CN101910086A - 陶瓷材料及其衍生产品的水热液相烧结方法 - Google Patents
陶瓷材料及其衍生产品的水热液相烧结方法 Download PDFInfo
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- CN101910086A CN101910086A CN2008801223423A CN200880122342A CN101910086A CN 101910086 A CN101910086 A CN 101910086A CN 2008801223423 A CN2008801223423 A CN 2008801223423A CN 200880122342 A CN200880122342 A CN 200880122342A CN 101910086 A CN101910086 A CN 101910086A
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- 238000006243 chemical reaction Methods 0.000 claims abstract description 45
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- 238000001556 precipitation Methods 0.000 claims description 3
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- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 2
- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 description 2
- OYLGJCQECKOTOL-UHFFFAOYSA-L barium fluoride Chemical compound [F-].[F-].[Ba+2] OYLGJCQECKOTOL-UHFFFAOYSA-L 0.000 description 2
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- 239000012267 brine Substances 0.000 description 2
- CXKCTMHTOKXKQT-UHFFFAOYSA-N cadmium oxide Inorganic materials [Cd]=O CXKCTMHTOKXKQT-UHFFFAOYSA-N 0.000 description 2
- AOWKSNWVBZGMTJ-UHFFFAOYSA-N calcium titanate Chemical compound [Ca+2].[O-][Ti]([O-])=O AOWKSNWVBZGMTJ-UHFFFAOYSA-N 0.000 description 2
- 229910021563 chromium fluoride Inorganic materials 0.000 description 2
- GRWVQDDAKZFPFI-UHFFFAOYSA-H chromium(III) sulfate Chemical compound [Cr+3].[Cr+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O GRWVQDDAKZFPFI-UHFFFAOYSA-H 0.000 description 2
- YCYBZKSMUPTWEE-UHFFFAOYSA-L cobalt(ii) fluoride Chemical compound F[Co]F YCYBZKSMUPTWEE-UHFFFAOYSA-L 0.000 description 2
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- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 description 2
- GWFAVIIMQDUCRA-UHFFFAOYSA-L copper(ii) fluoride Chemical compound [F-].[F-].[Cu+2] GWFAVIIMQDUCRA-UHFFFAOYSA-L 0.000 description 2
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- 230000009466 transformation Effects 0.000 description 1
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- 238000009827 uniform distribution Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
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- 238000005406 washing Methods 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
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- 229940105963 yttrium fluoride Drugs 0.000 description 1
- DEXZEPDUSNRVTN-UHFFFAOYSA-K yttrium(3+);trihydroxide Chemical compound [OH-].[OH-].[OH-].[Y+3] DEXZEPDUSNRVTN-UHFFFAOYSA-K 0.000 description 1
- RBORBHYCVONNJH-UHFFFAOYSA-K yttrium(iii) fluoride Chemical compound F[Y](F)F RBORBHYCVONNJH-UHFFFAOYSA-K 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
- ZXAUZSQITFJWPS-UHFFFAOYSA-J zirconium(4+);disulfate Chemical compound [Zr+4].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZXAUZSQITFJWPS-UHFFFAOYSA-J 0.000 description 1
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Abstract
本发明提供了一种从多孔基体生产独石的方法,所述方法包括:(i)提供具有间隙并含有至少第一反应物的多孔基体;(ii)使所述多孔基体与含有至少第二反应物的渗透介质接触;(iii)在促进所述至少第一反应物与所述至少第二反应物反应以提供至少第一产物的条件下,让所述渗透介质渗入所述多孔基体的至少部分间隙;以及(iv)允许所述至少第一产物形成并填充所述多孔基体的至少部分间隙,从而生成独石,其中,所述独石不含钛酸钡。
Description
相关申请
本申请要求2007年11月15日提交的美国临时专利申请第61/003,272号的优先权,其全部内容在此通过引用并入本文。
背景技术
许多先前已知的渗透步骤已被用于生产多组分的陶瓷或陶瓷复合物。这些步骤包括:(1)金属基体渗透,(2)熔化处理,(3)化学气相渗透(CVI),(4)氮化,(5)化学键合陶瓷处理,以及(6)陶瓷硬化渗透。所有这六种方法可用于渗透多孔纤维或者预成型的陶瓷颗粒基体或预制件。然而,这些方法中,每个方法开始时,通常需要使初始纤维或预制件的孔隙度最小化,这样烧结产品的形状与初始预制件的形状基本没有区别。
再者,先前的成果通常基于多步加工方法,所述多步加工方法包括陶瓷化合物填料或预制件(例如晶须、纤维或颗粒)的成型和通过液体、熔融渗透剂或气体(CVI)渗透这种压坯或陶瓷填料层。陶瓷体或陶瓷层应被渗透剂充分润湿,并具有一部分相互连接的开孔从而能够通过毛细管作用发生渗透。在高温和/或高压条件下,该渗透剂可能只好被加热或熔化多次以具有足够的流动性渗入压坯或填料层。
因此,存在需要在相对温和的温度和压力条件下可进行的烧结方法。优选地,这个方法是低成本、多样化的,并能提供各种材料、试剂,以及所期望的最终产品的形状和尺寸。
发明内容
在本发明的一种实施方式中,提供了从多孔基体生产独石的方法,所述方法包括:(i)提供具有间隙并含有至少第一反应物的多孔基体;(ii)使所述多孔基体与含有至少第二反应物的渗透介质接触;(iii)在促进所述至少第一反应物与所述至少第二反应物反应以提供至少第一产物的条件下,让所述渗透介质渗入所述多孔基体的至少部分间隙;以及(iv)允许所述至少第一产物形成并填充所述多孔基体的至少部分间隙,从而生成独石,其中,所述第一产物不含钛酸钡,BaTiO3。
另一实施方式提供生产非钛酸钡烧结陶瓷的方法,所述方法包括:(i)提供具有间隙并含有至少第一反应物的多孔基体;(ii)使所述多孔基体与含有至少第二反应物的渗透介质接触;(iii)在包括反应温度低于1000℃,反应压力小于70000psi和促进所述至少第一反应物与所述至少第二反应物反应以提供至少第一产物的条件下,让所述渗透介质渗入所述多孔基体的至少大部分间隙;以及(iv)允许所述第一产物形成并填充所述多孔基体的至少大部分间隙,从而生成非钛酸钡烧结陶瓷。
一种实施方式提供由水热液相烧结方法生成的组合物,所述方法包括让多孔基体的至少一个组分与液体含有的至少第一反应物发生反应以提供至少第一产物,在所述反应过程中,所述多孔基体的剩余部分作为支架用于促进从所述液体来形成所述第一产物,从而生成水热液相烧结组合物。在优选的实施方式中,所述烧结组合物不包括钛酸钡。
另一实施方式提供生产组合物的方法,所述方法包括:(i)提供具有摩尔体积的多孔基体;(ii)使至少部分所述多孔基体浸入含有反应物的溶剂中;以及(iii)通过至少一些所述反应物与至少部分所述基体的反应来形成产物,其中所述产物具有摩尔体积,并且其中步骤(iii)之前所述基体的摩尔体积与步骤(iii)之后所述产物的摩尔体积基本相同。在又一实施方式中,所述基体的摩尔体积与所述产物的摩尔体积可能不同,摩尔体积增大或减小。
另一实施方式提供包括调节所述固体基体或所述渗透介质的组分以产生烧结的、多组分陶瓷产品的方法,所述陶瓷产品保持与所述固体基体相同的形状。在一个附加的实施方式中,从所述固体基体(或“生坯”)至所述陶瓷产物的转变过程中,总的尺寸和体积也基本得以保持。
附图说明
图1表示在一种实施方式中基体至产物的摩尔分数转换作为离子加成反应的渗透时间的函数的典型曲线。
图2表示在一种实施方式中在渗透前以及在反应温度90℃下反应进行1小时至72小时后所测量的所述压坯的体密度和表观密度的典型曲线。
图3显示了在一种实施方式中不同渗透次数的各种压坯中存在的孔尺寸和累积孔体积的图。
具体实施方式
全部参考文献在此通过引用并入本文。
水热液相烧结的通用条件
在水热液相烧结(HLPS)的优选实施方式中,具有相邻孔隙的“未烧结的”或部分烧结的、多孔的固体基体可通过液相渗透介质的作用转变为烧结陶瓷。HLPS可在相对温和的条件下进行,通常不超过高压釜运行中遇到的温度和压力。HLPS可在宽的温度和压力范围内进行。例如,在一些实施方式中,HLPS条件可包括温度低于约2000℃,例如低于约1000℃、例如低于约500℃、例如低于约200℃、例如低于约100℃、例如低于约50℃、例如室温。反应压力可小于约100000psi,例如小于70000psi、例如小于约50000psi、例如小于约10000psi、例如小于约5000psi、例如小于约1000psi、例如小于约500psi、例如小于约100psi、例如小于约50psi、例如小于约10psi。在一种实施方式中,水热烧结方法可在约80℃至约180℃的温度范围内以及约1个大气压至约3个大气压(1个大气压为约15psi)的压力范围内进行。
理论上,任何能够与渗透物发生水热反应生成不同物质的起始材料可被用于生产水热烧结产品。因此,基于预期的最终用途,可选择多种起始材料,成型为具有所需形状和尺寸的多孔固体基体,随后进行转化为烧结最终产物的本发明方法的步骤。
在一种实施方式中,所述多孔固体基体从金属氧化物粉末得到。所述粉末可以是无定形的或者结晶的,优选结晶的。而且,所述金属氧化物粉末可具有宽的粒度范围,平均粒度为约0.01微米至约100微米,包括例如约0.02微米至约50微米,例如约0.04微米至约20微米,例如约0.08微米至约10微米。在一种实施方式中,所述粉末的平均粒度为约0.1微米至约5微米。
所述金属氧化物中的金属可选自:IIa族金属的氧化物、IIb族金属的氧化物、IIIb族金属的氧化物、IVb族金属的氧化物、Vb族金属的氧化物、过渡金属的氧化物、镧系金属的氧化物、锕系金属的氧化物或者它们的混合物。优选地,所选的金属氧化物或烧结最终产物可在化学、陶瓷、磁性、电子、超导、机械、建筑或者甚至生物学方面具有潜在的应用。所述烧结最终产物可具有工业实用性或家用实用性。所述最终产物不一定需要包含与反应物相同的材料。例如,可由包含钡和/或钛的反应物生成基本不含钛酸钡的产物。在一个示例性的实施方式中,反应物中所含有的钡和/或钛主要作为中间反应物,因此在所述最终产物中不包括钡和/或钛。
本申请所述的“水热反应”可包括在含水介质或非水液态介质中发生的转化。而且,这种转化可包括相同化学物质的溶解和再沉淀,一种化学物质的溶解及其与另一种化学物质结合以形成复合材料,其中起始化学物质仍不同或者一种化学物质与另一种化学物质反应以生成不同于起始物质的新化学成分。因此,所述水热烧结方法可用通过沉淀(或再沉淀)、离子加成、离子取代或它们的组合得到的成分填充多孔固体基体中的间隙或空隙。所述成分可包含与固体基体中的成分相同的化学物质、由两种不同的化学物质共同-再沉淀得到的复合物、由两种化学物质之间的反应得到的新产物、由介质中含有的渗透剂物质得到的再沉淀物质,或者它们的组合。
在一种实施方式中,可在至少大部分未烧结多孔固体基体与介质中存在的预选的渗透剂物质发生反应以生成新产物的条件下进行HLPS。例如,可选择所述多孔固体基体与所述渗透剂物质,从而发生下列代表性的反应以生成所显示出的多种功能陶瓷产品和结构陶瓷产品。这些不平衡反应更加一般的形式稍后在说明书中定义。
(i)铁电-Pb(Zr,Ti)O3
1.1Pb2++xZr(OH)4+(1-x)TiO2→Pb(Zrx,Ti1-x)O3
(ii)铁电-BaSnO3
1.1Ba2++1SnO2→BaSnO3
(iii)磁学-CoFe2O4
2.2Fe2++1/2Co2O3→CoFe2O4
(iv)催化-NiMoO4
1NiO+1.1MoO4→NiMoO4
(v)陶瓷-SrCrO4
1Sr2++0.55Cr2O7→SrCrO4
(vi)生物-Ca10(PO4)6(OH)2
4Ca2++3Ca2P2O7+H2O→Ca10(PO4)6(OH)2
(vii)陶瓷-SrTiO3
1.1Sr+2+1TiO2→SrTiO3
(viii)陶瓷-Ba0.5Sr0.5TiO3
0.55Ba2++0.55Sr2++1TiO2→Ba0.5Sr0.5TiO3
(ix)陶瓷-BaTiO3
1.1Ba2++1TiO2→BaTiO3
(x)陶瓷-BaZr0.1Ti0.9O3
1.1Ba2++0.11Zr+4+0.9TiO2→BaZr0.1Ti0.9O3
(xi)陶瓷-Ba0.87Ca0.13Ti0.88Zr0.12O3
0.96Ba2++0.14Ca+2+0.13Zr+4+0.88TiO2→Ba0.87Ca0.13Ti0.88Zr0.12O3
多孔固体基体的制备
固体基体可包括不易在溶液中溶解的材料。如果所述基体可溶于水,可以选择条件,从而使所述基体的溶解度随温度的改变或添加非水性液体(例如,醇类或本申请的渗透剂介质制备章节中所讨论其它溶剂)而降低。在一种实施方式中,所述多孔固体基体从粉末得到。所述粉末可以是任何种类。例如,所述粉末可以是金属氧化物粉末。合适的金属氧化物粉末的例子可包括,铍氧化物(例如,BeO),镁氧化物(例如,MgO)、钙氧化物(例如,CaO,CaO2)、锶氧化物(例如,SrO)、钡氧化物(BaO)、钪氧化物(例如,Sc2O3)、钛氧化物(例如,TiO,TiO2,Ti2O3)、铝氧化物(例如,Al2O3)、钒氧化物(例如,VO,V2O3,VO2,V2O5)、铬氧化物(例如,CrO,Cr2O3,CrO3,CrO2)、锰氧化物(例如,MnO,Mn2O3,MnO2,Mn2O7)、铁氧化物(例如,FeO,Fe2O3)、钴氧化物(例如,CoO,Co2O3,Co3O4)、镍氧化物(例如,NiO,Ni2O3)、铜氧化物(例如,CuO,Cu2O)、锌氧化物(例如,ZnO)、镓氧化物(例如,Ga2O3,Ga2O)、锗氧化物(例如,GeO,GeO2)、锡氧化物(例如,SnO,SnO2)、锑氧化物(例如,Sb2O3,Sb2O5)、铟氧化物(例如,In2O3)、镉氧化物(例如,CdO)、银氧化物(例如,Ag2O)、铋氧化物(例如,Bi2O3,Bi2O5,Bi2O4,Bi2O3,BiO)、金氧化物(例如,Au2O3,Au2O)、锌氧化物(例如,ZnO)、铅氧化物(例如,PbO,PbO2,Pb3O4,Pb2O3,Pb2O)、铑氧化物(例如,RhO2,Rh2O3)、钇氧化物(例如,Y2O3)、钌氧化物(例如,RuO2,RuO4)、锝氧化物(例如,Tc2O,Tc2O3)、钼氧化物(例如,MoO2,Mo2O5,Mo2O3,MoO3)、钕氧化物(例如,Nd2O3)、锆氧化物(例如,ZrO2)、镧氧化物(例如,La2O3)、铪氧化物(例如,HfO2)、钽氧化物(例如,TaO2,Ta2O5)、钨氧化物(例如,WO2,W2O5)、铼氧化物(例如,ReO2,Re2O3)、锇氧化物(例如,OsO,OsO2)、铱氧化物(例如,IrO2,Ir2O3)、铂氧化物(例如,PtO,PtO2,PtO3,Pt2O3,Pt3O4)、汞氧化物(例如,HgO,Hg2O)、铊氧化物(例如,TlO2,Tl2O3)、钯氧化物(例如,PdO,PdO2)、镧系氧化物、锕系氧化物,等等。表1提供了一些例子。此外,根据所涉及的具体的应用,金属氧化物的混合物也可用于制造预制件。
表1.含有金属氧化物的固体基体样品的摩尔体积变化
基体 | 基体的摩尔体积 | 产物 | 产物的摩尔体积 | %摩尔体积变化 |
BeO | 8.31 | BeSO4 | 42.03 | 405.82 |
BeO | 8.31 | BeSO4·4H2O | 103.59 | 1,146.65 |
氧化镁 | 11.26 | - | - | - |
MgO | 11.26 | MgCO3 | 27.64 | 145.51 |
MgO | 11.26 | MgSO4 | 45.25 | 301.88 |
MgO | 11.26 | MgC2O4-2H2O | 60.56 | 437.79 |
3MgO | 33.78 | Mg3(PO4)2-8H2O | 187.55 | 455.21 |
MgO | 11.26 | MgAl2O4 | 40.07 | 255.91 |
氧化钪 | 35.69 | - | - | - |
Sc2O3 | 35.69 | ScPO4 | 37.72 | 5.67 |
氧化锶 | 与H2O反应 | - | - | - |
Y2O3 | 44.89 | Y2(SO4)3·8H2O | 234.66 | 422.72 |
(1/2)Y2O3 | 22.45 | YPO4 | 38.71 | 72.46 |
(3/2)Y2O3 | 67.34 | Y3Al5O12 | 131.92 | 95.90 |
(3/2)Y2O3 | 67.34 | Y3Fe5O12 | 142.73 | 111.96 |
氧化钛 | 19.15 | - | - | - |
TiO2 | 19.15 | MgTiO3 | 31.21 | 62.96 |
TiO2 | 19.15 | CaTiO3 | 34.16 | 78.33 |
TiO2 | 19.15 | SrTiO3 | 35.98 | 87.84 |
TiO2 | 19.15 | BaTiO3 | 38.74 | 102.24 |
TiO2 | 19.15 | MgTiO3 | 33.14 | 73.04 |
TiO2 | 19.15 | FeTiO3 | 32.14 | 67.81 |
TiO2 | 19.15 | NiTiO3 | 30.91 | 61.39 |
氧化锆(IV) | 21.69 | - | - | - |
ZrO2 | 21.69 | Zr(SO4)2 | 88.00 | 305.63 |
氧化钒(III) | 30.78 | - | - | - |
V2O3 | 30.78 | MgV2O4 | 44.23 | 43.71 |
氧化钒(V) | 54.29 | - | - | - |
V2O5 | 54.29 | Mg2V2O7 | 84.67 | 55.96 |
氧化铬(III) | 29.12 | - | - | - |
Cr2O3 | 29.12 | Cr2(SO4)3 | 52.68 | 80.93 |
Cr2O3 | 14.56 | CrC2O4·H2O | 64.03 | 339.82 |
Cr2O3 | 14.56 | CrPO4 | 31.95 | 119.46 |
Cr2O3 | 29.12 | MgCr2O4 | 43.70 | 50.10 |
Cr2O3 | 29.12 | FeCr2O4 | 44.77 | 53.75 |
Cr2O3 | 14.56 | CoCrO4 | 44.15 | 203.25 |
Cr2O3 | 14.56 | CuCrO4 | 42.88 | 194.52 |
Cr2O3 | 29.12 | ZnCr2O4 | 44.12 | 51.53 |
氧化锰(II) | 13.21 | - | - | - |
MnO | 13.21 | MnCO3 | 31.07 | 135.20 |
MnO | 13.21 | MnSO4 | 46.46 | 251.75 |
MnO | 13.21 | MnC2O4·2H2O | 73.06 | 453.09 |
氧化铁(II) | 11.97 | - | - | - |
FeO | 11.97 | FeCO3 | 29.37 | 145.33 |
FeO | 11.97 | FeSO4 | 41.62 | 247.59 |
FeO | 11.97 | FeC2O4·2H2O | 78.90 | 558.97 |
FeO | 35.92 | Fe3(PO4)2·8H2O | 194.42 | 441.25 |
氧化铁(III) | 30.42 | - | - | - |
Fe2O3 | 30.42 | Fe2(SO4)3 | 128.99 | 324.08 |
Fe2O3 | 15.21 | FePO4·2H2O | 65.10 | 328.08 |
Fe2O3 | 30.42 | MgFe2O4 | 48.76 | 60.31 |
Fe2O3 | 30.42 | NiFe2O4 | 45.37 | 49.17 |
Fe2O3 | 30.42 | CuFe2O4 | 44.14 | 45.11 |
Fe2O3 | 30.42 | MnFe2O4 | 48.45 | 59.27 |
Fe2O3 | 30.42 | ZnFe2O4 | 46.02 | 51.30 |
氧化钴(II) | 11.64 | CoCO3 | 28.32 | 143.39 |
CoO | 11.64 | CoSO4 | 41.78 | 259.06 |
CoO | 11.64 | CoSO4·7H2O | 138.47 | 1,090.11 |
CoO | 11.64 | CoSO4·H2O | 56.17 | 382.77 |
CoO | 11.64 | CoC2O4 | 48.66 | 318.20 |
CoO | 34.91 | Co3(PO4)2·8H2O | 184.43 | 428.35 |
氧化钴(II,III) | 39.41 | CoCO3 | 28.32 | -28.14 |
Co3O4 | 13.14 | CoSO4 | 41.78 | 218.02 |
Co3O4 | 13.14 | CoSO4·7H2O | 138.47 | 954.09 |
Co3O4 | 13.14 | CoSO4·H2O | 56.17 | 327.59 |
Co3O4 | 13.14 | CoC2O4 | 48.66 | 270.41 |
Co3O4 | 39.41 | Co3(PO4)2·8H2O | 184.43 | 367.97 |
氧化钴(III) | 16.01 | CoCO3 | 28.32 | 76.89 |
Co2O3 | 16.01 | CoSO4 | 41.78 | 160.95 |
Co2O3 | 16.01 | CoSO4·7H2O | 138.47 | 764.92 |
Co2O3 | 16.01 | CoSO4·H2O | 56.17 | 250.86 |
Co2O3 | 16.01 | CoC2O4 | 48.66 | 203.93 |
Co2O3 | 48.03 | Co3(PO4)2·8H2O | 184.43 | 283.98 |
氧化镍(II) | 11.11 | - | - | - |
NiO | 11.11 | NiCO3 | 27.05 | 143.33 |
NiO | 11.11 | NiSO4 | 38.59 | 247.22 |
氧化铜(II) | 12.61 | - | - | - |
CuO | 12.61 | CuCO3 | 31.68 | 151.34 |
CuO | 12.61 | CuSO4 | 44.34 | 251.72 |
CuO | 37.82 | Cu3(PO4)2 | 84.52 | 123.49 |
氧化锌 | 14.54 | - | - | - |
ZnO | 14.54 | ZnCO3 | 28.29 | 94.59 |
ZnO | 14.54 | ZnSO4 | 42.49 | 192.33 |
ZnO | 43.61 | Zn3(PO4)2 | 96.54 | 121.39 |
氧化钡 | 26.80 | - | - | - |
BaO | 26.80 | BaCO3 | 46.04 | 71.77 |
BaO | 26.80 | BaSO4 | 51.98 | 93.95 |
BaO | 26.80 | BaC2O4 | 84.78 | 216.34 |
氧化铝 | 25.55 | - | - | - |
Al2O3 | 25.55 | Al2(SO4)3 | 128.05 | 401.10 |
Al2O3 | 12.78 | AlPO4 | 47.64 | 272.84 |
Al2O3 | 25.55 | MgAl2O4 | 39.09 | 52.95 |
Al2O3 | 25.55 | MgAl2O4+CO2 | 39.09 | 52.95 |
Al2O3 | 25.55 | FeAl2O4 | 44.00 | 72.20 |
Al2O3 | 25.55 | ZnAl2O4 | 42.64 | 66.86 |
Al2O3 | 25.55 | BeAl2O4 | 34.79 | 36.13 |
Al2O3 | 25.55 | CaAl2O4 | 53.03 | 107.53 |
Al2O3 | 25.55 | CoAl2O4 | 40.48 | 41.31 |
所述基体也可包括氢氧化物,例如金属氢氧化物。例如,所述金属氢氧化物可包括氢氧化镁(例如,Mg(OH)2)、氢氧化钙(例如,Ca(OH)2)、氢氧化锶(例如,Sr(OH)2)以及氢氧化钡(例如,Ba(OH)2)、氢氧化铬(例如,Cr(OH)2)、氢氧化钛(例如,Ti(OH)2)、氢氧化锆(例如,Zr(OH)4)、氢氧化锰(例如,Mn(OH)2)、氢氧化铁(例如,Fe(OH)2)、氢氧化铜(例如,Cu(OH)2)、氢氧化锌(例如,Zn(OH)2)、氢氧化铝(例如,Al(OH)3)或者它们的组合。表2提供了一些例子。
所述基体也可包含氟化物,例如金属氟化物。例如,它可以包含氟化镁(例如,MgF2)、氟化钙(例如,CaF2)、氟化锶(例如,SrF2)以及氟化钡(例如,BaF2)、氟化铬(例如,CrF2)、氟化钛(例如,TiF3)、氟化锆(例如,ZrF4)、氟化锰(例如,MnF2)、氟化铁(例如,FeF2)、氟化铜(例如,CuF2)、氟化镍(例如,NiF2)、氟化锌(例如,ZnF2)、氟化铝(例如,AlF3)或者它们的组合。表3提供了一些例子。
所述基体也可包含混合的金属氧化物,例如金属钛酸盐。例如,它可包含钛酸镁(例如,MgTiO3)、钛酸钙(例如,CaTiO3)、钛酸锶(例如,SrTiO3)、钛酸钡(例如,BaTiO3)或者它们的组合。表4提供了一些例子。
所述基体也可包含硫酸盐,例如金属硫酸盐。例如,它可包含硫酸镁(例如,MgSO4)、硫酸钙(例如,CaSO4)、硫酸锶(例如,SrSO4)以及硫酸钡(例如,BaSO4)、硫酸铬(例如,Cr2(SO4)3)、硫酸钛(例如,TiSO4,Ti2(SO4)3)、硫酸锆(例如,ZrSO4)、硫酸锰(例如,MnSO4)、硫酸铁(例如,FeSO4)、硫酸铜(例如,CuSO4)、硫酸镍(例如,NiSO4)、硫酸锌(例如,ZnSO4)、硫酸铝(例如,Al2(SO4)3)或者它们的组合。表5提供了一些例子。
表2.含有金属氢氧化物的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
氢氧化铍 | 22.41 | - | - | - |
Be(OH)2 | 22.41 | BeSO4 | 42.03 | 87.55 |
Be(OH)2 | 22.41 | BeSO4·4H2O | 103.59 | 362.24 |
氢氧化镁 | - | - | - | - |
Mg(OH)2 | 24.30 | MgCO3 | 27.64 | 13.73 |
Mg(OH)2 | 24.30 | MgSO4 | 45.25 | 86.19 |
Mg(OH)2 | 24.30 | MgC2O4-2H2O | 60.56 | 149.16 |
3Mg(OH)2 | 72.91 | Mg3(PO4)2-8H2O | 187.55 | 157.22 |
氢氧化钙 | - | - | - | - |
Ca(OH)2 | 33.51 | CaCO3 | 36.93 | 10.21 |
Ca(OH)2 | 33.51 | CaSO4 | 45.99 | 37.25 |
Ca(OH)2 | 33.51 | CaC2O4 | 58.22 | 73.74 |
3Ca(OH)2 | 100.53 | Ca3(PO4)2 | 98.78 | -1.74 |
氢氧化锶 | 33.55 | - | - | - |
Sr(OH)2 | 33.55 | SrCO3 | 42.18 | 25.72 |
Sr(OH)2 | 33.55 | SrSO4 | 46.38 | 38.25 |
3Sr(OH)2 | 100.65 | Sr3(PO4)2 | 129.37 | 28.53 |
氢氧化钇 | 22.41 | - | - | |
Y(OH)3 | 44.82 | Y2(SO4)3·8H2O | 234.66 | 423.56 |
Y(OH)3 | 22.41 | YPO4 | 38.71 | 72.74 |
氢氧化锆 | - | - | - | - |
Zr(OH)4 | 49.00 | Zr(SO4)2 | 88.00 | 79.60 |
氢氧化锰 | 27.29 | - | - | |
Mn(OH)2 | 27.29 | MnCO3 | 31.07 | 13.86 |
Mn(OH)2 | 27.29 | MnSO4 | 46.46 | 70.27 |
Mn(OH)2 | 27.29 | MnC2O4·2H2O | 73.06 | 167.74 |
氢氧化铁(II) | 26.43 | - | - | - |
Fe(OH)2 | 26.43 | FeCO3 | 29.37 | 11.14 |
2Fe(OH)2 | 52.86 | Fe2(SO4)3 | 128.99 | 144.03 |
Fe(OH)2 | 26.43 | FePO4·2H2O | 65.10 | 146.33 |
氢氧化钴(II) | 25.82 | CoCO3 | 28.32 | 9.69 |
Co(OH)2 | 25.82 | CoSO4 | 41.78 | 61.81 |
Co(OH)2 | 25.82 | CoSO4·7H2O | 138.47 | 436.33 |
Co(OH)2 | 25.82 | CoSO4·H2O | 56.17 | 117.56 |
Co(OH)2 | 25.82 | CoC2O4 | 48.66 | 88.47 |
Co(OH)2 | 77.46 | Co3(PO4)2·8H2O | 184.43 | 138.10 |
氢氧化钴(III) | 27.49 | CoCO3 | 28.32 | 3.02 |
Co(OH)3 | 27.49 | CoSO4 | 41.78 | 51.98 |
Co(OH)3 | 27.49 | CoSO4·7H2O | 138.47 | 403.75 |
Co(OH)3 | 27.49 | CoSO4·H2O | 56.17 | 104.35 |
Co(OH)3 | 27.49 | CoC2O4 | 48.66 | 77.02 |
Co(OH)3 | 82.47 | Co3(PO4)2·8H2O | 184.43 | 123.64 |
氢氧化镍(II) | 22.34 | - | - | - |
Ni(OH)2 | 22.34 | NiCO3 | 27.05 | 21.06 |
Ni(OH)2 | 22.34 | NiSO4 | 38.59 | 72.75 |
氢氧化铜(II) | 28.95 | - | - | - |
Cu(OH)2 | 28.95 | CuCO3 | 31.68 | 9.44 |
Cu(OH)2 | 28.95 | CuSO4 | 44.34 | 53.15 |
3Cu(OH)2 | 86.85 | Cu3(PO4)2 | 84.52 | -2.69 |
氢氧化锌 | 32.55 | - | - | - |
Zn(OH)2 | 32.55 | ZnCO3 | 28.29 | -13.11 |
Zn(OH)2 | 32.55 | ZnSO4 | 42.49 | 30.53 |
3Zn(OH)2 | 97.66 | Zn3(PO4)2 | 96.54 | -1.15 |
氢氧化钡 | 78.60 | - | - | - |
Ba(OH)2 | 78.60 | BaCO3 | 46.04 | -41.43 |
Ba(OH)2 | 78.60 | BaSO4 | 51.98 | -33.86 |
Ba(OH)2 | 78.60 | BaC2O4 | 84.78 | 7.87 |
氢氧化铝 | 32.50 | - | - | - |
2Al(OH)3 | 65.00 | Al2(SO4)3 | 128.05 | 97.00 |
Al(OH)3 | 32.50 | AlPO4 | 47.64 | 46.58 |
勃姆石 | 19.54 | - | - | - |
2AlO(OH) | 39.08 | MgAl2O4 | 40.07 | 2.54 |
水铝石 | 17.75 | - | - | - |
2AlO(OH) | 35.50 | MgAl2O4 | 40.07 | 12.90 |
表3.含有金属氟化物的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
氟化铍 | - | - | - | - |
BeF2 | 22.38 | BeSO4 | 42.03 | 87.79 |
BeF2 | 22.38 | BeSO4·4H2O | 103.59 | 362.84 |
氟化镁 | 19.79 | - | - | - |
MgF2 | 19.79 | MgCO3 | 27.64 | 39.69 |
MgF2 | 19.79 | MgSO4 | 45.25 | 128.66 |
MgF2 | 19.79 | MgC2O4-2H2O | 60.56 | 205.99 |
3MgF2 | 59.37 | Mg3(PO4)2-8H2O | 187.55 | 215.90 |
氟化钙 | 24.55 | - | - | - |
CaF2 | 24.55 | CaCO3 | 36.93 | 50.43 |
CaF2 | 24.55 | CaSO4 | 45.99 | 87.33 |
CaF2 | 24.55 | CaC2O4 | 58.22 | 137.14 |
3CaF2 | 73.66 | Ca3(PO4)2 | 98.78 | 34.11 |
氟化锶 | 29.63 | - | - | - |
SrF2 | 29.63 | SrCO3 | 42.18 | 42.37 |
SrF2 | 29.63 | SrSO4 | 46.38 | 56.56 |
3SrF2 | 88.88 | Sr3(PO4)2 | 129.37 | 45.55 |
氟化钇 | 36.48 | - | - | - |
YF3 | 72.95 | Y2(SO4)3·8H2O | 234.66 | 221.67 |
氟化锆(IV) | 37.75 | - | - | - |
ZrF4 | 37.75 | Zr(SO4)2 | 88.00 | 133.12 |
氟化铬(II) | 23.74 | - | - | - |
CrF2 | 47.49 | Cr2(SO4)3 | 52.68 | 10.93 |
CrF2 | 23.74 | CrC2O4·H2O | 64.03 | 169.67 |
CrF2 | 23.74 | CrPO4 | 31.95 | 34.55 |
氟化锰(II) | 23.35 | - | - | - |
MnF2 | 23.35 | MnCO3 | 31.07 | 33.05 |
MnF2 | 23.35 | MnSO4 | 46.46 | 98.97 |
MnF2 | 23.35 | MnC2O4·2H2O | 73.06 | 212.87 |
氟化铁(II) | 22.94 | - | - | - |
FeF2 | 22.94 | FeCO3 | 29.37 | 28.03 |
FeF2 | 22.94 | FeSO4 | 41.62 | 81.39 |
FeF2 | 22.94 | FePO4·2H2O | 65.10 | 183.75 |
氟化钴(II) | 21.73 | - | - | - |
CoF2 | 21.73 | CoCO3 | 28.32 | 30.31 |
CoF2 | 21.73 | CoSO4 | 41.78 | 92.23 |
CoF2 | 21.73 | CoSO4·7H2O | 138.47 | 537.15 |
CoF2 | 21.73 | CoSO4·H2O | 56.17 | 158.46 |
CoF2 | 21.73 | CoC2O4 | 48.66 | 123.90 |
CoF2 | 7.24 | Co3(PO4)2·8H2O | 184.43 | 2,445.80 |
氟化钴(III) | 29.88 | - | - | - |
CoF3 | 29.88 | CoCO3 | 28.32 | -5.22 |
CoF3 | 29.88 | CoSO4 | 41.78 | 39.83 |
CoF3 | 29.88 | CoSO4·7H2O | 138.47 | 363.46 |
CoF3 | 29.88 | CoSO4·H2O | 56.17 | 88.00 |
CoF3 | 29.88 | CoC2O4 | 48.66 | 62.86 |
CoF3 | 89.64 | Co3(PO4)2·8H2O | 184.43 | 105.75 |
氟化镍(II) | 20.57 | - | - | - |
NiF2 | 20.57 | NiCO3 | 27.05 | 31.46 |
NiF2 | 20.57 | NiSO4 | 38.59 | 87.59 |
氟化铜(II) | 24.01 | - | - | - |
CuF2 | 24.01 | CuCO3 | 31.68 | 31.97 |
CuF2 | 24.01 | CuSO4 | 44.34 | 84.69 |
3CuF2 | 72.02 | Cu3(PO4)2 | 84.52 | 17.36 |
氟化锌 | 21.10 | - | - | - |
ZnF2 | 21.10 | ZnCO3 | 28.29 | 34.03 |
ZnF2 | 21.10 | ZnSO4 | 42.49 | 101.36 |
3ZnF2 | 63.31 | Zn3(PO4)2 | 96.54 | 52.49 |
氟化钡 | 35.83 | - | - | - |
BaF2 | 35.83 | BaCO3 | 46.04 | 28.48 |
BaF2 | 35.83 | BaSO4 | 51.98 | 45.07 |
BaF2 | 35.83 | BaC2O4 | 84.78 | 136.61 |
氟化铝 | 27.09 | - | - | - |
2AlF3 | 54.18 | Al2(SO4)3 | 128.05 | 136.35 |
AlF3 | 27.09 | AlPO4 | 47.64 | 75.85 |
表4.含有混合金属氧化物的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
偏钛酸镁 | 31.21 | - | - | - |
MgTiO3 | 31.21 | MgCO3 | 27.64 | -11.43 |
MgTiO3 | 31.21 | MgSO4 | 45.25 | 44.98 |
MgTiO3 | 31.21 | MgC2O4-2H2O | 60.56 | 94.01 |
3MgTiO3 | 93.64 | Mg3(PO4)2-8H2O | 187.55 | 100.29 |
钛酸钙 | 34.16 | - | - | - |
CaTiO3 | 34.16 | CaCO3 | 36.93 | 8.13 |
CaTiO3 | 34.16 | CaSO4 | 45.99 | 34.66 |
CaTiO3 | 34.16 | CaC2O4 | 58.22 | 70.46 |
3CaTiO3 | 102.47 | Ca3(PO4)2 | 98.78 | -3.60 |
钛酸锶 | 35.98 | - | - | - |
SrTiO3 | 35.98 | SrCO3 | 42.18 | 17.24 |
SrTiO3 | 35.98 | SrSO4 | 46.38 | 28.92 |
3SrTiO3 | 107.94 | Sr3(PO4)2 | 129.37 | 19.86 |
钛酸钡 | 38.74 | - | - | - |
BaTiO3 | 38.74 | BaCO3 | 46.04 | 18.85 |
BaTiO3 | 38.74 | BaSO4 | 51.98 | 34.19 |
BaTiO3 | 38.74 | BaC2O4 | 84.78 | 118.87 |
钛酸锰(II) | 33.14 | - | - | - |
MnTiO3 | 33.14 | MnCO3 | 31.07 | -6.27 |
MnTiO3 | 33.14 | MnSO4 | 46.46 | 40.18 |
MnTiO3 | 33.14 | MnC2O4·2H2O | 73.06 | 120.42 |
钛酸铁(II) | 32.14 | - | - | - |
FeTiO3 | 32.14 | FeCO3 | 29.37 | -8.61 |
FeTiO3 | 32.14 | FeSO4 | 41.62 | 29.48 |
FeTiO3 | 32.14 | FePO4·2H2O | 65.10 | 102.55 |
钛酸镍(II) | 30.91 | - | - | - |
NiTiO3 | 30.91 | NiCO3 | 27.05 | -12.51 |
NiTiO3 | 30.91 | NiSO4 | 38.59 | 24.85 |
表5.含有金属硫酸盐的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
硫酸镁 | 45.25 | - | - | - |
MgSO4 | 45.25 | MgCO3 | 27.64 | -38.91 |
MgSO4 | 45.25 | MgC2O4-2H2O | 60.56 | 33.82 |
3MgSO4 | 135.75 | Mg3(PO4)2-8H20 | 187.55 | 38.15 |
硫酸钙 | 45.99 | - | - | - |
CaSO4 | 45.99 | CaCO3 | 36.93 | -19.70 |
CaSO4 | 45.99 | CaC2O4 | 58.22 | 26.59 |
3CaSO4 | 137.98 | Ca3(PO4)2 | 98.78 | -28.41 |
硫酸锶 | 46.38 | - | - | - |
SrSO4 | 46.38 | SrCO3 | 42.18 | -9.06 |
3SrSO4 | 139.15 | Sr3(PO4)2 | 129.37 | -7.03 |
硫酸钡 | 51.98 | - | - | - |
BaSO4 | 51.98 | BaCO3 | 46.04 | -11.43 |
BaSO4 | 51.98 | BaC2O4 | 84.78 | 63.10 |
硫酸铬(II) | 52.68 | - | - | - |
Cr2(SO4)3 | 52.68 | CrC2O4·H2O | 64.03 | 21.55 |
Cr2(SO4)3 | 52.68 | CrPO4 | 31.95 | -39.35 |
硫酸锰(II) | 46.46 | - | - | - |
MnSO4 | 46.46 | MnCO3 | 31.07 | -33.13 |
MnSO4 | 46.46 | MnC2O4·2H2O | 73.06 | 57.24 |
硫酸铁(II) | 41.62 | - | - | - |
FeSO4 | 41.62 | FeCO3 | 29.37 | -29.42 |
FeSO4 | 41.62 | FePO4·2H2O | 65.10 | 56.43 |
硫酸镍(II) | 38.59 | - | - | - |
NiSO4 | 38.59 | NiCO3 | 27.05 | -29.92 |
硫酸铜(II) | 44.34 | - | - | - |
CuSO4 | 44.34 | CuCO3 | 31.68 | -28.55 |
3CuSO4 | 133.01 | Cu3(PO4)2 | 84.52 | -36.46 |
硫酸锌 | 42.49 | - | - | - |
ZnSO4 | 42.49 | ZnCO3 | 28.29 | -33.43 |
ZnSO4 | 127.48 | Zn3(PO4)2 | 96.54 | -24.27 |
硫酸铝 | 128.05 | - | - | - |
Al2(SO4)3 | 64.03 | AlPO4 | 47.64 | -25.59 |
硫酸钴(II) | 41.78 | - | - | - |
CoSO4 | 41.78 | CoCO3 | 28.32 | -32.21 |
CoSO4 | 41.78 | CoC2O4 | 48.66 | 16.47 |
CoSO4 | 125.33 | Co3(PO4)2·8H2O | 184.43 | 47.15 |
(1/2)Y2(SO4)3·8H2O | 117.33 | YPO4 | 38.71 | -67.01 |
所述基体也可包含硅酸盐,例如金属硅酸盐。例如,它可包含偏硅酸锂、原硅酸锂、偏硅酸钠、硅酸铍、硅酸钙、原硅酸锶、偏硅酸钡、硅酸锆、偏硅酸锰、硅酸铁、原硅酸钴、原硅酸锌、偏硅酸镉、红柱石、硅线石、蓝晶石、高岭石或者它们的组合。表6提供了一些例子。
所述基体也可包含羟磷灰石,例如金属羟磷灰石。例如,它可包含碳酸钙、四水合硝酸钙、氢氧化钙或者它们的组合。表7提供了一些例子。
除了上述任何材料之外,所述基体还可包含惰性填充材料和其他材料。惰性填充材料可以是被合并入所述固体基体以填充孔并且实质上不与渗透剂发生化学键合反应的任何材料。例如,所述惰性材料可以是木材、塑料、玻璃、金属、陶瓷、灰烬或者它们的组合。
所述粉末可用平均粒度、粒度分布和比表面积来表征,平均粒度的范围为约0.005μm至500μm,例如约0.01μm至约100μm。细的平均粒度和窄的粒度分布对于提高溶解是理想的。
通过任何常规技术(包括挤压成型、注塑成型、模压成型、等静压成型和泥浆浇铸)所述粉末可成型为任何期望形状和尺寸的生坯。也可成型为陶瓷薄膜。在压坯成型中所使用的任何润滑剂、粘合剂的类似材料可被使用,并且它们应该对所得材料无有害影响。这些材料的优选类型为在相对较低的温度(优选的低于500℃)下加热时,蒸发或烧掉所述材料而不留下明显的残渣。
表6.含有硅酸盐的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
偏硅酸锂 | 35.70 | - | - | - |
2LiSiO4 | 71.40 | Li2CO3+2SiO2 | 89.74 | 25.69 |
2LiSiO4 | 71.40 | Li2SO4+2SiO2 | 104.47 | 46.31 |
2LiSiO4 | 71.40 | Li2SO4·H2O+2SiO2 | 116.84 | 63.64 |
2LiSiO4 | 71.40 | Li2C2O4+2SiO2 | 102.77 | 43.93 |
3LiSiO4 | 107.10 | Li3PO4+3SiO2 | 129.15 | 20.59 |
原硅酸锂 | - | - | - | |
Li2SiO3 | 41.43 | Li2CO3+SiO2 | 62.38 | 50.56 |
Li2SiO3 | 41.43 | Li2SO4+SiO2 | 77.11 | 86.11 |
Li2SiO3 | 41.43 | Li2SO4·H2O+SiO2 | 89.48 | 115.96 |
Li2SiO3 | 41.43 | Li2C2O4+SiO2 | 75.43 | 82.05 |
(3/2)Li2SiO3 | 62.15 | Li3PO4+(3/2)SiO2 | 88.11 | 41.77 |
偏硅酸钠 | 46.77 | - | - | - |
Na2SiO3 | 46.77 | Na2CO3+SiO2 | 69.09 | 47.73 |
Na2SiO3 | 46.77 | Na2SO4+SiO2 | 79.97 | 70.99 |
Na2SiO3 | 46.77 | Na2SO4·10H2O+SiO2 | 248.04 | 430.37 |
Na2SiO3 | 46.77 | Na2C2O4+SiO2 | 84.63 | 80.95 |
(3/2)Na2SiO3 | 70.15 | Na3PO4+(3/2)SiO2 | 105.58 | 50.51 |
(3/2)Na2SiO3 | 70.15 | Na3C6H5O7·5H2O+(3/2)SiO2 | 228.22 | 225.32 |
硅酸铍 | 36.95 | - | - | |
(1/2)Be2SiO4 | 18.47 | BeSO4+SiO2 | 55.71 | 201.58 |
(1/2)Be2SiO4 | 18.47 | BeSO4·4H2O+SiO2 | 117.27 | 534.81 |
硅酸镁 | 43.83 | - | - | - |
(1/2)Mg2SiO4 | 21.91 | MgCO3+SiO2 | 41.32 | 88.57 |
(1/2)Mg2SiO4 | 21.91 | MgSO4+SiO2 | 58.93 | 168.91 |
(1/2)Mg2SiO4 | 21.91 | MgC2O4-2H2O+SiO2 | 74.24 | 238.74 |
(3/2)Mg2SiO4 | 65.74 | Mg3(PO4)2-8H2O+SiO2 | 228.59 | 247.69 |
硅酸钙 | 39.78 | - | - | - |
CaSiO3 | 39.78 | CaCO3+SiO2 | 64.29 | 61.62 |
CaSiO3 | 39.78 | CaSO4+SiO2 | 73.36 | 84.39 |
CaSiO3 | 39.78 | CaC2O4+SiO2 | 85.58 | 115.13 |
3CaSiO3 | 119.34 | Ca3(PO4)2+SiO2 | 180.87 | 51.55 |
原硅酸锶 | 59.40 | - | - | - |
(1/2)Sr2SiO4 | 29.70 | SrCO3+SiO2 | 55.86 | 88.07 |
(1/2)Sr2SiO4 | 29.70 | SrSO4+SiO2 | 60.06 | 102.22 |
(3/2)Sr2SiO4 | 89.11 | Sr3(PO4)2+SiO2 | 170.41 | 91.25 |
偏硅酸钡 | 48.50 | - | - | - |
BaSiO3 | 48.50 | BaCO3+SiO2 | 73.40 | 51.33 |
BaSiO3 | 48.50 | BaSO4+SiO2 | 79.34 | 63.58 |
BaSiO3 | 48.50 | BaC2O4+SiO2 | 112.14 | 131.21 |
硅酸锆 | 39.42 | - | - | |
ZrSiO4 | 39.42 | Zr(SO4)2+SiO2 | 115.36 | 192.63 |
偏硅酸锰(II) | 37.65 | - | - | - |
MnSiO3 | 37.65 | MnCO3+SiO2 | 58.43 | 55.19 |
MnSiO3 | 37.65 | MnSO4 | 73.82 | 96.08 |
MnSiO3 | 37.65 | MnSO4·H2O | 84.65 | 124.85 |
MnSiO3 | 37.65 | MnSO4·4H2O | 126.06 | 234.82 |
MnSiO3 | 37.65 | MnC2O4·2H2O | 100.42 | 166.71 |
2MnSiO3 | 75.30 | Mn2P2O7 | 131.22 | 74.27 |
硅酸铁(II) | 47.39 | - | - | - |
(1/2)Fe2SiO4 | 94.78 | FeCO3+SiO2 | 84.10 | -11.27 |
(1/2)Fe2SiO4 | 94.78 | FeSO4+SiO2 | 96.34 | 1.65 |
(1/2)Fe2SiO4 | 94.78 | FeC2O4·2H2O+SiO2 | 133.62 | 40.99 |
(3/2)Fe2SiO4 | 31.59 | Fe3(PO4)2·8H2O+SiO2 | 212.66 | 573.12 |
原硅酸钴(II) | 45.35 | - | - | - |
(1/2)Co2SiO4 | 22.67 | CoCO3+SiO2 | 42.00 | 85.24 |
(1/2)Co2SiO4 | 22.67 | CoSO4+SiO2 | 55.46 | 144.60 |
(1/2)Co2SiO4 | 22.67 | CoSO4·7H2O+SiO2 | 152.15 | 571.09 |
(1/2)Co2SiO4 | 22.67 | CoSO4·H2O+SiO2 | 69.85 | 208.09 |
(1/2)Co2SiO4 | 22.67 | CoC2O4+SiO2 | 62.34 | 174.96 |
(3/2)Co2SiO4 | 68.02 | Co3(PO4)2·8H2O+SiO2 | 225.47 | 231.48 |
原硅酸锌 | 54.37 | - | - | - |
(1/2)Zn2SiO4 | 27.18 | ZnCO3+(1/2)SiO2 | 41.97 | 54.38 |
(1/2)Zn2SiO4 | 27.18 | ZnSO4+(1/2)SiO2 | 56.17 | 106.65 |
(3/2)Zn2SiO4 | 81.55 | Zn3(PO4)2+(3/2)SiO2 | 137.58 | 68.71 |
偏硅酸镉 | 36.96 | - | - | - |
CdSiO3 | 36.96 | CdCO3+SiO2 | 61.67 | 66.85 |
CdSiO3 | 36.96 | CdSO4 | 71.81 | 94.30 |
CdSiO3 | 36.96 | CdSO4·H2O | 87.12 | 135.72 |
CdSiO3 | 36.96 | CdSO4·8H2O | 141.84 | 283.77 |
CdSiO3 | 36.96 | CdC2O4 | 87.73 | 137.37 |
红柱石 | 51.52 | - | - | - |
Al2SiO5 | 51.52 | Al2(SO4)3·16H2O+SiO2 | 251.21 | 387.56 |
Al2SiO5 | 51.52 | Al2(SO4)3·18H2O+SiO2 | 421.70 | 718.43 |
(1/2)Al2SiO5 | 25.76 | AlPO4+SiO2 | 61.32 | 138.01 |
硅线石 | 49.86 | - | - | - |
Al2SiO5 | 49.86 | Al2(SO4)3·16H2O+SiO2 | 251.21 | 403.83 |
Al2SiO5 | 49.86 | Al2(SO4)3·18H2O+SiO2 | 421.70 | 745.75 |
(1/2)Al2SiO5 | 24.93 | AlPO4+SiO2 | 61.32 | 145.96 |
蓝晶石 | 51.52 | - | - | - |
Al2SiO5 | 51.52 | Al2(SO4)3·16H2O+ | 251.21 | 387.56 |
SiO2 | ||||
Al2SiO5 | 51.52 | Al2(SO4)3·18H2O+SiO2 | 421.70 | 718.43 |
(1/2)Al2SiO5 | 25.76 | AlPO4+SiO2 | 61.32 | 138.01 |
高岭石 | 99.68 | - | - | - |
Al2O3·2SiO2·2H2O | 99.68 | Al2(SO4)3·16H2O+2SiO2 | 237.53 | 138.31 |
Al2O3·2SiO2·2H2O | 99.68 | Al2(SO4)3·18H2O+2SiO2 | 408.02 | 309.34 |
Al2O3·2SiO2·2H2O | 49.84 | AlPO4+SiO2 | 75.00 | 50.49 |
表7.含有羟磷灰石的固体基体样品的摩尔体积变化
基体 | 基体摩尔体积 | 产物 | 产物摩尔体积 | %摩尔体积变化 |
碳酸钙 | 36.93 | - | - | - |
5CaCO3 | 184.66 | Ca5(PO4)3(OH) | 159.21 | -13.78 |
四水合硝酸钙 | 129.75 | - | - | - |
5Ca(NO3)2·4H2O | 648.76 | Ca5(PO4)3(OH) | 159.21 | -75.46 |
氢氧化钙 | 33.68 | - | - | - |
5Ca(OH)2 | 168.39 | Ca5(PO4)3(OH) | 159.21 | -5.45 |
在起始粉末压坯中的孔可以较小,例如,约0.01微米(μm)至约100μm,例如约0.1μm至约1μm,并且在整个压坯中均匀分布,从而使渗透剂溶液能够完全渗入所述粉末压坯。孔体积含量(闭孔率和开孔率)和孔尺寸可通过标准方法来测定。例如,可使用压汞孔径测试仪来评价这三个参数。
以上得到的预制件随后可进行以下讨论的步骤。
渗透介质的制备
如先前所描述的,水热烧结可利用含水介质或非水介质。液体溶剂的选择可取决于所述渗透剂物质,所述渗透剂物质可以是渗透介质的一部分。在水热烧结方法的条件下,所述渗透剂物质在液体溶剂中可具有较大的溶解度。例如,如果所述渗透剂物质是离子型的,那么液体溶剂可以是水。某些非离子型的渗透剂在含水介质中也可具有足够的溶解度。
此外,诸如醇类(例如甲醇、乙醇、丙醇、异丙醇等等)、多元醇(例如乙二醇、1,2-丙二醇、1,3-丙二醇等等)、某些低分子量的醚(例如呋喃、四氢呋喃)、胺类(例如甲胺、乙胺、吡啶等等)、低分子量酮类(例如丙酮)、亚砜类(例如二甲亚砜)、乙腈等等之类的水溶性有机溶剂也可存在于含水混合物中。在某些情况下,可将表面活性剂(例如聚硅氧烷、聚乙二醇和氧化烷基二甲基胺等等)加至含水混合物中。
渗透介质优选地含有水溶性金属盐(即离子形式的金属)。这些盐的阳离子可来自下列金属:例如,铍、镁、钙、锶、钡、钪、钛、钒、铬、锰、铁、钴、镍、铜、锌、铝、镓、锗、锡、锑、铟、镉、银、铅、铑、钌、锝、钼、钕、锆、镱、镧、铪、钽、钨、铼、锇、铱、铂、金、汞、铊、钯、镧系金属阳离子、锕系金属阳离子和/或它们的混合物。一般而言,溶于渗透溶液的盐的阴离子可来自下列基团:例如,氢氧化物、硝酸盐、氯化物、醋酸盐、甲酸盐、丙酸盐、苯基乙酸盐、苯甲酸盐、羟基苯甲酸盐、氨基苯甲酸盐、甲氧基苯甲酸盐、硝基苯甲酸盐、硫酸盐、氟化物、溴化物、碘化物、碳酸盐、草酸盐、磷酸盐、柠檬酸盐以及硅酸盐或它们的混合物。可选择渗透剂中包含的金属离子与氧化物粉末中金属离子的摩尔比例来实现期望的化学计量反应产物。溶液中需要过量的金属离子以帮助实现反应完全。
基于渗透介质和基体材料,得到的烧结产物可以是例如钛酸盐(如果涉及含有钛的材料)。例如,具有钛铁矿结构的钛酸盐可从水中的TiO2和Fe2+、Mg2+、Mn2+、Co2+、Ni2+的盐或它们的组合的盐来得到。具有钙钛矿结构的钛酸盐可从Ca2+、Sr2+、Ba2+的盐水溶液或它们的组合的盐水溶液来制备。此外,可得到包括Mg2TiO4、Zn2TiO4、和Co2TiO4在内的具有尖晶石结构的化合物。并且,在一种实施方式中,通过本发明的方法可得到例如具有通式为BaxTiyOx+2y(其中x和y为整数)的钛酸钡的不同相,只要x≠1,y≠1且x+2y≠3。
可选地,得到的烧结产物可以是碳酸盐、硫酸盐、草酸盐或它们的组合;如果使用常规烧结方法,可使用的材料包括在该材料能烧结之前可分解的材料;例如,在常规烧结方法中,当在能够烧结之前加热时,碳酸盐会分解为其氧化物。
用于生产烧结陶瓷的通用HLPS方法
HLPS反应装置
在一种实施方式中,通过液相渗透介质的作用由HPLS将“未烧结的”或部分烧结的多孔固体基体转变为烧结陶瓷。为进行渗透步骤,可将所述部分烧结的多孔固体基体浸入渗透剂溶液中。所述部分烧结的多孔固体基体可被置于网架上这样其所有表面暴露于渗透介质。渗透可在特氟龙反应室内发生,密封所述反应室以控制水热反应条件。此外,所述特氟龙反应室可位于高压釜内。鉴于所述渗透介质的初始pH由反应物来确定,通过使用高压釜所提供的温度和压力可随意地控制反应温度和压力。在一种实施方式中,在水热反应过程中,温度和压力可分别低于250℃和5个大气压。
HLPS反应
HLPS方法可包括各种化学反应。例如,水热反应过程可通过溶解-再沉淀反应机理发生。可选地,所述反应可通过离子取代反应发生。在前一种情况下,少部分压制的多孔固体基体可溶解提供可与渗透剂溶液中的离子反应的溶解的物质;所述渗透剂溶液中的离子可以是金属离子。在一种实施方式中,添加的所述渗透剂的量可以足够在单一步骤中产生完全反应。可选地,可包括多个步骤。例如,可包括多次渗透。在一种实施方式中,钛酸锶可从氧化钛基体形成,此后,通过另一渗透可形成锶磷灰石。可选地,通过多次渗透可形成碳酸盐,然后该碳酸盐可形成保护性的草酸盐层。在另一实施方式中,所述压坯可被部分渗透和干燥,并且可重复所述渗透步骤直至生成最终产物。
生成的独石的形状可保持固体基体的形状。在一种实施方式中,当在基体的孔隙内形成的反应产物的摩尔体积大于氧化物粉末的摩尔体积(即,正摩尔体积变化-即,转变为更大的摩尔体积)时,成核形成的产物填充了压坯空隙并且增加所述压坯的密度。所述摩尔体积变化不一定为正;它也可以为负(即,转化为更小的摩尔体积)或没有变化,这取决于离子种类和反应机理。例如,在反应过程中部分基体可溶解消失,孔隙度提高,同时生成新的化学键合和负摩尔体积变化。类似地,如果形成的新材料的摩尔体积与基体损失的摩尔体积相同,那么基本上没有摩尔体积变化。
HLPS反应可通过例如离子加成和/或离子取代发生。在加成反应中,可将渗透介质中的离子(阴离子或阳离子)添加至基体主体而不取代基体中另外的离子。离子加成的例子可包括从氧化物转变为氢氧化物或从氧化物转变为碳酸盐。离子取代的例子可包括从氢氧化物转变为碳酸盐或从氢氧化物转变为草酸盐。此外,所述反应可通过歧化作用发生,其中不可溶的无机主体/基体材料可被分解为两种不可溶的无机产物。例如,氧化物、氟化物和硫酸盐可发生歧化作用。一般的反应可描述如下:
请注意,A、A’、C的盐都可溶于所选的溶剂(水或一些其它溶剂混合物)。AOH、A(OH)2和COH是强碱。C可以是单价有机阳离子(NR4+)或无机阳离子(NH4+、K+、Na+和Li+)。X是可溶离子,如硝酸盐或氯化物。A可以是二价碱土金属离子的混合物,例如Mg2+、Ca2+、Sr2+或Ba2+,或单价离子Li+、Na+、K+、NH4 +或NR4 +。A’可以是既非碱土金属又非碱金属的二价阳离子,例如铅。B是+2、+3、+4或+5价的过渡金属离子、稀土元素离子、锕系金属离子或主族金属离子。B金属包含微溶于渗透介质的主体,B可包括很多化学物质。例如,B可以是氧化物或水合氧化物,但是B也可以是诸如金属硫酸盐或金属磷酸盐之类的其它化合物。除非另有指定,所有物质是可溶的,并且所有不可溶的化合物具有标记。
加成反应
氧化产物
2AOH+BO2(s)=A2BO3(s)+H2O
2AX+2COH+BO2(s)=A2BO3(s)+H2O+2CX
A(OH)2+BO2(s)=ABO3(s)+H2O
A(OH)2+B2O3(s)=AB2O4(s)+H2O
AX2+2COH+BO2(s)=ABO3(s)+H2O+2CX
AX2+2COH+B2O3(s)=AB2O4(s)+H2O+2CX
2AOH+B2O5(s)=2ABO3(s)+H2O
A(OH)2+3B’(OH)2(s)+B2O5(s)=3[B’(A1/3B2/3)O3](s)+4H2O(基体包含两个不可溶的主体)
AX2+3B’X2+8COH+B2O5(s)=3[B’(A1/3B2/3)O3](s)+8CX+4H2O
取代反应
碳酸盐
A2CO3+BSO4(s)=BCO3(s)+A2SO4
A2CO3+B(OH)2(s)=BCO3(s)+2AOH
B(OH)2(s)+CO2=BCO3(s)+H2O
草酸盐
A2C2O4+B(OH)2(s)=BC2O4(s)+2AOH
A2C2O4+BSO4(s)=BC2O4(s)+A2SO4
A2C2O4+BO(s)=BC2O4(s)+A2O
A2SO4+B(OH)2(s)=BSO4(s)+2AOH
A2SO4+BCO3(s)=BSO4(s)+A2CO3
氟化物
2CF+H2O+BO(s)=BF2(s)+2COH
6CF+3H2O+B2O3(s)=2BF3(s)+6COH
2CF+B(OH)2(s)=BF2(s)+2COH
3CF+B(OH)3(s)=BF3(s)+3COH
歧化反应
C2CO3+H2O+BB’O3(s)=BCO3(s)+B’O2+2COH
CO2+BB’O3(s)=BCO3(s)+B’O2(s)
尖晶石
A(OH)2+B2O3=BA2O4+H2O
AO+B2O3=BA2O4
ACO3+B2O3=BA2O4+CO2
ASO4+B2O3+H2O=BA2O4+H2SO4
A(C2O4)+B2O3+H2O=BA2O4+H2C2O4
混合反应-加成和取代
磷酸盐
3C3PO4+5B(OH)2(s)=B5(PO4)3OH(s)+9COH
3C3PO4+5H2O+5BO(s)=B5(PO4)3OH(s)+9COH
氟磷酸盐
3C3PO4+5BF2(s)=B5(PO4)3F(s)+9CF
在反应过程中也可发生非均质成核。如先前所描述的,密度的变化可取决于基体材料的类型和/或形成的产物类型。一旦水热反应完成,可通过例如时效来进一步除去开孔。
对于水热方法而言,温度设定可以是简单过程或复杂过程。例如,加热循环可以是等温的,但可使用两套不同的温度。例如,首先使用相对较高的温度例如250℃来加强均质成核,随后可在较低的温度例如大约90℃下对致密化的材料进行时效处理。
上述反应完成之后,可在溶液中冲洗或浸泡所述致密化的基体以冲走过量的渗透溶液。冲洗溶液可以是pH为5的醋酸铵。在一种实施方式中,随后可在温度约90℃至约250℃的烘箱中干燥所述致密化的基体。在所述烧结陶瓷中可能存在的残余孔隙度可通过加热至更高温度(例如约600℃或低于600℃)来进一步除去。
通过HLPS方法烧结的陶瓷产品具有各种应用。例如,它可用于建筑材料(例如,水泥)、化学材料(例如,催化剂、过滤)、电气材料或它们的组合。
所述烧结材料的表征
烧结材料的孔隙度
HLPS可生成具有非常均匀和非常细小的微结构的烧结产品。烧结材料的孔隙度可以是,例如小于约40%,例如小于约30%,例如小于约20%,例如小于约15%,例如小于约10%,例如小于约5%,或甚至实际上完全致密。所述压坯的总孔隙度可使用标准技术中的例如压汞孔径测试仪来测定。密度可使用诸如阿基米德法或压汞孔径分析仪之类的常规技术来估算。
烧结材料的尺寸和形状
HLPS方法的烧结材料的一个特征是其具有与起始的生坯相同的形状甚至相同的尺寸。在一种实施方式中,其中产物基本无摩尔体积变化,不引起压坯收缩,这与许多陶瓷的制造方法相反,因此,几乎不需要或根本不需要加工烧结材料。
烧结材料的成分
如实施例中所示例的,很多化学成分可用于制造烧结材料。此外,形成烧结材料所涉及的不同金属氧化物和盐的数目不必以任何特定的方式来限定。此外,最终产物的化学计量可通过生坯和渗透介质中存在的反应物的摩尔比例来决定。烧结材料的成分可以使用X射线衍射定量分析(QXRD)和电感耦合等离子体(ICP)来测定。
微结构和相关机械性能
HLPS方法的烧结产物可具有基本类似网状的相互连接的网络微结构。从HLPS方法获得的独石也可表现出诸如核-壳结构之类的复合结构。此外,所述产物具有优异的机械性能,例如高的抗拉强度、抗压强度和理想的拉伸模量。这种初期增强可由化学键合产生,所述化学键合在物理连接的颗粒之间形成并且所述化学键合在离子取代、离子加成、奥斯特瓦尔德熟化(即,可形成新网络的重结晶)的过程中或它们的组合的过程中形成。在一种实施方式中,奥斯特瓦尔德熟化可包括在碱性介质中对碳酸盐材料进行时效处理。此外,如前所述,在有正摩尔体积变化的情况下可实现致密化。
非限定性实施例
实施例1.烧结钛酸钡(BaTiO
3
)陶瓷材料的形成
生坯的制备
锐钛矿型二氧化钛(TiO2)的压坯(直径为1英寸,宽为2-3mm)在约100MPa压力下在圆形模压机(die press)中形成。因此,得到了50%致密的二氧化钛压坯。然后将“生”坯在500℃以下的P温度下焙烧以烧尽在预成型步骤中使用的粘合剂。
焙烧之后的生坯重约2.5g。
压坯的水热液相烧结
在不同反应时间(1小时到194小时),温度为90℃条件下使41.2mL的1摩尔氢氧化钡Ba(OH)2·8H2O溶液渗入生坯。高压釜中的填充程度为约75%至80%,并且高压釜中包括约2atm的水蒸气压力。在过量的钡离子中进行所述过程,这样钡对钛的摩尔比例(Ba∶Ti)为约1.2∶1。然后,过滤、冲洗并干燥所述烧结压坯。
致密化陶瓷的表征
对所述样品进行使用具有15%ZrSiO4标准的基体清洗法(Chung,F.H.Appl.Crvst.,1974,7,579)的X射线定量分析和电感耦合等离子体。结果被示意性地绘制在图1中。
使用压汞孔径测试仪来测量表观密度和体密度,如图2所示。72小时反应时间之后,压坯为85%理论密度。图3表示了累积孔尺寸分布随反应时间的变化。结果表明生坯的致密化的发生是HLPS方法导致的,并且烧结过程在整个样品中均匀地发生(即,残余孔隙度保持连续)。
实施例2.烧结钛酸锶(SrTiO
3
)的形成
通过类似于实施例1中描述的步骤,通过干压二氧化钛粉末,制得总重量为7.402g的两个压坯。接着,在蒸馏的去离子(DI)水(53.01g)中制备Sr(OH)2·8H2O(27.00g)水溶液。然后将所述压坯置于网中并浸入含有氢氧化锶溶液的90mL容器中。将所述容器密封并置于预热(105℃)的烘箱中24小时。随后,将所述压坯在50mL醋酸铵缓冲液(pH约5.0)中冲洗十分钟,并真空下过滤。然后,将烧结压坯在100℃的电烘炉中干燥过夜。
实施例3.烧结钛酸锶钡(Ba
0.5
Sr
0.5
TiO
3
)的形成
将两个总重量为7.565g的二氧化钛压坯置于网中并浸入含有碱性溶液的90mL容器中,所述碱性溶液由在DI水(59.430g)中溶解的Sr(OH)2·8H2O(13.975g)和Ba(OH)2·8H2O(16.612g)来制备。然后,将密封的容器置于预热的(105℃)的烘箱中并在该烘箱中放置26小时。之后,在50mL醋酸铵缓冲液(pH约5.0)中冲洗所述压坯10分钟并过滤。然后,将产品压坯在100℃的电烘炉中干燥过夜。
实施例4.烧结钛酸锆钡(BaZr
0.1
Ti
0.9
O
3
)的形成
通过类似于实施例3所描述的步骤得到钛酸钡锆的烧结压坯,除两个氧化钛压坯重量为6.230g之外,所述碱性渗透溶液由30.105g Ba(OH)2·8H2O,3.005gZrO(NO3)2和48.75g DI水来制备。
实施例5.烧结三氧化锆钛酸钡钙(Ba
0.87
Ca
0.13
Ti
0.88
Zr
0.12
O
3
)的形成
如实施例3所描述的,获得总重量为7.910g的两个氧化钛压坯,并将所述压坯浸入碱性溶液中,所述碱性溶液由33.985g Ba(OH)2·8H2O,1.200gCa(OH)2,4.694g ZrO(NO3)2和25.200g DI水来制备。将含有所述压坯和渗透溶液的密封容器置于预热(115℃)的烘箱中30小时。在这时间之后,分离所述压坯,在50mL醋酸铵缓冲液(pH约5.0)中冲洗所述压坯并在真空下过滤。然后将这些烧结的压坯在100℃的电烘炉中干燥过夜。
实施例6.烧结铁电陶瓷的形成
Pb(Zr,Ti)O
3
的制备
根据先前所描述的步骤,将2.5g TiO2粉末压制成压坯。将1M氯化铅水溶液(68.9mL,用氢氧化钠调节pH值至约12)与1M氯氧化锆水溶液(31.3mL)混合。将混合溶液连同TiO2压坯(Pb∶Zr∶Ti摩尔比为约1.1∶0.5∶0.5)一起置于60mL容器中。
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
BaSnO
3
的制备
根据先前所描述的步骤,将5.0g SnO2粉末压成两个重量大概相等的压坯。将1M氢氧化钡水溶液(36.5mL)连同SnO2压坯(Ba∶Sn摩尔比为约1.1∶1.0)一起放入60mL容器中。
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
烧结的氧化锡锶(SrSnO3)压坯也可用这种方法来制备。
实施例7.具有磁性的烧结陶瓷材料(CoFe
2
O
4
)的形成
根据先前所描述的步骤,将5.0g Co2O3粉末压成两个重量大概相等的压坯。将1M硫酸铁(II)水溶液(33.2mL,用氢氧化钠调节pH值至约12)连同Co2O3压坯(Fe∶Co摩尔比为约2.2∶1.0)一起放入60mL容器中。
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
使用其他二价离子可类似地实施所述步骤,所述其他二价离子例如但不限于:Ba2+、Sr2+、Ca2+、Pb2+和Mn2+。
实施例8.具有催化性能的烧结陶瓷材料的形成
NiMoO
4
的制备
根据先前所描述的步骤,将5.0g NiO粉末压成两个重量大概相等的压坯。将1M钼酸铵(NH4)2MoO4(VI)水溶液(73.6mL,溶液pH值为约6)连同NiO压坯(Mo∶Ni摩尔比为约1.1∶1.0)一起放入60mL容器中。
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
该步骤可被改进以提供其他混合的二价金属钼氧化物,例如锶和钙的钼氧化物。
SrCrO
4
的制备
根据先前所描述的步骤,将5.0g SrO粉末压成两个重量大概相等的压坯。将由7.8g K2Cr2O7溶于浓硫酸制得的1M重铬酸盐水溶液(26.5mL)连同SrO压坯(Cr∶Sr摩尔比为约1.1∶1.0)一起放入60mL容器中。
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
也可使用其他二价例子来代替锶。例如,含有钡、钙、镁或锌的化合物也可制备。
实施例9.具有生物应用的烧结陶瓷材料的形成
具有生物应用的烧结陶瓷材料也可用本发明的方法来制备。例如,假肢组件可从金属氧化物粉末来模压成型并随后烧结以提供适于在矫形外科中使用的骨替代部件。
Ca
10
(OH)
2
(PO
4
)
6
的制备
然后,取出烧结的压坯,在醋酸铵缓冲液中冲洗所述压坯约十分钟,过滤,随后在真空中室温条件下干燥。
氟磷灰石的制备
用超声处理法将0.4g CaF2粉末与2.5vol% PVA粘合剂混合。然后冷冻干燥,并用约300MPa的压力在约0.3英寸的压模中将其干压成小球。将样品在箱式炉中、环境大气压、400℃条件下退火3小时。将100ml去离子水注入特氟龙罐中,并加入1g K3PO4和50g KOH。关闭所述罐的盖子并让其冷却至室温。将CaF2片置于特氟龙盘上,并浸入所述特氟龙罐中。关闭所述罐的盖子,并将其置于95℃预热的烘箱中,保温7天,用去离子水冲洗所述样品。
涂覆了钛酸锶的锶磷灰石的制备,将12g TiO2粉末(Fisher)分散在140ml添加了1%PVA的去离子水里。声波处理混合物30分钟,在-40℃条件下带壳冷冻(shell frozen)所述混合物,然后冰冻干燥。以20000lbs的载荷用水压法将其压成1英寸的小球。然后,在550℃条件下将生坯在炉中煅烧过夜以除去粘合剂。
由溶于100ml去离子水中的14g Sr(OH)2来制备氢氧化锶溶液。把所述小球放入所述溶液中,并在90℃下反应5天。取出所述小球,并用去离子水洗涤。然后,将其放入含有100ml去离子水和10g K3PO4的另一种溶液中7天。
鉴于上述所公开的内容,对于本领域的那些技术人员其他步骤是显而易见的,所述其他步骤可能与前述实施例中已详细描述的步骤不同,但是,虽然如此,所述其他步骤不背离本发明的范围和实质。上述实施例仅用于示例本发明具体的实施方式,因此,不应以任何方式解释上述实施例中包括或省略的主题作为限制本发明。这些其他显而易见的步骤以及从其得到的烧结材料被认为落入本发明的范围,本发明的限定仅以下面紧接的权利要求来限定。
实施例10.HLPS法造成的体积变化
表1至表7提供了样品的摩尔体积变化,所述样品具有固体基体,所述固体基体分别含有氧化物、氢氧化物、氟化物、混合金属氧化物、硫酸盐、硅酸盐和羟磷灰石。如图所示,所述摩尔体积变化不一定为正或不一定为负。
其他优选实施方式
在本发明的优选实施方式中,描述了从多孔固体基体生产烧结陶瓷的方法(及得到的产品),所述方法包括:(a)使具有相邻孔隙的固体基体与预选的渗透介质接触,(b)在有效引起所述基体中的大部分溶解的条件下,让所述介质渗入所述基体的孔隙;(c)在有效引起所述基体内所传输的大部分再沉淀的条件下,让所述介质传输溶解的大部分,这样获得烧结陶瓷。具体而言,所述预选的渗透介质优选地包含与合适的液体混合的预选的渗透剂物质。更优选地,所述方法还包括让来自所述基体的大部分与所述介质的渗透剂物质结合以提供产物的步骤,所述产物在所述基体内再沉淀。
在优选的实施方式中,所述方法生产的产物为化合物,所述化合物由来自所述基体的大部分与所述渗透剂物质之间的化学计量反应得到:[A基体+B渗透剂=AB]。
在优选的实施方式中,所述方法生产的产物为复合物,在所述复合物中来自所述基体的大部分与所述渗透剂物质在化学上仍然不同:[A基体+B渗透剂=A+B(但作为复合物)]。
在本发明的又一实施方式中,提供了还包括所述烧结陶瓷进行至少一个附加步骤的方法,所述附加步骤旨在除去可能存在于烧结陶瓷中的任何残余孔隙度。所述至少一个附加步骤可以是加热步骤,在该步骤中将所述烧结陶瓷加热至足以提供完全致密陶瓷的温度。优选地,所述加热步骤的温度不超过约600℃。
在本发明的独立实施方式中,提供了从多孔固体金属氧化物基体来生产烧结陶瓷的方法,所述方法包括:(a)使具有相邻孔隙的固体金属氧化物基体与预选的渗透液体介质接触;(b)在有效引起所述基体中的大部分溶解的条件下,让所述液体介质渗入所述基体的孔隙;(c)在有效引起所述基体内传输的大部分再沉淀的条件下,让所述液体介质传输溶解的大部分,这样获得烧结陶瓷。再次,所述预选的渗透液体介质可含有与合适的液体混合的预选的渗透剂物质。而且,所述烧结陶瓷可包括混合金属氧化物。优选地,所述混合金属氧化物可选自:IIa族金属氧化物、IIb族金属氧化物、IIIb族金属氧化物、IVb族金属氧化物或Vb族金属氧化物。所述金属氧化物也可包括过渡金属氧化物、镧系金属氧化物或锕系金属氧化物。在本发明的一种实施方式中,所述渗透剂物质包括至少一种类型的金属的盐或金属盐的混合物。可选地,渗透剂物质可选自提供IIa族金属离子、IIb族金属离子、IIIb族金属离子、IVb族金属离子、Vb族金属离子、过渡金属离子、镧系金属离子、锕系金属离子或其混合物离子的化学物质。上述离子的反离子也可从带负电的无机基团或有机基团中选择。
在优选的实施方式中,由本发明的方法生产的烧结陶瓷包括基本致密的固体,更优选地,包括完全致密的固体。另外优选的是可表征为具有约15%或更少(按体积计)的残余孔隙度的烧结陶瓷。根据优选的方法,初始多孔基体的形状和尺寸基本保留在所述烧结陶瓷中。然而,本发明的方法也可生产含有混合金属氧化物的烧结陶瓷,该混合金属氧化物的摩尔体积大于初始金属氧化物基体的摩尔体积。在本发明的又一实施方式中,本发明可生产含有混合金属氧化物的烧结陶瓷,该混合金属氧化物的摩尔体积小于初始金属氧化物基体的摩尔体积。优选地,上述方法中的步骤(b)的条件、步骤(c)的条件或这两步的条件包括不比运行的高压釜中遇到的那些条件更苛刻的条件。换句话说,上述方法中步骤(b)的条件、步骤(c)的条件或这两步的条件优选地温度不超过约250℃,压力不超过约5个大气压。
上述实施例以及优选的实施方式意在举例说明本发明的范围,不应当以任何方式以此限定本发明。由于在公开的内容中提供了详细的描述,其他实施方式对于本领域的普通技术人员必然是明显的。这样的其他实施方式被认为落入本发明的范围和实质,本发明的范围和实质仅由下面的权利要求书限定。
Claims (56)
1.一种从多孔基体生产独石的方法,所述方法包括:
(i)提供具有间隙并含有至少第一反应物的多孔基体;
(ii)使所述多孔基体与含有至少第二反应物的渗透介质接触;
(iii)在促进所述至少第一反应物与所述至少第二反应物反应以提供至少第一产物的条件下,让所述渗透介质渗入所述多孔基体的至少部分间隙;
(iv)允许所述至少第一产物形成并填充所述多孔基体的至少部分间隙,从而生产独石,其中所述第一产物不含钛酸钡。
2.如权利要求1所述的方法,其中,所述第一产物具有比所述多孔基体更大的摩尔体积。
3.如权利要求1所述的方法,其中,所述第一产物具有与所述多孔基体基本相同的摩尔体积。
4.如权利要求1所述的方法,其中,所述第一产物具有比所述多孔基体更小的摩尔体积。
5.如权利要求1所述的方法,其中,所述独石具有相互连接的微结构。
6.如权利要求1所述的方法,其中,所述第一反应物包括金属氧化物、金属氢氧化物、金属硫酸盐、金属氟化物、金属钛酸盐或它们的组合。
7.如权利要求6所述的方法,其中,所述金属包括钙、镁、锶、钛、锆、铬、锰、铁、镍、铜、铝或它们的组合。
8.如权利要求1所述的方法,其中,所述多孔基体、所述第一反应产物和所述独石中的至少一个包括下述材料:如果使用常规烧结方法,该材料加热至能够烧结的温度之前,所述材料分解。
9.如权利要求1所述的方法,其中,所述第二反应物包括草酸盐、碳酸盐、硫酸盐、磷酸盐、柠檬酸盐、金属离子或它们的组合。
10.如权利要求1所述的方法,其中,所述第二反应物包括金属盐的混合物。
11.如权利要求1所述的方法,其中,所述渗透介质是流体。
12.如权利要求1所述的方法,其中,所述独石具有复合微结构。
13.如权利要求1所述的方法,其中,所述独石具有核-壳结构。
14.如权利要求1所述的方法,其中,所述步骤(iv)还包括对所述独石进行时效处理。
15.如权利要求1所述的方法,其中,所述独石通过奥斯特瓦尔德熟化在步骤(iv)中生成。
16.如权利要求1所述的方法,其中,通过离子加成、离子取代、歧化作用、沉淀或它们的组合形成所述第一产物。
17.如权利要求1所述的方法,其中,所述第一产物含有化学键合。
18.如权利要求1所述的方法,其中,所述独石具有按体积计的约15%或更少的残余孔隙度。
19.如权利要求1所述的方法,其中,所述独石是陶瓷。
20.如权利要求1所述的方法,所述方法还包括重复所述步骤(ii)至所述步骤(iv)至少一次。
21.一种生产非钛酸钡烧结陶瓷的方法,所述方法包括:
(i)提供具有间隙并含有至少第一反应物的多孔基体;
(ii)使所述多孔基体与含有至少第二反应物的渗透介质接触;
(iii)在包括反应温度低于1000℃、反应压力小于70000psi以及促进所述至少第一反应物与所述至少第二反应物反应以提供至少第一产物的条件下,让所述渗透介质渗入所述多孔基体的至少大部分间隙,以及;
(iv)允许所述至少第一产物形成并填充所述多孔基体的至少大部分间隙,从而生成非钛酸钡烧结陶瓷。
22.如权利要求21所述的方法,其中,所述烧结陶瓷含有混合金属氧化物。
23.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括IIa族金属的氧化物。
24.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括IIb族金属的氧化物。
25.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括IIIb族金属的氧化物。
26.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括IVb族金属的氧化物。
27.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括Vb族金属的氧化物。
28.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括过渡金属的氧化物。
29.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括镧系金属的氧化物。
30.如权利要求21所述的方法,其中,所述多孔基体包括金属氧化物,所述金属氧化物包括锕系金属的氧化物。
31.如权利要求21所述的方法,其中,所述第二反应物包括至少一种金属的盐。
32.如权利要求21所述的方法,其中,所述第二反应物包括IIa族金属离子、IIb族金属离子、IIIb族金属离子、IVb族金属离子、Vb族金属离子、过渡金属离子、镧系金属离子、锕系金属离子或它们的混合物。
33.如权利要求21所述的方法,其中,所述第一产物具有比所述多孔基体更大的摩尔体积。
34.如权利要求21所述的方法,其中,所述第一产物具有与所述多孔基体基本相同的摩尔体积。
35.如权利要求21所述的方法,其中,所述第一产物具有比所述多孔基体更小的摩尔体积。
36.如权利要求21所述的方法,其中,所述烧结陶瓷具有按体积计的约15%或更小的残余孔隙度。
37.如权利要求21所述的方法,其中,所述烧结陶瓷具有按体积计的约5%或更小的残余孔隙度。
38.如权利要求21所述的方法,其中,所述烧结陶瓷基本上完全致密。
39.如权利要求21所述的方法,其中,通过离子加成、离子取代、歧化作用或它们的组合形成步骤(iv)中的反应物。
40.如权利要求21所述的方法,其中,通过沉淀形成步骤(iv)中的反应物。
41.一种由水热液相烧结方法生成的组合物,所述方法包括让多孔基体中的至少一个组分与液体所含有的至少第一反应物发生反应以提供至少第一产物,在所述反应过程中,所述多孔基体的残余部分作为支架用于促进所述至少第一产物从所述液体中形成,从而生成水热液相烧结组合物。
42.如权利要求41所述的组合物,其中,所述第一产物具有与所述多孔基体基本相同的摩尔体积。
43.如权利要求41所述的组合物,其中,所述第一产物具有比所述多孔基体更大的摩尔体积。
44.如权利要求41所述的组合物,其中,所述第一产物具有比所述多孔基体更小的摩尔体积。
45.如权利要求41所述的组合物,其中,所述多孔基体包括金属氧化物、金属氢氧化物、金属硫酸盐、金属氟化物、金属钛酸盐或它们的组合。
46.如权利要求41所述的方法,其中,所述第一反应物包括草酸盐、碳酸盐、硫酸盐、磷酸盐、柠檬酸盐、金属离子或它们的组合。
47.如权利要求41所述的方法,其中,所述多孔基体包括钙、镁、锶、钛、锆、铬、锰、铁、镍、铜、铝或它们的组合。
48.如权利要求41所述的方法,其中,所述多孔基体包括如下材料:如果使用常规烧结方法,所述材料在其能够烧结之前分解。
49.如权利要求41所述的组合物,其中,所述组合物具有复合微结构。
50.一种含有权利要求41所述的组合物的建筑材料、化学材料或它们的组合。
51.一种生产组合物的方法,所述方法包括:
(i)提供具有摩尔体积的多孔基体;
(ii)使至少部分所述多孔基体浸入含有反应物的渗透介质中,以及;
(iii)通过至少一些所述反应物与至少部分所述基体的反应来形成产物,
其中,所述产物具有摩尔体积,并且
其中,在步骤(iii)之前所述基体的摩尔体积与步骤(iii)之后所述产物的摩尔体积基本相同或不同。
52.如权利要求51所述的方法,其中,步骤(iii)之前所述基体的摩尔体积小于步骤(iii)之后所述产物的摩尔体积。
53.如权利要求51所述的方法,其中,步骤(iii)之前所述基体的摩尔体积大于步骤(iii)之后所述产物的摩尔体积。
54.如权利要求51所述的方法,其中,所述固体基体不易溶于所述渗透介质。
55.如权利要求51所述的方法,其中,步骤(iii)之前所述基体的形状小于步骤(iii)之后所述产物的形状。
56.如权利要求51所述的方法,其中,所述基体包括惰性填充材料。
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