CN101636364A - 制造多部件结构的方法以及这种结构 - Google Patents

制造多部件结构的方法以及这种结构 Download PDF

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CN101636364A
CN101636364A CN200780048508A CN200780048508A CN101636364A CN 101636364 A CN101636364 A CN 101636364A CN 200780048508 A CN200780048508 A CN 200780048508A CN 200780048508 A CN200780048508 A CN 200780048508A CN 101636364 A CN101636364 A CN 101636364A
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parts
profiled member
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sintering
under
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CN101636364B (zh
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E·霍克
S·费彻尔
L·沃尔克尔
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Dentsply Sirona Inc
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Abstract

本发明涉及一种由烧结的氧化物陶瓷材料制造多部件结构的方法，该多部件结构包括第一部件，它至少局部地包围第二部件。该方法的改进构造保证：为进行连接，不需要将单个部件构造成多部件式的。为此提出：由氧化物陶瓷坯件制成第一成型件和第二成型件，其中第一成型件和第二成型件相对于所述第一部件和第二部件放大了一个补偿了烧结收缩的放大系数，将被另一个成型件至少部分地包围的那个成型件烧结，将已烧结的成型件与另一成型件组装并接着一起烧结。

Description

制造多部件结构的方法以及这种结构
本发明涉及一种由烧结的氧化物陶瓷材料，如部分稳定的氧化锆制造多部件结构的方法，该多部件结构包括第一部件，它至少局部地包包围第二部件，使用以下方法步骤：
-由氧化物陶瓷坯件制成第一成型件和第二成型件，其中第一成型件和第二成型件相对于所述第一部件和第二部件放大了一个补偿了烧结收缩的放大系数，
-将被另一个成型件至少部分地包围的那个成型件烧结，
-将已烧结的成型件作为所述第二部件与所述第一成型件组装并接着一起烧结。
陶瓷材料，尤其是氧化锆，由于良好的耐高温性作为工程陶瓷尤其是因为磨损小而广泛使用于机械制造中。由于生物相容性和化学惰性，在牙科领域里陶瓷材料也作为用于借助CAD/CAM方法来制造假冠桥结构的基础，在牙根固定时制成无金属的牙齿植入体。相应部件的制造原则上这样进行：首先制成坯件，它例如通过铣削而加工成，其中首先制成加大的形状，它相比于最终形状放大了一定量，以补偿烧结收缩。这样简化了加工，从而可以制成高精度的小构件。
在牙科方面的使用实例可见WO-A-99/47065或WO-A-96/29951。
按照相应的方法也用来制造工程部件，例如喷嘴、阀门、泵零部件、导纱器、用于焊接技术的定位销钉或者螺纹。
在多部件式结构中，要包容另一个构件的那个构件由多个部件组成，因为否则的话就不能进行连接了。
上述种类的方法可以见DE-A-3122345。其中第一部件有孔，第二部件定心地装入该孔里。因为第二部件已经进行了烧结，而且外部部件，也就是第一部件在烧结过程中经受全部的收缩，因此在烧结过程中在部件之间的接触位置上形成压配合，并使接触面完全地烧结起来。相互之间就不再有活动性了。
按照GB-A-2210363，为了在两个部件之间实现压配合，将更致密的由陶瓷制成的内部件体的一部分插入到由陶瓷制成的外部多孔的部件体里，以便随后使所述部件体一起烧结起来。
本发明的任务是提出一种开头所述种类的方法以及多部件结构，这种结构由透烧的氧化物陶瓷材料制成，而不必为能进行连接而将单个部件构造成多部件式的。
按照本发明如下来解决此任务：分别使用一体的成型件作为所述第一成型件和作为所述第二成型件；将所述第二成型件透烧以制成所述第二部件；并且将所述第一成型件布置在第二部件的一个部位里，在此部位里，在将第一成型件和第二部件一起烧结之后，通过透烧而制成的第一部件被第二部件如此包包围，使得在不破坏第一和/或第二部件的情况下阻止第一部件与第二部件松脱。
尤其是规定了：所述第一成型件设有开口，该开口的有效横截面在透烧之后或者小于第二成型件在透烧后在第一部件之内延伸的区域的有效横截面，或者小于第二部件在所述开口之前和之后的有效横截面。
根据按照本发明的教导，可以将多个结构部件连接起来，而这些结构部件按其最终几何形状不分开的话就不可能组装起来。例如可以列举一种穿过壳体开口的带有活塞的活塞杆，活塞的横截面大于开口的横截面。如果使活塞首先烧结成，并且壳体作为生坯件或者预烧结坯件，那么开口远大于在最终状态下的情况，从而使透烧的活塞杆可以用其活塞穿过开口。接着进行透烧，壳体就收缩一定的量，从而保证壳体和带活塞的活塞杆形成规定的精确配合的几何形状匹配。当再次对活塞热处理时，活塞的形状不再改变。
按照本发明可以制成多部件式的结构，其单个部件能相互保持准确规定的几何取向和配对关系。由陶瓷坯件以这样的尺寸制成一体的单个部件，该尺寸在各个方向上都放大了烧结收缩系数，以便对此进行补偿。然后至少将要由另一个部件包容的成型件透烧。接着使透烧的部件与另一个尚未透烧的部件连接起来，并紧接着将这两个部件透烧。因此形成了具有规定的部件取向和配对关系的整个结构，从而可以按所希望的程度实现旋转轴承、推力轴承、压配合或者类似的结构，而单个部件不必构造成多部件式的。在透烧状态下，也就是在最终状态下，可以在第一和第二部件之间实现高配合精度，在一定情况下具有所希望的间隙。
作为坯件可以使用由压制的氧化物陶瓷粉末制成的生坯件或者由压制的氧化物陶瓷粉末制成的预烧结坯件。两种原始材料可以使处理更简单，其中由于相对最终件放大的形状，可以实现加工并达到高精度的最终几何形状。
作为氧化物陶瓷粉末使用以下金属氧化物粉末中的至少一种：Al2O3、TiO2、Y2O3、BaTiO3、氧化锆、氧化锆混合晶体。尤其是使用一种氧化锆粉末，它由TOSOH公司提供，名称为3Y-TZP。
尤其是使用具有以下成分的氧化锆粉末：
90-98％重量百分比  氧化锆
0-4％重量百分比    氧化铪
1-7％重量百分比    氧化钇
0-1％重量百分比    下列元素的氧化物之一：铝、镓、锗、铟、
                   锌、铅、镧
0-2％重量百分比    氧化染色添加物。
相应的染色添加物可以是Er2O3、Pr6O11或Fe2O3。
氧化物陶瓷粉末本身首先尤其是等压地在压力150MPa≤P≤350MPa下，优选在大约200MPa的情况下被压制，以便必要时在热处理之后进行预烧结。优选的温度在600℃和1200℃之间，其中持续时间可以选0.5小时到6小时。如果在大约850℃的条件下进行2小时的预烧结的话，那么可以得到特别好的结果。
当然同样也可以进行轴向压制。
透烧本身应该在1300℃至1650℃之间的温度范围里，时间为1小时至3小时，其中优选的数值范围为1500℃和2小时。
与此无关地，透烧应在这样程度里进行，使得坯件致密烧结至理论密度的90％至100％，尤其是96％至100％。
不仅在预烧结时，然而尤其是在透烧时，部件的加热都只通过对流来进行，而不是通过热辐射来加热。因此确保了：透烧的部件具有非常高的尺寸精度。测量表明：可以制成精度在1μm和2μm范围内的部件，从而保证了部件相互之间的高精度的确定的配合。
在制造部件本身时可以组合切削和铣削加工，因此具有制造技术方面的优点，而且节省成本。
本发明也提出一种按前面所述方法制成的结构元件，其具有以下特征：第一部件是具有开口的壳体，该开口被作为第二部件的、带有活塞的活塞杆穿过，其中所述开口的有效横截面小于布置在壳体里的活塞的横截面。
此外本发明还通过一种按前面所述方法制成的结构元件，其具有以下特征：优选为曲拐轴是所述第二部件，而且该轴的一个部段被作为第一部件的孔板包围，其中所述部段相对轴线有偏移，或者所述轴具有这样的部段，该部段的有效尺寸在透烧状态下大于孔板的由轴所穿过的穿口。
本发明的特征也在于一种结构元件，所述结构是牙齿植入体，该牙齿植入体具有支承着牙科技术的构造体的植入体元件作为所述第二部件，并具有被作为所述第一部件的螺栓穿过的通孔，其中螺栓的加宽端部的横截面分别大于所述通孔的有效横截面。
本发明的其它细节、优点和特征不仅可见于权利要求书、由权利要求书可见的特征(本身特征和/或组合特征)，而且也可见于以下对于按附图所示优选的实施例所作的说明。
附图所示为：
图1：未烧结状态下泵的壳体和柱塞；
图2：未烧结状态下的壳体和已烧结状态下的柱塞；
图3：在透烧状态下的壳体和在该壳体里可移动的柱塞；
图4：在未烧结状态下的活节壳连同活节；
图5：在未烧结状态下的按图4所示的活节壳和已烧结状态下的活节；
图6：按图4和5所示的已烧结状态下的活节壳和活节；
图7：未烧结状态下的植入体和螺栓；
图8：未烧结状态下的按图7所示的植入体和烧结状态下的螺栓；
图9：按图7和8所示的烧结状态下的植入体和螺栓；
图10：未烧结状态下的轴连同环；
图11：烧结状态下的按图10所示的轴；
图12：按图10和11所示的烧结状态下的轴和环。
按照附图所示纯粹从原理上说明了用于制造多部件结构的按照本发明的方法，其中在相互啮合作用的部件之间保证了高的配合精度和所希望的密封。
在图1-3中，按照原理图所示的由壳体10和柱塞12组成的泵对按照本发明的方法进行了说明。
图3表示了柱塞12和壳体10的最终配合，其中柱塞12穿过壳体10的开口14并用其头部16可以在壳体10之内来回运动。头部16的外径大于开口的内径。
为了按照现有技术制造一种相应的结构，壳体必须构造成分体的，以便可以使柱塞通过其头部定位于壳体的内腔里。按照本发明壳体10然而可以构造成一体的，因为人们利用了陶瓷材料在烧结时收缩很大的特性。
无论是柱塞12还是壳体16都由氧化物陶瓷材料制成，尤其是由氧化锆组成，正如该材料由TOSOH公司以名称TZ-3YB或TZ-3YB-E所提供的那样。将相应的氧化锆粉末材料压制，其中尤其是以压力为200MPa进行等压压制。然后对这样制成的生坯件进行加工。这可以通过车削、铣削或者它们的组合来进行。这些部件制成这样的几何形状，这种几何形状相对于透烧的柱塞12或壳体10放大了一个放大系数，该放大系数补偿了烧结收缩。对应于这些部件的最终构件10、12或者部段14、16的坯件部分(成型件)在图1中用标号110、112、114、116标出。
由图1可见：构件110、112并不能相互插入，因为柱塞头部116大于开口114的净直径。
如果构件110、112由坯件车削或铣削出，那么也可以使用预烧结的加工的物体作为坯件。
与此无关地在随后的工序中对于由生坯件或者预烧结坯件构成的带有柱塞头部116的柱塞112进行烧结。此工序优选在温度为1500℃的范围进行，时间持续2小时。此前进行了预烧结，它在温度大致为800℃的条件下进行，同样也是2小时。
在热处理时，也就是在透烧或预烧结时，应该注意：坯件只是通过对流而不是通过直接辐射来加热。
取决于收缩情况，柱塞112的尺寸这样发生变化，以至于头部16可以穿过壳体110的开口114，如由图2所示那样。然后对应于前面所述的方法重新进行透烧，结果使壳体110收缩，以便这样实现与柱塞12和柱塞头部16的所希望的几何形状的匹配。柱塞112不再改变形状。
按照本发明将多部件结构的部件部分地相互独立无关地进行烧结，以便使各种不同的烧结状态连接起来，因而可以实现多个部件的配合。
因为单个部件可以高精度地制成，因此多部件结构就其最终几何形状来说同样也是高精度的，因此就确保了一种确定的几何形状配对。
按照本发明的方法也按照由图4至8所说明的例子来详细加以说明，其中单个元件的制造可以对应于以前所作的说明来进行。
在图4至6中将带有活节头部20的活节26精确配合地装入在活节壳22的容纳座24里，其中活节26和活节壳22都由氧化物陶瓷材料制成。在图4中，这些元件表示为生坯件并用标号120、122、124、126标识。在此状态下活节头部126并不匹配于活节壳122的容纳座124。反而是部件120、122的几何形状相比于透烧的活节20或活节壳22来说放大了一个放大系数，该放大系数补偿了烧结收缩。然后使活节120烧结，从而使其头部20可以装入到活节壳122的开口124里。接着使活节壳122连同插入在开口124里的透烧的活节头20进行烧结，从而可以按图6实现活节20和活节壳的所希望的精确配合的连接。
按照本发明的教导也可以在植入体30和螺栓32之间实现高配合精度，螺栓用其杆部36穿过通孔34，杆部的端部有头部38、40，其直径大于通孔34的直径。为了能够实现植入体30和螺栓32的对应配合，根据本发明的教导首先制造植入体130和螺栓132的生坯件，它们表示于原理图7中。然后使螺栓132烧结。孔134和头部138、140的尺寸于是相符，从而在由于烧结而引起的收缩之后，头部38、40的直径小于作为生坯件的植入体130里的通孔134，如图8所示那样。当透烧的螺栓32插入到未透烧的植入体130的通孔134里之后，即头部38、40侧面突出于植入体130，就进行透烧，以得到对应于图9所示的由螺栓32穿过的植入体30，植入体30精确配合地必要时具有所希望的间隙地接纳螺栓32。
按图10至12，纯粹原理性地表示了另一种结构，其元件由透烧的氧化物陶瓷材料制成，其中按如下方法进行连接：第一部件进行透烧，而第二部件不烧结或者预烧结，以便随后使两个部件一起烧结。图10表示了轴41的一个部段，该轴41具有凹槽42。就此而言也可以称作为曲拐轴。为了将一体的环44装入到凹槽42里去，而且环44的内径在透烧状态下小于在透烧状态下轴41的界定了凹槽42的部段46、48，按照本发明如下来进行。首先使未烧结的或预烧结的轴41进行透烧(图11中的轴141)。由于轴41的烧结，发生了收缩。环44的内径在未烧结或预烧结状态下大于界定了透烧的轴141的凹槽142的部段146或148的相应直径。接着使环44对准凹槽142，以便然后将环44与烧结的轴141一起透烧。已经烧结过的轴141因此不会进一步收缩。只有环144收缩。这样来选择环44的内径，使得由于在烧结时出现的收缩形成最终尺寸，在该最终尺寸中，烧结环144的内径小于邻接的部段146、148的外径。因此实现构件141、144的连接，这些构件不可松脱地相互连接起来，而在装配时不必将环144构造成多部件式的。
权利要求书(按照条约第19条的修改)
1.由烧结的氧化物陶瓷材料、如部分稳定的氧化锆制造多部件结构的方法，所述多部件结构包括第一部件(10，22，30，144)，该第一部件至少局部地包围第二部件(12，26，32，141)，使得在不破坏第一和/或第二部件的情况下阻止第一部件与第二部件松脱，使用以下方法步骤：
-由氧化物陶瓷坯件制成一体的第一成型件(110，122，130，44)和一体的第二成型件(112，126，132，41)，其中第一成型件和第二成型件相对于所述第一部件(10，22，30，144)和第二部件(12，26，32，141)放大了一个补偿了烧结收缩的放大系数，
-将所述第二成型件透烧以制成所述第二部件(12，26，32，141)，
-将所述第二部件和第一成型件组装并接着一起烧结，
其特征在于，所述第一成型件(110，122，132，44)设有开口，该开口的有效横截面在烧结之后或者小于第二成型件(112，126，132，41)在烧结后在第一部件(10，22)之内延伸的区域的有效横截面，或者小于第二部件(32，141)在所述开口之前和之后的有效横截面。

Claims (14)

1.由烧结的氧化物陶瓷材料、如部分稳定的氧化锆制造多部件结构的方法，所述多部件结构包括第一部件(10，22，30，144)，该第一部件至少局部地包围第二部件(12，26，32，141)，使用以下方法步骤：
-由氧化物陶瓷坯件制成第一成型件(110，122，130，44)和第二成型件(112，126，132，41)，其中第一成型件和第二成型件相对于所述第一部件(10，22，30，144)和第二部件(12，26，32，141)放大了一个补偿了烧结收缩的放大系数，
-将被另一个成型件至少部分地包围的那个成型件烧结，
-将已烧结的成型件作为所述第二部件与所述第一成型件组装并接着一起烧结，
其特征在于，分别使用一体的成型件作为所述第一成型件(110，122，130，44)和作为所述第二成型件(112，126，132，41)；将所述第二成型件透烧以制成所述第二部件(12，26，32，141)；并且将所述第一成型件(110，122，130)布置在第二部件(12，26，32，141)的一个部位(24，142)里，在此部位里，在将第一成型件和第二部件一起透烧之后，通过透烧而制成的第一部件(10，22，30，144)被第二部件如此包包围，使得在不破坏第一和/或第二部件的情况下阻止第一部件与第二部件松脱。
2.按权利要求1所述的方法，其特征在于，所述第一成型件(110，122，132，44)设有开口，该开口的有效横截面在烧结之后或者小于第二成型件(112，126，132，41)在烧结后在第一部件(10，22)之内延伸的区域的有效横截面，或者小于第二部件(32，141)在所述开口之前和之后的有效横截面。
3.按权利要求1或2所述的方法，其特征在于，使用由压制的氧化物陶瓷粉末制成的生坯件作为坯件。
4.按上述权利要求中至少一项所述的方法，其特征在于，通过轴向挤压或者等压地在压力P为150MPa≤P≤350MPa的情况下压制氧化物陶瓷粉末。
5.按上述权利要求中至少一项所述的方法，其特征在于，使用由压制的氧化物陶瓷粉末材料制成的预烧结坯件作为坯件。
6.按上述权利要求中至少一项所述的方法，其特征在于，在温度T1≥450℃的条件下，尤其是600℃≤T1≤1200℃的条件下将生坯件预烧结时间t1，其中0.5小时≤t1≤6小时。
7.按上述权利要求中至少一项所述的方法，其特征在于，将预烧结的坯件在温度T2为300℃≤T2≤650℃的条件下致密烧结时间t2，其中1小时≤t2≤3小时。
8.按上述权利要求中至少一项所述的方法，其特征在于，作为氧化物陶瓷粉末使用以下至少一种金属氧化物粉末：Al2O3、TiO2、MgO、Y2O3、BaTiO3、氧化锆、氧化锆混合晶体粉末。
9.按上述权利要求中至少一项所述的方法，其特征在于，所述氧化锆混合晶体粉末具有以下成分：
90-98％重量百分比  氧化锆
0-4％重量百分比    氧化铪
1-7％重量百分比    氧化钇
0-1％重量百分比    下列元素的氧化物之一：铝、镓、锗、铟、
                   锌、铅、镧
0-2％重量百分比    氧化染色添加物，
其中染色添加物优选是：Er2O3，Pr6O11或Fe2O3。
10.按上述权利要求中至少一项所述的方法，其特征在于，将坯件致密烧结至理论密度的90％至100％，尤其是96％至100％。
11.一种至少按照权利要求1制成的结构，其特征在于，所述第一部件是具有开口(14)的壳体(10)，该开口被作为所述第二部件的活塞杆(12)穿过，该活塞杆具有活塞(16)，该活塞(16)的有效横截面大于所述开口的横截面，并且能够在壳体里来回运动。
12.一种至少按照权利要求1制成的结构，其特征在于，所述第二部件(141)是优选曲拐轴；并且所述轴的一个部段被孔板(144)包围，其中该部段相对轴线有偏移，或者所述轴具有这样的部段(146，148)，该部段的有效尺寸在致密烧结状态下大于孔板的由轴所穿过的穿口。
13.一种至少按照权利要求1制成的结构，其特征在于，所述结构是牙齿植入体(30)，该牙齿植入体具有支承着牙科技术的构造体的植入体元件作为所述第一部件，该第一部件具有被作为所述第二部件的螺栓(32)穿过的通孔(34)，其中螺栓的加宽端部如头部(38，40)的横截面分别大于所述通孔的有效横截面。
14.一种至少按照权利要求1制成的结构，其特征在于，所述结构是具有能通过开口插入的容纳座(24)的活节壳(22)作为第一部件，其中活节(26)的头部(20)作为第二部件插入在容纳座(24)里，该容纳座的开口侧的横截面小于活节头(20)的最大横截面。
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