WO2022172940A1 - 無機構造体及びその製造方法 - Google Patents
無機構造体及びその製造方法 Download PDFInfo
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- WO2022172940A1 WO2022172940A1 PCT/JP2022/005031 JP2022005031W WO2022172940A1 WO 2022172940 A1 WO2022172940 A1 WO 2022172940A1 JP 2022005031 W JP2022005031 W JP 2022005031W WO 2022172940 A1 WO2022172940 A1 WO 2022172940A1
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- inorganic
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- inorganic particles
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- inorganic structure
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- 238000004519 manufacturing process Methods 0.000 title claims description 21
- 239000010954 inorganic particle Substances 0.000 claims abstract description 117
- 239000002245 particle Substances 0.000 claims abstract description 108
- 229910052751 metal Inorganic materials 0.000 claims abstract description 36
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 34
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 27
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 27
- 239000010936 titanium Substances 0.000 claims abstract description 27
- 150000001875 compounds Chemical class 0.000 claims abstract description 24
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 21
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 20
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 12
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 10
- 229910052783 alkali metal Inorganic materials 0.000 claims description 7
- 229910052788 barium Inorganic materials 0.000 claims description 7
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- 229910052796 boron Inorganic materials 0.000 claims description 7
- 229910052791 calcium Inorganic materials 0.000 claims description 7
- 229910052712 strontium Inorganic materials 0.000 claims description 7
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- 238000002156 mixing Methods 0.000 claims description 6
- 239000004411 aluminium Substances 0.000 abstract 1
- 239000011859 microparticle Substances 0.000 abstract 1
- 238000012360 testing method Methods 0.000 description 92
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 54
- 239000000843 powder Substances 0.000 description 52
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- 239000000126 substance Substances 0.000 description 23
- LYTNHSCLZRMKON-UHFFFAOYSA-L oxygen(2-);zirconium(4+);diacetate Chemical compound [O-2].[Zr+4].CC([O-])=O.CC([O-])=O LYTNHSCLZRMKON-UHFFFAOYSA-L 0.000 description 20
- 238000000034 method Methods 0.000 description 19
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- 229910010272 inorganic material Inorganic materials 0.000 description 5
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- 229910002012 Aerosil® Inorganic materials 0.000 description 2
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- 230000002776 aggregation Effects 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 2
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- 239000012535 impurity Substances 0.000 description 2
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- 230000003287 optical effect Effects 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
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- XJDNKRIXUMDJCW-UHFFFAOYSA-J titanium tetrachloride Chemical compound Cl[Ti](Cl)(Cl)Cl XJDNKRIXUMDJCW-UHFFFAOYSA-J 0.000 description 2
- DUFCMRCMPHIFTR-UHFFFAOYSA-N 5-(dimethylsulfamoyl)-2-methylfuran-3-carboxylic acid Chemical compound CN(C)S(=O)(=O)C1=CC(C(O)=O)=C(C)O1 DUFCMRCMPHIFTR-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
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- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
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- 229910052706 scandium Inorganic materials 0.000 description 1
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 1
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- 239000011163 secondary particle Substances 0.000 description 1
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 1
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- 239000006104 solid solution Substances 0.000 description 1
- 239000012798 spherical particle Substances 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 229910052714 tellurium Inorganic materials 0.000 description 1
- PORWMNRCUJJQNO-UHFFFAOYSA-N tellurium atom Chemical compound [Te] PORWMNRCUJJQNO-UHFFFAOYSA-N 0.000 description 1
- 229910052716 thallium Inorganic materials 0.000 description 1
- BKVIYDNLLOSFOA-UHFFFAOYSA-N thallium Chemical compound [Tl] BKVIYDNLLOSFOA-UHFFFAOYSA-N 0.000 description 1
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
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- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
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- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3244—Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
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- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
- C04B2235/449—Organic acids, e.g. EDTA, citrate, acetate, oxalate
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- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/80—Phases present in the sintered or melt-cast ceramic products other than the main phase
- C04B2235/85—Intergranular or grain boundary phases
Definitions
- the present invention relates to an inorganic structure and a manufacturing method thereof.
- a sintering method is known as a method of manufacturing an inorganic structure made of ceramics.
- the sintering method is a method of obtaining a sintered body by heating an aggregate of solid powder made of an inorganic substance at a temperature lower than the melting point.
- Patent Document 1 discloses a glass powder made of WO 3 , TiO 2 or a solid solution thereof and containing crystals having photocatalytic properties. It is disclosed that a shaped compact is obtained. It is also described that such a solidified molded product is useful as a photocatalytic functional material having excellent photocatalytic properties.
- An object of the present invention is to provide an inorganic structure that can be produced by a simple method and has a high density, and a method for producing the inorganic structure.
- an inorganic structure includes a plurality of inorganic particles, and a bonding portion that covers the surface of each of the plurality of inorganic particles and bonds each of the plurality of inorganic particles.
- the joint portion contains an amorphous compound containing at least one of aluminum and titanium, oxygen, and one or more metal elements, and a plurality of fine particles having an average particle size of 100 nm or less.
- the average particle size of the plurality of inorganic particles is 1 ⁇ m or more, and the volume ratio of the plurality of inorganic particles is 30% or more.
- the above method includes the step of pressurizing and heating the mixture under conditions of a pressure of 10-600 MPa and a temperature of 50-300°C.
- the volume ratio of the plurality of inorganic particles in the mixture is 30% or more.
- FIG. 1 is a cross-sectional view schematically showing an example of an inorganic structure according to this embodiment.
- FIG. 2 is a schematic cross-sectional view for explaining the method for manufacturing an inorganic structure according to this embodiment.
- FIG. 3 is a scanning electron microscope (SEM) image of the test sample of Example 1 at 500 ⁇ magnification.
- FIG. 4 is an SEM image of the test sample of Example 1 magnified 2000 times.
- FIG. 5 is an SEM image of the second alumina powder magnified 2000 times.
- FIG. 6 is an SEM image of the second alumina powder magnified 10,000 times.
- FIG. 7 is an SEM image of the test sample of Reference Example 1 magnified 2000 times.
- FIG. 8 is an SEM image of the test sample of Reference Example 1 magnified 10,000 times.
- FIG. 1 is a cross-sectional view schematically showing an example of an inorganic structure according to this embodiment.
- FIG. 2 is a schematic cross-sectional view for explaining the method for manufacturing an inorganic structure according
- FIG. 9 is an EDX spectrum of the part where particles exist in the test sample of Example 1;
- FIG. 10 is an EDX spectrum of the portion binding particles in the test sample of Example 1;
- 11 is a diagram showing the results of mapping analysis on the test sample of Example 1.
- FIG. 12 shows the XRD pattern of the secondary alumina powder (fumed alumina) as a raw material, the XRD pattern of the test sample of Reference Example 2, and the XRD patterns of ⁇ -alumina and ⁇ -alumina registered with ICSD.
- FIG. 13 is an SEM image of the cross section of the test sample of Example 1, which was processed with a cross-section polisher and magnified 2000 times.
- FIG. 14 is an SEM image of the cross section of the test sample of Example 1, which was subjected to cross-section polishing and magnified 5000 times.
- FIG. 15 is an SEM image of the cross section of the test sample of Example 1, which was subjected to cross-section polishing and magnified 10,000 times.
- FIG. 16 is an SEM image of the cross section of the test sample of Example 1, which was subjected to cross-section polishing and magnified 50,000 times.
- FIG. 17 is an SEM image of the cross section of the test sample of Example 1, which was subjected to cross-section polishing and magnified 2000 times.
- FIG. 18 is a binarized image of the SEM image of FIG.
- FIG. 19 is an SEM image of the test sample of Example 2 magnified 500 times.
- FIG. 20 is an SEM image of the test sample of Example 2 magnified 2000 times.
- FIG. 21 is an SEM image of titania powder magnified 2000 times.
- FIG. 22 is an SEM image of titania powder magnified 10,000 times.
- FIG. 23 is an SEM image of the test sample of Reference Example 3 magnified 2000 times.
- FIG. 24 is an SEM image of the test sample of Reference Example 3 magnified 10000 times.
- FIG. 25 is the EDX spectrum of the part where particles exist in the test sample of Example 2;
- FIG. 26 is an EDX spectrum of the portion binding particles in the test sample of Example 2;
- 27 is a diagram showing the results of mapping analysis on the test sample of Example 2.
- FIG. 28 shows the XRD pattern of the raw material titania powder (fumed titania), the XRD pattern of the test sample of Reference Example 3, and the XRD patterns of rutile-type TiO 2 and anatase-type TiO 2 registered with ICSD.
- FIG. 29 is a cross-sectional SEM image of the test sample of Example 2, which was cross-section polished and magnified 2000 times.
- FIG. 30 is an SEM image of the cross section of the test sample of Example 2, which was subjected to cross-section polishing and magnified 5000 times.
- FIG. 31 is an SEM image of the cross section of the test sample of Example 2, which was cross-section polished and magnified 10,000 times.
- FIG. 29 is a cross-sectional SEM image of the test sample of Example 2, which was cross-section polished and magnified 2000 times.
- FIG. 30 is an SEM image of the cross section of the test sample of Example 2, which was subjected to cross-section polishing and magnified 5000 times.
- FIG. 31
- FIG. 32 is an SEM image of the cross section of the test sample of Example 2, which was processed with a cross-section polisher and magnified 50000 times.
- FIG. 33 is an SEM image of the cross section of the test sample of Example 2, which was cross-section polished and magnified 2000 times.
- FIG. 34 is a binarized image of the SEM image of FIG.
- An inorganic structure 1 of the present embodiment includes a plurality of inorganic particles 2 and bonding portions 3, as shown in FIG. Adjacent inorganic particles 2 are bonded to each other via bonding portions 3 to form an inorganic structure 1 in which a plurality of inorganic particles 2 are aggregated.
- the inorganic particles 2 are composed of an inorganic substance, and the inorganic substance contains at least one metal element selected from the group consisting of alkali metals, alkaline earth metals, transition metals, base metals and semi-metals.
- alkaline earth metals include beryllium and magnesium, in addition to calcium, strontium, barium and radium.
- Transition metals include, for example, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, tungsten, platinum, and gold.
- Base metals include aluminum, zinc, gallium, cadmium, indium, tin, mercury, thallium, lead, bismuth and polonium.
- Metalloids include boron, silicon, germanium, arsenic, antimony and tellurium.
- the inorganic substance preferably contains aluminum.
- the inorganic particles 2 containing a metal element as described above can be easily bonded via the bonding portion 3 by a pressure heating method, as will be described later.
- the inorganic substance constituting the inorganic particles 2 is, for example, at least one selected from the group consisting of oxides, nitrides, hydroxides, hydroxide oxides, sulfides, borides, carbides and halides of the above metal elements. is preferably The oxides of metal elements described above may include phosphates, silicates, aluminates and borates in addition to compounds in which only oxygen is bonded to metal elements.
- the inorganic substance constituting the inorganic particles 2 may be a composite anion compound containing the metal element.
- a complex anion compound is a substance containing a plurality of anions in a single compound, and examples thereof include acid fluorides, acid chlorides, and oxynitrides.
- Inorganic substances constituting the inorganic particles 2 are preferably oxides or nitrides of the above metal elements. Since such an inorganic substance has high stability against oxygen and water vapor in the atmosphere, it is possible to obtain the inorganic structure 1 having excellent chemical stability and reliability.
- the inorganic substance constituting the inorganic particles 2 is an oxide.
- the oxide of the metal element is preferably a compound in which only oxygen is bonded to the metal element.
- a specific example of the inorganic substance forming the inorganic particles 2 is aluminum oxide.
- a specific example of the inorganic particles 2 is alumina particles. Since aluminum oxide has high acid resistance and alkali resistance, it is possible to obtain the inorganic structure 1 having high durability even under acidic or alkaline conditions.
- the inorganic particles 2 are composed of a simple metal oxide or a composite metal oxide. It is preferable that the simple metal oxide contains one type of metal element and the composite metal oxide contains two or more types of metal elements. When the inorganic particles 2 contain a simple metal oxide or a composite metal oxide of the above metal element, the obtained inorganic structure 1 becomes a ceramic that is stable and excellent in various properties.
- the inorganic particles 2 preferably contain a simple metal oxide or a composite metal oxide as a main component. Specifically, the inorganic particles 2 preferably contain 80 mol % or more of the simple metal oxide or the composite metal oxide, more preferably 90 mol % or more, and even more preferably 95 mol % or more.
- Each of the plurality of inorganic particles 2 is preferably crystalline. That is, the inorganic particles 2 preferably contain the inorganic substance described above and the inorganic substance is crystalline. By including a crystalline inorganic substance in the inorganic particles 2, it is possible to obtain an inorganic structural body 1 with higher durability than in the case of including an amorphous inorganic substance.
- the inorganic particles 2 may be single-crystal particles or polycrystalline particles.
- the average particle diameter of the plurality of inorganic particles 2 is 1 ⁇ m or more. When the average particle diameter of the inorganic particles 2 is within this range, the inorganic particles 2 are strongly bonded to each other, and the strength of the inorganic structure 1 can be increased. In addition, since the average particle diameter of the inorganic particles 2 is within this range, the ratio of pores existing inside the inorganic structure 1 is 20% or less, as described later, so that the strength of the inorganic structure 1 can be increased.
- the average particle size of the inorganic particles 2 is preferably 5 ⁇ m or more, more preferably 10 ⁇ m or more.
- the average particle size of the plurality of inorganic particles 2 is preferably 50 ⁇ m or less, more preferably 30 ⁇ m or less, even more preferably 25 ⁇ m or less, and particularly preferably 20 ⁇ m or less.
- the value of "average particle size” is measured using an observation means such as a scanning electron microscope (SEM) or a transmission electron microscope (TEM), and several to several tens of fields of view. A value calculated as an average value of the particle diameters of the particles observed inside is adopted.
- the shape of the inorganic particles 2 is not particularly limited, but can be spherical, for example.
- the inorganic particles 2 may be whisker-like (needle-like) particles or scale-like particles.
- the whisker-like particles or scale-like particles have higher contact with other particles and contact with the bonding portion 3 than spherical particles, so that the strength of the inorganic structure 1 as a whole can be increased.
- the bonding portion 3 bonds each of the plurality of inorganic particles 2 .
- Adjacent inorganic particles 2 are bonded via bonding portions 3, whereby the inorganic particles 2 are three-dimensionally bonded to each other, so that a bulk body with high mechanical strength can be obtained.
- the joint portion 3 is in direct contact with the inorganic particles 2 .
- the bonding portion 3 covers at least part of the surface of each of the plurality of inorganic particles 2 .
- the bonding portion 3 preferably covers the entire surface of each of the plurality of inorganic particles 2 .
- the joint portion 3 contains a plurality of fine particles 4 with an average particle diameter of 100 nm or less. Since the joint portion 3 contains such a plurality of fine particles 4, the structure becomes dense, and the strength of the inorganic structural body 1 can be increased.
- the average particle diameter of the fine particles 4 may be 80 nm or less, 50 nm or less, or 30 nm or less. Further, the average particle diameter of the fine particles 4 may be 1 nm or more, 5 nm or more, or 10 nm or more.
- the average particle size of the plurality of fine particles 4 can be measured using a scanning electron microscope (SEM) or a transmission electron microscope (TEM), as described above.
- the fine particles 4 may contain at least one oxide selected from the group consisting of aluminum oxide, titanium oxide, and composite oxides of aluminum and titanium. Since these oxides have high acid resistance and alkali resistance, the inorganic structure 1 having high durability even under acidic or alkaline conditions can be obtained.
- the oxide contained in the fine particles 4 may be a crystalline compound or an amorphous compound. From the viewpoint of suppressing the occurrence of cracks originating from the voids between the inorganic particles 2 and the bonding portions 3, the fine particles 4 preferably contain aluminum oxide.
- Each of the plurality of fine particles 4 is preferably crystalline. That is, the fine particles 4 preferably contain the inorganic substance described above and are crystalline particles. Since the inorganic particles 2 are crystalline particles, it is possible to obtain the inorganic structural body 1 with higher durability than in the case of amorphous particles.
- the fine particles 4 may be single-crystal particles or polycrystalline particles.
- the fine particles 4 may contain crystals of at least one of ⁇ -alumina and ⁇ -alumina. Further, the fine particles 4 may contain crystals of at least one of rutile-type titanium dioxide and anatase-type titanium dioxide.
- the joint 3 contains an amorphous compound containing at least one of aluminum and titanium, oxygen, and one or more metal elements.
- the metal element contained in the joint portion 3 is a metal element other than aluminum and titanium, and is, for example, at least one selected from the group consisting of alkaline earth metals, transition metals, base metals and semimetals.
- the metal element contained in the joint 3 may be zirconium.
- each of the plurality of fine particles 4 and the joint portion 3 contain the same metal element.
- the joint 3 preferably contains an amorphous compound containing aluminum.
- the joint portion 3 preferably contains an amorphous compound containing titanium.
- the joint 3 preferably contains an amorphous compound containing aluminum and titanium.
- the joint portion 3 does not substantially contain alkali metal elements, B, V, Te, P, Bi, Pb and Zn. Moreover, it is preferable that the joint portion 3 does not substantially contain Ca, Sr, and Ba.
- the phrase "the joint portion does not substantially contain alkali metal elements B, V, Te, P, Bi, Pb and Zn" means that the joint portion 3 is intentionally free of alkali metal elements B, V, , Te, P, Bi, Pb and Zn.
- the joint portion contains alkali metal elements, B, V, Te, P, Bi, Pb and Zn.
- the phrase "the bond substantially does not contain Ca, Sr, and Ba” means that the bond 3 does not intentionally contain Ca, Sr, and Ba. . Therefore, when Ca, Sr and Ba are mixed into the joint portion 3 as unavoidable impurities, the condition that "the joint portion does not substantially contain Ca, Sr and Ba" is satisfied.
- the volume ratio of the plurality of inorganic particles 2 is 30% or more.
- the obtained inorganic structural body 1 becomes a structure in which the characteristics of the inorganic particles 2 are easily utilized. Specifically, when the inorganic particles 2 contain an inorganic compound with low thermal conductivity, the thermal insulation of the inorganic structure 1 as a whole can be improved. Conversely, when the inorganic particles 2 contain an inorganic compound with high thermal conductivity, the thermal conductivity of the inorganic structure 1 as a whole can be improved.
- the volume ratio of the inorganic particles 2 is preferably larger than the volume ratio of the joints 3 . Moreover, in the inorganic structure 1, the volume ratio of the plurality of inorganic particles 2 is more preferably 50% or more.
- Pores may be present in at least one location inside the bonding portion 3 and between the bonding portion 3 and the inorganic particles 2 .
- the cross section of the inorganic structure 1 preferably has a porosity of 20% or less. That is, when observing the cross section of the inorganic structure 1, the average value of the ratio of pores per unit area is preferably 20% or less. When the porosity is 20% or less, the proportion of the inorganic particles 2 bonded to each other by the bonding portions 3 increases, so the inorganic structural body 1 becomes denser and stronger. Therefore, it is possible to improve the machinability of the inorganic structure 1 .
- the inorganic structure 1 is prevented from cracking starting from the pores, so that the bending strength of the inorganic structure 1 can be increased.
- the cross-sectional porosity of the inorganic structure 1 is preferably 10% or less, more preferably 8% or less, and even more preferably 5% or less. The smaller the porosity in the cross section of the inorganic structure 1 is, the more the cracks starting from the pores are suppressed, so the strength of the inorganic structure 1 can be increased.
- the porosity can be obtained as follows. First, the cross section of the inorganic structure 1 is observed to identify the inorganic particles 2, the joints 3, and the pores. Then, the unit area and the area of pores in the unit area are measured, the ratio of pores per unit area is obtained, and the obtained value is taken as the porosity. It is more preferable to determine the ratio of pores per unit area at a plurality of locations on the cross section of the inorganic structure 1, and then use the average value of the ratios of pores per unit area as the porosity. When observing the cross section of the inorganic structure 1, an optical microscope, a scanning electron microscope (SEM), or a transmission electron microscope (TEM) can be used. Also, the unit area and the area of pores in the unit area may be measured by binarizing the image observed with a microscope.
- SEM scanning electron microscope
- TEM transmission electron microscope
- the size of the pores present inside the inorganic structure 1 is not particularly limited, it is preferably as small as possible.
- the small size of the pores suppresses cracks originating from the pores, so that the strength of the inorganic structure 1 can be increased and the machinability of the inorganic structure 1 can be improved.
- the pore size of the inorganic structure 1 is preferably 5 ⁇ m or less, more preferably 1 ⁇ m or less, and even more preferably 100 nm or less.
- the size of the pores present inside the inorganic structure 1 can be determined by observing the cross section of the inorganic structure 1 with a microscope, similarly to the porosity described above.
- the inorganic structure 1 only needs to have a structure in which the inorganic particles 2 are bonded to each other via the bonding portions 3 . Therefore, the shape of the inorganic structure 1 is not limited as long as it has such a structure.
- the shape of the inorganic structure 1 can be plate-like, film-like, rectangular, block-like, rod-like, or spherical, for example.
- its thickness is not particularly limited, but can be, for example, 100 ⁇ m or more.
- the inorganic structure 1 of the present embodiment is formed by a pressure heating method as described later. Therefore, the inorganic structure 1 having a large thickness can be easily obtained.
- the thickness of the inorganic structure 1 can be 500 ⁇ m or more, can be 1 mm or more, or can be 1 cm or more. Although the upper limit of the thickness of the inorganic structure 1 is not particularly limited, it can be set to 50 cm, for example.
- the inorganic structure 1 the plurality of inorganic particles 2 are bonded to each other at the bonding portion 3 , so they are not bonded with an organic binder containing an organic compound, and are not bonded with an inorganic binder other than the bonding portion 3 . Therefore, the inorganic structure 1 becomes a structure that retains the properties of the inorganic particles 2 and the bonding portions 3 . For example, when the inorganic particles 2 and the joints 3 contain an inorganic material having high thermal conductivity, the resulting inorganic structure 1 also has excellent thermal conductivity. Further, when the inorganic particles 2 and the bonding portions 3 contain an inorganic material having high electrical insulation, the resulting inorganic structure 1 also has excellent electrical insulation.
- the inorganic structure 1 of the present embodiment includes a plurality of inorganic particles 2 and the bonding portion 3 that covers the surface of each of the plurality of inorganic particles 2 and bonds each of the plurality of inorganic particles 2 .
- the joint portion 3 contains an amorphous compound containing at least one of aluminum and titanium, oxygen, and one or more metal elements, and a plurality of fine particles 4 having an average particle size of 100 nm or less.
- the average particle diameter of the plurality of inorganic particles 2 is 1 ⁇ m or more.
- the volume ratio of the plurality of inorganic particles 2 is 30% or more.
- a plurality of inorganic particles 2 are bonded via highly dense bonding portions 3 . Therefore, it is possible to obtain the inorganic structure 1 having excellent denseness and mechanical strength.
- the inorganic structure 1 of the present embodiment can be a structure in which only the inorganic particles 2 are bonded via the bonding portions 3, as shown in FIG.
- the inorganic structural body 1 can be obtained by pressing while heating to 50 to 300° C., so a member with low heat resistance can be added to the inorganic structural body 1 .
- the inorganic structure 1 may contain organic matter and resin particles in addition to the inorganic particles 2 and the bonding portions 3 .
- the inorganic structure 1 is not limited to a member having low heat resistance such as an organic substance, and the inorganic structure 1 may contain particles containing an inorganic compound other than the inorganic particles 2 and the bonding portions 3 .
- the method for manufacturing the inorganic structure 1 includes a step of obtaining a mixture by mixing a plurality of inorganic particles 11, a plurality of fine particles 12, and an aqueous solution 13 containing a metal element; and applying pressure and heat.
- the powder of the inorganic particles 11, the powder of the fine particles 12, and the aqueous solution 13 containing the metal element are mixed to prepare a mixture.
- the inorganic particles 11 may be made of the same inorganic substance as the inorganic particles 2 described above.
- the average particle size of the plurality of inorganic particles 11 can be the same average particle size as that of the plurality of inorganic particles 2 described above, and is 1 ⁇ m or more.
- the volume ratio of the plurality of inorganic particles 11 in the mixture is 30% or more, preferably 50% or more.
- the fine particles 12 contain at least one oxide selected from the group consisting of aluminum oxide, titanium oxide, and composite oxides of aluminum and titanium.
- the average particle diameter of the plurality of fine particles can employ the same average particle diameter as the fine particles 4 described above, and is 100 nm or less.
- the fine particles 12 contain at least one selected from the group consisting of aluminum oxide particles, titanium oxide particles, and composite oxide particles of aluminum and titanium.
- Alumina particles are particles containing aluminum oxide.
- Titania particles are particles containing titanium oxide.
- Composite oxide particles of aluminum and titanium are particles containing a composite oxide of aluminum and titanium.
- the fine particles 12 are preferably fume-like particles. That is, the aluminum oxide particles are preferably fumed alumina. Fumed alumina is a particle produced by combustion hydrolysis of aluminum trichloride. Also, the titanium oxide particles are preferably fumed titania. Fumed titania is a particle produced by combustion hydrolysis of titanium tetrachloride. Further, the composite oxide particles of aluminum and titanium are preferably fumed aluminum-titanium composite oxide. Fumed aluminum-titanium composite oxides are particles produced by combustion hydrolysis of aluminum trichloride and titanium tetrachloride. The fume-like particles form bulky secondary particles by aggregation and agglomeration of primary particles.
- the fume-like particles have an average primary particle size of, for example, about 5 nm to 50 nm. Therefore, the fume-like particles have high reactivity with the aqueous solution 13, and can easily form an amorphous compound containing at least one of aluminum and titanium, oxygen, and a metal element.
- the aqueous solution 13 containing metal elements is an aqueous solution containing metal elements that can be contained in the joint 3 as ions.
- the metal element contained in the aqueous solution 13 is preferably at least one selected from the group consisting of alkaline earth metals, transition metals, base metals and semimetals as described above.
- the solvent for dissolving the metal element is preferably pure water or ion-exchanged water. In addition to water, the solvent may contain an acidic substance or an alkaline substance, or may contain an organic solvent (for example, alcohol).
- the inorganic structure 1 in which the bonding portion 3 includes an amorphous compound containing aluminum, oxygen, and zirconium aluminum oxide particles are used as the fine particles 12, and an aqueous solution of zirconium oxyacetate is used as the aqueous solution 13. be able to. Further, when the inorganic structure 1 in which the bonding portion 3 includes an amorphous compound containing titanium, oxygen, and zirconium is manufactured, titanium oxide particles can be used as the fine particles 12, and an aqueous solution of zirconium oxyacetate can be used as the aqueous solution 13. .
- the inorganic structural body 1 containing an amorphous compound containing aluminum, titanium, oxygen, and zirconium is manufactured in the joint portion 3
- composite oxide particles of aluminum and titanium are used as the fine particles 12, and oxy
- An aqueous zirconium acetate solution can be used.
- aluminum oxide particles and titanium oxide particles are used as the fine particles 12, and zirconium oxyacetate is used as the aqueous solution 13.
- Aqueous solutions can be used.
- a mixture of inorganic particles 11, fine particles 12, and an aqueous solution 13 is filled inside the mold .
- the mold 14 is heated as necessary.
- the inside of the mold 14 becomes in a high pressure state.
- the fine particles 12 are highly reactive, the fine particles 12 and the aqueous solution 13 react with each other.
- the inorganic structure 1 in which the plurality of inorganic particles 2 are bonded to each other through the bonding portions 3 can be obtained.
- the conditions for heating and pressurizing the mixture obtained by mixing the inorganic particles 11, the fine particles 12, and the aqueous solution 13 are not particularly limited as long as the conditions allow the reaction between the fine particles 12 and the aqueous solution 13 to proceed.
- the temperature at which the mixture is heated is more preferably 80 to 250°C, more preferably 100 to 200°C.
- the pressure when pressurizing the mixture is more preferably 50 to 600 MPa, further preferably 200 to 600 MPa.
- the pressurization time is preferably 1 minute to 360 minutes, more preferably 10 minutes to 240 minutes.
- the bonding portion 3 containing an amorphous compound containing at least one of aluminum and titanium, oxygen, and one or more metal elements is formed. It is formed.
- the bonding portion 3 covers the surface of each of the plurality of inorganic particles 2 and bonds each of the plurality of inorganic particles 2 .
- Some of the fine particles 12 do not react with the aqueous solution 13 and remain as fine particles 4 . Therefore, the joint portion 3 contains a plurality of fine particles having an average particle diameter of 100 nm or less.
- the obtained bonding portion 3 has a dense structure, and the inorganic particles 11 can be strongly bonded to each other.
- a method of forming an aggregate of inorganic particles a method of pressing only powder of inorganic particles to form a green compact and then sintering it at a high temperature (for example, 1700° C. or higher) is also conceivable.
- a high temperature for example, 1700° C. or higher
- the powder compact of inorganic particles is sintered at a high temperature, the resulting structure has many pores and is insufficient in mechanical strength.
- precise temperature control is required, which increases the manufacturing cost.
- the mixture obtained by mixing the inorganic particles 11, the fine particles 12, and the aqueous solution 13 is heated and pressurized, so that a dense and strong structure can be obtained. Obtainable.
- the product can be obtained by applying pressure while heating at 50 to 300° C., which eliminates the need for precise temperature control, making it possible to reduce production costs.
- the method for manufacturing the inorganic structure 1 of the present embodiment includes a step of obtaining a mixture by mixing a plurality of inorganic particles 11, a plurality of fine particles 12, and an aqueous solution 13 containing a metal element.
- the production method further includes a step of pressurizing and heating the mixture under conditions of a pressure of 10 to 600 MPa and a temperature of 50 to 300°C.
- the average particle diameter of the plurality of inorganic particles 11 is 1 ⁇ m or more.
- the plurality of fine particles 12 contain at least one oxide selected from the group consisting of aluminum oxide, titanium oxide, and composite oxides of aluminum and titanium, and have an average particle diameter of 100 nm or less.
- the volume ratio of the plurality of inorganic particles 11 in the mixture is 30% or more. Therefore, according to the manufacturing method of the present embodiment, the inorganic structure 1 with high density can be manufactured by a simple method.
- the inorganic structure 1 can have a plate-like shape with a large thickness, and is dense, so that it is excellent in chemical stability.
- the inorganic structure 1 has high mechanical strength and can be cut like a general ceramic member, and can also be surface-processed. Therefore, the inorganic structure 1 can be suitably used as a building member.
- the construction member is not particularly limited, examples thereof include exterior wall materials (siding) and roof materials. Moreover, materials for roads and materials for outer grooves can also be mentioned as construction members.
- the inorganic structure 1 can also be suitably used as a member for electronic devices.
- members for electronic devices include structural materials, heat-resistant members, insulating members, heat-dissipating members, heat-insulating members, sealing materials, circuit boards, and optical members.
- Example 1 powder of primary alumina particles (advanced alumina AA-18 manufactured by Sumitomo Chemical Co., Ltd.) having an average particle diameter of about 20 ⁇ m was prepared. Also, a powder of secondary alumina particles (fumed alumina, AEROXIDE (registered trademark) Alu C manufactured by Nippon Aerosil Co., Ltd.) having an average particle diameter of about 15 nm was prepared. Next, 0.2 g of the first alumina powder and 0.2 g of the second alumina powder were mixed with acetone using an agate mortar and an agate pestle to obtain a mixed powder. In addition, in the said mixed powder, the volume ratio (vol%) of the 1st alumina powder and the 2nd alumina powder was 50:50.
- zirconium oxyacetate powder (ZrO(CH 3 COO) 2 , manufactured by Mitsuwa Kagaku Co., Ltd.) was dissolved in 6 ml of deionized water to obtain a 40% zirconium oxyacetate aqueous solution.
- the entire amount of the mixed powder was put into a cylindrical molding die ( ⁇ 10) having an internal space. Furthermore, 100 ⁇ l of an aqueous zirconium oxyacetate solution was added to the inside of the molding die and mixed with a plastic spatula.
- the mixed powder containing the zirconium oxyacetate aqueous solution was heated and pressurized under conditions of 200°C, 400 MPa, and 60 minutes. In this way, a cylindrical test sample of this example was obtained.
- the second alumina powder containing the zirconium oxyacetate aqueous solution was heated and pressurized under conditions of 200°C, 400 MPa, and 60 minutes to obtain a test sample containing no first alumina particles.
- test sample was prepared in the same manner as in Reference Example 1, except that the mixed powder containing the aqueous zirconium oxyacetate solution was heated and pressurized under conditions of 200° C., 400 MPa, and 240 minutes.
- FIG. 3 shows an SEM image of the test sample of Example 1 magnified 500 times.
- FIG. 4 shows an SEM image of the test sample of Example 1 magnified 2000 times.
- FIG. 5 shows an SEM image of the second alumina powder magnified 2000 times.
- FIG. 6 shows an SEM image of the second alumina powder magnified 10,000 times.
- FIG. 7 shows an SEM image of the test sample of Reference Example 1 magnified 2000 times.
- FIG. 8 shows an SEM image of the test sample of Reference Example 1 magnified 10000 times.
- FIG. 9 shows the EDX spectrum of the portion of the test sample of Example 1 where particles are present.
- FIG. 10 shows the EDX spectrum of the part binding the particles in the test sample of Example 1.
- FIG. 11 shows the results of the mapping analysis on the test samples of Example 1.
- the part where the particles exist contains aluminum (Al) and oxygen (O), so it is derived from the first alumina particles (inorganic particles 2) of the raw material. was confirmed.
- the portion (bonding portion 3) where the particles are bonded contains aluminum (Al), zirconium (Zr) and oxygen (O), and Al, Zr and O are uniformly dispersed. This suggests the presence of an Al--Zr--O compound produced by the reaction between the raw material secondary alumina particles (fine particles 4) and the aqueous zirconium oxyacetate solution.
- a trace amount of carbon (C) is present in the joint 3, it is considered that this is an organic residue derived from the starting zirconium oxyacetate aqueous solution.
- FIG. 12 shows the XRD pattern of the second alumina powder (fumed alumina) as a raw material, the XRD pattern of the test sample of Reference Example 2, and the XRD patterns of ⁇ -alumina and ⁇ -alumina registered with ICSD.
- the joint portion 3 contains crystals of ⁇ -alumina and ⁇ -alumina derived from the secondary alumina particles as the raw material, and at least part of the secondary alumina particles do not react and the average particle diameter is 100 nm or less. is thought to remain as the fine particles 4.
- test sample of Reference Example 1 with a pressurization time of 60 minutes was also measured, and an XRD pattern similar to that of the test sample of Reference Example 2 with a pressurization time of 240 minutes was obtained. From this, it is considered that even if the pressurization time is increased from 60 minutes to 240 minutes, the crystal phase does not change significantly and the fine particles 4 remain.
- the test sample of Reference Example 2 does not contain the first alumina powder, the first alumina powder contains aluminum oxide like the second alumina powder. Similar XRD patterns are expected to be obtained. Therefore, it is considered that the joint portion 3 of the test sample of Example 1 contains the amorphous compound containing Zr and the fine particles 4 .
- the joint 3 contained aluminum, oxygen and zirconium. From the results of the crystal structure analysis, no peak derived from zirconium was found in the XRD pattern of the test sample of Reference Example 2. From these results, it is considered that the joint 3 contains an amorphous compound containing aluminum, oxygen and zirconium.
- test sample of Example 1 had gaps between the inorganic particles 2 and the bonding portion 3, and cracks originating from these gaps were observed.
- the test sample of Example 1 does not have many pores that are seen in conventional green compacts obtained by pressing only powder of inorganic particles, and has a dense structure with few macropores. was confirmed.
- the porosity was 4.3%.
- the porosity was calculated in the same manner as above for two locations different from those in FIG. As a result, the average porosity of the three locations was 3.2%, which is a very small porosity value.
- Example 2 powder of primary alumina particles (advanced alumina AA-18 manufactured by Sumitomo Chemical Co., Ltd.) having an average particle diameter of about 20 ⁇ m was prepared. A second titania particle powder (fumed titania, AEROXIDE (registered trademark) TiO 2 P25 manufactured by Nippon Aerosil Co., Ltd.) having an average particle diameter of about 20 nm was also prepared. Next, 0.197 g of the first alumina powder and 0.203 g of the titania powder were mixed with acetone using an agate mortar and an agate pestle to obtain a mixed powder. In the mixed powder, the volume ratio (vol%) of the first alumina powder and the titania powder was 50:50.
- AEROXIDE registered trademark
- TiO 2 P25 manufactured by Nippon Aerosil Co., Ltd.
- zirconium oxyacetate powder (ZrO(CH 3 COO) 2 , manufactured by Mitsuwa Kagaku Co., Ltd.) was dissolved in 6 ml of deionized water to obtain a 40% zirconium oxyacetate aqueous solution.
- the entire amount of the mixed powder was put into a cylindrical molding die ( ⁇ 10) having an internal space. Furthermore, 150 ⁇ l of an aqueous zirconium oxyacetate solution was added to the inside of the molding die and mixed with a plastic spatula.
- the mixed powder containing the zirconium oxyacetate aqueous solution was heated and pressurized under conditions of 200°C, 400 MPa, and 30 minutes. In this way, a cylindrical test sample of this example was obtained.
- the titania powder containing the zirconium oxyacetate aqueous solution was heated and pressurized under conditions of 200°C, 400 MPa, and 30 minutes to obtain a test sample containing no primary alumina particles.
- FIG. 19 shows an SEM image of the test sample of Example 2 magnified 500 times.
- FIG. 20 shows an SEM image of the test sample of Example 2 magnified 2000 times.
- FIG. 21 shows an SEM image of the titania powder magnified 2000 times.
- FIG. 22 shows an SEM image of the titania powder magnified 10,000 times.
- FIG. 23 shows an SEM image of the test sample of Reference Example 3 magnified 2000 times.
- FIG. 24 shows an SEM image of the test sample of Reference Example 3 magnified 10000 times.
- the bonding portion 3 covers the surface of each of the first alumina particles (a plurality of inorganic particles 2) and bonds each of the first alumina particles. It is understood that
- FIG. 25 shows the EDX spectrum of the portion of the test sample of Example 2 where particles are present.
- FIG. 26 shows the EDX spectrum of the particle binding portion in the test sample of Example 2.
- FIG. 27 shows the results of the mapping analysis on the test samples of Example 2.
- the part where the particles are present contains aluminum (Al) and oxygen (O), so it is derived from the first alumina particles (inorganic particles 2) of the raw material. was confirmed. Further, from the EDX spectrum of FIG. 26 and the mapping analysis results of FIG. and O are uniformly dispersed. This suggests the presence of a Ti--Zr--O compound produced by the reaction between the raw material second titania particles (fine particles 4) and the aqueous zirconium oxyacetate solution. Although a small amount of C is present in the joint 3, it is considered that this is an organic residue derived from the starting zirconium oxyacetate aqueous solution.
- FIG. 28 shows the XRD pattern of the raw material titania powder (fumed titania), the XRD pattern of the test sample of Reference Example 3, and the XRD patterns of rutile-type TiO 2 and anatase-type TiO 2 registered with ICSD.
- the joint portion 3 contains crystals of rutile-type TiO 2 and anatase-type TiO 2 derived from the second titania particles, which are the raw materials, and at least a part of the second titania particles does not react and the average particle It is considered that they remain as fine particles 4 having a diameter of 100 nm or less.
- test sample of Example 2 does not have many pores that can be seen in conventional green compacts obtained by pressing only powder of inorganic particles, and has a dense structure with few macropores. I was able to confirm that.
- test sample of Example 2 did not have as many cracks originating from the voids between the inorganic particles 2 and the bonding portion 3 as observed in the test sample of Example 1.
- the porosity was 1.1%.
- the porosity was calculated in the same manner as described above for two locations different from those shown in FIG. As a result, the average porosity of the three locations was 1.7%, which is a very small porosity value.
- Example 1 fumed alumina was used as the fine particles 4, and in Example 2, fumed titania was used as the fine particles 4 to fabricate the inorganic structure 1.
- fumed aluminum-titanium composite oxide is used as the fine particles 4, it is considered that the inorganic structure 1 similar to fumed alumina and fumed titania can be obtained.
- an inorganic structure that can be produced by a simple method and has a high density, and a method for producing the inorganic structure.
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Abstract
Description
本実施形態の無機構造体1は、図1に示すように、複数の無機粒子2と、結合部3とを備えている。そして、隣接する無機粒子2が結合部3を介して互いに結合することにより、複数の無機粒子2が集合してなる無機構造体1を形成している。
次に、無機構造体1の製造方法について説明する。図2に示すように、無機構造体1の製造方法は、複数の無機粒子11と、複数の微粒子12と、金属元素を含む水溶液13とを混合することにより混合物を得る工程と、当該混合物を加圧及び加熱する工程とを含んでいる。
次に、無機構造体1を備える部材について説明する。無機構造体1は、上述のように、厚みの大きな板状とすることができ、さらに緻密であるため化学的安定性にも優れている。また、無機構造体1は、機械的強度が高く、一般的なセラミックス部材と同様に切断することができると共に、表面加工することもできる。そのため、無機構造体1は、建築部材として好適に用いることができる。建築部材としては特に限定されないが、例えば、外壁材(サイディング)、屋根材などを挙げることができる。また、建築部材としては、道路用材料、外溝用材料も挙げることができる。
(実施例1)
まず、平均粒子径が約20μmの第1アルミナ粒子の粉末(住友化学株式会社製のアドバンストアルミナAA-18)を準備した。また、平均粒子径が約15nmの第2アルミナ粒子の粉末(フュームドアルミナ、日本アエロジル株式会社製AEROXIDE(登録商標)Alu C)を準備した。次いで、上記第1アルミナ粉末0.2gと上記第2アルミナ粉末0.2gとを、メノウ乳鉢とメノウ乳棒を用い、アセトンを加えて混合することにより、混合粉末を得た。なお、当該混合粉末において、第1アルミナ粉末と第2アルミナ粉末の体積比率(vol%)は、50:50であった。
まず、内部空間を有する円筒状の成形用金型(Φ10)の内部に、実施例1と同じ第2アルミナ粉末0.3gを投入した。さらに、成形用金型の内部に、実施例1で調製したオキシ酢酸ジルコニウム水溶液300μlを添加し、プラスチック製のスパチュラで混合した。
オキシ酢酸ジルコニウム水溶液を含んだ混合粉末を、200℃、400MPa、240分の条件で加熱及び加圧した以外は、参考例1と同様にして試験サンプルを作製した。
上記のようにして作製した試験サンプルについて、構造観察、元素分析、結晶構造解析、気孔の観察、気孔率の測定を行った。
実施例1で作製した円柱状の試験サンプルを割断した断面を、走査型電子顕微鏡(SEM)を用いて観察した。なお、試験サンプルの観察面には、金のスパッタリングを施した。図3では、実施例1の試験サンプルを500倍に拡大したSEM像を示した。図4では、実施例1の試験サンプルを2000倍に拡大したSEM像を示した。また、参考までに、図5では、第2アルミナ粉末を2000倍に拡大したSEM像を示した。図6では、第2アルミナ粉末を10000倍に拡大したSEM像を示した。図7では、参考例1の試験サンプルを2000倍に拡大したSEM像を示した。図8では、参考例1の試験サンプルを10000倍に拡大したSEM像を示した。
実施例1で作製した円柱状の試験サンプルを割断した断面を、エネルギー分散型X線分析装置(EDX)を用いて観察した。図9では、実施例1の試験サンプルにおける粒子が存在する部分のEDXスペクトルを示す。図10では、実施例1の試験サンプルにおける粒子を結合している部分のEDXスペクトルを示す。図11では、実施例1の試験サンプルにおけるマッピング分析の結果を示す。
粉末X線回折(XRD)装置を用いて、参考例2の試験サンプルを粉砕した粉末を測定してXRDパターンを取得した。図12では、原料である第2アルミナ粉末(フュームドアルミナ)のXRDパターン、参考例2の試験サンプルのXRDパターン、並びにICSDに登録されたγアルミナ及びηアルミナのXRDパターンを示す。
まず、円柱状である実施例1の試験サンプルの断面に、クロスセクションポリッシャー加工(CP加工)を施した。次に、走査型電子顕微鏡(SEM)を用い、試験サンプルの断面について、2000倍、5000倍、10000倍及び50000倍の倍率でSEM像を観察した。図13、図14、図15及び図16では、2000倍、5000倍、10000倍及び50000倍にそれぞれ拡大した実施例1の試験サンプルにおける断面のSEM像を示した。
まず、円柱状である実施例1の試験サンプルの断面に、クロスセクションポリッシャー加工(CP加工)を施した。次に、走査型電子顕微鏡(SEM)を用い、試験サンプルの断面について、2000倍の倍率でSEM像を観察した。試験サンプルの断面を観察することにより得られたSEM像を図17に示す。次に、得られたSEM像について二値化することにより、気孔部分を明確にした。そして、二値化した画像から気孔部分の面積割合を算出して気孔率を得た。図17のSEM像を二値化した画像を図18に示す。なお、二値化した画像のうち黒色部分が気孔である。
(実施例2)
まず、平均粒子径が約20μmの第1アルミナ粒子の粉末(住友化学株式会社製のアドバンストアルミナAA-18)を準備した。また、平均粒子径が約20nmの第2チタニア粒子の粉末(フュームドチタニア、日本アエロジル株式会社製AEROXIDE(登録商標)TiO2 P25)を準備した。次いで、上記第1アルミナ粉末0.197gと上記チタニア粉末0.203gとを、メノウ乳鉢とメノウ乳棒を用い、アセトンを加えて混合することにより、混合粉末を得た。なお、当該混合粉末において、第1アルミナ粉末とチタニア粉末の体積比率(vol%)は、50:50であった。
まず、内部空間を有する円筒状の成形用金型(Φ10)の内部に、実施例2と同じチタニア粉末0.3gを投入した。さらに、成形用金型の内部に、実施例2で調製したオキシ酢酸ジルコニウム水溶液150μlを添加し、プラスチック製のスパチュラで混合した。
上記のようにして作製した試験サンプルについて、構造観察、元素分析、結晶構造解析、気孔の観察、気孔率の測定を行った。
実施例2で作製した円柱状の試験サンプルを割断した断面を、走査型電子顕微鏡(SEM)を用いて観察した。なお、試験サンプルの観察面には、金のスパッタリングを施した。図19では、実施例2の試験サンプルを500倍に拡大したSEM像を示した。図20では、実施例2の試験サンプルを2000倍に拡大したSEM像を示した。また、参考までに、図21では、チタニア粉末を2000倍に拡大したSEM像を示した。図22では、チタニア粉末を10000倍に拡大したSEM像を示した。図23では、参考例3の試験サンプルを2000倍に拡大したSEM像を示した。図24では、参考例3の試験サンプルを10000倍に拡大したSEM像を示した。
実施例2で作製した円柱状の試験サンプルを割断した断面を、エネルギー分散型X線分析装置(EDX)を用いて観察した。図25では、実施例2の試験サンプルにおける粒子が存在する部分のEDXスペクトルを示す。図26では、実施例2の試験サンプルにおける粒子を結合している部分のEDXスペクトルを示す。図27では、実施例2の試験サンプルにおけるマッピング分析の結果を示す。
粉末X線回折(XRD)装置を用いて、参考例3の試験サンプルを粉砕した粉末を測定してXRDパターンを取得した。図28では、原料であるチタニア粉末(フュームドチタニア)のXRDパターン、参考例3の試験サンプルのXRDパターン、並びにICSDに登録されたルチル型TiO2及びアナターゼ型TiO2のXRDパターンを示す。
まず、円柱状である実施例2の試験サンプルの断面に、クロスセクションポリッシャー加工(CP加工)を施した。次に、走査型電子顕微鏡(SEM)を用い、試験サンプルの断面について、2000倍、5000倍、10000倍及び50000倍の倍率でSEM像を観察した。図29、図30、図31及び図32では、2000倍、5000倍、10000倍及び50000倍にそれぞれ拡大した実施例2の試験サンプルにおける断面のSEM像を示した。
まず、円柱状である実施例2の試験サンプルの断面に、クロスセクションポリッシャー加工(CP加工)を施した。次に、走査型電子顕微鏡(SEM)を用い、試験サンプルの断面について、2000倍の倍率でSEM像を観察した。試験サンプルの断面を観察することにより得られたSEM像を図33に示す。次に、得られたSEM像について二値化することにより、気孔部分を明確にした。図33のSEM像を二値化した画像を図34に示す。そして、二値化した画像から気孔部分の面積割合を算出して気孔率を得た。なお、二値化した画像のうち黒色部分が気孔である。
2 無機粒子
3 結合部
4 微粒子
11 無機粒子
12 微粒子
13 金属元素を含む水溶液
Claims (9)
- 複数の無機粒子と、
前記複数の無機粒子の各々の表面を覆い、前記複数の無機粒子の各々を結合する結合部と、
を備え、
前記結合部は、アルミニウム及びチタンの少なくともいずれか一方と酸素と一種以上の金属元素とを含む非晶質化合物と、平均粒子径が100nm以下の複数の微粒子とを含有し、
前記複数の無機粒子の平均粒子径は1μm以上であり、
前記複数の無機粒子の体積割合は30%以上である、無機構造体。 - 前記結合部は、アルカリ金属元素、B、V、Te、P、Bi、Pb及びZnを実質的に含まない、請求項1に記載の無機構造体。
- 前記結合部は、Ca、Sr及びBaを実質的に含まない、請求項1又は2に記載の無機構造体。
- 前記複数の微粒子の各々と前記結合部とは同じ金属元素を含む、請求項1から3のいずれか一項に記載の無機構造体。
- 前記複数の無機粒子の体積割合が50%以上である、請求項1から4のいずれか一項に記載の無機構造体。
- 気孔率が20%以下である、請求項1から5のいずれか一項に記載の無機構造体。
- 前記複数の無機粒子の各々は結晶質である、請求項1から6のいずれか一項に記載の無機構造体。
- 厚みが100μm以上である、請求項1から7のいずれか一項に記載の無機構造体。
- 平均粒子径が1μm以上の複数の無機粒子と、酸化アルミニウム、酸化チタン、及びアルミニウムとチタンとの複合酸化物からなる群より選択される少なくとも一種の酸化物を含み、平均粒子径が100nm以下の複数の微粒子と、金属元素を含む水溶液とを混合することにより、混合物を得る工程と、
前記混合物を、圧力が10~600MPaであり、かつ、温度が50~300℃である条件下で加圧及び加熱する工程と、
を含み、
前記混合物における前記複数の無機粒子の体積割合は30%以上である、無機構造体の製造方法。
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