CN108203091A - 一种连续制备石墨烯导热膜的方法 - Google Patents
一种连续制备石墨烯导热膜的方法 Download PDFInfo
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Abstract
本发明属于石墨烯技术领域,具体涉及一种连续制备石墨烯导热膜的方法,本发明直接将含有40~60wt%水分的氧化石墨进行高温剥离,然后进行分散、脱泡、涂布、剥离、切边、还原等工序制备出高导热系数和强电磁屏蔽效能的石墨烯导热膜。本发明方法直接将含有40~60wt%水分的氧化石墨进行高温剥离,省去干燥氧化石墨的工序,能耗低、生产成本低;相比于采取直接分散氧化石墨制备浆料,本发明在高温剥离后制备的浆料浓度更高,可达到3~20wt%。
Description
技术领域
本发明属于石墨烯技术领域,具体涉及一种连续制备石墨烯导热膜的方法。
背景技术
导热散热在当今电子、通讯、照明、航空及国防军工等许多领域都具有重大的应用需求。市场上主流的导热材料仍多以铝和铜或其合金为主,而近几年石墨导热膜被广泛应用并迅速占领传统材料的市场份额。石墨烯导热膜的具有以下几个方面的优势:导热系数较高300-1500w/m·k,高于铝的各种合金及单质铜材料;同时重量比铝轻25%,比铜轻75%。
目前使用氧化石墨制备高定向石墨烯导热膜的方法有:一、将氧化石墨分散在溶剂,形成氧化石墨烯浆料,再采用喷涂、刮涂或者挤压涂布等方式涂布在基材上,再通过干燥形成氧化石墨烯膜,然后将氧化石墨烯膜通过化学还原或者热还原得到石墨烯膜(如CN105084858A)。这种方式制备的过程中,氧化石墨烯浆料的固含量都很低(0.5~2%),在干燥过程中需要去除大量的溶剂,需要很大的能耗,并且由于氧化石墨烯膜的耐温特性,在高于100℃干燥时导致氧化石墨烯膜表面外观差,最终制备的石墨烯导热膜客户无法接受。二、将氧化石墨先干燥,做成粉末或者颗粒,然后经过高温剥离,制得薄层的石墨烯片,再将石墨烯片分散在溶剂中,制备成浆料,经过喷涂、刮涂或者挤压涂布等方式涂布在基材上,再干燥形成石墨烯膜,再通过热还原得到高导热系数的石墨烯膜(Adv.Mater.2014,26(26):4521-6),这种方式首先将氧化石墨进行干燥,消耗很大的能源,成本高。
所以开发一种高效、低能耗的连续制备石墨烯导热膜的方法具有重大的经济意义。
发明内容
本发明的目的一是用来解决现有技术中制备石墨烯导热膜需较低固含量的氧化石墨烯浆料,需高温脱除溶剂导致能耗大,且高温脱除溶剂过程中会导致氧化石墨烯膜表面外观差的技术问题;二是解决制备石墨烯导热膜先干燥再剥离过程繁琐,能耗高、成本高的问题;提供一种连续制备石墨烯导热膜的方法。
根据本发明的一个方面,本发明提供了一种连续制备石墨烯导热膜的方法,包括以下步骤:
1)将含40~60wt%水分的氧化石墨使用螺杆挤出机加工成线条状,然后切成颗粒状,得到氧化石墨颗粒;所述氧化石墨颗粒的粒径大小为1~5mm;
2)将步骤1)的氧化石墨颗粒通过高温炉进行高温剥离,剥离过程采用氮气或者氩气进行保护,制备得到氧化石墨烯粉体;高温剥离温度范围在800~1500℃;高温剥离过程中,步骤1)中颗粒粒径越小,高温剥离处理时间越短;
3)使用高速分散机将氧化石墨烯粉体分散在溶剂中,形成均匀的氧化石墨烯浆料;所述高速分散机的线速度范围是5~50m/min;本发明中分散的均匀程度对石墨烯导热膜的导热性能有重要的影响,越均匀导热系数越高;只有当粘度为20000-100000mPa.s,细度小于30μm时才能制备出本发明导热性能的石墨烯导热膜;所述的高速分散设备设置有冷却层,可防止浆料温度升高,避免影响分散效果;
4)通过脱泡机将步骤3)分散好的氧化石墨烯浆料在真空条件下进行脱泡;避免对后续过程的影响;大于0.2mm的气泡不允许有,小于0.2mm的气泡含量小于0.02mL/L;如果气泡没有达到要求,会导致最终的石墨烯导热膜表面外观不良;
5)将步骤4)脱泡后的氧化石墨烯浆料使用刮刀涂布或挤出涂布的方式,将氧化石墨烯浆料涂布在基材上形成一定的厚度的氧化石墨烯薄膜,氧化石墨烯薄膜经过涂布机烘箱干燥除去溶剂;再进行连续收卷,做成卷材;所述基材为钢带、PET、500~2000目的不锈钢网或500~1000目的尼龙网;所述的厚度为0.8~3mm;涂布机烘箱的干燥温度为70~150℃;在除去溶剂的过程中,由于溶剂挥发形成的毛细压力,将氧化石墨烯片在x-y面形成定向排列;所述基材为钢带、PET、500~2000目的不锈钢网、500~1000目的尼龙网等;所述的厚度为0.8~3mm,涂布的厚度影响最终石墨烯导热膜的厚度;涂布机烘箱的干燥温度在70~150℃;
6)将步骤5)中的卷材经过剥离设备将氧化石墨烯膜从基材上剥离,然后采用切边设备切除氧化石墨烯膜边缘,形成连续的氧化石墨烯膜卷材;剥离下来的基材,经过超声清洗,干燥,可以重复使用;本发明基材的重复使用,可降低制造成本,提升竞争力;
7)将步骤6)制备连续的的氧化石墨烯卷材放入热风烘箱中由室温升温至150℃~500℃下进行热处理;
8)将步骤7)热风烘箱初步还原处理过的氧化石墨烯放入高温感应加热炉中由室温升温至2200~2800℃进行热处理;将石墨烯片的缺陷进行修复和重排,提高石墨化程度,提高材料导热系数;
9)将步骤8)高温石墨化处理后的石墨烯膜经过辊压或真空辊压,提高密度,辊压的压力为10~30MPa;
10)将步骤9)辊压或真空辊压后的石墨烯膜转贴到硅胶保护膜上,形成最终产品。
本发明所述的一种连续制备石墨烯导热膜的方法,其进一步技术方案可以为,步骤2)所得的氧化石墨烯粉体的片层大小为2~10μm,氧化石墨烯粉体的层数为1~8层。
本发明所述的一种连续制备石墨烯导热膜的方法,其进一步技术方案可以为,步骤3)所述溶剂为乙醇、水、NMP、DMF、呋喃、四氢呋喃中任意一种或多种溶剂组成的混合溶剂。
本发明所述的一种连续制备石墨烯导热膜的方法,其进一步技术方案可以为,步骤3)所述氧化石墨烯浆料的中氧化石墨烯的浓度是3~20wt%。
本发明所述的一种连续制备石墨烯导热膜的方法,其进一步技术方案可以为,步骤7)所述的热风烘箱的升温速率1~3℃/min。
本发明所述的一种连续制备石墨烯导热膜的方法,其进一步技术方案可以为,步骤8)所述的高温感应加热炉的升温速率2~10℃/min。
本发明制备的石墨烯导热膜密度范围0.015~2.21g/cm3;石墨烯导热膜的厚度范围8~1000μm;石墨烯导热膜的导热系数800~1900W/m·K;石墨烯导热膜的屏蔽性能,电磁频率在30M~3GHz范围,石墨烯导热膜的电磁屏蔽效能为60~90dB;石墨烯导热膜的电导率在5~20×105S/m;石墨烯导热膜拉伸强度20~80MPa;石墨烯导热膜在R0.5/180°情况下,折弯次数>30万次。
本发明开发的连续低成本制备石墨烯导热膜的方法,直接将含有一定水分的氧化石墨进行高温剥离,这样就可以节省干燥氧化石墨的能源;通过高温剥离得到的石墨烯片,表面的官能团大部分已经被还原,这样将得到的石墨烯片分散在溶剂中可以得到更高固含量的浆料,因为石墨烯片的大部分官能团都已经失去,所以在涂布干燥的时候,烘箱的温度可以提高,溶剂挥发的速度增快,干燥效率提高。
与现有技术相比,本发明具有如下优点:
1.本发明方法直接将含有40~60wt%水分的氧化石墨烯进行高温剥离,省去干燥氧化石墨烯的工序,能耗低、生产成本低;
2.相比于采取直接分散氧化石墨制备浆料,本发明在高温剥离后制备的浆料浓度更高,可达到3~20wt%。
本发明采用将氧化石墨先进行高温剥离,相比于直接将氧化石墨烯分散在溶剂中制备成浆料进行制备氧化石墨烯膜(CN 105084858A),本发明可以制备更高固含量的浆料;本发明的固含量可以做到3~20wt%,比现有技术的固含量高的情况下,制备的石墨烯导热膜的导热系数达到现有技术的水平,这样的情况下,本发明的技术制备石墨烯导热膜的效率更高,成本更低;另外干燥时也可以采用更高的温度,干燥效率相比于现有技术更高;与Adv.Mater.2014,26(26):4521-6中技术方案中的将氧化石墨先干燥再剥离,本发明少了干燥的过程,能耗更低,有明显的的成本优势。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明了,下面结合具体实施方式,对本发明进一步详细说明。应该理解,这些描述只是示例性的,而并非要限制本发明的范围。
本发明采用的氧化石墨烯原料生产厂家为常州第六元素材料科技股份有限公司的SE2430W或南京久和纳米科技有限公司的JH005A;其余试剂为市售常规试剂,高速分散机为带有冷却层的双行星搅拌机。
实施例1
1)将45wt%水分的氧化石墨,使用螺杆连续挤出设备做成线条状,然后切成颗粒状得氧化石墨颗粒,颗粒的大小为1mm;
2)在氩气保护下于1000℃高温炉中进行高温剥离,所得的氧化石墨烯粉体的片层大小为8μm,层数6层;
3)使用线速度35m/min的高速分散设备将氧化石墨烯粉体分散在乙醇中,形成固含量18wt%的氧化石墨烯浆料;浆料粘度60450mPa.s,细度小于30μm;
4)通过薄膜脱泡机将制备好的氧化石墨烯浆料在200pa真空下进行脱泡;
5)使用刮刀涂布方式将氧化石墨烯浆液涂到PET薄膜上,再经过涂布机的烘箱烘干,再剥离收卷,得到氧化石墨烯薄膜,其厚度为0.8mm,涂布机整个烘道的温度分布如表1所示:
表1涂布机烘道的温度分布
烘道/节 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 |
温度/℃ | 85 | 90 | 95 | 100 | 110 | 120 | 130 | 120 | 110 | 100 | 95 | 85 | 80 |
6)将氧化石墨烯膜从基材上剥离下来,切除两侧的边缘,形成连续的氧化石墨烯膜卷材;
7)以1.5℃/min的升温速率于热风烘箱中从室温升温至300℃干燥;
8)在氩气保护下于高温感应加热炉中以3℃/min的升温速率从室温升温至2700℃;
9)压力30MPa进行真空辊压;
10)贴到硅胶保护膜上,便于加工;
本实施方式制备的石墨烯导热膜密度2.0g/cm3;石墨烯导热膜的厚度40μm;石墨烯导热膜的导热系数1300W/m·K;石墨烯导热膜的电导率为7×105S/m;石墨烯导热膜拉伸强度65MPa;石墨烯导热膜在R0.5/180°情况下,折弯次数>30万次。
实施例2
1)将48wt%水分的氧化石墨,使用螺杆连续挤出设备做成线条状,然后切成颗粒状得氧化石墨烯颗粒,颗粒的大小为3mm;
2)在氩气保护下于1200℃高温炉中进行高温剥离,所得的石墨烯粉体的片层大小为7μm,层数5层;
3)使用线速度40m/min的高速分散设备将氧化石墨烯粉体分散在水中,形成固含量10wt%的氧化石墨烯浆料;浆料粘度43000mPa.s,细度小于30μm;
4)通过薄膜脱泡机将制备好的氧化石墨烯浆料在100pa真空下进行脱泡;
5)使用刮刀涂布方式将氧化石墨烯浆液涂到1000目316L不锈钢网上,再经过涂布机的烘箱烘干,再剥离收卷,得到氧化石墨烯薄膜,其厚度为1.0mm,涂布机烘箱的干燥温度如表2:
表2涂布机烘道的温度分布
烘道/节 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 |
温度/℃ | 75 | 85 | 100 | 110 | 120 | 130 | 135 | 125 | 115 | 105 | 95 | 80 | 80 |
6)将氧化石墨烯膜从基材上剥离下来,切除两侧的边缘,形成连续的氧化石墨烯膜卷材;
7)以1.8℃/min的升温速率于热风烘箱中从室温升温至350℃;
8)在氩气保护下于高温感应加热炉中以5℃/min的升温速率将从室温升温至2500℃;
9)压力20MPa下进行辊压;
10)贴到硅胶保护膜上,便于加工;
本实施方式所述石墨烯导热膜密度1.68g/cm3;石墨烯导热膜的厚度30μm;石墨烯导热膜的导热系数1500W/m·K;石墨烯导热膜的电导率为8×105S/m;石墨烯导热膜拉伸强度65MPa;石墨烯导热膜在R0.5/180°情况下,折弯次数>30万次。
实施例3
1)将56wt%水分的氧化石墨,使用螺杆连续挤出设备做成线条状,然后切成颗粒状得氧化石墨颗粒,颗粒的大小为5mm;
2)在氩气保护下于1450℃高温炉中进行高温剥离,所得的氧化石墨烯粉体的片层大小为6μm,层数6层;
3)使用线速度30m/min的高速分散设备将氧化石墨烯粉体分散在DMF中,形成固含量4wt%的氧化石墨烯浆料;浆料粘度35000mPa.s,细度小于30μm;
4)通过薄膜脱泡机将制备好的氧化石墨烯浆料在200pa真空下进行脱泡;
5)使用刮刀涂布方式将氧化石墨烯浆液涂到1500目尼龙网上,再经过涂布机的烘箱烘干,再剥离收卷,得到氧化石墨烯薄膜,其厚度为1.5mm,涂布机烘箱的干燥温度分布为表3:
表3涂布机烘道的温度分布
烘道/节 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 |
温度/℃ | 85 | 95 | 100 | 110 | 120 | 135 | 140 | 130 | 120 | 105 | 95 | 85 | 80 |
6)将氧化石墨烯膜从基材上剥离下来,切除两侧的边缘,形成连续的氧化石墨烯膜卷材;
7)以2.5℃/min的升温速率于热风烘箱中从室温升温至400℃干燥热处理;
8)在氩气气保护下于高温感应加热炉中以5℃/min的升温速率将从室温升温至2300℃热处理;
9)压力18Mpa下进行辊压;
10)贴到硅胶保护膜上,便于加工;
本实施方式所述石墨烯导热膜密度2.1g/cm3;石墨烯导热膜的厚度20μm;石墨烯导热膜的导热系数1600W/m·K;石墨烯导热膜的电导率为8×105S/m;石墨烯导热膜拉伸强度60MPa;石墨烯导热膜在R0.5/180°情况下,折弯次数>30万次。
实施例4
为显示本发明制备出的石墨烯导热膜在低密度下也能具有良好的电磁屏蔽效能,制备低密度的石墨烯导热膜测量其电磁屏蔽效能。
实施例4与实施例1除不进行第9)的真空辊压处理外,其余所用原料和制备方法均一致。其密度为0.15g/cm3,按照ANSI/ASTM D4935-2010测量平面材料电磁屏蔽效率的标准试验方法,在30MHz~1500MHz的频率范围内对平面波的电磁屏蔽效能(SE)进行测量,结果如下表4:
表4典型频率点上电磁屏蔽效能
频率/MHz | 屏蔽效能/dB |
30 | 75.5 |
100 | 83.9 |
150 | 92.6 |
200 | 100.9 |
500 | 97.9 |
1000 | 94.3 |
1100 | 89.3 |
1500 | 91.4 |
石墨烯膜的屏蔽效能达到金属铜和银相同的性能,但是其密度只有金属铜和银的几十分之一,可以为很多应用大幅减重。
尽管已经详细描述了本发明的实施方式,但是应该理解的是,在不偏离本发明的精神和范围的情况下,可以对本发明的实施方式做出各种改变、替换和变更。
Claims (8)
1.一种连续制备石墨烯导热膜的方法,其特征在于:包括以下步骤:
1)将含40~60wt%水分的氧化石墨使用螺杆挤出机加工成线条状,然后切成颗粒状,得氧化石墨颗粒;所述氧化石墨颗粒的粒径大小为1~5mm;
2)将步骤1)的氧化石墨烯颗粒通过高温炉进行高温剥离,剥离过程采用氮气或者氩气进行保护,制备得到氧化石墨烯粉体;高温剥离温度范围在800~1500℃;
3)使用高速分散机将氧化石墨烯粉体分散在溶剂中,形成均匀的氧化石墨烯浆料;所述高速分散机的线速度范围是5~50m/min;
4)通过脱泡机将步骤3)分散好的氧化石墨烯浆料在真空条件下进行脱泡;
5)将步骤4)脱泡后的氧化石墨烯浆料使用刮刀涂布或挤出涂布的方式,将氧化石墨烯浆料涂布在基材上形成一定的厚度的氧化石墨烯薄膜,氧化石墨烯薄膜经过涂布机烘箱干燥除去溶剂;再进行连续收卷,做成卷材;所述基材为钢带、PET、500~2000目的不锈钢网或500~1000目的尼龙网;所述的厚度为0.8~3mm;涂布机烘箱的干燥温度为70~150℃;
6)将步骤5)中的卷材经过剥离设备将氧化石墨烯膜从基材上剥离,然后采用切边设备切除氧化石墨烯膜边缘,形成连续的氧化石墨烯膜卷材;
7)将步骤6)制备连续的的氧化石墨烯卷材放入热风烘箱中由室温升温至150℃~500℃下进行热处理,对氧化石墨烯进行初步还原;
8)将步骤7)热风烘箱初步还原处理过的氧化石墨烯放入高温感应加热炉中由室温升温至2200~2800℃进行热处理;
9)将步骤8)高温石墨化处理后的石墨烯膜经过辊压或真空辊压,提高密度,辊压的压力为10~30MPa;
10)将步骤9)辊压或真空辊压后的石墨烯膜转贴到硅胶保护膜上,形成最终产品。
2.根据权利要求1所述方法,其特征在于:步骤2)所得的氧化石墨烯粉体的片层大小为2~10μm,氧化石墨烯粉体的层数为1~8层。
3.根据权利要求1所述方法,其特征在于:步骤3)所述溶剂为乙醇、水、NMP、DMF、呋喃、四氢呋喃中任意一种或多种。
4.根据权利要求1所述方法,其特征在于:步骤3)所述氧化石墨烯浆料的中氧化石墨烯的浓度是3~20wt%。
5.根据权利要求1所述方法,其特征在于:步骤3)所述氧化石墨烯浆料粘度为20000-100000mPa.s,细度小于30μm。
6.根据权利要求1所述方法,其特征在于:步骤7)所述的热风烘箱的升温速率为1~3℃/min。
7.根据权利要求1所述方法,其特征在于:步骤8)所述的高温感应加热炉的升温速率为2~10℃/min。
8.根据权利要求1-7任一所述方法,其特征在于:所述石墨烯导热膜密度为0.015~2.21g/cm3;石墨烯导热膜的厚度范围为8~1000μm;石墨烯导热膜的导热系数为800~1900W/m·K;石墨烯导热膜在电磁频率在30M~3GHz范围下,石墨烯导热膜的电磁屏蔽效能为60~90dB;石墨烯导热膜的电导率为5~20×105S/m;石墨烯导热膜拉伸强度为20~80MPa;石墨烯导热膜在R0.5/180°的检测条件下,折弯次数>30万次。
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WO2018133338A1 (zh) | 2018-07-26 |
EP3536665B1 (en) | 2020-06-17 |
US20190031513A1 (en) | 2019-01-31 |
US10961124B2 (en) | 2021-03-30 |
EP3536665A1 (en) | 2019-09-11 |
EP3536665A4 (en) | 2019-11-20 |
KR20190070944A (ko) | 2019-06-21 |
KR102043815B1 (ko) | 2019-11-12 |
JP6633259B1 (ja) | 2020-01-22 |
CN108203091B (zh) | 2019-01-18 |
JP2020504702A (ja) | 2020-02-13 |
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