JP7719438B2 - Method for forming a sheet or film comprising a collection of carbon black aggregates and a collection of metal nanoparticles - Google Patents

Description

In this invention, first, a first suspension is prepared by dispersing a collection of carbon black aggregates, in which the aggregates are entangled with each other via alcohol, in alcohol. Second, a second suspension is prepared by mixing a collection of nano-sized fine crystals of a metal compound that precipitates a metal upon thermal decomposition with alcohol. Third, the mixture of the two suspensions is filled into the chamber of a vacuum impregnation device, and the pressure inside the chamber is reduced to 1/5 of the saturated vapor pressure of the first alcohol as the minimum pressure, to prepare a raw material for forming a sheet or film in the chamber. Fourth, a sheet or film is formed using the raw material by the T-die method. Fifth, the sheet or film is heated to a temperature at which the metal compound completes thermal decomposition, causing the collection of metal nanoparticles to precipitate simultaneously.
As a result, the gaps between the entangled carbon black aggregates are filled with metal nanoparticles, and the entangled aggregates are covered with a layer of metal nanoparticles.
On the other hand, while the size of gases and water vapor is 0.3-0.5 nm, aggregates are made up of carbon particles with sizes of 10-100 nm strung together in an irregular and complex shape. Therefore, a sheet or film made up of a collection of entangled aggregates has many pores with sizes of 0.3-0.5 nm or more. For this reason, a sheet or film made up of a collection of entangled aggregates does not have gas barrier properties.
The size of the aggregates is 100 to 500 nm. Therefore, a sheet or film made of a collection of entangled aggregates has low mechanical strength because the aggregates are not bonded to each other.
Furthermore, a sheet or film made of a collection of aggregates in which the aggregates are entangled with one another reflects the color of the aggregates, resulting in a blackish sheet or film that does not look attractive.
Furthermore, the resistivity of carbon black is six orders of magnitude greater than that of metals, but thirteen orders of magnitude less than that of synthetic resins. Therefore, a sheet or film made of aggregates does not have electrical and thermal conductivity comparable to that of metals.
In contrast, in the sheet or film of the present invention, the gaps between entangled carbon black aggregates are filled with layers of metal-bonded metal nanoparticles, and the surfaces of the entangled aggregates are covered with layers of metal-bonded metal nanoparticles, thereby simultaneously providing a variety of excellent properties.
First, since the sheet or film is made up of a collection of aggregates in which aggregates are entangled with one another, the sheet or film has excellent light-blocking and heat-dissipating properties.
Second, the collection of metallically bonded metal nanoparticles forms a path in the sheet or film through which electrons can travel continuously, giving the sheet or film electrical and thermal conductivity comparable to that of a metal.
Thirdly, the sheet or film is covered with a layer of metal-bonded nanoparticles, which blocks pores through which gases and water vapor pass, thereby imparting gas barrier properties to the sheet or film.
Fourth, liquids have surface tension and cannot penetrate the sheet or film.
Fifth, the aggregates are held together by the metallurgically bonded nanoparticles, giving the sheet or film a combination of tensile , compressive, and shear strength.
Sixth, the heat resistance and flame resistance of the sheet or film are higher than those of plastic sheets or films.
Seventh, the surface of the sheet or film is covered with a cluster of metal-bonded nanoparticles, giving the sheet or film a metallic luster.
Thus, the sheet or film of the present invention simultaneously possesses a variety of properties that surpass those of conventional plastic sheets or films.
According to the JIS packaging terminology, a film is defined as "a membrane-like material made of plastic with a thickness of less than 250 μm," and a sheet is defined as "a thin plate-like material made of plastic with a thickness of 250 μm or more." In the present invention, in accordance with the JIS, a wide and thin membrane-like material made of a collection of carbon black aggregates is defined as a sheet when it is 250 μm or more thick, and as a film when it is less than 250 μm thick.
Prior to the present invention, the inventors of the present invention filed an invention in which a thin film or film made of a collection of carbon black aggregates is prepared, and the surface of the thin film or film is covered with a coating made of a collection of laminated metal nanoparticles, thereby imparting both gas barrier properties and metallic gloss to the thin film or film. This invention was filed as Japanese Patent Application No. 2021-07055.
The present invention is an improvement application of an earlier application, and the improvement lies in that the gaps between entangled aggregates of carbon black aggregates are filled with clusters of stacked metal nanoparticles, and the surface of the aggregate cluster is covered with clusters of stacked metal nanoparticles, thereby simultaneously imparting tensile strength, compressive strength, and shear strength.

Prior art close to the present invention includes light-shielding thin films and light-shielding films, and heat-dissipating thin films and heat-dissipating films.
For example, Patent Document 1 discloses a conventional light-blocking film. Specifically, the exterior of a liquid beverage container is covered with a light-blocking shrink film to prevent light from reaching the liquid beverage and suppress deterioration of the functional ingredients in the liquid beverage due to light exposure. However, even the highest light-blocking shrink film has a total light transmittance of only 92%, and continuous exposure to ultraviolet light slowly deteriorates the liquid beverage.

Also, Patent Document 2 describes a conventional heat-dissipating film. Specifically, a heat-dissipating layer with excellent heat dissipation properties due to infrared radiation is formed by laminating a water-insoluble inorganic compound and a heat-resistant synthetic resin on a metal film with excellent thermal conductivity. However, the emissivity of the heat-dissipating layer made of a water-insoluble inorganic compound and a heat-resistant synthetic resin is low, at 0.8-0.9.

Japanese Patent Application Laid-Open No. 2019-201569 JP 2014-193529 A

The problem to be solved by the present invention is to impart not only gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to those of metals to a sheet or film made of a collection of carbon black aggregates, but also tensile strength, compressive strength, and shear strength at the same time.

A method for producing a raw material used in forming a sheet or film made of a collection of carbon black aggregates that has been given gas barrier properties, metallic luster, and electrical and thermal conductivity equivalent to those of a metal, is as follows:
A first suspension is prepared in advance, in which aggregates, which are primary agglomerates of carbon particles constituting carbon black, are entangled with each other via a first alcohol having a weight greater than that of the aggregates of carbon black, and the entangled aggregates are dispersed in the first alcohol. A second suspension is prepared in advance, in which aggregates of fine crystals of the metal compound, which are one order of magnitude smaller than the aggregates, are mixed with a second alcohol having a boiling point 15°C or more higher than that of the first alcohol and lower than the temperature at which thermal decomposition of a metal compound that precipitates a metal by thermal decomposition begins, in a weight less than that of the second alcohol. Thereafter, the second suspension, which is greater in weight than the first suspension, and the first suspension are filled into a container, and the two suspensions are stirred to prepare a mixture of the two suspensions. Thereafter, the mixture of the two suspensions is filled into the chamber of a vacuum impregnation device, and the chamber is sealed. Furthermore, the vacuum pump of the vacuum impregnation device is operated. and reducing the pressure inside the chamber to a minimum pressure that is 1/5 of the saturated vapor pressure of the first alcohol at the temperature inside the chamber, thereby causing 4/5 or less of the first alcohol to be vaporized and discharged from the chamber, and also causing a portion of the second alcohol to be vaporized and discharged from the chamber in accordance with the magnitude of the saturated vapor pressure of the second alcohol at the temperature inside the chamber, and the amounts of both the first alcohol and the second alcohol to decrease, causing the mixture of the two types of suspensions to become a new suspension, and as the two types of alcohols evaporate, the new suspension moves into gaps between the entangled aggregates, and also adsorbs onto the surfaces of the entangled aggregate groups, thereby forming a mixture consisting of the new suspension and the aggregate groups in the chamber, and the mixture is used as a raw material for forming a sheet or film.
A method for producing raw materials used in forming sheets or films consisting of aggregates of carbon black that have gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to those of metals.

By sequentially performing two extremely simple processes described below, a raw material for forming a sheet or film made of a collection of carbon black aggregates that has gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to that of a metal is produced. Prior to the preparation of the raw material, a first suspension and a second suspension are prepared in advance.
The first process involves simply filling a container with the first suspension and the second suspension and stirring the two suspensions. The second process involves filling a chamber of a vacuum impregnation apparatus with the stirred suspensions, sealing the chamber, and then operating the vacuum pump of the vacuum impregnation apparatus to reduce the pressure inside the chamber to a minimum pressure that is one-fifth of the saturated vapor pressure of the first alcohol at the temperature inside the chamber.
Carbon black is an inexpensive industrial material produced by burning oil or gas in a large furnace under oxygen-rich conditions. Alcohol is the most commonly used organic solvent. The two processes are extremely simple, and the process in a vacuum impregnation device is also extremely simple. Therefore, the raw material used to form sheets or films can be produced inexpensively using inexpensive raw materials at low processing costs.
Next, the phenomena that occur in the two processes and the effects that the two processes bring about will be described.
In the first process, the first and second suspensions are filled into a container and the two suspensions are stirred. During this process, the metal compound that precipitates metal upon thermal decomposition does not disperse or dissolve in either the first or second alcohol. Furthermore, the first and second alcohols are miscible. On the other hand, carbon black aggregates are clusters of carbon particles, each 10-100 nm in size, bound together in an irregular, complex, string-like structure (called a "structure"). Furthermore, the aggregates are 100-500 nm in size, and the number of carbon particles is 100-1000. Furthermore, the microcrystals of the metal compound are nanosized, an order of magnitude smaller than the aggregate size. Therefore, when the first and second suspensions are stirred, the first and second alcohols are mixed, resulting in a third suspension in which the mixed alcohols are mixed with clusters of nanosized microcrystals of the metal compound. As a result, the third suspension, instead of the first alcohol, fills the gaps between the entangled aggregates of carbon black, and the aggregates become a mixture dispersed in the third suspension. Note that, because the metal compound does not disperse or dissolve in the mixed alcohol, the microcrystals in the third suspension are similar in size to the microcrystals in the second suspension and are one order of magnitude smaller than the aggregates.
In other words, metal compounds that precipitate metals upon thermal decomposition disperse at a rate of approximately 10% by weight in methanol, which has one carbon atom. As the number of carbon atoms in the alcohol increases, the weight percentage of metal compounds dispersed in the alcohol decreases, and metal compounds do not disperse or dissolve in alcohols with a certain number of carbon atoms or more. Therefore, the first suspension is composed of an alcohol with a certain number of carbon atoms or more. Furthermore, since the second alcohol has a boiling point 15°C or more higher than that of the first alcohol, the number of carbon atoms in the second alcohol is equal to or greater than that of the first alcohol. Therefore, like the first alcohol, metal compounds do not disperse or dissolve in the second alcohol. Therefore, metal compounds do not disperse or dissolve in a mixture of two types of alcohol. Furthermore, the second alcohol has a higher viscosity than the first alcohol.
In the second process, the stirred mixture of the two suspensions is filled into the chamber of a vacuum impregnation device, and the pressure inside the chamber is reduced to a minimum pressure of 1/5 of the saturated vapor pressure of the first alcohol at the temperature inside the chamber. This causes 4/5 or less of the first alcohol to evaporate from the mixed alcohol, and the evaporated first alcohol is discharged from the chamber to the outside of the vacuum impregnation device. A portion of the second alcohol evaporates in an amount corresponding to the saturated vapor pressure of the second alcohol at the temperature inside the chamber, and the evaporated second alcohol is discharged from the chamber to the outside of the vacuum impregnation device. As a result, the third suspension becomes a mixture of the two alcohols with reduced amounts of both alcohols, and becomes a fourth suspension in which the mixed two alcohols are mixed with aggregates of fine crystals of the metal compound. As the two alcohols evaporate, the fourth suspension moves within the mixed two alcohols. As a result, the fourth suspension, instead of the third suspension, enters the gaps between the entangled carbon black aggregates. Furthermore, the fourth suspension, instead of the third suspension, is adsorbed onto the surface of the entangled aggregates. As a result, a mixture consisting of the fourth suspension and the aggregates is created in the chamber. This mixture is used as a raw material for forming a sheet or film consisting of the carbon black aggregates. The two vaporized alcohols are recovered in a recovery machine and reused.
In other words, if the boiling points of two alcohols differ by 15°C or more, the saturated vapor pressures of the two alcohols at each temperature will be different. For example, the saturated vapor pressure of ethanol is 1.068 atmospheres at 80°C, which is close to its boiling point of 78.5°C, and 0.712 atmospheres at 70°C. A temperature increase of just 10°C, close to the boiling point, increases the saturated vapor pressure by nearly 50%. Therefore, if the boiling points of two alcohols differ by 15°C or more, the saturated vapor pressure of the first alcohol will be higher than that of the second alcohol at each temperature. Therefore, if the pressure inside the chamber of a vacuum impregnation device is reduced to a minimum pressure that is one-fifth of the saturated vapor pressure of the first alcohol at the temperature inside the chamber, less than four-fifths of the first alcohol will vaporize. Meanwhile, the second alcohol evaporates in accordance with the magnitude of its saturated vapor pressure at the temperature inside the chamber. However, because the boiling point of the second alcohol is 15°C or more higher than that of the first alcohol, the amount of the second alcohol that evaporates is less than half the amount of the first alcohol that evaporates. As a result, the amounts of both alcohols decrease, and the third suspension becomes a new fourth suspension. Meanwhile, even if the second alcohol evaporates in an amount less than four-fifths of the first alcohol, less than half the amount of the first alcohol that evaporates, the total amount of the two alcohols is still more than half the total amount of the two alcohols in the third suspension. Therefore, the fourth suspension still exhibits the properties of a liquid alcohol rather than the properties of the microcrystalline solid metal compound. Therefore, when the pressure in the chamber is reduced to 1/5 of the saturated vapor pressure of the first alcohol at the temperature in the chamber, the fourth suspension moves into the gaps between the entangled aggregates, and the fourth suspension fills the gaps between the entangled aggregates, replacing the third suspension. Furthermore, the fourth suspension is adsorbed onto the surface of the collection of entangled aggregates, replacing the third suspension.
In contrast, when the second alcohol is composed of an alcohol having a boiling point close to that of the first alcohol and the pressure inside the chamber is reduced to 1/5 of the saturated vapor pressure of the first alcohol at the temperature inside the chamber, the closer the boiling points of the two alcohols are, the greater the amount of vaporization of both alcohols, and the properties of the solid metal compound microcrystals become dominant over the properties of the liquid alcohol in the fourth suspension. As a result, the fourth suspension is less likely to penetrate into the gaps between the entangled aggregates, and the carbon black aggregates do not become entangled through the fourth suspension. For this reason, an alcohol with a boiling point 15°C or more higher than that of the first alcohol was used as the second alcohol.
As described above, even when the pressure inside the chamber is reduced to a minimum pressure of 1/5 of the saturated vapor pressure of the first alcohol at the temperature inside the chamber, the total amount of the two alcohols is more than 1/2 of the total amount of the two alcohols in the third suspension, and the fourth suspension, which has predominantly alcoholic properties, replaces the third suspension and enters the gaps between the entangled carbon black aggregates, causing the carbon black aggregates to entangle with each other through the fourth suspension. Furthermore, the fourth suspension is adsorbed onto the surface of the entangled aggregate clusters. In this way, a mixture of the aggregate clusters and the fourth suspension is formed inside the chamber. This mixture is used as a raw material for forming a sheet or film composed of the carbon black aggregate clusters.

The method of making the first suspension described in paragraph 6 comprises:
As the first alcohol described in paragraph 6, an alcohol having a viscosity of 3-5 mPa·sec at 20°C is used, and the alcohol and carbon black aggregates having a weight less than that of the alcohol are filled into a container, and the carbon black aggregates are stirred and immersed in the alcohol. Thereafter, an ultrasonic homogenizer is placed in the container, and the homogenizer is operated in the alcohol to homogenize the carbon black aggregates, which are primary agglomerates of carbon particles constituting the carbon black, to a size smaller than that of the aggregates. A method for preparing a first suspension according to paragraph 6, wherein small bubbles are generated in the alcohol, and then the bubbles disappear almost simultaneously, at which time shock waves generated when the bubbles burst are continuously generated in the alcohol, and the shock waves are continuously irradiated to the fine parts of the agglomerates, which are clumps of the aggregates entangled with each other, thereby releasing the entangled parts of the aggregates, and the alcohol is adsorbed to the released entangled parts, thereby preparing a first suspension in which a collection of aggregates entangled via the alcohol is dispersed in the alcohol .

In other words, the smallest unit that cannot be decomposed of carbon black is the aggregate, which is a primary agglomeration of carbon particles. As described in paragraph 7, this aggregate is a collection of carbon particles, each 10-100 nm in size, bound together in an irregular, complex, string-like structure (called a "structure"). The size of the aggregate is 100-500 nm, and the number of carbon particles is 100-1000. This structure easily entangles these aggregates, forming agglomerates, which are secondary agglomerations of carbon particles and aggregate clusters. Therefore, carbon black is largely composed of agglomerates, the largest of which can reach nearly 1 mm in size, forming a powder. For this reason, it is difficult to prepare a suspension of agglomerate clusters in alcohol, and it is even more difficult to form a sheet or film composed of agglomerate clusters. For this reason, a homogenizer is operated in a low-viscosity alcohol of 3-5 mPa·sec at 20°C, shock waves are continuously applied to the collection of agglomerates, and the sites where aggregates are directly entangled are separated by the irradiation of shock waves, and the alcohol is adsorbed onto the separated sites, entangling the aggregates via the alcohol. As a result, a first suspension is formed in which the collection of aggregates entangled via the alcohol is dispersed in the low-viscosity alcohol.
That is, an alcohol having a viscosity of 3-5 mPa·sec at 20° C. was used as the first alcohol for the following three reasons.
First, metal compounds do not disperse or dissolve in alcohols with 5 or more carbon atoms. That is, metal compounds disperse at a rate of nearly 10% by weight in methanol with one carbon atom, and the metal compounds disperse in a molecular state in methanol. On the other hand, as the number of carbon atoms and molecular weight increase, the dispersibility of metal compounds in alcohol decreases, and metal compounds do not disperse or dissolve in alcohols with 5 or more carbon atoms. Therefore, the first suspension is formed using an alcohol with 5 or more carbon atoms. Furthermore, because the boiling point of the second alcohol is 15°C or more higher than that of the first alcohol, the number of carbon atoms in the second alcohol is equal to or greater than the number of carbon atoms in the first alcohol. Therefore, like the first alcohol, metal compounds do not disperse or dissolve in the second alcohol. Therefore, even when the first suspension is mixed with the second suspension, the size of the nano-sized crystals of the metal compound remains unchanged, and a collection of these nano-sized crystals forms a third suspension mixed with the two alcohols. Some of these alcohols with 5 or more carbon atoms have a viscosity of 3-5 mPa·sec at 20°C.
Second, alcohols with relatively high viscosities have higher boiling points than alcohols with relatively low viscosities. That is, the boiling point of an alcohol with a viscosity of 6 mPa·s at 20°C is higher than the boiling point of an alcohol with a viscosity of 5 mPa·s at 20°C. On the other hand, the boiling point of the second alcohol is 15°C or more higher than the boiling point of the first alcohol and lower than the temperature at which thermal decomposition of the metal compound begins. Therefore, if the first alcohol has a viscosity of more than 5 mPa·s at 20°C, the boiling point of the first alcohol increases, and the boiling point of the second alcohol, which is 15°C or more higher than the first alcohol, exceeds the thermal decomposition temperature of some metal compounds, narrowing the range of metal compounds that can be selected to precipitate metals by thermal decomposition.
Third, when a homogenizer is operated in alcohol having a viscosity of 3-5 mPa·sec at 20°C, the sites where aggregates are directly entangled with each other are released in a short time, and alcohol having the viscosity is adsorbed to the sites, causing the aggregates to entangle with each other via the alcohol, thereby producing a first suspension.
In other words, when a homogenizer device is operated in alcohol, fine shock waves are generated in the alcohol, and these shock waves move through the alcohol while exciting the alcohol molecules. On the other hand, the lower the viscosity of the alcohol, the less likely the alcohol molecules are excited by the shock waves, and the less likely the energy of the shock waves is lost. Because the viscosity of alcohol is low at 3-5 mPa·sec, the energy of the shock waves is less likely to be lost, and fine shock waves are repeatedly irradiated onto the collection of agglomerates, which are coagulated masses. As a result, fine shock waves are repeatedly irradiated onto the areas where aggregates are directly entangled with each other, and because the aggregates are extremely lightweight substances with sizes of 100-500 nm, the directly entangled areas are released, and because the collection of agglomerates is immersed in the low-viscosity alcohol, the low-viscosity alcohol is adsorbed onto the areas of the aggregates where the entanglement has been released. As a result, the collection of aggregates entangled via the alcohol is dispersed in the alcohol. As a result, the aggregates become entangled with each other via the low-viscosity alcohol, and a first suspension is created in which a collection of entangled aggregates is dispersed in the low-viscosity alcohol.
When an ultrasonic homogenizer is used as the homogenizer, a huge number of bubbles smaller than the size of the aggregates are simultaneously generated, and then the bubbles disappear almost simultaneously. This generation and disappearance of bubbles occurs repeatedly according to the ultrasonic generation cycle, and the generation and disappearance of bubbles is repeated in low-viscosity alcohol (this phenomenon is called cavitation). The shock waves generated when the bubbles burst are continuously generated in the low-viscosity alcohol, and the shock waves are hardly absorbed and are continuously irradiated even to the fine details of the agglomerates, causing the areas where aggregates are directly entangled to separate in a short period of time, and alcohol is adsorbed to the separated areas. Therefore, the ultrasonic homogenizer repeatedly generates and disappears bubbles according to the ultrasonic generation cycle, thereby separating the areas where aggregates are directly entangled in a short period of time.
The aggregates have an irregular, complex structure in which carbon particles are strung together, and the size and structure of each aggregate are different. Therefore, even if the shock waves emitted by the homogenizer device are repeatedly irradiated onto the agglomerates, all of the sites where the aggregates in the aggregate collection are directly entangled are separated, resulting in the collection of aggregates being separated into individual aggregates, and the separated aggregates cannot be dispersed in alcohol. Therefore, the separation of entangled aggregates using the homogenizer device is a process in which alcohol is adsorbed onto the sites where the aggregates are directly entangled. This process allows the collection of aggregates in which the aggregates are entangled via alcohol to be easily dispersed in alcohol. The aggregates are collections of carbon particles with sizes of 10-100 nm, which are bonded together in an irregular, complex, string-like structure, with the size of the aggregates being 100-500 nm. Therefore, in collections of aggregates in which aggregates are entangled with each other via alcohol, the entangled aggregates are not bonded to each other, but are dispersed in the alcohol.
Incidentally, the following alcohols exist as alcohols with a viscosity of 3-5 mPa·s at 20°C: 1-pentanol, which has a viscosity of 3.3 mPa·s at 20°C and a boiling point of 138°C, and other structural isomers of pentyl alcohol, which has five carbon atoms. These include 2-pentanol, which has a viscosity of 4.1 mPa·s at 20°C and a boiling point of 119°C; 2-methyl-2-butanol (also known as t-amyl alcohol), which has a viscosity of 3.5 mPa·s at 20°C and a boiling point of 102°C; 3-methyl-1-butanol (also known as isoamyl alcohol), which has a viscosity of 3.7 mPa·s at 20°C and a boiling point of 131°C; 2-methyl-1-butanol, which has a viscosity of 5.1 mPa·s at 20°C and a boiling point of 128°C; and 3-methyl-2-butanol, which has a viscosity of 3.4 mPa·s at 20°C and a boiling point of 113°C.
The first suspension is prepared by running a homogenizer on a mixture of the first alcohol and the carbon black aggregate. The first alcohol is a general-purpose organic solvent, and the carbon black is a general-purpose industrial material. Therefore, the first suspension can be prepared inexpensively.
As described above, an alcohol having a viscosity of 3-5 mPa·sec at 20°C is used as the first alcohol described in paragraph 6, and the alcohol and carbon black aggregates having a weight less than that of the alcohol are filled into a container. Thereafter, a homogenizer is operated in the alcohol, and shock waves are repeatedly applied to the carbon black aggregates via the alcohol, causing the aggregates to entangle with each other via the alcohol, and a first suspension is created in which the entangled aggregate aggregates are dispersed in the alcohol.

The method of making the first suspension described in paragraph 8, comprising:
The method for preparing the first suspension described in paragraph 8, wherein the carbon black described in paragraph 8 is Ketjen black, and the first suspension is prepared according to the method for preparing the first suspension described in paragraph 8, using the Ketjen black as the carbon black described in paragraph 8.

In other words, the characteristics of carbon black vary greatly depending on the manufacturing method, and carbon black is classified by the name of the manufacturing method. The properties of carbon black vary depending on this manufacturing method.
Furnace black is carbon black produced by incomplete combustion of oil or gas in high-temperature gas, and is subdivided into oil furnaces and gas furnaces depending on the raw material used. Among furnace blacks, Ketjenblack uses hydrocarbon oil as the raw material, and produces carbon black through incomplete combustion of the oil.
Other types of carbon black include channel black, which is made by burning natural gas and scraping off the deposits that form on channel steel; acetylene black, which is obtained by thermally decomposing acetylene gas; and thermal black, which is produced by repeatedly burning and decomposing gas in a heat-storing furnace.
Acetylene black is produced using acetylene gas, which has the highest purity among the raw materials for carbon black, so it has the fewest impurities of all carbon blacks and has the most developed structure and primary particles.
In contrast, Ketjenblack has the smallest primary particles of all carbon blacks, the largest number of primary particles per unit mass, and the largest BET surface area (an index that represents the size of the specific surface area due to the adsorption of gas molecules), and therefore has the best light-blocking properties of all carbon blacks. For this reason, a sheet or film made of Ketjenblack aggregates using Ketjenblack as the carbon black acts as a sheet or film with excellent UV degradation prevention. Furthermore, Ketjenblack has a thermal emissivity of 0.97, the highest thermal emissivity of any carbon black, and therefore a sheet or film made of Ketjenblack aggregates acts as an excellent heat-dissipating sheet or film.
That is, Ketjen black has a primary particle diameter of 34 nm, the number of primary particles per unit mass is 1 x ¹⁰⁷ particles/g, a BET surface area of 1270 ^m2 /g, and a porosity of 78%. In contrast, acetylene black has a primary particle diameter of 40 nm, a small BET surface area of 76 ^m2 /g, and a low porosity of 22%. Therefore, a sheet or film made of aggregates of Ketjen black has better light-blocking properties than a sheet or film made of aggregates of other carbon blacks.
Therefore, if Ketjen black is used as the carbon black described in paragraph 8, a first suspension is prepared according to the method described in paragraph 8, and the first suspension is then used as the first suspension described in paragraph 6 to prepare the raw material described in paragraph 6, and a sheet or film is formed using the raw material, a sheet or film is formed that has better light-blocking properties and higher thermal emissivity than sheets or films made of other aggregates of carbon black.

The method of making the second suspension described in paragraph 6 comprises:
A metal compound having a first property of dispersing in a molecular state in methanol but not dissolving in methanol, and a second property of precipitating a metal by thermal decomposition, is dispersed in methanol to prepare a methanol dispersion of the metal compound, and the methanol is evaporated from the methanol dispersion of the metal compound to precipitate a cluster of fine crystals of the metal compound. The cluster of fine crystals of the metal compound is then filled into a container, and a plate covering the entire surface of the cluster of fine crystals of the metal compound is placed on top of the cluster of fine crystals of the metal compound. A compressive load equivalent to 1-10 kg weight is applied to the entire surface of the plate, depending on the size of the container, to crush the cluster of fine crystals of the metal compound. An impact acceleration of 0.2-0.5 G is then repeatedly applied to the sides and bottom of the container in three directions, front-to-back, left-to-right, and up-to-down, depending on the size of the container, causing the crushed cluster of fine crystals of the metal compound to move within the container so as to fill voids, and the cluster of fine crystals is rearranged within the container. The entire surface of the plate is then crushed. the plate is then removed from the container, and the second alcohol described in paragraph 6 is filled into the container in a weight greater than the weight of the collection of fine crystals of the metal compound, and the collection of fine crystals of the metal compound with the second alcohol is stirred to create a second suspension in the container, wherein the collection of fine crystals of the metal compound with the second alcohol is mixed with the second alcohol.

By carrying out the following four extremely simple steps in succession, a second suspension containing a collection of nano-sized microcrystals of a metal compound mixed in a second alcohol is created in a container.
First, a metal compound that precipitates metals upon thermal decomposition is dispersed in methanol, and the metal compound becomes a molecular state and disperses in the methanol. When the metal compound dissolves in methanol, the metals that make up the metal compound become metal ions and are eluted into the methanol, and the dissolved metal compound cannot return to the metal compound before dissolution. Therefore, when the methanol is evaporated from the methanol solution, crystals of the metal compound before dissolution do not precipitate. Therefore, a metal compound that does not dissolve in methanol and disperses is used.
Second, methanol is evaporated from the methanol dispersion of the metal compound to precipitate a collection of fine crystals of the metal compound smaller than 100 nm. In other words, in the methanol dispersion of the metal compound, the metal compound is in a molecular state and uniformly dispersed in the methanol. Therefore, when the methanol is evaporated, the metal compound before dispersion precipitates as granular fine crystals smaller than 100 nm. These fine crystals are a collection of crystals formed by the accumulation of crystals formed by single molecules of the metal compound, since the metal compound dispersed in the methanol in a molecular state precipitates as fine crystals. Therefore, when stress is applied to the fine crystals, they easily break down and become even finer. However, the finer the crystals, the more difficult it is to apply stress to them, and there is a limit to how fine the crystals can be. The evaporated methanol is recovered in a recovery machine and reused.
Third, the microcrystals of the metal compound precipitated in the second process are crushed into nano-sized microcrystals. To this end, a container is filled with a collection of granular microcrystals created in the second process, a plate is placed over the entire collection of granular metal compound microcrystals in the container, and a compressive load is applied to the entire collection of microcrystals via the plate. At this time, the larger the microcrystals, the more easily they are crushed. Therefore, the larger the microcrystals, the more easily they are crushed, and the crushing of the microcrystals progresses while the compressive load is applied. Meanwhile, voids are formed by the crushing of the microcrystals, and the microcrystals move to fill the voids while the compressive load is applied. Furthermore, to crush the microcrystals into a collection of uniformly sized microcrystals, the applied compressive load is temporarily stopped, and then impact acceleration is repeatedly applied to the sides and bottom of the container in three directions: front-to-back, left-to-right, and up-to-down. As a result, the collection of fine crystals is restrained within the container by the plate material and does not scatter, but moves within the container to fill the voids, and the collection of fine crystals is rearranged. When the collection of fine crystals is rearranged, the voids are filled with fine crystals. After this, the collection of fine crystals is further crushed, and the finer crystals are further refined into uniformly sized fine crystals. For this purpose, the compressive load is again applied to the collection of fine crystals via the plate material. At this time, the finer crystal collection is further crushed into fine crystals of uniform size. After this, the impact acceleration is again repeatedly applied to the container in three directions, and the rearrangement of the finer crystal collection is further promoted. This pair of processes consisting of the process of applying a compressive load and the process of repeatedly applying impact acceleration in three directions is repeated, and the crystals are further refined into a collection of uniformly sized fine crystals. On the other hand, the finer the crystals, the more difficult it becomes to apply stress to the crystals even when a compressive load is applied, and there is a limit to the degree to which the crystals can be refined. When the crystal size reaches its limit, applying a compressive load to the plate material does not crush the crystals, and the plate material stops moving even when a compressive load is applied to the plate material. At this point, the pair of processes is stopped. As a result, the fine crystals are reduced to 18-22 nm, which is nearly one-fifth the size at the time of precipitation. The compressive load applied to the plate material is equivalent to 1-10 kg weight, depending on the size of the container. The impact acceleration applied to the container is 0.2-0.5 G, depending on the size of the container.
Fourth, a second alcohol is filled into the container in a weight greater than the weight of the nano-sized cluster of microcrystals of the metal compound in the container, and when the second alcohol is stirred, a second suspension in which the nano-sized cluster of microcrystals is mixed with the alcohol is produced in the container. Note that the weight of the viscous alcohol added is greater than the weight of the cluster of microcrystals, thereby improving the mixing of the microcrystals in the suspension.
As explained above, the suspension is prepared by successively carrying out the four extremely simple steps described above. Furthermore, the metal compound and alcohol are common industrial chemicals. Therefore, the suspension can be prepared inexpensively at low cost.
On the other hand, the boiling point of the second alcohol is at least 15°C higher than the boiling point of the first alcohol, and lower than the temperature at which the thermal decomposition of the metal compound that precipitates the metal by thermal decomposition begins, as described in paragraph 6. This boiling point property provides the second suspension with the following four effects:
First, metal compounds that precipitate metals upon thermal decomposition do not disperse or dissolve in second alcohols, just as they do in first alcohols. That is, the first alcohols are 1-pentanol, which has five carbon atoms, and other structural isomers of pentyl alcohol, which also has five carbon atoms. The second alcohols, which have boiling points 15°C or more higher than that of the first alcohol, have five or more carbon atoms. Therefore, metal compounds do not disperse or dissolve in second alcohols, which have five or more carbon atoms. For this reason, when a collection of nano-sized microcrystals of a metal compound is mixed with the second alcohol and the second alcohol is further stirred, a second suspension is created in which the collection of nano-sized microcrystals of the metal compound is mixed in the second alcohol in the form of nano-sized microcrystals.
Second, as described in paragraph 7, when a mixture of the first suspension and the second suspension is filled into the chamber of a vacuum impregnation apparatus and the pressure in the chamber is reduced to a minimum pressure of 1/5 of the saturated vapor pressure of the first alcohol at the temperature in the chamber, 4/5 or less of the first alcohol and a portion of the second alcohol evaporate, reducing the amounts of both alcohols constituting the third suspension, and the third suspension becomes a fourth suspension. Meanwhile, because the boiling point of the second alcohol is 15°C or more higher than that of the first alcohol, the amount of the second alcohol that evaporates is less than half the amount of the first alcohol that evaporates. Therefore, the properties of the fourth suspension remain dominated by the properties of the remaining two alcohols. As the two alcohols evaporate, the fourth suspension migrates into the gaps between the entangled aggregates, and the fourth suspension fills the gaps between the aggregates, replacing the third suspension. The fourth suspension is adsorbed onto the surface of the aggregates, which are entangled with each other, and as a result, a mixture of the aggregates and the fourth suspension is formed in the chamber, and the mixture can be used as a raw material for forming a sheet or film made of the aggregates of carbon black.
Third, the viscosity of the second alcohol, which has a boiling point 15°C or more higher than that of the first alcohol, is higher than that of the first alcohol. Meanwhile, the amount of vaporization of the second alcohol is less than half the amount of vaporization of the first alcohol. Therefore, the viscosity of the alcohol constituting the fourth suspension is higher than that of the alcohol constituting the third suspension. As a result, nano-level fine crystals of the metal compound are adsorbed to each other based on the viscosity of the alcohol constituting the fourth suspension, and the clusters of adsorbed fine crystals move into the gaps between the entangled aggregates. Furthermore, the fourth suspension is adsorbed to the surface of the clusters of aggregates based on the viscosity of the alcohol. Because the viscosity of the alcohol constituting the fourth suspension is higher than that of the alcohol constituting the third suspension, the mixture formed in the chamber of the vacuum impregnation device, consisting of the fourth suspension and the clusters of aggregates, can be handled, and the mixture can be filled into an extruder. Furthermore, the mixture extruded into a T-die spreads into the shape of a sheet or film in the T-die. Therefore, the mixture can be used as a raw material for forming a sheet or film.
Fourth, because the boiling point of the second alcohol is lower than the temperature at which thermal decomposition of the metal compound begins, when the temperature of the fourth suspension is raised and reaches the boiling point of the second alcohol, the second alcohol vaporizes, and clusters of fine crystals of the metal compound having a size of 18-22 nm are deposited in layers. Furthermore, when the temperature at which the metal compound begins to thermally decompose is reached, the fine crystals having a size of 18-22 nm decompose into inorganic or organic molecules and metal molecules, and the inorganic or organic molecules absorb the heat of vaporization and vaporize. When vaporization is complete, the clusters of metal molecules form metal nanoparticles having a size of approximately 10 nm, and the clusters of metal nanoparticles precipitate simultaneously, forming a cluster of metal nanoparticles. Since the metal nanoparticles do not contain impurities and are deposited in an active state, adjacent metal nanoparticles are metallically bonded at the contact points, and the clusters of metal-bonded metal nanoparticles are laminated. As a result, the gaps between the entangled aggregates are filled by clusters of metal-bonded metal nanoparticles. Furthermore, the surface of the aggregates, in which the aggregates are entangled, is covered by a layer of metal-bonded metal nanoparticles. As a result, the metal-bonded metal nanoparticles form a path in the sheet or film through which electrons continuously move. Therefore, the sheet or film has metal-like electrical conductivity, thermal conductivity, electromagnetic wave shielding properties, and antistatic properties. Furthermore, the metal-bonded metal nanoparticles not only bond the entanglements between the aggregates but also bond all of the entangled aggregates together, thereby providing the sheet or film with tensile strength, compressive strength, and shear strength.
As described above, the second alcohol exhibits four excellent properties, and forms a second suspension in which nano-sized fine crystals of a metal compound that precipitates a metal upon thermal decomposition are mixed in the second alcohol.
Incidentally, the following alcohols exist as second alcohols: The boiling points of the first alcohols, as described in paragraph 11, are in the range of 102-138°C.
There is a structural isomer of pentyl alcohol with five carbon atoms. Of the eight structural isomers of pentyl alcohol, the following structural isomer of pentyl alcohol can be used as the second alcohol. 3 _- Pentanol has the rational formula _CH3CH2CH (OH) _CH2CH3 , a boiling point of ₁₁₅ °C, and a viscosity of 6.5 mPa·s at 20°C. 2-Methyl-1-butanol has the rational formula _CH3CH2CH ( _CH3 ) _CH2OH , a boiling point of 128°C, and a viscosity _of 5.1 mPa·s at 20°C.
Furthermore, 1-hexanol, which has six carbon atoms, has the rational formula _CH3 ( _CH2 ) _5OH , a boiling point of 157°C, and a viscosity of 5.2 mPa·s at 20°C. 1-heptanol, which has seven carbon atoms, has the rational formula _CH3 ( _CH2 ) _6OH , a boiling point of 176°C, and a viscosity of _{7.4 mPa·s at 20°C. Furthermore, 4-methyl-2-pentanol, which has six carbon atoms, has the rational formula (CH3)2CHCH2CH ( OH} ) _CH3 , a boiling point of 132°C, and a viscosity of 5.2 mPa·s at 20°C.
Therefore, when 2-methyl-1-butanol having a boiling point of 128° C. is used as the second alcohol, any one of 2-methyl-2-butanol having a boiling point of 102° C. and 3-methyl-2-butanol having a boiling point of 113° C. can be used as the first alcohol. Furthermore, when 4-methyl-2-pentanol having a boiling point of 132° C. is used as the second alcohol, any one of 2-methyl-2-butanol having a boiling point of 102° C. and 3-methyl-2-butanol having a boiling point of 113° C. can be used as the first alcohol. Furthermore, when 1-hexanol having a boiling point of 157° C. is used as the second alcohol, any one of 2-methyl-2-butanol having a boiling point of 102° C., 3-methyl-2-butanol having a boiling point of 113° C., 2-pentanol having a boiling point of 119° C., 3-methyl-1-butanol having a boiling point of 131° C., and 1-pentanol having a boiling point of 138° C. can be used as the first alcohol. Furthermore , when 1-heptanol having a boiling point of 176° C. and a viscosity of 7.4 mPa sec is used as the second alcohol, any one of six alcohols can be used as the first alcohol, including 2-methyl-1-butanol having a boiling point of 128° C. and a viscosity of 5.1 mPa sec, in addition to the five alcohols.
Here, we consider two types of alcohols, the difference between the boiling points of the second alcohol and the first alcohol being 19°C. For the fourth suspension to maintain its predominantly alcoholic properties, the pressure in the chamber must be reduced to a minimum pressure of 1/5 of the saturated vapor pressure of the first alcohol at the temperature in the chamber. This is explained using the amount of vaporized alcohol. In other words, if the fourth suspension maintains its predominantly alcoholic properties even after reduced pressure treatment in the chamber, the fourth suspension will move as the two alcohols evaporate, filling the gaps between the entangled aggregates in place of the third suspension, forming a raw material in the chamber for use in forming a sheet or film. Furthermore, if the raw material formed in the chamber has a higher viscosity than the first alcohol, the raw material can be filled into an extruder. Furthermore, the raw material extruded into a T-die will expand into the shape of a sheet or film in the T-die. The two alcohols discussed here are 1-hexanol, a second alcohol with a boiling point of 157°C and a saturated vapor pressure of 0.124 kPa at 25°C, and 1-pentanol, a first alcohol with a boiling point of 138°C and a saturated vapor pressure of 0.293 kPa at 25°C.
First, the chamber, which is at 25°C, is reduced in pressure to one-third of the saturated vapor pressure of the first alcohol. When the pressure in the chamber is reduced to 0.098 kPa, which corresponds to one-third of the saturated vapor pressure of 1-pentanol at 25°C (0.293 kPa), 67% of the 1-pentanol evaporates. In contrast, 21% of the 1-hexanol evaporates. As a result, 33% of the 1-pentanol and 79% of the 1-hexanol remain. Therefore, the total amount of remaining alcohol is greater than half of the total amount of alcohol in the third suspension. Therefore, the properties of the remaining alcohol dominate in the fourth suspension. On the other hand, because the remaining proportion of 1-hexanol is high in the fourth suspension, the viscosity of 1-hexanol is reflected, resulting in a viscosity of 4.6 mPa·s at 20°C. This viscosity is 1.4 times that of 1-pentanol. The viscosity of 1-hexanol at 20°C is 5.2 mPa·s, and the viscosity of 1-pentanol at 20°C is 3.3 mPa·s. Therefore, even when the pressure inside the chamber is reduced to 0.098 kPa, the alcohol properties of the fourth suspension are dominant. Therefore, as the two types of alcohol evaporate, the fourth suspension moves into the gaps between the aggregates that are entangled with each other. Furthermore, since the fourth suspension has a viscosity close to that of 1-hexanol, the raw material formed in the chamber can be filled into an extruder, and the raw material extruded into the T-die spreads into the shape of a sheet or film in the T-die.
Next, the pressure inside the chamber, which is at 25°C, is reduced to one-quarter of the saturated vapor pressure of the first alcohol at 25°C. When the pressure inside the chamber is reduced to one-quarter of the saturated vapor pressure of 0.293 kPa, which is the saturated vapor pressure of 1-pentanol, 75% of the 1-pentanol vaporizes. On the other hand, when the pressure inside the chamber is reduced to 0.073 kPa, 41% of the 1-hexanol vaporizes. As a result, 25% of the 1-pentanol remains, and 59% of the 1-hexanol remains. Therefore, the total amount of remaining alcohol is greater than one-half of the total amount of alcohol in the third suspension. Therefore, the properties of the remaining alcohol dominate in the fourth suspension. Furthermore, because the fourth suspension has a high remaining proportion of 1-hexanol, the viscosity of 1-hexanol is reflected, and the fourth suspension has a viscosity of 4.6 mPa·s at 20°C. Therefore, even if the pressure inside the chamber is reduced to ¼ of the saturated vapor pressure of the first alcohol at the temperature inside the chamber, the properties of the alcohol are dominant in the fourth suspension. Therefore, as the two types of alcohol evaporate, the fourth suspension moves into the gaps between the aggregates that are entangled with each other. Furthermore, because the fourth suspension has a viscosity similar to that of 1-hexanol, the raw material formed inside the chamber can be filled into an extruder, and the raw material extruded into the T-die spreads into the shape of a sheet or film in the T-die.
Furthermore, the pressure inside the chamber, which is at 25°C, is reduced to 1/5 of the saturated vapor pressure of the first alcohol at 25°C. When the pressure inside the chamber is reduced to 1/5 of the saturated vapor pressure of 0.293 kPa, which is the saturated vapor pressure of 1-pentanol at 25°C, 80% of the 1-pentanol vaporizes. On the other hand, when the pressure inside the chamber is reduced to 0.059 kPa, 52% of the 1-hexanol vaporizes. As a result, 20% of the 1-pentanol remains, and 48% of the 1-hexanol remains. Therefore, the total amount of remaining alcohol is greater than 1/2 of the total amount of alcohol in the third suspension. Therefore, the properties of the remaining alcohol dominate in the fourth suspension. Furthermore, the viscosity of the fourth suspension reflects the viscosity of the 1-hexanol, which has a high remaining proportion, and has a viscosity of 4.7 mPa·s at 20°C.
When the difference in boiling points between the two alcohols was 19°C and the pressure was reduced to 1/5 of the saturated vapor pressure of the first alcohol, 68% of the alcohol remained. On the other hand, even when the difference in boiling points between the two alcohols was reduced by 4°C to 15°C, the vapor pressures of the two alcohols only became slightly closer, so the total amount of remaining alcohol exceeded 50% of the total amount of alcohol in the third suspension, and the properties of the remaining alcohol became dominant in the fourth suspension.
Furthermore, the pressure inside the chamber, which is at 25°C, is reduced to 1/10 of the saturated vapor pressure of the first alcohol at 25°C. When the pressure inside the chamber is reduced to 1/10 of the saturated vapor pressure of 0.293 kPa of 1-pentanol at 25°C, 90% of the 1-pentanol vaporizes. On the other hand, when the pressure inside the chamber is reduced to 0.029 kPa, 77% of the 1-hexanol vaporizes. As a result, 10% of the 1-pentanol remains, and 23% of the 1-hexanol remains. Therefore, the total amount of remaining alcohol is less than 1/2 of the total amount of alcohol in the third suspension. Therefore, in the fourth suspension, the properties of the remaining alcohol become inferior, and the properties of the fine crystals of the solid metal compound become dominant.
From the above results, it is possible to reduce the pressure in the chamber to 1/5 of the saturated vapor pressure of the first alcohol at the temperature in the chamber as the minimum pressure. In the chamber, the fourth suspension has predominantly alcoholic properties, and when the two types of alcohol evaporate, the fourth suspension moves into the gaps between the entangled aggregates. This causes the fourth suspension to enter the gaps between the aggregates, replacing the third suspension. Furthermore, the fourth suspension is adsorbed onto the surface of the entangled aggregates. As a result, a mixture of the aggregates and the fourth suspension is formed in the chamber, and this mixture can be used as a raw material for forming a sheet or film composed of the aggregates of carbon black.

The method of making the second suspension described in paragraph 12 comprises:
The metal compound described in paragraph 12 is an inorganic metal compound consisting of an inorganic salt having a metal complex ion in which an inorganic molecule or an inorganic ion is coordinately bonded to a metal ion, and the inorganic metal compound is used as the metal compound described in paragraph 12, and a method for preparing the second suspension described in paragraph 12 is performed in accordance with the method for preparing the second suspension described in paragraph 12.

In other words, when an inorganic metal compound consisting of an inorganic salt in which inorganic molecules or inorganic ions act as ligands and have metal complex ions coordinated to metal ions is heat-treated in a reducing atmosphere, the coordinate bonds are first broken and the compound decomposes into the inorganic substance and the metal. As the temperature is further increased, the inorganic substance absorbs the heat of vaporization and vaporizes, and the vaporization of the inorganic substance is completed in the temperature range of 180-220°C, resulting in the deposition of the metal.
That is, among the ions constituting the inorganic metal compound, the metal ion located at the center of the molecule is the largest, and the distance between the metal ion and the ligand is the longest. When this inorganic metal compound is heat-treated in a reducing atmosphere, the coordinate bond between the metal ion and the ligand is first broken, resulting in decomposition into the metal and the inorganic substance. As the temperature rises further, the inorganic substance absorbs the heat of vaporization and vaporizes. Once the inorganic substance has completely vaporized, the metal precipitates, completing the thermal decomposition. The temperature at which the metal precipitates is the lowest among the temperatures at which metal precipitates during the thermal decomposition of metal compounds. Furthermore, inorganic metal compounds composed of inorganic salts containing metal complex ions disperse in methanol at nearly 10% by weight and are insoluble in methanol. Therefore, inorganic metal compounds composed of inorganic salts containing metal complex ions can be used as the metal compounds that precipitate metals upon thermal decomposition described in paragraph 12.
On the other hand, metal complex ions in which inorganic molecules or inorganic ions act as ligands and are coordinated to metal ions are easier to synthesize than other metal complex ions. Examples of such metal complex ions include ammine metal complex ions in which ammonia (NH3 ₎ acts as a ligand and is coordinated to a metal ion; aqua metal complex ions in which water ( _H2O ) acts as a ligand and is coordinated to a metal ion; hydroxo metal complex ions in which a hydroxyl group (OH- ⁾ acts as a ligand and is coordinated to a metal ion; and chloro metal complex ions in which chloride ions (Cl- ⁾ or chloride ions (Cl- ⁾ and ammonia (NH3 ₎ act as ligands and are coordinated to a metal ion. Furthermore, inorganic metal compounds containing such metal complex ions and inorganic salts such as chlorides, sulfates, and nitrates are easy to synthesize. Because the molecular weight of the inorganic salt is small, the inorganic compounds are vaporized and the metal precipitates in a temperature range of 180-220°C. This temperature at which the metal precipitates is the lowest temperature at which metals precipitate through thermal decomposition of metal compounds. These inorganic metal compounds are common industrial chemicals.
As explained above, when an inorganic metal compound consisting of an inorganic salt having a metal complex ion in which an inorganic molecule or an inorganic ion is coordinately bonded to a metal ion is used as the metal compound described in paragraph 12 and a second suspension is prepared according to the method described in paragraph 12, the second suspension described in paragraph 6 is prepared.

The method of making the second suspension described in paragraph 12 comprises:
The metal compound described in paragraph 12 is an octylate metal compound, and the method for preparing the second suspension described in paragraph 12 is performed by using the octylate metal compound as the metal compound described in paragraph 12 and following the method for preparing the second suspension described in paragraph 12.

In other words, in a metal octylate compound in which the oxygen ion constituting the carboxyl group of octylic acid is covalently bonded to a metal ion, the metal ion is the largest ion, and the distance between the oxygen ion constituting the carboxyl group and the metal ion is longer than the distance between other ions. When a metal octylate compound with this molecular structure is heat-treated in an air atmosphere, the bond between the oxygen ion constituting the carboxyl group and the metal ion is first broken when the temperature exceeds the boiling point of octylic acid, resulting in separation into octylic acid and the metal. Because octylic acid is composed of saturated fatty acids and does not have an unsaturated structure in which carbon atoms are in excess of hydrogen atoms, octylic acid absorbs the heat of vaporization and vaporizes, and the metal precipitates upon completion of vaporization. Furthermore, metal octylate compounds disperse in methanol up to approximately 10 wt % and are insoluble in methanol. Therefore, metal octylate compounds can be used as metal compounds that precipitate metals by thermal decomposition as described in paragraph 12.
Metal octylate compounds are organometallic compounds belonging to the carboxylic acid metal compounds, which have both a first characteristic that the oxygen ions constituting the carboxyl group of the carboxylic acid are covalently bonded to the metal ion and a second characteristic that the carboxylic acid is a saturated fatty acid. Octylate compounds have a branched structure, a short linear chain, and the boiling point of octylate is the lowest at 228°C. Therefore, thermal decomposition is completed at 290°C in the air, resulting in the deposition of metal. Other carboxylic acid metal compounds that combine these two characteristics include metal laurate compounds and metal stearates, in addition to metal octylate compounds. Because both lauric acid and stearic acid have linear structures, the boiling points of lauric acid and stearic acid are 296°C and 376°C, respectively, which are higher than the boiling point of octylate. Therefore, the temperature at which thermal decomposition is completed and metal is deposited is higher than that of metal octylate compounds. Therefore, metal octylate compounds deposit metal at the lowest thermal decomposition temperature among organometallic compounds.
_That is, octylic acid is a branched saturated fatty acid with the rational formula _CH3 ( _CH2 ) _3CH ( _C2H5 )COOH, branched at CH to form alkanes _CH3 ( _CH2 ) ₃ and _C2H5 , with a carboxyl group COOH bonded to CH. Branched saturated fatty acids have shorter chain lengths than straight-chain saturated fatty acids and a lower boiling point _of 228°C. In contrast, lauric acid and stearic acid are straight-chain saturated fatty acids with higher boiling points than branched saturated fatty acids.
Octylic acid and caprylic acid (also known as _octanoic acid) have the same molecular formula, _C8H16O2 , but are _isomers with different molecular structures. As mentioned above, octylic acid is a fatty acid with a branched structure. On the other hand, caprylic acid is a fatty acid with a linear structure and the rational formula is _CH3 ( _CH2 ) _6COOH . Therefore, although metal octylic acid compounds and metal caprylic acid compounds have the same molecular formula, their molecular structures are different. In other words, in metal caprylic acid compounds, a metal ion is coordinated to a carboxylate anion, which is an anion generated by the ionization of caprylic acid. Therefore, metal caprylic acid compounds precipitate metal oxides upon thermal decomposition in an atmospheric environment. In other words, in metal caprylic acid compounds, the carboxylate ion approaches and coordinates with the metal ion, which is the largest ion, thereby shortening the distance between the metal ion and the oxygen ion that constitutes the carboxylate ion. This results in the longest distance between the oxygen ion and the ion covalently bonded on the opposite side of the metal ion. When the temperature of a metal caprylic acid compound with this molecular structure exceeds the boiling point of caprylic acid, the bond between the oxygen ion and the ion covalently bonded on the opposite side of the metal ion is severed, and the compound decomposes into caprylic acid and the metal oxide, which is a compound of the metal ion and the oxygen ion. If the temperature is further increased, the caprylic acid absorbs the heat of vaporization and vaporizes, and immediately after the vaporization is complete, the metal oxide precipitates.
Furthermore, metal octylate compounds are inexpensive industrial chemicals that can be easily synthesized. That is, when octylic acid, the most commonly used organic acid, is reacted with a strong alkali, an alkali metal octylate compound is produced, and when an alkali metal octylate compound is reacted with an inorganic metal compound, metal octylate compounds composed of various metals are synthesized. Therefore, metal octylate compounds are the least expensive organometallic compounds. For this reason, although the heat treatment temperature is higher than that of the inorganic metal compounds described in paragraphs 14-15, they are less expensive organometallic compounds than inorganic metal compounds.
As described above, when a metal octylate compound is used as the metal compound described in paragraph 12 and a second suspension is prepared according to the method described in paragraph 12, the second suspension described in paragraph 6 is prepared.

A method for continuously forming a sheet or film made of a collection of carbon black aggregates that has gas barrier properties, metallic luster, and electrical and thermal conductivity equivalent to those of a metal, using the raw material used in forming the sheet or film described in paragraph 6, is as follows:
A first suspension is prepared according to the method described in paragraph 8, the first suspension is used as the first suspension described in paragraph 6, a second suspension is prepared according to the method described in paragraph 12, the second suspension is used as the second suspension described in paragraph 6, a raw material to be used in forming a sheet or film made of a collection of carbon black aggregates is prepared according to the method described in paragraph 6, the raw material is continuously charged into an extruder, and further, the screw of the extruder is continuously moved, the raw material charged in the extruder is continuously extruded from the extruder into a T-die, and a sheet or film to be formed is continuously extruded. The raw material is continuously extruded in the form of a sheet or film by the pressure from the extruder from the lip of the T-die having a width of 18-22 nm and a gap corresponding to the thickness of the sheet or film to be produced, and the extruded sheet or film is continuously passed through a heat treatment furnace heated to a temperature at which the metal compound constituting the raw material completes its thermal decomposition. During this process, the fine crystals having a size of 18-22 nm described in paragraph 12 decompose into inorganic molecules or organic molecules and metal molecules, and the inorganic molecules or organic molecules absorb the heat of vaporization and vaporize. When the vaporization is complete, the clusters of metal molecules form metal nanoparticles with a size of about 10 nm, and the clusters of metal nanoparticles precipitate all at once. Since the metal nanoparticles do not contain impurities and precipitate in an active state, adjacent metal nanoparticles are metallically bonded at the contact points, and the clusters of metallically bonded metal nanoparticles are stacked. As a result, the gaps between the aggregates, where the aggregates are entangled with each other, are filled with the clusters of metallically bonded metal nanoparticles, and the surfaces of the clusters of aggregates, where the aggregates are entangled with each other, are covered with the clusters of metallically bonded metal nanoparticles. a sheet or film that has passed through the heat treatment furnace is continuously wound up by a winding machine, thereby continuously forming a sheet or film that is made of an aggregate of carbon black that has been endowed with gas barrier properties, metallic luster, electrical conductivity and thermal conductivity similar to that of a metal; and a method for continuously forming a sheet or film that is made of an aggregate of carbon black that has been endowed with gas barrier properties, metallic luster, electrical conductivity and thermal conductivity similar to that of a metal, using the raw materials used in forming the sheet or film described in paragraph 6.

In other words, by carrying out the following five processes in succession, a sheet or film made of a collection of carbon black aggregates is continuously formed, which has gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to that of a metal.
First, a first suspension is prepared according to the method described in paragraph 8, and the first suspension is used as the first suspension described in paragraph 6. A second suspension is prepared according to the method described in paragraph 12, and the second suspension is used as the second suspension described in paragraph 6. The raw material prepared according to the method described in paragraph 6 is continuously charged into an extruder. Second, the extruder screw is continuously driven, and the raw material charged into the extruder is continuously extruded from the extruder into a T-die. Third, the raw material extruded into the T-die is continuously extruded as a sheet or film from the lip of the T-die by pressure from the extruder. Fourth, the sheet or film extruded from the lip of the T-die is continuously passed through a heat treatment oven. Fifth, the sheet or film that has passed through the heat treatment oven is continuously wound up by a winder. As a result, a sheet or film composed of aggregates of carbon black that is endowed with gas barrier properties, metallic luster, and metallic-like electrical and thermal conductivity is continuously formed.
Next, the phenomena occurring in the five processes and the effects brought about by the five processes will be described.
In the first process, the feedstock prepared according to the method described in paragraph 6 can be loaded into an extruder because the new suspension described in paragraph 6, i.e., the fourth suspension described in paragraphs 7, 13 and 19, is predominantly alcoholic in nature and has a higher viscosity than the first alcohol.
In the second process, the material charged in the extruder is forced through a T-die by the action of the extruder screw, and again, the new suspension described in paragraph 6, i.e., the fourth suspension described in paragraphs 7, 13 and 19, is predominantly alcoholic in nature, so the material is forced through the T-die.
In the third process, the material extruded into the T-die continues to be extruded from the lip of the T-die as a sheet or film.
In other words, a T-die is a mold shaped like a clothing hanger and consists of three sections. First, the material extruded from the extruder is extruded into an inlet section with a narrow gap and a fixed length from the extruder outlet. During this process, the material advances through the inlet section while being subjected to compressive stress from the extruder, and is then extruded into a fan-shaped area called a manifold. Next, the material extruded into the manifold is constantly subjected to compressive stress from the extruder, so it is stretched to the width of the desired sheet or film shape in the manifold and also stretched in the longitudinal direction of the sheet or film, forming the material into a shape similar to that of a sheet or film. After this, it is extruded into a region with a fixed length called a lip, which has a gap equal to the thickness of the sheet or film and the width of the sheet or film. Finally, the sheet or film extruded into the lip is extruded out of the T-die through the lip while being subjected to compressive stress. The thickness of the sheet or film is determined by the preset lip gap, and the width of the sheet or film is determined by the preset lip width.
Next, the behavior of the raw material and the sheet or film in the T-die will be described. When the raw material is extruded into the T-die, it continues to be compressed at the entrance of the T-die where the gap narrows. When compressive stress is applied to the raw material, it deforms, and the liquid alcohol seeps out to the surface of the raw material due to the deformation of the raw material. In contrast, the nano-sized microcrystal clusters of the metal compound move slightly as the alcohol seeps out to the surface of the raw material, but because they are a collection of solid particles adsorbed to each other due to the viscosity of the alcohol that constitutes the fourth suspension, they remain in the gaps between the entangled aggregates. Furthermore, the nano-sized microcrystal clusters of the metal compound adsorbed to the surface of the entangled aggregate clusters also move slightly as the alcohol seeps out to the surface of the raw material, but because they are a collection of solid particles adsorbed to each other due to the viscosity of the alcohol that constitutes the fourth suspension, they continue to adsorb to the surface of the entangled aggregate clusters. In other words, the alcohol that seeps out to the surface of the raw material is excess alcohol that constitutes the raw material, and the alcohol adsorbed to the surface of the aggregates does not move from the surface of the aggregates. The alcohol that seeps onto the surface of the raw material is expelled from the surface as the raw material continues to be compressed. Meanwhile, the aggregates that make up the raw material continue to be compressed, deforming the aggregates and causing them to become increasingly entangled. Meanwhile, the nano-sized crystallites of the metal compound are compressed in the gaps between the entangled aggregates, deforming as the aggregates deform, adsorbing to the aggregates and moving along with them. However, because they are a collection of solid particles adsorbed to each other based on the viscosity of the alcohol that makes up the fourth suspension, they remain in the gaps between the entangled aggregates. Furthermore, the nano-sized crystallites of the metal compound adsorbed on the surface of the entangled aggregates also deform as the aggregates deform, adsorbing to the aggregates and moving along with them, but continue to adsorb to the surface of the entangled aggregates. The raw material then enters the manifold. The raw material that enters the manifold is stretched to the width of the sheet or film shape, and the stretched raw material continues to be extruded. Because the volume of the manifold is larger than the volume of the inlet, the raw material entering the manifold is placed under negative pressure, and alcohol once again seeps out onto the surface of the raw material. Meanwhile, as the raw material is stretched, the aggregates are deformed, and the nano-sized crystal clusters of the metal compound deform along with the deformation of the aggregates, adsorb to the aggregates, and move along with them. Furthermore, as the aggregates deform and move, they become increasingly entangled with each other. Next, the sheet or film is continuously compressed by the lip, and alcohol seeps out onto the surface of the sheet or film once again. As the sheet or film moves along the lip, the exuded alcohol is expelled from the surface of the sheet or film due to the continued compression of the sheet or film. Meanwhile, the aggregate clusters that make up the sheet or film are also continuously compressed, causing the aggregates to deform and become intricately entangled with each other. Furthermore, the nano-sized crystals of the metal compound are compressed in the gaps between the entangled aggregates and move due to the compressive stress, but remain in the gaps between the entangled aggregates. The nano-sized crystals of the metal compound adsorbed on the surface of the entangled aggregates are also continuously subjected to compressive stress, and due to the deformation of the aggregates, they are adsorbed to the aggregates and move together with the aggregates, but continue to adsorb to the surface of the entangled aggregates. Thus, the sheet or film extruded from the lip is composed of a complexly entangled aggregate collection, with most of the alcohol having been expelled, a nano-sized crystals of the metal compound that has entered the gaps between the entangled aggregates, and a nano-sized crystals of the metal compound adsorbed on the surface of the entangled aggregate collection. Meanwhile, a small amount of alcohol remains in the extruded sheet or film, and due to the viscosity of the alcohol, the sheet or film extruded from the lip is moved to a heat treatment furnace without being cut. The discharged alcohol is recovered in a recovery machine and reused.
In the fourth treatment, the sheet or film extruded from the lip of the T-die is passed continuously through a heat treatment furnace, where the nano-sized crystallites of the metal compound are thermally decomposed, causing a cluster of metal particles with a size of about 10 nm to precipitate all at once.
That is, when the sheet or film enters the heat treatment furnace, the small amount of remaining alcohol first evaporates from the sheet or film, resulting in the deposition of a cluster of fine crystals of the metal compound, each 18-22 nm in size. Next, the temperature at which the metal compound begins to thermally decompose is reached, and the fine crystals, each 18-22 nm in size, decompose into inorganic or organic molecules and metal molecules, which then absorb the heat of vaporization and vaporize. Furthermore, once the vaporization of the inorganic or organic molecules is complete, the clusters of metal molecules form metal nanoparticles, each approximately 10 nm in size, which then precipitate en masse, forming a cluster of metal nanoparticles. Because the metal nanoparticles do not contain impurities and are deposited in an active state, adjacent metal nanoparticles form metal bonds at the contact points, resulting in a cluster of metal-bonded metal nanoparticles. As a result, the gaps between the complexly entangled aggregates are filled with clusters of metal-bonded metal nanoparticles. Furthermore, the surface of the aggregates, in which the aggregates are intricately entangled, is covered with a layer of metal-bonded metal nanoparticles.
In the fifth step, the sheet or film that has passed through the heat treatment furnace is continuously wound up by a winder, resulting in the continuous formation of a sheet or film made of aggregates of carbon black that has been endowed with gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to that of a metal.
The sheet or film formed from the aggregates thus formed has the following effects.
First, because the aggregates, which are entangled with each other, form a sheet or film, the sheet or film has a low total light transmittance of 0% and excellent light-blocking properties. Therefore, even if the sheet or film is continuously irradiated with ultraviolet light, it will not deteriorate. In addition, the thermal emissivity of carbon black is high, at 0.95-0.97, so the sheet or film acts as a heat-dissipating film.
Second, the gaps between the entangled aggregates are filled with metal-bonded nanoparticle clusters, and the surfaces of the entangled aggregate clusters are covered with metal-bonded nanoparticle clusters. Therefore, the metal-bonded nanoparticle clusters form a path for continuous electron movement in the sheet or film. This gives the sheet or film metal-like electrical conductivity, thermal conductivity, electromagnetic wave shielding, and antistatic properties.
Third, the surface of the aggregate clusters, in which the aggregates are entangled, is covered with nearly 20 layers of metal-bonded metal nanoparticle clusters, giving the sheet or film gas barrier properties. That is, while the size of gases and water vapor is 0.3-0.5 nm, aggregates are composed of carbon particles with sizes of 10-100 nm strung together in an irregular, complex shape. Therefore, in aggregate clusters in which aggregates are intricately entangled, numerous pores with sizes of 0.3-0.5 nm or larger are present. Furthermore, in clusters of granular metal nanoparticles with sizes of approximately 10 nm, clusters of metal nanoparticles that are metal-bonded at the contact points form numerous voids of 1-2 nm between adjacent metal nanoparticles. Therefore, clusters of metal-bonded metal nanoparticles that fill the gaps between the intricately entangled aggregates have pores with sizes of 0.3-0.5 nm or larger. In contrast, when metal-bonded metal nanoparticle clusters are stacked on the surface of a cluster of aggregates in which aggregates are intricately entangled, and the number of stacked metal-bonded metal nanoparticle clusters is increased, the voids penetrating the metal-bonded metal nanoparticle clusters are blocked by randomly stacked metal-bonded metal nanoparticle clusters. Experiments have shown that when metal-bonded metal nanoparticle clusters are randomly stacked up to nearly 20 layers, the metal-bonded metal nanoparticle clusters are impermeable to air, nitrogen gas, and water vapor. For this reason, the entire surface of the sheet or film is covered with metal nanoparticle clusters stacked up to nearly 20 layers of granular metal nanoparticle clusters having a size of about 10 nm. Note that because the weight of the second suspension is greater than the weight of the first suspension, the surface of the aggregate cluster is covered with nearly 20 stacked metal-bonded metal nanoparticle clusters. Further increasing the weight of the second suspension increases the number of stacked metal-bonded metal nanoparticle clusters.
Fourth, the sheet or film blocks liquids. That is, the surface of the aggregates, which are entangled with each other, is covered with nearly 20 layers of metal-bonded metal nanoparticles, and the surface tension of the liquid gives the sheet or film the ability to block liquids. Therefore, it can be used as a sheet or film that blocks liquids.
Fifth, the color of a sheet or film made of a collection of aggregates is close to black and looks unattractive. When the surface of a sheet or film is covered with a collection of stacked metal nanoparticles, the sheet or film has a metallic luster. This allows the sheet or film to have both gas barrier properties and a metallic luster.
Sixth, the gaps between the entangled aggregates are filled by stacking clusters of metal-bonded metal nanoparticles. Furthermore, the surfaces of the clusters of entangled aggregates are covered by stacking clusters of metal-bonded metal nanoparticles. Therefore, the clusters of metal-bonded metal nanoparticles bond the aggregates together and further bond the entangled aggregates together. Therefore, the sheet or film has a certain level of tensile strength, compressive strength, and shear strength based on the bonding strength of the clusters of metal-bonded metal nanoparticles.
Seventh, the heat resistance and flame retardancy are higher than those of sheets or films made of plastics. That is, the ignition temperature of carbon black in the atmosphere exceeds 500°C. Therefore, sheets or films made of clusters of metal nanoparticles and clusters of aggregates have higher heat resistance and flame retardancy than sheets or films made of plastics.
Eighth, the width of the sheet or film can be freely changed by changing the shape of the manifold and lip of the T-die.
Ninth, the thickness of the sheet or film can be freely changed by adjusting the gap between the lips of the T-die.
Tenth, carbon black is an inexpensive industrial material, and alcohol is the most commonly used organic solvent. Furthermore, the processing in a T-die is a simple extrusion molding process. Therefore, inexpensive raw materials can be used to form inexpensive sheets or films with low processing costs.
Eleventh, a sheet or film made of a collection of aggregates can be safely produced. Specifically, carbon black is immersed in alcohol and treated as a first suspension and a second suspension to form a sheet or film, so the carbon black does not scatter as dust. Furthermore, the temperature at which the metal compound thermally decomposes is more than 200°C lower than the ignition temperature of carbon black in the atmosphere, so the carbon black does not ignite.
As a result, the sheet or film of the present invention not only solves the problems described in paragraph 5, but also has a variety of excellent properties, making the sheet or film applicable in a variety of fields.

The method for bonding sheets or films formed by the method described in paragraph 18 together is as follows:
a method for pressing sheets together, comprising overlapping portions of the sheets formed by the method described in paragraph 18 to be pressed together, and applying compressive stress to one surface of the overlapped portions, thereby bringing metal nanoparticles formed on the surfaces of both the overlapped sheets into contact with each other, and further generating frictional heat at the contact portions of the metal nanoparticles, which causes the metal nanoparticles to bond together due to the frictional heat, and the overlapped portions to be pressed together due to the bonding of the metal nanoparticles ;
or
A method for laminating films formed by the method described in paragraph 18, in which the portions to be laminated are overlapped and compressive stress is applied to one surface of the overlapped portions, thereby causing metal nanoparticles formed on the surfaces of both of the overlapped films to come into contact with each other, and further, frictional heat is generated at the contact points of the metal nanoparticles, which causes the metal nanoparticles to bond together, and the overlapped portions are laminated together due to the bonding of the metal nanoparticles .

That is, the portions where the sheets or films are to be bonded are overlapped, and a compressive load is applied to the overlapping portions. As a result, the metal nanoparticles come into contact with each other on both overlapping surfaces. Furthermore, excessive frictional heat is instantaneously generated at the contact points of the metal nanoparticles, which bonds the metal nanoparticles together. The bonding of the metal nanoparticles results in the sheets or films being bonded together. Because the bonded portions are formed by a collection of a huge number of metal nanoparticles, sheets or films with small masses are firmly bonded together. On the other hand, the gaps formed between adjacent metal nanoparticles by the bonding of the metal nanoparticles are extremely small, at 1-2 nm, so surface tension prevents all liquid from leaking from the bonded portions. Therefore, by overlapping and bonding sheets or films together, a container filled with liquid made of a sheet or film can be created. Furthermore, this container simultaneously possesses the various properties of the above-mentioned sheets or films.
That is, the sheets formed by the method described in paragraph 18 are overlapped at the portions to be bonded together, and one surface of the overlapping portions is compressed. As a result, the vast number of metal nanoparticles covering the surfaces of the sheets come into contact with each other on both sides of the overlapping sheets. At this time, frictional heat is generated at the contact points between the contacting metal nanoparticles, and this frictional heat bonds the vast number of metal nanoparticles together. The surfaces of the overlapping sheets are bonded together by the bonding of the vast number of metal nanoparticles together. As a result, the sheets, each having a small mass, are bonded together with a certain bonding force due to the bonding of the vast number of metal nanoparticles together.
Similarly, the films formed by the method described in paragraph 18 are overlapped at the portions to be bonded together, and one surface of the overlapped portion is compressed. As a result, the vast number of metal nanoparticles covering the surfaces of the films on both sides of the overlapped film come into contact with each other. At this time, frictional heat is generated at the contact points between the contacting metal nanoparticles, and the vast number of metal nanoparticles are bonded together by this frictional heat. The surfaces of the overlapped films are bonded together by the bonding of the vast number of metal nanoparticles. As a result, the films, each having a small mass, are bonded together with a certain bonding force due to the bonding of the vast number of metal nanoparticles.
It should be noted that sheets or films can be easily sealed together using a sealing machine known as a plastic bag sealer. However, because the sheets or films are sealed together by bonding metal nanoparticles, there is no need to heat the sealed area of the sheets or films.

The method for pressing the sheet or film formed by the method described in paragraph 18 onto a substrate or a part includes the steps of:
A method for pressing a sheet or film formed by the method described in paragraph 18 to a substrate or part, comprising cutting the sheet or film formed by the method described in paragraph 18 to a predetermined shape, placing the cut sheet or the cut film on the surface of a substrate or part, and further compressing the surface of the cut sheet or the cut film, thereby causing a cluster of metal nanoparticles covering the surface of the cut sheet or the cut film to come into contact with the surface of the substrate or the part, and further generating frictional heat at the contact points of the metal nanoparticles, which bonds the cluster of metal nanoparticles to the surface of the substrate or the part, and pressing the cut sheet or the cut film to the surface of the substrate or the part.

In other words, the primary carbon particles in the aggregates are bonded to each other through the interaction of the π electrons of the carbon atoms, so the bonding strength between the carbon atoms is weak. Therefore, the primary particles can be easily cut. Furthermore, the metal nanoparticles are granular particles, and the volume of the bond between adjacent metal nanoparticles is extremely small. Therefore, a sheet or film consisting of a collection of metal-bonded metal nanoparticles and a collection of aggregates can be cut into various sizes and shapes. Furthermore, the collection of metal nanoparticles covering the surface of the sheet or film can be used as a bonding means. This allows the cut sheet or film to be bonded to the surface of various substrates or parts, regardless of their material and shape, simultaneously imparting the various properties of the sheet or film to the substrate or part.
That is, the sheet or film formed by the method described in paragraph 18 is cut into a predetermined shape, and the cut sheet or cut film is placed on the surface of a substrate or part. The surface of the cut sheet or cut film is then compressed. As a result, the surface of the cut sheet or cut film is covered with a vast number of metal nanoparticles, which come into contact with the surface of the substrate or part, and frictional heat is generated at the contact points of the metal nanoparticles. This frictional heat bonds the vast number of metal nanoparticles to the surface of the substrate or part. As a result, the cut sheet or the cut film is pressed against the surface of the substrate or part with a certain bonding force.

FIG. 1 is a diagram showing a schematic diagram of a state in which the gaps between entangled Ketjenblack particles are filled with clusters of silver nanoparticles.

Example 1
The first suspension described in paragraphs 10-11 was prepared using Ketjenblack (EC600JD, a product of Lion Corporation) as the carbon black and 1-pentanol (a product of Fujifilm Wako Pure Chemical Industries, Ltd.) as the alcohol. Ketjenblack exhibits excellent light-blocking properties due to its small average particle diameter of 34 nm and large specific surface area of 1270 m ² /g. Furthermore, the amount of dibutyl phthalate required to fill the voids between Ketjenblack particles is large at 495 cm ³ /100 g, resulting in a high degree of particle connection and particle aggregation. Therefore, when 1-pentanol is interposed between the entanglement of Ketjenblack aggregates, the highly entangled aggregates are dispersed in the 1-pentanol. Furthermore, when the highly entangled aggregates are bonded together with a collection of metal-bonded metal nanoparticles, the mechanical strength of the sheet or film is increased. 1-pentanol has a viscosity of 3.3 mPa·sec at 20°C and a boiling point of 138°C.
First, 15 g of Ketjen Black and 20 g of 1-pentanol were charged into a container, and the 1-pentanol was stirred to immerse the Ketjen Black in the 1-pentanol.
Thereafter, an ultrasonic homogenizer (LUH150, product of Yamato Scientific Co., Ltd.) was operated in the 1-pentanol in the container, and an ultrasonic signal of 20 kHz was applied for 5 minutes to prepare a first suspension in which aggregate groups were dispersed in 1-pentanol.

Example 2
Diamine silver chloride [Ag(NH ₃ ) ₂ ]Cl (a product of Tanaka Kikinzoku Kogyo Co., Ltd.), an inorganic metal compound having a silver complex ion in which ammonia is coordinately bonded to a silver ion, is used as the metal compound that precipitates silver upon thermal decomposition, and fine crystals of diamine silver chloride are mixed with 1-hexanol (a product of Fujifilm Wako Pure Chemical Industries, Ltd.) to prepare the second suspension described in paragraphs 12 and 13. 1-Hexanol has a boiling point of 157°C and a viscosity of 5.2 mPa·s at 20°C.
First, 18 g (equivalent to 0.1 moles) of diamine silver chloride and 180 g of methanol were charged into a container, and the methanol was stirred to disperse the diamine silver chloride in the methanol. The container was then heated to 65°C, the methanol was evaporated, and diamine silver chloride crystals were precipitated. A plate covering the entire diamine silver chloride crystals in the container was then placed over the collection of diamine silver chloride crystals, and a 1 kg weight was placed on the plate. After the weight was removed, impact accelerations of 0.2 G were applied three times each to the bottom and sides of the container in three directions: up and down, front and back, and left and right. In this way, a compressive load and impact acceleration were each applied three times to the collection of diamine silver chloride crystals. A weight was then placed on the plate, but since no movement was observed in the plate, it was considered that the crushing of the diamine silver chloride crystals was complete. Thereafter, the plate material was removed, and the container was filled with 20 g of 1-hexanol. The 1-hexanol was stirred to prepare a second suspension in which the clusters of fine crystals of diammine silver chloride were mixed with 1-hexanol.

Example 3
The first suspension prepared in Example 1 and the second suspension prepared in Example 2 are used to prepare a raw material used in forming a sheet or film made of a collection of carbon black aggregates.
The first suspension prepared in Example 1 and the second suspension prepared in Example 2 were filled into a container, and the two suspensions were stirred. The two stirred suspensions were filled into the chamber of a vacuum impregnation apparatus, and the chamber was sealed. The vacuum pump of the vacuum impregnation apparatus was then operated, and the pressure inside the chamber was reduced to 0.059 kPa, which corresponds to 1/5 of the saturated vapor pressure of 1-pentanol at 25°C (0.293 kPa). As a result, 80% of the 1-pentanol evaporated. Meanwhile, 52% of the 1-hexanol evaporated. As a result, 20% of the 1-pentanol remained, and 48% of the 1-hexanol remained. Therefore, the suspension obtained by mixing the first suspension and the second suspension was a mixture of 20% of the remaining 1-pentanol and 48% of the remaining 1-hexanol, and this mixed alcohol became a new suspension in which aggregates of fine crystals of diammine silver chloride were mixed. This new suspension penetrates into the gaps between the entangled aggregates and adsorbs onto the surfaces of the entangled aggregates. The mixture of this new suspension and the aggregates is used as the raw material for forming a sheet or film.

Example 4
For the first suspension prepared in Example 1, 30 g of the Ketjen black used in Example 1 and 35 g of the 1-pentanol used in Example 1 were charged into a container, and the 1-pentanol was stirred to immerse the Ketjen black in the 1-pentanol.
Thereafter, the ultrasonic homogenizer used in Example 1 was operated in the 1-pentanol in the container, and an ultrasonic signal of 20 kHz was applied for 5 minutes to prepare a first suspension in which aggregate groups were dispersed in 1-pentanol.

Example 5
The second suspension described in paragraphs 12-13 is prepared using copper octylate Cu[OOCCH(C ₂ H ₅ )C ₄ H ₉ ] ₂ (a product of Fujifilm Wako Pure Chemical Industries, Ltd.) as the metal compound from which copper precipitates by thermal decomposition, and using the 1-hexanol used in Example 2.
First, 35 g (equivalent to 0.1 mole) of copper octylate and 350 g of methanol were charged into a container, and the methanol was stirred to disperse the copper octylate in the methanol. The container was then heated to 65°C, the methanol was evaporated, and copper octylate crystals were precipitated. A plate covering the entire copper octylate crystals in the container was then placed over the cluster of copper octylate crystals, and a 1 kg weight was placed on the plate. After the weight was removed, an impact acceleration of 0.3 G was applied three times each to the bottom and sides of the container in three directions: up and down, front and back, and left and right. In this way, a compressive load and an impact acceleration were each applied three times to the cluster of copper octylate crystals. A weight was then placed on the plate, but since no movement was observed in the plate, it was considered that the crushing of the copper octylate crystals was complete. Thereafter, the plate material was removed, and the container was filled with 40 g of 1-hexanol. The 1-hexanol was stirred to prepare a second suspension in which the clusters of copper octylate fine crystals were mixed with 1-hexanol.

Example 6
Using the first suspension prepared in Example 4 and the second suspension prepared in Example 5, a raw material to be used in forming a sheet or film composed of a collection of carbon black aggregates was prepared using a vacuum impregnation apparatus in the same manner as in Example 3.
In this example, the pressure inside the chamber was reduced to 0.073 kPa, which corresponds to 1/4 of the saturated vapor pressure of 1-pentanol at 25°C (0.293 kPa). As a result, 75% of the 1-pentanol evaporated. Meanwhile, 41% of the 1-hexanol evaporated. As a result, 25% of the 1-pentanol and 59% of the 1-hexanol remained. The remaining two alcohols mixed together to form a suspension in which the mixed alcohol contained clusters of fine crystals of copper octylate. This suspension penetrates into the gaps between the entangled aggregates and adsorbs onto the surfaces of the entangled aggregate clusters. The mixture consisting of this suspension and the aggregate clusters was used as the raw material for forming a sheet or film.

Example 7
Using the raw material prepared in Example 3, a film having a width of 100 mm, a thickness of 30 μm, and a length of 50 cm was formed using a T-die (equipment owned by Bax Co., Ltd.) The width and thickness of the film can be freely changed by adjusting the lip width and gap setting of the T-die.
Thereafter, the prepared film was left in a hydrogen atmosphere at 180° C. for 5 minutes for heat treatment.
First, the light-shielding property of the prepared film was measured according to JIS-L-1055A method, and it was found to be an excellent light-shielding film with a light-shielding rate of 99.99%.
Next, the thermal emissivity of the film was measured using an analyzer consisting of a Fourier transform infrared spectrophotometer and a radiation measurement unit (equipment owned by Kobelco Research Institute, Inc.) The thermal emissivity was found to be high at 0.97, making it an excellent heat dissipation film.
These excellent light blocking and heat radiation results are based on the properties of Ketjen Black.
Furthermore, the gas barrier properties of the prepared film were measured by differential pressure gas chromatography based on the gas permeability test method described in JIS-K-7126-1 (using an analyzer owned by DJK Corporation). Under an environment of 20°C and 65% humidity, the gas permeability for carbon dioxide gas was 110 (ml/ ^m2 d·MPa), the gas permeability for oxygen gas was 60 (ml/ ^m2 d·MPa), and the gas permeability for nitrogen gas was 10 (ml/ ^m2 d·MPa). The water vapor permeability was 2-3 (g/ ^m2 ·d).
These results show that the gas barrier performance is superior to that of a film made of biaxially oriented polypropylene film coated with polyvinylidene chloride, which is the plastic film with the best gas barrier performance.
Next, the surface resistance of the prepared film was measured at multiple points on its surface using a surface resistance meter (for example, a surface resistance meter ST-4 manufactured by Simco Japan Co., Ltd.). The surface resistance was 1 x 10 ³ Ω/□, which is close to that of metal. Therefore, the prepared film also functions as a film that combines electrical conductivity, thermal conductivity, electromagnetic wave shielding, and antistatic properties based on the resistivity of metal.
Furthermore, the tensile strength of the produced film was measured in accordance with the standard of JIS-K7127. The tensile strength was 200 MPa. This tensile strength was 1.5 times that of a PET film and was close to the tensile strength of a silver foil.
The film was then cut, and the film surface and cut surface were observed using an electron microscope. An ultra-low accelerating voltage SEM owned by JFE Techno Research Corporation was used as the electron microscope. This device allows surface observation at ultra-low accelerating voltages starting from 100 volts, and allows the film surface to be observed directly without forming a conductive coating.
First, secondary electron beams between 900-1000 volts were extracted from the electron beam reflected from the film surface and image processing was performed. The film surface was covered with a collection of granular particles approximately 10 nm in size. Furthermore, energy between 900-1000 volts of the electron beam reflected from the film surface was extracted and image processing was performed, and the material of the granular particles was analyzed based on the image density. Since no density was observed, it was determined that the particles were composed of a single atom. Furthermore, the energy and intensity of characteristic X-rays from multiple points on the surface were image processed and the type of elements that made up the granular particles were analyzed. The granular particles were composed only of silver atoms. From these results, it was determined that the film was covered with silver nanoparticles approximately 10 nm in size.
Furthermore, the cut surface of the film was observed under a microscope. It was found that silver nanoparticles were stacked in layers of around 20 on the surface of the carbon-atom-only material, covering the film's surface. Furthermore, the silver nanoparticles filled the gaps formed by the carbon-atom-only material.
These results indicate that the film's surface is covered with around 20 layers of silver nanoparticles, and that the gaps formed by the aggregates of Ketjen Black, a substance composed only of carbon atoms, are filled with clusters of silver nanoparticles. Figure 1 shows a schematic diagram of a cross section of the film. 1 is the cross section of a primary carbon particle of Ketjen Black, and 2 is a silver nanoparticle with a size of around 10 nm, with the clusters of silver nanoparticles filling the gaps formed by the entangled Ketjen Black.
The excellent gas barrier properties and surface resistance close to that of metal are due to the fact that approximately 20 layers of silver nanoparticles are stacked to cover the surface of the film. The film also has a silvery luster. Furthermore, the gaps formed by the Ketjen Black aggregates are filled by the clusters of silver nanoparticles, resulting in a tensile strength close to that of silver foil.
The metal nanoparticles are not limited to silver. As explained in paragraphs 14 and 15, by using an inorganic metal compound made of an inorganic salt having a metal complex ion in which an inorganic molecule or an inorganic ion is coordinately bonded to a metal ion, a collection of metal nanoparticles made of various materials covers the surface of the film and fills the gaps formed by the aggregates.

Example 8
The raw material prepared in Example 6 was molded into a sheet having a width of 100 mm, a thickness of 300 μm and a length of 20 cm using a T-die (equipment owned by Bax Corporation).
Furthermore, the prepared sheet was left in the air at 290° C. for 1 minute for heat treatment.
First, the light-shielding property of the prepared sheet was measured in the same manner as in Example 7. The light-shielding rate was 99.99%, and it was found to be an excellent light-shielding sheet.
Next, the thermal emissivity of the prepared sheet was measured in the same manner as in Example 7. The thermal emissivity was as high as 0.97, and it was found to be an excellent heat dissipation sheet.
Furthermore, the gas barrier properties of the prepared sheet were measured in the same manner as in Example 7. The sheet had gas barrier properties similar to those of Example 7.
Next, similarly to Example 7, the surface resistance of the prepared sheet was measured at multiple points on its surface using a surface resistance meter. The surface resistance was 1 x ¹⁰ Ω/□, which was close to that of metal. Based on the resistivity of metal, the prepared sheet also functions as a sheet that combines electrical conductivity, thermal conductivity, electromagnetic wave shielding, and antistatic properties.
Furthermore, the tensile strength of the produced sheet was measured in accordance with the standard of JIS-K7127. The tensile strength was 380 MPa. This tensile strength was greater than the tensile strength of a sheet made of composite fibers of aramid fiber and nylon fiber, and was close to the tensile strength of copper foil.
Thereafter, the prepared sheet was cut, and the surface and cut surface of the sheet were observed under an electron microscope in the same manner as in Example 7.
The surface of the sheet was covered with copper nanoparticles with a size of about 10 nm. Furthermore, the surface of the sheet was covered with about 20 layers of copper nanoparticles stacked together, and the gaps formed by the Ketjen Black aggregates were filled with clusters of copper nanoparticles.
The excellent gas barrier properties and surface resistance close to that of metal are due to the fact that copper nanoparticles are stacked in layers of around 20 to cover the surface of the sheet. The surface of the sheet also has the luster of copper. Furthermore, the gaps formed by the Ketjen Black aggregates are filled by clusters of copper nanoparticles, resulting in tensile strength close to that of copper foil.
The metal nanoparticles are not limited to copper. As explained in paragraphs 16-17, by using a metal octylate compound, a collection of metal nanoparticles made of various materials covers the surface of the sheet and fills the gaps formed by the aggregates.

Example 9
This is an example in which the film prepared in Example 7 is pressure-bonded to a liquid crystal polymer film. The liquid crystal polymer film has low water absorption, a low dielectric loss tangent, gas barrier properties, heat resistance, and flame retardancy. When the film prepared in Example 7 is pressure-bonded to this liquid crystal polymer film, it is possible to add electrical conductivity and thermal conductivity similar to silver, the luster of silver, the light-shielding and heat-dissipating properties of Ketjen Black, and even higher gas barrier properties and heat resistance.
A liquid crystal polymer film (CTQ-25, product of Kuraray Co., Ltd.) with a thickness of 25 μm was cut to a size of 15 cm x 15 cm, placed on a plate, and the four edges were fixed with insect pins. Next, the film prepared in Example 7 was cut to a size of 12 cm x 12 cm and placed on top of the liquid crystal polymer film. Furthermore, a plate measuring 12 cm x 12 cm was placed on top of the liquid crystal polymer film, and five 5 kg weights were placed on top of the plate at equal intervals diagonally.
After this, the weight and plate were removed, and the liquid crystal polymer film was cut into a size of 12 cm x 12 cm. A double film was created by pressing a film consisting of a collection of silver nanoparticles and a collection of aggregates onto the liquid crystal polymer film. The double film was allowed to fall from a height of 2 m, but no damage was found. Therefore, the two films were bonded with a certain strength, and the film produced in Example 7 had a certain shear strength.
The film to which the film prepared in Example 7 is pressed is not limited to a liquid crystal polymer film. Since a collection of metal nanoparticles bonds two types of films, there are no restrictions on the material of the films to be bonded. Furthermore, the metal nanoparticles are not limited to silver nanoparticles. Depending on the application, two types of film materials are selected to create a double film.

Example 10
In this example, the sheet prepared in Example 8 is pressure-bonded to a polypropylene sheet, which is the most commonly used plastic sheet. This gives the polypropylene sheet electrical conductivity and thermal conductivity similar to copper, the luster of copper, the light-shielding and heat-dissipating properties of Ketjenblack, and high gas barrier properties.
A polypropylene sheet with a thickness of 300 μm was cut to a size of 15 cm × 15 cm, placed on a plate, and secured at all four edges with pins. Next, the sheet prepared in Example 8 was cut to a size of 12 cm × 12 cm and placed on the polypropylene sheet. A 12 cm × 12 cm plate was then placed on top of the polypropylene sheet, and five 5 kg weights were placed on top of the plate at equal intervals diagonally.
After this, the weight and plate material were removed, and the polypropylene sheet was cut into a size of 12 cm x 12 cm. A double sheet was created by pressing a sheet consisting of a collection of copper nanoparticles and a collection of aggregates onto the polypropylene sheet. The double sheet was allowed to fall from a height of 2 m, but no damage was caused. Therefore, the two sheets are bonded with a certain strength, and the sheet produced in Example 8 has a certain shear strength.
The sheet to which the sheet prepared in Example 8 is pressed is not limited to a polypropylene sheet. Since a collection of metal nanoparticles bonds two types of films, there are no restrictions on the material of the sheets to be bonded. Furthermore, the metal nanoparticles are not limited to copper nanoparticles. Depending on the application, two types of sheet materials are selected to create a double sheet.

1. Cross section of Ketjen Black primary carbon particle 2. Silver nanoparticles

Claims (9)

A method for producing a raw material used in forming a sheet or film made of a collection of carbon black aggregates that has gas barrier properties, metallic luster, and electrical and thermal conductivity equivalent to those of a metal, is as follows:
A first suspension is prepared in advance, in which aggregates, which are primary agglomerates of carbon particles constituting carbon black, are entangled with each other via a first alcohol having a weight greater than that of the aggregates of carbon black, and the aggregates of the entangled aggregates are dispersed in the first alcohol. The first suspension is then dispersed in a second alcohol having a boiling point 15°C or more higher than that of the first alcohol and lower than the temperature at which thermal decomposition of a metal compound that precipitates a metal by thermal decomposition begins. A second suspension is prepared in advance by mixing a collection of fine crystals of the metal compound having a size of 18-22 nm , which is one order of magnitude smaller than the aggregates having a size of 100-500 nm , in a weight amount less than that of the second alcohol. Then, the second suspension having a weight greater than that of the first suspension and the first suspension are filled into a container, and the two types of suspensions are stirred to prepare a mixture of the two types of suspensions. Then, the mixture of the two types of suspensions is filled into a chamber of a vacuum impregnation device, and the chamber is sealed. Furthermore, the vacuum pump of the vacuum impregnation device is operated, and the pressure in the chamber is reduced to a minimum pressure that is 1/5 of the saturated vapor pressure of the first alcohol at the temperature in the chamber, thereby and a mixture of the two types of suspensions becomes a new suspension, and as the two types of alcohol evaporate, the new suspension moves into gaps between the aggregates that are entangled with each other, and is adsorbed onto the surfaces of the aggregates that are entangled with each other, thereby forming a mixture of the new suspension and the aggregates in the chamber, and the mixture is used as a raw material for forming a sheet or film.
A method for producing raw materials used in forming sheets or films consisting of aggregates of carbon black that have gas barrier properties, metallic luster, and electrical and thermal conductivity comparable to that of metals. A method for preparing the first suspension according to claim 1, comprising the steps of:
The first alcohol described in claim 1 is an alcohol having a viscosity of 3-5 mPa·sec at 20°C, and the alcohol and carbon black aggregates, the weight of which is less than that of the alcohol, are filled into a container, and the carbon black aggregates are stirred and immersed in the alcohol. Thereafter, an ultrasonic homogenizer is placed in the container, and the homogenizer is operated in the alcohol, and bubbles smaller than the size of aggregates, which are primary agglomerates of carbon particles that make up the carbon black, are generated in the alcohol. 2. The method for preparing a first suspension according to claim 1, wherein bubbles are generated in the alcohol, and then the bubbles disappear almost simultaneously, and at this time, shock waves generated when the bubbles burst continue to be generated in the alcohol, and the shock waves are continuously irradiated to the fine parts of agglomerates, which are clumps of the aggregates entangled with each other, thereby disentangling the entangled parts of the aggregates, and the alcohol is adsorbed to the disentangled parts, thereby preparing a first suspension in which a collection of aggregates entangled via the alcohol is dispersed in the alcohol. The method for preparing the first suspension according to claim 2 comprises the steps of:
A method for preparing the first suspension according to claim 2, wherein the carbon black according to claim 2 is Ketjen black, and the first suspension is prepared according to the method for preparing the first suspension according to claim 2, using the Ketjen black as the carbon black according to claim 2. The method for preparing the second suspension according to claim 1 comprises the steps of:
A metal compound having a first property of dispersing in a molecular state in methanol but not dissolving in methanol, and a second property of precipitating a metal by thermal decomposition, is dispersed in methanol to prepare a methanol dispersion of the metal compound, and then the methanol is evaporated from the methanol dispersion of the metal compound to precipitate a cluster of fine crystals of the metal compound. The cluster of fine crystals of the metal compound is then filled into a container, and a plate covering the entire surface of the cluster of fine crystals of the metal compound is placed over the cluster of fine crystals of the metal compound. A compressive load equivalent to 1-10 kg weight, depending on the size of the container, is applied to the entire surface of the plate to crush the cluster of fine crystals of the metal compound. Impact accelerations of 0.2-0.5 G are repeatedly applied to the sides and bottom of the container in three directions, front-to-back, left-to-right, and up-to-down, depending on the size of the container, causing the crushed clusters of fine crystals of the metal compound to move within the container to fill voids, and the clusters of fine crystals are rearranged within the container. The entire surface of the plate is then crushed. the compressive load is applied again to the plate, and further, the impact acceleration in the three directions is repeatedly applied to the side and bottom of the container; the pair of processes consisting of the process of applying the compressive load and the process of applying the impact acceleration are repeated; when the crystals reach their limit of micronization, the crystals do not break even when the compressive load is applied to the plate, and therefore the plate stops moving even when the compressive load is applied to the plate, and at this point, the pair of processes are stopped, and a cluster of fine crystals of 18-22 nm in size of the metal compound is created in the container; thereafter, the plate is removed from the container; the second alcohol described in claim 1 is filled into the container in a weight greater than the weight of the cluster of fine crystals of the metal compound; the cluster of fine crystals of 18-22 nm in size of the metal compound is stirred; and a second suspension is created in the container in which the cluster of fine crystals of 18-22 nm in size of the metal compound is mixed with the second alcohol. The method for preparing the second suspension according to claim 4 comprises the steps of:
A method for preparing the second suspension according to claim 4, wherein the metal compound according to claim 4 is an inorganic metal compound consisting of an inorganic salt having a metal complex ion in which an inorganic molecule or an inorganic ion is coordinately bonded to a metal ion, and the inorganic metal compound is used as the metal compound according to claim 4, and the second suspension is prepared according to the method for preparing the second suspension according to claim 4. The method for preparing the second suspension according to claim 4 comprises the steps of:
A method for preparing the second suspension described in claim 4, wherein the metal compound described in claim 4 is an octylate metal compound, and the second suspension is prepared using the octylate metal compound as the metal compound described in claim 4 according to the method for preparing the second suspension described in claim 4. A method for continuously forming a sheet or film made of aggregates of carbon black, which has gas barrier properties, metallic luster, and electrical and thermal conductivity equivalent to those of a metal, using a raw material used in forming the sheet or film according to claim 1, comprises the steps of:
A sheet or film is produced by preparing a raw material used in forming a sheet or film made of a collection of carbon black aggregates according to the method of claim 1, by preparing a first suspension according to the method of claim 2, using the first suspension as the first suspension according to claim 1, preparing a second suspension according to the method of claim 4, using the second suspension as the second suspension according to claim 1, continuously charging the raw material into an extruder, and continuously moving the screw of the extruder to extrude the raw material charged in the extruder from the extruder into a T-die. The raw material is continuously extruded in the form of a sheet or film by the pressure from the extruder from the lip of the T-die having a width of 18-22 nm and a gap of the thickness of the sheet or film to be produced, and the extruded sheet or film is continuously passed through a heat treatment furnace heated to a temperature at which the metal compound constituting the raw material completes its thermal decomposition. During this process, the fine crystals having a size of 18-22 nm as described in claim 4 decompose into inorganic or organic molecules and metal molecules, and the inorganic or organic molecules absorb the heat of vaporization and vaporize. When the vaporization is completed, the clusters of metal molecules form metal nanoparticles with a size of about 10 nm, and the clusters of metal nanoparticles precipitate all at once. Since the metal nanoparticles do not contain impurities and precipitate in an active state, adjacent metal nanoparticles are metallically bonded at the contact points, and the clusters of metallically bonded metal nanoparticles are stacked. As a result , the gaps between the aggregates, where the aggregates are entangled with each other, are filled with the clusters of metallically bonded metal nanoparticles, and the surfaces of the clusters of aggregates, where the aggregates are entangled with each other, are covered with the clusters of metallically bonded metal nanoparticles. a sheet or film made of an aggregate of carbon black that has been imparted with gas barrier properties, metallic luster, electrical conductivity and thermal conductivity similar to that of a metal, using the raw material used in forming the sheet or film according to claim 1, the sheet or film being made of an aggregate of carbon black that has been imparted with gas barrier properties, metallic luster, electrical conductivity and thermal conductivity similar to that of a metal, and the raw material used in forming the sheet or film according to claim 1 being laminated and covered with carbon black; and the sheet or film that has been passed through the heat treatment furnace being continuously wound up by a winder, thereby continuously forming a sheet or film made of an aggregate of carbon black that has been imparted with gas barrier properties, metallic luster, electrical conductivity and thermal conductivity similar to that of a metal. The method for press-bonding sheets or films formed by the method according to claim 7 to each other comprises the steps of:
A method for pressure-bonding sheets, comprising: overlapping portions of the sheets formed by the method according to claim 7 to be pressure-bonded together; applying compressive stress to one surface of the overlapping portions; thereby bringing metal nanoparticles formed on the surfaces of both the overlapping sheets into contact with each other; furthermore, generating frictional heat at the contact portions of the metal nanoparticles; bonding the metal nanoparticles together due to the frictional heat; and pressure-bonding the overlapping portions together due to the bonding of the metal nanoparticles together .
or
A method for laminating films together, comprising overlapping the portions of the films formed by the method described in claim 7 to be laminated together and applying compressive stress to one surface of the laminated portions, thereby bringing metal nanoparticles formed on the surfaces of both of the laminated films into contact with each other, and further generating frictional heat at the contact points of the metal nanoparticles, which causes the metal nanoparticles to bond together, and the bonding of the metal nanoparticles to each other causes the laminated portions to be laminated together . A method for press-bonding the sheet or film formed by the method according to claim 7 to a substrate or a part comprises the steps of:
A method for pressing a sheet or film formed by the method of claim 7 to a substrate or a part, comprising cutting the sheet or film formed by the method of claim 7 to a predetermined shape, placing the cut sheet or the cut film on the surface of a substrate or a part, and further compressing the surface of the cut sheet or the cut film, thereby causing a cluster of metal nanoparticles covering the surface of the cut sheet or the cut film to come into contact with the surface of the substrate or the part, and further generating frictional heat at the contact points of the metal nanoparticles, which causes the cluster of metal nanoparticles to bond to the surface of the substrate or the part, and pressing the cut sheet or the cut film to the surface of the substrate or the part.