COMPOSITE STRUCTURE FORMATION METHOD, PRE-FORMED CONTROLLED PARTICLES FORMED OF FINE PARTICLES NON-CHEMICALLY BONDED TOGETHER, AND COMPOSITE STRUCTURE FORMATION SYSTEM INVOLVING CONTROLLED PARTICLES

摘要

A composite structure formation method includes the steps of storing a plurality of pre-formed controlled particles in a storage mechanism, 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 an entire contents of the controlled particles including 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. 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.

主权项

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 being formed by using the fine particles whose mean primary particle diameter is 0.1 μm or more and 5 μm 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 an entire contents of the controlled particles including 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.