JP2022542020A - 多孔質焼結膜及び多孔質焼結膜を調製する方法 - Google Patents
多孔質焼結膜及び多孔質焼結膜を調製する方法 Download PDFInfo
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- JP2022542020A JP2022542020A JP2022502836A JP2022502836A JP2022542020A JP 2022542020 A JP2022542020 A JP 2022542020A JP 2022502836 A JP2022502836 A JP 2022502836A JP 2022502836 A JP2022502836 A JP 2022502836A JP 2022542020 A JP2022542020 A JP 2022542020A
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Abstract
Description
Claims (31)
- 成形された金型キャビティ内に液体射出組成物を粒子射出成形することによって多孔質焼結体を製造する方法であって、
液体射出組成物が、
少なくとも1つのポリマー結合剤、及び
液体射出組成物の総体積に基づいて、20~50体積%の固体無機粒子
を含む、成形された金型キャビティ内に液体射出組成物を流すことと、
成形された金型キャビティ内でポリマー結合剤の固化を引き起こして、固体無機粒子を取り囲む固体結合剤を含む固化した射出組成物を形成することと
を含む、方法。 - 金型キャビティから固化した射出組成物を除去することと、
固化した射出組成物から固体結合剤を除去して、多孔質非焼結体を形成することと、
多孔質非焼結体を焼結して、多孔質焼結膜を形成することと
をさらに含む、請求項1に記載の方法。 - 固体無機粒子が、樹枝状又は繊維状であり、2.0グラム/立方センチメートル未満の見掛け密度を有する、請求項1又は2に記載の方法。
- 固体無機粒子が、粒子の理論密度の5~35%の範囲にある相対見掛け密度を有する、請求項1~3のいずれか一項に記載の方法。
- 多孔質焼結膜が、50~80%の範囲にある多孔度を有する、請求項2~4のいずれか一項に記載の方法。
- ポリマー結合剤が、ワックス、ポリプロピレン、ポリエチレングリコール、ポリオキシメチレン、ポリメチルメタクリレート、エチルビニルアセテート、及びそれらの組合せから選択される熱可塑性ポリマーを含む、請求項1~5のいずれか一項に記載の方法。
- ポリマー結合剤が、固化した射出組成物を摂氏40度~80度の範囲にある温度の水、有機溶媒、及びそれらの組合せから選択される液体溶媒と接触させることによって、固化した射出組成物から除去され得る一次結合剤を含む、請求項1~6のいずれか一項に記載の方法。
- 一次結合剤が、ワックス及びポリエチレングリコールから選択される、請求項7に記載の方法。
- 固化した射出組成物を摂氏40度~100度の範囲にある温度の水及び有機溶媒から選択される液体溶媒と接触させることによって、固化した射出組成物から一次結合剤を除去することをさらに含む、請求項7又は8に記載の方法。
- 有機溶媒が、ヘプタン、ヘキサン、ハイドロフルオロエーテル、ジクロロエチレン、トリクロロエチレン、及びそれらの混合物から選択される、請求項9に記載の方法。
- ポリマー結合剤が、固化した射出組成物を摂氏600度以下の温度まで加熱することによって、固化した射出組成物から除去され得る二次結合剤を含む、請求項7~10のいずれか一項に記載の方法。
- 二次結合剤が、ポリプロピレン、ポリオキシメチレン、ポリメチルメタクリレート、エチルビニルアセテートから選択される、請求項11に記載の方法。
- 一次結合剤の少なくとも一部を除去した後、固化した射出組成物を摂氏600度以下の温度まで加熱して、固体結合剤を除去することをさらに含む、請求項9~12のいずれか一項に記載の方法。
- 多孔質焼結体が、三次元の管を含む形状を有する環状ろ過膜である、請求項1~13のいずれか一項に記載の方法。
- 管が、管の軸の方向で見た場合、円形断面を有する、請求項14に記載の方法。
- 管が、管の軸の方向で見た場合、非円形断面を有する、請求項14に記載の方法。
- 非円形断面がひだのあるパターンを含む、請求項16に記載の方法。
- 多孔質焼結体が三次元の非管状ろ過膜である、請求項1~13のいずれか一項に記載の方法。
- 液体射出組成物であって、
液体射出組成物の総体積に基づいて、
50~80体積%のポリマー結合剤と、
固体無機粒子の理論密度の5~35%の範囲にある相対見掛け密度を有する20~50体積%の固体無機粒子と
を含む、液体射出組成物。 - 無機粒子が、樹枝状又は繊維状であり、2.0グラム/立方センチメートル未満の見掛け密度を有する、請求項19に記載の組成物。
- 焼結粒子を含み、50~80%の範囲にある多孔度を有する、射出成形された多孔質焼結体。
- 粒子が樹枝状粒子である、請求項21に記載の射出成形された多孔質焼結体。
- 粒子が繊維状粒子である、請求項21に記載の射出成形された多孔質焼結体。
- 三次元の管を含む形状を有する環状ろ過膜の形態である、請求項21~23のいずれか一項に記載の射出成形された多孔質焼結体。
- 管が、管の軸の方向で見た場合、円形断面を有する、請求項24に記載の射出成形された多孔質焼結体。
- 管が、管の軸の方向で見た場合、非円形断面を有する、請求項24に記載の射出成形された多孔質焼結体。
- 非円形断面がひだのあるパターンを含む、請求項26に記載の射出成形された多孔質焼結体。
- 2つの対向する主要な表面と、2つの対向する表面の間の厚さとを含み、非円柱形状を有する、請求項21~23のいずれか一項に記載の射出成形された多孔質焼結体。
- 少なくとも1つの主要な表面が、高くなった隆起部、チャネル、又はワッフリングなどのパターンを含む構造を有する、請求項28に記載の射出成形された多孔質焼結体。
- 射出成形金型マーキングをさらに含む、請求項21~29のいずれか一項に記載の射出成形された多孔質焼結体。
- 分割線マーク(金型の分割線によって形成される)、インジェクタピンマーク(金型の射出ピンによって形成される)、ゲートマーク(金型のゲート又はゲート開口部によって形成される)、又はキャビティ番号(金型表面のキャビティ番号マークによって形成される)のうちの1つ又は複数を更に含む、請求項21~29のいずれか一項に記載の射出成形された多孔質焼結体。
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