Graphene and fluorpolymer composite

• US 9,458,325 B2
• Filed: 10/02/2013
• Issued: 10/04/2016
• Est. Priority Date: 10/02/2013
• Status: Active Grant

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Zhang, Qi, Qi, Yu, Dooley, Brynn, Hu, Nan-Xing
• Primary Examiner(s): ZIMMER, MARC S
• Application Number:
  US14/044,446
• Publication Number:
  US 20150093584A1
• Time in Patent Office: 1,098 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B32B 19/00 Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
• CPC Class Codes: B32B 19/043 of natural rubber or synthetic rubber
• CPC Class Codes: B32B 19/045 of synthetic resin
• CPC Class Codes: B32B 2264/0257 Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2305/30 Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2307/746 Slipping, anti-blocking, low friction
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: C08J 2327/12 containing fluorine atoms
• CPC Class Codes: C08J 3/128 Polymer particles coated by inorganic and non-macromolecular organic compounds
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08K 9/06 with silicon-containing compounds
• CPC Class Codes: C08L 33/00 Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
• CPC Class Codes: C09C 1/0081 Composite particulate pigments or fillers, i.e. containing at least two solid phases, except those consisting of coated particles of one compound C09C1/0015, C09C1/0078 take precedence
• CPC Class Codes: C09C 1/44 Carbon
• CPC Class Codes: C09D 127/18 Homopolymers or copolymers of tetrafluoroethene
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane

Abstract

A composition comprises a liquid continuous phase and a plurality of composite particles dispersed therein. The composite particles each comprise a fluorosilane-treated graphene-comprising particle and a fluoropolymer particle.

Claims

1. A composition, comprising:

a liquid continuous phase; and

a plurality of composite particles dispersed in the liquid continuous phase, the composite particles each comprising a fluorosilane-treated graphene-comprising particle and a fluoropolymer particle.

2. The composition of claim 1, wherein the composition further comprises a sacrificial polymeric binder.

3. The composition of claim 2, wherein the sacrificial polymer binder is selected from the group consisting of a poly(alkylene carbonate), a poly(acrylic acid), an acrylic copolymer, a methacrylic copolymer, a poly(methacrylic acid), and mixtures thereof.

4. The composition of claim 1, wherein the fluorosilane-treated graphene-comprising particle is made by treating a graphene-comprising particle with a trichlorosilane compound comprising a linear fluoroalkyl substituent having at least 6 carbon atoms that are substituted with fluorine.

5. The composition of claim 1, wherein the fluorosilane-treated graphene-comprising particles are selected from the group consisting of fluorosilane-treated graphene, fluorosilane-treated graphene platelets and mixtures thereof.

6. The composition of claim 1, wherein the composite particles are present in an amount ranging from about 50 weight % to about 99 weight %, based on the total weight of the solid in the composition.

7. The composition of claim 1, wherein the total solid ranges from about 10 weight % to about 80 weight % of the total weight of the composition.

8. The composition of claim 1, wherein the fluoropolymer particle is a fluoroplastic resin.

9. The composition of claim 8, wherein the fluoroplastic resin is selected from the group consisting of polytetrafluoroethylene (PTFE);

perfluoroalkoxy polymer resin (PFA); and

fluorinated ethylenepropylene copolymers (FEP).

10. A process for making a fluorosilane-treated graphene/fluorocarbon polymer composite, the process comprising:

mixing graphene-comprising particles, a fluorosilane compound and a first liquid continuous phase to form a fluorosilane-treated graphene-comprising particle dispersion; and

mixing the fluorosilane-treated graphene-comprising particles with a fluorocarbon polymer dispersion to form a dispersion of composite particles comprising fluorosilane-treated graphene-comprising particles adhered to fluorocarbon polymer particles in a second liquid continuous phase.

11. The process of claim 10, wherein the graphene-comprising particles are selected from the group consisting of graphene, graphene platelets, graphene nanosheets and mixtures thereof.

12. The process of claim 10, wherein the fluorosilane is selected from the group consisting of (3,3,3-trifluoropropyl)trichlorosilane, nonafluorohexyl trichlorosilane, nonafluorohexyl trimethoxysilane, nonafluorohexyl trialkoxysilane, pentafluorophenylpropyl trichlorosilane, pentafluorophenylpropyl trimethoxysilane, pentafluorophenylpropyl trialkoxysilane, (tridecafluoro-1,1,2,2-tetra-hydrooctyl)trichlorosilane, (tridecafluoro-1,1,2,2-tetra-hydrooctyl)trialkoxysilane, perfluoroalkylethyltriethoxysilanes, (tridecafluoro-1,1,2,2-tetra-hydrooctyl)trichlorosilane, (3,3,3-trifluoropropyl)trialkoxysilane, perfluorododecyl-1H,1H,2H,2H-triethoxysilane, p-trifluoromethyltetrafluorophenyltriethoxysilane, and mixtures thereof.

13. The process of claim 10, wherein the fluorosilane compound is a trichlorosilane compound comprising a linear fluoroalkyl substituent having at least 6 carbon atoms that are substituted with fluorine.

14. The process of claim 10, wherein the first liquid continuous phase comprises a compound selected from the group consisting of ketones, amides, sulfoxides, alcohols, ethers, esters, hydrocarbons, chlorinated hydrocarbons and mixtures thereof.

15. The process of claim 10, wherein the second liquid continuous phase comprises a compound selected from the group consisting of ketones, amides, sulfoxides, alcohols, ethers, esters, hydrocarbons, chlorinated hydrocarbons and mixtures thereof.

16. A process of making a coated article comprising

mixing graphene-comprising particles, a fluorosilane compound and a first liquid continuous phase to form a fluorosilane-treated graphene-comprising particle dispersion;

mixing the fluorosilane-treated graphene-comprising particles with a fluorocarbon polymer dispersion to form a dispersion of composite particles comprising fluorosilane-treated graphene-comprising particles adhered to fluorocarbon polymer particles in a second liquid continuous phase;

mixing a sacrificial polymer binder with the dispersion of composite particles;

coating the mixture onto a substrate;

and heating the coated mixture to a temperature and for a time period that is sufficient to thermally decompose the sacrificial polymer binder.

17. The process of claim 16, wherein the sacrificial polymer binder is selected from the group consisting of a poly(alkylene carbonate), a poly(acrylic acid), an acrylic copolymer, a methacrylic copolymer, a poly(methacrylic acid), and mixtures thereof.

18. An article comprising:

a substrate; and

a composite layer formed on the substrate, the composite layer comprising a plurality of fluorosilane-treated graphene-comprising particles and a fluorocarbon polymer.

19. The article of claim 18, wherein the article is a xerographic component selected from the group consisting of a fuser member, a pressure roller and a release agent donor member.

20. The article of claim 18, wherein the fluorosilane-treated graphene-comprising particles are made by treating a graphene-comprising particle with a trichlorosilane compound comprising a linear fluoroalkyl substituent having at least 6 carbon atoms substituted with fluorine.