实的菱形棱柱状颗粒团聚,很不容易分开。如美国专利5,194,243(建立在USPP2,763,620,2,915,475,3,385,663,4,117,105和4,344,928所述的早期研究基础上)提出的氢氧化铝精制水热法引入晶种概念,采用勃姆石晶种转化勃姆石前体。发现为了制得亚微米级各向基本等轴颗粒的勃姆石分散体,需要高含量的,至少15%勃姆石晶种方能有效。
所有一切努力制作的片状或各向等轴的勃姆石颗粒都不容易以各个颗粒分散在聚合物中,除非事先采用表面活性剂处理提高其分散性。所用的典型的表面活性剂包括氨基硅烷,它具有粘附在亲水性表面颗粒的勃姆石的能力,使这些颗粒表面与有机聚合物相容性更好而使颗粒分散其中。这样避免了没有这种处理往往会发生的结块。这种倾向随颗粒变小而增加,因为随着颗粒变小,它的表面能必然增加。
本发明提供了一种新颖的勃姆石,它能容易地以纳米级粒子分散在热塑性聚合物中而无需任何表面处理,与现有技术的勃姆石填料相比,它明显改进了它的混合性能。
发明概述
按照本发明一个方面,提供一种改性的聚合物材料,其包括聚合物基料和聚合物基料中的勃姆石颗粒,所述勃姆石颗粒主要含有长径比至少约3∶1各向异性形状的颗粒。
按照本发明另一个方面,提供一种改性的聚合物材料,其包括聚合物基料和不含表面活性剂,且被分散在聚合物基料中的长径比至少约3∶1。
按照本发明还有一个方面,提供勃姆石材料其主要含有长径比至少约3∶1的勃姆石颗粒。
按照本发明还有一个方面,提供制备一种产品的方法,其包括提供一种改性聚合物材料,该材料聚合物基料和主要含有各向异性形状的长径比至少约3∶1的颗粒的勃石颗粒,并将改性聚合物材料挤出成挤出产物,其中所述勃姆石颗粒分散于所述挤出产物中。
附图简要说明
图1A与图1B所示为现有技术很好分散的勃姆石颗粒(图1A)和本发明针形勃姆石(图1B)。
图2A,2B和2C所示为仅尼龙6和掺入两种不同含量勃姆石的尼龙的UV-可见光谱。
图3A,3B和3C是UV光谱为图2A,2B和2C的三种配方的富里叶变换IR光谱。
图4所示为同样三种配方的相应的N 1s光谱。
图5所示为含有6.62体积%勃姆石的尼龙6的高放大倍数透射电子显微照片。
图6A和图6B所示为仅尼龙6、含3.15体积%常用勃姆石的尼龙以及含3.15体积%本发明针形勃姆石的尼龙的不同物理性能条形图。
图7所示为含有1.86体积%勃姆石的热塑性聚氨酯(陶氏化学公司销售的Isoplast 301)的高放大倍数透射描电子显微照片
图8是条形图,显示氨基硅烷添加剂对提高含有分散于其中的5体积%针形勃姆石颗粒的环氧树脂的储能模量(Storage modulus)的作用。
详细说明
本发明提供勃姆石,它含有针形(或各向异性)晶体,其中最长尺寸至少为50nm,较佳为50-2000nm,更佳为100-1000nm,而与长度垂直的尺寸基本相同,且优选均小于50nm;且长径比定义为最长尺寸与垂直于长度的次最长尺寸之比率,这个比率至少为3∶1,且较佳至少为6∶1。在该描述中,为清楚起见,以下将这些颗粒称之为针形。
出乎意料的是,水热法条件加上低含量的晶种,及混合物酸性pH造成勃姆石优选沿某一晶轴生长,使得水热处理持续时间越长,制成的勃姆石针形颗粒越长。惊人的是这些针形勃姆石颗粒不需要表面处理就能各自均匀分散,也就是说通过常规的配混技术在聚合物内基本上均匀分布,实质上不形成团粒。这种均匀各自分散质量在下文中称之为纳米分散性。
按照本发明针形颗粒经BET法测量,其表面积至少为75m2/g,且优选为100-300m2/g。
本发明还包括通过掺入0.5-20体积%,优选为2-10体积%(以聚合物+勃姆石的总体积计)的本发明针形勃姆石颗粒而改性的聚合物。针形勃姆石颗粒可以分散于其中的聚合物的实例有:聚酰胺(包括例如尼龙6和尼龙12),热塑性聚氨酯,聚亚烷基二醇,乙烯/乙烯醇聚合物,环氧树脂,丙烯酸酯类树脂等。更一般地说,聚合物优选热塑性聚合物,因为在常规聚合物配混技术中采用高强力混合机、挤出机等,这种聚合物具有很好的分散性。还应认识到采用填料改进聚合物的物理性能是热塑性聚合物中最常见的目的(objective)。本发明产品具有独特性质(可能是颗粒针形所致)使得挤出时勃姆石颗粒会排列一致,使得经这种针形颗料增强的聚合物大大提高了诸如弯曲强度等在挤出方向的物理性能。
可以相信,针形勃姆石颗粒这种独特分散性得自于它们能与聚合物链上极性基团形成氢键,这有利于形成单分散状态。针形勃姆石颗粒也能分散于那些添加如氨基硅烷一类常用分散剂的基本为非极性的其它聚合物之中。
因为诸如酚醛类与丙烯酸酯类热固性树脂也是适当的极性树脂,可以认为针形勃姆石颗粒可以各个颗粒完全分散于这类树脂之中,如果在例如组分形成聚合物的情况下在交联阶段明显进行之前或在空合树脂如酚醛树脂的B阶段完成掺合。
本发明针形勃姆石颗粒可以通过水热处理制备,在该处理中将勃姆石前体分散/悬浮在水中,在压热器中在100-300℃,较佳在150-250℃的温度,自发产生的压力1×105-8.5×106,较佳5×105-1.2×106牛/m2下加热1-24小时,较佳1-3小时。分散体中勃姆石前体固体含量为5-40%,较佳为10-30%。除勃姆石前体之外,分散体还含有2-15重量%,较佳5-10重量%(以前体重量计)的勃姆石颗粒。勃姆石颗粒起晶种作用,在晶种周围由前体转化而成的勃姆石可结晶。由于水热处理的条件与较低晶种含量,勃姆石晶体优先沿单一晶轴生长,并呈现保持各自分散的针形。
勃姆石前体可以是任何一种氢氧化铝,如三羟铝石或三水铝矿,但也可以是磨碎的铝土矿。也可以采用γ-氧化铝作原料。在采用不纯材料如铝土矿生产针形勃姆石颗粒情况下最好在将得到的勃姆石颗粒掺入到聚合物中之前先清洗掉诸如硅或氢氧化钛、以及至少某些在天然铝土矿中存在的常见残留杂质二氧化硅。
除了出乎意料地方便并完全纳米分散在具有极性基团的聚合物之外,勃姆石针形颗粒还可以经诸如氨基硅烷,如购自Aldrich化学公司的A-1100的表面活性剂进行合适表面处理之后也容易分散于其它聚合物中。
由于颗粒的纳米分散性,它们的尺寸很小,将这种颗粒填料掺入聚合物薄膜,则对薄膜的透光率影响很小或实际没有影响,甚至掺入量高达10体积%也是如此。这证实在某些场合下是很有价值的性质。这也意味着得到的薄壁注塑中容易带有颗粒团聚物所造成的表面薄弱或断裂的点的情况将被大大消除。
水热处理之后,分离任何尚未反应的原料与任何硬团聚物往往是有益的。这通常通过简单离心分离,或甚至简单地将胶溶的勃姆石颗粒的液相从沉淀或未反应的固相中倾析出去就可以做到。
针形勃姆石的制备
实施例1
压热器内装上250g从Alcoa公司购得的CV3002三水铝矿,25g从SASOL公司生产的商品名为Catapal B的假勃姆石的勃姆石,1000g去离子水和56g的18%硝酸。所述勃姆石在加入到三水铝矿和其余的水与酸之前,预先在100g水和7g硝酸中分散。
将压热器在45分钟内升温到180℃,在所述温度下保温二小时,并以530rpm速率搅拌。自发产生的压力达到并保持在150psi。然后从压热器内取出勃姆石分散体。在95℃时去除液体部分,将所得固体物料磨碎到小于100目。
得到的勃姆石呈图1B所示针形颗粒。该图连同图1A一起说明了由SASOL生产的C-200勃姆石所代表的现有技术的勃姆石。须指出C-200与工业上最常见的勃姆石粉一样,其颗粒主要呈等轴性(在三个互相垂直方向上等尺寸),除一些明显的团聚物之外。针形晶体很少。相反本发明颗粒,基本上全部是单独的,而且是针形。直径约为10-20nm,长度约为100-200nm。
实施例2
本实施例说明本发明勃姆石与尼龙6的混合技术,并比较由此得到的两种不同勃姆石掺入量的产品与未改性聚合物的性质。
将颗粒状尼龙6在80℃下干燥过夜,然后与指定量的填料混合。然后将所述混合物通过Werner&Pfleiderer ZSK-30双螺杆排气式挤出机,挤出机机筒保持235-245℃,螺杆转速保持300rpm。将挤出物料冷却,造粒,并在80℃下干燥。
然后试样用温度为250-270℃的挤出料筒与保持70-90℃的模具由造粒材料注塑。
三个试样制成这样:一只试样无填料,一只试样含有3.15体积%本发明针形勃姆石,一只试样含有6.62体积%的同一勃姆石。图2A、2B、2C、3A、3B、3C和图4是这三个试样的UV-VIS光谱,FTIR光谱和XPS,N 1s谱。图2A与图2B和2C的比较说明纳米复合物在400-700nm波长范围基本上无吸收,所述波长范围相当于大部分可见/UV波长范围。图3A与图3B和3C比较表明勃姆石对透过试样薄膜的透光率的影响。目的是表明随着勃姆石含量的增加,在3060cm-1附近遇到的特征位移最小。已知与形成氢键有关,清楚地表明在尼龙与勃姆石之间的氢键键合至少是促进勃姆石在尼龙中纳米分散的一种机理。
图4表示相同现象,随着勃姆石含量的增加,在约400eV处发生N 1s结合能峰值的位移。
图5表示含6.62体积%的勃姆石颗粒的产品的剥离表面。图像是使用放大倍数为×51K的透射电子显微镜摄的。从所述图像可清晰地看到单独针形勃姆石颗粒均匀,并各自分散在聚合物中,无团聚现象。
实施例3
本实施例中,掺常用勃姆石,举例说明掺具有如图1A所示SASOL产的C-200的颗粒,掺入量与本发明勃姆石相似,其颗粒如图1B所示。在每种情况中,被评价试样按实施例2的方法配混。对未经改性的尼龙6,含有常用勃姆石,以及含有本发明勃姆石的同种聚合物样品分别测定弹性模量,弯曲模量,30℃与135℃的储能模量E’,拉伸强度,以及热变形温度。测试结果以条形图方式显示在图6A与6B。从条形图上清楚可见,针形勃姆石性能要比常规勃姆石优越并且往往高许多。
实施例4
在本实施例中,本发明勃姆石分散于环氧树脂中。所选树脂连同固化剂是Buehler的Epo-Kwik。将前一实施例所用的勃姆石与树脂组分混合至均匀,再分成四份样品,其中三个样品加入不同的表面活性剂,加入量为配方中勃姆石重量的0.5%。这些试剂为四乙氧基硅烷(TEOS),γ-环氧丙氧基丙基三甲氧基硅烷(GPTS)和3-氨丙基三乙氧基硅烷(A-1100)。第四个样品不含添加剂。将混合物在电热板上搅拌过夜,温度设定为40-85℃。然后每一混合物经四次超声探头处理,每次时间为2.5-3分钟,每次处理间歇在冰浴中冷却。然后将样品置于铝盘内,在真空下放置20分钟去除真空气。然后将环氧树脂的固化剂成分以树脂量的五分之一的量加入到混合物内,仔细搅拌然后在室温下固化过夜。当设置定在4#,温度为100℃时,三小时完成固化。然后测试固化样品评价它的储能模量,测量结果以条形图方式显示在图8,并与未改性环氧树脂值进行比较。从条形图可见,仅仅勃姆石储能模量没有大的提高,但掺入表面活性剂后,储能模量提高三分之一。
实施例5
本实施例表示在陶氏化学公司提供的注册商标为ISOPLAST 301的热塑性聚氨酯中添加本发明的勃姆石的作用。
所述聚合物首先在100℃下干燥,按实施例1制得的针形勃姆石颗粒在50℃下干燥,每种情况都干燥过夜。然后采用实施例2所述的设备将勃姆石(1.86体积%)与所述聚合物混合,并将挤出物冷却与造粒。混合粒料在80℃下干燥,然后注塑成评价样品。图7所示为勃姆石颗粒完全分散的透射电子显微照片。
Claims (25)
1.一种改性聚合物材料,其包括:
聚合物基料;以及
聚合物基料中的勃姆石颗粒,所述勃姆石颗粒主要包括长径比至少为3∶1的针形颗粒,其中长径比是最长尺寸与次最长尺寸之比,且最长尺寸在50-2000nm之间。
2.如权利要求1所述的材料,其特征在于所述长径比至少6∶1。
3.如权利要求1所述的材料,其特征在于所述勃姆石颗粒的最长尺寸在100-1000nm之间。
4.如权利要求1所述的材料,其特征在于所述勃姆石颗粒占改性聚合物材料体积的0.5-20%。
5.如权利要求1所述的材料,其特征在于所述勃姆石颗粒占改性聚合物材料体积的2-10%。
6.如权利要求1所述的材料,其特征在于所述勃姆石颗粒不含表面活性剂。
7.如权利要求1所述的材料,其特征在于所述勃姆石颗粒分散在聚合物基料内。
8.如权利要求1所述的材料,其特征在于所述勃姆石颗粒基本上各自均匀地分散在聚合物基料内。
9.如权利要求8所述的材料,其特征在于在聚合物基料中所述勃姆石颗粒基本上没有团聚物。
10.如权利要求1所述的材料,其特征在于所述聚合物基料包含热塑性聚合物。
11.如权利要求10所述的材料,其特征在于所述热塑性聚合物基料包含聚酰胺。
12.如权利要求11所述的材料,其特征在于所述聚合物基料包含尼龙。
13.如权利要求1所述的材料,其特征在于所述聚合物基料包含热固化树脂。
14.如权利要求13所述的材料,其特征在于所述聚合物基料包含酚醛类树脂和丙烯酸酯类树脂中的至少一种。
15.如权利要求1所述的材料,其特征在于所述勃姆石颗粒在聚合物基料内定向排列。
16.如权利要求15所述的材料,其特征在于所述改性聚合物材料包括挤出产品。
17.一种制备产品的方法,其包括:
提供一种改性聚合物材料,其包括聚合物基料和主要包括长径比至少为3∶1的针形勃姆石颗粒,其中长径比是最长尺寸与次长尺寸之比;并
将改性聚合物材料挤出成挤出产品,其中所述的勃姆石颗粒分散在所述的挤出产品中。
18.如权利要求17所述的方法,其特征在于所述勃姆石颗粒在挤出产品内基本上定向排列。
19.如权利要求17所述的方法,其特征在于所述改性聚合物材料被挤出到模具中形成制作。
20.如权利要求17所述的方法,其特征在于所述的聚合物基料包含热塑性聚合物。
21.如权利要求20所述的方法,其特征在于所述热塑性聚合物包括聚酰胺。
22.如权利要求17所述的方法,其特征在于所述长径比至少为6∶1。
23.如权利要求17所述的方法,其特征在于所述勃姆石颗粒的最长尺寸在50-2000nm之间。
24.如权利要求17所述的方法,其特征在于所述勃姆石颗粒占改性聚合物材料体积的0.5-20%。
25.如权利要求17所述的方法,其特征在于所述勃姆石颗粒基本上各自均匀地分散。
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