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US 2016/0096194 A1Published application
Method for producing composite structural material
AssigneeKuraray Co., Ltd.
InventorsKentaro Yoshida, Ryoichi Sasaki, Mamoru Omoda, Wataru Hirose, Manabu Shibata, Tatsuya Oshita
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Abstract
The composite structural material of the present invention includes a base (X) and a layer (Y) stacked on the base (X). The layer (Y) includes a reaction product (R) of a metal oxide (A) and a phosphorus compound (B). In the infrared absorption spectrum of the layer (Y) in the range of 800 to 1400 cm−1, the wave number (n1) at which the infrared absorption reaches maximum is in the range of 1080 to 1130 cm−1.
Claims14
1-23. (canceled)
24:
- A method for producing a composite structural material, comprising:
- mixing a metal oxide, a compound comprising a site capable of reacting with the metal oxide, and a solvent, such that a coating liquid comprising the metal oxide, the compound, and the solvent is formed;
- applying the coating liquid onto a base (X) such that a precursor layer of a layer (Y) is formed on the base (X);
- and
- treating the precursor layer such that the layer (Y) is formed,
- wherein the treating of the precursor layer comprises heat-treating the precursor layer at a temperature of 110° C. or higher,
- the composite structural material comprises the base (X) and the layer (Y) stacked on the base (X),
- the compound comprises a phosphorus compound, and
- a number of moles of metal atom contained in the compound is in the range of 0 to 1 times a number of moles of phosphorus atom contained in the phosphorus compound.
6 more elements
25:
- The method of claim 24, wherein
- the layer (Y) comprises a reaction product, obtained by a process comprising reacting the metal oxide and the phosphorus compound, and
- in an infrared absorption spectrum of the layer (Y) in the range of 800 to 1400 cm−1, a wave number (n1) at which the infrared absorption reaches maximum is in the range of 1080 to 1130 cm−1.
(canceled)
27:
- The method of claim 25,
- wherein an absorbance (A1) at the wave number (n1) and an absorbance (A2) at a wave number (n2) satisfy a relationship of (A2)/(A1)≦0.2 in an infrared absorption spectrum of the layer (Y), and
- the wave number (n2) is a wave number at which an infrared absorption due to stretching vibration of hydroxyl group reaches maximum in the infrared absorption spectrum of the layer (Y) in the range of 2500 to 4000 cm−1.
28:
- The method of claim 25, wherein a half width of the absorption peak at the wave number (n1) is 200 cm−1 or less.
29:
- The method of claim 24, wherein the mixing of the metal oxide, the compound, and the solvent comprises
- preparing a liquid comprising the metal oxide,
- preparing a solution comprising the phosphorus compound, and
- mixing the liquid and the solution.
1 more element
30:
- The method of claim 29, wherein
- the preparing of the liquid comprises subjecting, to condensation or hydrolysis condensation, at least one selected from the group consisting of a compound (L) comprising a metal atom to which a hydrolyzable characteristic group is bonded, a partial hydrolysate of the compound (L), a total hydrolysate of the compound (L), a partially hydrolyzed condensate of the compound (L), and a partial condensate of the total hydrolysate of the compound (L).
31:
- The method of claim 30, wherein the compound (L) comprises a compound (L′) of formula (I):
- M1X1mR1(n-m) (I),
- where
- M1 is Al, Ti, or Zr;
- X1 is F, Cl, Br, I, R2O—, R3C(═O)O—, (R4C(═O))2CH—, or NO3;
- R1, R2, R3, and R4 each are independently an alkyl group, an aralkyl group, an aryl group, or an alkenyl group;
- when a plurality of any of X1, R1, R2, R3, and R4 are present in formula (I), the plurality of X1, R1, R2, R3, and R4 are the same as or different from each other;
- n is equal to a valence of M1;
- and
- m is an integer of 1 to n.
7 more elements
32:
- The method of claim 24,
- wherein the coating liquid further comprises a polymer
- comprising at least one functional group selected from the group consisting of hydroxyl group, carboxyl group, carboxylic anhydride group, and a salt of carboxyl group.
33:
- The method of claim 24,
- wherein the coating liquid further comprises an acid compound selected from the group consisting of acetic acid, hydrochloric acid, nitric acid, trifluoroacetic acid, and trichloroacetic acid.
34:
- The method of claim 26,
- wherein duration of the heat-treating of the precursor layer is in the range of 0.1 second to 1 hour.
35-36. (canceled)
37:
- The method of claim 27, wherein a half width of the absorption peak at the wave number (n1) is 200 cm−1 or less.
Dependencies are inferred from the claim text.