Title of Invention

PROCESS FOR THE PRODUCTION OF INVERSE OPAL-LIKE STRUCTURES

Abstract The invention relates to a process for the production of inverse opal-like structures using core/shell particles whose shell forms a matrix and whose core is essentially solid and has an essentially monodisperse size distribution.
Full Text process for the producation of inverse opal-like structures.
The invention relates to the use of core/shell particles as template for the
production of inverse opal.like structures, and to a process for the produc-
tion of inverse opal-like structures.
The term three-dimensional photonic structures is generally taken to mean
systems which have a regular, three-dimensional modulation of the di-
electric constants (and thus also of the refractive index). If the periodic
modulation length corresponds approximately to the wavelength of (visi-
ble) light, the structure interacts with the light in the manner of a three-
dimensional diffraction grating, which is evident from angle-dependent
colour phenomena. An example of this is the naturally occurring precious
stone opal, which consists of silicon dioxide spheres in spherical closest
packing with air- or water-filled cavities in between. The inverse structure
thereto is notionally formed by regular spherical cavities being arranged in
closest packing in a solid material. An advantage of inverse structures of
this type over the normal structures is the formation of photonic band gaps
with much lower dielectric constant contrasts still (K. Busch et al. Phys.
Rev. Letters E, 198, 50, 3896). TiO2 in particular is a suitable material for
the formation of a photonic structure since it has a high refractive index.
Three-dimensional inverse structures can be produced by template syn-
thesis:
• Monodisperse spheres are arranged in spherical closest packing as
structure-forming templates.
• The cavities between the spheres are filled with a gaseous or liquid pre-
cursor or a solution of a precursor utilising capillary effects.
• The precursor is converted (thermally) into the desired material.
• The templates are removed, leaving behind the inverse structure.
Many such processes are disclosed in the literature. For example, SiO2
spheres can be arranged in closest packing and the cavities filled with
tetraethyl orthotitanate-containing solutions. After a number of conditioning
steps, the spheres are removed using HF in an etching process, leaving
behind the inverse structure of titanium dioxide (V. Colvin et al. Adv.
Mater. 2001, 13, 180).
De La Rue et al. (De La Rue et al. Synth. Metals, 2001, 116, 469) describe
the production of inverse opals consisting of TiO2 by the following method:
a dispersion of 400 nm polystyrene spheres is dried on a filter paper under
an IR lamp. The filter cake is washed by sucking through ethanol, trans-
ferred into a glove box and infiltrated with tetraethyl orthotitanate by
means of a water-jet pump. The filter paper is carefully removed from the
latex/ethoxide composite, and the composite is transferred into a tubular
furnace. Calcination in a stream of air is carried out in the tubular furnace
at 575°C for 8 h, causing the formation of titanium dioxide from the ethox-
ide and burning out the latex particles. An inverse opal structure of TiO2
remains behind.
Martinelli et al. (M. Martinelli et al. Optical Mater. 2001, 17, 11) describe
the production of inverse TiO2 opals using 780 nm and 3190 nm polysty-
rene spheres. A regular arrangement in spherical closest packing is
achieved by centrifuging the aqueous sphere dispersion at 700 - 1000
rpm for 24 - 48 hours followed by decantation and drying in air. The regu-
larly arranged spheres are moistened with ethanol on a filter in a Buchner
funnel and then provided dropwise with an ethanolic solution of tetraethyl
orthotitanate. After the titanate solution has percolated in, the sample is
dried in a vacuum desiccator for 4 — 12 hours. This filling procedure is
repeated 4 to 5 times. The polystyrene spheres are subsequently burnt out
at 600°C - 800°C for 8 - 10 hours.
Stein et al. (A. Stein et al. Science, 1998, 281, 538) describe the synthesis
of inverse TiO2 opals starting from polystyrene spheres having a diameter
of 470 nm as template. These are produced in a 28-hour process, sub-
jected to centrifugation and air-dried. The latex templates are then applied
to a filter paper. Ethanol is sucked into the latex template via a Buchner
funnel connected to a vacuum pump. Tetraethyl orthotitanate is then
added dropwise with suction. After drying in a vacuum desiccator for 24 h,
the latices are burnt out at 575°C for 12 h in a stream of air.
Vos et al. (W. L. Vos et al. Science, 1998, 281, 802) produce inverse TiO2
opals using polystyrene spheres having diameters of 180 - 1460 nm as
template. In order to establish spherical closest packing of the spheres, a
sedimentation technique is used supported by centrifugation over a period
of up to 48 h. After slow evacuation in order to dry the template structure,
an ethanolic solution of tetra-n-propoxy orthotitanate is added to the latter
in a glove box. After about 1 h, the infiltrated material is brought into the
air in order to allow the precursor to react to give TiO2. This procedure is
repeated eight times in order to ensure complete filling with TiO2. The
material is then calcined at 450°C.
The production of photonic structures from inverse opals is very compjex
and time-consuming by the processes described in the literature:
• lengthy/complex production of the template or the arrangement of the
spheres forming the template-forming structure in spherical closest
packing
• filling of the cavities of the template structure with precursors, which is
lengthy/complex since it frequently has to be carried out a number of
times
• lengthy/complex procedure for removal of the templates
• only limited or no possibility of the production of relatively large
photonic structures having an inverse opal structure and scale-up of
the laboratory synthesis into industrial production.
The disadvantages make the production of the desired photonic materials
having an inverse opal structure more difficult. There is consequently a
demand for a production process which is simple to implement and can
also be scaled up to an industrial scale.
Core/shell particles whose shell forms a matrix and whose core is essen-
tially solid and has an essentially monodisperse size distribution are
described in the earlier German patent application DE 10145450.3
Surprisingly, it has been found that core/shell particles of this type are
eminently suitable as template for the production of inverse opal struc-
tures.
The present invention therefore relates firstly to the use of the core/shell
particles whose shell forms a matrix and whose core is essentially solid
and has an essentially monodisperse size distribution as template for the
production of inverse opal structures.
The present invention furthermore relates to a process for the production
of inverse opal structures, characterised in that
a) a dispersion of core/shell particles whose shell forms a matrix
and whose core is essentially solid is dried,
b) optionally one or more precursors of suitable wall materials are
added, and
c) the cores are subsequently removed.
The use according to the invention of core/shell particles results, in par-
ticular, in the following advantages
- on drying of dispersions of core/shell particles, cracking in the
template (= arrangement of the spheres)) during drying can be
reduced or even prevented entirely,
- large-area regions of high order can be obtained in the template,
- stresses which arise during the drying process can be compen-
sated for by the elastic nature of the shell,
- if polymers form the shell, these can intertwine with one another
and thus mechanically stabilise the regular sphere arrangement in
the template,
- if the shell is strongly bonded to the core - preferably by grafting -
via an interlayer, the templates can be processed via melt proc-
esses.
It is therefore particularly preferred in accordance with the invention for the
shell in the core/shell particles to be bonded to the core via an interlayer.
In order to achieve the optical or photonic effect according to the inven-
tion, it is desirable for the core/shell particles to have a mean particle
diameter in the range from about 5 nm to about 2000 nm. It may be par-
ticularly preferred here for the core/shell particles to have a mean particle
diameter in the range from about 5 to 20 nm, preferably 5 to 10 nm. In this
case, the cores may be known as "quantum dots"; they exhibit the corre-
sponding effects known from the literature. In order to achieve colour
effects in the region of visible light, it is particularly advantageous for the
core/shell particles to have a mean particle diameter in the range from
about 50 - 500 nm. Particular preference is given to the use of particles in
the range 100 - 500 nm, since in particles in this size range (depending
on the refractive-index contrast which can be achieved in the photonic
structure), the reflections of various wavelengths of visible light differ sig-
nificantly from one another, and thus the opaiescence which is particularly
important for optical effects in the visible region occurs to a particularly
pronounced extent in a very wide variety of colours. However, it is also
preferred in a variant of the present invention to employ multiples of this
preferred particle size, which then result in reflections corresponding to the
higher orders and thus in a broad colour play.
In a preferred embodiment of the invention, the interlayer is a layer of
crosslinked or at least partially crosslinked polymers. The crosslinking of
the interlayer here can take place via free radicals, for example induced by
UV irradiation, or preferably via di- or oligofunctional monomers. Preferred
interlayers in this embodiment comprise 0.01 to 100% by weight, particu-
larly preferably 0.25 to 10% by weight, of di- or oligofunctional monomers.
Preferred di- or oligofunctional monomers are, in particular, isoprene and
allyl methacrylate (ALMA). Such an interlayer of crosslinked or at least
partially crosslinked polymers preferably has a thickness in the range from
10 to 20 nm. If the interlayer comes out thicker, the refractive index of the
layer is selected so that it corresponds either to the refractive index of the
core or to the refractive index of the shell.
If copolymers which, as described above, contain a crosslinkable mono-
mer are employed as interlayer, the person skilled in the art will have
absolutely no problems in suitably selecting corresponding copolymeris-
able monomers. For example, corresponding copolymerisable monomers
can be selected from a so-called Q-e-scheme (cf. textbooks on macro-
molecular chemistry). Thus, monomers such as methyl methacrylate and
methyl acrylate can preferably be polymerised with ALMA.
In another, likewise preferred embodiment of the present invention, shell
polymers are grafted directly onto the core via a corresponding function-
alisation of the core. The surface functionalisation of the core here forms
the interlayer according to the invention. The type of surface functionalisa-
tion here depends principally on the material of the core. Silicon dioxide
surfaces can, for example, be suitably modified with silanes carrying cor-
respondingly reactive end groups, such as epoxy functions or free double
bonds. In the case of polymeric cores, the surface modification can be car-
ried out, for example, using a styrene which is functionalised on the aro-
matic ring, such as bromostyrene. This functionalisation then allows
growing-on of the shell polymers to be achieved. In particular, the inter-
layer can also effect adhesion of the shell to the core via ionic interactions
or complex bonds.
In a preferred embodiment, the shell of these core/shell particles consists
of essentially uncrosslinked organic polymers, which are preferably grafted
onto the core via an at least partially crosslinked interlayer.
The shell here can consist either of thermoplastic or elastomeric polymers.
The core can consist of a very wide variety of materials. The only essential
factor for the purposes of the present invention is that the core and, in a
variant of the invention, preferably also the interlayer and shell can be
removed under conditions under which the wall material is stable. The
choice of suitable core/shell/interlayer-wall material combinations presents
the person skilled in the art with absolutely no difficulties.
It is furthermore particularly preferred in a variant of the invention for the
core to consist of an organic polymer, which is preferably crosslinked.
In another variant of the invention which is explained in greater detail
below, the cores consist of an inorganic material, preferably a metal or
semimetal or a metal chalcogenide or metal pnictide. For the purposes of
the present invention, chalcogenides are taken to mean compounds in
which an element from group 16 of the Periodic Table of the Elements is
the electronegative bonding partner; pnictides are taken to mean those in
which an element from group 15 of the Periodic Table of the Elements is
the electronegative bonding partner. Preferred cores consist of metal chal-
cogenides, preferably metal oxides, or metal pnictides, preferably nitrides
or phosphides. Metal in the sense of these terms are all elements which
can occur as electropositive partner compared with the counterions, such
as the classical metals of the sub-groups, or the main-group metals from
the first and second main group, but also all elements from the third main
group, as well as silicon, germanium, tin, lead, phosphorus, arsenic, anti-
mony and bismuth. The preferred metal chalcogenides and metal pnictides
include, in particular, silicon dioxide, aluminium oxide, gallium nitride,
boron nitride, aluminium nitride, silicon nitride and phosphorus nitride. The
starting material employed for the production of the core/shell particles to
be employed in accordance with the invention in a variant of the present
invention are preferably monodisperse cores of silicon dioxide, which can
be obtained, for example, by the process described in US 4,911,903. The
cores here are produced by hydrolytic polycondensation of tetraaikoxy-
silanes in an aqueous-ammoniacal medium, where firstly a sol of primary
particles is produced, and the resultant SiO2 particles are subsequently
converted into the desired particle size by continuous, controlled metered
addition of tetraalkoxysilane. This process enables the production of
monodisperse SiO2 cores having mean particle diameters of between 0.05
and 10 mm with a standard deviation of 5%. The starting material
employed can also be monodisperse cores of non-absorbent metal oxides,
such as TiO2, ZrO2, ZnO2, SnO2 or AI2O3, or metal-oxide mixtures. Their
production is described, for example, in EP 0 644 914. Furthermore, the
process of EP 0 216 278 for the production of monodisperse SiO2 cores
can readily be applied to other oxides with the same result. Tetraethoxy-
silane, tetrabutoxytitanium, tetrapropoxyzirconium or mixtures thereof are
added in one portion, with vigorous mixing, to a mixture of alcohol, water
and ammonia, whose temperature is set precisely to 30 to 40°C using a
thermostat, and the resultant mixture is stirred vigorously for a further 20
seconds, giving a suspension of monodisperse cores in the nanometre
region. After a post-reaction time of from 1 to 2 hours, the cores are sepa-
rated off in a conventional manner, for example by centrifugation, washed
and dried.
The wall of the inverse opal structures obtainable in accordance with the
invention is, in an embodiment of the present invention, preferably formed
from an inorganic material, preferably a metal chalcogenide or metal pnic-
tide. In the present description, this material is also referred to as wall
material. For the purposes of the present invention, chalcogenides are
taken to mean compounds in which an element from group 16 of the Peri-
odic Table is the electronegative bonding partner; pnictides are taken to
mean those in which an element from group 15 of the Periodic Table is the
electronegative bonding partner. Preferred wall materials are metal chal-
cogenides, preferably metal oxides, or metal pnictides, preferably nitrides
or phosphides. Metal in the sense of these terms are all elements which
can occur as electropositive partner compared with the counterions, such
as the classical metals of the sub-groups, such as, in particular, titanium
and zirconium, or the main-group metals from the first and second main
groups, but also all elements from the third main group, as well as silicon,
germanium, tin, lead, phosphorus, arsenic, antimony and bismuth. The
preferred metal chalcogenides include, in particular, silicon dioxide, alu-
minium oxide and particularly preferably titanium dioxide.
The starting material (precursor) employed for the production of the
inverse opals in accordance with this variant of the invention can in princi-
ple be all conceivable precursors which are liquid, sinterable or soluble
and which can be converted into stable solids by a sol-gel-analogous con-
version. Sinterable precursors here are taken to mean ceramic or pre-
ceramic particles, preferably nanoparticles, which can be converted into a
moulding - the inverse opal - by - as usual in ceramics - sintering, if
desired with elimination of readily volatile by-products. The relevant
ceramic literature (for example H.P. Baldus, M. Jansen, Angew. Chem.
1997, 109, 338-354) discloses precursors of this type to the person skilled
in the art. Gaseous precursors, which can be infiltrated into the template
structure by a CVD-analogous method known per se, can furthermore also
be employed. In a preferred variant of the present invention, use is made
of solutions of one or more esters of a corresponding inorganic acid with a
lower alcohol, such as, for example, tetraethoxysilane, tetrabutoxytitanium,
tetrapropoxyzirconium or mixtures thereof.
In a second, likewise preferred variant of the invention, the wall of the
inverse opal is formed from the polymers of the shell of the core/shell par-
ticles, which are preferably crosslinked with one another. In this variant of
the invention, the addition of precursors in step b) can be omitted or
replaced by the addition of crosslinking agents. In this variant of the
invention, it may be preferred for the cores to consist of an inorganic mate-
rial described above.
In the process according to the invention for the production of an inverse
opal structure, a dispersion of the core/shell particles described above is
dried in a first step. The drying here is carried out under conditions which
enable the formation of a "positive" opal structure, which then serves as
template in the remainder of the process. This can be carried out, for
example, by careful removal of the dispersion medium, by slow sedimen-
tation or by the application of a mechanical force to a pre-dried mass of
core/shell particles.
For the purposes of the present invention, the action of mechanical force
can be the action of a force which takes place in the conventional proc-
essing steps of polymers. In preferred variants of the present invention,
the action of mechanical force takes place either:
through uniaxial pressing or
action of force during an injection-moulding operation or
during a transfer moulding operation,
during (co)extrusion or
during a calendering operation or
during a blowing operation.
If the action of force takes place through uniaxial pressing, the mouldings
according to the invention are preferably films. Films according to the
invention can preferably also be produced by calendering, film blowing or
flat-film extrusion. The various ways of processing polymers under the
action of mechanical forces are well known to the person skilled in the art
and are revealed, for example, by the standard textbook Adolf Franck,
"Kunststoff-Kompendium" [Plastics Compendium]; Vogel-Verlag; 1996.
The processing of core/shell particles through the action of mechanical
force, as is preferred here, is furthermore described in detail in interna-
tional patent application WO 2003025035.
A precursor of suitable wall materials is preferably subsequently added to
the template, as described above. In a preferred variant of the process
according to the invention for the production of inverse opal structures, the
precursor is therefore a solution of an ester of an inorganic ortho-acid with
a lower alcohol, preferably tetraethoxysilane, tetrabutoxytitanium, tetra-
propoxyzirconium or mixtures thereof. Suitable solvents for the precursors
are, in particular, lower alcohols, such as methanol, ethanol, n-propanol,
isopropanol or n-butanol.
As has been shown, it is advantageous to allow the precursors or alterna-
tively the crosslinking agent to act on the template structure of core/shell
particles for some time under a protective-gas cushion before condensa-
tion of the wall material in order to effect uniform penetration into the cavi-
ties. For the same reason, it is advantageous for the precursors or the
crosslinking agent to be added to the template structure under reduced
pressure, preferably in a static vacuum of p The formation of the wall material from the precursors is carried out either
by addition of water and/or by heating the reaction batch. In the case of
alkoxide precursors, heating in air is generally sufficient for this purpose.
Under certain circumstances, it may be advantageous to wash the impreg-
nated template briefly with a small amount of a solvent in order to wash off
precursor adsorbed onto the surface. With this step, the formation of a
thick layer of wall material, which can act as diffuser, on the surface of the
template can be prevented. For the same reason, it may be advantageous
also to dry the impregnated structure under mild conditions before the cal-
cination.
The removal of the cores in step c) can be carried out by various methods.
For example, the cores can be removed by dissolution or by burning out.
In a preferred variant of the process according to the invention, step c)
comprises calcination of the wall material, preferably at temperatures
above 200°C, particularly preferably above 400°C. If, in the variant of the
invention described above, a precursor is employed for the formation of
the wall, it is particularly preferred for all the core/shell particles to be
removed together with the cores.
If the cores consist of suitable inorganic materials, these can be removed
by etching. This procedure is particularly preferred if the shell polymers
are intended to form the wall of the inverse opal structure. Silicon dioxide
cores, for example, can preferably be removed using HF, in particular
dilute HF solution. It may in turn be preferred in this procedure for
crosslinking of the shell to take place before removal of the cores, as
described above.
If the cavities of the inverse opal structure are to be re-impregnated with
liquid or gaseous materials, however, it may also be preferred for the shell
to be crosslinked only to a very small extent, or not at all. The impregna-
tion here can consist, for example, in inclusion of liquid crystals, as
described, for example, in Ozaki et al., Adv. Mater. 2002, 14, 514 and Sato
et al., J. Am. Chem. Soc. 2002, 124, 10950.
Those obtainable in accordance with the invention are suitable firstly for
the above-described use as photonic material, preferably with the impreg-
nation mentioned, but secondly also for the production of porous surfaces,
membranes, separators, filters and porous supports. These materials can
also be used, for example, as fluidised beds in fluidised-bed reactors.
Owing to the considerations mentioned here, it is advantageous for the
shell of the core/shell particles according to the invention to comprise one
or more polymers and/or copolymers or polymer precursors and, if desired,
auxiliaries and additives, where the composition of the shell may be
selected in such a way that it is essentially dimensionally stable and tack-
free in a non-swelling environment at room temperature.
With the use of polymer substances as shell material and, if desired, core
material, the person skilled in the art gains the freedom to determine their
relevant properties, such as, for example, their composition, the particle
size, the mechanical data, the glass transition temperature, the melting
point and the core:shell weight ratio and thus also the applicational prop-
erties of the core/shell particles, which ultimately also affect the properties
of the inverse opal structure produced therefrom.
Polymers and/or copolymers which may be present in the core material or
of which it consists are high-molecular-weight compounds which conform
to the specification given above for the core material. Both polymers and
copolymers of polymerisable unsaturated monomers and polycondensates
and copolycondensates of monomers containing at least two reactive
groups, such as, for example, high-molecular-weight aliphatic, aliphatic/
aromatic or fully aromatic polyesters, polyamides, polycarbonates, poly-
ureas and polyurethanes, but also amino and phenolic resins, such as, for
example, melamine-formaldehyde, urea-formaldehyde and phenol-form-
aldehyde condensates, are suitable.
For the production of epoxy resins, which are likewise suitable as core
material, epoxide prepolymers, which are obtained, for example, by reac-
tion of bisphenol A or other bisphenols, resorcinol, hydroquinone, hexane-
diol or other aromatic or aliphatic diols or polyols, or phenol-formaldehyde
condensates, or mixtures thereof with one another, with epichlorohydrin or
other di- or polyepoxides, are usually mixed with further condensation-
capable compounds directly or in solution and allowed to cure.
The polymers of the core material are advantageously, in a preferred vari-
ant of the invention, crosslinked (co)polymers, since these usually only
exhibit their glass transition at high temperatures. These crosslinked
polymers may either already have been crosslinked during the polymeri-
sation or polycondensation or copolymerisation or copolycondensation or
they may have been post-crosslinked in a separate process step after the
actual (co)polymerisation or (co)polycondensation.
A detailed description of the chemical composition of suitable polymers
follows below.
In principle, polymers of the classes already mentioned above, if they are
selected or constructed in such a way that they conform to the specifica-
tion given above for the shell polymers, are suitable for the shell material
and for the core material.
Polymers which meet the specifications for a shell material are likewise
present in the groups of polymers and copolymers of polymerisable un-
saturated monomers and polycondensates and copolycondensates of
monomers containing at least two reactive groups, such as, for example,
high-molecular-weight aliphatic, aliphatic/aromatic or fully aromatic poly-
esters and polyamides.
Taking into account the above conditions for the properties of the shell
polymers (= matrix polymers), selected units from all groups of organic film
formers are in principle suitable for their preparation.
Some further examples are intended to illustrate the broad range of poly-
mers which are suitable for the production of the shells.
If the shell is intended to have a comparatively low refractive index, poly-
mers such as polyethylene, polypropylene, polyethylene oxide, polyacry-
lates, polymethacrylates, polybutadiene, polymethyl methacrylate, poly-
tetrafluoroethylene, polyoxymethylene, polyesters, polyamides, polyepox-
ides, polyurethane, rubber, polyacrylonitrile and polyisoprene, for
example, are suitable.
If the shell is intended to have a comparatively high refractive index, poly-
mers having a preferably aromatic basic structure, such as polystyrene,
polystyrene copolymers, such as, for example, SAN, aromatic-aliphatic
polyesters and polyamides, aromatic polysulfones and polyketones, poly-
vinyl chloride, polyvinylidene chloride and, on suitable selection of a high-
refractive-index core material, also polyacrylonitrile or polyurethane, for
example, are suitable for the shell.
In an embodiment of core/shell particles which is particularly preferred in
accordance with the invention, the core consists of crosslinked polystyrene
and the shell of a polyacrylate, preferably polyethyl acrylate, polybutyl
acrylate, polymethyl methacrylate and/or a copolymer thereof.
With respect to the ability of the core/shell particles to be converted into
inverse opal structures, it is advantageous, if the wall material results from
a precursor solution, for the core:shell weight ratio to be in the range from
20:1 to 1.4:1, preferably in the range from 6:1 to 2:1 and particularly pref-
erably in the range 5:1 to 3.5:1. If the wall of the inverse opal structure is
formed from shell polymers, it is preferred for the core:shell weight ratio to
be in the range from 5:1 to 1:10, in particular in the range from 2:1 to 1:5
and particularly preferably in the region below 1:1.
The core/shell particles which can be used in accordance with the inven-
tion can be produced by various processes.
A preferred way of obtaining the particles is a process for the production of
core/shell particles by a) surface treatment of monodisperse cores, and b)
application of the shell of organic polymers to the treated cores. In a proc-
ess variant, the monodisperse cores are obtained in a step a) by emulsion
polymerisation.
In a preferred process variant, a crosslinked polymeric interlayer, which
preferably contains reactive centres to which the shell can be covalently
bonded, is applied to the cores in step a), preferably by emulsion polym-
erisation or by ATR polymerisation. ATR polymerisation here stands for
atom transfer radical polymerisation, as described, for example, in K.
Matyjaszewski, Practical Atom Transfer Radical Polymerisation, Polym.
Mater. Sci. Eng. 2001, 84. The encapsulation of inorganic materials by
means of ATRP is described, for example, in T. Werne, T. E. Patten, Atom
Transfer Radical Polymerisation from Nanoparticles: A Tool for the Prepa-
ration of Weil-Defined Hybrid Nanostructures and for Understanding the
Chemistry of Controlled/"Living" Radical Polymerisation from Surfaces, J.
Am. Chem. Soc. 2001, 123, 7497-7505 and WO 00/11043. The perform-
ance both of this method and of emulsion polymerisations is familiar to the
person skilled in the art of polymer preparation and is described, for
example, in the above-mentioned literature references.
The liquid reaction medium in which the polymerisations or copolymerisa-
tions can be carried out consists of the solvents, dispersion media or dilu-
ents usually employed in polymerisations, in particular in emulsion polym-
erisation processes. The choice here is made in such a way that the emul-
sifiers employed for homogenisation of the core particles and shell precur-
sors are able to develop adequate efficacy. Suitable liquid reaction media
for carrying out the process according to the invention are aqueous media,
in particular water.
Suitable for initiation of the polymerisation are, for example, polymerisation
initiators which decompose either thermally or photochemically, form free
radicals and thus initiate the polymerisation. Preferred thermally activat-
able polymerisation initiators here are those which decompose at between
20 and 180°C, in particular at between 20 and 80°C. Particularly preferred
polymerisation initiators are peroxides, such as dibenzoyl peroxide di-tert-
butyl peroxide, peresters, percarbonates, perketals, hydroperoxides, but
also inorganic peroxides, such as H2O2, salts of peroxosulfuric acid and
peroxodisulfuric acid, azo compounds, alkylboron compounds, and hydro-
carbons which decompose homolytically. The initiators and/or photoinitia-
tors, which, depending on the requirements of the polymerised material,
are employed in amounts of between 0.01 and 15% by weight, based on
the polymerisable components, can be used individually or, in order to
utilise advantageous synergistic effects, in combination with one another.
In addition, use is made of redox systems, such as, for example, salts of
peroxodisulfuric acid and peroxosulfuric acid in combination with low-
valency sulfur compounds, particularly ammonium peroxodisulfate in com-
bination with sodium dithionite.
Corresponding processes have also been described for the production of
polycondensation products. Thus, it is possible for the starting materials
for the production of polycondensation products to be dispersed in inert
liquids and condensed, preferably with removal of low-molecular-weight
reaction products, such as water or - for example on use of di(lower alkyl)
dicarboxylates for the preparation of polyesters or polyamides - lower
alkanols.
Polyaddition products are obtained analogously by reaction by compounds
which contain at least two, preferably three, reactive groups, such as, for
example, epoxide, cyanate, isocyanate or isothiocyanate groups, with
compounds carrying complementary reactive groups. Thus, isocyanates
react, for example, with alcohols to give urethanes, with amines to give
urea derivatives, while epoxides react with these complementary groups to
give hydroxyethers and hydroxyamines respectively. Like the polyconden-
sations, polyaddition reactions can also advantageously be carried out in
an inert solvent or dispersion medium.
It is also possible for aromatic, aliphatic or mixed aromaticaliphatic poly-
mers, for example polyesters, polyurethanes, polyamides, polyureas, poly-
epoxides or also solution polymers, to be dispersed or emulsified
(secondary dispersion) in a dispersion medium, such as, for example, in
water, alcohols, tetrahydrofuran, hydrocarbons, and to be post-condensed,
crosslinked and cured in this fine distribution.
The stable dispersions required for these polymerisation polycondensation
or polyaddition processes are generally prepared using dispersion auxilia-
ries.
The dispersion auxiliaries used are preferably water-soluble, high-mole-
cular-weight organic compounds containing polar groups, such as poly-
vinylpyrrolidone, copolymers of vinyl propionate or acetate and vinylpyr-
rolidone, partially saponified copolymers of an acrylate and acrylonitrile,
polyvinyl alcohols having different residual acetate contents, cellulose
ethers, gelatine, block copolymers, modified starch, low-molecular-weight
polymers containing carboxyl and/or sulfonyl groups, or mixtures of these
substances.
Particularly preferred protective colloids are polyvinyl alcohols having a
residual acetate content of less than 35 mol%, in particular from 5 to 39
mol%, and/or vinylpyrrolidone-vinyl propionate copolymers having a vinyl
ester content of less than 35% by weight, in particular from 5 to 30% by
weight.
It is possible to use nonionic or ionic emulsifiers, if desired also as a mix-
ture. Preferred emulsifiers are optionally ethoxylated or propoxylated,
relatively long-chain alkanols or alkylphenols having different degrees of
ethoxylation or propoxylation (for example adducts with from 0 to 50 mol of
alkylene oxide) or neutralised, sulfated, sulfonated or phosphated deriva-
tives thereof. Neutralised dialkylsulfosuccinic acid esters or alkyldiphenyl
oxide disulfonates are also particularly suitable.
Particularly advantageous are combinations of these emulsifiers with the
above-mentioned protective colloids, since particularly finely divided dis-
persions are obtained therewith.
Special processes for the production of monodisperse polymer particles
have also already been described in the literature (for example R.C.
Backus, R.C. Williams, J. Appl, Physics 19, p. 1186, (1948) and can
advantageously be employed, in particular, for the production of the cores.
It need merely be ensured here that the above-mentioned particle sizes
are observed. A further aim is the greatest possible uniformity of the poly-
mers. The particle size in particular can be set via the choice of suitable
emulsifiers and/or protective colloids or corresponding amounts of these
compounds.
Through the setting of the reaction conditions, such as temperature, pres-
sure, reaction duration and use of suitable catalyst systems, which influ-
ence the degree of polymerisation in a known manner, and the choice of
the monomers employed for their production — in terms of type and pro-
portion - the desired property combinations of the requisite polymers can
be set specifically. The particle size here can be set, for example, through
the choice and amount of the initiators and other parameters., such as the
reaction temperature. The corresponding setting of these parameters does
not present any difficulties at all to the person skilled in the art in the area
of polymerisation.
Monomers which result in polymers having a high refractive index are
generally those which contain aromatic moieties or those which contain
hetero atoms having a high atomic number, such as, for example, halogen
atoms, in particular bromine or iodine atoms, sulfur or metal ions, i.e.
atoms or atomic groups which increase the polarisability of the polymers.
Polymers having a low refractive index are accordingly obtained from
monomers or monomer mixtures which do not contain the said moieties
and/or atoms of high atomic number or only do so in a small proportion.
A review of the refractive indices of various common homopolymers is
given, for example, in Ullmanns Encyklopadie der technischen Chemie
[Ullmann's Encyclopaedia of Industrial Chemistry], 5th Edition, Volume
A21, page 169. Examples of monomers which can be polymerised by
means of free radicals and result in polymers having a high refractive
index are:
Group a): styrene, styrenes which are alkyl-substituted on the phenyl
ring, a-methylstyrene, mono- and dichlorostyrene, vinylnaphthalene, iso-
propenylnaphthalene, isopropenylbiphenyl, vinylpyridine, isopropenyl-
pyridine, vinylcarbazole, vinylanthracene, N-benzylmethacrylamide, p-
hydroxymethacrylanilide.
Group b): acrylates containing aromatic side chains, such as, for exam-
ple, phenyl (meth)acrylate (= abbreviated notation for the two compounds
phenyl acrylate and phenyl methacrylate), phenyl vinyl ether, benzyl
(meth)acrylate, benzyl vinyl ether, and compounds of the formulae:
In order to improve clarity and simplify the notation of carbon chains in the
formulae above and below, only the bonds between the carbon atoms are
shown. This notation corresponds to the depiction of aromatic cyclic com-
pounds, where, for example, benzene is depicted by a hexagon with alter-
nating single and double bonds.
Also suitable are compounds containing sulfur bridges instead of oxygen
bridges, such as, for example:
In the above formulae, R stands for hydrogen or methyl. The phenyl rings
in these monomers may carry further substituents. Such substituents are
suitable for modifying the properties of the polymers produced from these
monomers within certain limits. They can therefore be used in a targeted
manner to optimise, in particular, the applicationally relevant properties of
the mouldings according to the invention.
Suitable substituents are, in particular, halogen, NO2, alkyl groups having
one to twenty C atoms, preferably methyl, alkoxides having one to twenty
C atoms, carboxyalkyl groups having one to twenty C atoms, carbonylalkyl
groups having one to twenty C atoms or -OCOO-alkyl groups having one
to twenty C atoms. The alkyl chains in these radicals may themselves
optionally be substituted or interrupted by divalent hetero atoms or groups,
such as, for example, -O-, -S-, -NH-, -COO-, -OCO- or -OCOO-, in non-
adjacent positions.
Group c): monomers containing hetero atoms, such as, for example,
vinyl chloride, acrylonitrile, methacrylonitrile, acrylic acid, methacrylic acid,
acrylamide and methacrylamide, or organometallic compound, such as, for
example,
Group d): an increase in the refractive index of polymers is also
achieved by copolymerisation of carboxyl-containing monomers and con-
version of the resultant "acidic" polymers into the corresponding salts with
metals of relatively high atomic weight, such as, for example, preferably
with K, Ca, Sr, Ba, Zn, Pb, Fe, Ni, Co, Cr, Cu, Mn, Sn or Cd.
The above-mentioned monomers, which make a considerable contribution
towards the refractive index of the polymers prepared therefrom, can be
homopolymerised or copolymerised with one another. They can also be
copolymerised with a certain proportion of monomers which make a lesser
contribution towards the refractive index. Such copolymerisable monomers
having a lower refractive index contribution are, for example, acrylates,
methacrylates, vinyl ethers or vinyl esters containing purely aliphatic radi-
cals.
In addition, crosslinking agents which can be employed for the production
of crosslinked polymer cores from polymers produced by means of free
radicals are also all bi- or polyfunctional compounds which are copoly-
merisable with the above-mentioned monomers or which can subsequently
react with the polymers with crosslinking.
Examples of suitable crosslinking agents will be presented below, divided
into groups for systematisation:
Group 1: bisacrylates, bismethacrylates and bisvinyl ethers of aromatic
or aliphatic di- or polyhydroxyl compounds, in particular of butanediol
(butanediol di(meth)acrylate, butanediol bisvinyl ether), hexanediol (hex-
anediol di(meth)acrylate, hexanediol bisvinyl ether), pentaerythritol,
hydroquinone, bishydroxyphenylmethane, bishydroxyphenyl ether, bis-
hydroxymethylbenzene, bisphenol A or with ethylene oxide spacers, pro-
pylene oxide spacers or mixed ethylene oxide/propylene oxide spacers.
Further crosslinking agents from this group are, for example, di- or poly-
vinyl compounds, such as divinyibenzene, or methylenebisacrylamide, tri-
allyl cyanurate, divinylethyleneurea, trimethylolpropane tri(meth)acrylate,
trimethylolpropane trivinyl ether, pentaerythritol tetra(meth)acrylate, penta-
erythritol tetravinyl ether, and crosslinking agents having two or more dif-
ferent reactive ends, such as, for example, (meth)allyl (meth)acrylates of
the formulae:
(in which R denotes hydrogen or methyl).
Group 2: reactive crosslinking agents which act in a crosslinking man-
ner, but in most cases in a post-crosslinking manner, for example during
warming or drying, and which are copolymerised into the core or shell
polymers as copolymers.
Examples thereof are: N-methylol(meth)acrylamide, acrylamidoglycolic
acid, and ethers and/or esters thereof with C1 to C6-alcohols, diacetone-
acrylamide (DAAM), glycidyl methacrylate (GMA), methacryloyloxypropyl-
trimethoxysilane (MEMO), vinyltrimethoxysilane, m-isopropenylbenzyl iso-
cyanate (TMI).
Group 3: carboxyl groups which have been incorporated into the poly-
mer by copolymerisation of unsaturated carboxylic acids are crosslinked in
a bridge-like manner via polyvalent metal ions. The unsaturated carboxylic
acids employed for this purpose are preferably acrylic acid, methacrylic
acid, maleic anhydride, itaconic acid and fumaric acid. Suitable metal ions
are Mg, Ca, Sr, Ba, Zn, Pb, Fe, Ni, Co, Cr, Cu, Mn, Sn, Cd. Particular
preference is given to Ca, Mg and Zn, Ti and Zr. In addition, monovalent
metal ions, such as, for example, Na or K, are also suitable.
Group 4: post-crosslinked additives, which are taken to mean bis- or
polyfunctionalised additives which react irreversibly with the polymer (by
addition or preferably condensation reactions) with formation of a network.
Examples thereof are compounds which contain at least two of the follow-
ing reactive groups per molecule: epoxide, aziridine, isocyanate acid chlo-
ride, carbodiimide or carbonyl groups, furthermore, for example,
3,4-dihydroxyimidazolinone and derivatives thereof (®Fixapret@ products
from BASF).
As already explained above, post-crosslinking agents containing reactive
groups, such as, for example, epoxide and isocyanate groups, require
complementary reactive groups in the polymer to be crosslinked. Thus,
isocyanates react, for example, with alcohols to give urethanes, with
amines to give urea derivatives, while epoxides react with these comple-
mentary groups to give hydroxyethers and hydroxyamines respectively.
The term post-crosslinking is also taken to mean photochemical curing or
oxidative or air- or moisture-induced curing of the systems.
The above-mentioned monomers and crosslinking agents can be com-
bined and (co)polymerised with one another as desired and in a targeted
manner in such a way that an optionally crosslinked (co)polymer having
the desired refractive index and the requisite stability criteria and mecha-
nical properties is obtained.
It is also possible additionally to copolymerise further common monomers,

for example acrylates, methacrylates, vinyl esters, butadiene, ethylene or
styrene, in order, for example, to set the glass transition temperature or
the mechanical properties of the core and/or shell polymers as needed.
It is likewise preferred in accordance with the invention for the application
of the shell of organic polymers to be carried out by grafting, preferably by
emulsion polymerisation or ATR polymerisation. The methods and mono-
mers described above can be employed correspondingly here.
The following examples are intended to explain the invention in greater
detail without limiting it.
Examples
Example 1: Production of the core/shell particles
A mixture, held at 4°C, consisting of 1519 g of deionised water, 2.8 g of
1,4-butanediol diacrylate (MERCK), 25.2 g of styrene (MERCK) and
1030 mg of sodium dodecylsulfate (MERCK) is introduced into a 51 jack-
eted reactor, held at 75°C and fitted with double-propeller stirrer, argon
protective-gas inlet and reflux condenser and dispersed with vigorous stir-
ring.
Immediately thereafter, the reaction is initiated by successive injection of
350 mg of sodium dithionite (MERCK), 1.75 g of ammonium peroxodisul-
fate (MERCK) and a further 350 mg of sodium dithionite (MERCK), each
dissolved in about 20 ml of water. The injection is carried out by means of
disposable syringes.
After 20 min, a monomer emulsion consisting of 56.7 g of 1,4-butanediol
diacrylate (MERCK), 510.3 g of styrene (MERCK), 2.625 g of sodium do-
decylsulfate (MERCK), 0.7 g of KOH and 770 g of water is metered in con-
tinuously over a period of 120 min via the rotary piston pump.
The reactor contents are stirred for 30 min without further addition.
A second monomer emulsion consisting of 10.5 g of allyl methacrylate
(MERCK), 94.50 g of methyl methacrylate (MERCK), 0.525 g of sodium
dodecylsulfate (MERCK) and 140g of water is subsequently metered in
continuously over a period of 30 min via the rotary piston pump.
After about 15 min, 350 mg of ammonium peroxodisulfate (MERCK) are
added, and the mixture is then stirred for a further 15 min.
Finally, a third monomer emulsion consisting of 200 g of ethyl acrylate
(MERCK), 0.550 g of sodium dodecylsulfate (MERCK) and 900 g of water
is metered in continuously over a period of 240 min via the rotary piston
pump. The mixture is subsequently stirred for a further 120 min.
Before and after each introduction of monomer emulsions and after intro-
duction of the initial mixture, argon is passed into the jacketed reactor as
protective-gas cushion for about one minute.
Next day, the reactor is warmed to 95°C, and a steam distillation is carried
out in order to remove residual unreacted monomers from the latex disper-
sion.
This results in a dispersion of core/shell particles in which the shell has a
proportion by weight of about 22%. The core of polystyrene is crosslinked,
the interlayer is likewise crosslinked ( p(MMA-co-ALMA)) and serves for
grafting the shell of uncrosslinked ethyl acrylate.
Example 2: Production of an inverse opal structure
In order to form the template-forming structure, i.e. the organisation of the
core/shell particles in spherical close packing, 5 g of the latex dispersion
are poured into a shallow glass dish having a diameter of 7 cm and dried
in air, giving flakes which shimmer in colours.
One such flake is evacuated in a round-bottomed flask using a rotary
slide-valve oil pump. A precursor solution consisting of 5 ml of tetra-n-butyl
orthotitanate in 5 ml of absolute ethanol is subsequently added in a static
vacuum so that the dissolved precursor, driven by capillary forces, is able
to penetrate into the cavities of the template. An argon cushion is added
above the solution containing the impregnated template. This arrangement
is left to stand for a few hours before the impregnated flake is removed in
a stream of argon protective gas and calcined at 500°C in a corundum
boat in a tubular furnace.
As a result, inverse structures are obtained which consist of closest-
packed cavities in TiO2 (Figure 1).
BRIF DESCRIPTION OF THE ACCOMPANYING DRAWING
Figures:
Figure 1: Scanning electron photomicrograph of the inverse opal struc-
ture of titanium dioxide (Example 2). The regular arrangement of the iden-
tical cavities is evident over a large region. The cavities are connected to
one another by channels, giving the possibility of filling via the liquid or
gas phase
WE CLAIM:
1. Process for the production of inverse opal structures, characterized in that
a) a dispersion of core/shell particles)whose shell forms a matrix and whose
core is essentially solid is dried,
b) optionally one or more precursors suitable wad materials are added,
and
c) the cores are subsequently removed.
2. Process for the production of inverse opal structures as claimed in claim 1,
wherein in a step; a2), the application of a mechanical force to a mass of the
core/shell particles pre-dried in step a1) takes place.
3. Process for the production of inverse opal structures as claimed in claim 2,
wherein the action of a mechanical force tekes place through uniaxial pressing or
during an in jection-moulding operation or during a transfer moulding operation
or during (co)extrusion or during a calendaring operation or during a blowing
operation.
4. Process for the production of inverse opal structures as claimed in at least one
of claims 1 to 3, wherein the precursor in step b) is a solution of an ester of an
inorganic ortho-acid with a lower alcohol.
5. Process for the production of inverse opal structures as claimed in at least one
of claims 1 to 4 where in step b) is carried out under reduced pressure, preferably
in a static vacuum of p 6. Process for the production of inverse opal structures as claimed in at least one
of the preceding claims, wherein step c) comprises calcinations, preferably at
temperatures above 200°C, particularly preferably above 400°C.
7. Process for the production of inverse opal structures as claimed in at least one
of claims 1 to 5, wherein step c) is an etching process, preferably etching with
HF.
8. Process for the production of inverse opal structures as claimed in at least one
of the preceding claims, wherein the core/shell particles are removed in step c).
The invention relates to a process for the production of inverse opal-like
structures using core/shell particles whose shell forms a matrix and whose core
is essentially solid and has an essentially monodisperse size distribution.

Documents:

769-kolnp-2005-granted-abstract.pdf

769-kolnp-2005-granted-claims.pdf

769-kolnp-2005-granted-correspondence.pdf

769-kolnp-2005-granted-description (complete).pdf

769-kolnp-2005-granted-drawings.pdf

769-kolnp-2005-granted-examination report.pdf

769-kolnp-2005-granted-form 1.pdf

769-kolnp-2005-granted-form 18.pdf

769-kolnp-2005-granted-form 2.pdf

769-kolnp-2005-granted-form 3.pdf

769-kolnp-2005-granted-form 5.pdf

769-kolnp-2005-granted-gpa.pdf

769-kolnp-2005-granted-reply to examination report.pdf

769-kolnp-2005-granted-specification.pdf

769-kolnp-2005-granted-translated copy of priority document.pdf


Patent Number 225215
Indian Patent Application Number 769/KOLNP/2005
PG Journal Number 45/2008
Publication Date 07-Nov-2008
Grant Date 05-Nov-2008
Date of Filing 02-May-2005
Name of Patentee MERCK PATENT GMBH
Applicant Address FRANKFURTER STRASSE 250, 64293 DARMSTADT
Inventors:
# Inventor's Name Inventor's Address
1 WINKLER, HOLGER ROMERSTRASSE 63A, 64291 DARMSTADT
2 HELLMANN, GOTZ HUXELREBENWEG 72, 55129 MAINZ
3 RUHL, TILMANNN MOZARTSTRASSE 10, 64347 GRIESHEIM
4 SPAHN, PETER SPESSARTSTRASSE 75, 63457 HANAU
PCT International Classification Number C04B 38/00
PCT International Application Number PCT/EP2003/009717
PCT International Filing date 2003-09-02
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 102 45 848.0 2002-09-30 Germany