Layered product and process for producing same

• US 10,518,506 B2
• Filed: 06/08/2015
• Issued: 12/31/2019
• Est. Priority Date: 06/12/2014
• Status: Active Grant

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Miyazono, Koki, Katayama, Yutaka, Kawabata, Yusuke, Tamaki, Eiichiro, Kubota, Yasuo
• Primary Examiner(s): Zacharia, Ramsey
• Application Number:
  US15/317,588
• Publication Number:
  US 20170106626A1
• Time in Patent Office: 1,667 Days
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/302 Conductive
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2439/00 Containers; Receptacles closures therefor B32B2435/00
• CPC Class Codes: B32B 2439/40 Closed containers
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/14 next to a particulate layer
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B32B 9/045 of synthetic resin
• CPC Class Codes: C08J 7/043 Improving the adhesiveness of the coatings per se, e.g. forming primers adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50
• CPC Class Codes: C08J 7/044 Forming conductive coatings; Forming coatings having anti-static properties
• CPC Class Codes: C08J 7/048 Forming gas barrier coatings
• CPC Class Codes: C08J 7/06 : with compositions not containing macromolecular substances
• CPC Class Codes: F28F 21/02 : of carbon, e.g. graphite
• CPC Class Codes: G01N 27/30 : Electrodes, e.g. test electrodes; Half-cells G01N27/414 takes precedence
• CPC Class Codes: G01N 27/308 : at least partially made of carbon
• CPC Class Codes: H01B 1/04 : mainly consisting of carbon-silicon compounds, carbon or silicon

Abstract

Provided are a laminate that has high smoothness, planar homogeneity, and substrate adhesion and undergoes little change in physical properties even if degradation of surface quality due to physical contact in use has occurred, and a method for producing the homogeneous laminate in a convenient manner in a small number of steps. A laminate includes a substrate made of a polymer material and a partially oxidized thin layer graphite piece layer including partially oxidized thin layer graphite pieces and having an average thickness to of 3.0 nm to 10,000 nm, the layer being formed on the substrate and bonded to the substrate via a chemical bond.

Claims

1. A laminate comprising at least:

a substrate made of a polymer material; and

a partially oxidized thin layer graphite piece layer comprising partially oxidized thin layer graphite pieces and having an average thickness to of 3.0 nm to 10,000 nm,

the layer being formed on the substrate and bonded to the substrate via a chemical bond;

wherein the chemical bond is formed by a binding agent having a first binding functional group forming a first chemical bond with the substrate and a second binding functional group forming a second chemical bond with partially oxidized thin layer graphite pieces;

wherein the first binding functional group is selected from the groups of a hydroxyl group, a carboxyl group, an alkoxysilyl group and a thiol group, and the second functional group is selected from the groups of a primary amino group, a secondary amino group, a tertiary amino group, and a quaternary ammonium group.

2. The laminate according to claim 1, wherein the partially oxidized thin layer graphite pieces have a degree of oxidation (0/C) of 0.07 to 0.85.

3. The laminate according to claim 1, wherein the partially oxidized thin layer graphite piece layer is substantially free of a binder.

4. The laminate according to claim 1, wherein the chemical bond is selected from the group consisting of an ionic bond, a hydrogen bond, and a covalent bond.

5. The laminate according to claim 1, wherein the binding agent is a polymer binding agent.

6. The laminate according to claim 1, wherein the partially oxidized thin layer graphite piece layer has a surface resistivity Ra with a coefficient of variation CV of 10% or less.

7. The laminate according to claim 1, wherein the partially oxidized thin layer graphite piece layer has an insulating portion having a degree of oxidation (O/C) of at least 0.15 and an electrically conductive portion having a degree of oxidation (0/C) of less than 0.15.

8. An electrode material comprising the laminate according to claim 1.

9. A heat radiation material comprising the laminate according to claim 1.

10. A gas barrier material comprising the laminate according to claim 1.

11. A gas tank comprising the gas barrier material according to claim 10.

12. A method for producing the laminate of claim 1, the method comprising in sequence:

loading a binding agent onto a substrate made of a polymer material, the binding agent having a first binding functional group capable of forming a chemical bond with the substrate and a second binding functional group capable of forming a chemical bond with partially oxidized thin layer graphite pieces, thereby chemically binding the substrate to the first binding functional group;

loading a coating agent comprising partially oxidized thin layer graphite pieces onto the binding agent by application, thereby chemically binding the second binding functional group to the partially oxidized thin layer graphite pieces; and

reducing at least some of the partially oxidized thin layer graphite pieces in a liquid.