CN100500614C - 高度填充的金属氧化物的水分散体 - Google Patents

高度填充的金属氧化物的水分散体 Download PDF

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CN100500614C
CN100500614C CNB2005800249494A CN200580024949A CN100500614C CN 100500614 C CN100500614 C CN 100500614C CN B2005800249494 A CNB2005800249494 A CN B2005800249494A CN 200580024949 A CN200580024949 A CN 200580024949A CN 100500614 C CN100500614 C CN 100500614C
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metal oxide
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莫妮卡·奥斯瓦尔德
科琳娜·基斯纳
罗纳德·魏斯
安德鲁·J·劳尔
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Abstract

本发明提供含有金属氧化物粉末的水分散体，所述金属氧化物粉末具有精细部分和粗糙部分，其中：所述金属氧化物粉末是二氧化硅、氧化铝、二氧化钛、二氧化锆、二氧化铈或上述金属氧化物的两种或多种的混合氧化物;所述精细部分以聚集体的形式存在，并在所述分散体中具有低于200nm的平均聚集体直径;所述粗糙部分由平均直径为1-20μm的颗粒组成;所述精细部分与所述粗糙部分的比例为2∶98至30∶70，和相对于所述分散体的总量，所述金属氧化物粉末的含量为50-85重量%。通过包括如下步骤的方法制备所述水分散体：通过利用至少200kJ/m3的能量输入，在水中分散粉状的精细部分制得精细部分的分散体，和在低能量输入的分散条件下将以粉末形式的粗糙部分引入至所述精细部分的分散体中。本发明还涉及使用所述分散体制备模塑制品的方法。

Description

高度填充的金属氧化物的水分散体
技术领域
本发明涉及高度填充的金属氧化物的水分散体及其制备方法。本发明还涉及利用所述分散体制备陶瓷模塑制品的方法，以及所述的陶瓷模塑制品。
背景技术
长期已知的是由分散体或根据溶胶-凝胶方法制备陶瓷模塑制品。溶胶-凝胶方法的不足在于仅能获得低的“未成熟的”(green)密度。因此，在干燥和烧结时出现高的收缩速率。而这些过程步骤必须非常缓慢地进行，通常需要数天和数周，以避免形成裂缝。如果由含有细分散的金属氧化物颗粒的分散体获得模塑制品，所述不足则可以减少。尽管比在溶胶-凝胶方法中更高的填充含量降低了收缩速率，然而所述分散体的填充含量被限为最多约60重量％。
为了能够获得更高的填充含量，US 6193926中提出了具有低于1μm尺寸的精细部分和大于1μm尺寸的粗糙部分的二氧化硅、氧化铝、碳化硅或氮化硅在水中的双峰分散体。通过在剪切条件下向所述双峰分散体中加入氟化合物可以获得模塑制品，所述双峰分散体通过在精细部分的分散体中加入粗糙部分而获得，将含有氟化物的双峰分散体加入至模具中并在其中凝胶。
所述方法的不足在于为了获得模塑制品，氟化合物必须是所述分散体的必要组分。而且US 6193926并未公开所述双峰分散体具有的填充含量。仅简单地给出了具有精细部分的分散体的优选填充含量。另外，所述文献并未公开如何获得精细颗粒的分散体，以及如何将粗糙部分加入至精细颗粒的分散体。
还已知DE-A-19943103公开了从高度填充的双峰分散体制备无定形的二氧化硅模塑制品。通过在相同的分散条件下向预先制备的分散剂中加入以粉末形式的精细部分和粗糙部分制得所述分散体。其中，精细部分由颗粒尺寸为1-100nm的颗粒组成。现已发现用所述方法在相同的分散条件下不能获得在特定的颗粒尺寸范围内的相当的易于浇注的分散体。因此，所述的粉末颗粒尺寸对于可浇注的分散体不是决定性因素。
发明内容
本发明的目的是提供高度填充的金属氧化物分散体，其适于制备陶瓷模塑制品。特别地，所述分散体在相当长的时间内应保留其可浇注性和提供仅显示轻微收缩的陶瓷模塑制品。
本发明提供含有金属氧化物粉末的水分散体，所述金属氧化物粉末具有精细部分和粗糙部分，其中：
-所述金属氧化物粉末是二氧化硅、氧化铝、二氧化钛、二氧化锆、二氧化铈或上述金属氧化物的两种或多种的混合氧化物，
-所述精细部分以聚集体的形式存在，并在所述分散体中具有低于200nm的平均聚集体直径，
-所述粗糙部分由平均直径为1-20μm的颗粒组成，
-所述精细部分与所述粗糙部分的比例为2:98至30:70，和
-相对于所述分散体的总量，所述金属氧化物粉末的含量为50-85重量％。
术语“聚集的”在本文中理解为存在被烧结在一起的初级粒子。在根据本发明的分散体中的平均聚集体直径例如可以通过动态光散射测量确定。根据本发明，其低于200nm，优选低于100nm。
对作为粗糙部分使用的化合物的晶体结构和聚集体结构没有限制。因此，根据本发明的分散体的粗糙部分可以包括球形、针形或棒状晶体、或者也可以以无定形的形式存在。
粗糙部分颗粒的平均直径的上限优选低于10μm，特别优选低于5μm。
在粗糙部分由氧化铝构成的情形中，如果所述氧化铝仅以轻微聚集的形式存在，则是有利的。术语“轻微聚集的”在本文中是指单个的颗粒聚结在一起，而整个部分是以单个的、未聚集的颗粒的形式存在。如果粗糙部分包括多铝红柱石，则如果其以针状晶体的形式存在则是有利的。
根据本发明，精细部分和粗糙部分可以包括相同的或不同的金属氧化物组分。因此，例如可以制备其中两种组分都是氧化铝的氧化铝陶瓷。例如也可以是所述精细部分由氧化铝构成而所述粗糙部分由二氧化硅构成。以这种方式，可以获得具有多铝红柱石组分的烧结的模塑制品。如果所述精细部分例如具有硅-铝混合的氧化物结构和所述粗糙部分是氧化铝和/或二氧化硅或多铝红柱石粉末，也可以获得相同的结果。
“混合氧化物粉末”被理解为其中金属氧化物组分以原子水平紧密混合的粉末。这些粉末的初级粒子具有M(I)-O-M(II)键，其中，M(I)代表第一金属组分，和M(II)代表第二金属组分。另外，也可以存在不具有M(I)-O-M(II)键的金属氧化物区域。
精细部分和粗糙部分可以各自包括颗粒尺寸的多峰分布。具有颗粒尺寸双峰分布的分散体对于制备模塑制品是优选的。由此可以理解精细部分和粗糙部分各自在分散体中具有单峰分布。同时，也包括其中粗糙部分和精细部分具有较小比例的较粗糙颗粒的情形。
对精细部分和粗糙部分的BET表面积没有限制。根据本发明的分散体的精细部分的BET表面积优选可以是10-500m2/g，特别优选50-200m2/g，而粗糙部分的BET表面积优选是0.1-10m2/g。
优选地，根据本发明的分散体的精细部分可以由热解法制备的金属氧化物粉末构成。
术语“热解的”被理解为火焰水解的或火焰氧化的过程。在此金属氧化物前体在气相中被转化为在由氢气和氧气之间的反应制得的火焰中的金属氧化物。首先形成高度分散的无孔的初级粒子，其在进一步的反应期间聚结以形成聚集体，并且这些聚集体可以结合在一起形成附聚物。这些颗粒的表面积可以具有酸性的或碱性的中心。
在根据本发明的分散体的粗糙部分是氧化铝的情形中，如果α-氧化铝的含量至少是95％，已被证明是有利的。
根据本发明的分散体还可以含有不高于10重量％的pH调节添加剂，如酸、碱或盐，和/或表面活性添加剂，如聚丙烯酸酯。所述添加剂的选择主要取决于分散体中的金属氧化物的类型，并为本领域技术人员所已知。加入添加剂可以稳定根据本发明的分散体不沉淀以及降低粘度。另一方面，存在添加剂对于制备模塑制品是不利的。因此，根据本发明的分散体中的添加剂的存在应保持在最小量。
本发明还提供根据本发明的分散体的制备方法，其包括如下步骤：
-通过利用至少200kJ/m3的能量输入，在水中分散粉状的精细部分制得精细部分的分散体，其任选地含有pH调节剂和/或表面活性添加剂，其中所述精细部分的分散体中的精细部分的含量是30-60重量％，
-在低能量输入的分散条件下，将以粉末形式的粗糙部分加入至所述精细部分的分散体中，其含量使得精细部分和粗糙部分的总含量为50-85重量％。
用于制备精细部分的分散体的合适的分散设备包括例如转子/定子机，如Ultra Turrax(IKA company)，或者来自Ystral company的设备，以及球磨机、搅动球磨机、行星式捏合机(planetary kneaders)或高能研磨机。
当使用高能研磨机时，在高压下将两股预分散的液流通过喷嘴射出。两股分散体液流相互冲击，由此互相研磨颗粒。在另一实施方式中，预分散体同样经受高能，而颗粒的碰撞在具有铠装的壁区域进行。为了获得较小的颗粒尺寸，所述操作可以根据需要尽可能多地重复。
必要的是，引入粗糙部分在比制备精细部分的分散体大大降低的能量输入下进行。为此目的，溶解器或带齿齿轮板(toothed gear plate)例如是合适的。
如果引入粗糙部分颗粒和在与制备精细部分的分散体相同的条件下进行，粘度会快速上升，同时会形成凝胶。
同样，在低能量输入下向粗糙部分的分散体中引入精细部分的粉末不会获得根据本发明的分散体。在此情形下，获得易于凝胶的高粘性的分散体。
本发明还提供具有粗略的最终形状的模塑制品的制备方法，其中：
a)将根据权利要求1-6所述的水分散体转移至模具，任选地改变pH值，
b)干燥所述模塑制品，
c)固化所述分散体后，从所述模具移出模塑制品，其中步骤b)和c)可以互换。
在将分散体转移至模具之前，也可以向根据本发明的分散体中加入酸或碱。对于酸，可以优选使用HCl、HF、H3PO4和/或H2SO4，对于碱，例如优选使用NH3、NaOH、四甲基氢氧化铵和/或KOH。
根据本发明的分散体向模具的转移可以优选地通过浇注进行。本领域技术人员已知的所有模具基本上都适合用作模具。合适的材料基本上是传统上用于陶瓷中的所有材料。在本文中，所述材料优选显示对于分散体低的粘合，例如为塑料、聚硅氧烷、玻璃、二氧化硅玻璃或石墨。
特别优选的是聚乙烯(PE)、聚丙烯(PP)、聚四氟乙烯(PTFE)、聚酰胺、聚硅氧烷橡胶和石墨。另外，也可以使用涂布的材料例如涂布有PTFE的金属。所述模具也可以由片或空心片(sheet bubble)构成。可以使用任何类型的片。优选的例如是材料PE、PP、PET、PTFE、纤维素、纤维素水合物、羊毛纤维加强的纤维素或聚酰胺的片。
本发明还提供通过所述方法可获得的具有粗略的最终形状的模塑制品。在固化所述分散体时发生1-10％的收缩，以形成尺寸稳定的模塑制品。
实施例
实施例1(根据本发明)
精细部分的分散体：将36kg完全去离子的水置于60升容积的不锈钢间歇容器中。吸入16.5kg氧化铝，型号C(DEGUSSA AG)，利用分散体和来自Ystral company的吸入混合器(在4500rpm下操作)进行粗略地预分散。在吸入过程期间，调节pH为4.5并通过加入50％的乙酸维持。加入粉末后，用转子/定子流入均质器(型号Z 66，来自Ystral company，其具有四个处理环，定子缝宽度为1mm和转速为11,500rpm)完成分散步骤。在11,500rpm下进行15-分钟分散后，调节pH值，并通过再加入50％的乙酸维持在pH值为4.5。总共需要570g的50％的乙酸，通过加入1.43kg的水调节固体浓度为30重量％。
分散体中氧化铝颗粒的平均聚集体尺寸(中值)是87nm。
根据本发明的分散体：将1200g平均粒径为1.68μm和α-氧化铝含量>95％的氧化铝粉末(
Figure C200580024949D00091
 625-31 Nabeltec company)用分散设备(具有带齿齿轮板，在1300rpm下操作，来自
Figure C200580024949D00092
 company)缓慢地加入到500g精细部分的分散体中。
获得的分散体具有氧化铝含量为79.4重量％和pH值为5。其可浇注并且在一个月内对于沉淀是稳定的而且不凝胶。
实施例2(根据本发明)
精细部分的分散体：首先，以与实施例1类似的方法制备分散体，只是使用具有BET表面积为约65m2/g的热解法制备的氧化铝粉末。选择氧化铝粉末的用量以使在分散体中的氧化铝含量是55重量％。用高压均质器(来自Sugino Machine Ltd.的Ultimaizer System，型号为HJP-25050)在压力250MPa下对该分散体进行研磨。
分散体中氧化铝颗粒的平均聚集体尺寸(中值)是83nm。
为了进一步的操作，用水将分散体调节至氧化铝含量为40重量％。
根据本发明的分散体：将930g平均粒径为1.68μm和α-氧化铝含量>95％的氧化铝粉末(
Figure C200580024949D00101
 625-31，Nabeltec company)用分散设备(具有带齿齿轮板，在1300rpm下操作，来自
Figure C200580024949D00102
 company)缓慢地加入到500g精细部分的分散体中。
获得的分散体具有氧化铝含量为79重量％和pH值为5。其可浇注并且在一个月内对于沉淀是稳定的而且不凝胶。
实施例3(对比例)
使用分散设备(具有带齿齿轮板，在1300rpm下操作，来自
Figure C200580024949D00103
 company)将50g作为精细部分的表面积为65m2/g的热解法氧化铝粉末和950g氧化铝粉末(
Figure C200580024949D00104
 625-31)在再加入9.4g的TMAH下加入至231.88g的完全去离子水和2g的25％的四甲基氢氧化铵(TMAH)的溶液中。在数分钟内分散体增稠。
实施例4(对比例)
使用转子/定子系统，在8000rpm的转速下，尝试将140g具有BET表面积为65m2/g的热解法制备的氧化铝粉末和950g氧化铝粉末(
Figure C200580024949D00111
 625-31)加入到200g的水中。甚至在加入氧化铝结束之前，已经形成凝胶状块。
将根据本发明实施例1和2的分散体浇注至模具中，在室温下干燥，在1300℃下烧结。获得的模塑制品没有裂缝。

Claims (8)

1.包含金属氧化物粉末的水分散体，所述金属氧化物粉末具有精细部分和粗糙部分，特征在于：
-所述金属氧化物粉末是二氧化硅、氧化铝、二氧化钛、二氧化锆、二氧化铈或上述金属氧化物的两种或多种的混合氧化物，
-所述精细部分是以聚集体的形式存在的热解法制备的金属氧化物粉末，并在所述分散体中具有低于100nm的平均聚集体直径，其BET表面积是10-500m2/g，
-所述粗糙部分由平均直径为1-20μm的颗粒组成，
-所述精细部分与所述粗糙部分的比例为2:98至30:70，和
-相对于所述分散体的总量，所述金属氧化物粉末的含量为50-85重量％。
2.如权利要求1所述的水分散体，其特征在于所述水分散体中的金属氧化物粉末的颗粒尺寸分布是双峰的。
3.如权利要求1或2所述的水分散体，其特征在于所述粗糙部分的BET表面积是0.1-10m2/g。
4.如权利要求1或2所述的水分散体，其特征在于所述粗糙部分是氧化铝，并且其中α-氧化铝的含量至少是95％。
5.如权利要求1或2所述的水分散体，其特征在于所述分散体含有不高于10重量％的pH调节添加剂和/或表面活性添加剂。
6.如权利要求1-5所述的水分散体的制备方法，包括如下步骤：
-通过利用至少200kJ/m3的能量输入，在水中分散粉状的精细部分制得精细部分的分散体，其任选地含有pH调节剂和/或表面活性添加剂，其中在所述精细部分的分散体中的精细部分的含量是30-60重量％，
-在低能量输入的分散条件下将以粉末形式的粗糙部分加入至所述精细部分的分散体中，其含量使得精细部分和粗糙部分的总含量为50-85重量％。
7.具有粗略的最终形状的模塑制品的制备方法，其中：
a)将根据权利要求1-5所述的水分散体转移至模具，任选地改变pH值，
b)干燥所述模塑制品，
c)固化所述分散体后，从所述模具移出模塑制品，其中步骤b)和c)可以互换。
8.根据权利要求7的制备方法获得的具有粗略的最终形状的模塑制品。
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