Porous plate-shaped filler, method for producing same, and heat insulation film

• US 10,464,287 B2
• Filed: 10/19/2016
• Issued: 11/05/2019
• Est. Priority Date: 04/23/2014
• Status: Active Grant

• Current Assignee: NGK Insulators Limited
• Original Assignee: NKG Insulators, Ltd.
• Inventors: Oribe, Akinobu, Tomita, Takahiro, Kobayashi, Hiroharu
• Primary Examiner(s): Yang, Z. Jim
• Application Number:
  US15/297,429
• Publication Number:
  US 20170036303A1
• Time in Patent Office: 1,112 Days
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 2103/18 Dissimilar materials
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 2103/52 Ceramics
• CPC Class Codes: B23K 26/0624 using ultrashort pulses, i.e. pulses of 1ns or less
• CPC Class Codes: B23K 26/362 Laser etching
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B23K 26/402 involving non-metallic material, e.g. isolators
• 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 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: C01G 25/02 Oxides
• 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 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2201/32 for the thermal conductivity, e.g. K-factors
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3246 Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
• CPC Class Codes: C04B 2235/52 : Constituents or additives characterised by their shapes
• CPC Class Codes: C04B 2235/5276 : Whiskers, spindles, needles or pins
• 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 2235/6025 : Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 2235/6026 : Computer aided shaping, e.g. rapid prototyping
• CPC Class Codes: C04B 2235/612 : Machining
• CPC Class Codes: C04B 2235/6567 : Treatment time
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/9607 : Thermal properties, e.g. thermal expansion coefficient
• CPC Class Codes: C04B 35/486 : Fine ceramics
• CPC Class Codes: C04B 35/491 : based on lead zirconates and lead titanates , e.g. PZT
• CPC Class Codes: C04B 35/622 : Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
• CPC Class Codes: C04B 38/0074 : expressed as porosity percentage
• 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 38/02 : by adding chemical blowing agents
• 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 38/08 : by adding porous substances
• CPC Class Codes: C08G 77/04 : Polysiloxanes
• CPC Class Codes: C08K 2201/016 : Additives defined by their aspect ratio
• CPC Class Codes: C08K 3/22 : of metals
• CPC Class Codes: C08K 7/24 : inorganic
• CPC Class Codes: C08L 83/04 : Polysiloxanes
• CPC Class Codes: C09D 1/00 : Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C09D 183/04 : Polysiloxanes
• 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 7/40 : Additives
• CPC Class Codes: C09D 7/61 : inorganic
• CPC Class Codes: F16L 59/00 : Thermal insulation in general
• CPC Class Codes: F16L 59/029 : layered

Abstract

A porous plate-shaped filler of the present invention is a plate shape having an aspect ratio of 3 or more, a surface shape is one of a round shape, an oval and a round-corner polygonal shape, and its minimum length is from 0.1 to 50 μm. Furthermore, a sectional shape is one of an arch shape, an elliptic shape, and a quadrangular shape in which at least a part of corners is rounded. Consequently, it is possible to obtain the heat insulation film in which the porous plate-shaped fillers 1 are easy to be laminated and the heat insulation effect improves.

Claims

1. A heat insulation film comprising a porous plate-shaped filler which is a plate shape having major surfaces each of which contains a plurality of pores, a thickness of from 0.1 to 50 μ

m, a length to thickness aspect ratio of 3 or more and in which a surface shape is a round-corner polygonal shape, wherein a radius R of an arc of the round-corner polygonal shape in the surface shape is not less than the thickness,

wherein a thermal conductivity of the heat insulation film is 1 W/(m·

K) or less.

2. The heat insulation film according to claim 1, wherein the porous plate-shaped filler has a cross-sectional shape parallel to a thickness direction thereof that is one of an arch shape, an elliptic shape, and a quadrangular shape in which at least a part of corners is rounded.

3. The heat insulation film according to claim 2, wherein the porous plate-shaped filler has a radius R of an arc of the quadrangular shape in which at least a part of corners in the cross-sectional shape parallel to the thickness direction is rounded is ⅕

or more of the thickness.

4. The heat insulation film according to claim 1, wherein the porous plate-shaped filler includes pores having an average pore diameter of 10 to 500 nm.

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

K) or less.

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

K) or less.

7. A method for producing the heat insulation film according to claim 1, which comprises processing a green sheet made from a material including a component of the porous plate-shaped filler by use of a laser processing machine capable of performing irradiation with laser at a pulse width of 10 picoseconds or less, before or after firing, to form the porous plate-shaped filler having a predetermined surface shape.

8. A method for producing the heat insulation film according to claim 1, which comprises dropping or discharging slurry made from a material including a component of the porous plate-shaped filler and adjusted into a viscosity of 100 to 10000 cps, to form the porous plate-shaped filler whose cross-sectional shape parallel to a thickness direction thereof is one of an arch shape, an elliptic shape, and a quadrangular shape in which at least a part of corners is rounded.

9. The method for producing the heat insulation film according to claim 8, which comprises dropping or discharging the slurry by use of an ink jet type spotter device.

10. A method for producing the heat insulation film according to claim 1, which comprises adhering, to an adhering portion having a predetermined shape, slurry made from a material including a component of the porous plate-shaped filler and adjusted into a viscosity of 100 to 10000 cps;

and pressing the adhering portion onto a substrate surface, thereby adhering the slurry adhered to the adhering portion to the substrate surface, to form the porous plate-shaped filler whose cross-sectional shape parallel to a thickness direction thereof is one of an arch shape, an elliptic shape, and a quadrangular shape in which at least a part of corners is rounded.

11. The method for producing the heat insulation film according to claim 10, which comprises adhering the slurry to the substrate surface by use of a needle type dispenser device.

12. The heat insulation film according to claim 1, wherein the porous plate-shaped fillers are arranged in the form of layers.

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

m to 5 mm.