CN104130598A - α -氧化铝薄片 - Google Patents

α -氧化铝薄片 Download PDF

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CN104130598A
CN104130598A CN201410165870.4A CN201410165870A CN104130598A CN 104130598 A CN104130598 A CN 104130598A CN 201410165870 A CN201410165870 A CN 201410165870A CN 104130598 A CN104130598 A CN 104130598A
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thin slice
tio
sio
pigment
solution
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CN104130598B (zh
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铃木龙太
格哈德·普法夫
扎比内·舍恩
松田宪之
新田胜久
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Merck Patent GmbH
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Abstract

本发明涉及具有限定的厚度和粒径分布的氧化铝薄片,以及它们在清漆、油漆、汽车涂料、印刷油墨、母料、塑料和化妆品制剂中以及作为效果颜料的基材的用途。

Description

α -氧化铝薄片
本发明涉及α-Al2O3薄片;并涉及它们在油漆(paint)、工业涂料、汽车涂料、印刷油墨、化妆品制剂中的用途,特别是它们作为效果颜料的透明基材(substrate)的用途。 
通过使用基于天然或合成透明薄片的珠光颜料可以实现珍珠光泽(luster)、金属光泽、随角异色性或多色效果。基于α-Al2O3薄片的珠光颜料在文献中是已知的并可从Merck KGaA以商标购得。 
效果颜料的基材的重要因素是颗粒尺寸、形状、表面性能、折射率等。由于大颗粒和小颗粒在颗粒表面上具有不同比例的光反射和透射,因此颗粒尺寸的均匀性对于生动且均匀的颜色是必不可少的。而且,颗粒尺寸极大地影响珠光颜料的着色,因为它与光的波长密切相关。即颗粒尺寸越小,表面积越大,从而增加着色和提高反射率并提供更鲜艳的颜色。然而,在Al2O3薄片表面上涂覆金属或金属氧化物时,在其上提供均匀的涂层通常是不容易的且因此导致纵横比降低,这随后降低了光干涉的效果,因此恶化了由此产生的珠光色的光泽度(glossiness)。 
以具有颗粒直径大于10μm且纵横比(颗粒直径/厚度)为5-10的六边形薄片形式的α-Al2O3可从日本专利公开号111239/1982获知。 
日本专利公开号72572/1991公开了以具有平均颗粒直径为0.5-3μm的薄片形式的α-Al2O3。 
日本专利公开号39362/1992描述了以具有垂直于c轴的平面长成片的六方晶系的细片状颗粒形式的Al2O3。 
U.S.5,702,519中公开了由氧化铝(作为主要成分)和二氧化钛(作为次要成分)组成的Al2O3薄片。Al2O3薄片具有约5-60μm的平均颗粒直径、小于1μm的厚度和>20的纵横比。 
WO2006/101306A1和WO2008/026829A1涉及锌掺杂的Al2O3薄片和基于这些Al2O3薄片的珠光颜料。Al2O3薄片具有0.5μm以下的平均厚度、≥15μm的平均颗粒直径和≥50μm的纵横比(直径/厚度)。这些锌掺杂的Al2O3薄片在酸性条件下不稳定且因此不适合所有的应用。 
现有技术的Al2O3薄片具有以下缺点:它们不具有高的化学稳定性和/或不具有适合在化妆品和油漆应用中使用的薄片期望的平滑性。 
本发明的目的是提供同时具有高的化学稳定性、平滑表面和高的白度的改进的Al2O3薄片。 
令人惊讶地,现已发现,通过使用具有精确定义的尺寸、粒径和厚度分布的氧化铝薄片可以提高这种氧化铝薄片和基于氧化铝薄片的效果颜料的性质。特别是通过改变粒径分布可以影响氧化铝薄片和基于氧化铝薄片的效果颜料的光学性能。 
因此,本发明涉及透明氧化铝薄片,其特征在于,它们的厚度为小于500nm、D90值为30-45μm和D50值为15-30μm。 
相比于现有技术,根据本发明的Al2O3薄片表现出改进的光学性能,特别是增加的彩度、较高的光泽、较低的雾度和出色的修饰(finishing)以及同时高的化学稳定性。 
根据本发明的氧化铝薄片特别是用作效果颜料的基材,特别是用于工业应用中。然而,它们也可以用于通常使用氧化铝薄片的所有组合物(例如在油墨、涂料优选汽车涂料、塑料、化妆品制剂)中和作为效果颜料的基材。 
本发明的Al2O3薄片具有特征在于其中体积尺寸分数按照以下分布的高斯分布的粒径分布: 
-D50在15-30μm、优选15-25μm的范围内 
-D90在30-45μm、优选30-40μm的范围内。 
在本专利申请中,通过使用Malvern MS2000来评价氧化铝薄片的D10、D50和D90。 
粒径分布D50也称为中值粒径或粒径分布的中值,它是在累计分布中在50%处的颗粒直径的值并且是表征颜料的颗粒尺寸的重要参数之一。 
相应地,D90值表示Al2O3薄片的最大纵向尺寸,再次由通过激光粒度测定仪以球当量的形式测定,其中占所有Al2O3颗粒的整体的90%的颗粒达到最大值或者低于该值。 
在一个优选的实施方案中,根据本发明的氧化铝薄片的D10值<9.5,优选≤9.0。 
D10值表示Al2O3薄片的纵向尺寸的值,由通过激光粒度测定仪以球当量的形式测定,其中占所有Al2O3薄片的整体的10%的颗粒达到最大值或者低于该值。 
在一个优选的实施方案中,根据本发明的Al2O3薄片具有小于80、优选5-60和特别是10-50的厚度分布的标准偏差。 
在本专利申请中,平均厚度是基于固化漆膜测定,在所述固化漆膜中Al2O3薄片基本上平行于基底平面取向。为此,在扫描电子显微镜(SEM)下观察固化漆膜的横截面,确定100个Al2O3薄片的厚度,并进行统计平均。 
期望的尺寸和厚度分布可通过薄片的适当分级来获得,如通过选择的筛等进行分级。 
根据本发明的Al2O3薄片的厚度为小于500nm,优选为130-400nm,特别是150-350nm。 
根据本发明的Al2O3薄片优选具有30-200特别是50-150的纵横比(直径/厚度比)。 
在一个优选的实施方案中,本发明的Al2O3薄片为α-Al2O3薄片。 
Al2O3薄片可以通过如文献中所述的本身已知的方法制备。 
在一个优选的实施方案中,Al2O3薄片是从铝盐水溶液通过用碱金属碳酸盐水溶液沉淀开始制备的。向起始溶液中添加碱金属盐如硫酸钠或钾和磷酸或/和磷酸盐和任选的至少一种掺杂剂,例如钛、锆、二氧化硅、铟、锡、锌或铟化合物。沉淀步骤之后接着是干燥(通过 加热来蒸发、脱水),和包括以下步骤的熔融盐处理: 
(1)制备至少一种水溶性和/或水不溶性铝盐的水溶液或浆体, 
(2)向铝盐溶液中添加碱溶液以沉淀氢氧化铝颗粒,和在所述沉淀之前、期间或者之后向水溶液添加磷化合物和任选的至少一种掺杂剂, 
(3)蒸发水,随后干燥步骤(2)中的沉淀产物以形成含颗粒和碱盐的氧化铝的干燥形式, 
(4)将在步骤(3)中得到的干燥形式煅烧,优选在900-1400℃的温度下煅烧0.5-10小时(优选1-6小时)以得到以熔融盐形式的Al2O3薄片, 
(5)除去在步骤(4)中获得的煅烧材料的水溶性部分, 
(6)调节颗粒尺寸和厚度,例如通过筛分、研磨和/或沉降。 
合适的铝盐的实例是硫酸铝、氯化铝、硝酸铝、聚氯化铝、氢氧化铝、勃姆石、碱性硫酸铝及其组合。 
作为矿化剂的合适的碱金属盐的实例包括硫酸钠、硫酸钾、硫酸锂、硫酸镁、氯化钠和氯化钾。 
磷化合物优选选自磷酸、磷酸盐、焦磷酸、磷酸钠、磷酸氢二铵和磷酸钾。一种或多种磷化合物的量基于氧化铝薄片计优选为0.05-2重量%。 
用于沉淀的pH调节剂的优选实例是氨、氢氧化钠、氢氧化钾、碳酸钠、碳酸钾及其组合。 
为了控制颗粒尺寸、厚度、光学性能和/或表面形态,添加基于Al2O3薄片计0.01-5重量%的一种或多种掺杂剂可能是有用的。 
掺杂剂优选选自下列化合物的组:TiO2、ZrO2、SiO2、In2O3、SnO2、ZnO及其组合。 
在一个优选的实施方案中,掺杂剂是TiO2,基于Al2O3薄片优选以0.05-3重量%的量使用。 
根据本发明的Al2O3薄片非常适合作为制备效果颜料的基材。为此,它们优选涂覆有至少一层高折射率层,如金属氧化物,例如TiO2、 ZrO2、SnO2、ZnO、Ce2O3、Fe2O3、Fe3O4、FeTiO5、Cr2O3、CoO、Co3O4、VO2、V2O3、NiO、还有钛的低氧化物(TiO2被部分还原,氧化态从<4至2,如低级氧化物Ti3O5、Ti2O3、TiO)、钛氧氮化物、FeO(OH)的层,薄的半透明金属层,例如包括Al、Fe、Cr、Ag、Au、Pt或Pd或其组合。TiO2层可以是金红石型或锐钛矿型。通常,当TiO2是金红石型时,可以获得最高的质量和光泽度同时最稳定的效果颜料。为了获得金红石型,可以使用能够指引TiO2成为金红石型的添加剂。有用的金红石指引剂(director)公开于U.S.4,038,099、U.S.5,433,779和EP0271767中。优选的金红石指引剂是SnO2。 
优选的基于Al2O3薄片的效果颜料涂覆有一层或多层金属氧化物,优选只涂覆一层金属氧化物层,特别是TiO2、Fe2O3、Fe3O4、SnO2、ZrO2或者Cr2O3。特别优选的是涂覆有TiO2或者Fe2O3及其混合物的Al2O3薄片。 
各个高折射率层的厚度取决于所期望的干涉色。在Al2O3薄片表面上各个层的厚度优选为20-400nm,优选30-300nm,尤其是30-200nm。 
Al2O3薄片表面上层的数量优选为1或2、还有3、4、5、6或7层。 
特别地,Al2O3薄片表面上的由高和低折射率层组成的干涉叠层(interference package)产生具有增加的光泽度和进一步增加的干涉色或随角异色性的效果颜料。 
用于涂层的合适的无色低折射率材料优选金属氧化物或相应的氧化物的水合物,例如SiO2、Al2O3、AlO(OH)、B2O3、如MgF2的化合物、或者所述金属氧化物的混合物。 
在多层施用到Al2O3薄片表面上的情况下,干涉体系特别是TiO2-SiO2-TiO2层序列。 
此外,根据本发明的效果颜料也可以具有半透明金属层作为外层。这种类型的涂层例如从DE3825702A1是已知的。金属层优选是具有5-25nm层厚度的铬或铝层。 
Al2O3薄片也可涂覆有一层或多层例如选自铬、镍、银、铋、铜、锡或哈氏合金的金属或金属合金。涂覆有金属硫化物的Al2O3薄片涂覆有例如钨、钼、铈、镧或稀土元素的硫化物。 
此外,基于Al2O3薄片的效果颜料可最后涂覆有机染料作为顶涂层,最好用普鲁士蓝或胭脂红。 
特别优选的基于根据本发明的Al2O3薄片的效果颜料具有以下层序列: 
Al2O3薄片+TiO2
Al2O3薄片+TiO2/Fe2O3
Al2O3薄片+Fe2O3
Al2O3薄片+TiO2+Fe2O3
Al2O3薄片+TiO2+Fe3O4
Al2O3薄片+TiO2+SiO2+TiO2
Al2O3薄片+Fe2O3+SiO2+TiO2
Al2O3薄片+TiO2/Fe2O3+SiO2+TiO2
Al2O3薄片+TiO2+SiO2+TiO2/Fe2O3
Al2O3薄片+TiO2+SiO2
Al2O3薄片+TiO2+SiO2/Al2O3
Al2O3薄片+TiO2+Al2O3
Al2O3薄片+SnO2
Al2O3薄片+SnO2+TiO2
Al2O3薄片+SnO2+Fe2O3
Al2O3薄片+SiO2
Al2O3薄片+SiO2+TiO2
Al2O3薄片+SiO2+TiO2/Fe2O3
Al2O3薄片+SiO2+Fe2O3
Al2O3薄片+SiO2+TiO2+Fe2O3
Al2O3薄片+SiO2+TiO2+Fe3O4
Al2O3薄片+SiO2+TiO2+SiO2+TiO2
Al2O3薄片+SiO2+Fe2O3+SiO2+TiO2
Al2O3薄片+SiO2+TiO2/Fe2O3+SiO2+TiO2
Al2O3薄片+SiO2+TiO2+SiO2+TiO2/Fe2O3
Al2O3薄片+SiO2+TiO2+SiO2
Al2O3薄片+SiO2+TiO2+SiO2/Al2O3
Al2O3薄片+SiO2+TiO2+Al2O3
Al2O3薄片+TiO2+普鲁士蓝 
Al2O3薄片+TiO2+胭脂红 
在上述优选的实施方案中的TiO2层可为金红石型或锐钛矿型。在优选实施方案中提及的上述Al2O3薄片可以是掺杂或未掺杂的。 
在本申请中,术语“涂层”或“层”是指根据本发明的Al2O3薄片的完整的包封。 
基于掺杂或未掺杂的Al2O3薄片的效果颜料优选由基于总的颜料40-90重量%的Al2O3薄片和10-60重量%的涂层组成。 
Al2O3薄片可以由CVD或PVD法通过湿法化学涂覆来进行涂覆。 
具有一层或多层、优选一层或多层金属氧化物层的α-Al2O3薄片的涂覆优选通过湿化学法进行,其中可以使用为制备珠光颜料而开发的湿法化学涂覆法。这种类型的方法描述于例如DE1467468、DE1959988、DE2009566、DE2214545、DE2215191、DE2244298、DE2313331、DE1522572、DE3137808、DE3137809、DE3151343、DE3151354、DE3151355、DE3211602、DE3235017中,或其它专利文献以及本领域技术人员公知的在其他出版物中。 
在湿涂的情况下,将Al2O3薄片悬浮在水中,并在适合于水解的pH下添加一种或多种可水解的金属盐,所述金属盐以金属氧化物或金属氧化物的水合物直接沉淀到薄片上而无需发生二次沉淀的方式选择。通过同时计量加入碱和/或酸使pH通常保持恒定。随后将颜料分离,洗涤,在50-150℃下干燥6-18小时,并煅烧0.5-3小时,其中可以相对于存在的各涂料优化煅烧温度。通常,煅烧温度是500-1000℃,优选600-900℃。如果需要,可以在施涂各涂层之后将颜料分离、干 燥和任选地煅烧,然后再重新悬浮以施用其它层。 
向Al2O3薄片和/或向已涂覆的Al2O3薄片施用SiO2层,通常是通过在合适的pH下添加钾或钠水玻璃溶液进行。 
此外,涂覆还可以在流化床反应器中通过气相涂覆进行,其中可以使用例如在EP0045851和EP0106235中提出的相应方法制备珠光颜料。 
基于根据本发明的Al2O3薄片的效果颜料的色度和彩度可以通过选择不同的涂覆量或由此产生的层厚度而在非常宽的范围变化。在纯量的选择之外,还可以通过在视觉或测量技术控制下接近所需要的颜色来实现对一定色度和/或彩度的微调。 
为了增加光、水和天气稳定性,取决于应用领域,经常建议对修饰的颜料进行后涂覆或后处理。合适的后涂覆或后处理例如是在2215191C2、DE-A3151354、DE-A3235017或DE-A3334598中描述的方法。后涂覆进一步提高了化学和光化学稳定性或简化了颜料的处理,特别是在引入到各种介质中的情况下。为了改进耐候性、分散性和/或与使用介质的相容性,例如可以将Al2O3或者ZrO2或者其混合物的功能性涂料施用到颜料表面。此外,有机后涂覆是可能的,例如用如在EP0090259、EP0634459、WO99/57204、WO96/32446、WO99/57204、U.S.5,759,255、U.S.5,571,851、WO01/92425或者J.J.Ponjeé,Philips Technical Review,第44卷,No.3,81ff.和P.H.Harding J.C.Berg,J.Adhesion Sci.Technol.第11卷No.4,第471-493页中所述的硅烷。 
根据本发明,已经发现基于具有期望的尺寸分布的Al2O3薄片的效果颜料在所有类型的组合物包括塑料、化妆品以及特别是在汽车油漆中是有用的。 
根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料与多种颜色体系相容,优选来自油漆、汽车涂料、工业涂料和印刷油墨以及化妆品制剂的领域。对于制备印刷油墨而言,例如凹版印刷、柔性版印刷、胶版印刷和胶版再涂印刷(offset overvarnishing), 多种粘结剂(特别是水溶性等级,例如由BASF、Marabu、Sericol、Hartmann、Gebr.Schmidt、Sicpa、Aarberg、Siegberg、GSB-Wahl、Follmann、Ruco或者Coates Screen INKS GmbH所售的)是合适的。印刷油墨可以是基于水的或基于溶剂的。颜料另外还适用于纸和塑料的激光标记和在农业领域的应用(例如用于温室片材和例如帐篷遮阳篷的着色)。 
不言而喻的是,对于不同的应用而言,根据本发明的涂覆和未涂覆的Al2O3薄片也可以有利地用于与有机染料、有机颜料或其它颜料(例如,透明的和不透明的白色、彩色和黑色颜料)以及与薄片状氧化铁、全息颜料、LCP(液晶聚合物)和常规的基于金属氧化物涂覆的云母和SiO2薄片的彩色和黑色光泽颜料等的共混物中。根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料可以与市售的颜料和填料以任何比例混合。 
可提及的填料例如是天然和合成云母、尼龙粉、纯的或填充的三聚氰胺树脂、滑石、SiO2、玻璃、高岭土、铝、镁、钙或锌的氧化物或氢氧化物、BiOCl、硫酸钡、硫酸钙、碳酸钙、碳酸镁、碳以及这些物质的物理或化学组合。对于填料的颗粒形状没有限制。根据要求它可以是例如薄片状、球状或针状。 
根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料是简单且容易处理的。通过简单地搅拌就可以将Al2O3薄片和基于Al2O3薄片的效果颜料引入到使用其的体系中。Al2O3薄片和效果颜料的费力研磨和分散是没有必要的。 
根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料可用于着色涂料材料、印刷油墨、塑料、农用膜、扣状糊剂、用于种子的包衣、用于食品的着色、药物的包衣或化妆品制剂。Al2O3薄片和效果颜料在将其用于着色体系中的浓度通常为0.01-50重量%,优选0.1-5重量%,基于体系的总固含量计。该浓度通常取决于具体的应用。 
包含0.1-50重量%、特别是0.5-7重量%的量的根据本发明的 Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料的塑料常常对于特定的光泽度效果是显著的。 
在涂料领域中,尤其是在汽车涂料和汽车修饰中,以0.5-10重量%的量使用基于根据本发明的Al2O3薄片的效果颜料。 
在涂层材料中,根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料具有通过单层涂层(单涂层体系或者在双涂层体系中作为底涂层)获得期望的颜色和光泽度的优势。 
在粘结剂体系的着色中,例如用于凹版印刷、胶印或丝网印刷用油漆和印刷油墨,基于Al2O3薄片与来自Eckart GmbH的-铝和金黄铜糊剂的效果颜料已经证实是特别适合的。效果颜料以2-50重量%、优选5-30重量%以及特别是8-15重量%的量掺入到印刷油墨中。含有根据本发明的效果颜料与金属效果颜料组合的印刷油墨表现出较纯的色度并且由于良好的粘度值而提高的适印性。 
本发明同样提供了颜料制剂,其含有根据本发明的涂覆或未涂覆的Al2O3薄片和其它效果颜料、粘结剂和如果需要的添加剂,所述制剂为基本上无溶剂自由流动的颗粒形式。这样的颗粒含有高达95重量%的根据本发明的效果颜料。颜料制剂(其中根据本发明的Al2O3薄片和基于根据本发明的Al2O3薄片的效果颜料是在有或没有添加剂的情况下用粘结剂和用水和/或有机溶剂糊住,随后将糊干燥并使其成为紧实的颗粒形式(例如球粒、丸、块、母料或片))特别适合作为印刷油墨用前体。 
因此,本发明还涉及涂覆(=效果颜料)或未涂覆的Al2O3薄片在油漆、涂料、汽车涂料、汽车修饰、工业涂料、油漆、粉末涂料、印刷油墨、安全印刷油墨、塑料、陶瓷材料、化妆品等领域的组合物中的用途。涂覆和未涂覆的Al2O3薄片还可以用在玻璃、纸张、纸张涂覆、电子照相印刷工艺的调色剂、种子、温室片材和防水油布、用于机器或装置绝缘的导热性自支撑电绝缘性柔性片材中,作为纸张和塑料的激光标记中的吸收剂,作为塑料的激光焊接中的吸收剂,用在水、有机和/或水性溶剂的颜料糊中,用在颜料制剂和干制剂(例如颗粒剂) 中,例如用在工业和汽车领域的透明涂层中,用在防晒剂中,作为填料,特别是用在汽车涂料和汽车修饰中。 
除非另有说明,在本申请中所有百分比数据都是重量百分比。 
以下实施例是为了更详细地解释本发明而非限制本发明。在上下文中,所有的百分比都是重量百分比。 
实施例
对比实施例1(U.S.5,702,519的实施例2)
通过在60℃以上加热将111.9g十八水合硫酸铝、57.3g无水硫酸钠和46.9g硫酸钾溶于300ml去离子水中。向该溶液中加入3.0g的34.4%的硫酸氧钛溶液。将所得的溶液称为水溶液(a)。 
将0.45g十二水合磷酸三钠和55.0g碳酸钠加入到150L去离子水中。将所得的溶液称为水溶液(b)。 
在搅拌下将水溶液(b)加入到保持在约60℃的水溶液(a)。继续搅拌15分钟。所得的两种溶液(a)和(b)的混合物是凝胶。将该凝胶蒸发至干,并将经干燥的产物在1200℃下加热5小时。将水加入到经加热的产物以溶解游离硫酸盐。滤出不溶性固体,用水洗涤,最后干燥。用X-射线衍射仪检测所得到的氧化铝薄片。衍射图案只具有因刚玉结构(α-氧化铝结构)的峰。D50为13.0μm,D90为22.0μm和厚度为200nm。 
α-Al2O3薄片的厚度分布是83。 
实施例1:Al2O3薄片的制备 
通过在60℃以上加热将74.6g十八水合硫酸铝、57.1g聚氯化铝(PAC:Central Glass Co.,LTD,10%的溶液,作为Al2O3)、57.3g无水硫酸钠和46.9g硫酸钾溶解在300ml去离子水中。向该溶液中加入3.0g的34.4%的硫酸氧钛溶液。将所得的溶液称为水溶液(a)。 
将0.45g十二水合磷酸三钠和55.0g碳酸钠加入到300mL去离子水中。将所得的溶液称为水溶液(b)。 
在搅拌下将水溶液(b)加入到保持在约60℃的水溶液(a)中。继续搅拌1小时。所得的两种溶液(a)和(b)的混合物是浆体。将该浆体蒸发至干,并将经干燥的产物在1150℃下加热6小时。将水加入到经加热的产物以溶解游离硫酸盐。滤出不溶性固体,用水洗涤,最后干燥产物。 
用X-射线衍射仪检测所得到的氧化铝薄片。衍射图案只具有因刚玉结构(α-氧化铝结构)的峰。 
所得到的Al2O3薄片的D50值为16.0μm,D90值为30.8μm和厚度为200nm。 
α-Al2O3薄片的厚度分布是28。 
实施例2:Al2O3薄片的制备 
通过在60℃以上加热将74.6g十八水合硫酸铝、57.1g聚氯化铝(PAC:Central Glass Co.,LTD,10%的溶液,作为Al2O3)、57.3g无水硫酸钠和46.9g硫酸钾溶解在300ml去离子水中。向该溶液中加入3.0g的34.4%的硫酸氧钛溶液和5.5g的5.0%的氯化铟(III)溶液。将所得的溶液称为水溶液(a)。 
将0.45g十二水合磷酸三钠和55.0g碳酸钠加入到300mL去离子水中。将所得的溶液称为水溶液(b)。 
在搅拌下将水溶液(b)加入到保持在约60℃的水溶液(a)中。继续搅拌1小时。所得的两种溶液(a)和(b)的混合物是浆体。将该浆体蒸发至干,并将经干燥的产物在1200℃下加热4小时。将水加入到经加热的产物以溶解游离硫酸盐。滤出不溶性固体,用水洗涤,最后干燥产物。 
用X-射线衍射仪检测所得到的氧化铝薄片。衍射图案只具有因刚玉结构(α-氧化铝结构)的峰。 
得到的Al2O3薄片的D50值为19.0μm,D90值为35.6μm和厚度为250nm。 
α-Al2O3薄片的厚度分布是32。 
对比实施例1.1:Al2O3薄片的涂覆 
将20g对比实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含有125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出银色时,停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到发白和少许光泽的珠光颜料。 
实施例1.1:Al2O3薄片的涂覆 
将20g实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含有125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出银色时,停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到具有高度发白而有光泽的珠光颜料。在光泽的角度,与对比实施例1.1相比,可以在更宽泛的角度看到光泽的外观。 
实施例2.1:Al2O3薄片的涂覆 
将20g实施例2的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含有125g的TiCl4的溶液。同时加入10%的NaOH溶液,以保持pH在2.1。当所得产物呈现出银色时,停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟以得到具有高度发白且有光泽的珠光颜料。在光泽的角度,与对比实施例1.1相比,可以在更宽泛的角度看到光泽的外观。 
对比实施例1.2:Al2O3薄片的涂覆 
将20g对比实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约75℃)中加入每升含有300g的FeCl3的溶液。 同时加入10%的NaOH溶液以保持pH在3.0。当所得产物呈现出最大程度的淡红的颜色时,停止加入FeCl3溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在800℃下煅烧30分钟,得到具有适度光泽和棕红色的着色珠光颜料。 
实施例1.2:
将20g实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约75℃)中加入每升含有300g的FeCl3的溶液。同时加入10%的NaOH溶液以保持pH在3.0。当所得产物呈现出最大程度的淡红的颜色时,停止加入FeCl3溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在800℃下煅烧30分钟以得到具有高光泽和纯红色的着色的珠光颜料。与对比实施例1.2的颜料的外观相比,该颜料表现出更高的光泽和更干净的红色。 
对比实施例1.3:Al2O3薄片的涂覆 
将20g对比实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含有50g的SnCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1,直到SnCl4溶液的总添加体积为17ml。接着,向所得悬浮液中加入每升含125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出银色时,停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到发白和少许光泽的珠光颜料。 
实施例1.3:Al2O3薄片的涂覆 
将20g实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含有50g的SnCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1,直到SnCl4溶液的总添加体积为17ml。接着,向所得悬浮液中加入每升含125g的TiCl4的溶液。 同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出银色时,停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到高度发白和高光泽的珠光颜料。在光泽的角度,与对比实施例1.3相比,可以在更宽泛的角度看到光泽的外观。 
对比实施例1.4:Al2O3薄片的涂覆 
将20g对比实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出淡黄色时,停止加入TiCl4溶液。然后向所得悬浮液中加入每升含50g的Na2SiO3的溶液。同时加入10%的HCl溶液以保持pH在7。接着,向所得的悬浮液中加入每升含125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出淡蓝色时停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到蓝-发白且有点光泽的珠光颜料。 
实施例1.4:Al2O3薄片的涂覆 
将20g实施例1的氧化铝薄片悬浮在400ml去离子水中。向所得悬浮液(保持在约65℃)中加入每升含125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出淡黄色时,停止加入TiCl4溶液。然后向所得悬浮液中加入每升含50g的Na2SiO3的溶液。同时加入10%的HCl溶液以保持pH在7。接着,向所得的悬浮液中加入每升含125g的TiCl4的溶液。同时加入10%的NaOH溶液以保持pH在2.1。当所得产物呈现出淡蓝色时停止加入TiCl4溶液。滤出悬浮固体,用水洗涤,并干燥。最后,将经干燥的固体在850℃下煅烧30分钟,得到高度发蓝和光泽的珠光颜料。在光泽的角度,与对比实施例1.4相比,可以在更宽泛的角度看到更强发蓝的颜色和高光泽外观。 
测量 
评价粒径D 10 、D 50 和D 90
通过使用Malvern MS2000评价氧化铝薄片的D10、D50和D90。 
厚度、粒径和厚度分布的测定
制备0.01g/l的氧化铝薄片浆体,并将0.1ml该浆体滴到平的基底如硅晶片上。干燥基底并将其切成适当尺寸。以SEM(扫描电子显微镜)为基础将基底设置成几乎垂直的倾斜角度并测定氧化铝薄片的厚度。 
测量超过100个氧化铝薄片的厚度用于计算厚度分布。用高斯分布等式计算厚度的标准偏差。 
喷涂面板的制备
根据以下配方制备用于汽车的底涂层(base coat)油漆。 
*来自Dainippon Ink&Chemicals公司的丙烯酸树脂 
**来自Dainippon Ink&Chemicals公司的三聚氰胺树脂 
将上述丙烯酸-三聚氰胺树脂体系(100pbw)与根据实施例1或2的20pbw的珠光颜料结合。用稀释剂稀释所得到的化合物,使得所得到的油漆具有用于足够的喷涂稠度(12-15秒,对于杯#4)。将该油漆通过喷涂施用到基材上以形成底涂层。 
进一步用无色透明顶涂层(top clear coat)油漆来涂覆底涂层,所述油漆是根据下列配方制备。 
透明顶涂层在40℃下暴露于空气中30分钟,然后在135℃下固化30分钟。 
雾度-光泽度(haze-gloss)(BYK)是评估光泽和雾度的分析设备。在本专利申请中,在60°镜面光泽度的值是通过雾度-光泽度测定并表示光泽度的值。相比于现有技术,经涂覆的Al2O3薄片显示出非常高的光泽度值。高光泽度值对在应用中实现良好的外观是必要的。通过此设备测得的雾度值受反射角的扩展的影响。在本专利申请中,更宽的扩展角度对于珠光外观是重要的。根据本发明经涂覆的Al2O3薄片显示出非常高的雾度-光泽度值。 
为区分不同的评价结果,在将面板用透明顶涂层涂覆以用于雾度-光泽度测量之前,使用用底涂层喷涂的面板。 
使用Wave-scan dual(BYK)作为分析设备来测量样品的表面平整度。Wa值表示在0.1-0.3mm范围内的循环平整度。在本专利申请中,值越小,表示表面越平,这显示根据本发明的颜料的优点。 
测量具有透明顶涂层的喷涂面板的Wa。平坦的表面有更好的整理外观。 
根据上面给出的实施例的珠光颜料的光学性能汇总于下表中: 
表1:

Claims (16)

1.Al2O3薄片,其具有小于500nm的颗粒厚度以及15-30μm的D50值和30-45μm的D90值。
2.根据权利要求1的Al2O3薄片,其特征在于所述Al2O3薄片是α-氧化铝薄片。
3.根据权利要求1或2的Al2O3薄片,其特征在于所述Al2O3薄片具有小于80的厚度分布标准偏差。
4.根据权利要求1至3的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片掺杂有TiO2、ZrO2、SiO2、SnO2、In2O3、ZnO及其组合。
5.根据权利要求1至4的一项或多项的Al2O3薄片,其特征在于基于所述Al2O3薄片的掺杂量为0.01-5重量%。
6.根据权利要求1至5的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片掺杂有TiO2
7.根据权利要求1至6的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片涂覆有至少一层的金属氧化物、至少两种金属氧化物的混合物、金属、金属硫化物、钛的低氧化物、氮氧化钛、FeO(OH)、SiO2、金属合金或者稀土化合物。
8.根据权利要求1至7的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片涂覆有至少一层的金属氧化物或者至少两种金属氧化物的混合物。
9.根据权利要求1至8的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片涂覆有以下层顺序:
Al2O3薄片+TiO2
Al2O3薄片+TiO2/Fe2O3
Al2O3薄片+Fe2O3
Al2O3薄片+TiO2+Fe2O3
Al2O3薄片+TiO2+Fe3O4
Al2O3薄片+TiO2+SiO2+TiO2
Al2O3薄片+Fe2O3+SiO2+TiO2
Al2O3薄片+TiO2/Fe2O3+SiO2+TiO2
Al2O3薄片+TiO2+SiO2+TiO2/Fe2O3
Al2O3薄片+TiO2+SiO2
Al2O3薄片+TiO2+SiO2/Al2O3
Al2O3薄片+TiO2+Al2O3
Al2O3薄片+SnO2
Al2O3薄片+SnO2+TiO2
Al2O3薄片+SnO2+Fe2O3
Al2O3薄片+SiO2
Al2O3薄片+SiO2+TiO2
Al2O3薄片+SiO2+TiO2/Fe2O3
Al2O3薄片+SiO2+Fe2O3
Al2O3薄片+SiO2+TiO2+Fe2O3
Al2O3薄片+SiO2+TiO2+Fe3O4
Al2O3薄片+SiO2+TiO2+SiO2+TiO2
Al2O3薄片+SiO2+Fe2O3+SiO2+TiO2
Al2O3薄片+SiO2+TiO2/Fe2O3+SiO2+TiO2
Al2O3薄片+SiO2+TiO2+SiO2+TiO2/Fe2O3
Al2O3薄片+SiO2+TiO2+SiO2
Al2O3薄片+SiO2+TiO2+SiO2/Al2O3
Al2O3薄片+SiO2+TiO2+Al2O3
Al2O3薄片+TiO2+普鲁士蓝
Al2O3薄片+TiO2+胭脂红。
10.根据权利要求1至9的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片涂覆有金红石型或锐钛矿型TiO2
11.根据权利要求1至10的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片涂覆有金红石型TiO2
12.根据权利要求1至11的一项或多项的Al2O3薄片,其特征在于所述Al2O3薄片由基于总颜料计40-90重量%的Al2O3薄片和10-60重量%的涂层组成。
13.根据权利要求1至12的一项或多项的Al2O3薄片的制备方法,其特征在于以下步骤:
(1)制备至少一种水溶性和/或水不溶性铝盐的水溶液或浆体,
(2)向铝盐溶液中添加碱溶液以沉淀氢氧化铝颗粒,和在所述沉淀之前、期间或者之后向水溶液添加磷化合物和任选的至少一种掺杂剂,
(3)蒸发水,随后干燥步骤(2)的沉淀产物以形成含颗粒和碱盐的氧化铝的干燥形式,
(4)煅烧在步骤(3)中得到的干燥形式以得到熔融盐形式的Al2O3薄片,
(5)除去在步骤(4)中获得的煅烧材料的水溶性部分,
(6)调节颗粒尺寸和厚度。
14.根据权利要求1至12的一项或多项的Al2O3薄片作为效果颜料的基础材料以及在以下领域的组合物中的用途:在油漆、涂料、汽车涂料、汽车修饰、工业涂料、油漆、粉末涂料、印刷油墨、安全性印刷油墨、塑料、陶瓷材料、化妆品、玻璃、纸张、纸张涂覆、电子照相印刷工艺的调色剂、种子、温室片材和防水油布、用于机器或装置绝缘的导热性自支撑电绝缘性柔性片材中,作为纸张和塑料的激光标记中的吸收剂,作为塑料的激光焊接中的吸收剂,在水、有机和/或水性溶剂的颜料糊中,在颜料制剂和干制剂中。
15.组合物,其包含基于整个组合物计0.01-95重量%量的根据权利要求1至12的一项或多项的涂覆或未涂覆的Al2O3薄片。
16.含根据权利要求1至12的一项或多项的Al2O3薄片的组合物,特征在于所述组合物包含选自水、多元醇、极性和非极性油、脂肪、蜡、成膜剂、聚合物、共聚物、表面活性剂、自由基清除剂、抗氧化剂、稳定剂、增味剂、硅油、乳化剂、溶剂、防腐剂、增稠剂、流变添加剂、香料、着色剂、效果颜料、UV吸收剂、表面活性助剂和/或化妆品活性化合物、填料、粘结剂、珠光颜料、彩色颜料和有机染料的至少一种组分。
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