Porous plate-shaped filler aggregate, producing method therefor, and heat-insulation film containing porous plate-shaped filler aggregate

• US 10,392,310 B2
• Filed: 08/08/2016
• Issued: 08/27/2019
• Est. Priority Date: 02/10/2014
• Status: Active Grant

• Current Assignee: NGK Insulators Limited
• Original Assignee: NGK Insulators Limited
• Inventors: Oribe, Akinobu, Kobayashi, Hiroharu, Tomita, Takahiro, Maeda, Shinsaku, Awakura, Yasutaka
• Primary Examiner(s): Yang, Z. Jim
• Application Number:
  US15/230,726
• Publication Number:
  US 20160340256A1
• Time in Patent Office: 1,114 Days
• CPC Class Codes: B23K 2101/003 Pistons
• CPC Class Codes: B23K 2101/18 Sheet panels
• CPC Class Codes: B23K 2103/52 Ceramics
• CPC Class Codes: B23K 2103/54 Glass
• CPC Class Codes: B23K 26/0622 by shaping pulses
• CPC Class Codes: B23K 26/0624 using ultrashort pulses, i.e. pulses of 1ns or less
• CPC Class Codes: B23K 26/364 for making a groove or trench, e.g. for scribing a break initiation groove
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 26/40 taking account of the properties of the material involved
• CPC Class Codes: B26D 3/08 Making a superficial cut in the surface of the work without removal of material, e.g. scoring, incising
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: C01P 2004/20 extending in two dimensions, e.g. plate-like
• CPC Class Codes: C01P 2004/22 with a polygonal circumferential shape
• CPC Class Codes: C04B 20/0008 Materials specified by a shape not covered by C04B20/0016 - C04B20/0056, e.g. nanotubes
• CPC Class Codes: C04B 2235/3246 Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
• CPC Class Codes: C04B 2235/5292 Flakes, platelets or plates
• CPC Class Codes: C04B 2235/5296 with a defined aspect ratio, e.g. indicating sphericity spherical constituents C04B2235/528
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 : submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/6025 : Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 2235/612 : Machining
• CPC Class Codes: C04B 2237/38 : Fiber or whisker reinforced
• CPC Class Codes: C04B 35/01 : based on oxide ceramics
• CPC Class Codes: C04B 35/486 : Fine ceramics
• CPC Class Codes: C04B 35/62218 : obtaining ceramic films, e.g. by using temporary supports
• CPC Class Codes: C04B 35/62222 : obtaining ceramic coatings coating of mortars, concrete, artificial or natural stone or ceramics C04B41/45; laminated ceramic products B32B18/00; coating metallic materials C23; coating of glass C03C17/00, applying ceramic coatings on silicon for semi-conductor purposes H01L
• CPC Class Codes: C04B 35/62625 : Wet mixtures
• CPC Class Codes: C04B 35/634 : Polymers C04B35/636 takes precedence
• CPC Class Codes: C04B 35/638 : Removal thereof
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 38/009 : Porous or hollow ceramic granular materials, e.g. microballoons C04B18/027, C04B20/002 take precedence
• CPC Class Codes: C04B 38/06 : by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
• CPC Class Codes: C04B 38/067 : Macromolecular compounds C04B38/062 takes precedence; polysaccharides C04B38/0645
• CPC Class Codes: C04B 38/08 : by adding porous substances
• CPC Class Codes: C08K 7/24 : inorganic
• CPC Class Codes: C09D 1/00 : Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C09D 201/00 : Coating compositions based on unspecified macromolecular compounds
• CPC Class Codes: C09D 5/00 : Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced electrically insulating plastics, resins or waxes H01B3/30; Filling pastes
• CPC Class Codes: C09D 7/61 : inorganic
• CPC Class Codes: C09D 7/70 : characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: F16L 59/04 : Arrangements using dry fillers, e.g. using slag wool which is added to the object to be insulated by pouring, spreading, spraying or the like

Abstract

The porous plate-shaped filler aggregate includes a plurality of the porous plate-shaped fillers. The porous plate-shaped fillers have a uniform plate shape with an aspect ratio of 3 or more, a minimum length of 0.1 to 50 μm, a porosity of 20 to 99%, and the deviation of the maximum length among a plurality of the porous plate-shaped fillers, which is obtained by the following formula, is 10% or less.
Deviation of the maximum length (%)=standard deviation of the maximum length/average value of the maximum length×100

(Here, ‘maximum length’ is the longest length when the porous plate-shaped fillers are held between a pair of parallel planes.)

Claims

1. A heat-insulation film comprising a plurality of porous plate-shaped fillers, wherein the fillers are arranged as adjacent layers of fillers in the film, the porous plate-shaped fillers have a uniform plate shape with an aspect ratio of 3 or more, a thickness of 0.1 to 50 μ

m, a porosity of 20 to 99%, and a deviation of a length among a plurality of the porous plate-shaped fillers, obtained by the following formula, is 10% or less;

Deviation of the length (%)=standard deviation of the length/average value of the length×

100.

2. The heat-insulation film according to claim 1, wherein the porous plate-shaped fillers have pores with an average pore diameter of 10 to 500 nm.

3. The heat-insulation film according to claim 1, wherein a thermal conductivity of the porous plate-shaped fillers is 1 W/(m·

K) or less.

4. The heat-insulation film according to claim 1, wherein a volumetric heat capacity of the porous plate-shaped fillers is 10 to 3000 kJ/(m³·

K).

5. A method for producing the heat insulation film of claim 1, wherein during production of the plurality of porous plate-shaped fillers, a cut with a depth of 0.2 times or more a thickness of a green sheet after firing is formed on one surface of the green sheet formed from a material containing a component of the porous plate-shaped fillers to fire the green sheet and thereafter grind an obtained sheet-shaped fired body along the cut.

6. The method according to claim 5, wherein a method for forming the cut is a method by using an edged tool or a laser processing machine such as to allow laser irradiation at a pulse width of 10 pico-second or less.

7. The method according to claim 6, wherein the edged tool has a latticed edge.

8. The method according to claim 6, wherein a method for forming the cut on one surface of the green sheet by using the edged tool is a method for pressing the edged tool against one surface of the green sheet by a pressing machine or a rolling machine.

9. The method according to claim 8, wherein a pressure for pressing the edged tool against one surface of the green sheet is 3 MPa or more.

10. The method according to claim 5, wherein a method for grinding the sheet-shaped fired body along the cut is any method selected from the group consisting of a method by manual breaking, a method by using a grinder, a method by using a shredder and a method by irradiating ultrasonic waves.

11. A method for producing the heat insulation film of claim 1, wherein during production of the plurality of porous plate-shaped tillers, a green sheet formed from a material containing a component of the porous plate-shaped fillers is fired, and a cut with a depth of 0.2 times or more a thickness of a sheet-shaped fired body is formed on one surface of the obtained sheet-shaped fired body to grind the sheet-shaped fired body along the cut.

12. The method according to claim 11, wherein a method for forming the cut is a method by using an edged tool or a laser processing machine such as to allow laser irradiation at a pulse width of 10 pico-second or less.

13. The method according to claim 12, wherein the edged tool has a latticed edge.

14. The method according to claim 12, wherein a method for forming the cut on one surface of the sheet-shaped fired body by using the edged tool is a method for pressing the edged tool against one surface of the sheet-shaped fired body by a pressing machine or a rolling machine.

15. The method according to claim 14, wherein a pressure for pressing the edged tool against one surface of the sheet-shaped fired body is 3 MPa or more.

16. The method according to claim 11, wherein a method for grinding the sheet-shaped fired body along the cut is any method selected from the group consisting of a method by manual breaking, a method by using a grinder, a method by using a shredder and a method by irradiating ultrasonic waves.

17. The heat-insulation film according to claim 1, wherein a thickness of the film is 1 μ

m to 5 mm.

18. The heat-insulation film according to claim 1, wherein a thermal conductivity is 1 W/(m·

K) or less.