JP3848545B2 - Dissimilar metal-containing metal oxide particles, production method and use thereof - Google Patents
Dissimilar metal-containing metal oxide particles, production method and use thereof Download PDFInfo
- Publication number
- JP3848545B2 JP3848545B2 JP2001117447A JP2001117447A JP3848545B2 JP 3848545 B2 JP3848545 B2 JP 3848545B2 JP 2001117447 A JP2001117447 A JP 2001117447A JP 2001117447 A JP2001117447 A JP 2001117447A JP 3848545 B2 JP3848545 B2 JP 3848545B2
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- Prior art keywords
- metal
- metal oxide
- oxide particles
- particles
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Description
【0001】
【発明の属する技術分野】
本発明は、異種金属を添加することによって熱線遮蔽性等の特性を付与してなる金属酸化物粒子において前記特性に優れる金属酸化物系粒子と、その製造方法および用途に関する。
【0002】
【従来の技術】
Sn含有酸化インジウム(ITO)、Sb含有酸化スズ(ATO)、Al含有酸化亜鉛などは白色導電性粒子として知られている。これらの金属酸化物粒子は、上記Sn,Sb,Al等の異種金属を0.1〜20%含有するとき、その作り方により、可視光の透過性に優れた熱線遮蔽性剤となる場合がある。これら異種金属添加金属酸化物粒子は、例えば、酸化インジウム系、酸化スズ系では、主成分となる金属と異種金属の各化合物(塩化物、硝酸塩等)をアルカリで加水分解することにより水酸化物の共沈体を得て、これを高温で焼成することにより得られる。
【0003】
ところが、Al,In等の異種金属を含有する酸化亜鉛(ZnO)は、上述の方法で作った場合、導電性はあるが、熱線遮蔽性能はないか、あっても実用的なレベルに達しない。これに対し、本発明者らが開発した製造方法(特開平8−253317号公報参照)によれば、熱線遮蔽性能を有するZnO系粒子を得ることが出来る。この方法は、亜鉛源、モノカルボン酸、アルコールからなる混合物をAl,In等のIIIb族金属元素やIVb 族金属元素の化合物の存在下で加熱する方法である。
【0004】
しかし、特開平8−253317号公報記載のこの方法で得られたAl,In等含有ZnO粒子でも、その熱線遮蔽性能がITO粒子やATO粒子に比べて劣るため、これを熱線遮蔽膜として用いる場合、ITOやATOを含む熱線遮蔽膜と同じ熱線遮蔽率を得るためには、その塗布量を高くせざるを得ないという問題点があった。
【0005】
ITO粒子やATO粒子についても、これらは高価であるので、より熱線遮蔽性能の高い粒子とすることによって、その使用量を減少できるようにすることが求められている。
【0006】
【発明が解決しようとする課題】
そこで、本発明が解決しようとする課題は、熱線遮蔽性能や可視光透過性などの機能が特に優れる異種金属含有金属酸化物粒子、特に、熱線遮蔽性能に優れるZnO系、In2O3系、SnO2系などの導電性金属酸化物粒子と、その製造方法および用途を提供することである。
【0007】
【課題を解決するための手段】
本発明者は、上記課題を解決するため、Al,In等含有ZnO系粒子につい種々の面から分析を行い、上記の問題が起きる原因を追求した。その結果、原因は、添加された異種金属が1次粒子の表面側に偏っていて内部にまで十分に存在していないことにあることを見出した。そして、上記原因は、添加された異種金属が1次粒子の中央部に一定値以上存在することで解消されることを見出した。さらに、このようなAl,In等含有ZnO系粒子を製造するのに好適な方法を見出した。そして、以上のことはAl,In等含有ZnO系粒子以外の金属酸化物粒子にも適用できることを見出して、本発明を完成した。
【0008】
したがって、本発明にかかる異種金属含有金属酸化物粒子(以下単に「金属酸化物粒子」と言う)は、金属(M)に異種金属(Md)を添加してなる金属酸化物系粒子において、異種金属(Md)の含有率(Md/M)が、平均0.5〜20原子%であり、かつ、1次粒子中央部で0.5原子%以上あることを特徴とする。
【0009】
本発明にかかる、異種金属含有金属酸化物粒子の製造方法は、異種金属(Md)の含有率(Md/M)が平均0.5〜20原子%である異種金属含有金属酸化物粒子を製造する方法であって、金属(M)の下記一般式(I)で示される化合物および/または加水分解縮合物と異種金属(Md)の化合物とアルコールを含有するがカルボン酸は含まない溶液を加熱して金属酸化物粒子を析出させる工程を含み、以下の(a)および(b)であることを特徴とする。
【0010】
(a)前記加熱が加圧下で行われること。
【0011】
(b)前記溶液中の水分量が前記異種金属(Md)に対するモル比で100倍モル以下であること。
【0012】
M(O)(m-x-y-z)/2(OCOR)x(OH)y(OR’)z (I)
(但し、Mはm価の金属原子;Rは、水素原子、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;R’は、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;m、x、yおよびzは、x+y+z≦m、0<x≦m、0≦y<m、0≦z<mを満たす。)
そして、本発明にかかる金属酸化物粒子含有組成物は、本発明にかかる上記金属酸化物粒子を0.1重量%以上含有してなる。
【0013】
【発明の実施の形態】
〔金属酸化物系粒子〕
本発明にかかる金属酸化物粒子において、異種金属(Md)の含有率(Md/M)は、1次粒子全体の平均が0.5〜20原子%(好ましくは1〜10原子%、より好ましくは2〜10原子%、特に好ましくは4原子%以上)であり、かつ、1次粒子中央部で0.5原子%以上(好ましくは1原子%以上、より好ましくは2原子%以上、特に好ましくは4原子%以上)である。
【0014】
上記異種金属(Md)の含有率(Md/M)における1次粒子全体の平均値(平均含有率)をαavとし1次粒子中央部の値(中央含有率)をαc とすると、平均含有率に対する中央含有率(αc /αav)は、好ましくは0.2以上であり、さらに好ましくは0.5以上、最も好ましくは0.8以上である。
【0015】
上記平均含有率αavと中央含有率αc の測定方法は、1次粒子の集合体(αavの場合)または単体(αc の場合)について、FE−TEM(透過型電子顕微鏡)によりそれらの透過像を観察しながら、粒子の外に金属の偏析物が無いところを探して、高分解能XMAにより下記所望の空間分解能(スポット径)で元素分析を行う。そして、各金属に帰属するピーク強度から、異種金属(Md)の含有率を求めるという方法である。なお、スポット径は、プローブを絞ることにより下限を1nmφにできるとともに、任意に連続的にスポット径を拡大することができる。偏析物の確認については、FE−TEMでの観察による投影図において、通常、肉眼で確認できないレベルであれば偏析物は無いものとする。
【0016】
上記平均含有率αavの測定に関しては、さらに詳しくは、FE−TEMでの観察により、1次粒子の集合体として偏析物の見られない約10個の粒子について、これら粒子をすべて含むような空間分解能(スポット径)で元素分析することによって行うこととする。
【0017】
上記中央含有率αc の測定に関しては、さらに詳しくは、FE−TEMにより1次粒子1個の投影像について偏析物の無い状態で観察し、その投影像の中央部分を1nmφの空間分解能(スポット径)で元素分析することによって行うとする。投影像の中央部分を分析する際は、通常、常識的に判断して投影像のおよそ中心であると思われる部分について行えばよいが、少なくともスポットが投影像の輪郭線に接触しない程度の投影像内部について行えばよく、好ましくは投影像の形状を上記およそ中心部を基準に、長さ基準で80%に縮小した領域内、より好ましくは50%に縮小した領域内、さらにより好ましくは20%に縮小した領域内で行えばよい。なお、例えば、粒子形状が針状等であって投影像の形状も針状等であれば、常識的に投影像のおよそ中心と判断した部分であってもそこに設定したスポットが投影像の輪郭線に接触してしまうことがあり得るが、このような場合は、上記投影像のおよそ中心であると思われる部分を中心に、最大長さ部分の長さの50%を直径とする領域内で行えばよい。中央含有率αc の最終的な測定結果は、10個の粒子についての平均値とした。
【0018】
また、1次粒子が厚み(粒径)30nmを超える部分を有する場合は(粒子によっては100nmを超える場合もある)、例えば、粉体試料をエポキシ樹脂と混合し、硬化後、薄切片を得て、この薄切片よりイオンミリング法によって1次粒子の断面が露出した、通常、厚みが30nm以下の極薄片化試料を得るようにし、この極薄片化試料の一次粒子の断面部分について上記測定を行うことが好ましい。理由としては、厚みが30nmを超えると、FE−TEMの電子線透過が不完全になったりXAMの分解能が低減したりするからであり、厚さ方向の情報すべてが分析に関係する以上、測定結果の正確性に欠けることとなるからである。
【0019】
上記測定においては、FE−TEMとして例えば日立製作所製の電界放射型透過型電子顕微鏡(HF−2000型、加速電圧200kV)を用い、XMAとして例えばケヴェックス(Kevex)社製のX線マイクロアナライザー(Sigma型、エネルギー分散型、ビーム径:空間分解能10Åφ)を挙げることが出来る。
【0020】
主金属(M)や異種金属(Md)としては、特に限定はないが、たとえば、Be、Mg、Ca、Sr、Ba、Ra等のアルカリ土類金属元素;La、Ce等のランタノイド系金属元素;Ac等のアクチノイド系金属元素;Sc、Y等のIIIa族金属元素;Ti、Zr、Hf等のIVa族金属元素;V、Nb、Ta等のVa族金属元素;Cr、Mo、W等のVIa族金属元素;Mn、Tc、Re等のVIIa族金属元素;Fe、Co、Ni、Ru、Rh、Pd、Os、Ir、Pt等のVIII族金属元素;Cu、Ag、Au等のIb族金属元素;Zn、Cd、Hg等のIIb族金属元素;Al、Ga、In、Tl等のIIIb族金属元素;Ge、Sn、Pb等のIVb族金属元素;Sb、Bi等のVb族金属元素;Se、Te等のVIb族金属元素等を挙げることができ、これらが1種または2種以上併存していてもよい。
【0021】
主金属(M)としては、上記具体例のうち、Zn、Ti、Ce、Fe、Ni、V、Nb、Be、La、Mo、W、Re、In、Ga、Sn、Sb等は、金属の原子価や、粒子の大きさ、結晶構造、不純物の注入、欠陥の注入等によって、光、電気、磁気的機能を制御することができる。このため、紫外線吸収性、赤外線遮蔽性等の光選択透過機能を有する等の光学機能や、(光)導電機能、磁気機能等を有する点で好ましい。さらに、Fe、Ni、V、Nb、Be、La、Mo、W等では、透明性が高く、安定な粒子が得られる。Znは、結晶構造の制御、不純物濃度の制御によって、紫外線吸収性等の光学的性質や、電気的性質を制御できるようになり、好ましい。
【0022】
主金属(M)としては、熱線遮蔽性および可視光の透過率が共に高い点で、たとえば、In、Sn、Znが好ましい。
【0023】
異種金属(Md)としては、熱線遮蔽性および可視光の透過率が共に高い点で、たとえば、金属酸化物粒子が酸化インジウム粒子の場合は4価の金属が好ましく、Sn、Ti等が特に好ましい。金属酸化物粒子が酸化スズ粒子の場合は5価の金属元素が好ましく、Sb、P等が特に好ましい。金属酸化物粒子が酸化亜鉛粒子の場合は、3価の金属元素が好ましく、In、Al、Ga等が特に好ましい。
【0024】
本発明にかかる金属酸化物粒子には、アモルファス粒子も含まれるが、X線回折学的に見て、または電子線回折学的に見て、金属(M)の酸化物結晶性を示すものが好適である。通常、1次粒子径が5nm以上の場合はX線回折法により、また、1次粒子径が5nm以下の場合は電子線回折法により、結晶性であるか否かの確認並びに結晶性の場合には結晶構造、物性の同定を行うことができる。
【0025】
本発明にかかる金属酸化物粒子の1次粒子径は、透明性が高い点で0.1μm以下が好ましい。具体的には、以下の(1)および/または(2)および/または(3)を満足することが特に好ましい。
【0026】
(1)X線回折法(ウィルソン法)あるいは電子線回折法を用いて求めた、結晶子の大きさをDwとするとき、1nm≦Dw≦100nmであること。
【0027】
(2)下記数式で算出される比表面積径をDsとするとき、1nm≦Ds≦100nmであること。
【0028】
Ds=6/(ρ×S) ここで、Ds:μm
(但し、ρ:金属酸化物系粒子の真比重、S:B.E.T.法で測定される金属酸化物系粒子の比表面積(m2/g))
(3)透過型電子顕微鏡で粒子像を測定し、その結晶格子像および大きさの観測から求められる1次粒子径をDeとするとき、1nm≦De≦100nmであること。
【0029】
本発明の金属酸化物系粒子は、透明性に優れている点で 1次粒子径が1〜30nmであることが好ましく、熱線遮蔽剤や導電材料として用いる場合は、5nm≦Dw≦30nmが好ましい。
【0030】
本発明にかかる金属酸化物粒子は、カルボン酸(残)基を含有することが好ましい。ここで、カルボン酸(残)基とは、−COO−基を意味し、具体的には、カルボキシル基(−COOH)、カルボキシレート基(−COO-)、加水分解によってカルボキシル基および/またはカルボキシレート基を生成するエステル基等のことである。カルボン酸(残)基としては、飽和脂肪酸(残)基が好ましく、炭素数1〜4の脂肪酸(残)基がさらに好ましく、アセトキシ基(CH3COO−)が最も好ましい。
【0031】
カルボン酸(残)基は、吸着および/または化学結合で金属酸化物粒子の表面に存在することにより、2次凝集を抑えて分散性を向上させるので、この金属酸化物粒子を含有する樹脂組成物を塗料としたときに塗膜の透明性が高くなる。
【0032】
カルボン酸(残)基の含有量は、金属(M)に対し好ましくは0.01〜14モル%、より好ましくは0.1〜7モル%、最も好ましくは1〜5モル%である。カルボン酸(残)基の含有量が金属(M)に対し0.01モル%未満であると、粒子の分散性が低下し、粒子が2次凝集しやすくなる。他方、カルボン酸(残)基の含有量が金属元素(M)に対し14モル%超であると、金属酸化物としての機能、たとえば、赤外線遮蔽性や紫外線遮蔽性が低下する。
【0033】
本発明にかかる金属酸化物粒子の粒子形状は特に限定されない。形状の具体例としては、球状、楕円球状、立方体状、直方体状、ピラミッド状、針状、柱状、棒状、筒状、りん片状、(六角)板状等の薄片状などが例示される。
〔金属酸化物粒子の製造方法〕
上記金属酸化物粒子を製造する方法については、特に限定はないが、たとえば、次に述べる方法を好ましいものとして挙げることができる。
【0034】
金属(M)の化合物および/または加水分解縮合物と異種金属(Md)の化合物とアルコールを含有する溶液を加熱して金属酸化物粒子を析出させる工程を含み、以下の(a)および/または(b)であることを特徴とする。
【0035】
(a)前記加熱が加圧下で行われること。
【0036】
(b)前記溶液中の水分量が前記異種金属(Md)に対するモル比で100倍モル以下であること。
【0037】
上記(a)については、加熱時の圧力は、常圧(大気圧)を1kg/cm2 とする絶対圧Pで示すと、P>1kg/cm2 を満たし、好ましくは1.5kg/cm2 ≦P≦100kg/cm2 を満たすことである。加圧効果が高く、かつ経済的な設備で行えると言う点で、3kg/cm2 ≦P≦20kg/cm2 を満たすことが特に好ましく、5kg/cm2 ≦P≦10kg/cm2 を満たすことが最も好ましい。
【0038】
加圧方法としては、たとえば、アルコールの沸点より高い温度に加熱する方法や、気相部を窒素ガスやアルゴンガスなどの不活性ガスで加圧にする方法などを採用できる。
【0039】
上記加熱温度については、アルコールの沸点等にもよるが、好ましくは50℃〜300℃、より好ましくは100℃〜アルコールの臨界温度、最も好ましくはアルコールの常圧沸点より20℃以上高い温度である。
【0040】
上記(b)については、前記溶液中の水分量には、遊離の水分量を意味するが、金属(M)の化合物や異種金属(Md)の化合物が結晶水を有する場合の結晶水も含まれる。この水分量は、カールフィッシャー法によって測定することができる。ここでいう水分量は、使用する原料中に含まれる水(使用するアルコールおよびその他の溶媒成分中の遊離の水、金属(M)の化合物や異種金属(Md)の化合物中の結晶水等の水の総和)の、使用する全異種金属(Md)の化合物中の全異種金属(Md)に対するモル比を意味しており、加熱反応において副生する水については考慮しないとする。
【0041】
この水分量は、使用する異種金属(Md)全量に対するモル比で50倍モル以下であると好ましく、20倍モル以下であるとさらに好ましい。水分量が多すぎると、金属(M)の酸化物の結晶子中に異種金属(Md)が含有されにくくなり、機能性の高い異種金属含有金属酸化物粒子が得られにくくなる。
【0042】
主金属(M)の化合物は、下記一般式(I)で示される構造を有するものである。具体的には、金属酸化物粒子の説明において前述した。
【0043】
M(O)(m-x-y-z)/2(OCOR)x(OH)y(OR’)z (I)
(但し、Mはm価の金属原子;Rは、水素原子、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;R’は、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;m、x、yおよびzは、x+y+z≦m、0<x≦m、0≦y<m、0≦z<mを満たす。)
上記一般式(I)における、RやR’としては、分散性の高い金属酸化物系粒子が得られやすくなるため、メチル基等の炭素数1〜4のアルキル基が好ましく、メチル基が特に好ましい。上記一般式(I)における、xとしては1≦x≦mを満たすものが好ましく、yとしては0≦x<m/2を満たすものが好ましく、zとしては1≦x<m/2を満たすものが好ましい。これらの場合に、分散性の高い金属酸化物系粒子が得られやすいからである。
【0044】
一般式(I)で表される化合物としては溶解速度の速いものを用いると、分散性に優れた粒子が得られるため好ましい。ここに、溶解速度とは、反応で直接測定することもできるが、25℃において、式(I)の化合物2重量部(以下、部と略す)を25±3℃のイオン交換水(pH5〜8)200部に混合し、攪拌したとき、完全に溶解して透明な溶液が得られるまでの時間tで定義される。一般式(I)で表される化合物の溶解速度は、好ましくは2分間以内、さらに好ましくは1分間以内、最も好ましくは30秒間以内である。
【0045】
一般式(I)で表される化合物の加水分解縮合物は、一般式(I)で示される構造を有する金属元素(M)の化合物を加水分解および/または縮合して得られる加水分解物および/または縮合物であり、モノマーから高分子化合物までの化合物である。縮合物は、主金属(M)元素と酸素(O)とがメタロキサン結合した結合鎖−(M−O)n(但し、nは1以上)を有する化合物である。縮合物の縮合度については、限定はなく、結晶子の大きさ、形態のそろった金属酸化物系粒子を得るためには、縮合度(平均)が好ましくは100以下、さらに好ましくは10以下である。
【0046】
本発明にかかる製造方法で用いられる異種金属(Md)の化合物としては、たとえば、上記一般式(I)で金属元素(M)を前述の金属元素(Md)に代えた化学構造を有する化合物や、異種金属(Md)の金属アルコキシド類を挙げることができる。前者については、具体的には、金属酸化物粒子の項で前述した。
【0047】
本発明にかかる製造方法で用いられるアルコールとしては、特に限定はないが、たとえば、1価アルコールで水溶性の高いアルコールが好ましい。このようなアルコールとしては、たとえば、以下のA)〜C)等の水に対する溶解度1重量%以上のアルコールを挙げることができ、水に対する溶解度10重量%以上のアルコールがさらに好ましい。
【0048】
A)メタノール、エタノール、n−プロピルアルコール、イソプロピルアルコール、n−ブタノール、sec−ブタノール、t−ブチルアルコール等の炭素数1〜4の1〜3級の脂肪族アルコール
B)シクロヘキサノール、ベンジルアルコール
C)グリコール誘導体
a)エチレングリコールモノメチルエーテル、エチレングリコールモノエチルエーテル、エチレングリコールモノイソプロピルエーテル、エチレングリコールモノn−ブチルエーテル、ジエチレングリコールエチルエーテル、ジエチレングリコールブチルエーテル、プロピレングリコールモノメチルエーテル、プロピレングリコールモノエチルエーテル、プロピレングリコールモノイソプロピルエーテル、プロピレングリコールモノn−ブチルエーテル、ジプロピレングリコールメチルエーテル、トリプロピレングリコールメチルエーテル、3−メチル−3−メトキシブタノール等のアルキレングリコールエーテル類
b)エチレングリコールアセテート、プロピレングリコールアセテート等のアルキレングリコールアセテート類
本発明にかかる製造方法では、主金属(M)の化合物(I)および/またはその加水分解縮合物とアルコールを混合して、これらを含む溶液を調製する。ここでいう溶液は、乳化状や懸濁状のものを含む。異種金属の化合物についても同様である。上記混合は、金属化合物(加水分解縮合物)の粉体をそのままアルコールに添加する方法であってもよく、また、一旦別の溶媒に添加して予め懸濁液または希釈溶液を調製しておき、これをアルコールに添加すると言う方法によってもよい。懸濁液または希釈溶液の調製に用いる溶媒としては、アルコールまたはその酢酸エステルが好ましく、加熱保持する際に用いるアルコールがさらに好ましい。
【0049】
本発明における製造方法では、主金属(M)の化合物、異種金属(Md)の化合物およびアルコールを含む混合物の加熱を行うが、混合から加熱における一連の操作手順については、特に限定はなく、例えば、1)常温または50℃以下で上記混合物を調製し、昇温および加熱する方法や、2)主金属(M)の化合物および異種金属(Md)の化合物とアルコールとのうちの少なくとも一方を好ましくは加圧下で加熱しておき、もう一方を加熱したものに混合する予備加熱法等を好ましく挙げることができる。予備加熱法としては、具体的には、例えば、a)アルコールを加熱しておき、主金属(M)の化合物および異種金属(Md)の化合物を添加する方法、b)主金属(M)の化合物および異種金属(Md)の化合物(またはこれらの懸濁体、均一溶液)を加熱しておき、アルコールを添加する方法、c)アルコールと主金属(M)の化合物および異種金属(Md)の化合物(またはこれらの懸濁体、均一溶液)とを別々に加熱しておき両者を混合する方法などが好ましく挙げられる。上記1)および2)の方法のなかでも、2)の予備加熱法がより好ましく、反応温度を選択しやすく、粒子径や組成の制御が容易に行える。このとき、予備加熱された少なくとも一方を加圧状態にしておいて混合する方法は、混合と同時に加圧下での加熱処理を開始することができるため、異種金属(Md)の含有率の高い粒子が得られやすく好ましい。
【0050】
金属化合物(加水分解縮合物)をアルコールや他の溶媒に添加混合する方法については、特に限定はなく、▲1▼総量を一挙に、たとえば1分間以内に添加混合する一括添加法や、▲2▼1分間を超える時間をかけて連続的に添加する連続フィードや、▲3▼少量ずつ、2回以上に分けて添加するパルス添加法(各パルスは連続フィードでもよく、一括添加でもよい)等の方法が採用できる。▲2▼または▲3▼の場合は、添加によって生じるアルコールを含む溶液の温度変化が小さい方が1次粒子径の揃った粒子が得られ易く好ましい。具体的には、溶液の温度変化が10℃以内に収まるように添加速度等を制御することが好ましい。
【0051】
金属化合物(加水分解縮合物)をアルコールや他の溶媒に混合する場合の添加速度としては、この添加速度を〔金属化合物(加水分解縮合物)モル/アルコール(モル)/添加時間(分)〕で表したとき、好ましくは0.0001〜2、さらに好ましくは0.0005〜1.0である。この添加速度が0.0001未満であると、1次粒子が0.1μm以下のものを得るのが困難になるおそれがある。他方、この添加速度が2を超えると、上述の温度制御が特に反応スケールが大きくなると困難となり、粒子径の揃った粒子が得難くなる。
【0052】
金属化合物(加水分解縮合物)とアルコールとの混合比は、特に限定はないが、金属化合物(加水分解縮合物)の総量添加終了後の仕込換算のモル比で表して、その下限が、異種金属Mdが均一に1次粒子内に含有されるためには、好ましくは金属(M)の原子価であるm以上、さらに好ましくは2m以上である。上記モル比の上限は、生産性の観点から、好ましくは50以下、さらに好ましくは20以下である。
【0053】
本発明にかかる製造方法においては、粒子の結晶性を高めて熱線遮蔽性能などの性能を高くするために所定温度を30分以上保持するが、具体的な加熱条件としては、好ましくは180℃以上で1時間以上、さらに好ましくは200℃以上で3時間以上である。ここで、加熱温度は反応容器のボトム温度で表す。
【0054】
本発明にかかる製造方法では、加熱中、溶液は攪拌所要動力0.0001kw/m3 以上で攪拌されていることが好ましく、より好ましくは0.001kw/m3 以上であり、特に0.01〜10kw/m3 で攪拌されていることが好ましい。
【0055】
本発明にかかる製造方法では、得られる粒子の分散性を高める目的で、金属化合物(加水分解縮合物)の添加終了後の任意の段階で、脂肪族カルボン酸や脂肪族アミンを、主金属(M)に対し0.1〜10モル%添加する。脂肪族カルボン酸や脂肪族アミンを添加しない場合、主金属(M)の種類によっては、金属酸化物粒子が2次凝集体粒子となる場合がある。
【0056】
上記本発明にかかる製造方法によれば、熱線遮蔽性能や可視光透過性などの機能に優れ、添加金属を含有する金属酸化物系粒子を容易に得させることができる。
〔金属酸化物粒子の用途〕
本発明にかかる金属酸化物粒子は、上記した本発明の金属酸化物粒子を0.1重量%以上含有する組成物である。例えば、バインダー樹脂に対して上記した異種金属含有金属酸化物粒子を0.1重量%以上含有する塗料組成物や成形材料組成物やフィルムである。この組成物は、上記本発明にかかる金属酸化物粒子を含むため、熱線遮蔽性等の特性が特に優れている。
【0057】
以下に、この組成物が塗料組成物と成形材料組成物と金属酸化物粒子含有フィルムについて、順に詳しく説明する。
塗料組成物
塗料組成物は、光選択透過性機能等の光機能、導電機能等の電気機能、光触媒機能等の触媒機能等の各種機能性に優れ、しかも、耐候性が高い塗膜を得させることができる。特に、本発明の熱線遮蔽性に優れる金属酸化物粒子を含むものは、経済性および熱性遮蔽性と可視光透過性に優れ、有用である。
【0058】
塗料組成物に用いられるバインダー樹脂としては、熱可塑性または熱硬化性(熱硬化性、紫外線硬化性、電子線硬化性、湿気硬化性、これらの併用等も含む)の各種合成樹脂や天然樹脂等の有機系バインダーや、無機系バインダー等を挙げることができる。
【0059】
合成樹脂としては、たとえば、アルキド樹脂、アミノ樹脂、ビニル樹脂、アクリル樹脂、エポキシ樹脂、ポリアミド樹脂、ポリウレタン樹脂、熱硬化性不飽和ポリエステル樹脂、フェノール樹脂、塩素化ポリオレフィン樹脂、シリコーン樹脂、アクリルシリコーン樹脂、フッ素樹脂、キシレン樹脂、石油樹脂、ケトン樹脂、ロジン変性マレイン酸樹脂、液状ポリブタジエン、クマロン樹脂等を挙げることができ、これらが1種または2種以上使用される。天然樹脂としては、たとえば、セラック、ロジン(松脂)、エステルガム、硬化ロジン、脱色セラック、白セラック等を挙げることができ、これらが1種または2種以上使用される。
【0060】
合成樹脂として、エチレン−プロピレン共重合ゴム、ポリブタジエンゴム、スチレン−ブタジエンゴム、アクリロニトリル−ブタジエン共重合ゴム等の天然または合成のゴム等を用いてもよい。合成樹脂と併用する成分として、硝酸セルロース、セルロースアセテートブチレート、酢酸セルロース、エチルセルロース、ヒドロキシプロピルメチルセルロース、ヒドロキシエチルセルロース等を挙げることができる。
【0061】
塗料組成物に用いられるバインダー樹脂の形態については、特に限定はなく、溶剤可溶型、水溶性型、エマルション型、分散型(水/有機溶剤等の任意の溶剤)等を挙げることができる。
【0062】
水溶性型のバインダー樹脂としては、たとえば、水溶性アルキド樹脂、水溶性アクリル変性アルキド樹脂、水溶性オイルフリーアルキド樹脂(水溶性ポリエステル樹脂)、水溶性アクリル樹脂、水溶性エポキシエステル樹脂、水溶性メラミン樹脂等を挙げることができる。
【0063】
エマルション型のバインダー樹脂としては、たとえば、(メタ)アクリル酸アルキル共重合ディスパージョン;酢酸ビニル樹脂エマルション、酢酸ビニル共重合樹脂エマルション、エチレン−酢酸ビニル共重合樹脂エマルション、アクリル酸エステル(共)重合樹脂エマルション、スチレン−アクリル酸エステル(共)重合樹脂エマルション、エポキシ樹脂エマルション、ウレタン樹脂エマルション、アクリル−シリコーンエマルション、フッ素樹脂エマルション等を挙げることができる。
【0064】
無機系バインダーとしては、シリカゲル、アルカリケイ酸、シリコンアルコキシド等の金属アルコキシド、これらの(加水分解)縮合物、リン酸塩等を挙げることができる。
【0065】
塗料組成物を後述の紫外線吸収性フィルムの製造等に用いる場合、成膜温度等の成膜条件や、得られるフィルムの可撓性や耐候性の観点からは、塗料組成物に用いられるバインダー樹脂としては、ポリウレタン樹脂、アクリル樹脂、フッ素樹脂等が好ましい。
【0066】
塗料組成物中の金属酸化物粒子の割合は、たとえば、金属酸化物粒子およびバインダー樹脂の固形分合計量に対して0.1〜99重量%であり、好ましくは10〜90重量%である。金属酸化物粒子の割合が0.1重量%未満であると、紫外線遮蔽性や導電性等の粒子を添加することによって得られる効果が低下する。他方、金属酸化物粒子の割合が90重量%を超えると、可視光透過性および可撓性が低下する。塗料組成物に含まれる金属酸化物粒子が導電性で、塗料組成物から得られる塗膜を導電膜、帯電防止膜等の機能膜として用いる場合は、塗料組成物中の金属酸化物粒子の割合は、金属酸化物粒子およびバインダー樹脂の固形分合計量に対して、さらに好ましくは50〜90重量%であり、最も好ましくは70〜85重量%である。
【0067】
塗料組成物は、金属酸化物粒子とバインダー樹脂以外に要求性能に従って、架橋剤等の硬化剤;硬化助剤等の硬化触媒;可塑剤;消泡剤・レベリング剤;チクソトロピック剤;艶消し剤;界面活性剤;難燃剤;顔料湿潤剤・分散剤;滑剤;紫外線吸収剤;光安定剤;酸化防止剤;その他(熱)安定剤;防腐剤;防かび剤;防藻剤;防食・防錆剤;染料;顔料等の添加剤を含有するものでもよい。
【0068】
硬化剤としては、たとえば、空気(酸素)等の乾性油系に用いられる硬化剤;単官能または多官能の不飽和モノマー等のポリエステル樹脂、ポリアクリル樹脂、エポキシ樹脂に用いられる硬化剤;1級、2級アミノ基を含むポリアミン、ポリアミドや、メチロール基を有するアミノ樹脂、カルボキシル基を有する多塩基酸や高酸価ポリエステル等のエポキシ基を有するバインダー樹脂に用いられる硬化剤;イソシアネート基を有するポリイソシアネート、ウレタン基を有するポリイソシアネート、メチロール基、1級および/または2級のアミノ基、アルコキシメチレン基を有するアミノ樹脂等の水酸基を有するバインダー樹脂に用いられる硬化剤;金属キレート剤等のカルボキシル基を有するバインダー樹脂に用いられる硬化剤;水分、多官能エポキシ化合物、水酸基含有化合物等のシリコーン基を有するバインダー樹脂に用いられる硬化剤等を挙げることができ、これらが1種または2種以上使用される。
【0069】
塗料組成物を後述の金属酸化物粒子含有フィルムの製造等に用いる場合、塗料組成物が光安定剤を含むものであると、耐候性が向上する。塗料組成物が硬化剤としてポリイソシアネートを含むものであると、汎用性が高い。フィルムを製造する場合の塗料組成物の硬化方法については、経済的に加熱硬化法が好ましい。
【0070】
塗料組成物は、溶媒を含むものでもよく、塗料組成物の使用目的やバインダー樹脂の種類によって適宜選択される。溶媒としては、たとえば、アルコール類、脂肪族および芳香族カルボン酸エステル類、ケトン類、エーテル類、エーテルエステル類、脂肪族および芳香族炭化水素類、ハロゲン化炭化水素類等の有機系溶剤;水;鉱物油;植物油、ワックス油、シリコーン油等を挙げることができ、これらが1種または2種以上使用される。
【0071】
塗料組成物の製造方法としては、たとえば、有機溶剤に金属酸化物粒子を添加しスラリー化した後、この金属酸化物粒子を含むスラリーに、バインダー樹脂を混合して塗料組成物を製造する方法等を挙げることができる。
【0072】
塗料組成物は、たとえば、ガラス、陶器等の無機物や、樹脂等の有機物等の基材の表面に塗布することができる。特に、有機物の基材表面に塗布して得られる塗膜は、耐候性が高く、可撓性に優れる。上記無機物や有機物の形状については、特に限定はなく、フィルム状、シート状、板状、繊維状等の形状を挙げることができる。これらのうちでも、後述のフィルムや、繊維等に有用である。
【0073】
上記基材として用いられる樹脂の材質としては、特に限定はなく、たとえば、LDPE、HDPE、アモルファスポリエチレン、OPP(延伸ポリプロピレン)、CPP(結晶化ポリプロピレン)等のポリプロピレン、ポリイソブチレンなどのポリオレフィン系;EVA(エチレン・酢酸ビニル共重合体)系;ポリスチレン系;軟質又は硬質ポリ塩化ビニル;EVOH(エチレン・ビニルアルコール共重合体)系;PVA系(ビニロン系);PVDC系(ポリ塩化ビニリデン);ポリエチレンテレフタレート、ポリエチレンナフタレート、ポリブチレンナフタレート等のポリエステル系;ポリカーボネート系;ポリウレタン系;ポリアミド系;ポリイミド系;ポリアクリロニトリル系;ポリサルフォン系;ポリエーテルサルフォン系;ポリフェニレンサルファイド系;ポリアリレート系;ポリエーテルイミド系;アラミド系;(メタ)アクリル系;ポリエーテルエーテルケトン系;テトラフルオロエチレン・エチレン共重合体、テトラフルオロエチレン・ヘキサフルオロプロピレン共重合体、ポリテトラフルオロエチレン、ポリトリフルオロエチレン、ポリフッ化ビニリデン、ポリフッ化ビニル、テトラフルオロエチレン・ペルフルオロアルキルビニルエーテル共重合体、ポリフッ化ビニル、テトラフルオロエチレン・ヘキサフルオロプロピレン・ペルフルオロアルキルビニルエーテル共重合体、ポリクロロトリフルオロエチレンなどのフッ素系樹脂等を挙げることができる。
【0074】
光学レンズ等の極めて高度な可視光透過性、透明性が要求される用途で用いる場合には、PMMA、MMA−スチレンランダム共重合体、ポリカーボネート、透明ポリプロピレン、MMAとα−メチルスチレンまたはシクロヘキシルメタクリレート等の共重合体、ABS樹脂のMMA変性タイプ、ポリスチレン、ポリアリレート、ポリサルフォン、ポリエーテルサルフォン、透明エポキシ樹脂、ポリ−4−メチルペンテン−1、フッ素化ポリイミド、非晶質フッ素樹脂、透明フェノキシ樹脂、非晶質ナイロン樹脂、フルオレン系等の各種樹脂を基材として使用することができる。
【0075】
また、廃棄処理問題から、生分解性に対する要求に応えるものとして、生分解性樹脂を基材として用いることは今後ますます重要になる。このような場合、たとえば、ポリ−3−ハイドロキシ酪酸エステル、キチン・キトサン系、ポリアミノ酸系、セルロース系、ポリカプロラクトン系、アルギン酸系、ポリビニルアルコール系、脂肪族ポリエステル系、糖類系、ポリウレタン系、ポリエーテル系などの生分解性プラスチック等を基材として用いることが好ましい。
【0076】
基材としては、上述の基材に予めUV吸収膜を配したものや、塗料組成物からなる塗膜と基材との密着性などを高める目的でプライマー層等を予め配したものものでもよい。
【0077】
これらの中でも、プラスチックフィルム、シートのうち、耐候性が高い点でフッ素系樹脂、ポリエステル系樹脂、(メタ)アクリル系樹脂、ポリカーボネート系樹脂が好ましい。
【0078】
塗料組成物を塗布する方法については、特に限定はなく、ディッピング法、ロールコーター法、フローコート法、スクリーン印刷法、バーコーター法、スピンコーター法、刷毛塗り法、スプレー法等を挙げることができる。また、塗料組成物を塗布して得られる乾燥膜厚については、特に限定はなく、好ましくは0.5〜100μm、さらに好ましくは1〜30μmである。
【0079】
塗料組成物を塗布・成膜した後、耐水性、耐溶剤性、耐酸、耐アルカリ等の耐薬品性、耐擦傷性等の点から、熱硬化(室温硬化を含む)、湿気硬化、紫外線硬化、電子線硬化等の硬化方法で硬化膜とすることが好ましい。
【0080】
塗料組成物をガラス板等の透明板に塗布して得られた中間膜が透明板上に形成された塗工透明板を用いて、合わせガラスを得ることができる。合わせガラスは、接着剤シートを塗工透明板と別に用意した透明板とで挟むように重ねて製造することができる。なお、塗工透明板の中間膜と接着剤シートとを重ねるようにする。
【0081】
接着剤シートとしては、ポリビニルブチラール系樹脂、ポリウレタン樹脂、エチレン−酢酸ビニル共重合体系樹脂、エチレン−(メタ)アクリル酸エステル共重合体系樹脂等の軟質樹脂または硬質樹脂を材質とするシートを挙げることができ、軟質樹脂が好ましい。接着剤シートの厚みは、好ましくは0.1〜2mm、さらに好ましくは0.5〜1mmである。
成形材料組成物
この成形材料組成物は、光選択透過性機能等の光機能、導電機能等の電気機能、光触媒機能等の触媒機能等の各種機能性に優れ、耐候性および可撓性の高い成形体を得させることができる。
【0082】
成形材料組成物に用いられるバインダー樹脂としては、ポリアミド(6−ナイロン、66−ナイロン、12−ナイロン等)、ポリイミド、ポリウレタン、ポリオレフィン(ポリエチレン、ポロプロピレン等)、ポリエステル(PET,PBT,PEN等)、ポリ塩化ビニル、ポリ塩化ビニリデン、ポリ酢酸ビニル、ポリスチレン、(メタ)アクリル樹脂、ABS樹脂、シリコーン樹脂、フッ素樹脂およびこれらの原料となる単量体等の熱可塑性樹脂;フェノール樹脂(フェノール・ホルマリン樹脂、クレゾール・ホルマリン樹脂等)、エポキシ樹脂、アミノ樹脂(尿素樹脂、メラミン樹脂、グアナミン樹脂等)およびこれらの原料となる単量体等の熱硬化性樹脂等を挙げることができ、これらが1種または2種以上使用される。
【0083】
成形材料組成物に用いられるバインダー樹脂としては、ポリビニルブチラール系、ポリウレタン系、エチレン−酢酸ビニル共重合体系、エチレン−(メタ)アクリル酸エステル共重合体系等の軟質樹脂または硬質樹脂等も挙げることができ、これらが1種または2種以上使用される。
【0084】
成形材料組成物に用いられるバインダー樹脂として、上述の無機系バインターを用いてもよい。
【0085】
成形材料組成物中の金属酸化物粒子の割合は、たとえば、金属酸化物粒子およびバインダー樹脂の固形分合計量に対して0.1〜99重量%であり、好ましくは0.3〜10重量%である。金属酸化物粒子の割合が0.1重量%未満であると、紫外線遮蔽性や導電性等の粒子を添加することによって得られる効果が低下する。他方、金属酸化物粒子の割合が99重量%を超えると、強度や、可視光透過性および可撓性が低下する。
【0086】
成形材料組成物は、金属酸化物粒子とバインダー樹脂以外に要求性能に従って、硬化剤、硬化促進剤、着色剤、離型剤、カップリング剤、シリコーン化合物、反応性希釈剤、可塑剤、安定化剤、難燃助剤、架橋剤等の添加剤を含有するものでもよい。
【0087】
硬化剤は、バインダー樹脂として熱硬化性樹脂を用いる際に必要となる場合がある。たとえば、バインダー樹脂としてエポキシ樹脂を用いる場合は、ポリアミド類、脂肪族ポリアミン類、環状脂肪族ポリアミン類、芳香族ポリアミン類あるいはこれらの一部を変性したアミン類、酸無水物類、ジシアンジアミド類、イミダゾール類、アミンイミド類、ヒドラジド類、フェノールノボラック、クレゾールノボラック等のノボラック系硬化剤等を挙げることができ、これらが1種または2種以上使用される。また、バインダー樹脂としてフェノール樹脂を用いる場合は、ウロトロピンやホルマール等を挙げることができ、これらが1種または2種以上使用される。これらの使用量は、バインダー樹脂に対して適宜の量で用いられる。
【0088】
可塑剤は、組成物の加工性をさらに向上させるためのもので、たとえば、リン酸エステル類、フタル酸エステル類、脂肪族−または二塩基酸エステル類、二価アルコールエステル類、オキシ酸エステル類、ポリグリコール類等が挙げられ、特にバインダー樹脂としてエポキシ樹脂を用いる場合はポリグリコール類が好ましい。 安定化剤は、バインダー樹脂の分解を抑制するものであり、たとえば、ステアリン酸鉛、ステアリン酸亜鉛等が挙げられる。
【0089】
成形材料組成物の製造方法としては、たとえば、金属酸化物粒子とバインダー樹脂とを、ロール、ニーダー、ミキサー等の混合装置を用いて均一に混合する方法等を挙げることができる。
【0090】
成形材料組成物の成形方法としては、たとえば、押出し成形、射出成形、注形、圧縮成形、低圧トランスファー成形、キャスト成形等を挙げることができる。
【0091】
成形材料組成物は、たとえば、フィルム状に成形してもよく、得られたフィルムは、粒子の熱線遮蔽性が高く、可視光透過性に優れる。
【0092】
成形材料組成物を成形して得られた金属酸化物粒子含有シートをガラス板等の透明板で挟み、適宜硬化させることによって、合わせガラスを得ることができる。金属酸化物粒子含有シートの厚みは、好ましくは0.1〜2mm、さらに好ましくは0.5〜1mmである。
金属酸化物粒子含有フィルム
金属酸化物粒子含有フィルムは、上記本発明にかかる金属酸化物粒子含有組成物(塗料組成物)から得られた塗膜を基材フィルム上に形成したフィルムである。この金属酸化物粒子含有フィルムは、本発明の金属酸化物粒子を含むため、光選択透過性機能等の光機能、導電機能等の電気機能、光触媒機能等の触媒機能等の各種機能性に優れ、耐候性が高い。
【0093】
金属酸化物粒子含有フィルムに用いられる基材フィルムとしては、塗料組成物の項で詳しく説明した、基材として用いられる樹脂からなるフィルム等を挙げることができる。好ましいものについても同様である。
【0094】
基材フィルムの膜厚については、特に限定はなく、好ましくは5〜500μm、さらに好ましくは10〜200μmである。
【0095】
基材フィルム表面に塗料組成物を塗布する方法、乾燥膜厚等については、特に限定はなく、上述のものが好ましい。
【0096】
金属酸化物粒子含有フィルムは、塗料組成物から得られる塗膜が基材フィルム上に形成されたものであれば特に限定はなく、用途、要求特性等に応じてさらに加工されたものでもよい。金属酸化物粒子含有フィルムは、基材フィルムと接しない塗膜の表面、および/または、塗膜と接しない基材フィルムの表面に、粘着層や保護層(耐擦傷性付与のためのハードコート膜等)を形成したものでもよく、他のフィルムとラミネートしたラミネートフィルムであってもよい。
【0097】
金属酸化物粒子含有フィルムを紫外線遮蔽性フィルムとして用いる場合の紫外線透過率については、特に限定はないが、好適には50%以下、さらに好適には10%以下である。紫外線透過率は、JIS R 3106記載の装置および測定方法で得られた値である。
【0098】
金属酸化物粒子含有フィルムの可視光線透過率については、特に限定はないが、好適には70%以上、さらに好適には80%以上である。可視光線透過率は、波長範囲380〜780nmで測定し、JIS R 3106記載の装置、測定方法および計算方法で得られた値である。
【0099】
金属酸化物粒子含有フィルムのヘイズについては、特に限定はないが、好適には10%以下、さらに好適には5%以下、最も好適には3%以下である。ヘイズは、濁度計で測定して得られた値である。
【0100】
金属酸化物粒子含有フィルムの耐侯性は、JIS B 7753−93に記載のサイシャインカーボンアーク灯式耐光性および耐候性試験機を用いて、促進耐候性試験を行って、初期100時間後のヘイズ値および色相を基準にして、さらに1000時間試験後のヘイズ値および色相を比較した場合、ヘイズの変化が2%未満であると好ましく、着色(変色)がないとさらに好ましい。
【0101】
【実施例】
以下に実施例によりさらに詳細に本発明を説明するが、本発明はこれに限定されるものではない。
【0102】
本実施例における評価等は次の手法により行った。
1.金属酸化物粒子の評価
<粉末試料の作製法>
得られた分散体中の微粒子を遠心分離操作によって分離した後、メタノールによる洗浄、さらにアセトンによる洗浄を充分行った後、30℃で1日真空乾燥し、さらに80℃にて1日真空乾燥し、揮発成分を完全に除去して微粒子の粉末を得、これを粉末試料とした。
<異種金属(Md)の含有率>
平均含有率αavと中央含有率αc は、先に定義した方法で求めた。
【0103】
表2に示す含有率αav-1は、上記平均含有率αavの測定方法において、偏析物が見られる状態であっても約1000個の粒子についてそのすべてが含まれるスポット径を設置して測定したときの異種金属(Md)の含有率である。表2において、含有率αavの値が粒子P−1と粒子Pc −1において含有率αav-1の値を下回ると言うことは、粒子P−1については少し偏析物が見られ、粒子Pc −1については多量の偏析物が見られたことを意味する。
【0104】
上記測定には、FE−TEM(電界放射型透過型電子顕微鏡、日立製、HF−2000型、加速電圧200kV)とXMA(X線マイクロアナライザー、Kevex製、Sigma型、エネルギー分散型、ビーム径(空間分解能)10Åφ)とを用い、主金属(M)に対する異種金属(Md)の平均含有率(αav)と中央含有率(αc )を求めた。
<カルボン酸(残)基含有量>
粉末試料1gを0.01Nの水酸化ナトリウム水溶液に混合し、3日間撹拌した後、遠心分離操作によって得た上澄みをイオンクロマト分析することによって測定した。ここでは、主金属(M)に対するアセトキシ基等のカルボン酸(残)基のモル%を算出した。
<結晶性>
粉末X線回折により評価した。
<結晶子径Dc(hkl)、Dw>
粉末試料の粉末X線回折測定を行い求めた。
【0105】
Dc(hkl):Scherrer法(Cauchy関数近似による)によって、得られる各回折面(hkl)に対して垂直な方向の結晶子径
Dw:Wilson法を用いて求めた結晶子の大きさ及び格子歪
1.塗工フィルムの評価
<熱線遮蔽性能>
アクリル樹脂バインダーに粒子を分散させ、粒子が10g/m2 となるようにPETフィルムに成膜し、1.5μm光における透過率T1.5 を測定し、以下の基準で判定した。
【0106】
○:T1.5 <40%
×:T1.5 ≧40%
−実施例1(1)−
攪拌機、添加口、温度計、留出ガス出口、窒素ガス導入口および圧力調整弁を備え、外部より加熱し得る耐圧100kg/cm2 のステンレス(SUS316)製反応器、および、添加口にボールバルブを介して直結する添加槽、留出ガス出口に直結する冷却器および留出液トラップを備えた反応装置(反応装置全体が100kg/cm2 の耐圧仕様)を用意した。この反応装置に2−ブトキシエタノール(以下、EGB)1000部を仕込み、気相部を窒素ガスで置換した後、常温より昇温し、窒素を導入して気相部圧を5kg/cm2 に保ち、液温度を160℃に維持した。
【0107】
次いで、無水酢酸亜鉛(松垣薬品工業製)152部、無水酢酸インジウム4.85部の各粉末をEGB191部に混合することにより原料懸濁体(A−1)を調製し、添加槽に仕込んだ。気相部圧5kg/cm2 、ボトム温度160℃に維持されたEGB溶媒に、原料懸濁体(A−1)を添加槽より、30secで添加混合した。液温は添加によって、一旦、140℃に低下したが、13分後に160℃に戻り、以後、160℃±3℃で気相部圧5kg/cm2 に6時間保持することによって、In含有ZnO粒子(P−1)の懸濁体(D−1)を得た。
【0108】
−比較例1−
実施例1(1)において、無水酢酸亜鉛を酢酸亜鉛2水和物に代えるとともに水/Mdモル比が110となるよう原料配合を代えることにより得た原料懸濁体(Ac−1)を、常圧、160℃に維持されたEGBに添加する以外は、同様にして、In含有ZnO粒子(Pc−1)の懸濁体(Dc−1)を得た。
【0109】
実施例1(1)、比較例1で得られた各粒子の解析結果を表2に示す。
【0110】
−実施例1(2)−
表1に示す原料懸濁体を調製し、表1に示す温度、圧力条件で添加し、表1に示す温度、圧力条件で加熱処理を行った以外は、実施例1(1)と同様にして、反応を行い、酸化物粒子(P−2)の懸濁体(D−2)を得た。なお、このとき、溶媒としてはプロピレングリコールモノメチルエーテル(以下PGMと称す)を用いた。
【0111】
実施例1(1)、実施例1(2)、比較例1で得られた粒子P−1,P−2、Pc−1についての解析結果を表2に示す。
【0112】
−実施例1(5)−
実施例1(1)における反応装置にn−ブタノール900部を仕込み、気相部を窒素ガスで置換した後、常温より昇温し、液温度を280℃に維持した。気相圧はゲージ圧43kg/cm2 であった。
【0113】
無水酢酸インジウム(III )粉末216部、チタニウム(IV)n−ブトキシド12.6部、n−ブタノール270部を混合することにより、原料懸濁体(A−5)を調製し、添加槽に仕込んだ。
【0114】
ボトム温度280℃に維持されたn−ブタノール溶媒に、原料懸濁体(A−5)を添加槽より、30secで添加混合した。添加により、一旦、240℃に温度が低下したが、再度280℃に昇温後、280±3℃で4時間保持することによって、Ti含有In2 O3 粒子(P−5)が7.3重量%で分散した懸濁体(D−5)を得た。得られた粒子P−5の解析結果を表3に示す。
【0115】
−実施例1(6)〜1(16)−
表4または5に示す添加原料を、同表に示す添加条件(温度および圧力)下でボトム溶液に添加し、同表に示す加熱処理保持条件下で一定時間保持することによって、酸化物微粒子(P−6〜P−16)が分散した懸濁体(D−6〜D−16)を得た。なお、溶媒として用いるエチレングリコールモノエチルエーテルアセテートは、以下EGEAと称す。得られた粒子P−6〜P−16についての解析結果を表6に示す。
【0116】
−実施例2(1)−
実施例1(1)で得られた懸濁体(D−1)について遠心分離操作を行い、固形分を得た。この固形分を乾燥して、In含有ZnO粒子(P−1)の粉体を得た。
【0117】
この粉体10部、アクリル樹脂溶液(固形分濃度50%)20部、トルエン20部を混合し、ホモジナイザーで分散処理をすることによって、塗料組成物(C−1)を得た。この組成物をPETフィルムに、乾燥膜厚10μmに塗布乾燥することによって、塗工フィルム(F−1)を得た。
【0118】
得られた塗工フィルム(F−1)の1.5μmにおける光透過率は30%であった。
【0119】
−比較例2−
実施例2において、懸濁体(D−1)の代わりに懸濁体(Dc−1)を用いて、In含有ZnO粒子(Pc−1)を得た。これを用いて、実施例2(1)と同様にして、塗料組成物(Cc−1)と塗工フィルム(Fc−1)を得た。得られた塗工フィルム(Fc−1)の1.5μmにおける光透過率は52%であった。
【0120】
−実施例2(2)−
実施例2(1)において、懸濁体(D−1)の代わりに懸濁体(D−2)を用いて、In含有ZnO粒子(P−2)を得た。これを用いて、実施例2(1)と同様にして、塗料組成物(C−2)、乾燥膜厚10μmの塗工フィルム(F−2)を得た。
【0121】
得られた塗工フィルム(F−2)の1.5μmにおける光透過率は25%であった。
【0122】
−実施例2(3)−
実施例2(1)において、懸濁体(D−1)の代わりに懸濁体(D−5)を用いて、Ti含有In2 O3 粒子(P−5)を得た。これを用いて、実施例2(1)と同様にして、塗料組成物(C−5)、乾燥膜厚10μmの塗工フィルム(F−5)を得た。
【0123】
得られた塗工フィルム(F−5)の1.5μmにおける光透過率は10%以下であった。
【0124】
【表1】
【0125】
【表2】
【0126】
【表3】
【0127】
【表4】
【0128】
【表5】
【0129】
【表6】
【0130】
【発明の効果】
本発明にかかる金属酸化物粒子は、熱線遮蔽性能や可視光透過性などの機能に優れる。
【0131】
本発明にかかる金属酸化物粒子の製造方法は、熱線遮蔽性能や可視光透過性などの機能に優れる金属酸化物粒子を容易に得させることができる。
【0132】
本発明にかかる金属酸化物粒子含有組成物は、上記本発明の金属酸化物粒子を含有するため、熱線遮蔽性や透明性等が高く、しかも、光選択透過性機能等の光機能、導電機能等の電気機能、光触媒機能等の触媒機能等の各種機能性に優れ、しかも、耐候性が高い塗膜等を得させる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a metal oxide particle excellent in the above-mentioned characteristics in a metal oxide particle provided with characteristics such as heat ray shielding properties by adding a different metal, and a production method and use thereof.
[0002]
[Prior art]
Sn-containing indium oxide (ITO), Sb-containing tin oxide (ATO), Al-containing zinc oxide and the like are known as white conductive particles. When these metal oxide particles contain 0.1 to 20% of dissimilar metals such as Sn, Sb, Al, etc., they may be heat ray shielding agents with excellent visible light transmittance depending on how they are made. . For example, in the case of indium oxide and tin oxide, these different metal-added metal oxide particles are hydroxides by hydrolyzing each compound (chloride, nitrate, etc.) of the metal as the main component and the different metal with an alkali. Is obtained by baking at a high temperature.
[0003]
However, zinc oxide (ZnO) containing dissimilar metals such as Al and In, when made by the above-described method, is conductive, but has no heat ray shielding performance, or even does not reach a practical level. . On the other hand, according to the manufacturing method developed by the present inventors (see JP-A-8-253317), ZnO-based particles having heat ray shielding performance can be obtained. In this method, a mixture comprising a zinc source, a monocarboxylic acid and an alcohol is heated in the presence of a compound of a group IIIb metal element such as Al or In or a compound of a group IVb metal element.
[0004]
However, even when using ZnO particles containing Al, In or the like obtained by this method described in JP-A-8-253317, the heat ray shielding performance is inferior to that of ITO particles or ATO particles, and therefore this is used as a heat ray shielding film. In order to obtain the same heat ray shielding rate as that of a heat ray shielding film containing ITO or ATO, there is a problem that the coating amount has to be increased.
[0005]
Since ITO particles and ATO particles are also expensive, it is required to reduce the amount used by making particles with higher heat ray shielding performance.
[0006]
[Problems to be solved by the invention]
Therefore, the problem to be solved by the present invention is to dissimilar metal-containing metal oxide particles having particularly excellent functions such as heat ray shielding performance and visible light transmission properties, in particular, ZnO-based, In2OThreeSeries, SnO2It is to provide conductive metal oxide particles such as a system, and a production method and use thereof.
[0007]
[Means for Solving the Problems]
In order to solve the above-described problems, the present inventors have analyzed the ZnO-based particles containing Al, In and the like from various aspects, and have pursued the cause of the above-described problems. As a result, it has been found that the cause is that the added foreign metal is biased toward the surface side of the primary particles and does not sufficiently exist inside. And it discovered that the said cause was eliminated when the added dissimilar metal exists more than a fixed value in the center part of a primary particle. Furthermore, the present inventors have found a suitable method for producing such Al, In-containing ZnO-based particles. And the above thing was discovered that it can apply also to metal oxide particles other than ZnO type particle | grains containing Al, In, etc., and completed this invention.
[0008]
Therefore, the different metal-containing metal oxide particles according to the present invention (hereinafter simply referred to as “metal oxide particles”) are different from the metal oxide particles obtained by adding different metals (Md) to metal (M). The metal (Md) content (Md / M) is an average of 0.5 to 20 atomic% and 0.5 atomic% or more at the center of the primary particles.
[0009]
The method for producing different metal-containing metal oxide particles according to the present invention,A method for producing different metal-containing metal oxide particles having an average content (Md / M) of different metal (Md) of 0.5 to 20 atomic%,It contains a compound represented by the following general formula (I) of the metal (M) and / or a hydrolysis condensate, a compound of a different metal (Md), and an alcohol.Does not contain carboxylic acidHeating the solution to precipitate metal oxide particles, and comprising the following (a) and(b).
[0010]
(A) The heating is performed under pressure.
[0011]
(B) The water content in the solution is 100 times or less in terms of a molar ratio to the foreign metal (Md).
[0012]
M (O)(mxyz) / 2(OCOR)x(OH)y(OR ’)z (I)
(Where M is an m-valent metal atom; R is at least one selected from a hydrogen atom, an optionally substituted alkyl group, a cycloalkyl group, an aryl group and an aralkyl group; R ′ is a substituent group) And at least one selected from an alkyl group, a cycloalkyl group, an aryl group and an aralkyl group; m, x, y and z are x + y + z ≦ m, 0 <x ≦ m, 0 ≦ y <m, 0 ≦ z <m is satisfied.)
And the metal oxide particle containing composition concerning this invention contains the said metal oxide particle concerning this invention 0.1weight% or more.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
[Metal oxide particles]
In the metal oxide particles according to the present invention, the content (Md / M) of the dissimilar metal (Md) is 0.5 to 20 atom% (preferably 1 to 10 atom%, more preferably) of the entire primary particles. Is 2 to 10 atom%, particularly preferably 4 atom% or more, and 0.5 atom% or more (preferably 1 atom% or more, more preferably 2 atom% or more, particularly preferably at the center of the primary particle). Is 4 atomic% or more).
[0014]
When the average value (average content rate) of the entire primary particles in the content rate (Md / M) of the different metal (Md) is αav and the value (center content rate) at the center of the primary particles is αc, the average content rate The median content (αc / αav) with respect to is preferably 0.2 or more, more preferably 0.5 or more, and most preferably 0.8 or more.
[0015]
The measurement method of the average content rate αav and the central content rate αc is as follows. For the aggregate of primary particles (in the case of αav) or simple substance (in the case of αc), those transmission images are obtained by FE-TEM (transmission electron microscope). While observing, a place where there is no metal segregation outside of the particles is searched, and elemental analysis is performed with high resolution XMA at the desired spatial resolution (spot diameter) described below. And it is the method of calculating | requiring the content rate of a dissimilar metal (Md) from the peak intensity which belongs to each metal. Note that the lower limit of the spot diameter can be reduced to 1 nmφ by narrowing the probe, and the spot diameter can be arbitrarily increased continuously. Regarding the confirmation of the segregated material, it is assumed that there is no segregated material as long as it is normally a level that cannot be confirmed with the naked eye in the projection drawing observed with the FE-TEM.
[0016]
Regarding the measurement of the average content rate αav, more specifically, a space in which about 10 particles in which no segregated material is observed as an aggregate of primary particles are observed by FE-TEM and all these particles are included. The analysis is performed by elemental analysis with resolution (spot diameter).
[0017]
Regarding the measurement of the center content αc, more specifically, the projection image of one primary particle is observed without a segregated material by FE-TEM, and the central portion of the projection image is observed with a spatial resolution (spot diameter of 1 nmφ). ) To perform by elemental analysis. When analyzing the central part of the projected image, it is usually necessary to use a part that seems to be the approximate center of the projected image based on common sense, but at least the projection that does not touch the contour of the projected image. The shape of the projected image is preferably within the area reduced to 80% on the basis of the length, and more preferably within the area reduced to 50%, and even more preferably 20 It may be performed within the area reduced to%. For example, if the particle shape is needle-like and the projected image is needle-like, the spot set there is the projected image even if it is a part that is commonly determined to be the center of the projected image. In such a case, an area having a diameter that is 50% of the length of the maximum length centered around a portion that is considered to be approximately the center of the projected image. Can be done within. The final measurement result of the median content αc was an average value for 10 particles.
[0018]
In addition, when the primary particle has a portion exceeding 30 nm in thickness (particle size) (some particles may exceed 100 nm), for example, a powder sample is mixed with an epoxy resin, and a thin slice is obtained after curing. Thus, an ultra-thinned sample having a primary particle cross-section exposed by ion milling from the thin slice, usually having a thickness of 30 nm or less, is obtained, and the above measurement is performed on the cross-section portion of the primary particle of this ultra-thinned sample. Preferably it is done. The reason is that if the thickness exceeds 30 nm, the electron beam transmission of the FE-TEM becomes incomplete or the resolution of the XAM is reduced. Since all the information in the thickness direction is related to the analysis, the measurement is performed. This is because the result is inaccurate.
[0019]
In the above measurement, for example, a field emission transmission electron microscope (HF-2000 type, acceleration voltage 200 kV) manufactured by Hitachi, Ltd. is used as FE-TEM, and an X-ray microanalyzer (Sigma, manufactured by Kevex, Inc.) is used as XMA. Type, energy dispersion type, beam diameter: spatial resolution 10 mm).
[0020]
The main metal (M) and the dissimilar metal (Md) are not particularly limited. For example, alkaline earth metal elements such as Be, Mg, Ca, Sr, Ba and Ra; lanthanoid metal elements such as La and Ce Actinoid metal elements such as Ac; Group IIIa metal elements such as Sc and Y; Group IVa metal elements such as Ti, Zr and Hf; Group Va metal elements such as V, Nb and Ta; Cr, Mo, W, etc. Group VIa metal element; Group VIIa metal element such as Mn, Tc, Re; Group VIII metal element such as Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt; Group Ib such as Cu, Ag, Au Metal elements; Group IIb metal elements such as Zn, Cd and Hg; Group IIIb metal elements such as Al, Ga, In and Tl; Group IVb metal elements such as Ge, Sn and Pb; Group Vb metal elements such as Sb and Bi ; Group VIb metal elements such as Se and Te, etc., and these may be one or two You may coexist.
[0021]
As the main metal (M), among the above specific examples, Zn, Ti, Ce, Fe, Ni, V, Nb, Be, La, Mo, W, Re, In, Ga, Sn, Sb, etc. Light, electricity, and magnetic functions can be controlled by valence, particle size, crystal structure, impurity injection, defect injection, and the like. For this reason, it is preferable at the point which has optical functions, such as having light selective transmission functions, such as ultraviolet absorptivity and infrared shielding, a (light) conductive function, a magnetic function. Furthermore, Fe, Ni, V, Nb, Be, La, Mo, W, and the like have high transparency and stable particles can be obtained. Zn is preferable because it can control optical properties such as ultraviolet absorption and electrical properties by controlling the crystal structure and impurity concentration.
[0022]
As the main metal (M), for example, In, Sn, and Zn are preferable because both the heat ray shielding property and the visible light transmittance are high.
[0023]
As the dissimilar metal (Md), for example, when the metal oxide particles are indium oxide particles, a tetravalent metal is preferable, and Sn, Ti, and the like are particularly preferable in terms of both high heat ray shielding and visible light transmittance. . When the metal oxide particles are tin oxide particles, pentavalent metal elements are preferable, and Sb, P, and the like are particularly preferable. When the metal oxide particles are zinc oxide particles, trivalent metal elements are preferable, and In, Al, Ga, and the like are particularly preferable.
[0024]
The metal oxide particles according to the present invention include amorphous particles, but those showing the oxide crystallinity of the metal (M) from the viewpoint of X-ray diffraction or electron diffraction. Is preferred. Usually, when the primary particle diameter is 5 nm or more, it is confirmed by X-ray diffraction method, and when the primary particle diameter is 5 nm or less, it is confirmed whether or not it is crystalline by electron beam diffraction method. The crystal structure and physical properties can be identified.
[0025]
The primary particle diameter of the metal oxide particles according to the present invention is preferably 0.1 μm or less in view of high transparency. Specifically, it is particularly preferable that the following (1) and / or (2) and / or (3) is satisfied.
[0026]
(1) When the crystallite size obtained by X-ray diffraction (Wilson method) or electron diffraction is Dw, 1 nm ≦ Dw ≦ 100 nm.
[0027]
(2) When the specific surface area diameter calculated by the following formula is Ds, 1 nm ≦ Ds ≦ 100 nm.
[0028]
Ds = 6 / (ρ × S) where Ds: μm
(Where ρ: true specific gravity of metal oxide particles, S: specific surface area of metal oxide particles measured by BET method (m2/ G))
(3) When a particle image is measured with a transmission electron microscope and the primary particle diameter determined from the observation of the crystal lattice image and the size is De, 1 nm ≦ De ≦ 100 nm.
[0029]
The metal oxide particles of the present invention preferably have a primary particle diameter of 1 to 30 nm in terms of excellent transparency, and when used as a heat ray shielding agent or a conductive material, 5 nm ≦ Dw ≦ 30 nm is preferable. .
[0030]
The metal oxide particles according to the present invention preferably contain a carboxylic acid (residual) group. Here, the carboxylic acid (residual) group means a —COO— group, specifically, a carboxyl group (—COOH), a carboxylate group (—COO).-), An ester group that generates a carboxyl group and / or a carboxylate group by hydrolysis. The carboxylic acid (residual) group is preferably a saturated fatty acid (residual) group, more preferably a fatty acid (residual) group having 1 to 4 carbon atoms, and an acetoxy group (CHThreeCOO-) is most preferred.
[0031]
Since the carboxylic acid (residual) group is present on the surface of the metal oxide particles by adsorption and / or chemical bonding, secondary aggregation is suppressed and dispersibility is improved. Therefore, the resin composition containing the metal oxide particles When the object is a paint, the transparency of the coating film is increased.
[0032]
The content of the carboxylic acid (residual) group is preferably 0.01 to 14 mol%, more preferably 0.1 to 7 mol%, and most preferably 1 to 5 mol% with respect to the metal (M). When the content of the carboxylic acid (residual) group is less than 0.01 mol% with respect to the metal (M), the dispersibility of the particles is lowered, and the particles are easily agglomerated. On the other hand, when the content of the carboxylic acid (residual) group is more than 14 mol% with respect to the metal element (M), the function as a metal oxide, for example, infrared shielding property or ultraviolet shielding property is lowered.
[0033]
The particle shape of the metal oxide particles according to the present invention is not particularly limited. Specific examples of the shape include a spherical shape, an elliptical spherical shape, a cubic shape, a rectangular parallelepiped shape, a pyramid shape, a needle shape, a column shape, a rod shape, a cylindrical shape, a flake shape, and a (hexagonal) plate shape.
[Method for producing metal oxide particles]
The method for producing the metal oxide particles is not particularly limited. For example, the following method can be mentioned as a preferable one.
[0034]
Heating the solution containing the compound of metal (M) and / or hydrolysis condensate, the compound of different metal (Md) and alcohol to precipitate metal oxide particles, comprising the following (a) and / or (B).
[0035]
(A) The heating is performed under pressure.
[0036]
(B) The water content in the solution is 100 times or less in terms of a molar ratio to the foreign metal (Md).
[0037]
As for the above (a), the heating pressure is 1 kg / cm at normal pressure (atmospheric pressure).2In the absolute pressure P, P> 1 kg / cm2Preferably 1.5 kg / cm2≦ P ≦ 100kg / cm2Is to satisfy. 3kg / cm in terms of high pressure effect and economical equipment2≦ P ≦ 20kg / cm2It is particularly preferable to satisfy 5 kg / cm2≦ P ≦ 10kg / cm2Most preferably.
[0038]
As a pressurizing method, for example, a method of heating to a temperature higher than the boiling point of alcohol, a method of pressurizing the gas phase part with an inert gas such as nitrogen gas or argon gas, or the like can be adopted.
[0039]
The heating temperature is preferably 50 ° C to 300 ° C, more preferably 100 ° C to the critical temperature of the alcohol, most preferably 20 ° C higher than the normal pressure boiling point of the alcohol, although it depends on the boiling point of the alcohol. .
[0040]
For (b) above, the water content in the solution means free water content, but also includes water of crystallization when the metal (M) compound or the dissimilar metal (Md) compound has water of crystallization. It is. This water content can be measured by the Karl Fischer method. The amount of water referred to here is water contained in the raw material used (free water in the alcohol and other solvent components used, water of crystallization in the compound of metal (M) or compound of different metal (Md), etc. This means the molar ratio of the total sum of water) to the total dissimilar metal (Md) in the compound of all the dissimilar metals (Md) used, and water generated as a by-product in the heating reaction is not considered.
[0041]
This water content is preferably 50 times mol or less, and more preferably 20 times mol or less in terms of the molar ratio to the total amount of different metal (Md) used. When the amount of water is too large, it becomes difficult for the dissimilar metal (Md) to be contained in the crystallites of the metal (M) oxide, and it becomes difficult to obtain dissimilar metal-containing metal oxide particles having high functionality.
[0042]
The compound of the main metal (M) has a structure represented by the following general formula (I). Specifically, as described above in the description of the metal oxide particles.
[0043]
M (O)(mxyz) / 2(OCOR)x(OH)y(OR ’)z (I)
(Where M is an m-valent metal atom; R is at least one selected from a hydrogen atom, an optionally substituted alkyl group, a cycloalkyl group, an aryl group and an aralkyl group; R ′ is a substituent group) And at least one selected from an alkyl group, a cycloalkyl group, an aryl group and an aralkyl group; m, x, y and z are x + y + z ≦ m, 0 <x ≦ m, 0 ≦ y <m, 0 ≦ z <m is satisfied.)
In the general formula (I), R or R ′ is preferably an alkyl group having 1 to 4 carbon atoms, such as a methyl group, because a highly dispersible metal oxide particle is easily obtained. preferable. In the general formula (I), x preferably satisfies 1 ≦ x ≦ m, y preferably satisfies 0 ≦ x <m / 2, and z satisfies 1 ≦ x <m / 2. Those are preferred. This is because in these cases, highly dispersible metal oxide particles are easily obtained.
[0044]
As the compound represented by the general formula (I), it is preferable to use a compound having a high dissolution rate because particles having excellent dispersibility can be obtained. Here, the dissolution rate can be directly measured by reaction, but at 25 ° C., 2 parts by weight of the compound of the formula (I) (hereinafter abbreviated as “part”) is ion-exchanged water (pH 5 to 3 ° C.). 8) It is defined as the time t required to completely dissolve and obtain a transparent solution when mixed with 200 parts and stirred. The dissolution rate of the compound represented by formula (I) is preferably within 2 minutes, more preferably within 1 minute, and most preferably within 30 seconds.
[0045]
The hydrolyzed condensate of the compound represented by the general formula (I) includes a hydrolyzate obtained by hydrolyzing and / or condensing the compound of the metal element (M) having the structure represented by the general formula (I), and It is a condensate and is a compound from a monomer to a polymer compound. The condensate is a bond chain in which the main metal (M) element and oxygen (O) are metalloxane-bonded (MO).n(Where n is 1 or more). The degree of condensation of the condensate is not limited, and the degree of condensation (average) is preferably 100 or less, and more preferably 10 or less, in order to obtain metal oxide particles having a uniform crystallite size and shape. is there.
[0046]
Examples of the compound of the dissimilar metal (Md) used in the production method according to the present invention include a compound having a chemical structure in which the metal element (M) in the general formula (I) is replaced with the metal element (Md) described above. And metal alkoxides of different metals (Md). The former is specifically described above in the section of metal oxide particles.
[0047]
The alcohol used in the production method according to the present invention is not particularly limited. For example, monohydric alcohols with high water solubility are preferable. Examples of such alcohols include alcohols having a solubility in water of 1% by weight or more, such as the following A) to C), and alcohols having a solubility in water of 10% by weight or more are more preferable.
[0048]
A) 1-3 grade aliphatic alcohols having 1 to 4 carbon atoms such as methanol, ethanol, n-propyl alcohol, isopropyl alcohol, n-butanol, sec-butanol, t-butyl alcohol, etc.
B) Cyclohexanol, benzyl alcohol
C) Glycol derivatives
a) Ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol monoisopropyl ether, ethylene glycol mono n-butyl ether, diethylene glycol ethyl ether, diethylene glycol butyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether, propylene glycol monoisopropyl ether, Alkylene glycol ethers such as propylene glycol mono n-butyl ether, dipropylene glycol methyl ether, tripropylene glycol methyl ether, 3-methyl-3-methoxybutanol
b) Alkylene glycol acetates such as ethylene glycol acetate and propylene glycol acetate
In the production method according to the present invention, the compound (I) of the main metal (M) and / or the hydrolysis condensate thereof is mixed with an alcohol to prepare a solution containing them. The solution here includes emulsions and suspensions. The same applies to compounds of different metals. The above mixing may be a method in which the powder of the metal compound (hydrolysis condensate) is added as it is to the alcohol, or once added to another solvent to prepare a suspension or diluted solution in advance. Alternatively, this may be added to the alcohol. As the solvent used for preparing the suspension or diluted solution, alcohol or an acetate thereof is preferable, and alcohol used for heating and holding is more preferable.
[0049]
In the production method of the present invention, the mixture containing the main metal (M) compound, the dissimilar metal (Md) compound and the alcohol is heated. The series of operation procedures from mixing to heating is not particularly limited. 1) A method in which the above mixture is prepared at normal temperature or 50 ° C. or less, and a temperature is raised and heated. 2) At least one of a main metal (M) compound, a dissimilar metal (Md) compound and an alcohol is preferable. IsUnder pressureA preheating method or the like in which the other is heated and mixed with the heated one can be preferably mentioned. Specifically, as the preheating method, for example, a) a method in which an alcohol is heated and a compound of a main metal (M) and a compound of a different metal (Md) are added, and b) of a main metal (M) A method in which a compound and a compound of a different metal (Md) (or a suspension or a homogeneous solution thereof) are heated and an alcohol is added; c) a compound of an alcohol and a main metal (M) and a different metal (Md) A method in which the compound (or a suspension or a homogeneous solution thereof) is heated separately and the both are mixed is preferred. Among the methods 1) and 2), the preheating method 2) is more preferable, the reaction temperature can be easily selected, and the particle size and composition can be easily controlled. At this time, in the method of mixing with at least one preheated in a pressurized state, the heat treatment under pressure can be started simultaneously with mixing, so particles with a high content of different metal (Md) Is preferable because
[0050]
The method of adding and mixing the metal compound (hydrolysis condensate) to alcohol or other solvent is not particularly limited. (1) The total amount is added all at once, for example, within 1 minute. ▼ Continuous feed added continuously over a period of more than 1 minute, or (3) Pulse addition method of adding a small amount in two or more portions (each pulse may be continuous feed or batch addition), etc. This method can be adopted. In the case of {circle around (2)} or {circle around (3)}, it is preferable that the temperature change of the solution containing the alcohol generated by the addition is smaller because particles having a uniform primary particle size are easily obtained. Specifically, it is preferable to control the addition rate or the like so that the temperature change of the solution is within 10 ° C.
[0051]
When the metal compound (hydrolysis condensate) is mixed with alcohol or another solvent, the addition rate is [metal compound (hydrolysis condensate) mol / alcohol (mol) / addition time (min)]. Is preferably 0.0001 to 2, more preferably 0.0005 to 1.0. If the addition rate is less than 0.0001, it may be difficult to obtain primary particles having a particle size of 0.1 μm or less. On the other hand, when the addition rate exceeds 2, it becomes difficult to control the above-mentioned temperature especially when the reaction scale is large, and it becomes difficult to obtain particles having a uniform particle diameter.
[0052]
The mixing ratio of the metal compound (hydrolysis condensate) and alcohol is not particularly limited, but the lower limit is expressed in terms of the molar ratio in terms of charge after completion of the total addition of the metal compound (hydrolysis condensate). In order for the metal Md to be uniformly contained in the primary particles, it is preferably m or more, more preferably 2 m or more, which is the valence of the metal (M). The upper limit of the molar ratio is preferably 50 or less, more preferably 20 or less, from the viewpoint of productivity.
[0053]
In the production method according to the present invention, the predetermined temperature is maintained for 30 minutes or more in order to increase the crystallinity of the particles and enhance the performance such as heat ray shielding performance, but the specific heating condition is preferably 180 ° C. or more. 1 hour or more, more preferably 200 ° C. or more and 3 hours or more. Here, the heating temperature is represented by the bottom temperature of the reaction vessel.
[0054]
In the production method according to the present invention, during heating, the solution is stirred for a required power of 0.0001 kw / m.ThreeIt is preferable that stirring is performed as described above, and more preferably 0.001 kw / m.ThreeIn particular, 0.01 to 10 kw / mThreeIt is preferable that it is stirred at.
[0055]
In the production method according to the present invention, for the purpose of enhancing the dispersibility of the obtained particles, an aliphatic carboxylic acid or an aliphatic amine is added to the main metal (at any stage after the addition of the metal compound (hydrolysis condensate)). 0.1 to 10 mol% is added to M). When no aliphatic carboxylic acid or aliphatic amine is added, the metal oxide particles may become secondary aggregate particles depending on the type of the main metal (M).
[0056]
According to the production method of the present invention, it is possible to easily obtain metal oxide-based particles that are excellent in functions such as heat ray shielding performance and visible light transmittance and that contain an additive metal.
[Use of metal oxide particles]
The metal oxide particle according to the present invention is a composition containing 0.1% by weight or more of the metal oxide particle of the present invention described above. For example, it is a coating composition, a molding material composition or a film containing 0.1% by weight or more of the above-mentioned different metal-containing metal oxide particles with respect to the binder resin. Since this composition contains the metal oxide particles according to the present invention, it has particularly excellent properties such as heat ray shielding.
[0057]
Below, this composition explains in detail in order about a paint constituent, a molding material constituent, and a metal oxide particle content film.
Paint composition
The coating composition is excellent in various functions such as a light function such as a light selective permeability function, an electrical function such as a conductive function, and a catalyst function such as a photocatalytic function, and can provide a coating film having high weather resistance. . In particular, those containing metal oxide particles having excellent heat ray shielding properties of the present invention are useful because they are excellent in economic efficiency, thermal shielding properties and visible light transmittance.
[0058]
The binder resin used in the coating composition includes various synthetic resins and natural resins that are thermoplastic or thermosetting (including thermosetting, ultraviolet curable, electron beam curable, moisture curable, and combinations thereof). Organic binders, inorganic binders, and the like.
[0059]
Synthetic resins include, for example, alkyd resins, amino resins, vinyl resins, acrylic resins, epoxy resins, polyamide resins, polyurethane resins, thermosetting unsaturated polyester resins, phenol resins, chlorinated polyolefin resins, silicone resins, acrylic silicone resins. Fluorine resin, xylene resin, petroleum resin, ketone resin, rosin-modified maleic acid resin, liquid polybutadiene, coumarone resin, and the like, and one or more of these are used. Examples of the natural resin include shellac, rosin (pine resin), ester gum, hardened rosin, decolorized shellac, white shellac, and the like, and one or more of these are used.
[0060]
As the synthetic resin, natural or synthetic rubbers such as ethylene-propylene copolymer rubber, polybutadiene rubber, styrene-butadiene rubber, and acrylonitrile-butadiene copolymer rubber may be used. Examples of the component used in combination with the synthetic resin include cellulose nitrate, cellulose acetate butyrate, cellulose acetate, ethyl cellulose, hydroxypropyl methylcellulose, and hydroxyethyl cellulose.
[0061]
The form of the binder resin used in the coating composition is not particularly limited, and examples include a solvent-soluble type, a water-soluble type, an emulsion type, and a dispersion type (any solvent such as water / organic solvent).
[0062]
Examples of water-soluble binder resins include water-soluble alkyd resins, water-soluble acrylic-modified alkyd resins, water-soluble oil-free alkyd resins (water-soluble polyester resins), water-soluble acrylic resins, water-soluble epoxy ester resins, and water-soluble melamines. Examples thereof include resins.
[0063]
Examples of emulsion type binder resins include (meth) acrylic acid alkyl copolymer dispersions; vinyl acetate resin emulsions, vinyl acetate copolymer resin emulsions, ethylene-vinyl acetate copolymer resin emulsions, acrylic ester (co) polymer resins. An emulsion, a styrene-acrylic ester (co) polymer resin emulsion, an epoxy resin emulsion, a urethane resin emulsion, an acrylic-silicone emulsion, a fluororesin emulsion, and the like can be given.
[0064]
Examples of the inorganic binder include metal alkoxides such as silica gel, alkali silicic acid, and silicon alkoxide, their (hydrolyzed) condensates, and phosphates.
[0065]
When the coating composition is used for the production of an ultraviolet-absorbing film, which will be described later, the binder resin used in the coating composition from the viewpoint of film forming conditions such as film forming temperature and the flexibility and weather resistance of the film obtained. As these, polyurethane resin, acrylic resin, fluororesin and the like are preferable.
[0066]
The ratio of the metal oxide particles in the coating composition is, for example, 0.1 to 99% by weight, preferably 10 to 90% by weight, based on the total solid content of the metal oxide particles and the binder resin. When the ratio of the metal oxide particles is less than 0.1% by weight, the effect obtained by adding particles such as ultraviolet shielding property and conductivity is lowered. On the other hand, when the ratio of the metal oxide particles exceeds 90% by weight, the visible light transmittance and flexibility are lowered. When the metal oxide particles contained in the coating composition are conductive and the coating film obtained from the coating composition is used as a functional film such as a conductive film or an antistatic film, the ratio of the metal oxide particles in the coating composition Is more preferably 50 to 90% by weight, and most preferably 70 to 85% by weight, based on the total solid content of the metal oxide particles and the binder resin.
[0067]
In addition to the metal oxide particles and the binder resin, the coating composition comprises a curing agent such as a crosslinking agent, a curing catalyst such as a curing aid, a plasticizer, an antifoaming agent / leveling agent, a thixotropic agent, and a matting agent. Surfactant; Flame retardant; Pigment wetting agent / dispersant; Lubricant; UV absorber; Light stabilizer; Antioxidant; Other (thermal) stabilizer; Preservative; It may contain additives such as rusting agents; dyes; pigments.
[0068]
As the curing agent, for example, a curing agent used in a dry oil system such as air (oxygen); a curing agent used in a polyester resin such as a monofunctional or polyfunctional unsaturated monomer, a polyacrylic resin, or an epoxy resin; first grade Curing agents used for binder resins having epoxy groups such as polyamines having secondary amino groups, polyamides, amino resins having methylol groups, polybasic acids having carboxyl groups, and high acid value polyesters; polymers having isocyanate groups Curing agents used for binder resins having hydroxyl groups such as isocyanates, polyisocyanates having urethane groups, methylol groups, primary and / or secondary amino groups, and amino resins having alkoxymethylene groups; carboxyl groups such as metal chelating agents Curing agent used for binder resin having water; Ability epoxy compounds, mention may be made of a hydroxyl group-containing compound curing agent used in the binder resin having a silicone base such as such, it is used alone or in combination.
[0069]
When the coating composition is used for production of a metal oxide particle-containing film, which will be described later, the weather resistance is improved when the coating composition contains a light stabilizer. When the coating composition contains polyisocyanate as a curing agent, versatility is high. As a method for curing the coating composition in the case of producing a film, a heat curing method is economically preferable.
[0070]
The coating composition may contain a solvent, and is appropriately selected depending on the intended use of the coating composition and the type of binder resin. Examples of the solvent include organic solvents such as alcohols, aliphatic and aromatic carboxylic acid esters, ketones, ethers, ether esters, aliphatic and aromatic hydrocarbons, and halogenated hydrocarbons; water Mineral oil; vegetable oil, wax oil, silicone oil and the like can be mentioned, and these are used alone or in combination.
[0071]
As a method for producing a coating composition, for example, a method of producing a coating composition by adding metal oxide particles to an organic solvent to form a slurry, and then mixing a binder resin with the slurry containing the metal oxide particles. Can be mentioned.
[0072]
A coating composition can be apply | coated to the surface of base materials, such as inorganic substances, such as glass and earthenware, and organic substances, such as resin, for example. In particular, a coating film obtained by coating on the surface of an organic material has high weather resistance and excellent flexibility. The shape of the inorganic material or organic material is not particularly limited, and examples thereof include a film shape, a sheet shape, a plate shape, and a fiber shape. Among these, it is useful for the below-mentioned film, fiber, etc.
[0073]
The material of the resin used as the substrate is not particularly limited. For example, LDPE, HDPE, amorphous polyethylene, polypropylene such as OPP (drawn polypropylene), CPP (crystallized polypropylene), and polyolefins such as polyisobutylene; EVA (Ethylene / vinyl acetate copolymer) system; polystyrene system; soft or hard polyvinyl chloride; EVOH (ethylene / vinyl alcohol copolymer) system; PVA system (vinylon system); PVDC system (polyvinylidene chloride); polyethylene terephthalate Polyesters such as polyethylene naphthalate and polybutylene naphthalate; polycarbonates; polyurethanes; polyamides; polyimides; polyacrylonitriles; polysulphones; Nylen sulfide type; polyarylate type; polyether imide type; aramid type; (meth) acrylic type; polyether ether ketone type; tetrafluoroethylene / ethylene copolymer, tetrafluoroethylene / hexafluoropropylene copolymer, polytetra Fluoroethylene, polytrifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer, polyvinyl fluoride, tetrafluoroethylene / hexafluoropropylene / perfluoroalkyl vinyl ether copolymer, polychlorotrifluoro Fluorine resins such as ethylene can be used.
[0074]
PMMA, MMA-styrene random copolymer, polycarbonate, transparent polypropylene, MMA and α-methylstyrene or cyclohexyl methacrylate, etc. when used in applications requiring extremely high visible light transparency and transparency, such as optical lenses MMA modified type of ABS resin, polystyrene, polyarylate, polysulfone, polyethersulfone, transparent epoxy resin, poly-4-methylpentene-1, fluorinated polyimide, amorphous fluororesin, transparent phenoxy resin Various resins such as amorphous nylon resin and fluorene can be used as the base material.
[0075]
Moreover, it becomes increasingly important to use biodegradable resin as a base material in order to meet the demand for biodegradability due to disposal problems. In such a case, for example, poly-3-hydroxybutyric acid ester, chitin / chitosan, polyamino acid, cellulose, polycaprolactone, alginic acid, polyvinyl alcohol, aliphatic polyester, saccharide, polyurethane, poly It is preferable to use an ether-based biodegradable plastic or the like as the base material.
[0076]
The base material may be one in which a UV absorbing film is previously disposed on the above-mentioned base material, or one in which a primer layer is disposed in advance for the purpose of improving the adhesion between the coating film composed of the coating composition and the base material. .
[0077]
Among these, among plastic films and sheets, fluorine resins, polyester resins, (meth) acrylic resins, and polycarbonate resins are preferable in terms of high weather resistance.
[0078]
The method for applying the coating composition is not particularly limited, and examples thereof include a dipping method, a roll coater method, a flow coat method, a screen printing method, a bar coater method, a spin coater method, a brush coating method, and a spray method. . Moreover, there is no limitation in particular about the dry film thickness obtained by apply | coating a coating composition, Preferably it is 0.5-100 micrometers, More preferably, it is 1-30 micrometers.
[0079]
After coating / coating the coating composition, heat curing (including room temperature curing), moisture curing, UV curing in terms of water resistance, solvent resistance, acid resistance, chemical resistance such as alkali resistance, scratch resistance, etc. The cured film is preferably formed by a curing method such as electron beam curing.
[0080]
A laminated glass can be obtained using a coated transparent plate in which an intermediate film obtained by applying the coating composition to a transparent plate such as a glass plate is formed on the transparent plate. Laminated glass can be manufactured by stacking an adhesive sheet so as to be sandwiched between a coated transparent plate and a transparent plate prepared separately. Note that the intermediate film of the coated transparent plate and the adhesive sheet are stacked.
[0081]
Examples of the adhesive sheet include sheets made of soft resin or hard resin such as polyvinyl butyral resin, polyurethane resin, ethylene-vinyl acetate copolymer resin, ethylene- (meth) acrylate copolymer resin, etc. A soft resin is preferable. The thickness of the adhesive sheet is preferably 0.1 to 2 mm, more preferably 0.5 to 1 mm.
Molding material composition
This molding material composition is excellent in various functions such as light functions such as a light selective permeability function, electrical functions such as a conductive function, and catalytic functions such as a photocatalytic function, and obtains a molded article having high weather resistance and flexibility. Can be made.
[0082]
Binder resins used in the molding material composition include polyamide (6-nylon, 66-nylon, 12-nylon, etc.), polyimide, polyurethane, polyolefin (polyethylene, polypropylene, etc.), polyester (PET, PBT, PEN, etc.) , Polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polystyrene, (meth) acrylic resin, ABS resin, silicone resin, fluororesin, and thermoplastic resins such as these monomers; phenol resin (phenol formalin Resin, cresol / formalin resin, etc.), epoxy resin, amino resin (urea resin, melamine resin, guanamine resin, etc.) and thermosetting resins such as monomers used as raw materials thereof. Species or two or more are used.
[0083]
Examples of the binder resin used in the molding material composition include soft resins or hard resins such as polyvinyl butyral, polyurethane, ethylene-vinyl acetate copolymer, and ethylene- (meth) acrylate copolymer. These can be used alone or in combination of two or more.
[0084]
As the binder resin used in the molding material composition, the above-described inorganic binder may be used.
[0085]
The ratio of the metal oxide particles in the molding material composition is, for example, 0.1 to 99% by weight, preferably 0.3 to 10% by weight, based on the total solid content of the metal oxide particles and the binder resin. It is. When the ratio of the metal oxide particles is less than 0.1% by weight, the effect obtained by adding particles such as ultraviolet shielding property and conductivity is lowered. On the other hand, when the ratio of the metal oxide particles exceeds 99% by weight, strength, visible light permeability and flexibility are lowered.
[0086]
Molding composition is hardener, cure accelerator, colorant, mold release agent, coupling agent, silicone compound, reactive diluent, plasticizer, stabilization according to required performance in addition to metal oxide particles and binder resin It may contain additives such as an agent, a flame retardant aid and a crosslinking agent.
[0087]
The curing agent may be required when using a thermosetting resin as the binder resin. For example, when an epoxy resin is used as the binder resin, polyamides, aliphatic polyamines, cycloaliphatic polyamines, aromatic polyamines or amines modified with a part thereof, acid anhydrides, dicyandiamides, imidazole , Amine imides, hydrazides, phenol novolacs, cresol novolacs and other novolac-based curing agents, and the like are used alone or in combination. Moreover, when using a phenol resin as binder resin, urotropin, formal, etc. can be mentioned, These are 1 type (s) or 2 or more types used. These amounts are used in an appropriate amount with respect to the binder resin.
[0088]
Plasticizers are intended to further improve the processability of the composition, such as phosphate esters, phthalate esters, aliphatic- or dibasic acid esters, dihydric alcohol esters, oxyacid esters. Polyglycols, and the like, and particularly when an epoxy resin is used as the binder resin, polyglycols are preferred. The stabilizer suppresses the decomposition of the binder resin, and examples thereof include lead stearate and zinc stearate.
[0089]
As a manufacturing method of a molding material composition, the method etc. which mix a metal oxide particle and binder resin uniformly using mixing apparatuses, such as a roll, a kneader, a mixer, etc. can be mentioned, for example.
[0090]
Examples of the molding method of the molding material composition include extrusion molding, injection molding, casting, compression molding, low-pressure transfer molding, and cast molding.
[0091]
The molding material composition may be molded into a film, for example, and the obtained film has high heat ray shielding properties for particles and excellent visible light transmittance.
[0092]
Laminated glass can be obtained by sandwiching a metal oxide particle-containing sheet obtained by molding a molding material composition with a transparent plate such as a glass plate and curing it appropriately. The thickness of the metal oxide particle-containing sheet is preferably 0.1 to 2 mm, more preferably 0.5 to 1 mm.
Film containing metal oxide particles
The metal oxide particle-containing film is a film in which a coating film obtained from the metal oxide particle-containing composition (coating composition) according to the present invention is formed on a substrate film. Since this metal oxide particle-containing film contains the metal oxide particles of the present invention, it is excellent in various functions such as a light function such as a light selective transmission function, an electric function such as a conductive function, and a catalyst function such as a photocatalytic function. High weather resistance.
[0093]
As a base film used for a metal oxide particle containing film, the film etc. which consist of resin used as a base material demonstrated in the term of the coating composition in detail can be mentioned. The same applies to the preferred ones.
[0094]
There is no limitation in particular about the film thickness of a base film, Preferably it is 5-500 micrometers, More preferably, it is 10-200 micrometers.
[0095]
There are no particular limitations on the method of applying the coating composition on the surface of the substrate film, the dry film thickness, and the like, and the above-mentioned ones are preferred.
[0096]
The metal oxide particle-containing film is not particularly limited as long as the coating film obtained from the coating composition is formed on the substrate film, and may be further processed according to the application, required characteristics, and the like. The metal oxide particle-containing film is applied to the surface of the coating film that does not contact the base film and / or the surface of the base film that does not contact the coating film. Film or the like), or a laminate film laminated with another film.
[0097]
The ultraviolet transmittance when the metal oxide particle-containing film is used as an ultraviolet shielding film is not particularly limited, but is preferably 50% or less, and more preferably 10% or less. The ultraviolet transmittance is a value obtained by the apparatus and measurement method described in JIS R 3106.
[0098]
The visible light transmittance of the metal oxide particle-containing film is not particularly limited, but is preferably 70% or more, and more preferably 80% or more. The visible light transmittance is a value obtained by measuring in the wavelength range of 380 to 780 nm and using the apparatus, measurement method, and calculation method described in JIS R 3106.
[0099]
The haze of the metal oxide particle-containing film is not particularly limited, but is preferably 10% or less, more preferably 5% or less, and most preferably 3% or less. The haze is a value obtained by measuring with a turbidimeter.
[0100]
The weather resistance of the metal oxide particle-containing film is determined by performing an accelerated weather resistance test using a shine carbon arc lamp type light resistance and weather resistance tester described in JIS B 7753-93, and haze after an initial 100 hours. When the haze value and hue after 1000 hours test are further compared on the basis of the value and hue, the change in haze is preferably less than 2%, and more preferably not colored (discoloration).
[0101]
【Example】
The present invention will be described in more detail with reference to the following examples, but the present invention is not limited thereto.
[0102]
Evaluation in this example was performed by the following method.
1. Evaluation of metal oxide particles
<Preparation method of powder sample>
After the fine particles in the obtained dispersion are separated by centrifugation, washing with methanol and further washing with acetone are sufficiently performed, followed by vacuum drying at 30 ° C. for one day, and further vacuum drying at 80 ° C. for one day. The volatile component was completely removed to obtain a fine particle powder, which was used as a powder sample.
<Content of different metal (Md)>
The average content rate αav and the central content rate αc were determined by the method defined above.
[0103]
The content rate αav-1 shown in Table 2 was measured by setting a spot diameter including all of about 1000 particles even in a state where segregated materials were observed in the above-described method for measuring the average content rate αav. It is the content rate of the dissimilar metal (Md). In Table 2, when the value of the content rate αav is lower than the value of the content rate αav-1 in the particles P-1 and the particles Pc-1, a slight segregation is observed for the particles P-1, and the particles Pc − For 1, it means that a large amount of segregated material was observed.
[0104]
For the above measurement, FE-TEM (field emission type transmission electron microscope, manufactured by Hitachi, HF-2000 type, acceleration voltage 200 kV) and XMA (X-ray microanalyzer, manufactured by Kevex, Sigma type, energy dispersion type, beam diameter ( The average content (αav) and the central content (αc) of the dissimilar metal (Md) with respect to the main metal (M) were determined using the spatial resolution (10Åφ).
<Carboxylic acid (residual) group content>
1 g of the powder sample was mixed with 0.01N sodium hydroxide aqueous solution and stirred for 3 days, and then the supernatant obtained by centrifugation was measured by ion chromatography analysis. Here, mol% of carboxylic acid (residual) groups such as an acetoxy group relative to the main metal (M) was calculated.
<Crystallinity>
Evaluation was made by powder X-ray diffraction.
<Crystallite diameter Dc (hkl), Dw>
The powder sample was determined by powder X-ray diffraction measurement.
[0105]
Dc (hkl): crystallite diameter in a direction perpendicular to each diffraction surface (hkl) obtained by the Scherrer method (by Cauchy function approximation)
Dw: Crystallite size and lattice strain determined using the Wilson method
1. Evaluation of coating film
<Heat shielding performance>
Particles are dispersed in an acrylic resin binder, and the particles are 10 g / m2The film is formed on a PET film so that the transmittance T is 1.5 μm.1.5Was measured and judged according to the following criteria.
[0106]
○: T1.5<40%
X: T1.5≧ 40%
-Example 1 (1)-
With a stirrer, addition port, thermometer, distillate gas outlet, nitrogen gas inlet and pressure control valve, withstand pressure of 100 kg / cm that can be heated from the outside2Reactor made of stainless steel (SUS316), an addition tank directly connected to the addition port via a ball valve, a reactor directly connected to the distillate gas outlet, and a distillate trap (the whole reaction apparatus is 100 kg / cm2(Withstand pressure specification) was prepared. The reactor was charged with 1000 parts of 2-butoxyethanol (hereinafter referred to as EGB), the gas phase part was replaced with nitrogen gas, the temperature was raised from room temperature, nitrogen was introduced, and the gas phase part pressure was 5 kg / cm.2The liquid temperature was maintained at 160 ° C.
[0107]
Next, a raw material suspension (A-1) is prepared by mixing 152 parts of anhydrous zinc acetate (manufactured by Matsugaki Pharmaceutical Co., Ltd.) and 4.85 parts of anhydrous indium acetate with 191 parts of EGB, and charging it into the addition tank. It is. Gas phase pressure 5kg / cm2The raw material suspension (A-1) was added and mixed in 30 seconds from the addition tank to the EGB solvent maintained at a bottom temperature of 160 ° C. The liquid temperature once decreased to 140 ° C. due to the addition, but returned to 160 ° C. after 13 minutes, and thereafter, the vapor phase pressure was 5 kg / cm at 160 ° C. ± 3 ° C.2For 6 hours to obtain a suspension (D-1) of In-containing ZnO particles (P-1).
[0108]
-Comparative Example 1-
In Example 1 (1),It was obtained by replacing anhydrous zinc acetate with zinc acetate dihydrate and changing the raw material formulation so that the water / Md molar ratio was 110.A suspension (Dc-1) of In-containing ZnO particles (Pc-1) was similarly obtained except that the raw material suspension (Ac-1) was added to EGB maintained at 160 ° C. under normal pressure. Obtained.
[0109]
Table 2 shows the analysis results of the particles obtained in Example 1 (1) and Comparative Example 1.
[0110]
-Example 1 (2)−
Shown in Table 1SuharaA suspension of the sample is prepared and shown in Table 1.WarmThe reaction was conducted in the same manner as in Example 1 (1) except that the addition was performed under the conditions of temperature and pressure and the heat treatment was performed under the conditions of temperature and pressure shown in Table 1.,acidCompound particles (P-2) Suspension (D-2) In addition,At this time,As solventIsPropylene glycol monomethyl ether(Hereinafter referred to as PGM).
[0111]
Table 2 shows the analysis results of the particles P-1, P-2, and Pc-1 obtained in Example 1 (1), Example 1 (2), and Comparative Example 1.
[0112]
-Example 1 (5)-
After charging 900 parts of n-butanol into the reactor in Example 1 (1) and replacing the gas phase part with nitrogen gas, the temperature was raised from room temperature and the liquid temperature was maintained at 280 ° C. Gas phase pressure is gauge pressure 43kg / cm2Met.
[0113]
A raw material suspension (A-5) was prepared by mixing 216 parts of anhydrous indium acetate (III) powder, 12.6 parts of titanium (IV) n-butoxide and 270 parts of n-butanol, and charged into the addition tank. It is.
[0114]
The raw material suspension (A-5) was added to and mixed with the n-butanol solvent maintained at the bottom temperature of 280 ° C. in 30 seconds from the addition tank. The temperature once decreased to 240 ° C. due to the addition, but after increasing the temperature to 280 ° C. again, by holding at 280 ± 3 ° C. for 4 hours, Ti-containing In2OThreeA suspension (D-5) in which the particles (P-5) were dispersed at 7.3% by weight was obtained. Table 3 shows the analysis results of the obtained particle P-5.
[0115]
-Examples 1 (6) to 1 (16)-
By adding the additive raw material shown in Table 4 or 5 to the bottom solution under the addition conditions (temperature and pressure) shown in the same table, and maintaining the heat treatment holding conditions shown in the same table for a certain time, oxide fine particles ( Suspensions (D-6 to D-16) in which P-6 to P-16) were dispersed were obtained. The ethylene glycol monoethyl ether acetate used as a solvent is hereinafter referred to as EGEA. Table 6 shows the analysis results of the obtained particles P-6 to P-16.
[0116]
-Example 2 (1)-
The suspension (D-1) obtained in Example 1 (1) was centrifuged to obtain a solid content. This solid content was dried to obtain a powder of In-containing ZnO particles (P-1).
[0117]
A coating composition (C-1) was obtained by mixing 10 parts of this powder, 20 parts of an acrylic resin solution (solid content concentration 50%), and 20 parts of toluene and dispersing the mixture with a homogenizer. A coating film (F-1) was obtained by applying and drying this composition on a PET film to a dry film thickness of 10 μm.
[0118]
The light transmittance in 1.5 micrometers of the obtained coating film (F-1) was 30%.
[0119]
-Comparative Example 2-
In Example 2, In-containing ZnO particles (Pc-1) were obtained using the suspension (Dc-1) instead of the suspension (D-1). Using this, a coating composition (Cc-1) and a coating film (Fc-1) were obtained in the same manner as in Example 2 (1). The light transmittance at 1.5 μm of the obtained coated film (Fc-1) was 52%.
[0120]
-Example 2 (2)-
In Example 2 (1), In-containing ZnO particles (P-2) were obtained using the suspension (D-2) instead of the suspension (D-1). Using this, a coating composition (C-2) and a coating film (F-2) having a dry film thickness of 10 μm were obtained in the same manner as in Example 2 (1).
[0121]
The light transmittance in 1.5 micrometers of the obtained coating film (F-2) was 25%.
[0122]
-Example 2 (3)-
In Example 2 (1), using the suspension (D-5) instead of the suspension (D-1), the Ti-containing In2OThreeParticles (P-5) were obtained. Using this, in the same manner as in Example 2 (1), a coating composition (C-5) and a coating film (F-5) having a dry film thickness of 10 μm were obtained.
[0123]
The light transmittance in 1.5 micrometers of the obtained coating film (F-5) was 10% or less.
[0124]
[Table 1]
[0125]
[Table 2]
[0126]
[Table 3]
[0127]
[Table 4]
[0128]
[Table 5]
[0129]
[Table 6]
[0130]
【The invention's effect】
The metal oxide particles according to the present invention are excellent in functions such as heat ray shielding performance and visible light permeability.
[0131]
The method for producing metal oxide particles according to the present invention makes it possible to easily obtain metal oxide particles having excellent functions such as heat ray shielding performance and visible light permeability.
[0132]
Since the metal oxide particle-containing composition according to the present invention contains the metal oxide particles of the present invention, the heat ray shielding property and transparency are high. It is excellent in various functionalities such as electrical functions such as photocatalytic functions such as photocatalytic functions, and has high weather resistance.
Claims (3)
M(O)(m-x-y-z)/2(OCOR)x(OH)y(OR’)z (I)
(但し、Mはm価の金属原子;Rは、水素原子、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;R’は、置換基があってもよいアルキル基、シクロアルキル基、アリール基およびアラルキル基から選ばれた少なくとも1種;m、x、yおよびzは、x+y+z≦m、0<x≦m、0≦y<m、0≦z<mを満たす。)A method for producing different metal-containing metal oxide particles having an average content (Md / M) of different metal (Md) of 0.5 to 20 atomic%, wherein the metal (M) has the following general formula (I) And a step of precipitating metal oxide particles by heating a solution containing the compound represented by formula (1) and / or a hydrolysis condensate, a compound of a different metal (Md), and an alcohol but no carboxylic acid , with water content of 100 moles in terms of a molar ratio relative to the dissimilar metals (Md), said heating is carried out under pressure, and wherein the method of dissimilar metal-containing metal oxide particles.
M (O) (mxyz) / 2 (OCOR) x (OH) y (OR ') z (I)
(Where M is an m-valent metal atom; R is at least one selected from a hydrogen atom, an optionally substituted alkyl group, a cycloalkyl group, an aryl group and an aralkyl group; R ′ is a substituent group) And at least one selected from an alkyl group, a cycloalkyl group, an aryl group, and an aralkyl group, and m, x, y, and z are x + y + z ≦ m, 0 <x ≦ m, 0 ≦ y <m, 0 ≦ z <m is satisfied.)
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| CN100344709C (en) | 2003-03-17 | 2007-10-24 | 李海旭 | Composition for shielding heat rays, film formed therefrom, and method for forming the composition and film |
| ATE402985T1 (en) | 2003-07-23 | 2008-08-15 | Kansai Paint Co Ltd | ELECTRICALLY CONDUCTIVE WHITE PRIMER AND METHOD FOR PRODUCING MULTI-LAYER PAINT COATS |
| WO2005076752A2 (en) * | 2004-02-18 | 2005-08-25 | Nippon Shokubai Co., Ltd. | Metal oxide particle and its uses |
| JP5016192B2 (en) * | 2004-02-18 | 2012-09-05 | 株式会社日本触媒 | Metal oxide particles and uses thereof |
| JP4938985B2 (en) * | 2004-02-18 | 2012-05-23 | 株式会社日本触媒 | Metal oxide particles and uses thereof |
| JP4904714B2 (en) * | 2005-04-20 | 2012-03-28 | 住友金属鉱山株式会社 | Infrared shielding material fine particle dispersion, infrared shielding body, method for producing infrared shielding material fine particles, and infrared shielding material fine particles |
| JP4782091B2 (en) * | 2007-09-28 | 2011-09-28 | ヴァーレ・ジャパン株式会社 | Method for coating nickel oxide particles |
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