Thermal decomposition metallization process
A method for forming a conductive metal-polymer composite coated polymer includes providing a polymer substrate and immersing the polymer substrate in a metal solution. The method further includes decomposing the metal solution in a thermally controlled environment and reducing the metal solution to metal such that the metal is deposited on a surface of the polymer substrate. After reducing the metal solution, the method includes treating the surface with a polymer coating to form the metal-polymer composite coated polymer.
1 . A method for forming a conductive metal-polymer composite coated polymer, the method consisting of:
providing a cellulose-based polymer substrate having a permeable, open porous structure, the cellulose-based polymer selected from the group consisting of viscose rayon, extra-long staple cotton, lyocell, mercerized cotton, modal, and combinations thereof;
immersing the cellulose-based polymer substrate in a metal solution, the metal solution comprising an organometallic silver compound in an organic solvent;
decomposing the metal solution in a thermally controlled environment to reduce the organometallic silver such that the metal is deposited on a surface of the cellulose-based polymer substrate; and
treating the surface with a functional coating after reducing the metal solution to form the metal-polymer composite coated polymer.
2 . The method of claim 1 , wherein the metal solution is selected from the group consisting of organic or inorganic salts of copper, silver, aluminum, gold, iron, nickel, and combinations thereof.
3 . The method of claim 1 , wherein the organometallic silver compound is selected from the group consisting of silver acetate, silver octanoate, silver nonanoate, silver neodecanoate, silver undecanoate, silver dodecanoate, silver nitrate, diamminesilver (I), silver (I) hexafluoropentanedionate-cyclooctadiene, silver 2-ethylhexylcarbamate, silver phenolate, and combinations thereof.
4 . The method of claim 1 , wherein the metal solution comprises an organic solvent selected from the group consisting of xylene, acetone, toluene, benzene, n-methyl pyrrolidone, ethanol, water, and combinations thereof.
5 . The method of claim 1 , wherein the metal solution comprises an organometallic silver compound in toluene.
6 . The method of claim 1 , wherein the metal solution comprises an additive selected from the group consisting of ethyl cellulose, graphene nano-platelets, polystyrene-block-poly (ethylene-ran-butylene)-block-polystyrene-graft malefic anhydride, poly (ethylene-co-ethyl acrylate), ethylene-acrylic acid, hexadecyltrimethoxysilane, triethoxy (vinyl) silane, metallic nanoparticles, and combinations thereof.
7 . The method of claim 1 , wherein the functional coating is selected from a group consisting of ethyl cellulose, graphene nano-platelets, polystyrene-block-poly (ethylene-ran-butylene)-block-poly styrene-graft malefic anhydride, poly (ethylene-co-ethyl acrylate), ethylene-acrylic acid, hexadecyltrimethoxysilane, triethoxy (vinyl) silane, low density polyethylene, polyethylene terephthalate, poly (vinyl butryal-co-vinyl alcohol-co-vinyl acetate), poly vinyl butyral, polystyrene-block-polybutadiene-block-polystyrene, polyurethane, and combinations thereof.
8 . The method of claim 1 , further comprising, prior to immersing the cellulose-based polymer substrate in a metal solution, modifying the surface of the cellulose-based polymer substrate with a pretreatment surface modification solution.
9 . The method of claim 8 , wherein the pretreatment surface modification solution is selected from a group consisting of sulfuric acid, hydrochloric acid, hydrofluoric acid, nitric acid, phosphoric acid, perchloric acid, lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide, cesium hydroxide, calcium hydroxide, and combinations thereof.
10 . The method of claim 1 , wherein decomposing the metal solution comprises a continuous process.
11 . The method of claim 10 , wherein the cellulose-based polymer substrate is in contact with the metal solution for about 3 to about 12 seconds and is in the thermally controlled environment for about 40 to about 60 seconds.
12 . The method of claim 10 , wherein the cellulose-based polymer substrate is in contact with the metal solution for about 45 to about 55 seconds and is in the thermally controlled environment for about 160 to about 180 seconds.
13 . The method of claim 1 , further comprising immersing the cellulose-based polymer substrate in the metal solution, decomposing the metal solution in the thermally controlled environment, and reducing the metal solution to metal such that the metal is deposited on the surface of the cellulose-based polymer substrate more than once before treating the surface with the polymer coating.
14 . The method of claim 13 , wherein an average temperature in the thermally controlled environment is lower during a first decomposing step than in a subsequent decomposing step.
15 . The method of claim 1 , wherein an average temperature in the thermally controlled environment is in a range of about 90 to about 300° C.
16 . The method of claim 1 , wherein decomposing the metal solution in the thermally controlled environment includes maintaining conductive contact between a heating element and the cellulose-based polymer substrate.