透明纳米氧化锆分散液及其纳米颗粒膜的制备与性能研究
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摘要
氧化锆(ZrO2)具有化学惰性、热稳定性优异、硬度高、折光指数高等优点,其涂层可广泛用作高耐刮伤涂层、金属材料的防腐涂层、微电子装置的高耐磨涂层和绝缘涂层、食品包装用高阻隔涂层、光学(高折光指数)涂层、隔热涂层等等。纯无机ZrO2涂层虽然综合性能突出,但制备时常需要非常高的真空度或后期高温处理,限制了其实际应用领域。将纳米ZrO2颗粒与聚合物复合制备聚合物基纳米复合涂层具有制备条件温和、易于大规模应用的优点,但涉及纳米颗粒分散的难题,涂膜的透明性不高,即使解决了纳米颗粒的分散问题,在高含量ZrO2时,由于热力学的原因仍易发生相分离而产生团聚现象,涂膜透光率变差,因此,无法实现高透明性高ZrO2含量纳米复合涂层的制备。在本文中,我们以非水合成纳米ZrO2晶粒为原料,硅烷偶联剂为改性剂,通过透明ZrO2分散液的制备以及以此为基础的纳米颗粒涂料的制备、涂覆、固化制得了高透明性高ZrO2含量纳米颗粒涂层,由于涂层中不含有聚合物粘结剂,避免了ZrO2纳米粒子和聚合物之间的相分离问题。本文详细研究了非水合成纳米ZrO2晶粒在不同介质中的分散与稳定行为,并以制得的溶剂型或水性透明ZrO2分散液为基础,制备了纳米ZrO2颗粒膜,考察了涂膜的制备工艺与结构、性能之间的关系。主要研究内容与结果如下：
以缩水甘油基氧丙基三甲氧基硅烷(GPTMS)、β-氨丙基三乙氧基硅烷(APTES)和异氰酸酯基丙基三乙氧基硅烷(IPTES)作为改性剂,研究了非水合成纳米ZrO2晶粒在四氢呋喃(THF)、甲苯、吡啶、丙酮、水等分散介质中的分散与稳定行为。以THF作为分散介质,用GPTMS、APTES和IPTES改性纳米ZrO2时均可以得到透明的分散液；以吡啶或甲苯作分散介质时,采用APTES和IPTES可得到透明ZrO2分散液；用二甲基甲酰胺作为分散介质时,只有以IPTES为改性剂时可以得到透明分散液。GPTMS改性的纳米ZrO2粒子在THF中具有较好的贮存稳定性,IPTES改性的纳米ZrO2粒子在吡啶中具有较好的贮存稳定性。FTIR、13C-NMR、29Si-NMR及TGA结果表明,GPTMS、APTES和IPTES以不同的接枝模式键合到了纳米ZrO2颗粒的表面,使ZrO2表面分别带上了环氧基、氨基和乙氧基官能团。HRTEM和动态激光光散射表征表明,纳米ZrO2晶粒在THF中达到了初级粒径分散水平且单分散性好。APTES改性后的纳米ZrO2在少量盐酸或少量氢氧化钠存在下均可以再分散到水中,制得纳米ZrO2晶粒水性透明分散液,分散液的透明程度主要取决于水溶液的pH值和APTES/ZrO2摩尔比。
以GPTMS改性的纳米ZrO2/THF分散液为原料,六氟磷酸二苯碘鎓盐为紫外光阳离子引发剂,采用浸涂或旋涂工艺涂覆,在紫外光照射下引发纳米ZrO2颗粒表面的环氧基团进行交联固化,得到了透明、均匀、表面光滑且内部致密的纳米ZrO2颗粒膜,实现了结晶性纳米ZrO2颗粒膜的室温制备。考察了GPTMS/ZrO2摩尔比、分散液中ZrO2含量及涂膜工艺对纳米ZrO2颗粒膜表面形貌的影响。SEM观察结果表明,GPTMS/ZrO2摩尔比在0.15-0.3之间,旋涂速度在1000-2500rpm或浸涂速度在50-150mm/min范围内,均可以得到表面平整无开裂的纳米ZrO2颗粒膜。紫外-可见光谱结果显示,通过改变浸涂速度或旋涂速度可以精确控制ZrO2颗粒膜的厚度,利用膜厚的控制调节其光学特性,可以有效调控不同波长范围内的增透现象。纳米压痕仪和椭圆偏振仪测试表明,纳米ZrO2颗粒膜的微硬度、弹性模量和折光指数随GPTMS/ZrO2摩尔比的减小而增大,即随ZrO2的含量增加而增大。制得的纳米ZrO2颗粒膜的ZrO2含量较高,超过70wt%,透明性佳,折光指数高达1.77(632nm波长处),微硬度1.0GPa以上。
以AAPTMS改性的纳米ZrO2水分散液为原料,1,4-丁二醇二缩水甘油醚(BBDGE)作为交联剂,采用浸涂工艺或旋涂工艺涂覆于聚碳酸酯基材,在低的加热温度条件下,制备了具有优异综合性能的纳米ZrO2颗粒膜。考察了AAPTMS/ZrO2摩尔比及pH值对纳米ZrO2水分散液透明性及粒径分布的影响,并研究了AAPTMS/ZrO2摩尔比对AAPTMS-ZrO2颗粒膜的表面形貌、折光指数和力学性能的影响。HRTEM和动态光散射表明,当AAPTMS/ZrO2摩尔比大于0.12,pH在13-14之间时,可以得到透明的纳米ZrO2水分散液,且粒径分布均匀。SEM和紫外-可见光谱表明,在所采用的涂膜工艺下制得的AAPTMS-ZrO2颗粒膜表面平整且透光率高。椭圆偏振仪、纳米压痕仪、纳划伤测试和纸带摩擦测试结果表明,AAPTMS-ZrO2颗粒膜的折光指数、微硬度、弹性模量和耐划伤性均随AAPTMS/ZrO2摩尔比的减小而增大。制得的AAPTMS-ZrO2颗粒膜的ZrO2含量高,超过80wt%,折光指数高达1.77,可明显改善PC基材的耐刮伤性能,在透明塑料光学涂层方面具有较好的应用前景。
Zirconia (ZrO2) material possessing the advantages of chemical inertness, excellent thermal stability, high refractive index and high hardness, is an ideal candidate to construct functional coatings with great potential applications as optical coatings, scratch resistant coatings, barrier coatings for polymer substrates, and etc. Inorganic ZrO2 coatings could be fabricated by filtered cathodic vacuum arc, ion beam induced chemical vapor deposition and sputtering. The resulted ZrO2 films generally have high quality with refractive index as high as 2.1-2.3. But all the processes involved have to be conducted under extremely high vacuum using special and expensive apparatus, which limits their large scale application and causes high cost. Sol-gel process using zirconium alkoxide is alternative choice for preparation of inorganic ZrO2 thin coatings. However, to dense and crystallize the ZrO2 phase, annealing at high temperature is usually employed, limiting their application on plastic substrate. Polymer/ZrO2 organic-inorganic nanocomposite coatings fabricated via a sol-gel process or blending with ZrO2 nanoparticles have been developed quickly in recent years. This approach is mild and the obtained organic-inorganic hybrid film can be applied large-scalely on various substrates. The shortcoming of nanocomposite coatings lies in its difficulty to achieve high ZrO2 level because phase separation of ZrO2 nanoparticles easily takes place. To work out this problem, it had better to avoid using polymer. Recently, we have successfully fabricated homogeneous ZrO2 nanoparticles dispersions deagglomerated at primary particle size level using nonaqueous synthesized ZrO2 nanoparticles with the help of ligands. These dispersions make it possible to construct transparent ZrO2 nanoparticle films with high ZrO2 content. In this article, the dispersion behaviors of ZrO2 nanoparticles in various organic solvents or water were investigated. Highly transparent ZrO2 nanoparticles coatings with high refractive index and prominent mechanical properties were fabricated from the transparent solvent-based or waterborne ZrO2 nanoparticles dispersions. The detailed experiments and results are described as follows.
ZrO2 nanocrystals (4 nm), synthesized from zirconium-(IV) isopropoxide isopropanol complex and benzyl alcohol, were dispersed and functionalized in organic solvents using three kinds of bi-functional silane coupling agent (SCA), 3-glycidoxypropyltrimethoxysilane (GPTMS),3-aminopropyltriethoxysilane (APTES) and 3-isocyanatopropyltriethoxysilane (IPTES). Completely transparent ZrO2 dispersions were achieved in tetrahydrofuran (THF) with all three SCAs, in pyridine and toluene with APTES and IPTES, and in N, N-dimethylformamide with IPTES. Dynamic laser scattering (DLS) measurements and high resolution transmission electron microscopical (HRTEM) observation indicated that the ZrO2 nanocrystals are dispersed on primary particle size level. Fourier transform infrared spectroscopy, solid-state 13C-NMR and 29Si-NMR spectroscopy and thermogravimetric analysis demonstrated that all three SCAs are chemically attached to the surface of the ZrO2 nanoparticles, however, in different bonding modes. Except for GPTMS/ZrO2/THF dispersion and IPTES/ZrO2/pyridine dispersion, all other transparent dispersions have poor long-term stability. The increasing polarity, due to high amount of APTES attached and high hydrolysis and condensation degree of the bonded APTES, and the aggregation, due to inter-particle coupling via the bonded triethoxysilyl group, are the causes of the poor long-term stability for the ZrO2 dispersions with APTES and IPTES, respectively. Nevertheless, the APTES-functionalized ZrO2 precipitates can be de-agglomerated in water to get a stable and transparent aqueous ZrO2 dispersion via addition of a little hydrochloric acid or sodium hydroxide.
UV-curable ZrO2 nanoparticle coatings, prepared by dispersing highly-crystalline ZrO2 nanoparticles in tetrahydrofuran with the aid of 3-glycidoxypropyl-trimethoxysilane (GPTMS) and following addition of a cationic photoinitiator, were cast on silicon wafers (or glass substrates) by dip-coating or spin-coating and photopolymerized to get transparent ZrO2 nanoparticle films. Ellipsometrical characterization indicates that the refractive index of the film changes from 1.63 to 1.77 at wavelength of 632 nm when the molar ratio of GPTMS-to-ZrO2 decreases from 0.30 to 0.15. Nano-indentation tests show that the films exhibit robust mechanical performance though they are not heat-treated.
Highly-crystalline ZrO2 nanoparticles were functionalized with 3-(N-amino-ethyl)aminopropyltrimethoxysilane (AAPTMS) and dispersed in water at primary particle size level under basic condition (pH value of 13-14). The aqueous ZrO2 nanoparticles dispersion was cast on polycarbonate substrate with 1,4-butanediol digylcidyl ether as the cross-linker and then heated at 120℃for 1h to obtain ZrO2 nanoparticles films with as high as 81 wt% of ZrO2. The ZrO2 nanoparticle films are highly transparent and have refractive index changing from 1.70 to 1.77 at wavelength of 632 nm as the amount of AAPTMS attached to ZrO2 nanoparticles decreases. Nanoindentation tests show that the hardness of the film reaches 1.7 GPa, while punched tape abrasion and nanoscratch tests reveal that the films exhibit prominent scratch resistant performance.
以缩水甘油基氧丙基三甲氧基硅烷(GPTMS)、β-氨丙基三乙氧基硅烷(APTES)和异氰酸酯基丙基三乙氧基硅烷(IPTES)作为改性剂,研究了非水合成纳米ZrO2晶粒在四氢呋喃(THF)、甲苯、吡啶、丙酮、水等分散介质中的分散与稳定行为。以THF作为分散介质,用GPTMS、APTES和IPTES改性纳米ZrO2时均可以得到透明的分散液；以吡啶或甲苯作分散介质时,采用APTES和IPTES可得到透明ZrO2分散液；用二甲基甲酰胺作为分散介质时,只有以IPTES为改性剂时可以得到透明分散液。GPTMS改性的纳米ZrO2粒子在THF中具有较好的贮存稳定性,IPTES改性的纳米ZrO2粒子在吡啶中具有较好的贮存稳定性。FTIR、13C-NMR、29Si-NMR及TGA结果表明,GPTMS、APTES和IPTES以不同的接枝模式键合到了纳米ZrO2颗粒的表面,使ZrO2表面分别带上了环氧基、氨基和乙氧基官能团。HRTEM和动态激光光散射表征表明,纳米ZrO2晶粒在THF中达到了初级粒径分散水平且单分散性好。APTES改性后的纳米ZrO2在少量盐酸或少量氢氧化钠存在下均可以再分散到水中,制得纳米ZrO2晶粒水性透明分散液,分散液的透明程度主要取决于水溶液的pH值和APTES/ZrO2摩尔比。
以GPTMS改性的纳米ZrO2/THF分散液为原料,六氟磷酸二苯碘鎓盐为紫外光阳离子引发剂,采用浸涂或旋涂工艺涂覆,在紫外光照射下引发纳米ZrO2颗粒表面的环氧基团进行交联固化,得到了透明、均匀、表面光滑且内部致密的纳米ZrO2颗粒膜,实现了结晶性纳米ZrO2颗粒膜的室温制备。考察了GPTMS/ZrO2摩尔比、分散液中ZrO2含量及涂膜工艺对纳米ZrO2颗粒膜表面形貌的影响。SEM观察结果表明,GPTMS/ZrO2摩尔比在0.15-0.3之间,旋涂速度在1000-2500rpm或浸涂速度在50-150mm/min范围内,均可以得到表面平整无开裂的纳米ZrO2颗粒膜。紫外-可见光谱结果显示,通过改变浸涂速度或旋涂速度可以精确控制ZrO2颗粒膜的厚度,利用膜厚的控制调节其光学特性,可以有效调控不同波长范围内的增透现象。纳米压痕仪和椭圆偏振仪测试表明,纳米ZrO2颗粒膜的微硬度、弹性模量和折光指数随GPTMS/ZrO2摩尔比的减小而增大,即随ZrO2的含量增加而增大。制得的纳米ZrO2颗粒膜的ZrO2含量较高,超过70wt%,透明性佳,折光指数高达1.77(632nm波长处),微硬度1.0GPa以上。
以AAPTMS改性的纳米ZrO2水分散液为原料,1,4-丁二醇二缩水甘油醚(BBDGE)作为交联剂,采用浸涂工艺或旋涂工艺涂覆于聚碳酸酯基材,在低的加热温度条件下,制备了具有优异综合性能的纳米ZrO2颗粒膜。考察了AAPTMS/ZrO2摩尔比及pH值对纳米ZrO2水分散液透明性及粒径分布的影响,并研究了AAPTMS/ZrO2摩尔比对AAPTMS-ZrO2颗粒膜的表面形貌、折光指数和力学性能的影响。HRTEM和动态光散射表明,当AAPTMS/ZrO2摩尔比大于0.12,pH在13-14之间时,可以得到透明的纳米ZrO2水分散液,且粒径分布均匀。SEM和紫外-可见光谱表明,在所采用的涂膜工艺下制得的AAPTMS-ZrO2颗粒膜表面平整且透光率高。椭圆偏振仪、纳米压痕仪、纳划伤测试和纸带摩擦测试结果表明,AAPTMS-ZrO2颗粒膜的折光指数、微硬度、弹性模量和耐划伤性均随AAPTMS/ZrO2摩尔比的减小而增大。制得的AAPTMS-ZrO2颗粒膜的ZrO2含量高,超过80wt%,折光指数高达1.77,可明显改善PC基材的耐刮伤性能,在透明塑料光学涂层方面具有较好的应用前景。
Zirconia (ZrO2) material possessing the advantages of chemical inertness, excellent thermal stability, high refractive index and high hardness, is an ideal candidate to construct functional coatings with great potential applications as optical coatings, scratch resistant coatings, barrier coatings for polymer substrates, and etc. Inorganic ZrO2 coatings could be fabricated by filtered cathodic vacuum arc, ion beam induced chemical vapor deposition and sputtering. The resulted ZrO2 films generally have high quality with refractive index as high as 2.1-2.3. But all the processes involved have to be conducted under extremely high vacuum using special and expensive apparatus, which limits their large scale application and causes high cost. Sol-gel process using zirconium alkoxide is alternative choice for preparation of inorganic ZrO2 thin coatings. However, to dense and crystallize the ZrO2 phase, annealing at high temperature is usually employed, limiting their application on plastic substrate. Polymer/ZrO2 organic-inorganic nanocomposite coatings fabricated via a sol-gel process or blending with ZrO2 nanoparticles have been developed quickly in recent years. This approach is mild and the obtained organic-inorganic hybrid film can be applied large-scalely on various substrates. The shortcoming of nanocomposite coatings lies in its difficulty to achieve high ZrO2 level because phase separation of ZrO2 nanoparticles easily takes place. To work out this problem, it had better to avoid using polymer. Recently, we have successfully fabricated homogeneous ZrO2 nanoparticles dispersions deagglomerated at primary particle size level using nonaqueous synthesized ZrO2 nanoparticles with the help of ligands. These dispersions make it possible to construct transparent ZrO2 nanoparticle films with high ZrO2 content. In this article, the dispersion behaviors of ZrO2 nanoparticles in various organic solvents or water were investigated. Highly transparent ZrO2 nanoparticles coatings with high refractive index and prominent mechanical properties were fabricated from the transparent solvent-based or waterborne ZrO2 nanoparticles dispersions. The detailed experiments and results are described as follows.
ZrO2 nanocrystals (4 nm), synthesized from zirconium-(IV) isopropoxide isopropanol complex and benzyl alcohol, were dispersed and functionalized in organic solvents using three kinds of bi-functional silane coupling agent (SCA), 3-glycidoxypropyltrimethoxysilane (GPTMS),3-aminopropyltriethoxysilane (APTES) and 3-isocyanatopropyltriethoxysilane (IPTES). Completely transparent ZrO2 dispersions were achieved in tetrahydrofuran (THF) with all three SCAs, in pyridine and toluene with APTES and IPTES, and in N, N-dimethylformamide with IPTES. Dynamic laser scattering (DLS) measurements and high resolution transmission electron microscopical (HRTEM) observation indicated that the ZrO2 nanocrystals are dispersed on primary particle size level. Fourier transform infrared spectroscopy, solid-state 13C-NMR and 29Si-NMR spectroscopy and thermogravimetric analysis demonstrated that all three SCAs are chemically attached to the surface of the ZrO2 nanoparticles, however, in different bonding modes. Except for GPTMS/ZrO2/THF dispersion and IPTES/ZrO2/pyridine dispersion, all other transparent dispersions have poor long-term stability. The increasing polarity, due to high amount of APTES attached and high hydrolysis and condensation degree of the bonded APTES, and the aggregation, due to inter-particle coupling via the bonded triethoxysilyl group, are the causes of the poor long-term stability for the ZrO2 dispersions with APTES and IPTES, respectively. Nevertheless, the APTES-functionalized ZrO2 precipitates can be de-agglomerated in water to get a stable and transparent aqueous ZrO2 dispersion via addition of a little hydrochloric acid or sodium hydroxide.
UV-curable ZrO2 nanoparticle coatings, prepared by dispersing highly-crystalline ZrO2 nanoparticles in tetrahydrofuran with the aid of 3-glycidoxypropyl-trimethoxysilane (GPTMS) and following addition of a cationic photoinitiator, were cast on silicon wafers (or glass substrates) by dip-coating or spin-coating and photopolymerized to get transparent ZrO2 nanoparticle films. Ellipsometrical characterization indicates that the refractive index of the film changes from 1.63 to 1.77 at wavelength of 632 nm when the molar ratio of GPTMS-to-ZrO2 decreases from 0.30 to 0.15. Nano-indentation tests show that the films exhibit robust mechanical performance though they are not heat-treated.
Highly-crystalline ZrO2 nanoparticles were functionalized with 3-(N-amino-ethyl)aminopropyltrimethoxysilane (AAPTMS) and dispersed in water at primary particle size level under basic condition (pH value of 13-14). The aqueous ZrO2 nanoparticles dispersion was cast on polycarbonate substrate with 1,4-butanediol digylcidyl ether as the cross-linker and then heated at 120℃for 1h to obtain ZrO2 nanoparticles films with as high as 81 wt% of ZrO2. The ZrO2 nanoparticle films are highly transparent and have refractive index changing from 1.70 to 1.77 at wavelength of 632 nm as the amount of AAPTMS attached to ZrO2 nanoparticles decreases. Nanoindentation tests show that the hardness of the film reaches 1.7 GPa, while punched tape abrasion and nanoscratch tests reveal that the films exhibit prominent scratch resistant performance.
引文
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