Structure, laminated body thereof, and manufacturing method and manufacturing device thereof

Patent metadata

Field	Value
Publication number	US-11535941-B2
Application number	US-202016751941-A
Country	US
Kind code	B2
Filing date	Jan 24, 2020
Priority date	Jul 26, 2017
Publication date	Dec 27, 2022
Grant date	Dec 27, 2022

Abstract

A problem to be solved by the present invention is that there is no method for forming a dense structure on a porous structure at low cost. In addition, another object is to provide a high quality and inexpensive structure of a brittle material and a laminate thereof as an intermediate layer for facilitating formation of a dense structure on a porous structure. A structure is provided having a brittle particle assembly having a plurality of brittle particles, wherein the brittle particle assemblies are arranged adjacently to each other, and the brittle particles having a brittle material region in the periphery are crosslinked (connected) by the brittle material region to bond the brittle particles to each other, and thereby form a brittle material crosslinked structure region preventing the mobility of the brittle particles.

First claim

What is claimed is:

1. A structure comprising:
a brittle particle assembly including:
particles;
brittle material regions having substantially the same composition ratio of metal elements as the brittle particles, the brittle material regions covering each surface of the brittle particles; and
a brittle material crosslinked structure region having an amorphous structure having substantially the same composition ratio of metal elements as the brittle particles and a ratio of a metal element to a nonmetal element different from a ratio of the metal element to a nonmetal element in the brittle particles, the brittle material crosslinked structure region arranged on at least a part of the periphery of the brittle material particles, and the brittle material crosslinked structure region linking the brittle material particles arranged adjacently to each other with the brittle material regions arranged adjacently to each other,

wherein
the brittle particles include crystallites of 1 nm or more and 300 nm or less;
the brittle material crosslinked structure region has a shape along each surface of the brittle particles,
the brittle material crosslinked structure region prevents the mobility of the brittle particles, and
the structure has a compressive residual stress.

2. The structure according to claim 1 , wherein the brittle material crosslinked structure region has a three-dimensional network structure between the brittle particles.

3. The structure according to claim 1 , wherein the brittle material crosslinked structure region is arranged with a gap.

4. The structure according to claim 1 , wherein the brittle material crosslinked structure region is formed from the same element as the constituent element of the brittle particle.

5. The structure according to claim 1 , wherein the size of the brittle particles is less than 5 μm.

6. The structure according to claim 1 , wherein the hardness of the structure is 0.1 or more and less than 1 with respect to the hardness of the brittle particles.

7. A laminated structure comprising:
the structure according to claim 1 arranged on a base material.

8. The laminated structure according to claim 7 , wherein the brittle particles have a flat shape in a direction perpendicular to the base material.

9. The laminated structure according to claim 7 , wherein the base material is a porous body.

10. The laminated structure according to claim 8 , wherein the structure has the following relationship 0.02<internal compression stress/Vickers hardness.

11. The laminated structure according to claim 8 , wherein a value representing deformation of a short side/long side of the brittle particles becomes a value representing deformation of the brittle particles in an interface vicinity of the base material >a value of the brittle particles in the surface vicinity of the laminated structure.

12. The laminated structure according to claim 11 , wherein the laminated structure has a withstand voltage of 20 kV/mm or more.

13. The structure according to claim 1 , wherein the brittle particles have a ratio calculated by dividing the short side as the numerator and the long side as the denominator in the range of 0.1 to 0.99.

14. A manufacturing method of a laminated structure comprising:
crushing agglomerated particles in which primary particles in brittle particles of a raw material are agglomerated into primary particles;
activating a surface of the primary particles at a temperature range equal to or lower than a melting point of the primary particles under a reduced pressure atmosphere by using helium gas or argon gas as gaseous species to generate an active region;
ejecting the primary particles arranged with a plurality of the active regions to the base material; and
joining the primary particles arranged with the plurality of active regions via the active region,
wherein a gas flow rate is set to 5 L/min or more and 10 L/min or less when the helium gas is used to eject the primary particles or 5 L/min or more and 20 L/min or less when the argon gas is used to eject the primary particles,
the laminated structure includes a brittle particle assembly including:
the brittle particles;
brittle material regions having substantially the same composition ratio of metal elements as the brittle particles, the brittle material regions covering each surface of the brittle particles; and
a brittle material crosslinked structure region having an amorphous structure having substantially the same composition ratio of metal elements as the brittle particles and a ratio of a metal element to a nonmetal element different from a ratio of the metal element to a nonmetal element in the brittle particles, the brittle material crosslinked structure region arranged on at least a part of the periphery of the brittle material particles, and the brittle material crosslinked structure region linking the brittle material particles arranged adjacently to each other with the brittle material regions arranged adjacently to each other,

the brittle particles include crystallites of 1 nm or more and 300 nm or less;
the brittle material crosslinked structure region has a shape along each surface of the brittle particles,
the brittle material crosslinked structure region prevents the mobility of the brittle particles, and
the structure has a compressive residual stress.

15. The manufacturing method of the laminated structure according to claim 14 , wherein an active region is formed on the primary particle surface by a collision crushing effect of the primary particles and a thermal effect of a plasma.

16. The manufacturing method of a laminated structure according to claim 14 , wherein the surface of the primary particles is activated by an inductively coupled high-frequency plasma.

17. A manufacturing device of a structure comprising:
an aerosol generator, a crusher, vacuum pump, a plasma generator and a nozzle connected to the plasma generator:
wherein the crusher is arranged at a front stage of the plasma generator, the crusher crushes agglomerated particles sent from the aerosol generator in which primary particles in brittle particles of a raw material are agglomerated, and the crusher sends the primary particles to the plasma generator,
a surface of the primary particles is activated at a temperature range equal to or lower than a melting point of the primary particles under a reduced pressure atmosphere by using helium gas or argon gas as gaseous species to generate an active region,
the primary particles arranged with a plurality of the active regions are ejected to the base material by using the helium gas or the argon gas,
a gas flow rate is set to 5 L/min or more and 10 L/min or less when the helium gas is used to eject the primary particles or 5 L/min or more and 20 L/min or less when the argon gas is used to eject the primary particles, and
the primary particles having a plurality of the active regions are blown from the nozzle,
wherein the structure includes a brittle particle assembly including:
the brittle particles;
brittle material regions having substantially the same composition ratio of metal elements as the brittle particles, the brittle material regions covering each surface of the brittle particles; and
a brittle material crosslinked structure region having an amorphous structure having substantially the same composition ratio of metal elements as the brittle particles and a ratio of a metal element to a nonmetal element different from a ratio of the metal element to a nonmetal element in the brittle particles, the brittle material c

Assignees

• Aist

Inventors

• Shinoda Kentaro
• Saeki Takanori
• Mori Masakazu
• Akedo Jun

Classifications

• C23C24/10

  with intermediate formation of a liquid phase in the layer · CPC title

• C23C4/134

  Plasma spraying · CPC title

• C08K2003/2227

  of aluminium · CPC title

• Y10T428/31504

  Composite [nonstructural laminate] · CPC title

• B32B9/00

  Layered products comprising a {layer of a} particular substance not covered by groups B32B11/00 - B32B29/00 · CPC title