Composite structure formation method using pre-formed controlled particles formed of fine particles non-chemically bonded together

Patent metadata

Field	Value
Publication number	US-10046344-B2
Application number	US-201715403582-A
Country	US
Kind code	B2
Filing date	Jan 11, 2017
Priority date	Mar 10, 2008
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

A composite structure formation method includes the steps of storing a plurality of pre-formed controlled particles in a storage mechanism, supplying the controlled particles from the storage mechanism to an aerosolation mechanism constantly, disaggregating the supplied controlled particles into a plurality of the fine particles in the aerosolation mechanism to form an aerosol in which an entire contents of the controlled particles including the fine particles are dispersed in the gas; and spraying all of the fine particles in the aerosol toward the substrate to form a composite structure of the structure and the substrate. The controlled particles are controlled so that bonding strength between the fine particles includes a mean compressive fracture strength sufficient to substantially avoid disaggregation during the supply step, but which permits the controlled particles to be substantially completely disaggregated in the disaggregation step.

First claim

The invention claimed is:

1. A composite structure formation method based on an aerosol deposition method by which an aerosol with brittle material fine particles dispersed in a gas is sprayed toward a substrate to form a structure made of the brittle material fine particles, the composite structure formation method comprising the steps of: storing a plurality of pre-formed controlled particles in a storage mechanism, each of the controlled particles consists essentially of a plurality of the brittle material fine particles which have been intentionally packed together, each of the brittle material fine particles in each said controlled particle is not chemically bonded with the other brittle material fine particles in the controlled particle, the controlled particles being formed by using the fine particles whose mean primary particle diameter is 0.1 μm or more and 5 μm or less, the controlled particles having a mean circle-equivalent diameter of 20 μm or more, and the controlled particle having a carbon content of 1 weight % or less; supplying the controlled particles from the storage mechanism to an aerosolation mechanism constantly; disaggregating the supplied controlled particles into a plurality of the fine particles in the aerosolation mechanism to form an aerosol in which an entire contents of the controlled particles including the fine particles are dispersed in the gas; and spraying all of the fine particles in the aerosol toward the substrate to form a composite structure of the structure and the substrate, wherein the controlled particles are controlled so that bonding strength between the fine particles includes a mean compressive fracture strength sufficient to substantially avoid disaggregation during the supply step, but which permits the controlled particles to be substantially completely disaggregated in the disaggregation step; and wherein the mean compressive fracture strength of the controlled particles is 0.47 MPa or less.

2. The composite structure formation method according to claim 1 , further comprising the step of:
mixing the controlled particles with a gas introduced from a gas supply mechanism to produce a solid-gas mixed phase flow; and
supplying the solid-gas mixed phase flow to the aerosolation mechanism.

3. The composite structure formation method according to claim 1 , wherein the mean compressive fracture strength is controlled by manufacturing the controlled particles by adding the fine particles with at least one of water and a binder.

4. The composite structure formation method according to claim 1 , wherein the controlled particles are disaggregated by mechanical impact applied in the aerosolation mechanism.

5. The composite structure formation method according to claim 1 , wherein the mean compressive fracture strength of the controlled particles is 0.34 MPa or less.

6. The composite structure formation method according to claim 1 , wherein the mean compressive fracture strength of the controlled particles is from 0.47 MPA to 0.015 MPa.

7. The composite structure formation method according to claim 1 , wherein the controlled particles have a mean circularity of 0.65 or more.

8. The composite structure formation method according to claim 1 , wherein the controlled particles have a D10 of 6.6 μm or more.

9. The composite structure formation method according to claim 1 , wherein the controlled particles have a particle size distribution deviation ratio of 0.59 or less.

10. The composite structure formation method according to claim 1 , wherein the controlled particles have an angle of repose of 48 degrees or less.

11. The composite structure formation method according to claim 1 , wherein the controlled particles have a mean circle-equivalent diameter of 20 μm or more and 500 μm or less.

Assignees

• Toto Ltd

Inventors

• Hatono Hironori
• Mizukane Masahiro
• Okamoto Osamu

Classifications

• Y10T428/2982

  Particulate matter [e.g., sphere, flake, etc.] · CPC title

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• B05D1/12 Primary

  Applying particulate materials (B05D1/06, B05D1/10 take precedence) · CPC title

• B05B7/1404

  Arrangements for supplying particulate material · CPC title

• B02C19/065

  of the opposed-jet type (B02C19/068 takes precedence) · CPC title