Maßgeschneiderte Kieselgelträger für die metallocen-katalysierte Polyolefinsynthese

Die vorliegende Arbeit beschäftigt sich mit der Synthese und Charakterisierung von porösen Kieselgelen und ihrem Einsatz als Träger in der heterogenen metallocen-katalysierten Polymerisation von Ethylen. Im Vordergrund stand die Optimierung dieses Prozesses durch das Maßscheidern der Trägereigenschaften unter sonst identischen Polymerisationsbedingungen und das Erforschen des heterogenen Polymerisationsprozesses. Das verwendete Katalysatorsystem (Methylaluminoxan mit Dicyclopentadienylzirkoniumdichlorid) besitzt sehr hohe Aktivitäten und verbleibt im Falle der heterogenen Reaktionsführung im Produkt. Der Mechanismus verläuft über mehrere Phasen, wobei besonderes Augenmerk auf die Trägerpartikelfragmentierung gelenkt wurde. Es wurden zwei Synthesekonzepte für die Herstellung der Träger verfolgt. Im ersten Teil der Arbeit wurden monodisperse unporöse Kieselgel-Nanopartikel (Monosphere) zu Agglomeratträgern über einen Sprühtrocknungsprozess aufgebaut. Die Stabilität der Agglomerate wurde über den Zusatz von monodispersen Kieselgel-Binderpartikeln während der Herstellung variiert. Es wurden sowohl die porenstrukturellen als auch morphologischen Eigenschaften der Agglomeratprodukte untersucht und mit den physiko-chemischen Eigenschaften der Nanopartikel korreliert. In einem zweiten Ansatz wurden sphärische hochporöse Kieselgele mit abgestufter Porosität bei konstanter spezifischer Oberfläche hergestellt und als Träger in der Polyethylensynthese getestet.

Application of a hybrid blocking layer in dye-sensitized solar cells

In dye-sensitized solar cells a blocking layer between the transparent electrode and the mesoporous titanium dioxide film is used to prevent short-circuits between the hole-conductor and the front electrode. The conventional approach is to use a compact layer of titanium dioxide prepared by spin coating or spray pyrolysis. The thickness of the blocking layer is critical. On one hand, the layer has to be thick enough to cover the rough substrate completely. On the other hand, the serial resistance increases with increasing film thickness, because the layer acts as an ohmic resistance itself. In this thesis an amphiphilic diblock copolymer is used as a functional template to produce an alternative, hybrid blocking layer. The hybrid blocking layer is thinner than the conventional, compact titanium dioxide film and thereby possesses a higher conductivity. Still, this type of blocking layer covers the rough electrode material completely and avoids current loss through charge recombination. The novel blocking layer is prepared using a tailored, amphiphilic block copolymer in combination with sol-gel chemistry. While the hydrophilic poly(ethylene oxide) part of the polymer coordinates a titanium dioxide precursor to form a percolating network of titania particles, the hydrophobic poly(dimethylsiloxane) part turns into an insulating ceramic layer. With this technique, crack-free films with a thickness down to 24 nm are obtained. The presence of a conductive titanium dioxide network for current flow, which is embedded in an insulating ceramic material, is validated by conductive scanning force microscopy. This is the first time that such a hybrid blocking layer is implemented in a solar cell. With this approach the efficiency could be increased up to 27 % compared to the conventional blocking layer. Thus, it is demonstrated that the hybrid blocking layer represents a competitive alternative to the classical approach.

Hybrid inorganic-polymer coatings prepared via miniemulsion process

A synthetic route was designed for the incorporation of inorganic materials within water-based miniemulsions with a complex and adjustable polymer composition. This involved co-homogenization of two inverse miniemulsions constituting precursors of the desired inorganic salt dispersed within a polymerizable continuous phase, followed by transfer to a direct miniemulsion via addition to an o/w surfactant solution with subsequent homogenization and radical polymerization. To our knowledge, this is the first work done where a polymerizable continuous phase has been used in an inverse (mini)emulsion formation followed by transfer to a direct miniemulsion, followed by polymerization, so that the result is a water-based dispersion. The versatility of the process was demonstrated by the synthesis of different inorganic pigments, but also the use of unconventional mixture of vinylic monomers and epoxy resin as the polymerizable phase (unconventional as a miniemulsion continuous phase but typical combination for coating applications). Zinc phosphate, calcium carbonate and barium sulfate were all successfully incorporated in the polymer-epoxy matrix. The choice of the system was based on a typical functional coatings system, but is not limited to. This system can be extended to incorporate various inorganic and further materials as long as the starting materials are water-soluble or hydrophilic. rnThe hybrid zinc phosphate – polymer water-based miniemulsion prepared by the above route was then applied to steel panels using autodeposition process. This is considered the first autodeposition coatings process to be carried out from a miniemulsion system containing zinc phosphate particles. Those steel panels were then tested for corrosion protection using salt spray tests. Those corrosion tests showed that the hybrid particles can protect substrate from corrosion and even improve corrosion protection, compared to a control sample where corrosion protection was performed at a separate step. Last but not least, it is suggested that corrosion protection mechanism is related to zinc phosphate mobility across the coatings film, which was proven using electron microscopy techniques.