Alumina particle composite, method of manufacturing the alumina particle composite, resin composition and method of manufacturing the resin composition

Abstract

An alumina particle composite ( 1 ) includes an alumina particle ( 2 ) and an organic acid ( 3 ) chemically bonded to a surface of the alumina particle ( 2 ). Further, the alumina particle ( 2 ) has a short axis length of 1 to 10 nm, a long axis length of 20 to 400 nm, and an aspect ratio of 5 to 80, and is represented by Formula I, Al 2 O 3 .nH 2 O  Formula I where n is 0 or more.

1 . An alumina particle composite, comprising: 
 an alumina particle; and    an organic acid chemically bonded to a surface of the alumina particle.    
     
     
         2 . The alumina particle composite according to  claim 1 , 
 wherein the organic acid comprises a sulfonic acid group.    
     
     
         3 . The alumina particle composite according to  claim 2 , 
 wherein the organic acid is alkylbenzenesulfonic acid.    
     
     
         4 . The alumina particle composite according to  claim 1 , 
 wherein the organic acid is boric acid.    
     
     
         5 . The alumina particle composite according to  claim 1 , 
 wherein a content of the organic acid is 1 mmol or more with respect to 1 mol of the alumina particles.    
     
     
         6 . The alumina particle composite according to  claim 1 , 
 wherein the alumina particle has a short axis length of 1 to 10 nm, a long axis length of 20 to 400 nm, and an aspect ratio of 5 to 80, and    the alumina particle is represented by Formula I,      Al 2 O 3 .nH 2 O  Formula I    where n is 0 or more.    
     
     
         7 . The alumina particle composite according to  claim 6 , 
 wherein the alumina particle has a hollow inside.    
     
     
         8 . The alumina particle composite according to  claim 6 , 
 wherein when n is 0 in the Formula I, the alumina particle is a alumina.    
     
     
         9 . The alumina particle composite according to  claim 6 , 
 wherein when n is 1 in the Formula I, the alumina particle is boehmite.    
     
     
         10 . A method of manufacturing an alumina particle composite, comprising: 
 adding an alkali aqueous solution in an aqueous solution with an aluminum salt to produce a reaction mixture containing a gel material of aluminum hydroxide;    first heating the reaction mixture at a first temperature not lower than room temperature;    after the first heating, second heating the reaction mixture at a second temperature higher than the first temperature;    after the second heating, third heating the reaction mixture at a third temperature lower than the second temperature; and    after the third heating, fourth heating the reaction mixture at a fourth temperature not less than the room temperature; and    dispersing boehmite particles generated in the reaction mixture into a solvent, and adding an organic acid to the solvent.    
     
     
         11 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein the boehmite particles are dispersed into the solvent by using at least one means of an ultrasonic wave and high-pressure emulsion.    
     
     
         12 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein a ratio of a concentration of the aqueous solution with the aluminum salt and a concentration of the alkali aqueous solution is ¼ to ½ in molar ratio.    
     
     
         13 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein a concentration of the aqueous solution with the aluminum salt is within a range from 1.0 to 3.0 M, and a concentration of the alkali aqueous solution is within a range from 4.0 to 10.0 M.    
     
     
         14 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein a form of the boehmite particle is changed by changing pH of the reaction mixture.    
     
     
         15 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein the first temperature ranges from the room temperature to 140° C.    
     
     
         16 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein the second temperature ranges from 140 to 250° C.    
     
     
         17 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein the third temperature is not higher than 130° C.    
     
     
         18 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein time taken for cooling from the second temperature to the third temperature is within 10 minutes.    
     
     
         19 . The method of manufacturing an alumina particle composite according to  claim 10 , 
 wherein the fourth temperature ranges from 100 to 180° C.    
     
     
         20 . The method of manufacturing an alumina particle composite according to  claim 10 , further comprising: 
 baking a boehmite particle obtained by the fourth heating.    
     
     
         21 . A resin composition, comprising: 
 resin; and    an alumina particle composite contained in the resin as a filler, the alumina particle composite comprising: an alumina particle; and an organic acid chemically bonded to a surface of the alumina particle.    
     
     
         22 . The resin composition according to  claim 21 , 
 wherein a blended amount of the alumina particle composite is within a range from 1 to 50% by weight.    
     
     
         23 . The resin composition according to  claim 21 , 
 wherein the resin is at least one thermoplastic resin selected from polycarbonate, acrylic and methacrylic resins.    
     
     
         24 . The resin composition according to  claim 21 , 
 wherein the organic acid comprises a sulfonic acid group.    
     
     
         25 . The resin composition according to  claim 24 , 
 wherein the organic acid is alkylbenzenesulfonic acid.    
     
     
         26 . The resin composition according to  claim 21 , 
 wherein the organic acid is boric acid.    
     
     
         27 . The resin composition according to  claim 21 , 
 wherein a content of the organic acid is 1 mmol or more with respect to 1 mol of the alumina particles.    
     
     
         28 . The resin composition according to  claim 21 , 
 wherein the alumina particle has a short axis length of 1 to 10 nm, a long axis length of 20 to 400 nm, and an aspect ratio of 5 to 80, and    the alumina particle is represented by Formula I,      Al 2 O 3 .nH 2 O  Formula I    where n is 0 or more.    
     
     
         29 . The resin composition according to  claim 28 , 
 wherein the alumina particle has a hollow inside.    
     
     
         30 . The resin composition according to  claim 28 , 
 wherein when n is 0 in the Formula I, the alumina particle is a alumina.    
     
     
         31 . The resin composition according to  claim 28 , 
 wherein when n is 1 in the Formula I, the alumina particle is boehmite.    
     
     
         32 . A method of manufacturing a resin composition, comprising: 
 dispersing an alumina particle composite into a first solvent to produce an alumina particle-dispersion liquid;    mixing a monomer as a raw material of resin and the alumina particle-dispersion liquid; and    polymerizing the monomer in a state where the monomer and the alumina particle-dispersion liquid are mixed together,    wherein a method of manufacturing the alumina particle composite comprises: 
 adding an alkali aqueous solution in an aqueous solution with an aluminum salt to produce a reaction mixture containing a gel material of aluminum hydroxide;  
 first heating the reaction mixture at a first temperature not lower than room temperature;  
 after the first heating, second heating the reaction mixture at a second temperature higher than the first temperature;  
 after the second heating, third heating the reaction mixture at a third temperature lower than the second temperature; and  
 after the third heating, fourth heating the reaction mixture at a fourth temperature not less than the room temperature; and  
 dispersing boehmite particles generated in the reaction mixture into a second solvent, and adding an organic acid to the second solvent.  
   
     
     
         33 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the alumina particle-dispersion liquid is prepared by using at least one means of an ultrasonic wave and high-pressure emulsion.    
     
     
         34 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein a light transmittance of the alumina particle-dispersion liquid is 40% or more.    
     
     
         35 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the first solvent includes an organic solvent and water which is blended with the alumina particle composite in a ratio of 0.1 mmol or more to 1 mol.    
     
     
         36 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein a ratio of a concentration of the aqueous solution with the aluminum salt and a concentration of the alkali aqueous solution is ¼ to ½ in molar ratio.    
     
     
         37 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein a concentration of the aqueous solution with the aluminum salt is within a range from 1.0 to 3.0 M, and a concentration of the alkali aqueous solution is within a range from 4.0 to 10.0 M.    
     
     
         38 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein a form of the boehmite particle is changed by changing pH of the reaction mixture.    
     
     
         39 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the first temperature ranges from the room temperature to 140° C.    
     
     
         40 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the second temperature ranges from 140 to 250° C.    
     
     
         41 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the third temperature is not higher than 130° C.    
     
     
         42 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein time taken for cooling from the second temperature to the third temperature is within 10 minutes.    
     
     
         43 . The method of manufacturing a resin composition according to  claim 32 , 
 wherein the fourth temperature ranges from 100 to 180° C.    
     
     
         44 . The method of manufacturing a resin composition according to  claim 32 , further comprising: 
 baking a boehmite particle obtained by the fourth heating.