Aluminophosphate-metal oxide bonded body and production method for same

Patent metadata

Field	Value
Publication number	US-11219879-B2
Application number	US-201514867127-A
Country	US
Kind code	B2
Filing date	Sep 28, 2015
Priority date	Mar 29, 2013
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

An aluminophosphate-metal oxide bonded body including a metal oxide having a bonding surface on a part of the surface thereof, and aluminophosphate that is disposed on the bonding surface of the metal oxide, wherein an alkali metal, an alkaline earth metal or both of these is/are disposed on the bonding surface of the metal oxide, and the content rate of the alkali metal, alkaline earth metal or both is from 0.3 to 30.0% by mass with respect to all of the substances that are disposed on the bonding surface of the metal oxide. An aluminophosphate-metal oxide bonded body that provides a favorable bonded state even for complicated shapes is provided.

First claim

What is claimed is:

1. An aluminophosphate-metal oxide bonded body comprising a metal oxide having a bonding surface on a part of the surface thereof, and an aluminophosphate separation membrane bonded to the bonding surface of the metal oxide,
wherein the metal oxide contains at least one material selected from the group consisting of alumina, titania and silica by 70% by mass or more in total,
the metal oxide contains an alkali metal, an alkaline earth metal or both of these throughout the metal oxide, or a surface layer of the metal oxide whose surface is the bonding surface contains an alkali metal, an alkaline earth metal or both of these, and
in a portion of the metal oxide from the bonding surface to a depth of 1 μm, a content rate of the alkali metal, alkaline earth metal or both is from 0.3% to 30.0% by mass with respect to all substances that are present in the portion of the metal oxide.

2. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the alkali metal is sodium, and the alkaline earth metal is calcium, magnesium or both of these.

3. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the content rate of the alkali metal, alkaline earth metal or both of these is from 0.5% to 20.0% by mass with respect to all substances that are present in the portion of the metal oxide.

4. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein
the metal oxide is a structural body having at least one inner space, and
a value obtained by dividing the surface area of the bonding surface of the metal oxide by the space volume of the metal oxide is 100 or more.

5. The aluminophosphate-metal oxide bonded body according to claim 4 , wherein
the at least one inner space of the metal oxide is a space having at least one open end on the surface of the metal oxide,
the length of the at least one inner space in the direction to which the at least one inner space extends is 100 mm or more, and
the open end of the at least one inner space has a diameter of 5 mm or less.

6. The aluminophosphate-metal oxide bonded body according to claim 4 , wherein
the at least one inner space is a through hole having open ends on both end parts,
the metal oxide has a monolithic shape having 10 or more of the through holes, and
the through holes each has a cross-sectional surface having a diameter of 5 mm or less and being orthogonal to the direction to which the through holes extend.

7. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the aluminophosphate separation membrane has, within a surface thereof that faces the surface of the metal oxide, a surface which is not bonded to the metal oxide and whose surface area ratio to the surface of the aluminophosphate separation membrane that faces the surface of the metal oxide is 1% or less.

8. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the aluminophosphate separation membrane has a molecular structure being a structure having an oxygen 8-membered ring.

9. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the aluminophosphate separation membrane has an AEI structure.

10. The aluminophosphate-metal oxide bonded body according to claim 1 , wherein the crystal structure of the aluminophosphate separation membrane acts as a molecular sieve.

11. A method for producing the aluminophosphate-metal oxide bonded body, according to claim 1 , comprising;
a step of allowing seed crystals to adhere, wherein a seeding slurry containing aluminophosphate seed crystals is applied to a bonding surface, which is a part of a surface of a metal oxide, and
a synthesis step, wherein the metal oxide on which the seeding slurry has been applied is immersed in a raw material solution for membrane formation containing an aluminum source raw material, a structure directing agent and phosphorus acid and subjected to hydrothermal synthesis, whereby an aluminophosphate separation membrane is bonded to the bonding surface of the metal oxide to give an aluminophosphate-metal oxide bonded body,
wherein the metal oxide contains at least one material selected from the group consisting of alumina, titania and silica by 70% by mass or more in total,
alkali metal, an alkaline earth metal or both of these is/are disposed on the bonding surface of the metal oxide, and
the content rate of the alkali metal, alkaline earth metal or both of these is from 0.3% to 30.0% by mass with respect to all of the substances disposed on the bonding surface of the metal oxide.

12. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the liquid phase of the seeding slurry, in which the aluminophosphate seed crystals are dispersed, is water, ethanol or a mixture thereof.

13. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the concentration of the aluminophosphate seed crystals in the seeding slurry is from 0.01% to 1.00% by mass.

14. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the aluminophosphate seed crystals contain a structure directing agent.

15. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein
the aluminophosphate seed crystals have an average particle diameter of from 80 nm to 500 nm,
the metal oxide is porous and has pores that are opened on the bonding surface of the metal oxide, wherein each pore has an open pore diameter of from 0.3 to 1.5-times of the average particle diameter of the aluminophosphate seed crystals.

16. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the temperature condition in the hydrothermal synthesis is from 130° C. to 170° C.

17. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the time for the hydrothermal synthesis is from 10 hours to 50 hours.

18. The method for producing an aluminophosphate-metal oxide bonded body according to claim 11 , wherein the crystal structure of the aluminophosphate separation membrane acts as a molecular sieve.

Assignees

• Ngk Insulators Ltd

Inventors

• Hagio Takeshi
• Miyahara Makoto
• Uchikawa Tetsuya
• Ichikawa Makiko
• Noda Kenichi
• Yajima Kenji

Classifications

• B01D71/028

  Molecular sieves (carbon B01D71/021) · CPC title

• B01D71/022

  Metals · CPC title

• B01D69/12

  Composite membranes; Ultra-thin membranes · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B38/0035

  by evaporation induced self-assembly · CPC title