Ying Tiana,
Xingcai Zhangb,
Hong-Zhang Geng*ab,
Hai-Jie Yangc,
Chungang Lid,
Shi-Xun Daa,
Xiushan Lud,
Jie Wanga and
Song-Lin Jiaa
aState Key Laboratory of Separation Membranes and Membrane Processes, Tianjin Key Laboratory of Advanced Fibers and Energy Storage, School of Materials Science and Engineering, Tianjin Polytechnic University, Tianjin 300387, PR China. E-mail: genghz@tjpu.edu.cn; Fax: +86 22 83955055; Tel: +86 22 83955812
bDepartment of Electrical Engineering and Computer Science, Massachusetts Institute of Technology, Cambridge, Massachusetts 02139, USA. E-mail: genghz@mit.edu
cTianjin Polyester New Material Technology Engineering Center, Tianjin Wanhua Co., Ltd, Tianjin, 300385, PR China
dTianjin BoYuan New Materials Co. Ltd., Tianjin 300384, PR China
First published on 16th November 2017
Antistatic technology has been applied in all aspects of modern life, including the manufacture of electronic products, aerospace systems, daily necessities and so on. The main purpose of this study is to obtain, using the Mayer rod-coating method, a flexible antistatic film with high transmittance, low sheet resistance and strong adhesion. With the help of the dispersant, single-walled carbon nanotubes (SWCNTs) were dispersed in water to form an homogeneous dispersion. The SWCNT dispersion was coated onto a poly(ethylene terephthalate) (PET) film with use of a rod to produce a uniform film. The antistatic films obtained had special characteristics, such as high transparency, low sheet resistance and excellent resistance to water and heat. Sheet resistance varied between 102–105 Ω sq−1 by controlling the content of water-based polyurethane (WPU), changing the thickness of the films and the post-treatment. The best film had a sheet resistance of 423 Ω sq−1 with 82.7% transmittance. In particular, the addition of the WPU binder greatly improved the adhesion between the CNTs and the PET film. Scanning electron microscopy, energy dispersive X-ray spectroscopy and Scotch™ tape method were conducted to determine the microstructure, cleanliness, and adhesion of the film, respectively.
At present, the antistatic materials mainly include carbon black,9 carbon nanotubes (CNTs),10 carbonaceous fibers,11 metals and metal oxides,12,13 antistatic agents,14–17 conductive polymers,18–20 and so on. Although the use of metals and metal oxides can give high transparent antistatic films (TAFs), the cost is too high for general use. Conductive film made by adding an antistatic agent easily loses its efficacy, because the antistatic agent easily dissolves in water or loses from the substrate which can lead to contamination and static failure. Although carbon black is widely used as an antistatic agent, it is not the ideal choice because of its poor conductive properties and relatively poor dispersion. Because the conductive polymer itself has some shortcomings, such as poor rigidity, low transparency, and difficulty in forming, it cannot be used as a packaging film directly and ideally should be blended with another polymer matrix. However, properties, such as transparency, flexibility and tensile properties, of the polymer matrix may be affected by adding a large amount of conductive polymer that is used to improve the electrical properties of the films. CNTs, are a one-dimensional conductive material with excellent mechanical properties and electrical conductivity, which is widely used in transparent conducting thin films,21–24 chemical sensors,25 and light-emitting diodes,26,27 and so on. In antistatic applications, many researchers have utilized CNTs as a conductive material to make antistatic films. Huang et al. made use of multi-walled carbon nanotubes (MWCNTs) and cellulose to make films on glass, but the films did not have good conductivity or flexibility.28 Yoon et al. used in situ polymerization to make composites containing MWCNTs and poly(ethylene), and then used them to make films with a surface resistance of 1010 Ω, which was high enough for them to be used in practical applications.29 Kim et al. utilized MWCNTs and isopropyl alcohol to make films on poly(ethylene naphthalate). Using this method, the resistance decreased, but the transmittance was between 55% to 60% at the wavelength of 550 nm, which was too low.30 Kitamura et al. made a composite film containing aligned CNTs, but the surface resistance of this film was not uniform in all directions.31 For antistatic films, it is better to improve various properties at the same time. A method to fabricate antistatic films was found which could simultaneously have properties with good performances, such as transmittance, low sheet resistance, flexibility, large area, uniformity, and strong adhesion at room temperature. Single-walled carbon nanotubes (SWCNTs) have better conductivity than MWCNTs but have poor adhesion to the PET substrate, which caused short-lived antistatic film and pollution. To solve this problem, a water-based poly(urethane) (WPU) was chosen as a binder to improve the adhesion. Comparing organic solvent-based poly(urethane)s, WPU has many advantages such as non-toxicity, it is environmentally friendly, has high adhesion32 and it has been widely used in adhesives, coating materials,33–35 and so on.
In this research, SWCNTs were used as the conductive material and WPU as the binder to improve the adhesion between the CNTs and the PET substrate. The low-power bar coating technology, which can easily control the film thickness and has many advantages including its simplicity, it does not require use of raw materials, it keeps the nature of the original films, and was adapted to obtain large area, uniform, transparent and conductive films at room temperature. Finally, the TAFs made of CNTs were further post-treated to reduce the sheet resistance. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and the Scotch™ tape method were conducted to determine the properties of the TAFs. The results obtained showed that this method gave films which gave a good performance in antistatic applications.
Fig. 1 Schematic about preparation of CNT suspension, coating method, post-treatment and characterization of TAFs. |
Depending on the various applications, there are different requirements for transmittance and surface resistance of antistatic films, but the adhesion is very important for all the TAFs in practical applications. In this research, the environmentally friendly WPU adhesive, a linear thermoplastic polymer, was added to improve the adhesion of the TAFs. After rod coating, the CNT-TAFs were rinsed in deionized water and dried at 80 °C three times, and these were described as water washed CNT-TAFs, then these water washed CNT-TAFs were further immersed in nitric acid for 30 min followed by washing with deionized water to get acid treated CNT-TAFs.
Because of the short time of the acid treatment, the effect of the acid on the PET films was slight. The relationship between the sheet resistance and transmittance of water washed CNT-TAFs and acid treated CNT-TAFs at different weight ratios of SWCNT, WPU and TX-100 are shown in Fig. 3a and b, respectively. From Fig. 3a, it can be seen that the content of WPU has a great influence on the surface resistance of the films. The higher the content of WPU they contain, the greater is the surface resistance. The acid treatment can significantly reduce the surface resistance to less than 103 Ω and this can be seen by comparing Fig. 3b with Fig. 3a. Cao et al. used poly(phenylene sulfide), poly(ether ether ketone) and MWCNTs to fabricate films, but the conductivity of these films was low.37 Chou and Cheng utilized MWCNTs and polyimide to make films with a surface resistance of 1.02 × 106 Ω cm−2.38 Obviously, the surface resistance of these films were far higher than the acid treated CNT-TAFs obtained in this research. The adhesion factor (fa), which can be easily measured from transmission spectroscopy,39 was used to characterize the adhesion between SWCNTs and the PET substrate:
(1) |
As shown in Fig. 4a and d, the chains of WPU will twist with the CNTs in the mixed solution after stirring and there will exist many contact points between the WPU chains and the CNTs that are beneficial for fixing the CNTs. During the process of drying, most of the water will be evaporated and the chains of WPU gradually form a film through interdiffusion40 (Fig. 4e and f). Comparing Fig. 4b, c, e and f, the addition of WPU helps the CNTs to establish more contact points with the PET. Finally, the CNTs are fixed by WPU on the PET substrate. In the tape trial, this mechanism makes the films remain on the surface of PET substrate.
The CNT dispersions were added with different amounts of WPU, which was used as a binder. The more WPU that is added, the higher the adhesion and surface resistance of the CNT film is. After coating, the CNT films on the PET substrates were washed with water and soaked in nitric acid to remove additives and reduce the sheet resistance. Fig. 5 shows the SEM images of water washed and acid treated CNT-TAFs with different contents of WPU and these can be used to determine the surface morphology. By comparing Fig. 5a and b (or Fig. 5d and e) with Fig. 5c (or Fig. 5f), it can be seen that the higher the content of WPU, the more the additives remain on the surface of the TAFs. In particular, when the weight ratio of CNT:WPU is 1:25, it is difficult to see the CNTs in Fig. 5a and d. The surface of the CNT film became cleaner and more tidy after the acid treatment and this can be seen by comparing Fig. 5c and f with Fig. 5b and e, which explains why the resistance of acid treated film is lower than that of film washed with water as shown in Fig. 3a and b. CNTs are responsible for the conductivity and increasing the content of WPU will give a greater surface resistance and higher adhesion. Considering the surface morphology, surface resistance and adhesion of CNTs to PET substrate, the weight ratio of SWCNT to WPU of 1:1 was chosen as an optimized solution for CNT-TAFs and the acid treatment was adopted to reduce the sheet resistance. The thicknesses of films, which can be obtained by using atomic force microscopy (AFM) images, along the edge of film are around 50–100 nm depending on the different transmittances. The films also show a large area uniformity with less 3% variation in transmittance.
Fig. 5 SEM images of water washed films with SWCNT:WPU (a) 1:25, (b) 1:10, (c) 1:1, and acid treated films with SWCNT:WPU (d) 1:25, (e) 1:10, (f) 1:1. |
In practice, the antistatic film will inevitably contact with water or be used at high temperature. As is known, for the antistatic film prepared with surfactants, it is easy to lose the antistatic ability in water. To evaluate the water resistance of the optimized TAFs, the films were immersed in water and then taken out to test the sheet resistance after drying every 24 hours. The results are shown in Fig. 6a. It can be seen that the resistance of water washed CNT-TAFs were still very stable after multiple water immersion tests, which showed good resistance to water. However, the resistance of acid treated CNT-TAFs increased a lot after the first 24 hours and the resistance became stable in the following tests, which also showed good resistance to water. To test the duration of exposure to high temperature, the CNT-TAFs that had been post-treated were placed in an oven with a constant temperature of 80 °C, and then the films were taken out to test their sheet resistance every 12 h. From Fig. 6a, it can be seen that the water washed film has a good duration of high temperature for a long time. The resistance of acid treated CNT-TAFs increased a lot in the first 24 hours, which may because of the dedoping effect.41 But the resistance of acid treated CNT-TAFs was very stable after 24 h, and they also showed good resistance to high temperatures. To test the long-term stability of TAFs, a series of water washed CNT-TAFs and acid treated CNT-TAFs were fabricated using the same stable CNT suspension. The content of each component adopted the optimum weight ratio which was 1:1:50 of CNT:WPU:TX-100. Different surface resistances and transmittances were obtained by changing the film thickness. At first, the surface resistance and transmittance of these TAFs were tested immediately, and then the TAFs were put in normal atmospheric environment for more than one year. Finally, the transmittance and surface resistance were tested and compared in the same TAFs group. The resistance and transmittance of the water washed CNT-TAFs and acid treated CNT-TAFs both showed little change after one year as shown in Fig. 6b, which suggests that the films had long-term stability at room temperature. Also, the resistance of acid treated CNT-TAFs were lower than those of water washed CNT-TAFs after a long immersion or high temperature as shown in Fig. 6a, which may be because more dispersants were washed off in the acid treatment as shown in Fig. 6c and d. EDX was conducted to determine the weight ratio changes of the elements using different treatment processes. The element contents are shown in Table 1. In the water washed CNT-TAFs, the films contain CNTs, WPU, TX-100, and SDBS. In the acid treated CNT-TAFs, the films contain CNTs, WPU, TX-100, SDBS, and small amounts of nitric acid. CNTs with a high purity have excellent electrical conductivity after the purification process.42,43 There may still be a small amount residual catalyst inside the CNTs after purification, which may cause defects to the CNTs and thus, influence the conductivity of the CNT films. But this will have very little effect on the antistatic application, and it is the CNT content that mainly determines the antistatic property in antistatic films. The sulfur (S) element comes from the SDBS and the amount of the S element was greatly reduced after washing in water and acid. The nitrogen (N) element comes from nitrate oxidization and WPU, and the amount of the N element was increased after acid treatment and this may because of nitric acid doping. These results indicate that water and acid treatment can both remove SDBS, and that the acid treatment is more efficient than water treatment to remove the additives on the surface of the CNT films,44 so the surface resistance of acid treated CNT-TAFs are lower than those of water washed CNT-TAFs after a long water immersion or high temperature.
Processing method | Element content (wt%) | ||||
---|---|---|---|---|---|
C | O | S | N | Na | |
CNT-TAFs | 69.10 | 23.48 | 2.36 | 2.16 | 2.50 |
Water washed CNT-TAFs | 72.33 | 24.35 | 0.57 | 2.57 | 0.19 |
Acid treated CNT-TAFs | 72.97 | 23.66 | 0.37 | 2.91 | 0.10 |
The antistatic character was compared between the pure PET film and the acid treated CNT-TAFs as shown in Fig. 7. The two films were abraded and polystyrene microspheres were placed on the two films, then the two films were pulled gently so that they were vertical. The pure PET film adsorbed a lot of polypropylene microspheres as shown in Fig. 7a. However, the acid treated CNT-TAFs did not adsorb any polypropylene microspheres as shown in Fig. 7b. This phenomenon shows that the acid treated CNT-TAFs can be used as an antistatic film with high transmittance.
This journal is © The Royal Society of Chemistry 2017 |