Disclosed herein is a method of manufacturing a metal flake, including the steps of: applying metal ink containing an organic metal compound onto a substrate; calcining the metal ink applied on the substrate to form a thin metal film; separating the formed thin metal film from the substrate; and pul
Disclosed herein is a method of manufacturing a metal flake, including the steps of: applying metal ink containing an organic metal compound onto a substrate; calcining the metal ink applied on the substrate to form a thin metal film; separating the formed thin metal film from the substrate; and pulverizing the separated thin metal film. The method of manufacturing a metal flake is characterized in that the thickness and size of metal flakes can be easily adjusted, metal flakes having excellent conductivity and gloss can be obtained, and metal flakes can be mass-produced using environmentally friendly and economical methods.
대표청구항▼
1. A method of manufacturing a metal flake, comprising the steps of: applying metal ink containing a metal complex compound obtained by reacting one or more metals or metal compounds represented by Formula 1 below with one or more ammonium compounds represented by Formula 2, 3 or 4 below onto a subs
1. A method of manufacturing a metal flake, comprising the steps of: applying metal ink containing a metal complex compound obtained by reacting one or more metals or metal compounds represented by Formula 1 below with one or more ammonium compounds represented by Formula 2, 3 or 4 below onto a substrate;calcining the metal ink applied on the substrate to form a thin metal film;separating the formed thin metal film from the substrate; andpulverizing the separated thin metal film using a bead mill, an ultrasonic pulverizer or a micro pulverizer to form a metal flake having a thickness of 0.01 to 1 μm, a size of 0.5 to 100 μm and a reflectance of 30% or more,wherein the bead mill is charged with media beads made of zirconia, alumina or glass and having a size of 0.02 to 0.7 mm, andwherein the step of separating the thin metal film from the substrate is conducted by a process of separating the thin metal film from the substrate using ultrasonic waves or a vibrator after immersing the thin metal film formed on the substrate into salt water, or a process of separating the thin metal film from the substrate using a scraper or an air gun; MnX Formula 1wherein M is a metal or metal alloy, n is an integer of 1-10, and X is non-existent or at least one substituent selected from hydrogen, ammonium, oxygen, sulfur, halogen, cyanide, cyanate, carbonate, nitrate, nitrite, sulfate, phosphate, thiocyanate, chlorate, perchlorate, tetrafluoroborate, acetylacetonate, mercapto, amide, alkoxide, carboxylate, and derivatives thereof; wherein R1, R2, R3, R4, R5 and R6 are each independently selected from hydrogen, a substituted or unsubstituted aliphatic alkyl group of C1-C30, an alicyclic alkyl group, an aryl group or aralkyl group, a polymer compound, a heterocyclic compound, and derivatives thereof; and R1 and R2 or R4 and R5 are connected with each other to form a ring. 2. The method of manufacturing a metal flake according to claim 1, further comprising the step of: refining the formed metal flake, after the step of pulverizing the separated thin metal film. 3. The method of manufacturing a metal flake according to claim 2, wherein the step of refining the pulverized thin metal film is conducted by removing impurities from the metal flake using a solvent or by surface-treating the metal flake. 4. The method of manufacturing a metal flake according to claim 3, wherein the pulverized thin metal film is surface-treated with fatty acid, a silicon compound, a cellulose derivative, phosphoric acid, a phosphoric acid derivative, or mercaptan (thiol group) provided with an alkyl group of 6 to 24 carbon atoms. 5. The method of manufacturing a metal flake according to claim 4, wherein the fatty acid is oleic acid; the silicon compound is methylsilyl isocyanate; the cellulose derivative is polysaccharide; the phosphoric acid derivative is phosphonic acid; and the mercaptan (thiol group) provided with an alkyl group of 6 to 24 carbon atoms is 1-hexyl mercaptan, dodecyl mercaptan, lauryl mercaptan, hexdecyl mercaptan or octadecyl mercaptan. 6. The method of manufacturing a metal flake according to claim 1, wherein the metal ink includes at least one selected from the metal complex compound, metallic or nonmetallic compounds and at least one mixture thereof, and wherein the metal ink includes at least one additive selected from the group consisting of a solvent, a stabilizer, a dispersant, a binder resin, a release agent, a reductant, a surfactant, a wetting agent, a thixotropic agent, and a levelling agent. 7. The method of manufacturing a metal flake according to claim 6, wherein the solvent is selected from the group consisting of water, alcohols, glycols, acetate, ethers, ketones, aliphatic hydrocarbons, aromatic hydrocarbons, and halogenated hydrocarbons. 8. The method of manufacturing a metal flake according to claim 6, wherein the solvent is selected from the group consisting of methanol, ethanol, iso-propanol, 1-methoxypropanol, butanol, ethylhexyl alcohol, terpineol, ethylene glycol, glycerin, ethyl acetate, butyl acetate, methoxypropyl acetate, carbitol acetate, ethylcarbitol acetate, methyl cellosolve, butyl cellosolve, diethyl ether, tetrahydrofuran, dioxane, methyl ethyl ketone, acetone, dimethylformamide, 1-methyl-2-pyrrolidone, dimethyl sulfoxide, hexane, heptane, dodecane, paraffin oil, mineral spirits, benzene, toluene, xylene, chloroform, methylene chloride, carbon tetrachloride, and acetonitrile. 9. The method of manufacturing a metal flake according to claim 1, wherein the substrate is made of a material selected from the group consisting of plastics, resins, rubber materials, ceramic materials, metals or metal alloys, metal or nonmetal salts, papers, and composites thereof. 10. The method of manufacturing a metal flake according to claim 9, wherein the plastics are selected from the group consisting of polyimide (PI), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyether sulfone (PES), nylon, polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), polyvinyl alcohol (PVA), polyethylene (PE), polypropylene (PP), polycarbonate (PC), and polyarylate (PAR); the resins are selected from the group consisting of an acrylic resin, an urethane resin, a fluorine resin, a silicon resin, an epoxy resin, and a vinyl resin; the rubber materials are selected from the group consisting of butyl rubber, chloroprene rubber, styrene-butadiene rubber (SBR), ethylene-propylene rubber (EPR), and styrene-isoprene-styrene (SIS); the ceramic materials are selected from the group consisting of glass, silica, alumina, titanium oxides, zirconia, ceria, clay, stone, talc, and mica; the metals or metal alloys include aluminum, copper, nickel, iron, zinc, stainless, and brass; the metal or nonmetal salts are selected from the group consisting of sodium hydroxide and barium sulfate; and the papers are selected from the group consisting of synthetic paper, printing paper, packing paper, and corrugated paper. 11. The method of manufacturing a metal flake according to claim 1, wherein the substrate is made in the form of powder, a flake, a bead, a ball, fiber, film, foil, a sheet, a chip, a rod, wire, a needle or a whisker. 12. The method of manufacturing a metal flake according to claim 1, wherein the step of applying the metal ink onto the substrate is conducted by spin coating, roll coating, spray coating, dip coating, flow coating, comma coating, kiss coating, die coating, a doctor blade method, dispensing, inkjet printing, offset printing, screen printing, pad printing, gravure printing, flexography, stencil printing, imprinting, xerography, lithography, fluidized bed coating, atomic layer deposition (ALD), chemical vapor deposition (CVD), physical vapor deposition (PVD), ion plasma coating, electrostatic coating or electro-deposition. 13. The method of manufacturing a metal flake according to claim 1, wherein the step of calcining the applied metal ink is conducted by oxidation, reduction, heat treatment, hot air blowing, or irradiation of microwaves, infrared rays, ultraviolet rays, or laser. 14. The method of manufacturing a metal flake according to claim 1, wherein the step of calcining the applied metal ink comprises the step of introducing a reductant. 15. The method of manufacturing a metal flake according to claim 14, wherein the reductant comprises at least one of hydrazine, hydrazine monohydrate, acetic hydrazide, sodium or potassium borohydride, trisodium citrate, methyldiethanolamine, ethanolamine, diethanolamine, propanolamine, butanolamine, hexanolamine, dimethylethanolamine, 2-amino-2-methyl propanol, dimethylamineborane, butylamineborane, piperidine, N-methylpiperidine, piperazine, N,N′-dimethylpiperazine, 1-amino-4-methylpiperazine, pyrrolidine, N-methylpyrrolidine, and morpholine. 16. The method of manufacturing a metal flake according to claim 1, wherein the thin metal film formed by calcining the applied metal ink has a thickness of 0.005˜5 μm. 17. The method of manufacturing a metal flake according to claim 1, wherein, in the step of applying the metal ink and the step of calcining the applied metal ink, the steps of forming a protective coating film on the obtained thin metal film, applying metal ink onto the protective coating film and then calcining the applied metal ink are repeated to form a multilayered thin metal film. 18. The method of manufacturing a metal flake according to claim 17, wherein the protective coating film is made of any one selected from the group consisting of polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), a polyolefin resin, a urethane resin, an acrylic resin, a fluorine resin, a silicon resin, a polyvinyl ester resin, and wax. 19. The method of manufacturing a metal flake according to claim 17, wherein the step of applying the metal ink onto the substrate is conducted by entire coating or pattern coating. 20. The method of manufacturing a metal flake according to claim 1, wherein the step of applying the metal ink onto the substrate is conducted by entire coating or pattern coating. 21. The method of manufacturing a metal flake according to claim 20, wherein, in the pattern coating, the pattern is a honeycomb structure or a mesh structure. 22. The method of manufacturing a metal flake according to claim 1, wherein the substrate is made of carbon, graphite, carbon nanotubes, silicon, or sulfur.
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이 특허에 인용된 특허 (2)
Josephy, Karl; Rettker, James P.; Enlow, Howard H., Process for making angstrom scale and high aspect functional platelets.
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