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TWI277613B - Highly-filled, aqueous metal oxide dispersion - Google Patents

Highly-filled, aqueous metal oxide dispersion Download PDF

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TWI277613B
TWI277613B TW94125164A TW94125164A TWI277613B TW I277613 B TWI277613 B TW I277613B TW 94125164 A TW94125164 A TW 94125164A TW 94125164 A TW94125164 A TW 94125164A TW I277613 B TWI277613 B TW I277613B
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dispersion
fraction
fine
metal oxide
coarse
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TW94125164A
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Chinese (zh)
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Monika Oswald
Corinna Kissner
Roland Weiss
Andreas Lauer
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Degussa
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  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

Aqueous dispersion containing a metal oxide powder with a fine fraction and a coarse fraction, in which the metal oxide powder is silicon dioxide, aluminium oxide, titanium dioxide, zirconium dioxide, cerium oxide or a mixed oxide of two or more of the aforementioned metal oxides, the fine fraction is present in aggregated form and has a mean aggregate diameter in the dispersion of less than 200 nm, the coarse fraction consists of particles with a mean diameter of 1 to 20 mum, the ratio of fine fraction to coarse fraction is 2:98 to 30:70, and the content of metal oxide powder is 50 to 85 wt.%, referred to the total amount of the dispersion. The aqueous dispersion is produced by a process comprising the steps: production of a fine fraction dispersion by dispersing the pulverulent fine fraction in water by means of an energy input of at least 200 KJ/m<3>, and introducing the coarse fraction in the form of a powder into the fine fraction dispersion under dispersing conditions at a low energy input. Process for the production of moulded articles using the dispersion.

Description

1277613 (1) 九、發明說明 【發明所屬之技術領域】 本發明關於高度塡充之金屬氧化物水性分散液與彼之 製法。本發明亦關於使用此分散液製造陶瓷模製物件的方 法,以及關於陶瓷模製物件本身。 【先前技術】1277613 (1) Description of the Invention [Technical Field of the Invention] The present invention relates to a highly potent aqueous metal oxide dispersion and a process for the same. The invention also relates to a method of making a ceramic molded article using the dispersion, and to a ceramic molded article itself. [Prior Art]

由分散液開始或以溶膠-凝膠法製造陶瓷模製物件已 知一段長時間了。溶膠-凝膠法的唯一缺點爲只能達到低 「胚體」(green )密度。所以,乾燥與燒結時會發生高 收縮率。這些加工步驟必須非常慢地進行,通常得數天或 數週,以避免裂痕發生。若模製物件由包含金屬氧化物細 粒之分散液製得則此缺點可被減少。雖然使用比溶膠-凝 膠法高的塡料含量能夠降低收縮率,然而此類分散液的塡 料含量限制爲至多約60 wt. %。 爲了達到較高塡料含量,US 6 1 93 926提出一種呈雙 峰曲線之二氧化矽,氧化鋁,碳化矽或氮化矽的水分散液 ,其細粒部份的尺寸小於1 μηι而粗粒部份的尺寸大於1 μηι。於切變條件下將氟化合物加至呈雙峰曲線之分散液 (將該粗粒部份倂入該細粒部份的分散液而製得),然後 將含氟且呈雙峰曲線之分散液加入模子中並令其於模子中 膠化而得到模製物件。 此方法的缺點爲氟化合物成爲分散液要製成模製物件 的一個必要成分。再者,US 6193926並未揭示呈雙峰曲 -5- (2) ^ 1277613 線之分散液的塡料含量爲何。只有提到細粒部份分散液的 較佳塡料含量。又,此文獻未揭示如何得到細粒分散液以 及如何將該粗粒部份加入細粒分散液中。 另由DE-A- 1 9943 1 03知道由高度塡充、呈雙峰曲線It has been known for a long time to start from a dispersion or to make a ceramic molded article by a sol-gel method. The only drawback of the sol-gel process is that it can only achieve a low "green" density. Therefore, high shrinkage occurs during drying and sintering. These processing steps must be carried out very slowly, usually days or weeks to avoid cracking. This disadvantage can be reduced if the molded article is made of a dispersion containing metal oxide fine particles. Although the use of a higher than sol-gel method can reduce the shrinkage, the dispersion of such a dispersion is limited to a maximum of about 60 wt.%. In order to achieve a higher content of dip, US 6 1 93 926 proposes a bimodal curve of an aqueous dispersion of cerium oxide, aluminum oxide, cerium carbide or cerium nitride, the fine fraction of which is less than 1 μηι thick. The size of the granules is greater than 1 μηι. The fluorine compound is added to a dispersion in a bimodal curve under shear conditions (prepared by dispersing the coarse fraction into the dispersion of the fine fraction), and then the fluorine-containing and bimodal curve is dispersed. The liquid is added to the mold and gelatinized in the mold to obtain a molded article. The disadvantage of this method is that the fluorine compound becomes an essential component of the dispersion to be molded. Furthermore, US 6,193,926 does not disclose the content of the dip in the dispersion of the bimodal curve -5-(2) ^ 1277613. Only the preferred dip content of the fine fraction dispersion is mentioned. Further, this document does not disclose how to obtain a fine particle dispersion and how to add the coarse particle portion to the fine particle dispersion. Also known by DE-A-1 9943 1 03 is a highly charged, bimodal curve

之分散液製造非晶二氧化矽模製物件。此分散液係由將粉 末狀細粒部份與粗粒部份於相同分散條件下倂入預先製好 的分散劑中。該細粒部份由顆粒尺寸1至1 00 nm的粒子 所組成。今發現無法以所述方法、於相同分散條件下、在 所述顆粒尺寸範圍內製得同樣可傾倒分散液。所以粉末的 顆粒尺寸似乎不爲可傾倒分散液的決定性因素。 【發明內容】 本發明目的在於提出適合製造陶瓷模製物件之高度塡 充金屬氧化物分散液。特別地,此分散液應於長時間保有 其可傾倒性且使陶瓷模製物件具有低收縮。 本發明提出一種水性分散液,包含具有細粒部份與粗 粒部份之金屬氧化物粉末,其中 ' 該金屬氧化物粉末爲二氧化矽,氧化鋁,二氧化 鈦,二氧化鉻,氧化鈽或二或多個前述金屬氧化 物之混合氧化物, - 該細粒部份呈聚集形式且於分散液中的平均聚集 直徑爲低於200 nm, - 該粗粒部份由平均直徑1至20 μηι的粒子所組成 -6- (3)1277613 細粒部份對粗粒部份的比例爲2 : 98至30 : 70 ,及 - 金屬氧化物粉末的含量爲50至85 wt·% ’以分 散液總量計。The dispersion is used to produce an amorphous ceria molded article. This dispersion was obtained by injecting a powdery fine particle portion and a coarse particle portion into a pre-formed dispersant under the same dispersion conditions. The fine fraction is composed of particles having a particle size of 1 to 100 nm. It has now been found that the same pourable dispersion cannot be made in the manner described, under the same dispersion conditions, within the particle size range. Therefore, the particle size of the powder does not appear to be a decisive factor in the pourable dispersion. SUMMARY OF THE INVENTION An object of the present invention is to provide a highly cerium-rich metal oxide dispersion suitable for the production of ceramic molded articles. In particular, the dispersion should retain its pourability over a long period of time and impart a low shrinkage to the ceramic molded article. The present invention provides an aqueous dispersion comprising a metal oxide powder having a fine particle portion and a coarse particle portion, wherein 'the metal oxide powder is ceria, alumina, titania, chromium dioxide, cerium oxide or two Or a mixed oxide of a plurality of the foregoing metal oxides, - the fine fraction is in an aggregate form and has an average aggregate diameter in the dispersion of less than 200 nm, - the coarse fraction is from an average diameter of 1 to 20 μm The composition of the particles consists of 6-(3)1277613 fine fraction to the coarse fraction of 2:98 to 30:70, and - the content of metal oxide powder is 50 to 85 wt.%. Meter.

「聚集」一詞於本文中指出現有燒結在一起的一級粒 子。本發明分散液的平均聚集直徑可由例如,動態光散射 測量來測出。根據本發明,此値小於200 nm,較好爲小 於 1 00 nm 〇 作爲粗粒部份之化合物晶體結構與聚集結構並無限制 。所以’本發明分散液的粗粒部份可由球狀、針狀或桿狀 晶體所組成,或可呈非晶形式。 該粗粒部份粒子平均直徑的上限可較好爲小於 10 μιη ,最好爲小於5 μιη。The term "aggregation" is used herein to refer to the primary particles that are sintered together. The average aggregate diameter of the dispersion of the present invention can be measured, for example, by dynamic light scattering measurement. According to the present invention, the ruthenium is less than 200 nm, preferably less than 100 nm. The crystal structure and aggregate structure of the compound as a coarse fraction are not limited. Therefore, the coarse fraction of the dispersion of the present invention may be composed of spherical, needle-like or rod-shaped crystals, or may be in an amorphous form. The upper limit of the average diameter of the coarse fraction particles may preferably be less than 10 μηη, preferably less than 5 μηη.

若該粗粒部份由氧化鋁所組成,較好該氧化鋁呈輕微 聚集形式。於此,輕微聚集指個別粒子聚結在一起,但是 大部分呈個別未聚集粒子。若該粗粒部份由富鋁紅柱石所 組成,則較好其呈針狀晶體形式。 根據本發明,該細粒部份與粗粒部份可由相同或不同 金屬氧化物成分所組成。所以,例如,可製成二成分均爲 氧化鋁之氧化鋁陶瓷。亦可,例如,該細粒部份由氧化銘 所組成而該粗粒部份由二氧化矽所組成。同樣亦可製成由 富銘紅柱石組成之燒結模製物件。若該細粒部份具有例如 ,矽-鋁混合氧化物結構而該粗粒部份爲氧化鋁及/或二 氧化矽或富鋁紅柱石粉末,亦可得到同樣的結果。 (4) 1277613 混合氧化物粉末指金屬氧化物成分充分混合至原子等 級所成之粉末。這些粉末的一級粒子具有Μ ( I ) -0-M ( II)鍵結,其中Μ(Ι)爲第一金屬成分而Μ(ΙΙ)爲第二 金屬成分。此外,不具有Μ(Ι) -Ο-M ( II )鍵結之金屬 氧化物區域亦可存在。If the coarse fraction is composed of alumina, it is preferred that the alumina be in a slightly aggregated form. Here, slight aggregation means that individual particles coalesce together, but most of them are individual unaggregated particles. If the coarse fraction is composed of mullite, it is preferably in the form of needle crystals. According to the present invention, the fine particle portion and the coarse particle portion may be composed of the same or different metal oxide components. Therefore, for example, an alumina ceramic in which both components are alumina can be produced. Alternatively, for example, the fine fraction is composed of oxidized crystal and the coarse fraction is composed of cerium oxide. It is also possible to produce a sintered molded article composed of Fuming andalusite. The same result can be obtained if the fine particle portion has, for example, a yttrium-aluminum mixed oxide structure and the coarse granule portion is alumina and/or cerium oxide or mullite powder. (4) 1277613 Mixed oxide powder refers to a powder in which the metal oxide component is sufficiently mixed to an atomic level. The primary particles of these powders have a ruthenium (I) -0-M (II) bond, wherein ruthenium (Ι) is the first metal component and ruthenium (ΙΙ) is the second metal component. Further, a metal oxide region having no ytterbium (Ι)-Ο-M (II) bond may exist.

該細粒部份與粗粒部份可包括呈多峰曲線分布之粒子 尺寸。較佳是以粒子尺寸呈雙峰曲線分布之分散液來製造 模製物件。所以應了解此時該細粒部份與粗粒部份於分散 液中具有單峰曲線分布。同時,亦包括粗粒部份與細粒部 份具有少部分較粗粒子的例子。 該細粒部份與粗粒部份的ΒΕΤ表面積並無限制。本 發明分散液細粒部份的BET表面積較好爲10至500 m2/g ,最好爲50至200 m2/g,該粗粒部份的BET表面積較好 爲 0.1 至 10 m2/g。 &amp; 較好本發明分散液細粒部份可由熱解製成的金屬氧化 #物粉末所組成。 熱解一詞指火焰水解或火焰氧化法。所以,金屬氧化 物前驅物於氣相在火焰(氫與氧反應所成)中轉化爲金屬 氧化物。高度分散,非多孔性一級粒子首先形成,其於反 應進一步進行後聚結成聚集物(aggregates),進一步再 合倂成附聚物(agglomerates )。這些粒子的表面可爲酸 性或鹼性中心。 若本發明分散液粗粒部份爲氧化鋁,α-氧化鋁含量若 至少爲95%證實爲有利的。 -8 - (5) 1277613 本發明分散液可再包含最多10 wt.%的pH-調節添加 劑’例如,酸、鹼或鹽及/或界面活性劑添加劑,例如, 聚丙烯酸酯。添加劑的選擇主要取決於分散液中金屬氧化 物的類型’且爲熟習此項技藝人士所公知。加入添加劑可 以安定本發明分散液免於沉降並降低黏度。另一方面,添 加劑可能對模製物件的製造不利。所以本發明分散液中的 添加劑較好保持於最少量。 本發明亦提出製造本發明分散液之方法,此方法包括 下述步驟: - 以輸入能量至少爲200 KJ/m3將粉碎的細粒部份 分散於水中(其選擇性地含有pH-調節劑及/或 界面活性劑添加劑)而製造細粒部份分散液,其 中該細粒部份於該細粒部份分散液的含量爲30 至 6 0 w t · % - 以較低輸入能量之分散條件將呈粉末形式之該粗 粒部份加入該細粒部份分散液,其用量佔細粒部 份與粗粒部份總量的5 0至8 5 w t. %。 適合用來製造該細粒部份分散液的分散設備包括例如 ,轉子·定子機,例如,由 Ultra Turrax ( IKA company) ,或Ystral company製造的,以及球磨機,攪拌球磨機, 行星捏揉機或高能硏磨機。 當使用高能硏磨機時,經由噴嘴將兩個預分散液流於 高壓射出(flashed )。二分散液流互相撞擊而使其粒子互 相硏磨。另一具體例中,預分散液同樣被施以高壓,經由The fine fraction and the coarse fraction may include particle sizes distributed in a multimodal curve. Preferably, the molded article is manufactured by a dispersion in which the particle size is bimodal. Therefore, it should be understood that the fine fraction and the coarse fraction have a single-peak curve distribution in the dispersion at this time. At the same time, it also includes examples in which the coarse fraction and the fine fraction have a small portion of coarser particles. There is no limitation on the surface area of the fine particles and the coarse particles. The fine particle fraction of the dispersion of the present invention preferably has a BET surface area of 10 to 500 m2/g, preferably 50 to 200 m2/g, and the coarse fraction has a BET surface area of preferably 0.1 to 10 m2/g. It is preferred that the fine particle portion of the dispersion of the present invention be composed of a metal oxide powder prepared by pyrolysis. The term pyrolysis refers to flame hydrolysis or flame oxidation. Therefore, the metal oxide precursor is converted into a metal oxide in the gas phase in a flame (hydrogen and oxygen reaction). The highly dispersed, non-porous primary particles are first formed, which are further agglomerated into aggregates after further reaction, and further recombined into agglomerates. The surface of these particles may be acidic or basic. If the coarse fraction of the dispersion of the present invention is alumina, it is confirmed to be advantageous if the α-alumina content is at least 95%. -8 - (5) 1277613 The dispersion of the present invention may further comprise up to 10 wt.% of a pH-adjusting additive', for example, an acid, a base or a salt and/or a surfactant additive, for example, a polyacrylate. The choice of additives will depend primarily on the type of metal oxide in the dispersion&apos; and is well known to those skilled in the art. The addition of an additive stabilizes the dispersion of the present invention from settling and reduces viscosity. On the other hand, additives may be detrimental to the manufacture of molded articles. Therefore, the additive in the dispersion of the present invention is preferably kept at a minimum. The invention also proposes a process for producing the dispersion of the invention, the process comprising the steps of: - dispersing the pulverized fine fraction in water at an input energy of at least 200 KJ/m3 (which optionally contains a pH-adjusting agent and / or a surfactant additive) to produce a fine fraction dispersion, wherein the fine fraction is present in the fine fraction dispersion of 30 to 60 wt % - at a lower input energy dispersion condition The coarse fraction in the form of a powder is added to the fine fraction dispersion in an amount of from 50 to 85 w t. % of the total of the fine fraction and the coarse fraction. Dispersing equipment suitable for use in the production of the fine particle partial dispersion includes, for example, a rotor/stator machine, for example, manufactured by Ultra Turrax (IKA company), or Ystral company, and a ball mill, agitating ball mill, a planetary kneader or a high energy crucible. Mill. When a high energy honing machine is used, the two predispersions are flashed through a nozzle at a high pressure. The two dispersion streams collide with each other to cause the particles to honed each other. In another embodiment, the predispersion is also subjected to a high pressure, via

Claims (1)

1277613 (1) 十、申請專利範圍 鑑、::、 附件2A:第94 1 25 1 64號專利申請案 中文申請專利範圍替換本 民國95年9月29日修正 1 · 一種水性分散液,包含具有細粒部份與粗粒部份之 金屬氧化物粉末,其特徵爲 該金屬氧化物粉末爲二氧化矽,氧化鋁,二氧化 鈦,二氧化鉻,氧化鈽或二或多個前述金屬氧化 物之混合氧化物, - 該細粒部份呈聚集形式且於分散液中的平均聚集 直徑爲低於2 0 0 n m, - 該粗粒部份由平均直徑1至20 μηι的粒子所組成 • 細粒部份對粗粒部份的比例爲2 : 98至3 0 : 70 ,及 - 金屬氧化物粉末的含量爲50至85 wt.%,以分 散液總量計。 2·如申請專利範圍第1之水性分散液,其呈雙峰曲線 的· 3 ·如申請專利範圍第1或2項之水性分散液,其中該 細粒部份的BET表面積爲10至5 0 0 m2/g,該粗粒部份的 BET表面積爲0.1至1〇 m2/g。 4·如申請專利範圍第1或2項之水性分散液,其中該 細粒部份由熱解製成的金屬氧化物粉末所組成。 (2) Ϊ277613 5 ·如申請專利範圍第1或2項之水性分散液,其中該 粗粒部份的α -氧化鋁含量至少爲9 5 %。 6 ·如申請專利範圍第1或2項之水性分散液,其中該 分散液含至多10 wt·% ΡΗ·調節添加劑及/或界面活性劑 添加劑。 7 · —種製造如申請專利範圍第1或2項之水性分散液 之方法,包括下述步驟: • 以輸入能量至少爲200 KJ/m3將粉碎的細粒部份 分散於水中(其選擇性地含有pH-調節劑及/或 界面活性劑添加劑)而製造細粒部份分散液,其 中該細粒部份於該細粒部份分散液的含量爲30 至 6 0 w t · % - 以較低輸入能量之分散條件將呈粉末形式之該粗 粒部份加入該細粒部份分散液,其用量佔細粒部 份與粗粒部份總量的50至85 wt. %。 8 · —種製造模製物件的方法,該模製物件大致具有其 最終輪廓,此方法藉由 a ) 將如申請專利範圍第1或2項之水性分散液移至 模子內,視需要改變PH値’ b) 乾燥該模製物件, c ) 待該分散液固化後自模子移出該模製物件’ 其中該步驟b )與c )可交換順序執行。1277613 (1) X. Patent application scope, ::: Annex 2A: Patent application No. 94 1 25 1 64 Chinese patent application scope is replaced by the amendment of the Republic of China on September 29, 1995. 1 · An aqueous dispersion containing a metal oxide powder of a fine-grained portion and a coarse-grained portion, characterized in that the metal oxide powder is a mixture of cerium oxide, aluminum oxide, titanium oxide, chromium dioxide, cerium oxide or two or more of the foregoing metal oxides. Oxide, - the fine fraction is in agglomerated form and has an average aggregate diameter of less than 200 nm in the dispersion, - the coarse fraction consists of particles having an average diameter of 1 to 20 μηι • Fine fraction The ratio of the fraction to the coarse fraction is 2: 98 to 30: 70, and the content of the metal oxide powder is 50 to 85 wt.%, based on the total amount of the dispersion. 2. The aqueous dispersion of claim 1 which is in the form of a bimodal curve. The aqueous dispersion according to claim 1 or 2, wherein the fine fraction has a BET surface area of 10 to 50. 0 m2 / g, the coarse fraction has a BET surface area of 0.1 to 1 〇 m 2 / g. 4. The aqueous dispersion according to claim 1 or 2, wherein the fine fraction is composed of a metal oxide powder prepared by pyrolysis. (2) Ϊ277613 5 The aqueous dispersion according to claim 1 or 2, wherein the coarse fraction has an α-alumina content of at least 95%. An aqueous dispersion according to claim 1 or 2, wherein the dispersion contains up to 10 wt.% of a conditioning additive and/or a surfactant additive. 7. A method of producing an aqueous dispersion according to claim 1 or 2, comprising the steps of: • dispersing the pulverized fine fraction in water at an input energy of at least 200 KJ/m3 (selectivity thereof) a fine particle partial dispersion is prepared by containing a pH-adjusting agent and/or a surfactant additive, wherein the fine particle portion is contained in the fine particle portion dispersion in an amount of 30 to 60 wt. % - The low input energy dispersion condition is to add the coarse fraction in the form of a powder to the fine fraction dispersion in an amount of 50 to 85 wt.% based on the total amount of the fine fraction and the coarse fraction. 8 - A method of manufacturing a molded article, the molded article having substantially its final profile, by a) moving the aqueous dispersion as disclosed in claim 1 or 2 to a mold, and changing the pH as needed値' b) drying the molded article, c) removing the molded article from the mold after the dispersion is solidified, wherein the steps b) and c) are performed in an exchangeable sequence.
TW94125164A 2004-07-28 2005-07-25 Highly-filled, aqueous metal oxide dispersion TWI277613B (en)

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