Iron powder for exothermic composition, production method therefor, exothermic composition using said iron powder, and exothermic body production method

Patent metadata

Field	Value
Publication number	US-11629280-B2
Application number	US-201816612952-A
Country	US
Kind code	B2
Filing date	May 18, 2018
Priority date	May 18, 2017
Publication date	Apr 18, 2023
Grant date	Apr 18, 2023

Abstract

An iron powder for an exothermic composition according to the present invention has a bulk density of 0.3 to 1.5 g/cm 3 . Furthermore, an exothermic composition according to the present invention contains the iron powder, a carbon material, a halide salt, and water. Furthermore, an exothermic body production method according to the present invention includes: forming a coated member by coating a base material sheet with a flowable exothermic composition containing the iron powder, a carbon material, and water; and adjusting an amount of moisture in the coated member by removing water from the coated member. Furthermore, the present invention is directed to a production method for the iron powder (an iron powder for an exothermic composition) including: a reducing step of reducing iron oxide to obtain reduced iron; and a step of milling the reduced iron. In the reducing step, the iron oxide is reduced by introducing iron oxide and a solid reductant with a volatile matter content of 10% by mass or more into a heating furnace whose internal portion contains no sulfur gas or is set to an air or inert gas atmosphere, and setting the internal portion to a reducing gas atmosphere through heating under a condition that an ambient temperature of the internal portion is from 900 to 1000° C.

First claim

The invention claimed is:

1. An exothermic composition, comprising:
an iron powder with a bulk density of 0.3 to 1.5 g/cm 3 ,
a carbon material,
a halide salt, and
water,
wherein a pore volume as measured using a mercury intrusion method of said iron powder in a range of 1 μm or more is 0.3 cm 3 /g or more.

2. The exothermic composition according to claim 1 , wherein an average particle size of the iron powder is from 20 to 150 μm.

3. The exothermic composition according to claim 1 , wherein a metal iron content in the iron powder is from 60 to 95% by mass.

4. The exothermic composition according to claim 1 , wherein a BET specific surface area of the iron powder is 0.1 m 2 /g or more.

5. The exothermic composition according to claim 1 , wherein a surface layer of the iron powder is constituted by a fibrous matters that are arranged at random in three dimensions.

6. An exothermic body comprising the exothermic composition according to claim 2 .

7. The exothermic composition according to claim 1 , wherein a pore volume as measured using a mercury intrusion method of said iron powder in a range of 1 μm or more is 0.5 cm 3 /g or more.

8. The exothermic composition according to claim 1 , wherein a pore volume as measured using a mercury intrusion method of said iron powder in a range of 1 μm or more is 4.0 cm 3 /g or less.

9. The exothermic composition according to claim 1 , wherein a pore volume as measured using a mercury intrusion method of said iron powder in a range of 1 μm or more is 3.0 cm 3 /g or less.

10. The exothermic composition according to claim 1 , wherein an average particle size of the iron powder is from 30 μm to 150 μm.

11. The exothermic composition according to claim 1 , wherein an average particle size of the iron powder is from 40 μm to 150 μm.

12. The exothermic composition according to claim 1 , wherein an average particle size of the iron powder is from 30 μm to 100 μm.

13. The exothermic composition according to claim 1 , wherein an average particle size of the iron powder is from 40 μm to 100 μm.

14. The exothermic composition according to claim 1 , wherein a metal iron content in the iron powder is from 70% to 90% by mass.

15. The exothermic composition according to claim 1 , wherein a BET specific surface area of the iron powder is 0.2 m 2 /g or more.

16. The exothermic composition according to claim 1 , wherein a BET′ specific surface area of the iron powder is 50 m 2 /g or less.

17. The exothermic composition according to claim 1 , wherein a BET specific surface area of the iron powder is 40 m 2 /g or less.

18. The exothermic composition according to claim 1 , wherein said carbon material is one or more materials selected from the group consisting of activated carbon, carbon black, acetylene black, black lead, graphite, coal, and coal char.

19. The exothermic composition according to claim 1 , wherein said halide salt is one or more salts selected from the group consisting of sodium chloride, potassium chloride, calcium chloride, magnesium chloride, ferrous chloride, and ferric chloride.

20. The exothermic composition according to claim 1 , wherein said carbon material is present in an amount of 3 parts by mass to 30 parts by mass based on 100 parts by mass of said iron powder,
said halide salt is present in an amount of 3 parts by mass to 30 parts by mass based on 100 parts by mass of said iron powder, and
said water is present in an amount of 30% by mass to 70% by mass based on the total mass of said exothermic composition.

Assignees

• Kao Corp

Inventors

• Homma Taichi
• Suzuki Ryohei
• Maezawa Takahiro
• Tabata Tetsuya

Classifications

• B22F9/22

  using gaseous reductors · CPC title

• B22F9/20 Primary

  starting from solid metal compounds · CPC title

• A61F2007/038

  Carbon or charcoal, e.g. active · CPC title

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• C09K5/18 Primary

  Non-reversible chemical reactions · CPC title