Composite resinous material particles and process for producing same

Patent metadata

Field	Value
Publication number	US-10435519-B2
Application number	US-201013514411-A
Country	US
Kind code	B2
Filing date	Jul 16, 2010
Priority date	Jan 20, 2009
Publication date	Oct 8, 2019
Grant date	Oct 8, 2019

Abstract

A composite resin material particle of the present invention includes: a resin material particle that is a material for producing a resin molding product; and a conductive nano-material, wherein a dispersion mixing layer, which is obtained by dispersedly mixing the conductive nano-material from the surface to the inside of the resin material particle, is formed over all of the surface or at least a part of the surface of the resin material particle, the conductive nano-material is dispersedly mixed within a resin material of the resin material particle in the dispersion mixing layer, and the whole of the dispersion mixing layer forms a conductive layer.

First claim

The invention claimed is:

1. A composite resin material particle which is formed by a resin material particle that is a material for producing a resin molding product and a conductive nano-material, comprising:
a resin-only region that is solely composed of a resin material of the resin material particle; and
a dispersion mixing layer which is obtained by dispersedly mixing the conductive nano-material from a surface of the resin material particle to an inside of the resin material particle, wherein
the resin-only region is present in the inside of the composite resin material particle and 60% or higher of a surface of the resin-only region is enclosed by the dispersion mixing layer,
the dispersion mixing layer is formed over all of the surface or at least a part of the surface of the resin-only region,
the conductive nano-material is dispersedly mixed within the resin material of the resin material particle in the dispersion mixing layer,
the dispersion mixing layer forms a conductive layer,
the mixed thickness of the dispersion mixing layer is from 0.1 μm to 1 μm,
the conductive nano-material within the dispersion mixing layer has a shape with an outer diameter of 150 nm or smaller and a length of 500 nm or longer,
the dispersion mixing layer includes a conductive net that is composed of the conductive nano-materials,
the resin material is polytetrafluoroethylene, and
the conductive nano-material is one or more selected from the group consisting of a carbon nanotube, a carbon nanofiber, a carbon nanocoil, a carbon nanotwist, a carbon nanohorn, a metal nanoplate, a metal nanorod, and a metal nanowire.

2. The composite resin material particle according to claim 1 , wherein the dispersion mixing layer is formed over all of the surface of the composite resin material particle.

3. The composite resin material particle according to claim 1 , which is a powder having a diameter of 100 μm or smaller.

4. The composite resin material particle according to claim 1 , wherein the conductive nano-material has a shape with an outer diameter of 80 nm or smaller and a length of 500 nm or longer.

5. A production method of a composite resin material particle, comprising:
filling at least a resin material particle, a conductive nano-material, a solvent for propagating ultrasonic waves, and liquid carbon dioxide, into a pressure vessel;
holding the inside of the pressure vessel at a temperature and a pressure which can keep the liquid carbon dioxide in a subcritical or supercritical state;
dispersedly mixing the conductive nano-material from a surface of the resin material particle to an inside of the resin material particle by using ultrasonic waves;
thereafter evaporating the liquid carbon dioxide by reducing the pressure; and
further volatilizing the solvent either concurrently or with time lag, to obtain the composite resin material particle comprising: a resin-only region that is solely composed of a resin material of the resin material particle; and a dispersion mixing layer which is obtained by dispersedly mixing the conductive nano-material from the surface of the resin material particle to the inside of the resin material particle, wherein
the resin-only region is present in the inside of the composite resin material particle and 60% or higher of a surface of the resin-only region is enclosed by the dispersion mixing layer,
the mixed thickness of the dispersion mixing layer is from 0.1 μm to 1 μm,
the conductive nano-material within the dispersion mixing layer has a shape with an outer diameter of 150 nm or smaller and a length of 500 nm or longer,
the dispersion mixing layer includes a conductive net that is composed of the conductive nano-materials,
the resin material is polytetrafluoroethylene, and
the conductive nano-material is one or more selected from the group consisting of a carbon nanotube, a carbon nanofiber, a carbon nanocoil, a carbon nanotwist, a carbon nanohorn, a metal nanoplate, a metal nanorod, and a metal nanowire.

6. The production method of a composite resin material particle according to claim 5 , wherein the solvent is a highly volatile solvent at normal temperature and normal pressure.

7. The production method of a composite resin material particle according to claim 6 , wherein the solvent is one or more selected from the group consisting of an alcohol, a ketone, an ester, an ether, an organochloride, and an organofluoride.

8. The production method of a composite resin material particle according to claim 5 , wherein a ratio by weight of the solvent to the conductive nano-material is 20 or more.

9. The production method of a composite resin material particle according to claim 5 , wherein a ratio by weight of the liquid carbon dioxide:the solvent is from 0.05:1 to 20:1.

10. The production method of a composite resin material particle according to claim 5 , wherein a dispersant and/or a surfactant is added in the pressure vessel.

11. The production method of a composite resin material particle according to claim 5 , wherein the temperature is over 25° C. and below the melting point temperature of the resin material.

12. The production method of a composite resin material particle according to claim 5 , wherein the maximum pressure inside the pressure vessel is 100 MPa.

13. The production method of a composite resin material particle according to claim 5 , wherein a generator of the ultrasonic waves is a horn type of a 150 W or higher.

14. The production method of a composite resin material particle according to claim 5 , wherein the conductive nano-material has been oxidatively treated.

15. The production method of a composite resin material particle according to claim 5 , wherein a dispersion liquid, which is obtained by mixing and dispersing at least the conductive nano-material in the solvent, is filled into the pressure vessel together with the liquid carbon dioxide and the resin material particle.

16. The production method of a composite resin material particle according to claim 15 , wherein the dispersion liquid contains a dispersant and/or a surfactant.

17. The composite resin material particle according to claim 1 , wherein
the dispersion mixing layer is formed in island shapes, and
a distance between the island shapes is 500 nm or smaller.

18. The production method of a composite resin material particle according to claim 5 , wherein
the dispersion mixing layer is formed in island shapes, and
a distance between the island shapes is 500 nm or smaller.

19. The composite resin material particle according to claim 3 , wherein
the diameter of the composite resin material particle is 1 μm or greater and 100 μm or smaller.

20. The composite resin material particle according to claim 19 , wherein
the diameter of the composite resin material particle is 5 μm or greater and 100 μm or smaller.

21. The composite resin material particle according to claim 20 , wherein
the diameter of the composite resin material particle is 5 μm.

Assignees

• Yajima Takeru
• Ohta Hidetoshi
• Nose Norihiro
• Taiyo Nippon Sanso Corp

Inventors

• Yajima Takeru
• Ohta Hidetoshi
• Nose Norihiro

Classifications

• C08K3/044

  Carbon nanohorns or nanobells · CPC title

• C08K3/043

  Carbon nanocoils · CPC title

• C08K3/046

  Carbon nanorods, nanowires, nanoplatelets or nanofibres · CPC title

• C08K3/045

  Fullerenes · CPC title

• C08K3/041

  Carbon nanotubes · CPC title