U.S. patent application number 17/742597 was filed with the patent office on 2022-08-25 for lamellar particles with functional coating.
This patent application is currently assigned to VIAVI SOLUTIONS INC.. The applicant listed for this patent is VIAVI SOLUTIONS INC.. Invention is credited to Kelly Janssen, Fred Thomas, Jaroslaw Zieba.
Application Number | 20220268973 17/742597 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-25 |
United States Patent
Application |
20220268973 |
Kind Code |
A1 |
Zieba; Jaroslaw ; et
al. |
August 25, 2022 |
LAMELLAR PARTICLES WITH FUNCTIONAL COATING
Abstract
There is disclosed a functional lamellar particle including an
unconverted portion of the lamellar particle, wherein the
unconverted portion includes a first metal, a converted portion of
the lamellar particle disposed external to a surface of the
unconverted portion, wherein the converted portion includes a
chemical compound of the first metal; and a functional coating
disposed external to a surface of the converted portion.
Inventors: |
Zieba; Jaroslaw; (Santa
Rosa, CA) ; Janssen; Kelly; (Santa Rosa, CA) ;
Thomas; Fred; (Santa Rosa, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VIAVI SOLUTIONS INC. |
San Jose |
CA |
US |
|
|
Assignee: |
VIAVI SOLUTIONS INC.
San Jose
CA
|
Appl. No.: |
17/742597 |
Filed: |
May 12, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15908566 |
Feb 28, 2018 |
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17742597 |
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62465605 |
Mar 1, 2017 |
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International
Class: |
G02B 5/00 20060101
G02B005/00; B32B 15/00 20060101 B32B015/00; G02B 1/11 20060101
G02B001/11; C09C 1/62 20060101 C09C001/62; C09C 1/64 20060101
C09C001/64; C09C 1/00 20060101 C09C001/00; C23C 22/05 20060101
C23C022/05; C23C 22/73 20060101 C23C022/73; C09K 5/14 20060101
C09K005/14; H05K 9/00 20060101 H05K009/00 |
Claims
1.-19. (canceled)
20. A method, comprising: chemically converting a first material of
a lamellar particle into a compound of the first material; and
coating the compound of the first material with a functional
coating.
21. The method of claim 20, wherein the first material is a
metal.
22. The method of claim 20, wherein prior to the chemical
conversion, the lamellar has an aspect ratio at least 2:1.
23. The method of claim 20, wherein the functional coating can be a
layer of a metal oxide; a metal; a taggant; a surfactant; a steric
stabilizer; ormosil; organic compounds; polymer; dyes; UV
absorbers; antioxidants; heat treatments; and combinations
thereof.
24. The method of claim 20, wherein the functional coating is
applied by a process chosen from a sol-gel, a tumbling bed,
incorporation into a polymer, molecular boding, electroless
plating, electrolytic plating, chemical vapor deposition,
sputtering, vacuum evaporation, and a chemical bath.
25. The method of claim 20, wherein the chemical conversion is
performed by a reactant and the reactant is in a form of at least
one of solid state, liquid state, vapor state, and plasma
state.
26. The method of claim 25, wherein the liquid state is a chemical
bath.
27. The method of claim 26, wherein the chemical bath comprises
water and a solvent.
28. The method of claim 26, wherein the chemical bath comprises at
least one of an inorganic compound, and an organic compound.
29. The method of claim 28, wherein the inorganic compound
comprises at least one of sulfur, sulfides, sulfates, oxides,
hydroxides, isocyanates, thiocyanates, molybdates, chromates,
permanganates, carbonates, thiosulfates, and inorganic salts.
30. The method of claim 28, wherein the organic compound comprises
at least one of organic compound containing sulfur, nitrogen,
oxygen, and combinations thereof.
31. The method of claim 30, wherein the organic compound comprises
at least one of thiols, amines, thioamines, oxythio amines,
thiourea, isocyanates, thiocyanates, and silanes.
32. The method of claim 26, wherein the chemical bath comprises at
least one of inorganic and organic salts of metals or metalorganic
compounds of metals.
33. The method of claim 26, wherein the chemical bath comprises an
oxidizing agent.
34. The method of claim 26, wherein the chemical bath comprises at
least one of a surface modifier and inhibitors.
35. The method of claim 25, wherein the solid state is a tumbling
bed of pre-flakes.
36. The method of claim 25, wherein the vapor state is a fluidized
bed.
37. The method of claim 25, wherein the reactant is introduced in
the form of ionized gas, or is introduced into a plasma ignited in
a carrier gas, or introduced oxidation through heat.
38. The method of claim 20, wherein the lamellar particle comprises
a first material and a second material at least partially
encapsulating the first material.
39. The method of claim 38, wherein the second material and the
first material are different.
40. The method of claim 38, wherein the second material is
deposited on the first material by at least one of metal plating
processes, roll-to-roll metallization processes, chemical bath
deposition, physical vapor deposition, and chemical vapor
deposition.
41. The method of claim 38, further comprises depositing an
internal layer between at least a portion of the second material
and the first material.
42. The method of claim 41, wherein the internal layer is deposited
by one of sol-gel, chemical bath deposition, plating, physical
vapor deposition, and chemical vapor deposition.
Description
RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 62/465,605, filed Mar. 1, 2017, the disclosure of
which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This application generally relates to metal chemical
conversion pigments with a functional coating. Methods of making
the pigments are also disclosed.
BACKGROUND
[0003] Current methods of producing pigments are expensive, require
large capital investments, and/or yield pigment that requires
additional passivation and/or compatibilization processes. Thus,
there exists a need for a lower cost method of manufacturing
pigments that does not require additional passivation and
compatibilization processes.
SUMMARY
[0004] Aspects of the present disclosure relate to, among other
things, a functional lamellar particle including an unconverted
portion of the functional lamellar particle, wherein the
unconverted portion includes a first metal; a converted portion of
the functional lamellar particle disposed external to a surface of
the unconverted portion, wherein the converted portion includes a
chemical compound of the first metal; and a functional coating
disposed external to a surface of the converted portion.
[0005] It can be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the disclosure, as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate exemplary
embodiments of the present disclosure and together with the
description, serve to explain the principles of the disclosure.
[0007] FIG. 1 is a pre-conversion lamellar particle according to an
aspect of the disclosure;
[0008] FIG. 2 is a converted lamellar particle according to an
aspect of the disclosure;
[0009] FIG. 3 is a converted lamellar particle according to another
aspect of the disclosure;
[0010] FIG. 4 is a converted lamellar particle according to another
aspect of the disclosure;
[0011] FIG. 5 is a pre-conversion lamellar particle according to
another aspect of the disclosure;
[0012] FIG. 6 is a converted lamellar particle according to another
aspect of the disclosure;
[0013] FIG. 7 is a converted lamellar particle according to another
aspect of the disclosure;
[0014] FIG. 8 is a converted lamellar particle according to another
aspect of the disclosure;
[0015] FIG. 9 is a pre-conversion lamellar particle according to
another aspect of the disclosure;
[0016] FIG. 10A is a converted lamellar particle according to
another aspect of the disclosure;
[0017] FIG. 10B is another converted lamellar particle according to
another aspect of the disclosure;
[0018] FIG. 11A is a converted lamellar particle according to
another aspect of the disclosure;
[0019] FIG. 11B is a converted lamellar particle according to
another aspect of the disclosure;
[0020] FIG. 12A is a converted lamellar particle according to
another aspect of the disclosure;
[0021] FIG. 12B is a converted lamellar particle according to
another aspect of the disclosure;
[0022] FIG. 13 is a pre-conversion lamellar particle according to
another aspect of the disclosure;
[0023] FIG. 14 is a converted lamellar particle according to
another aspect of the disclosure;
[0024] FIG. 15 is a pre-conversion lamellar particle according to
another aspect of the disclosure;
[0025] FIG. 16A is a converted lamellar particle according to
another aspect of the disclosure;
[0026] FIG. 16B is a converted lamellar particle according to
another aspect of the disclosure;
[0027] FIG. 17 is a photograph of a pre-conversion lamellar
particle and a converted lamellar particle according to aspects of
the disclosure;
[0028] FIG. 18 is a graph of the visible spectrum of lamellar
particles according to various aspects of the disclosure;
[0029] FIG. 19 is a graph of the infrared spectrum of lamellar
particles according to various aspects of the disclosure;
[0030] FIG. 20 is a graph of the visible spectrum of lamellar
particles according to various aspects of the disclosure;
[0031] FIG. 21 is a graph of the infrared spectrum of lamellar
particles according to various aspects of the disclosure;
[0032] FIG. 22 is functional converted lamellar particle according
to an aspect of the disclosure;
[0033] FIG. 23 is a functional converted lamellar particle
according to another aspect of the disclosure; and
[0034] FIG. 24 is a functional converted lamellar particle
according to another aspect of the disclosure.
[0035] Throughout this specification and figures like reference
numbers identify like elements.
DETAILED DESCRIPTION
[0036] Reference is now made in detail to examples of the present
disclosure, examples of which are illustrated in the accompanying
drawings. Wherever possible, the same reference numbers will be
used throughout the drawings to refer to the same or like parts. As
used herein, the terms "approximately" and "substantially" indicate
a range of values within +/-5% of a stated value.
[0037] Aspects of the present disclosure relate to lamellar
particles and systems and methods for creating lamellar particles
with certain properties by manipulating these properties (including
visual and non-visual attributes) through chemical conversion. The
devices and methods herein allow for cost-competitive manufacturing
of high quantities of metallic pigment. These devices and methods
also establish manufacturing scale capability without excessive
capital investment. Further, the resulting particles yield pigment
that does not require additional passivation and compatibilization
processes. The pigment can be manufactured by a process of metal
chemical conversion (MCC). Based on the selection of materials and
structures incorporated into these MCC pigments, the methods
described herein offer pigments with a combination of specific
visual and non-visual attributes.
[0038] According to the present disclosure, a particle including,
but not limited to a lamellar particle, e.g., pre-conversion
lamellar particles 100, 200, 300, 400, and/or 500 of FIGS. 1, 5, 9,
13, and 15, can be converted to a lamellar particle with desired
properties (e.g., optical, physical, and/or chemical properties)
different than the properties of the pre-conversion lamellar
particle.
[0039] For example, the converted lamellar particle of the present
disclosure can result in specific, desired, and/or enhanced optical
properties, such as specific and/or desired wavelengths and/or
levels of absorption and/or reflectance. In particular, the
converted lamellar particle of the present disclosure can have
non-selective absorption of light at certain wavelengths ranging
from about 380 nm to about 760 nm at a level of 90% and greater of
the incident light to make the converted lamellar particle appear
black, non-selective reflectance of incident light at the level of
10% or greater to make the converted lamellar particle appear gray,
non-selective reflectance of incident light at wavelengths ranging
from about 380 nm to about 760 nm at the level of 80% and greater
to make the converted lamellar particle appear white, selective
light reflectance in the visible range of the spectrum to provide
visual color (e.g., capable of being viewed by the human eye),
selective light reflectance in the visible range of the spectrum at
reflectance levels that are required to provide visual color
combined with metallic reflectance of the metal core, and/or
selective reflectance of electromagnetic radiation in the infrared
part of the spectrum ranging from about 0.85 to about 20 microns
combined with one or more of the desired optical properties in the
visible range of the spectrum as listed above.
[0040] Further, the converted lamellar particles of the present
disclosure can additionally or alternatively result in specific,
desired, and/or enhanced non-optical properties, such as corrosion
resistance, heat conductivity (e.g., higher than 1.5 W/mK),
electrical conductivity (e.g., higher than 10-SS/m), ferromagnetic
properties (e.g., if pre-conversion lamellar particles 100, 200,
300, 400, and/or 500 of FIGS. 1, 5, 9, 13, and 15 possess
ferromagnetic properties), and/or hydrophobic properties (e.g.,
when conversion chemicals contain functional groups yielding low
surface energy). Further, the converted lamellar particles of the
present disclosure can have heat-rejecting properties and/or
infra-red wavelengths reflecting functions offering an alternative
way of managing energy conservation. Additionally or alternatively,
the converted lamellar particle can provide leafing and/or color
flopping options, black colors combined with different color hues
appearing at various viewing angles, shielding electro-magnetic
radiation, a flake format with a large range of thicknesses, linear
dimensions, and/or aspect ratios driven by their end application,
both metallic and flat color versions of the converted lamellar
particle, heat-reflecting properties, metallic pigments with
enhanced environmental stability (stable against heat, water,
oxygen, chemical, and/or UV exposure), and/or pigments compatible
with various chemical media, such as paints, inks, rubbers,
polymers including textiles materials, and ceramic materials
including construction materials such as cement and concrete.
[0041] A plurality of the converted lamellar particles described
herein can be combined to create pigment, including, but not
limited to a metallic effect pigment, a magnetic pigment, an EMI
attenuating pigment, an electrically conductive pigment, a heat
conducting pigment, or a pigment with a combination of any or all
of the preceding properties.
[0042] The lamellar particles of the present disclosure (e.g.,
pre-conversion lamellar particles 100, 200, 300, 400, and/or 500)
can be non-naturally occurring. In some examples, the lamellar
particles (e.g., pre-conversion lamellar particles 100, 200, 300,
400, and/or 500) can be formed by, for example, sol-gel, chemical
bath deposition, plating, physical vapor deposition, and chemical
vapor deposition.
[0043] The lamellar particles (e.g., pre-conversion lamellar
particles 100, 200, 300, 400, and/or 500) described herein can be
any shape. Lamellar particles (e.g., pre-conversion lamellar
particles 100, 200, 300, 400, and/or 500) can include a first side
substantially flat and/or straight in a first direction (e.g., the
x-direction of FIG. 1). As illustrated herein, the lamellar
particles (e.g., pre-conversion lamellar particles 100, 200, 300,
400, and/or 500) can include a second side that is substantially
flat and/or straight in a second direction (e.g., the y-direction
of FIG. 1) and/or substantially perpendicular to the first side. In
another aspect, the second side can instead be round, pointed,
wavy, etc. Further, the second side is not substantially
perpendicular to the first side. The lamellar particles (e.g.,
pre-conversion lamellar particles 100, 200, 300, 400, and/or 500)
can include a third side in a third direction (e.g., the
z-direction of FIG. 1). The third side can have any shape,
including, but not limited to, round, rectangular, and/or
irregular. In further examples, the lamellar particles (e.g.,
pre-conversion lamellar particles 100, 200, 300, 400, and/or 500)
can be described as flat, flat with an irregularly-shaped third
side (e.g., corn-flake shaped), flat with a round third side,
and/or flat with a rectangular third side. In some examples, the
pre-conversion lamellar particles 100, 200, 300, 400, and/or 500
may be a sheet and/or foil.
[0044] The lamellar particles (e.g., pre-conversion lamellar
particles 100, 200, 300, 400, and/or 500) described herein can be
any size. For example, pre-conversion lamellar particles 100, 200,
300, 400, and/or 500 can have any width (e.g., the x-direction of
FIG. 1) including, but not limited to, a width of approximately 2
microns to approximately 200 microns, approximately 4 microns to
approximately 100 microns, or approximately 10 microns to
approximately 50 microns. Pre-conversion lamellar particles 100,
200, 300, 400, and/or 500 can have any physical thickness (e.g.,
the y-direction of FIG. 1) including, but not limited to, a
physical thickness of approximately 0.1 microns to approximately 2
microns, approximately 0.5 microns to approximately 1.5 microns, or
approximately 1 micron. Further, pre-conversion lamellar particles
100, 200, 300, 400, and/or 500 can have any aspect ratio (e.g., the
ratio between the width of the pre-conversion lamellar particle and
the physical thickness of the pre-conversion lamellar particle)
including, but not limited to, an aspect ratio of approximately 5:1
or greater, approximately 5:1 to approximately 500:1, for example,
from approximately 10:1 to approximately 250:1, or approximately
100:1.
[0045] As illustrated in FIGS. 1-16B, certain properties or
attributes of an unconverted portion of pre-conversion lamellar
particles 100, 200, 300, 400, and/or 500, respectively, can change
when subjected to a conversion process. In an aspect, at least a
part of the unconverted portion can include a material that can, at
least partially, be converted from having a first property to
having a second property. For example, at least a part of the
unconverted portion, if subjected to a conversion process, can, at
least partially, be converted to change any property, including but
not limited to an optical, physical, and/or chemical property. In
an aspect, at least a part of the unconverted portion can include a
material including, but not limited to, aluminum, copper, stainless
steel, silver, gold, zinc, iron, bronzes, manganese, titanium,
zirconium, vanadium, niobium, chromium, molybdenum, nickel,
tungsten, tin, indium, bismuth, alloys of any of these metals, or a
combination thereof. In an aspect, a lamellar particle can include
an unconverted portion 180, 280, 380, 480, and 580 of the lamellar
particle, wherein the unconverted portion 180, 280, 380, 480, and
580 includes a first metal.
[0046] The conversion process can be any process that converts a
first property of at least a part of the unconverted portion 180,
280, 380, 480 and 580, to a second property. Various conversion
chemistries can be used to control color, chromaticity, gloss,
leafing, durability, heat or electrical conductivity, and other
properties of the resulting particles (e.g., converted lamellar
particles 150, 250, 350, 450, and/or 550). For example, the
conversion process can convert at least a part of the unconverted
portion 180, 280, 380, 480 and 580 from a first color to a second
color and/or convert at least a part of the unconverted portion
180, 280, 380, 480 and 580 from a first level of heat conductivity
to a second level.
[0047] The conversion process can include subjecting a
pre-conversion lamellar particle to a reactant. The reactant can be
in any state, such as plasma state, gas state, solid state, or
liquid state or a combination thereof. The reactant can include any
chemical or physical factors that can cause a reaction with at
least a part of the unconverted portion 180, 280, 380, 480 and 580
of the pre-conversion lamellar particle and convert, in a
controllable manner, at least a part of the unconverted portion to
a converted portion 170, 270, 370, 470, and 570.
[0048] In one example, a water and solvent-borne environment can be
used as the reactant. In some examples, the conversion process can
include the use of various types of chemical reactants, including
batch and continuous stirred tank reactants, tubular reactants,
tumbling bed reactants, fluidized bed reactants, continuous flow
tube and batch furnaces. In such examples, pre-conversion lamellar
particles 100, 200, 300, 400, or 500 can be subjected to
chemical(s) that cause at least partial conversion of
pre-conversion lamellar particles 100, 200, 300, 400, 500 or at
least a part of the unconverted portion 180, 280, 380, 480 and
580.
[0049] The chemical bath composition used herein can include an
inorganic compound or an organic compound. An example of an
inorganic compound can include at least one of sulfur, sulfides,
sulfates, oxides, hydroxides, isocyanates, thiocyanates,
molybdates, chromates, permanganates, carbonates, thiosulfates,
colloidal metals, inorganic salts, and mixtures thereof. An example
of an organic compound can include an organic compound that
contains sulfur, such as thiols, thioamine, oxythio amines,
thiourea, thiocyanates; nitrogen, such as amines, and isocyanates;
oxygen; silicon, such as silanes; or a combination thereof.
Further, the chemical bath can include at least one of inorganic or
organic salts of metals or metallic organic compounds of metals. In
yet another aspect, the chemical bath can include at least one of
an oxidizing agent, a surface modifier, and an inhibitor.
[0050] In an aspect, the unconverted portion 180, 280, 380, 480,
and 580 of a converted lamellar particle 150, 250, 350, 450, and
550 can provide a light reflectance in a spectral region ranging
from 0.4 to 20 microns and the converted portion 170, 270, 370,
470, and 570 can absorb light in a selected region of this spectral
range. In some examples, the selected regions can be in the visible
range. In an aspect, the unconverted portion 180, 280, 380, 480,
and 580 of a converted lamellar particle can provide infrared
reflectance.
[0051] The converted portion 170, 270, 370, 470, and 570 can absorb
light in a selected region capable of being viewed by the human
eye. The converted portion can modulate light in the visible range
to create a desired color. For example, converted portion 170, 270,
370, 470, and 570 can appear red to the human eye (e.g.,
approximately 380 nm to approximately 600 nm), black to the human
eye (e.g., absorbing approximately 380 nm to approximately 760 nm),
or white. Further, for example, converted portion 170, 270, 370,
470, and 570 can appear blue to the human eye (e.g., absorbing
approximately 500 nm to approximately 760 nm), or can appear green
to the human eye (e.g., absorbing approximately 380 nm to
approximately 500 nm and also absorbing approximately 600 nm to
approximately 760 nm).
[0052] The converted portion 170, 270, 370, 470, and 570 can absorb
light in a selected near-infrared region of the spectrum capable of
being detected by electronic sensors. The converted portion can
modulate light in the near-infrared range to provide a selected
level of absorption. For example, converted portion 170, 270, 370,
470, and 570 can absorb light from approximately 720 nm to
approximately 1100 nm, or can absorb light from approximately 950
nm to approximately 1700 nm.
[0053] In some examples, the unconverted external layer and/or the
unconverted inner core of the pre-conversion lamellar particles can
include additives (e.g., dyes) for selectively absorbing or
reflecting energy. In some examples, the unconverted external layer
and/or unconverted inner core of the pre-conversion lamellar
particles do not include additives (e.g., dyes) for selectively
absorbing or reflecting energy.
[0054] After the conversion process, the converted portion of a
converted lamellar particle can have any thickness, including, but
not limited to approximately 0.01 microns to approximately 0.9
microns, approximately 0.1 microns to approximately 0.8 microns, or
approximately 0.5 microns. The total size of the converted lamellar
particle and/or thickness of the converted portion of the converted
lamellar particle can depend on a variety of factors including, but
not limited to, the extent to which a reaction, such as a chemical
reaction, converts the pre-conversion lamellar particle. The
different optical and non-optical properties can be achieved by
adjusting varying aspects of the pre-conversion lamellar particle
and the conversion process. For example, the converted lamellar
particle can have different optical and/or non-optical properties
based on the material, structure, size, shape, and/or aspect ratio
of the pre-conversion lamellar particle, type of applied chemical
treatment, and process conditions, such as concentrations of
reactive ingredients, applied additives, pH, temperature, type of
agitation, and length of exposure. In some examples, the converted
lamellar particle can have at least one different non-optical
property than the pre-conversion lamellar particle. In one example,
the converted lamellar particle can have a different electrical
conductivity and/or thermal conductivity than the pre-conversion
lamellar particle. The measured sheet resistance can be 100 Ohms or
less and/or the thermal conductivity would be 3 W*m.sup.-1 K.sup.-1
or higher. The resistance and the thermal conductivity of the
converted lamellar particle can depend on the metal used in the
conversion process.
[0055] The amount of lamellar particle and/or the specific layers
(inner core, internal layer, and/or external layer, etc.) that are
converted can depend on a variety of factors, including but not
limited, the composition of the chemical conversion process (e.g.,
the composition of the chemical bath), its concentration, the time
of exposure to the conversion process, the temperature during the
conversion process, and/or the structure of the pre-conversion
lamellar particle (e.g., the inclusion of a corrosion barrier, an
internal layer, and/or barrier layer). In addition, the reactants
used in the chemical conversion process can include self-inhibiting
properties after converting to a certain depth into the
pre-conversion lamellar particle. For example, 0.5 percent of the
pre-conversion lamellar particle can be converted or 100 percent
can be converted, including all the ranges of percent conversion in
between.
[0056] Subjecting the pre-conversion lamellar particle to a
chemical conversion process can convert the pre-conversion lamellar
particle to a converted lamellar particle (e.g., converted lamellar
particles 150, 250, 350, 450, and/or 550) by converting a least a
part of the pre-conversion lamellar particle. For example, 0.5
percent of the pre-conversion lamellar particle can be converted or
100 percent can be converted, including all the ranges of percent
conversion in between. In an aspect, at least a part of the
lamellar particle is converted (e.g., converted portions of
lamellar particle 170, 270, 370, 470, and 570), while another part
remains unconverted (e.g., unconverted portions of the lamellar
particle 180, 280, 380, 480, and 580). In other examples, the
entire lamellar particle is converted. In such examples, a
converted lamellar particle would no longer include a material,
such as metal, but would instead include a chemical compound of the
material, such as a chemical compound of the metal.
[0057] The converted portions of lamellar particle 170, 270, 370,
470, and 570 can include at least a chemical compound of a
material, such as a first metal, included in the unconverted
portion 180, 280, 380, 480, and 580 of the pre-conversion lamellar
particle. For example, if the unconverted external layer 102, 202,
302, 402, and 502 of the pre-conversion lamellar particle 100, 200,
300, 400, 500 included copper and the pre-conversion lamellar
particle was subjected to sulfur during a conversion process, the
converted portion 170, 270, 370, 470, 570 of the converted lamellar
particle 150, 250, 350, 450, 550 could include a chemical compound
of copper, i.e., copper sulfide, and the unconverted portion 180,
280, 380, 480, 580 of the converted lamellar particle could include
copper. In some examples, a pre-conversion lamellar particle can be
completely converted or completely unconverted, including all
ranges of percent conversion in between.
[0058] In an aspect, if a pre-conversion lamellar particle has an
inner core and an external layer, such as shown in FIG. 5, then
each of the inner core and the external layer can be completely
converted or completely unconverted, including all ranges of
percent of conversion in between. For example, the converted
portion 170, 270, 370, 470, and 570 of the converted lamellar
particle 150, 250, 350, 450, and 550 can include (i) converted
external layer 204, 304, 404, and 504; and/or (ii) the converted
external layer 204, 304, 404, and 504 and the converted inner core
206, 306, 406, and 506. The unconverted portion 180, 280, 380, 480,
and 580 of the converted lamellar particle 150, 250, 350, 450, and
550 can include (i) the unconverted inner core 210, 310, 410, and
510; and/or (ii) the unconverted external layer 202, 302, 402, and
502 and the unconverted inner core 210, 310, 410, and 510. In an
aspect, in some examples, the entire unconverted external layer
102, 202, 302, 402, and 502 is converted. In some examples, the
entire unconverted external layer 102, 202, 302, 402, and 502 is
converted, as well as at least a part of the unconverted inner core
210, 310, 410, 510. In some examples, the unconverted portions of
the lamellar particle 180, 280, 380, 480, and 580 can include a
plurality of layers, such as an internal layer 420, 520 and/or a
plurality of materials.
[0059] In some examples, the plurality of layers can include at
least two different materials, such as two different metals. Some
or all of the different materials can be a metal(s). In an aspect,
each layer of the plurality of layers can be made of a different
material than each other layer of the plurality of layers.
[0060] In an aspect, the converted portion 170, 270, 370, 470, and
570 of the lamellar particle can be external to a surface of the
unconverted portion 180, 280, 380, 480 and 580, which can include
an unconverted external layer 202, 302, 402, and 502, an internal
layer 420, 520, and/or an unconverted inner core 110, 210, 310,
410, and 510.
[0061] Any of the lamellar particles described herein or created by
processes described herein can be used in a variety of
applications. For example, among other applications, the converted
lamellar particles can be used for camouflage, sensing, charge
dissipation, dissipating heat, shielding against electromagnetic
interferences, and decorations. More specifically, the converted
lamellar particles and/or the conversion process can be used in
textiles. The converted lamellar particles can be used for
pigmentation of textiles and/or adding additional non-visual
attributes to fabrics. For example, the converted lamellar
particles can be used to create heat-rejecting fabrics,
infrared-rejecting fabrics, electromagnetic radiation shielding
fabrics, heat conducting fabrics, electrically-conductive yarns and
fabrics, yarns and fabrics with ferromagnetic properties,
camouflage, and/or radiation (e.g., infrared, heat,
electromagnetic) shielding properties. In some examples, converted
lamellar particles used for textiles may be smaller than those used
for other applications (e.g., automotive and architectural). For
example, converted lamellar particles used in textile applications
can be approximately 2 microns, or smaller than approximately 10
microns. Converted lamellar particles used in automotive
applications can be approximately 8 microns to approximately 200
microns and converted lamellar particles used in architectural
applications can be up to approximately 200 microns.
[0062] The converted lamellar particles and/or the conversion
processes can also be used as pigments for specialty paints, inks,
varnishes, and coatings that can provide coloration together with
non-visual attributes. For example, converted lamellar particles
and/or the conversion processes can be used in pigments for
metallic inks, heat and IR rejection, electromagnetic radiation
shielding, heat conductivity, electrical conductivity, and/or
ferromagnetic properties
[0063] The converted lamellar particles and/or the conversion
processes can also be used in construction and architectural
materials. For example, the converted lamellar particles can be
used in heat-rejecting paints for architectural applications,
heat-rejecting roofing, siding, and decking materials,
heat-rejecting cement and concrete, electromagnetic shielding
paints for architectural and construction applications, and/or
static charge controlling paints
[0064] The converted lamellar particles and/or the conversion
processes can be used in various automotive applications,
including, but not limited to, LIDAR, heat-reflecting exterior
automotive pigments and coatings, black single component pigments
with various color hue flop, semi-metallic pigments with unique
color hues, and/or heat and/or static charge dissipating pigments
for automotive interior applications.
[0065] The converted lamellar particles and/or the conversion
processes can be used in various applications in cosmetics and
healthcare, for example, direct skin-on application of pigments for
esthetic, protective, diagnostic, and/or medical treatments.
[0066] The converted lamellar particles and/or the conversion
processes can be used in various other applications, including, but
not limited to, RF antennas, magnetic taggants, special effect
pigments, and pigments for electroluminescent inks and
coatings.
[0067] The pre-conversion lamellar particles of the present
disclosure can have any layer structure. Pre-conversion lamellar
particles 100, 200, 300, 400, and 500 are merely exemplary. The
pre-conversion lamellar particles can include any number of layers,
such as a plurality of layers. These layer(s) can be made of any
material, such as a first metal, in any configuration, and/or in
any order. In an aspect, the pre-conversion lamellar particles 100,
200, 300, 400, and 500 can include an unconverted inner core 210,
310, 410, and 510 and an unconverted external layer 202, 302, 402,
and 502. In another aspect, the pre-conversion lamellar particles
100, 200, 300, 400, and 500 can include additional layers, such as
an internal layer 420, 520, between the unconverted inner core 210,
310, 410, and 510 and the unconverted external layer 202, 302, 402,
and 502. Further, unconverted inner core 210, 310, 410, and/or 510
can include a plurality of layers.
[0068] In one example, as illustrated in FIG. 1, the pre-conversion
lamellar particle 100 can be a monolithic particle composed of a
single material (e.g., a single metal, such as a first metal).
Pre-conversion lamellar particle 100 consists of one layer;
unconverted external layer 102. Once subjected to a conversion
process (including, but not limited to, those described above),
pre-conversion lamellar particle 100 can be converted to a
converted lamellar particle, including, but not limited to,
converted lamellar particle 150 of FIG. 2, 3, or 4. Converted
lamellar particle 150 can include a converted portion 170 and an
unconverted portion 180. The unconverted portion 180 can include a
first metal and the converted portion 170 can include a chemical
compound of the first metal. In this example, because the
pre-conversion lamellar particle 100 consists of unconverted
external layer 102, the converted portion of the external layer 104
is the same as the converted portion of the lamellar particle 170,
as shown in FIG. 2. Additionally, the unconverted portion of the
external layer 102 is the same as the unconverted portion of the
lamellar particle 180.
[0069] The physical thickness L.sub.1 of converted lamellar
particle 150 can be about the same physical thickness L.sub.0 of
the pre-conversion lamellar particle 100. Thus, the physical
thickness L.sub.1 can be approximately 0.1 microns to approximately
2 microns, approximately 0.5 microns to approximately 1.5 microns,
or approximately 1 micron. In some examples, however, thickness
L.sub.1 of converted lamellar particle 150 can be greater than the
physical thickness L.sub.0 of the pre-conversion lamellar particle
100. For example, the conversion process can cause at least a
portion of the pre-conversion lamellar particle 100 to expand. As
shown in FIG. 2, L.sub.1 is the sum of the thickness L.sub.2 of the
unconverted portion 102/180 and the two thicknesses L.sub.3 of the
converted portion 104/170 on either side of unconverted portion
102/180.
[0070] In an aspect, the thickness L.sub.3 of the converted portion
104/170 can range from about one percent to about 100 percent of
the total thickness L.sub.1 of the converted lamellar particle 150.
In an example, as shown in FIG. 2, the unconverted portion 102/180
can have a physical thickness L.sub.2 which is greater than the
physical thickness L.sub.3 of the converted portion 104/170. In
another example, as shown in FIG. 3, the unconverted portion
102/180 can have a physical thickness L.sub.2 which is less than
the thickness L.sub.3 of the converted portion 104/170. In yet
another example, as shown in FIG. 4, the unconverted portion
102/180 and the converted portion 104/170 can have variable
physical thicknesses. In this example, the converted portion
104/170 can include a first thickness L.sub.3 and a second
thickness L.sub.4. The physical thickness of the unconverted
portion 102/180 can vary in accordance with the physical thickness
of the converted portion 104/170.
[0071] In another example, as illustrated in FIG. 5, the
pre-conversion lamellar particle 200 can include an unconverted
external layer 202 external to at least three sides of an
unconverted inner core 210). In some examples, the unconverted
external layer 202 can be external to at least four sides, at least
five sides, or at least six sides of the unconverted inner core
210. The unconverted external layer 202 can completely encapsulate
the unconverted inner core 210. The unconverted inner core 210 can
be made of a first material and the unconverted external layer 202
can be made of a second material different than the first material.
In some examples, the first material can be a first metal and the
second material can be a second metal. In some examples, the first
material can include, but is not limited to, aluminum, copper,
stainless steel, silver, gold, zinc, iron, bronzes, manganese,
titanium, zirconium, vanadium, niobium, chromium, molybdenum,
nickel, tungsten, tin, indium, bismuth, alloys of any of these
metals or a combination thereof. The second material can include,
but is not limited to (i) metals or metal alloys, such as one or
more of aluminum, copper, silver, gold, zinc, iron, bronzes,
manganese, titanium, zirconium, vanadium, niobium, chromium,
molybdenum, nickel, tungsten, tin, indium, bismuth, alloys of any
of these metals or a combination thereof, (ii) dielectrics, such as
metal oxides, glasses, chalcogenides, halides, sulfides, minerals,
synthetic micro and nano-crystals, organic and inorganic polymers,
(iii) conductive materials, such as indium-tin oxide, tin oxide,
metal doped oxides, and conductive polymers, and/or (iv) metalloids
and non-metals, such as silicon, germanium, carbon, graphite, and
graphene. The materials listed in (ii)-(iv) can be partially and/or
not completely converted when subjected to chemical conversion. The
materials listed in (ii)-(iv) can provide various non-visual
attributes or can act as a conversion barrier. For example, the
first material can be less reactive to a given conversion process,
thus creating a location within the lamellar particle in which the
conversion is likely to stop, i.e., functioning as a "conversion
barrier." Further, in some examples, the unconverted inner core 210
and/or the unconverted external layer 202 can include a plurality
of layers, such as an internal layer, and/or a plurality of
materials. In some examples, each layer of the plurality of layers
can include the same materials or each layer of the plurality of
layers can include different materials.
[0072] Once subjected to a conversion process including, but not
limited to, those described above, pre-conversion lamellar particle
200 can be converted to a converted lamellar particle, including,
but not limited to, converted lamellar particle 250 of FIG. 6, 7,
or 8. Converted lamellar particle 250 can include a converted
portion 270 and an unconverted portion 280. The unconverted portion
280 can include a first metal and the converted portion 270 can
include a chemical compound of the first metal. In some examples,
about one percent to about 100 percent of unconverted external
layer 202 can be converted to a converted external layer 204. In
some examples, about zero percent to about 100 percent of
unconverted inner core 210 can be converted to a converted inner
core 206.
[0073] In the example illustrated in FIG. 6, 100 percent of the
unconverted external layer 202 was converted to converted external
layer 204 and zero percent of unconverted inner core 210 was
converted. Thus, the converted portion of the lamellar particle 270
is the same as the converted external layer 204 and the unconverted
portion of the lamellar particle 280 is the same as unconverted
inner core 210
[0074] In the example illustrated in FIG. 7, less than 100 percent
of the unconverted external layer 202 was converted to converted
external layer 204 and zero percent of unconverted inner core 210
was converted. Thus, the converted portion of the lamellar particle
270 includes the converted external layer 204; and the unconverted
portion of the lamellar particle 280 includes the unconverted
external layer 202 and the unconverted inner core 210. In an
aspect, with regard to FIG. 7, the unconverted external layer 202
can include a first metal and converted external layer 204 can
include a chemical compound of the first metal.
[0075] In the example illustrated in FIG. 8, 100 percent of the
unconverted external layer 202 was converted to converted external
layer 204 and at least a portion of unconverted inner core 210 was
converted to converted inner core 206. Thus, the converted portion
of the lamellar particle 270 includes the converted external layer
204 and the converted inner core 206; and the unconverted portion
of the lamellar particle 280 includes the unconverted inner core
210. In an aspect, with regard to FIG. 8, the unconverted inner
core 210 can include a first metal and converted inner core 206 can
include a chemical compound of the first metal.
[0076] In an additional example, as illustrated in FIG. 9, the
pre-conversion lamellar particle 300 can include an unconverted
inner core 310 sandwiched by unconverted external layers 302. For
example, unconverted external layers 302 can be external to a first
side of the unconverted inner core 310 and a second side of the
unconverted inner core 310 opposite the first side, but not
external to any of the other sides, i.e., the unconverted external
layers 302 do not encapsulate the unconverted inner core 310. The
unconverted inner core 310 can be made of a first material, and the
unconverted external layers 302 can be made of a second material.
In some examples, the first material is a first metal and the
second material is a second metal. In some examples, the first
material can include, but is not limited to, aluminum, copper,
stainless steel, silver, gold, zinc, iron, bronzes, manganese,
titanium, zirconium, vanadium, niobium, chromium, molybdenum,
nickel, tungsten, tin, indium, bismuth, alloys of any of these
metals or a combination thereof. The second material can include,
but is not limited to (i) metals or metal alloys, such as one or
more of aluminum, copper, stainless steel, silver, gold, zinc,
iron, bronzes, manganese, titanium, zirconium, vanadium, niobium,
chromium, molybdenum, nickel, tungsten, tin, indium, bismuth,
alloys of any of these metals or a combination thereof, (ii)
dielectrics, such as metal oxides, glasses, chalcogenides, halides,
sulfides, minerals, synthetic micro and nano-crystals, organic and
inorganic polymers, (iii) conductive materials, such as indium-tin
oxide, tin oxide, metal doped oxides, and conductive polymers,
and/or (iv) metalloids and non-metals, such as silicon, germanium,
carbon, graphite, and graphene. The materials listed in (ii)-(iv)
can partially and/or not completely converted when subjected to
chemical conversion. The materials listed in (ii)-(iv) can provide
various non-visual attributes or can act as conversion barrier. For
example, the first material can be less reactive to a given
conversion process, thus creating a location within the lamellar
particle in which the conversion is likely to stop i.e., can
function as a "conversion barrier." Further, in some examples, the
lamellar particle can include a plurality of layers, such as an
internal layer, and/or a plurality of materials.
[0077] Once subjected to a conversion process including, but not
limited to, those described above, pre-conversion lamellar particle
300 can be converted to a converted lamellar particle including,
but not limited to, converted lamellar particle 350 of FIG.
10A-10B, 11A-B, or 12A-B. Converted lamellar particle 350 can
include a converted portion 370 and an unconverted portion 380. The
unconverted portion 380 can include a first metal and the converted
portion 370 can include a chemical compound of the first metal. In
some examples, about one percent to about 100 percent of
unconverted external layers 302 can be converted to converted
external layers 304. In some examples, zero percent to 100 percent
of unconverted inner core 310 can be converted to converted inner
core 306.
[0078] In the example illustrated in FIG. 10A, 100 percent of the
unconverted external layer 302 was converted to converted external
layer 304 and zero percent of the unconverted inner core 310 was
converted. Thus, the converted portion of the lamellar particle 370
is the same as converted external layer 304; and the unconverted
portion of the lamellar particle 380 is the same as the unconverted
inner core 310.
[0079] In the example illustrated in FIG. 10B, 100 percent of the
unconverted external layer 302 was converted to converted external
layer 304 and a small percent (at least a part) of the unconverted
inner core 310 was converted to converted inner core 306. In
particular, the sides of the unconverted inner core 310 that did
not have an unconverted external layer 302 external thereto were
converted. Thus, the converted portion of the lamellar particle 370
includes the converted external layer 304 and at least a part,
i.e., the sides of, the converted inner core 306; and the
unconverted portion of the lamellar particle 380 is the same as the
unconverted inner core 310. In an aspect, the unconverted inner
core 310 can include a first metal and the converted inner core 306
can include a chemical compound of the first metal.
[0080] In the example illustrated in FIG. 11A, less than 100
percent of the unconverted external layer 302 was converted to
converted external layer 304 and zero percent of unconverted inner
core 310 was converted. Thus, the converted portion of the lamellar
particle 370 includes the converted external layer 304; and the
unconverted portion of the lamellar particle 380 includes the
unconverted external layers 302 and the unconverted inner core 310.
In an aspect, the unconverted external layer 302 can include a
first metal and the converted external layer 304 can include a
chemical compound of the first metal.
[0081] In the example illustrated in FIG. 11B, less than 100
percent of the unconverted external layer 302 was converted to
converted external layer 304 and a percentage (at least a part) of
unconverted inner core 310 was converted to converted inner core
306. In particular, the sides of the unconverted inner core 310
that did not have an unconverted external layer 302 external
thereto were converted. Thus, the converted portion of the lamellar
particle 370 includes the converted external layer 304 and at least
a part, i.e., the sides of the converted inner core 306; and the
unconverted portion of the lamellar particle 380 includes the
unconverted external layers 302 and the unconverted inner core 310.
In an aspect, the unconverted inner core 310 can include a first
metal and the converted inner core 306 can include a chemical
compound of the first metal. In another aspect, the unconverted
external layer 302 can include the first metal and the converted
external layer 304 can include a chemical compound of the first
metal.
[0082] In the example illustrated in FIG. 12A, 100 percent of the
unconverted external layer 302 was converted to converted external
layer 304 and at least a portion of the unconverted inner core 310
was converted to converted inner core 306. Thus, the converted
portion of the lamellar particle 370 includes the converted
external layers 304 and the converted inner core 306; and the
unconverted portion of the lamellar particle 380 includes the
unconverted inner core 310. In an aspect, the unconverted inner
core 310 can include a first metal and the converted inner core 306
can include a chemical compound of the first metal.
[0083] In the example illustrated in FIG. 12B, 100 percent of the
unconverted external layer 302 was converted to converted external
layer 304 and a small percentage (i.e., at least a part) of the
unconverted inner core 310 was converted to converted inner core
306. In particular, the sides of the unconverted inner core 310
that did not have an unconverted external layer 302 external
thereto were converted. Thus, the converted portion of the lamellar
particle 370 includes the converted external layers 304 and the
converted inner core 306; and the unconverted portion of the
lamellar particle 380 includes the unconverted inner core 310. In
an aspect, the unconverted inner core 310 can include a first metal
and the converted inner core 306 can include a chemical compound of
the first metal.
[0084] In the example illustrated in FIG. 13, the pre-conversion
lamellar particle 400 can include at least three layers. For
example, the pre-conversion lamellar particle 400 can include an
unconverted inner core 410, an internal layer 420, and/or an
unconverted external layer 402. In some examples, pre-conversion
lamellar particle 400 can include a first material in the
unconverted external layer 402 encapsulating a second material in
the unconverted inner core 410 with an internal layer 420 between
the first and second materials. The internal layer 420 can be
external of two sides (e.g., sandwiching unconverted inner core
410) to six sides (e.g., encapsulating unconverted inner core 410).
In some examples, the first material can include, but is not
limited to, aluminum, copper, stainless steel, silver, gold, zinc,
iron, bronzes, manganese, titanium, zirconium, vanadium, niobium,
chromium, molybdenum, nickel, tungsten, tin, indium, bismuth,
alloys of any of these metals or a combination thereof. The second
material can include, but is not limited to (i) metals or metal
alloys, such as one or more of aluminum, copper, stainless steel,
silver, gold, zinc, iron, bronzes, manganese, titanium, zirconium,
vanadium, niobium, chromium, molybdenum, nickel, tungsten, tin,
indium, bismuth, alloys of any of these metals or a combination
thereof, (ii) dielectrics, such as metal oxides, glasses,
chalcogenides, halides, sulfides, minerals, synthetic micro and
nano-crystals, organic and inorganic polymers, (iii) conductive
materials, such as indium-tin oxide, tin oxide, metal doped oxides,
and conductive polymers, and/or (iv) metalloids and non-metals,
such as silicon, germanium, carbon, graphite, and graphene. The
internal layer 420 can include any material, including materials
(ii)-(iv). The materials listed in (ii)-(iv) can be a less reactive
to a chemical conversion process. Their function can be to provide
other non-visual attributes or to act as conversion barrier. For
example, the internal layer 420 can be less reactive to a given
conversion process, thus creating a location with the lamellar
particle in which the conversion is likely to stop, i.e., function
as a "conversion barrier." Further, in some examples, the
unconverted inner core 410, and/or the unconverted external layer
402 can include a plurality of layers and/or a plurality of
materials.
[0085] Once subjected to a conversion process including, but not
limited to those described above, pre-conversion lamellar particle
400 can be converted to a converted lamellar particle, including
but not limited to converted lamellar particle 450 of FIG. 14.
Converted lamellar particle 450 can include a converted portion 470
and an unconverted portion 480. The unconverted portion 480 can
include a first metal and the converted portion 470 can include a
chemical compound of the first metal. In some examples, about one
percent to 100 percent of unconverted external layer 402 can be
converted to converted external layer 404. In some examples, zero
percent to 100 percent of unconverted inner core 410 can be
converted to converted inner core 406. In some examples, zero
percent to 100 percent of internal layer 420 can be converted.
[0086] In the example illustrated in FIG. 14, 100 percent of the
unconverted external layer 402 was converted to converted external
layer 404; and none of internal layer 420 and unconverted inner
core 410 were converted. Thus, the converted portion of the
lamellar particle 470 is the same as converted external layer 404;
and the unconverted portion of the lamellar particle 480 is the
internal layer 420 and the unconverted inner core 410. Similar to
converted lamellar particles 150, 250, and 350, the definition of
the converted portion of the lamellar particle 470 and unconverted
portion of lamellar particle 480 depends on which layers were
converted and to what extent. In an aspect, the unconverted inner
core 410 can include a first metal, the internal layer 420 can
include a material from those listed in (ii)-(iv) above, such as a
dielectric or barrier layer, and the converted inner core can
include a chemical compound of the first metal. In another aspect,
the unconverted external layer can include a first metal and the
converted external layer 404 can include a chemical compound of the
first metal. Additionally, or alternatively, the unconverted inner
core 410 can include a first metal, unconverted external layer 402
can include the first metal, and the converted external layer 404
can include a chemical compound of the first metal.
[0087] In an additional example, as illustrated in FIG. 15, the
pre-conversion lamellar particle 500 can include an unconverted
inner core 510 sandwiched by the unconverted external layer 502,
with an internal layer 520 between the unconverted inner core 520
and the unconverted external layer 502 on each side. For example,
unconverted external layer 502 can be external to the internal
layer 520 which can be in turn external to a first side and a
second side opposite the first side of the unconverted inner core
510, but not external to any of the other sides (e.g., at least
four sides of the unconverted inner core 510 are free of
unconverted external layers 502 and/or barrier layers 520). The
unconverted external layer 502 can be made of a second material and
the unconverted inner core 510 can be made of a first material. At
least the first material can be a metal. In some examples, the
first material and the second material can include, but are not
limited to, aluminum, copper, stainless steel, silver, gold, zinc,
iron, bronzes, manganese, titanium, zirconium, vanadium, niobium,
chromium, molybdenum, nickel, tungsten, tin, indium, bismuth,
alloys of any of these metals or a combination thereof. The second
material can include, but is not to (i) metals, such as one or more
of aluminum, copper, stainless steel, silver, gold, zinc, iron,
bronzes, manganese, titanium, zirconium, vanadium, niobium,
chromium, molybdenum, nickel, tungsten, tin, indium, bismuth,
alloys of any of these metals or a combination thereof. The
internal layer 520 can include, but is not limited to (ii)
dielectrics, such as metal oxides, glasses, chalcogenides, halides,
sulfides, minerals, synthetic micro and nano-crystals, organic and
inorganic polymers, (iii) conductive materials, such as indium-tin
oxide, tin oxide, metal doped oxides, and conductive polymers,
and/or (iv) metalloids and non-metals, such as silicon, germanium,
carbon, graphite, and graphene. The materials listed in (ii)-(iv)
can partially and/or not completely converted when subjected to
chemical conversion. The function of the materials listed in
(ii)-(iv) can provide various non-visual attributes, i.e., can act
as conversion barrier. For example, the internal layer 520 can be
less reactive to a given conversion process, thus creating a
location within the lamellar particle 500 in which the conversion
is likely to stop or a "conversion barrier." Further, in some
examples, the unconverted inner core 510 and/or the unconverted
external layer 502 can include a plurality of layers and/or a
plurality of materials.
[0088] Once subjected to a conversion process including, but not
limited to those described above, pre-conversion lamellar particle
500 can be converted to a converted lamellar particle, including,
but not limited, to converted lamellar particle 550 of FIGS. 16A-B.
Converted lamellar particle 550 can include a converted portion 570
and an unconverted portion 580. The unconverted portion 580 can
include a first metal and the converted portion 570 can include a
chemical compound of the first metal. In some examples, about one
percent to 100 percent of the unconverted external layers 502 can
be converted to converted external layers 504. In some examples,
zero percent to 100 percent of unconverted inner core 510 can be
converted to converted inner core 506. In some examples, zero
percent to 100 percent of internal layers 520 can be converted.
[0089] In the example illustrated in FIG. 16A, some or all of the
unconverted external layer 502 was converted to the converted
external layer 504; and none of the internal layers 520 and the
unconverted inner core 510 were converted. Thus, the converted
portion of the lamellar particle 570 includes the converted
external layer 504; and the unconverted portion of the lamellar
particle 580 can include internal layers 520 and the unconverted
inner core 510. In some examples, the unconverted portion 580 can
also include an unconverted external layer 502 (not shown in the
Figures). Similar to converted lamellar particles 150, 250, 350,
and 450, the definition of the converted portion of the lamellar
particle 570 and unconverted portion of lamellar particle 580
depends on which layers were converted and to what extent.
[0090] In an aspect, the unconverted inner core 510 can include a
first metal, the internal layer 520 can include a material from
those listed in (ii)-(iv) above, such as a dielectric or barrier
layer, and the converted inner core can include a chemical compound
of the first metal. In another aspect, the unconverted external
layer can include a first metal, the internal layer 520 can include
a material from those listed in (ii)-(iv) above, such as a
dielectric or barrier layer, and the converted external layer 504
can include a chemical compound of the first metal. Additionally,
or alternatively, the unconverted inner core 510 can include a
first metal, unconverted external layer 502 can include the first
metal, and the converted external layer 504 can include a chemical
compound of the first metal.
[0091] In the example illustrated in FIG. 16B, some or all of the
unconverted external layer 502 was converted to the converted
external layer 504; and none of the internal layers 520 and the
unconverted inner core 510 were converted. Thus, the converted
portion of the lamellar particle 570 includes the converted
external layer 504; and the unconverted portion of the lamellar
particle 580 can include internal layers 520 and the unconverted
inner core 510. In some examples, the unconverted portion 580 can
also include an unconverted external layer 502 (not shown in the
Figures). Similar to converted lamellar particles 150, 250, 350,
and 450, the definition of the converted portion of the lamellar
particle 570 and unconverted portion of lamellar particle 580
depends on which layers were converted and to what extent. In an
aspect, the unconverted inner core 510 can include a first metal
and the converted inner core 506 can include a chemical compound of
the first metal. In another aspect, the unconverted external layer
can include a first metal, the internal layer 520 can include a
material from those listed in (ii)-(iv) above, such as a dielectric
or barrier layer, and the converted external layer 504 can include
a chemical compound of the first metal. Additionally, or
alternatively, the unconverted inner core 510 can include a first
metal, unconverted external layer 502 can include the first metal,
and the converted external layer 504 can include a chemical
compound of the first metal.
[0092] A pigment comprising a plurality of the lamellar particles
of claim 1 that include at least two of the following properties:
magnetic, EMI attenuating, electrically conductive, and heat
conductive.
[0093] A method, comprising: chemically converting a first material
of a lamellar particle into a compound of the first material. The
first material is metal. Prior to the chemical conversion, the
lamellar has an aspect ratio at least 2:1. The first material is
external to or surrounds a second material. The compound of the
first material comprises a sulfide, phosphate, chromate, molybdate,
permanganate, vanadate, sulfate, carbonate, oxides, hydroxides,
nitrates, tungstanates, titanates, fluorotitanates, or a
combination thereof. The chemical conversion is performed by a
reactant and the reactant is in a form of at least one of solid
state, liquid state, vapor state, and plasma state. The liquid
state is a chemical bath. The solid state is a tumbling bed of
pre-flakes. The vapor state is a fluidized bed or a packed bed. For
the plasma state, the reactant is introduced in the form of ionized
gas or is introduced into a plasma ignited in a carrier gas such as
noble gases, oxygen, nitrogen, CO2, or introducing oxidation
through heat. The chemical bath comprises water and a solvent. The
chemical bath comprises at least one of an inorganic compound and
an organic compound. The inorganic compound comprises at least one
of sulfur, sulfides, sulfates, oxides, hydroxides, isocyanates,
thiocyanates, molybdates, chromates, permanganates, carbonates,
thiosulfates, and inorganic salts.
[0094] The organic compound comprises at least one of organic
compound containing sulfur, nitrogen, oxygen and combinations
thereof. The organic compound comprises at least one of thiols,
amines, thioamines, oxythio amines, thiourea, isocyanates,
thiocyanates, and silanes. The chemical bath comprises at least one
of inorganic and organic salts of metals or metalorganic compounds
of metals. The chemical bath comprises an oxidizing agent. The
chemical bath comprises at least one of a surface modifier and
inhibitors. The lamellar particle comprises a first material and a
second material at least partially encapsulating the first
material. The second material and the first material are different.
The second material is deposited on the first material by at least
one of metal plating processes, roll-to-roll metallization
processes, chemical bath deposition, physical vapor deposition, and
chemical vapor deposition. The method further comprises depositing
an internal layer between at least a portion of the second material
and the first material. The internal layer is deposited by one of
sol-gel, chemical bath deposition, plating, physical vapor
deposition, and chemical vapor deposition.
[0095] A lamellar particle comprising a first portion including a
first material, and a second portion external to the first portion,
wherein the second portion includes a chemical compound of the
first material.
[0096] As shown in FIGS. 21-24, there is also disclosed a
functional lamellar particle 700, comprising an unconverted portion
280 of the lamellar particle, wherein the unconverted portion 280
includes a first metal; a converted portion 270 of the lamellar
particle disposed external to a surface of the unconverted portion
280, wherein the converted portion 270 includes a chemical compound
of the first metal; and a functional coating 710 disposed external
to a surface of the converted portion 270. The functional lamellar
particle 700 can also include an unconverted inner core 210, a
converted inner core 206, an unconverted external layer 202, and a
converted external layer 204, as disclosed above with regard to
FIGS. 6-8.
[0097] The functional coating 710 can provide at least one function
to the lamellar particle including adjusting porosity, adjusting
surface area, controlling shear properties of a host system,
controlling dispersibility in a host system, adjusting chemical
compatibility and reactivity of surfaces of the lamellar particle,
providing a barrier (chemical and/or physical), providing
mechanical protection, chemically capping compounds on the surface
of the converted portion, adjusting surface energy, adjusting
hydrophilicity/hydrophobicity, controlling solvent intake,
controlling orientation and alignment of the lamellar particle in a
host system, increasing electrical and heat conductivity, adding or
increasing magnetic susceptibility, improving absorption or
reflectance of wavelengths in various parts of the spectral region,
providing ultraviolet protection to materials present in the
lamellar pigments, adding new spectral attributes such as
fluorescence, phosphorescence, QD effects, unique elemental
signatures for XRF detection, thermochromic, and photochromic
effects), adding metallic absorber functions for accentuating
spectral and non-spectral attributes, and combinations thereof. As
an example, thermochromic effects can be achieves with W-doped
VO.sub.2), photochromic effects can be achieved from doping with
AgCl, and electrochromic effects can be achieved with WO.sub.3.
[0098] In an aspect, the functional lamellar particles 700 can be
used for classified, decorative, and security applications.
[0099] The functional coating 710 can be a layer of a metal oxide;
a metal; a taggant; a surfactant; a steric stabilizer; ormosil;
organic compounds; polymer; dyes; UV absorbers; antioxidants; heat
treatments; and combinations thereof.
[0100] In an aspect, the functional coating 710 can be a metal
oxide chosen from SiO.sub.2, Al.sub.2O.sub.3, TiO.sub.2, ZnO,
Nb.sub.2O.sub.3, B.sub.2O.sub.3, WO.sub.3, AgCl-doped SiO.sub.2,
Y.sub.2O.sub.3-stabilized ZrO.sub.2, indium tin oxide, VO.sub.2 and
combinations thereof. The metal oxide can be applied external to a
surface of the converted portion 270 of the lamellar particle by
various processes, such as sol-gel, catalytic metal oxide
deposition, physical vapor deposition, chemical vapor deposition,
and atomic layer deposition. A functional coating 710 of a metal
oxide can provide at least one of the following properties to the
functional lamellar particle 700 including, but not limited to
porosity control, surface area adjustment, surface morphology
(smooth vs rough) control, chemical diffusion barrier, water
corrosion prevention, controlling solvent intake, structural
strengthening, UV protection, inhibition of photocatalysis,
changing optical properties, anchoring for silane or other
treatments, thermochromic effects, photochromic effects,
electrochromic effects, and elemental signature.
[0101] In an aspect, the functional coating 710 can be a metal
chosen from Mo, Zn, Ni, Ag, Cr, Au, Fe, and combinations thereof.
The metal can be applied external to a surface of the converted
portion 270 of the lamellar particle by various processes, such as
electroless and electroplating, catalytic chemical deposition,
chemical vapor deposition, sputtering, and vacuum evaporation. A
functional coating 710 of a metal can provide at least one of the
following properties to the functional lamellar particle 700
including, but not limited to changing optical, electrical, or
magnetic properties, thermal conductivity, elemental signature, and
antibacterial.
[0102] In an aspect, the functional coating 710 can be a taggant
chosen from quantum dots, inorganic and organic fluorescent and
phosphorescent materials (organic dyes, lanthanides-containing
nano-particles and layers), microstructures, and combinations
thereof. The taggant can be applied external to a surface of the
converted portion 270 of the lamellar particle by various
processes, such as incorporation into polymers, molecular bonding,
and sol-gel deposition. A functional coating 710 of a taggant can
provide at least one of the following properties to the functional
lamellar particle 700 including, but not limited to covert
security, and elemental signatures.
[0103] In an aspect, the functional coating 710 can be a surfactant
chosen from detergents, amphoterics, anionic, nonionic, cationic,
surface active polymers, PEG, saponin,
tridecafluorooctyltriethoxysilane+tetramethyl ammonium hydroxide,
and combinations thereof. The surfactant can be applied external to
a surface of the converted portion 270 of the lamellar particle by
various processes, such as by a chemical bath or a tumbling bed. A
functional coating 710 of a surfactant can provide at least one of
the following properties to the functional lamellar particle 700
including, but not limited to surface tension control, wetting and
dispersion, hydrophobicity, hydrophilicity, and leafing.
[0104] In an aspect, the functional coating 710 can be a steric
stabilizer chosen from polyethylene oxide, beta-diketones, carbonic
acids, carboxylates, amines, tetraalkylammonium compounds,
organophosphorous compounds, silanes (e.g.
methacryloxypropyltrimethoxysilane), long-chain alkyl/aryl alcohols
(octanol, stearyl alcohol, benzyl alcohol), polymer encapsulation
(adsorption or entanglement), PEG-methacrylate plus ethylhexyl
methacrylate (branched better than linear), tetra-n-octylammonium
bromide, and combinations thereof. The steric stabilizer can be
applied external to a surface of the converted portion 270 of the
lamellar particle by various processes, such as by a chemical bath
or a tumbling bed. A functional coating 710 of a steric stabilizer
can provide dispersion control.
[0105] In an aspect, the functional coating 710 can be ormosil
chosen from PDMS-SiO.sub.2, VTES-TEOS-acrylate, and combinations
thereof. The ormosil can be applied external to a surface of the
converted portion 270 of the lamellar particle by various
processes, such as by a chemical bath or a tumbling bed. A
functional coating 710 of ormosil can provide at least one of the
following properties to the functional lamellar particle 700
including, but not limited to water corrosion prevention, chemical
diffusion barrier, and mechanical protection.
[0106] In an aspect, the functional coating 710 can be an organic
compound chosen from fatty acids, diethylene glycol, Dynasylan.RTM.
1146 (a diaminofunctional silane), 3-aminopropyltriethoxysilane,
tridecafluorooctyltriethoxysilane, 2-perfluorooctanoate ethyl
trimethoxysilane, octadecyldimethyl trimethylsilylammonium
chloride, and combinations thereof. The organic compound can be
applied external to a surface of the converted portion 270 of the
lamellar particle by various processes, such as by a chemical bath
or a tumbling bed. A functional coating 710 of an organic compound
can provide at least one of the following properties to the
functional lamellar particle 700 including, but not limited to
dispersion, leafing, medium compatibility, adjusting surface
energy, hydrophobicity/hydrophilicity control, adhesion to paint
binders, and antistatic.
[0107] In an aspect, the functional coating 710 can be a polymer
chosen from monomers, oligomers, polymers, and combinations
thereof. The polymer can be applied external to a surface of the
converted portion 270 of the lamellar particle by various
processes, such as by a chemical bath or a tumbling bed. A
functional coating 710 of a polymer can provide at least one of the
following properties to the functional lamellar particle 700
including, but not limited to chemical diffusion barrier, optical
properties, carrier medium, anchor layer, mechanical strength,
controlling shearing properties.
[0108] In an aspect, the functional coating 710 can be a dye chosen
from phthalocyanines, porphyrins, and combinations thereof. The dye
can be applied external to a surface of the converted portion 270
of the lamellar particle by various processes, such as by a polymer
coating or a silica encapsulation. A functional coating 710 of a
dye can provide at least one of the following properties to the
functional lamellar particle 700 including, but not limited to
optical properties.
[0109] In an aspect, the functional coating 710 can be a UV
absorber chosen from titania, zinc oxide, ceria, zinc oxide bonded
to 4-methoxycinnamic acid and oleic acid, TINOSORB.RTM. S
(bis-ethylhexyloxyphenol methoxyphenyl triazine, TINOSORB.RTM. M
(bisoctrizole), UVINUL.RTM. A Plus (diethylamino hydroxybenzoyl
hexyl benzoat), UVASORB.RTM. HEB (iscotrizinol), UVINOLT150
(ethylhexyl triazone), hydroxyphenyltriazines, and combinations
thereof. The UV absorber can be applied external to a surface of
the converted portion 270 of the lamellar particle by various
processes, such as by a sol-gel or a chemical bath. A functional
coating 710 of a UV absorber can provide at least one of the
following properties to the functional lamellar particle 700
including, but not limited to UV protection.
[0110] In an aspect, the functional coating 710 can be an
antioxidant, such as a hindered amine light stabilizer, chosen from
2,2,6,6-tetramethylpiperidine and derivatives, and combinations
thereof. The antioxidant can be applied external to a surface of
the converted portion 270 of the lamellar particle by various
processes, such as by a chemical bath. A functional coating 710 of
an antioxidant can provide at least one of the following properties
to the functional lamellar particle 700 including, but not limited
to UV protection.
[0111] In an aspect, the functional coating 710 can be a layer
heat-treated in air, nitrogen, inert gas, a vacuum anneal, and
combinations thereof. A functional coating 710 of a layer
heat-treated can provide at least one of the following properties
to the functional lamellar particle 700 including, but not limited
to porosity control, surface area adjustment, and surface
morphology control.
Example 1
[0112] Pre-conversion lamellar particles were purchased from
Crescent Bronze (Oshkosh, Wis.) as a commercial product called
Brilliant Copper 104. These pre-conversion lamellar particles were
made solely of copper. The copper pre-conversion lamellar particles
had a width of about 12 microns and a physical thickness of about
0.2 to 0.6 microns. Five grams of the copper pre-conversion
lamellar particles were introduced into a 250 ml chemical bath
having a temperature of approximately 50.degree. C. for
approximately 60 minutes. The chemical bath included
(NH.sub.4).sub.2CO.sub.3/K.sub.2S in a 2:5 ratio+1% MBT
(2-Mercaptobenzothaizole), CAS #140-30-4, from Sigma-Aldrich) 8%
total solids concentration was present. The treated copper
particles (e.g., converted lamellar particles) were then removed
from the chemical bath and analyzed. The converted lamellar
particles appeared black in color and had a reflectance in a
visible range of less than 5 percent and an L*a*b* color space (L*)
value of less than 24. In particular, this sample had an L* less
than 20 and reflectance of less than 4 percent. A photograph of the
copper pre-conversion lamellar particles and the converted
pre-conversion lamellar particles is shown in FIG. 17. The analysis
of the pre-conversion lamellar particles, surface conversion
(partially treated particles), and the full conversion (fully
treated particles) is shown in Table 1 below and in the graphs
shown in FIGS. 18 and 19.
TABLE-US-00001 TABLE 1 Metal pre-flake maximum % R color: metal L*
70.5 69.4 @ 700 nm Surface conversion maximum % R color: black L*
19.9 3.3 @ 700 nm Full conversion maximum % R color: black L* 19.9
3.2 @ 400 nm
Example 2
[0113] Silver pre-conversion lamellar particles were purchased from
AMES Goldsmith, South Glen Falls, N.Y. 12803. The silver
pre-conversion lamellar particles product form AMES Goldsmith was
an electronic grade product MB-499. It had a width of about 10
microns and thickness ranging from about 0.1-0.6 microns. Three
sets of 1 gram silver pre-conversion lamellar particles were
introduced into three sets of 100 ml chemical bath at room
temperature for approximately 7 min, 30 min., and 45 min.
respectively. Each of the chemical baths included
(NH.sub.4).sub.2CO.sub.3/K.sub.2S in a 2:5 ratio+1% MBT
(2-Mercaptobenzothiazole). 3.5% total solids concentration was
present. The converted silver lamellar particles were then removed
from the chemical bath and were analyzed. Each set of converted
silver lamellar particles appeared as a different color. The
reflection values at different wavelengths in visible range were
color dependent at L*>35.
[0114] The analysis of the three sets of converted silver lamellar
particles is shown in Table 2 below and in the graphs shown in
FIGS. 20 and 21.
TABLE-US-00002 TABLE 2 Metal color: metal Maximum % R Minimum % R
L* 85.3 pre-flake 68.7 @ 700 nm 59.8 @ 400 nm 7 min color: (brown)
Maximum % R Minimum % R L* 37.9 exposure red 19.5 @ 700 nm 7.5 @
504 nm 30 min color: blue Maximum % R Minimum % R L* 38.5 exposure
green 12.6 @ 491 nm 7.1 @ 666 nm 45 min color: light Maximum % R
Minimum % R L* 45.2 exposure green 15.9 @ 526 nm 9.8 @ 700 nm
[0115] While principles of the present disclosure are described
herein with reference to illustrative embodiments for particular
applications, it should be understood that the disclosure is not
limited thereto. Those having ordinary skill in the art and access
to the teachings provided herein will recognize additional
modifications, applications, embodiments, and substitution of
equivalents all fall within the scope of the embodiments described
herein. Accordingly, the disclosure is not to be considered as
limited by the foregoing description.
* * * * *