Patent ID: 8241703
Filing Date: 2012-08-14
Classification: B01J,B02C,B05B,B05D,B28B,C23C,Y10T

Abstract:
1. A composite structure formation method based on an aerosol deposition method by which an aerosol with brittle material fine particles dispersed in a gas is sprayed toward a substrate to form a structure made of the brittle material fine particles, the composite structure formation method comprising the steps of: storing a plurality of pre-formed controlled particles in a storage mechanism, each of the controlled particles being an assembly intentionally packed with a plurality of fine particles which are not chemically bonded together and which include the brittle material fine particles, the controlled particles are formed by using only the fine particles whose mean primary particle diameter is 0.1 μm or more and 5 μm or less, and the controlled particles having a mean circle-equivalent diameter of 20 μm or more and 500 um or less; supplying the controlled particles from the storage mechanism to an aerosolation mechanism constantly; disaggregating the supplied controlled particles into a plurality of the fine particles in the aerosolation mechanism to form an aerosol in which the fine particles are dispersed in the gas; and spraying all of the fine particles in the aerosol toward the substrate to form a composite structure of the structure and the substrate, wherein the controlled particles are controlled so that bonding strength between the fine particles includes a mean compressive fracture strength sufficient to substantially avoid disaggregation during the supply step, but which permits the controlled particles to be substantially completely disaggregated in the disaggregation step.