JP2013500231A - 酸化セリウム安定化ジルコニアとジルコニアがドープされたアルミナとのナノ構造複合材料、使用方法、並びにその製造方法 - Google Patents
酸化セリウム安定化ジルコニアとジルコニアがドープされたアルミナとのナノ構造複合材料、使用方法、並びにその製造方法 Download PDFInfo
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- JP2013500231A JP2013500231A JP2012522196A JP2012522196A JP2013500231A JP 2013500231 A JP2013500231 A JP 2013500231A JP 2012522196 A JP2012522196 A JP 2012522196A JP 2012522196 A JP2012522196 A JP 2012522196A JP 2013500231 A JP2013500231 A JP 2013500231A
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- zirconia
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- alumina
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Abstract
Description
長い間、セラミックス材料は、あらゆる種類の関節、主に人工股関節および人工膝関節の人工的代替物として使用されている。アルミナは整形外科インプラントとして使用されている最も先進的なセラミックスの一つであった(Christel, P. Meunier, A., Dorlot, J.M., Crolet, J.M., Witvoet, J., Sedei, L., et al., Ann. NY Acad. Sci., 523: 234-56, (1998))。しかし、この材料で形成される関節の高脆弱性及び結果として生じる失敗は、医療グレードのジルコニアの使用を助長した。2005年までに、600,000を超えるジルコニア大腿骨頭が世界中、特にUSA及びヨーロッパにおいて移植された。ジルコニア材料の硬度における改良は、相転移強化機構(phase-transformation toughening mechanism)として文献に広く記載されており、相転移強化機構は、室温でジルコニアの準安定な正方晶相から安定な単斜晶相への転移を含み、結果として生じる体積膨張とともに、重要な圧縮応力を引き起こす。正方晶相(高温)から単斜晶相(室温)へのこの可逆的な転移を防止するためには、通常、ジルコニアに、ある特性を有する酸化物(例えば、CaO、MgO、Y2O3、CeO2)がドープされる。これにより、ジルコニアは、室温で正方晶構造を保持することが可能となる。その結果、亀裂の伝播を防止することによって、t→m転移により引き起こされる応力が制御され、結果として、材料の強度を向上させることができる(Nelly, J.B., and Denry, I., Dental Materials, 24, 289-298, (2008))。しかしながら、正方晶のジルコニアのこの準安定な特徴のため、その加工により(例えば、焼結部品の機械加工、及びその研磨でさえ)、単斜晶への自発的な転移が引き起こされ、結果としてセラミックス片が不安定になる。また、他方では、水と同様に、室温で体液に接触した安定化ジルコニアの品質が低下することは、よく証明されている(Sato, T., Ohtaki, S., Shimada, M., J. Mater. Sci., 20, 1466-1470, (1985))、(Sato, T., Shimada, M., J. Am. Ceram. Soc., 67, 212-213, (1984))、(Sato, T., Shimada, M., J. Am. Ceram. Soc., 68, 256-359, (1985))、(Lange, F.F., Dunlop, G.L., Davis, B.I., J. Am. Ceram. Soc., 69, 237-240, (1986))、(Chevalier, J., Cales, B., Drouin, J.M, J. Am. Ceram. Soc., 82, 2150-2154, (1999))、(Guo, X., J. Phys. Chem. Solids, 60, 539-546, (1999))。この理由のため、予期される壊滅的破損を考慮し、単斜晶セラミックス材料は関節としては、もはや使用されない。この現象は、ジルコニアの老朽化(ageing)として知られており、粒子及び微小ひび割れの出現とともに、焼結部の表面に複合的な影響を及ぼす。この現象は、酸化セラミックス材料においてより強調される。この現象は、亀裂の頂点で起こる水の吸収が原因であり、亀裂の伝播及び材料破壊の遅延を促進する、高湿度状態又は大気に接触した条件下での界面エネルギーの大きな減少を引き起こす。この現象はガラスにて最初に発見されたが、現在では、ほとんどのセラミックス材料で認められている(B. Lawn; Fracture of Brittle Solids, Cambridge University Press, (1993))。
本発明は、γ−アルミナがドープされた酸化セリウム安定化ジルコニアと、ジルコニアがドープされたα−アルミナと、のナノ構造複合材料、それを得るための方法、並びにその応用を提供する。
(a)γ−Al2O3がドープされ、粒子の平均寸法が50〜1000nmの間であるCeO2安定化ZrO2、及び、
(b)ZrO2がドープされ、粒子の平均寸法が150〜400nmの間であるα−Al2O3;
上記(a)において、γ−Al2O3の体積濃度が、上記(a)の全体に対して5%〜50%の間になるようにドープされており、上記γ−Al2O3の粒子の平均寸法は50nmよりも小さく、
上記(b)において、ZrO2の粒子の平均寸法は40nm以下であり、ZrO2の質量濃度が、上記(b)の全体に対して0.5%〜5%の間になるようにドープされている。
それらは、一見したところ物理的には区別できず、かつ機械的に分離できない二つ以上の構成要素から形成されている;
それらは、鉱物学的に異なっており、完全には溶解せず、中間相によって分離されているいくつかの相が存在する;
それらの機械的特性は、それらの構成の特性を単に合計したものよりも大きい(相乗効果)。
(a)アルミニウム塩又はアルミニウムアルコキシドの溶液と、CeO2安定化ZrO2粉末の懸濁液と、を混合する工程;
(b)上記工程(a)にて得られた懸濁液を乾燥する工程;
(c)上記工程(b)にて得られた、乾燥した粉末をふるいわけする工程;
(d)上記工程(c)にて得られた、ふるいわけされた粉末を熱処理する工程;
(e)ジルコニウム塩又はアルミニウムアルコキシドの溶液と、α−Al2O3粉末の懸濁液と、を混合する工程;
(f)上記工程(e)にて得られた懸濁液を乾燥する工程;
(g)上記工程(f)にて得られた、乾燥した粉末をふるいわけする工程;
(h)上記工程(g)にて得られた、ふるいわけされた粉末を熱処理する工程;
(i)上記工程(d)及び上記工程(h)にて得られた粉末を懸濁及び混合する工程;
(j)上記工程(i)にて得られた懸濁液を乾燥する工程;
(k)上記工程(j)にて得られた、乾燥した粉末をふるいわけする工程;
(l)上記工程(k)にて得られた、ふるいわけされた粉末を成形する工程;
(m)上記工程(l)にて得られた、成形した粉末を焼結する工程。
酸化セリウム安定化ジルコニア粉末(TZP−Ce)(酸化セリウムの全モル濃度は10%〜12%の間であり、平均粒径は0.05〜1μmである);
塩化アルミニウム又はアルミニウムアルコキシド;
高純度アルミナ粉末(平均粒径は0.1〜1μmの間である);
ジルコニウムアルコキシド;
溶剤としての無水エタノール。
図1は、遷移アルミナ相(α−アルミナ)(より明瞭な影)に吸収されたジルコニア結晶(暗影)の透過電子顕微鏡法(TEM)による顕微鏡写真である。
以下の実施例は当業者にとっての付加的な手引きとして提供され、いずれの場合であっても、本発明の範囲を制限するとは見做されない。
以下の組成物を作製した:
下記混合物の組成物 A80%/B20%(体積%):
(a)A=(ZrO212モル%CeO2)+20体積%のγ−アルミナ
(b)B=アルミナ+2.5%(質量)ZrO2。
アルミナ:
(a)Taimei(TM−DAR)(γ−Al2O3)
ジルコニア:
(a)Daiichi(TZP12モル%CeO2)
Zrイソプロポキシド(Sigma-Aldrich)(C12H28O4Zr)
塩化アルミニウム(AlCl3、純度99.9%)(Sigma-Aldrich)。
選択した第二の組成物は、以下のとおりである。
(a)A=(ZrO212モル%CeO2)+20体積%のγ−アルミナ
(b)B=アルミナ+2.5%(質量)ZrO2。
アルミナ:
(a)Taimei(TM−DAR)(γ−Al2O3)
ジルコニア:
(a)Daiichi(TZP12%モルCeO2)
Zrイソプロポキシド(Sigma-Aldrich)(C12H28O4Zr)
塩化アルミニウム(AlCl3、純度99.9%)(Sigma-Aldrich)。
Claims (24)
- (a)γ−Al2O3がドープされ、粒子の平均寸法が50〜1000nmの間であるCeO2安定化ZrO2と、
(b)ZrO2がドープされ、粒子の平均寸法が150〜400nmの間であるα−Al2O3とを含み、
上記(a)において、γ−Al2O3の体積濃度が、上記(a)の全体に対して5%〜50%の間になるようにドープされており、上記γ−Al2O3の粒子の平均寸法は50nmよりも小さく、
上記(b)において、ZrO2の粒子の平均寸法は40nm以下であり、ZrO2の質量濃度が、上記(b)の全体に対して0.5%〜5%の間になるようにドープされている、ナノ構造複合材料。 - 上記γ−Al2O3の体積濃度は、上記(a)の全体に対して20%であり、上記ZrO2の質量濃度は、上記(b)の全体に対して2.5%である、請求項1に記載の材料。
- 上記CeO2のモル濃度は、上記CeO2安定化ZrO2の全体に対して10%〜12%の間である、請求項1又は2に記載の材料。
- 上記(a)の体積濃度は、上記材料全体に対して60%〜80%の間である、請求項1〜3の何れか一項に記載の材料。
- (a)アルミニウム塩又はアルミニウムアルコキシドの溶液とCeO2安定化ZrO2粉末の懸濁液とを混合する工程と、
(b)上記工程(a)にて得られた懸濁液を乾燥する工程と、
(c)上記工程(b)にて得られた、乾燥した粉末をふるいわけする工程と、
(d)上記工程(c)にて得られた、ふるいわけされた粉末を熱処理する工程と、
(e)ジルコニウム塩又はアルミニウムアルコキシドの溶液とα−Al2O3粉末の懸濁液とを混合する工程と、
(f)上記工程(e)にて得られた懸濁液を乾燥する工程と、
(g)上記工程(f)にて得られた、乾燥した粉末をふるいわけする工程と、
(h)上記工程(g)にて得られた、ふるいわけされた粉末を熱処理する工程と、
(i)上記工程(d)及び上記工程(h)にて得られた粉末を懸濁及び混合する工程と、
(j)上記工程(i)にて得られた懸濁液を乾燥する工程と、
(k)上記工程(j)にて得られた、乾燥した粉末をふるいわけする工程と、
(l)上記工程(k)にて得られた、ふるいわけされた粉末を成形する工程と、
(m)上記工程(l)にて得られた、成形した粉末を焼結する工程と、
を含んでいる、請求項1〜4の何れか一項に記載の材料を調製する方法。 - 上記工程(a)において、質量濃度が60%〜75%の間のアルコール中におけるCeO2安定化ZrO2粉末の懸濁液を、質量濃度が95%〜97%の間のアルコールにより希釈されたアルミニウム溶液と混合する、請求項5に記載の方法。
- 上記アルコールは無水エタノールである、請求項6に記載の方法。
- 上記工程(a)において、アルミニウムアルコキシドを使用する、請求項5〜7の何れか一項に記載の方法。
- 上記工程(b)を、最初に70℃以下の温度で行い、次に110℃〜120℃の間の温度で、少なくとも24時間行うという二つの工程で行う、請求項5〜8の何れか一項に記載の方法。
- 上記工程(c)を、口径63μm以下のメッシュにおいて行う、請求項5〜9の何れか一項に記載の方法。
- 上記工程(d)を、5〜10℃/分の間の温度勾配で、800℃〜1000℃の間の最終温度まで加熱し、当該加熱を1〜3時間維持することによって行う、請求項5〜10の何れか一項に記載の方法。
- 上記工程(e)において、質量濃度が60%〜75%の間のアルコール中におけるα−Al2O3粉末の懸濁液を、質量濃度が50%〜55%の間のアルコールにより希釈されたジルコニウムアルコキシドの溶液と混合する、請求項5〜11の何れか一項に記載の方法。
- 上記アルコールは無水エタノールである、請求項12に記載の方法。
- 上記工程(e)において使用するジルコニウムアルコキシドは、ジルコニウムイソプロポキシドである、請求項5〜13の何れか一項に記載の方法。
- 上記工程(f)を、最初に70℃以下の温度で行い、次に110℃〜120℃の間の温度で、少なくとも24時間行うという二つの工程で行う、請求項5〜14の何れか一項に記載の方法。
- 上記工程(g)を、口径63μm以下のメッシュにおいて行う、請求項5〜15の何れか一項に記載の方法。
- 上記工程(h)を、5〜10℃/分の間の温度勾配で、850℃〜1000℃の間の最終温度まで加熱し、当該加熱を1〜3時間保持することによって行う、請求項5〜16の何れか一項に記載の方法。
- 上記工程(i)において、上記工程(d)及び上記工程(h)にて得られる上記粉末を、少なくとも72時間粉砕しながら、アルコール中で混合及び懸濁する、請求項5〜17の何れか一項に記載の方法。
- 上記アルコールはイソプロパノールである、請求項18に記載の方法。
- 上記工程(f)を、温度70℃以下で行う、請求項5〜19の何れか一項に記載の方法。
- 上記工程(j)を、温度70℃以下で行う、請求項5〜20の何れか一項に記載の方法。
- 上記工程(l)を、冷間等方圧加圧法、又は鋳造、圧迫鋳造及びテープ成形からなる群より選択される他のセラミックス形成方法によって行う、請求項5〜21の何れか一項に記載の方法。
- 上記工程(m)を、1450℃〜1500℃の間の温度で行う、請求項5〜22の何れか一項に記載の方法。
- 人工膝関節、人工股関節、ポンプ用の機械機器、人工歯根、アルカリ電池、定位神経学用のセラミック機器、及び刃物からなる群より選択される製品を製造するための、請求項1〜4の何れか一項に記載の材料の使用方法。
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ES200930516A ES2351759B1 (es) | 2009-07-27 | 2009-07-27 | Material compuesto nanoestructurado de circona estabilizada con ceriaa y alumina dopada con circona, procedimiento de obtencion y usos. |
PCT/ES2010/070510 WO2011015697A1 (es) | 2009-07-27 | 2010-07-23 | Material compuesto nanoestructurado de circona estabilizada con ceria y alúmina dopada con circona, procedimiento de obtención y usos |
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WO2011081103A1 (ja) * | 2009-12-28 | 2011-07-07 | パナソニック電工株式会社 | ジルコニア-アルミナ複合セラミック材料の製造方法、ジルコニア-アルミナ複合造粒粉、ジルコニアビーズ |
CN102358826B (zh) * | 2011-08-19 | 2013-08-07 | 湖南皓志新材料股份有限公司 | 一种铝掺杂的氧化锆复合抛光粉的制备方法 |
ES2413162B1 (es) | 2011-11-04 | 2014-05-16 | Consejo Superior De Investigaciones Científicas (Csic) | Material nanoestructurado compuesto de óxidos metálicos, procedimiento de obtención y uso. |
EP2829251B1 (en) * | 2013-07-22 | 2019-04-10 | Ivoclar Vivadent AG | Controlling of sintering kinetics of oxide ceramics |
EP3107861B1 (en) | 2014-02-21 | 2019-11-20 | Politecnico Di Torino | Process for producing zirconia-based multi-phasic ceramic composites |
EA027824B1 (ru) * | 2015-01-29 | 2017-09-29 | Общество с ограниченной ответственностью "НЭВЗ-Н" | Керамический материал и способ его получения |
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JPS6291419A (ja) * | 1985-09-24 | 1987-04-25 | Nippon Soda Co Ltd | 易焼結性アルミナ・ジルコニア複合粉末の製造方法 |
JPH1010148A (ja) * | 1996-06-25 | 1998-01-16 | Japan Aviation Electron Ind Ltd | 半導体姿勢センシングチップ |
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WO2011015697A1 (es) | 2011-02-10 |
US8546285B2 (en) | 2013-10-01 |
US20120238437A1 (en) | 2012-09-20 |
ES2351759A1 (es) | 2011-02-10 |
JP5543594B2 (ja) | 2014-07-09 |
ES2351759B1 (es) | 2011-12-07 |
EP2460782B1 (en) | 2015-10-07 |
EP2460782A4 (en) | 2013-06-26 |
EP2460782A1 (en) | 2012-06-06 |
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