EP0587160A1 - Procédé et moule pour la fabrication d'éléments en céramique - Google Patents

Procédé et moule pour la fabrication d'éléments en céramique Download PDF

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Publication number
EP0587160A1
EP0587160A1 EP93114497A EP93114497A EP0587160A1 EP 0587160 A1 EP0587160 A1 EP 0587160A1 EP 93114497 A EP93114497 A EP 93114497A EP 93114497 A EP93114497 A EP 93114497A EP 0587160 A1 EP0587160 A1 EP 0587160A1
Authority
EP
European Patent Office
Prior art keywords
slurry
filter
ceramics
mold
molding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP93114497A
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German (de)
English (en)
Inventor
Tomoyuki Awazu
Yasushi Tsuzuki
Akira Yamakawa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Electric Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP24187492A external-priority patent/JPH0691620A/ja
Priority claimed from JP5236493A external-priority patent/JPH06262612A/ja
Application filed by Sumitomo Electric Industries Ltd filed Critical Sumitomo Electric Industries Ltd
Publication of EP0587160A1 publication Critical patent/EP0587160A1/fr
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B28B1/265—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor pressure being applied on the slip in the filled mould or on the moulded article in the mould, e.g. pneumatically, by compressing slip in a closed mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B28B1/261—Moulds therefor
    • B28B1/262—Mould materials; Manufacture of moulds or parts thereof

Definitions

  • This invention relates to a molding process for various ceramic products, particularly to a pressure slipcast molding of ceramic slurry, and a mold used therefor .
  • a mixture consisting of powder and liquid (hereinafter “slurry") is pressurized to discharge the liquid therefrom.
  • slurry a mixture consisting of powder and liquid
  • the resulting molded article has a high geometric stability and the liquid discharge from the slurry can be made in reduced time.
  • porous molds made from gypsum or plastics have been used for the liquid discharge, (e.g. Japanese Patent Publication No. 2-42321, Japanese Patent Laid-Open Nos. 60-70701, 63-3906 and 61-297103).
  • the molding pressure is, at most only 10 kg/cm2 when a gypsum mold is used and about 50 kg/cm2 when a plastics mold is used. If the molding pressure exceeding these upper limit is applied to the porous mold, such high pressure may bring about the breakage of the molds.
  • a filter cloth 9 and a filter paper 10 are, as shown in FIG. 3, set at the frontal face of a metallic mold 3, which has holes of 1 - 3 mm inside diameter for dehydration. Only liquid (water) is discharged from the holes of the mold through the filter.
  • the liquid discharge part consists of the filter cloth 9, filter paper 10 and mold 3 having the holes 4 for dehydration
  • a high molding pressure can be applied.
  • the powder in the slurry enters the holes for dehydration pressing on the filter paper or filter cloth and then it becomes protrusions 11 are formed on the surface of the molded product, corresponding to the holes as shown in FIG. 4. Therefore, an after-treatment is necessary to remove the protrusion from the molded product, thereby resulting in a high production cost.
  • the present invention was made to overcome the above and other problems encountered in the prior art.
  • Another object of the present invention is to provide molds used for carrying out the above-mentioned molding process.
  • the basic idea of this invention is to enable the application of high pressure by using a mold made of a high-strength porous metal or ceramic material in a pressure slipcast molding process of a ceramic slurry.
  • the present invention provides a process for molding a ceramic slurry, in which a mold made wholly or partially of a porous metal or a porous ceramic is used.
  • the present invention also provides a mold made wholly or partially of a porous metal or a porous ceramic, for the purpose of molding ceramic slurry.
  • FIG. 1 is a vertical cross-sectional view showing a casting method employing a casting mold according to an embodiment of the present invention.
  • FIG. 2 is a view similar to FIG. 1, showing a casting method employing a casting mold according to a modification of the present invention.
  • FIG. 3 is a view similar to FIG. 1 employing a conventional casting mold.
  • FIG. 4 is a vertical cross-sectional view showing a cast article obtained using the conventional casting mold.
  • the basic concept of the present invention consists in that, in pressure slipcast molding of ceramics, a casting mold made of metal or ceramic of a higher strength is employed to enable application of a higher pressure.
  • a pressure not lower than 100 kgf/cm2 may be developed.
  • a pressure up to 1000 kgf/cm2 is also possible depending on the mold's design.
  • Ceramics materials are not limited to Al2O3 ceramics, Si3N4 ceramics, BN ceramics and so on.
  • porous metals and ceramics it is possible to polish the surface of porous metals and ceramics, to decrease their surface roughness, and to make it a mirror plane in some cases.
  • molded ceramic articles can be easily taken out of the mold and also be prevented from breaking.
  • the surface appearance of the molded ceramic articles become excellent.
  • ceramics for porous materials ceramics have a high chemical resistibility against acid, alkali and so on. Ceramics are neither corroded nor rusted and have sufficient durability. And they are excellent in strength and toughness, compared with other materials, therefore they do not become fatigued and have sufficient durability mechanically too.
  • diameters of pores in the porous materials which are components of a mold the wholly or partially, should be more than 0.1 ⁇ m so that dehydration and molding can be carried out in industrially practical time. If diameters of the pore are less than 0.1 ⁇ m, in case of using water for liquid of the slurry, the surface tension becomes higher, keeps the liquid (water) from flowing into pores of porous materials, and makes it difficult to discharge the liquid in the slurry through pores of porous materials.
  • the maximum diameter of the pores is twenty times as high as the diameter of the secondary particles of powders in the slurry and it can prevent the powders from flowing.
  • the filter paper or filter cloth on the surface of porous metal or ceramics facing the slurry. Even if diameters of pores on the surface of porous metal or ceramics are so large as to let the powders in the slurry enter the pores, the filter prevents powders from entering them and makes release easier. And if the surface of porous metal or ceramics is rough, the filter does not bring about an anchor effect and makes release smooth. Because the filter, made of paper or cloth has high flexibility, therefore it is possible to release the filter from molded ceramic articles slowly without producing chips. Protrusions on the surface of ceramics, in the conventional method as shown in FIG. 4, do not enter pores of porous metal or ceramics through the filter and then molded ceramic articles have an excellent surface.
  • the average diameter of pores in the filter paper or filter cloth should be more than 0.1 ⁇ m and less than twenty times as large as the diameter of the secondary particles in the slurry.
  • the average diameter of pores needs to be more than 0.1 ⁇ m. If the average diameter is larger than twenty times as large as the average diameter of the secondary powder in the slurry, it causes efflux of powder, namely a permeation of the slurry through the filter for the same reason as discussed above.
  • the paper filter may be formed of any material customarily employed for the paper filter, while the cloth filter may be formed of any material, such as synthetic fibers, e.g. polyester, nylon or acrylic fibers, or natural fibers, such as cotton, provided that such material can be woven or knitted to form a cloth.
  • synthetic fibers e.g. polyester, nylon or acrylic fibers, or natural fibers, such as cotton, provided that such material can be woven or knitted to form a cloth.
  • a mixture of powders was made by adding Y2O3, Al2O3 as assistant agents to Si3N4 powder , having an average diameter of 0.7 ⁇ m, then mixing it in ethylalcohol. Water and binder were added to the mixture. Making use of a nylon ball mill, they were made into a slurry. The powder content of the slurry was set to be 40 vol.%.
  • FIG. 1 shows a process for molding. Mold 3, having holes 5 for dehydration and attached to porous material 7, was set in mold 2 and the slurry was injected into it. The slurry was pressurized with a metallic pestle 1 fitted with a porous punch 6 at its terminal end. Water in the slurry 8 was discharged by applying pressure through porous materials 6, 7. As a result thereof, molded ceramic articles could be taken out.
  • Table 1 shows results of the density of molded articles and molding time. Table 1 No. Porous materials Molding pressure (kgf/cm2) Density of molded articles (%) Molding time (sec.) 1 SUS 316 5 49.8 1000 2 SUS 316 20 50.7 250 3 SUS 316 100 61.6 45 4 SUS 316 1000 63.4 12 *5 gypsum 5 48.9 850 *6 gypsum 20 gypsum fractured - *7 resin 5 49.7 800 *8 resin 20 50.8 200 *9 resin 100 resin fractured - * indicates comparisons
  • the slurry was made by mixing together Al2O3 powder having average diameter of 1 ⁇ m, distilled water using a ball mill and admixing with a binder.
  • the powder content of the slurry was set to be 53 vol.%.
  • Stainless steel having different diameters of pores and surface roughness, was used as porous materials, and the molding pressure applied in this case was 200 and 800 kgf/cm2.
  • the diameter of pores on the surface was determined by taking the average through observations under a microscope.
  • Table 2 shows results of the density of molded articles, molding time and mold release properties with respect to the porous materials, under various conditions.
  • Table 2 No. Molding pressure (kgf/cm2) Average diameter of pores of porous materials ( ⁇ m) Surface roughness of porous materials (Z) Density of molded articles (%) Molding time (sec.)
  • Y2O3, Al2O3 as assistant agents were added to Si3N4 powder having an average diameter of 0.5 ⁇ m. Then they were mixed in distilled water by making use of a ball mill. Some binder was added to the mixture and they were mixed further to make a slurry. The powder content of the slurry was 42 vol.%. Measurements of the particle size distribution indicated the mean particle diameter to be 0.53 ⁇ m.
  • Disks having a diameter of 40 mm and a thickness of 5 mm, were molded out of the slurry.
  • FIG. 2 shows a process for molding. Conditions were changed variously; diameters of pores in the porous stainless steel, surface roughness and diameters of pores in the filter. Casting without filter and casting as illustrated in FIG. 3 were practiced for comparison. And molding pressure applied in this case was 300 kgf/cm2.
  • Table 3 and 4 show how some conditions affect the molded ceramic articles and statuses of mold releasing. It may be seen from these Tables that satisfactory cast articles could be produced in accordance with the present invention.
  • Table 3 No. Process Filter present or none Average diameter of pores of filter ( ⁇ m) Materials of filter Average diameter of pores of metallic materials ( ⁇ m) 1 FIG. 2 none - - 20.1 2 FIG. 2 none - - 72.2 3 FIG. 2 none - - 8.2 4 FIG. 2 filter 0.05 resin film 20.1 5 FIG. 2 filter 0.05 resin film 72.2 6 FIG. 2 filter 0.4 filter paper 20.1 7 FIG. 2 filter 0.4 filter paper 72.2 8 FIG. 2 filter 0.4 filter paper 8.2 9 FIG. 2 filter 5.0 filter paper 20.1 10 FIG.
  • a mixture of powders was made by adding Y2O3, Al2O3 as assistant agents to Si3N4 powder having an average diameter of 0.8 ⁇ m, mixing it, in ethylalcohol and by drying it. Deionized water and a binder were added to the mixture. Making use of a nylon ball mill, they were made into slurry. The powder content of the slurry was set to be 40 vol.%.
  • Molding pressure (kgf/cm2) Density of molded articles (%) Molding time (sec.) 1 Al2O3 2 50.5 840 2 Al2O3 20 51.3 220 3 Al2O3 200 63.5 32 4 Al2O3 950 64.7 9 *5 gypsum 2 49.2 720 *6 gypsum 20 gypsum fractured - *7 resin 2 49.9 720 *8 resin 20 51.2 200 *9 resin 200 resin fractured - *indicates comparisons
  • the slurry was made by mixing together Al2O3 powder having an average diameter of 1 ⁇ m, distilled water and some binder.
  • the powder content of the slurry was to be 53 vol.%.
  • the process for molding was the same as Example 1, as shown in FIG. 1.
  • Al2O3 with different diameters of pores and surface roughness, was used.
  • the cavity rate of the Al2O3 was 38 vol.%, and the molding pressure applied in this case was 200 and 800 kgf/cm2.
  • Table 6 shows results of density of molded articles, molding time and mold release properties with respect to the porous materials under various conditions.
  • Table 6 No. Molding pressure (kaf/cm2) Average diameter of pores of porous materials ( ⁇ m) Surface roughness of porous materials (z) Density of molded articles (%) Molding time (sec.) Status of molded articles and mold releasing 1 200 0.07 0.2 - not stiffened in 300 - 2 200 0.71 0.2 68.2 72 satisfactory 3 200 0.71 0.7 67.9 69 peeled off 4 200 8.7 0.3 69.3 50 satisfactory 5 200 8.7 0.7 69.2 51 peeled off 6 200 24.4 0.3 68.1 35 peeled off 7 800 0.07 0.2 - not stiffened in 300 - 8 800 0.71 0.2 69.5 65 satisfactory 9 800 0.71 0.5 69.9 62 peeled off 10 800 0.71 0.7 69.7 64
  • Y2O3 and Al2O3 as assistant agents were added to Si3N4 powder having an average diameter of 0.5 ⁇ m. Then they were mixed in distilled water by making use of a ball mill. Some binder was added to the mixture and they were mixed further to make the slurry. The powder content of the slurry was 42 vol.%. The average diameter was indicated to be 0.53 ⁇ m by measurement of the size distribution.
  • Disks having a diameter of 40 mm and a thickness of 5 mm, were molded out of the slurry through the process for molding as shown in FIG. 2.
  • the porous material was Al2O3. And other conditions were changed variously; diameters and surface roughness of the porous materials and diameters of pores in the filter. Molding without the filter and molding as illustrated in FIG. 3 were also performed for comparison. And molding pressure applied in this case was 300 kgf/cm2. Table 7 and 8 show how some conditions affect the molded ceramic articles and its status of molded articles and mold releasing. They also show that a satisfactory molded ceramic articles could be produced in accordance with the present invention. Table 7 No.
  • FIG.2 Materials of filter Average diameter of pores of ceramics materials ( ⁇ m) 1 FIG.2 none - - 24.4 2 FIG.2 none - - 72.2 3 FIG.2 none - - 8.7 4 FIG.2 filter 0.08 resin film 24.4 5 FIG.2 filter 0.08 resin film 72.2 6 FIG.2 filter 0.6 filter paper 24.4 7 FIG.2 filter 0.6 filter paper 72.2 8 FIG.2 filter 0.6 filter paper 8.7 9 FIG.2 filter 0.6 filter paper 72.2 10 FIG.2 filter 4.0 filter paper 24.4 11 FIG.2 filter 4.0 filter paper 72.2 12 FIG.2 filter 4.0 filter paper 8.7 13 FIG.2 filter 4.0 filter paper 72.2 14 FIG.2 filter 23.2 filter cloth 24.4 15 FIG.2 filter 23.2 filter cloth 72.2 16 FIG.2 filter 23.2 filter cloth 8.7 17 FIG.3 filter 4.0 filter paper plus filter cloth diameter of holes for the hydration 1400 18 FIG.3 filter 4.0 filter paper plus filter cloth 2000 19 FIG.3 filter 4.0 filter paper plus filter cloth 2
  • molded ceramic articles having a high density and a smoothed surface could be surely produced in a relatively short time.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
EP93114497A 1992-09-10 1993-09-09 Procédé et moule pour la fabrication d'éléments en céramique Withdrawn EP0587160A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP241874/92 1992-09-10
JP24187492A JPH0691620A (ja) 1992-09-10 1992-09-10 セラミックスの成形法および成形型
JP52364/93 1993-03-12
JP5236493A JPH06262612A (ja) 1993-03-12 1993-03-12 セラミックスの成形法および成形型

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EP0587160A1 true EP0587160A1 (fr) 1994-03-16

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0756922A1 (fr) * 1995-07-27 1997-02-05 Sumitomo Electric Industries, Ltd. Procédé de moulage pour matériaux céramiques
US5660863A (en) * 1993-03-08 1997-08-26 Agency Of Industrial Science & Technology, Ministry Of International Trade & Industry Apparatus for production of ceramics reinforced with three-dimensional fibers
US6458298B1 (en) 1992-09-10 2002-10-01 Sumitomo Electric Industries, Ltd. Process for molding ceramics
US11731312B2 (en) 2020-01-29 2023-08-22 James R. Glidewell Dental Ceramics, Inc. Casting apparatus, cast zirconia ceramic bodies and methods for making the same

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
LU38021A1 (fr) * 1959-09-08
DE1127781B (de) * 1958-01-03 1962-04-12 Philips Nv Presse zur Herstellung von Gegenstaenden aus keramischem Material
FR2211873A5 (fr) * 1972-12-23 1974-07-19 Wilden Johann
DE2641975A1 (de) * 1976-09-16 1978-03-23 Gerstetter Reinhold Verfahren und vorrichtung zur herstellung von gegenstaenden aus keramik, porzellan o.dgl.
JPS5578119A (en) * 1978-12-07 1980-06-12 Nissan Motor Co Ltd Valve guide for internal combustion engine
JPS63160802A (ja) * 1986-12-24 1988-07-04 トヨタ自動車株式会社 鋳込み成形用石膏型の吸水力劣化防止方法
DE3741002A1 (de) * 1986-12-04 1988-07-14 Ngk Insulators Ltd Form und verfahren zur herstellung eines formkoerpers
JPH01280504A (ja) * 1987-06-25 1989-11-10 Sekisui Chem Co Ltd 水硬性無機質成形物の成形方法
EP0396766A1 (fr) * 1988-10-06 1990-11-14 Kawasaki Steel Corporation Moule de coulee pour moulage en pate
JPH03112605A (ja) * 1989-09-27 1991-05-14 Kubota Corp 石こう型表面の離型膜形成方法
JPH04357003A (ja) * 1990-12-10 1992-12-10 Oki Electric Ind Co Ltd 多孔質ｐｚｔセラミックスの製造方法

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1127781B (de) * 1958-01-03 1962-04-12 Philips Nv Presse zur Herstellung von Gegenstaenden aus keramischem Material
LU38021A1 (fr) * 1959-09-08
FR2211873A5 (fr) * 1972-12-23 1974-07-19 Wilden Johann
DE2641975A1 (de) * 1976-09-16 1978-03-23 Gerstetter Reinhold Verfahren und vorrichtung zur herstellung von gegenstaenden aus keramik, porzellan o.dgl.
JPS5578119A (en) * 1978-12-07 1980-06-12 Nissan Motor Co Ltd Valve guide for internal combustion engine
DE3741002A1 (de) * 1986-12-04 1988-07-14 Ngk Insulators Ltd Form und verfahren zur herstellung eines formkoerpers
JPS63160802A (ja) * 1986-12-24 1988-07-04 トヨタ自動車株式会社 鋳込み成形用石膏型の吸水力劣化防止方法
JPH01280504A (ja) * 1987-06-25 1989-11-10 Sekisui Chem Co Ltd 水硬性無機質成形物の成形方法
EP0396766A1 (fr) * 1988-10-06 1990-11-14 Kawasaki Steel Corporation Moule de coulee pour moulage en pate
JPH03112605A (ja) * 1989-09-27 1991-05-14 Kubota Corp 石こう型表面の離型膜形成方法
JPH04357003A (ja) * 1990-12-10 1992-12-10 Oki Electric Ind Co Ltd 多孔質ｐｚｔセラミックスの製造方法

Non-Patent Citations (6)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Week 8030, Derwent World Patents Index; AN 80-52627C *
DATABASE WPI Week 8832, Derwent World Patents Index; AN 88-225002 *
DATABASE WPI Week 9125, Derwent World Patents Index; AN 91-183034 *
DATABASE WPI Week 9304, Derwent World Patents Index; AN 93-030828 *
PATENT ABSTRACTS OF JAPAN vol. 017, no. 226 (M - 1405) 10 May 1993 (1993-05-10) *
PATENT ABSTRACTS OF JAPAN vol. 14, no. 52 (M - 928)<3995> 30 January 1990 (1990-01-30) *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6458298B1 (en) 1992-09-10 2002-10-01 Sumitomo Electric Industries, Ltd. Process for molding ceramics
US5660863A (en) * 1993-03-08 1997-08-26 Agency Of Industrial Science & Technology, Ministry Of International Trade & Industry Apparatus for production of ceramics reinforced with three-dimensional fibers
EP0756922A1 (fr) * 1995-07-27 1997-02-05 Sumitomo Electric Industries, Ltd. Procédé de moulage pour matériaux céramiques
US11731312B2 (en) 2020-01-29 2023-08-22 James R. Glidewell Dental Ceramics, Inc. Casting apparatus, cast zirconia ceramic bodies and methods for making the same

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