CN107532012A - 陶瓷复合材料的制造方法 - Google Patents

陶瓷复合材料的制造方法 Download PDF

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CN107532012A
CN107532012A CN201680007516.6A CN201680007516A CN107532012A CN 107532012 A CN107532012 A CN 107532012A CN 201680007516 A CN201680007516 A CN 201680007516A CN 107532012 A CN107532012 A CN 107532012A
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马赛阿斯·巴泰特
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Hublot SA
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Abstract

结合基于金属氧化物或准金属的基质(12)和分散在基质中的矿物色素(10)的复合材料(16)的制造方法,所述的基质(12)适合使光穿过,该方法包括使粉末状的矿物色素与粉末状的基质混合的步骤以及在充足压力下烧结基质的步骤,使得基质在所述压力下的致密化温度低于矿物色素的分解温度,其中,烧结温度大于或等于基质的致密化温度并低于矿物色素的分解温度。

Description

陶瓷复合材料的制造方法
技术领域
本发明涉及含有陶瓷的复合材料,尤其是基于金属氧化物或准金属的复合材料,及其相应的制造方法和用法。
背景技术
工业制造的彩色陶瓷通常是氧化铝或者是由色素填充并与色素混合的氧化锆。色素是在所述色素对其进行着色的介质中可溶的着色物质。特别地,色素被用于材料的大体积着色。
在某些情况下,由于在晶体结构中形成比如异质原子这样的瑕疵,可以直接给氧化物着色。
对于某些颜色而言,比如黑色、白色、蓝色和绿色,彩色陶瓷组件的制造是管理良好的,但并非所有颜色都是如此。
例如,尽管竭尽全力,也仍旧不可能生产出亮红色陶瓷。只能生产出红/橙色或红/棕色色度的陶瓷。
实际上,彩色陶瓷的制造方法包括混合陶瓷粉与矿物色素,然后将其全部注入模具,以便得到由聚合物包围的所谓的“生坯”。然后,例如,通过将其加热到600℃释放该生坯,因为包围所述生坯的聚合物升华了。最后,以接近陶瓷熔点的温度烧结生坯,因此使其致密化并产生固体块。
所采用的色素比率根据所需要的颜色变化,但是通常为按体积计算的的几个百分比(通常约为3%至5%)就足以给陶瓷着色。实际上,在烧结阶段,色素通常扩散进入白色陶瓷中并通过这种方式使其着上色素的颜色。
但是,当色素不扩散入陶瓷中时,陶瓷呈白色,这样减弱了添加色素的效用。产生的颜色通常为灰色,并且缺乏美感。
尤其是,没有红色色素能够在烧结步骤之后保持其颜色。产生的颜色反而接近橙色、枣红色乃至棕色。
本发明的具体目标是提出一种新型复合材料,通过所述复合材料在彩色陶瓷制造过程中显著扩大颜色的可能范围。
本发明的目的也是提出一种包含冷光色素的新型复合材料。
发明内容
为此目的,本发明涉及到制造复合材料的方法,所述复合材料包括:
-基于金属氧化物或准金属的基质,所述基质适合使光穿过(烧结之后),且基质的致密化温度取决于所述基质所经受的压力;
-分散在基质中的矿物色素,具有一定的分解温度,超过所述分解温度所述矿物色素分解;
其中,在低于80MPa的至少一个压力范围内,尤其是在大气压力下,基质的致密化温度大于矿物色素的分解温度;
所述方法包括以下步骤:
a)将粉末状的矿物色素与粉末状的基质混合;并且,
b)在一定的烧结温度以及大于或等于80MPa的充足压力下,充分烧结所述粉末基质,使得基质在所述压力下的致密化温度低于矿物色素的分解温度,其中,烧结温度大于或等于基质的致密化温度,且低于矿物色素的分解温度。
本发明还涉及到制造复合材料的方法,所述复合材料包括:
-基于金属氧化物或准金属的基质,其中,所述基质适合使光穿过(烧结之后),而且,且基质的致密化温度取决于所述基质所经受的压力;
-分散在基质中的矿物色素,具有一定的分解温度,超过所述分解温度所述矿物色素分解;
其中,在低于100MPa的至少一个压力范围内,尤其是在大气压力下,基质的致密化温度大于矿物色素的分解温度;
所述方法包括以下步骤:
a)将粉末状的矿物色素与粉末状的基质混合;并且,
b)在一定的烧结温度下以及大于或等于100MPa的充足压力下,充分烧结所述粉末基质,使得基质在所述压力下的致密化温度低于矿物色素的分解温度,其中,烧结温度大于或等于基质的致密化温度,且低于矿物色素的分解温度。
由于这些设置,可以实现通过非常大的色彩范围得到陶瓷复合材料,尤其是包括亮红色陶瓷。实际上,因为基质适合使光穿过,也就是基质是透明或半透明的,基质的作用是即使色素颗粒位于基质内的深处,也能使色素的颜色能够扩散到材料外面。这样做的效果是增大材料的着色表面并因此增加其颜色的生动性。
在根据本发明的方法的优选实施例中,可以有利地利用以下设置中的一项和/或其它项:
-矿物色素的平均直径介于0.2μm至10μm;
-在烧结过程中所施加的所述压力下基质的致密化温度低于1300℃;
-烧结温度(烧结过程中应用的温度)低于1300℃,乃至低于或等于1200℃;
-矿物色素代表所述复合材料的体积分数,体积分数介于所述复合材料的2%至50%;
-矿物色素基于铝酸钴CoAl2O4
-矿物色素呈离散颗粒状,每个颗粒分别包括核以及包围核的彩色涂层;
-彩色涂层是包含铁、铬、铝、钛、硅、锌、镍、钴、镉、铜、钒、铋和/或锰的一种氧化物;
-矿物色素的核适合使光穿过;
-矿物色素的核是由选自云母、氧化铝、锆以及二氧化钛中的一种材料制成的;
-彩色涂层的分子式是KAl2(AlSi3O10)(OH)2
-陶瓷基质基于铝酸镁MgAl2O4
-陶瓷基质基于使用钇来稳定的锆为基础;
-烧结过程中所施加的压力至少等于200MPa;
-矿物色素的颜色(尤其是前述彩色涂层)是亮红色的;
-矿物色素是发光的;
-矿物色素包含稀土铝酸盐和/或稀土硅酸盐;
-矿物色素基于掺杂铕的铝酸锶;
-烧结过程中施加的压力至少等于600MPa.
本发明的目的还有一种复合材料,包括:
-一种矿物色素;以及,
-一种基于金属氧化物或准金属的基质,其中,所述基质适合使光穿过,而且在压力作用下,基质的致密化温度低于矿物色素的分解温度。
在根据本发明的复合材料的各个实施例中,可以进一步有利地利用以下设置中的一项和/或其它一项:
-矿物色素体现所述复合材料的体积分数,体积分数介于所述复合材料的2%至50%;
-矿物色素基于铝酸钴CoAl2O4
-矿物色素可呈离散颗粒状,每个颗粒分别包括核以及包围核的彩色涂层;
-彩色涂层是一种包含铁、铬、铝、钛、硅、锌、镍、钴、镉、铜、钒、铋和/或锰的氧化物;
-矿物色素的核适合使光穿过;
-矿物色素的核是由选自云母、氧化铝、锆以及二氧化钛中的一种材料制成的;
-矿物色素是发光的;
-矿物色素包含稀土铝酸盐和/或稀土硅酸盐;
-矿物色素基于掺杂铕的铝酸锶;
-矿物色素的平均直径介于0.2μm至10μm;
-基质致密化的温度在压力下低于1300℃;
-就基质是由金属氧化物构成的意义而言,基质是陶瓷;
-基质基于铝酸镁尖晶石MgAl2O4.
最后,本发明进一步的目的是通过上述方法产生的复合材料在手表或珠宝制造过程中的用途。
附图说明
本发明通过阅读作为非限制性实例并参考附图列出的本发明的几个实施例的下列说明可以得到更好地理解,在附图中:
-图1是根据本发明的一个实施例的复合材料的简单制造方法的示意图;以及,
-图2显示了根据本发明的一个实施例的复合材料的晶体截面。
具体实施方式
如上文所述,本发明涉及一种复合材料,尤其是用于手表或珠宝制作的复合材料,所述材料包括:
-一种矿物色素;以及
-一种基于金属氧化物或准金属的基质,其中,基质适合使光穿过,而且在适当压力下,基质的致密化温度低于矿物色素的分解温度。
矿物色素可以体现体积分数,体积分数介于复合材料的2%至50%。
根据复合材料所需的颜色选择矿物色素。
关于蓝色和绿色,选择基于铝和钴的矿物色素,尤其是,具有尖晶石晶体结构的铝酸钴CoAl2O4。在这种情况下,材料是块状着色的。色素的蓝色或绿色以及色素颜色的生动性取决于其氧化水平。
除铝酸钴以外,还可以使用具有以下化学分子式的化合物;颜色为蓝色或绿色以及颜色的生动性还取决于氧化水平:
-(Co,Zn)Al2O4
-(Zn,Co)(Cr,Al)2O4
-Co(Al,Cr)2O4
-CoAl2O4/Co2SnO4.
根据复合材料所需的颜色,可添加一种元素或多种元素的组合,以改变化合物的颜色。在这些元素之中,尤其是铬、锂、镁、硅、锶、锡、钛和锌。而且,色素的蓝色或绿色以及色素颜色的生动性取决于其氧化水平。
关于红色和黄色,选择分别包含核以及包围所述核的彩色涂层的离散颗粒状的矿物色素。实际上,这些颜色的生动性太弱,以至于不能对材料进行块状着色。
最好是,矿物色素的核适合使光穿过,也就是说所述矿物色素是透明的或半透明的。
因此,如果在复合材料表面发现颗粒,并将其打磨,那么通过核仍然可以看到涂层的颜色。
例如,可以用从下列材料中选择的材料制造矿物色素的核:
-云母,例如,白云母或黑云母;
-氧化铝,Al2O3
-氧化锆,ZrO2
-二氧化钛,TiO2.
彩色涂层可以是含有铁、铬、铝、钛、硅、锌、镍、钴、镉、铜、钒、铋和/或锰的氧化物。
例如,尤其是可以涉及到:
-KAl2(AlSi3O10)(OH)2
-TiO2
-SiO2
-ZnO。
鉴于色素的颜色和生动性取决于其氧化水平,所以可能通过上述化合物得到所有颜色。
已知颜色是红色、黄色、绿色、紫罗兰色、黑色和蓝色。因此,可能得到产生蓝色和绿色的核/涂层类型的矿物色素。
彩色涂层的厚度以及构成矿物色素的各个元素的比例参与设置其颜色及生动性。
以下文件描述了具有二氧化钛和云母基的红色色素的实例:US4,344,987A、US5,522,923A和US4,086,100A。
矿物色素也可以是冷光源(磷光和/或荧光),所述冷光源包括稀土铝酸盐,例如掺有铕的铝酸锶。商标名下已知的系列产品就是这种情况,所述系列产品以各种色调和颜色存在。稀土硅酸盐或稀土铝酸盐的基质以及硅酸盐也可以是冷光源。
还有其它产品,比如由日本精工株式会社开发的“LumiBrite”或者更不令人关注的光源,比如包含放射性元素且其使用严格受限的无线发光源或者自动发光源。在这里所说的是氚、镭或钷。
某些气体也有发光能力,在这种情况下,将其密封在玻璃胶囊中。
在以下文件中列出了发光色素的某些实例:US3,294,699A、US2,544,236A、US5,607,621A、WO02/083814A1和US2,544,236A。
还可以使用有“干扰”特性的矿物色素,也就是说,所述矿物色素根据被观察角度呈现出不同色调。
例如,通过包含云母核、复合氧化物彩色涂层以及包围彩色涂层的二氧化钛层的矿物色素可以得到这种干扰特性,复合氧化物的彩色涂层包括包围核的钛、铁以及镍。
其它矿物色素可进一步借由其形状的性质显示其它色彩效果,比如珍珠效果。
矿物色素的平均直径可介于0.2μm至10μm。
有利的是,矿物色素的分解温度在1300℃以上。该温度相当于导致其颜色变化的矿物色素的分解温度,或者,换言之,相当于矿物质的颜色在所述温度改变。
选择基质,使其致密化温度在充足压力下低于矿物色素的分解温度,因而有利地低于1300℃。
通常,发光色素在惰性环境中无法抵抗高于800℃的温度。在这种情况下,有必要增加基质的致密化压力,从而使其在800℃下致密化,同时仍保持透明。
基质适合使光穿过,也就是说基质是透明或者半透明的。为此,例如,按照用于制造透明陶瓷的已知方法制备基质。尤其是在选择氧化物时以及在成形条件下存在这种适应性,所述成形条件是指致密化温度和压力。
如前文所见,基质基于金属氧化物或准金属氧化物。
准金属的概念是指无法归类为金属或非金属的化学元素,也就是说其理化特性介于金属与非金属的理化特性之间。
准金属的特征在于以下特性:
·其氧化物通常是两性的(金属特性有些碱性,非金属特性有些酸性);
·其表现像半导体(尤其是硼、硅和锗)。
因此,准金属在周期表中形成金属与非金属之间的斜带:
·硼5B
·硅14Si
·锗32Ge
·砷33As
·锑51Sb
·碲52Te
·砹85At
尤其是,基质可以是陶瓷。
可以与本发明相结合使用的陶瓷基质中包括铝酸镁尖晶石(MgAl2O4)、锆或纯氧化铝。
尤其是通过图1所示的过程可以制造根据本发明的复合材料,所述过程包括以下步骤:
a)在模具14中混合粉末状的矿物色素10与粉末状的基质12;
b)在充足的压力下烧结粉末基质,以便基质12的致密化温度在所述压力下保持在矿物色素10的分解温度以下,在低于矿物色素10的分解温度并至少等于基质的致密化温度的温度下发生烧结;
c)从模具14中取出复合材料16。
烧结过程中施加的压力通常大于或等于80MPa,乃至大于或等于100MPa,本发明特别适合在低于80MPa,乃至低于100MPa的至少一个压力范围内、致密化温度高于矿物色素分解温度的基质。
因此,在压力和热量下,矿物色素稳定,反之,基质覆盖所有矿物色素的颗粒。
在冷光色素的情况下,通常有必要使致密化温度低于800℃的限制,烧结过程中施加的压力通常高于600MPa。
在复合材料表面扩散的光足以确保颜色的生动性令人满意。
可在单向压力下利用SPS(“火花等离子体烧结”)冲压进行烧结,其中可在数分钟内增加温度。
还可以通过在等压下烧结来结束烧结。第一步涉及对粉末基质进行冲压,以便形成微丸或者通过传统的用于陶瓷的注射技术注入组件,然后进行初次烧结,初次烧结的效果是不必结束该方法就封闭孔隙。然后,在烤炉中完成烧结,一般情况下可在气体中将烤炉加压到大约200MPa。
实例1
采用含有低于百万分之10的Fe、Ca和Na杂质以及低于百万分之20的Si杂质,且粒径为0.2μm的铝酸镁尖晶石(MgAl2O4)粉末,例如,由Baikowski生产的产品号为S30CR的粉末。
矿物色素的剂量按体积计算可为5%至30%。
通常在1800℃以上的温度下进行尖晶石MgAl2O4的烧结。根据本发明,为了保留矿物色素并保持其生动性,在1200℃的温度下以及非常高的等压或单向压力下进行烧结。
在压力高于80MPa乃至高于100MPa的条件下,能够在该温度区域对尖晶石MgAl2O4进行致密化。
此外,可以在该温度区域使用大范围的色素,而不会将其分解。
这样,产生具有透明度的密实的陶瓷复合材料,该材料能够使用矿物色素在几十毫米的深度着色,而不仅仅是表面色素颗粒的色彩效果。
尤其是,32.76g的MgAl2O4尖晶石(来自Baikowski的S30CR)与4.6g的红色色素(具有KAl2(AlSi3O10)(OH)2涂层的TiO2核)混合,以便得到按体积计算含有10%色素的混合物。用4g混合物填充直径为30mm的石墨模具。在压力下通过1200℃的SPS冲压对混合物进行五分钟烧结,所述冲压力为70kN,相当于100MPa的压力。产生亮红色的密实陶瓷盘。
通过扫描电子显微镜(SEM)对样本放大1500倍得到图2所示的晶体截面,所述样本是根据实例1的方法所制造的且通过金刚石颗粒打磨到0.25μm精度的复合材料。光线区域与色素颗粒相对应。
示例2
采用通过钇来稳定化的锆,所述锆在200MPa以上的等压或单向压力且在1200℃的温度下进行烧结之后,可以得到透明或半透明的锆。
因此,通过混合按体积计算为30%的红色色素与通过钇来稳定化的锆(钇添加量约为8%)得到的效果与通过玻璃或MgAl2O4尖晶石得到的效果相似,意即能得到具有陷入内部的红色色素的透明基质。
因此,本发明提出颜色范围非常大的新型陶瓷复合材料,以及包含发光色素的新型复合材料。
尤其是,通过本发明可以得到亮红色的彩色陶瓷,这在以前是做不到的。
实际上,如前文所述,尽管关于制造红色陶瓷的大部分研究集中在获得在烧结步骤之后仍保持其颜色的红色色素,在本发明中,考虑与基质本身的对比,尤其是利用其烧结温度保持低于使矿物色素的颜色变色的温度的基质。
例如,本发明的彩色复合材料可用于制造对制表零件进行表面修光的部件,比如斜垫面、中段、表带扣等。这些材料在该应用过程中的优点是其耐磨性并且保证部件颜色不会因为施加于戴在手腕上的手表的约束而受损。因为对核进行着色,所以即便在表的表面被划的极端情况下,该划痕也不会呈现出与表面不同的颜色,因为不是涂层着色,而是块状着色。
所考虑的其它用途中的一个用途是例如利用磷光性色素制造表盘。用这种材料制造的表盘的硬度和磷光功率比已经涂了磷光漆的表盘大得多。因为材料的基质是透明的,所以通过1至2mm深的色素的照度是可见的,由此,可以看到色素相当大的表面,与仅在数微米起作用的涂层不同。
最后这项应用在深海潜水的运动手表领域特别引人注意。

Claims (20)

1.制造复合材料(16)的方法,所述复合材料包括:
-一种基于金属氧化物或准金属的基质(12),所述基质(12)适合在烧结之后使光穿过,且基质的致密化温度取决于所述基质所经受的压力;
-一种分散在基质中的矿物色素(10),具有一定的分解温度,超过所述分解温度所述矿物色素(10)分解;
其中,在低于80MPa的至少一个压力范围内,基质的致密化温度大于矿物色素的分解温度;
方法包括以下步骤:
a)将粉末状的矿物色素(10)与粉末状的基质(12)混合;并且,
b)在一定的烧结温度下以及大于或等于80MPa的压力下,充分烧结所述粉末混合物,使得基质(12)在所述压力下的致密化温度低于矿物色素(10)的分解温度,其中,烧结温度大于或等于基质的致密化温度,且低于矿物色素的分解温度。
2.根据权利要求1的方法,其中,矿物色素(10)的平均直径在0.2μm至10μm之间。
3.根据前述权利要求中任何一个权利要求的方法,其中,在烧结过程中所施加的所述压力下基质(12)的致密化温度低于1300℃。
4.根据前述权利要求中任何一个权利要求的方法,其中,矿物色素(10)代表所述复合材料的体积分数,体积分数介于所述复合材料(16)的2%至50%。
5.根据前述权利要求中任何一个权利要求的方法,其中,矿物色素(10)基于铝酸钴CoAl2O4
6.根据前述权利要求中任何一个权利要求的方法,其中,矿物色素(10)呈离散颗粒状,每个颗粒包括核以及包围核的彩色涂层。
7.根据前述权利要求中任何一个权利要求的方法,其中,彩色涂层是包含铁、铬、铝、钛、硅、锌、镍、钴、镉、铜、钒、铋和/或锰的氧化物。
8.根据权利要求6和7中任何一个权利要求的方法,其中,矿物色素的核(10)适合使光穿过。
9.根据权利要求8的方法,其中,矿物色素的核(10)是由选自云母、氧化铝、锆以及二氧化钛的材料制成的。
10.根据前述权利要求中任何一个权利要求的方法,其中,彩色涂层的分子式是KAl2(AlSi3O10)(OH)2
11.根据前述权利要求中任何一个权利要求的方法,其中,陶瓷基质基于铝酸镁尖晶石MgAl2O4
12.根据权利要求1至10中任何一个权利要求的方法,其中,陶瓷基质基于使用钇来稳定的锆。
13.根据权利要求12的方法,其中,烧结过程中所施加的压力至少等于200MPa。
14.根据前述权利要求中任何一个权利要求的方法,其中,矿物色素(10)的颜色是亮红色的。
15.根据权利要求1至4中任何一个权利要求的方法,其中,矿物色素(10)是发光的。
16.根据权利要求15的方法,其中,矿物色素(10)包含稀土铝酸盐和/或稀土硅酸盐。
17.根据权利要求16的方法,其中,矿物色素(10)基于掺杂铕的铝酸锶。
18.根据权利要求15至17中任何一个权利要求的方法,其中,烧结过程中施加的压力至少等于600MPa。
19.根据前述权利要求中任何一个权利要求的方法产生的复合材料(16)。
20.根据权利要求19的复合材料(16)在手表制造或珠宝制造中的用途。
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