Graphene and fluorpolymer composite

Patent metadata

Field	Value
Publication number	US-9458325-B2
Application number	US-201314044446-A
Country	US
Kind code	B2
Filing date	Oct 2, 2013
Priority date	Oct 2, 2013
Publication date	Oct 4, 2016
Grant date	Oct 4, 2016

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.

First claim

What is claimed is:

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.

Assignees

• Xerox Corp

Inventors

• Zhang Qi
• Qi Yu
• Dooley Brynn
• Hu Nan-Xing

Classifications

• C08K9/06

  with silicon-containing compounds · CPC title

• B32B2305/30

  Fillers, e.g. particles, powders, beads, flakes, spheres, chips · CPC title

• B32B2264/0257

  Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers · CPC title

• C09D127/18

  Homopolymers or copolymers of tetrafluoroethene · CPC title

• B32B9/007

  comprising carbon, e.g. graphite, composite carbon · CPC title