JP2016175802A - 複合体、ハニカム構造体及び複合体の製造方法 - Google Patents
複合体、ハニカム構造体及び複合体の製造方法 Download PDFInfo
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- JP2016175802A JP2016175802A JP2015057672A JP2015057672A JP2016175802A JP 2016175802 A JP2016175802 A JP 2016175802A JP 2015057672 A JP2015057672 A JP 2015057672A JP 2015057672 A JP2015057672 A JP 2015057672A JP 2016175802 A JP2016175802 A JP 2016175802A
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- Prior art keywords
- oxide
- oxide layer
- powder
- perovskite
- base material
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- 239000011863 silicon-based powder Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
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Classifications
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- B32—LAYERED PRODUCTS
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- B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/26—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on ferrites
- C04B35/2608—Compositions containing one or more ferrites of the group comprising manganese, zinc, nickel, copper or cobalt and one or more ferrites of the group comprising rare earth metals, alkali metals, alkaline earth metals or lead
- C04B35/2633—Compositions containing one or more ferrites of the group comprising manganese, zinc, nickel, copper or cobalt and one or more ferrites of the group comprising rare earth metals, alkali metals, alkaline earth metals or lead containing barium, strontium or calcium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/008—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression characterised by the composition
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
- B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
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Abstract
【解決手段】複合体は、基材と、前記基材上に形成され、ペロブスカイト型酸化物相を45体積%より多く含む酸化物層と、を備えている。この複合体は、第1部材22と、第2部材24と、第1部材22と第2部材24とを接合する接合部30と、を備え、第1部材22及び第2部材24のうちの少なくとも一方が前記基材であり、接合部30が前記酸化物層であるものとしてもよい。また、基材と、前記基材の一部又は全部の表面を被覆する被覆部と、を備え、前記被覆部が前記酸化物層であるものとしてもよい。前記ペロブスカイト型酸化物が、LaとCuとを含む酸化物及びSrとFeとを含む酸化物のうちの少なくとも一方であり、特に好ましくはLa2CuO4及びSrFeO3のうちの少なくとも一方である、複合体。
【選択図】図1
Description
基材と、
前記基材上に形成され、ペロブスカイト型酸化物相を45体積%より多く含む酸化物層と、を備えたものである。
基材上に酸化物層原料を配置した積層体を焼成し、前記基材上にペロブスカイト型酸化物相を45体積%より多く含む酸化物層を形成する工程、
を含むものである。
図1は、本発明の複合体の一実施形態である接合体20の構成の概略の一例を示す説明図である。接合体20は、図1に示すように、第1部材22と、第2部材24と、第1部材22と第2部材24とを接合する接合部30と、を備えている。第1部材22や第2部材24は、多孔質材としてもよいし、緻密材としてもよい。また、接合体20は、多孔質材と多孔質材とを接合したものとしてもよいし、多孔質材と緻密材とを接合したものとしてもよいし、緻密材と緻密材とを接合したものとしてもよい。第1部材22と第2部材24とは、同じ材質でもよいし、異なる材質でもよい。
この工程では、基材を作製する。例えば、第1部材や第2部材が多孔質セラミックス又は緻密セラミックスであるときには、原料を混合し、所定の成形方法で成形し成形した成形体を焼成することにより基材を作製するものとしてもよい。この多孔質セラミックスは、例えば、炭化ケイ素、炭化チタン、炭化ジルコニウム、炭化ホウ素などの炭化物、窒化珪素、窒化アルミニウム、窒化チタン、窒化ジルコニウムなどの窒化物、サイアロンなどの酸窒化物、ケイ化モリブデンなどのケイ化物、リン酸ジルコニウムなどから選択される1以上の無機材料を含んで形成するものとしてもよい。また、多孔質セラミックスは、例えば、コージェライト、ムライト、ゼオライト、チタン酸アルミニウム、酸化アルミニウム、酸化ジルコニウム、酸化チタン、酸化ケイ素及び酸化マグネシウムなどから選択される1以上の無機材料を含んで形成するものとしてもよい。この工程では、例えば、骨材である無機材料と、造孔材と、分散媒と、を混合して坏土やスラリーを調整してもよい。このとき、多孔質セラミックスの気孔率や平均細孔径は、上述した範囲、例えば、気孔率は10体積%以上の範囲、平均細孔径は1μm以上300μm以下の範囲になるように原料配合を調製することが好ましい。また、この工程では、多孔質セラミックスの気孔に含浸材を含浸する処理を行い、第1部材や第2部材とするものとしてもよい。この含浸処理は、例えば、多孔質セラミックスの上に含浸基材を形成し、含浸基材が溶融する温度で加熱するものとしてもよい。多孔質セラミックスが、Si結合SiC焼結体であるときに、含浸材は金属Siとしてもよい。
この工程では、第1部材及び第2部材を接合部により接合する接合処理を行う。第1部材及び第2部材は、上述したいずれかの部材を用いるものとすればよい。この接合工程は、例えば、(B−1)第1部材と第2部材との間に、接合部の原料を配置して積層体を製造する積層体製造工程と、(B−2)積層体を焼成する焼成工程と、を含むものとしてもよい。なお、第1部材と第2部材との間に接合部の原料を配置した積層体を別途用意し、(B−1)積層体製造工程を省略するものとしてもよい。
この工程では、第1部材と第2部材との間に接合部の原料を配置して積層体を製造する。接合部の原料は、ペロブスカイト型酸化物相を45体積%より多く含む酸化物層の原料(酸化物層原料)を含んでいる。酸化物層原料は、ペロブスカイト型酸化物そのものを含むものとしてもよいし、ペロブスカイト型酸化物を構成する金属を含む金属(単体でも合金でもよい)及びペロブスカイト型酸化物を構成する金属を含む化合物のうちの1以上を含むものとしてもよいし、この両方としてもよい。このうち、金属粉末と化合物粉末とを含むことがより好ましい。後の焼成工程で、ペロブスカイト型酸化物の合成とペロブスカイト型酸化物を含む酸化物層による第1部材と第2部材との接合とを同時に行うことが可能であり、プロセスコストを低減できる。
この工程では、積層体を焼成する。この工程では、酸化物層原料がペロブスカイト型酸化物を含む場合、ペロブスカイト型酸化物が焼結してペロブスカイト型酸化物相となる。また、酸化物層原料がペロブスカイト型酸化物を構成する金属を含む金属及びその化合物のうちの1以上を含む場合、これらが単独で又は複合的に酸化してペロブスカイト型酸化物相となる。
図3は、本発明の複合体の一実施形態である被覆体120の構成の概略の一例を示す説明図である。被覆体120は、図3に示すように、基材122と、基材122の表面を被覆する被覆部130と、を備えている。基材122は、多孔質材としてもよいし、緻密材としてもよい。被覆対象である基材122としては、例えば、上述した第1部材22や第2部材24で例示したものを用いることができる。
この工程では、基材を作製する。この基材作製工程は、上述した第1実施形態における基材作製工程と同様の工程とすることができる。
この工程では、基材を被覆部により被覆する被覆処理を行う。基材は、上述したいずれかの部材を用いるものとすればよい。この被覆工程は、例えば、(B−1)基材の表面の一部又は全部に、被覆部の原料を配置して積層体を製造する積層体製造工程と、(B−2)積層体を焼成する焼成工程と、を含むものとしてもよい。なお、基材の表面に被覆部の原料を配置した積層体を別途用意し、(B−1)積層体製造工程を省略するものとしてもよい。
この工程では、基材の表面に被覆部の原料を配置して積層体を製造する。被覆部の原料は、ペロブスカイト型酸化物相を45体積%より多く含む酸化物層の原料(酸化物層原料)を含んでいる。被覆部の原料は、上述した第1実施形態における積層体製造工程で説明した接合部の原料と同様のものとすることができる。
この工程では、積層体を、酸化性雰囲気下で焼成する。この焼成工程において、焼成温度、焼成時間、焼成雰囲気などの焼成条件は、被覆部の材質に応じて好適な範囲が設定され、例えば上述した第1実施形態における焼成条件と同様に設定することができる。
[実験例1〜5]
実験例1〜5では、ペロブスカイト型酸化物相としてLa2CuO4相を含む酸化物層を備えた接合体を製造した。具体的には、Cu粉末(14.3質量%)とLa(OH)3粉末(85.7質量%)とを配合して酸化物層原料粉末を得た。さらに、溶媒としてのαテルピネオールとバインダーとしてのポリビニルブチラール(PVB)とを加えて混合し、ペーストを作製した。作製したペーストを、自転公転回転機で脱泡した後、SUS製部材(Cr−Fe系合金、SUS430)(金属部材)に印刷した。この上にSi結合SiC製部材(多孔質セラミックス)を載せ、積層体を作製した。Si結合SiC製部材の上からアルミナ板で抑え、大気中80℃で4時間乾燥させたあと、大気中750℃で1時間焼成し、実験例1の接合体を製造した。
実験例6,7では、酸化物層中のLa2CuO4相の割合を変更した接合体を製造した。具体的には、Cu粉末とLa(OH)3粉末の比率をそれぞれ22.7質量%、77.3質量%とした以外は、実験例1と同様に実験例6の接合体を製造した。Cu粉末とLa(OH)3粉末の比率をそれぞれ36.6質量%、63.4質量%とした以外は、実験例1と同様に実験例7の接合体を製造した。
実験例8,9では、ペロブスカイト型酸化物相としてSrFeO3相を含む酸化物層を備えた接合体を製造した。具体的には、Fe粉末(27.4質量%)とSrCO3粉末(72.6質量%)とを配合して酸化物層原料粉末を得た以外は、実験例1と同様に実験例8の接合体を製造した。酸化物層原料粉末をSrFeO3粉末に変更し、焼成雰囲気をArに変更し、焼成温度を900℃に変更した以外は、実験例8と同様に実験例9の接合体を製造した。なお、実験例9で用いたSrFeO3粉末は、以下のように合成した。まず、Fe2O3とSrCO3を所望の組成となるよう秤量した。溶媒としてIPA、玉石に鉄芯入りナイロンボールを用いて4hボールミル混合してスラリーを得た。このスラリーを窒素雰囲気中、110℃×14h乾燥させ、混合粉を得た。この混合粉を、大気中1200℃で仮焼し、その後、溶媒としてIPA、玉石にZrO2製ボールを用いて16hボールミル粉砕した。このスラリーを上記と同様に乾燥させ、SrFeO3粉末を得た。
実験例10,11では、酸化物層がペロブスカイト型酸化物相を含まない接合体を製造した。具体的には、Fe粉末(98.9質量%)とTiO2粉末(1.1質量%)とを配合して酸化物層原料粉末を得た以外は、実験例1と同様に実験例10の接合体を得た。Fe粉末(69.3質量%)とZnO(30.7質量%)とを配合して酸化物層原料粉末を得た以外は、実験例2と同様に実験例11の接合体を得た。
上記作製した接合体を用い、接合部の結晶相を同定した。測定は、回転対陰極型X線回折装置(理学電機社製、RINT)を用い、上記作製した接合体から金属部材を取り除き、接合部を露出したものを測定試料とし、接合部表面のX線回折パターンを得た。X線回折測定の条件は、CuKα線源、50kV、300mA、2θ=20〜60°とした。図8に実験例1の、図9に実験例9の、図10に実験例10のX線回折パターンを示した。また、得られたX線回折データを、MDI社製「X線データ解析ソフトJADE7」を用いて解析した。実験例1〜9の接合部は、ペロブスカイト型酸化物相であるのに対して、実験例10,11の接合部は、ペロブスカイト型酸化物相ではないことが確認された。結晶相の構成割合は、MDI社製「X線データ解析ソフトJADE7」を用いて、RIR(Refernce Intensity Ratios)法にて決定した。
接合体の接合性は、接合体断面のSEM観察により評価した。上記作製した接合体を樹脂で包含し、ダイヤモンドスラリー等で鏡面程度まで研磨し観察試料を作製した。次に、SEMを用いて1500倍以上の倍率で観察して、多孔質セラミックス及び金属部材と接合部との剥離や、多孔質セラミックス、金属部材、接合部におけるクラックの発生を確認した。その後、以下の基準で評価した。上記剥離及び上記クラックの発生が認められなかった場合を「A(優良)」とした。大きな剥離又はクラックが認められた場合を、「F(不可)」とした。
接合体の接合強度は、引張試験(JIS R 1606に準拠)により評価した。接合強度が5.0MPa以上の場合を「A(優良)」、接合強度が3.0MPa以上5.0MPa未満の場合を「B(良)」、接合強度が1.5MPa以上3.0MPa未満の場合を「C(可)」、接合強度が1.5MPa未満の場合を「F(不可)」とした。
接合部の電気伝導率の評価は、以下のように行った。実験例1〜11の接合体を製造するにあたり、SUS製部材及びSi結合SiC製部材としてそれぞれφ2mmの孔を有するものを用い、SUS製部材のφ2mmの孔とSi結合SiC製部材のφ2mmの孔とが互い違いとなるように(孔が重ならないように)接合した(図11参照)。そして、SUS製部材のφ2mmの孔から露出した接合部(酸化物層)及びSi結合SiC製部材のφ2mmの孔から露出した接合部のそれぞれにAgペースト(デュポン製4922N)を塗布及び乾燥し、電気伝導率測定用の電極を作製した。作製した測定用電極に針状端子を押しつけ、直流2端子法で電気抵抗を測定した。測定した電気抵抗R(Ω)、測定電極面積S(cm2)、電極間距離L(cm)から、体積抵抗率r(Ωcm)をr=R×S/Lの式により算出し、電極部の電気伝導率ρ(Scm-1)を、ρ=1/Rの式により算出した。なお、この電気伝導率の評価は、耐熱試験前後に行った。耐熱試験は、測定試料の電極端子に通電し、接合体を800℃まで加熱して24時間保持するものとした。
実験例1〜7,実験例8,9、実験例10,11の各接合体について、原料の配合割合、焼成雰囲気、焼成温度、接合性、接合強度、接合部の電気伝導率(耐熱前及び耐熱後)を、表1,2,3にそれぞれ示した。ペロブスカイト型酸化物相を含まない接合部を備えた実験例10,11では、接合部の電気伝導率が、耐熱前で0.4S/cm以下、耐熱後では0.05S/cm以下と低かった。これに対して、ペロブスカイト型酸化物相を含む接合部を備えた実験例1〜9では、少なくとも耐熱後の電気伝導率が0.1S/cm以上と高かった。このことから、ペロブスカイト型酸化物相を含む接合部を備えた複合体では、導電性をより高められることがわかった。また、ペロブスカイト型酸化物相を含む接合部を備えた複合体では、耐熱試験による電気伝導率の低下が少なかった。この理由は、例えば、図12〜15に示す平衡状態図から分かるように、ペロブスカイト型酸化物では、平衡安定相自身が導電性を持つため、温度変化に対して導電性が変化しないのに対し、実験例10や11のように異種元素を固溶することによって導電性が付与されている材料の場合、温度によって固溶域(固溶できる組成範囲)が変わり、温度変化に対して導電性が変化するためと推察された。
Claims (17)
- 基材と、
前記基材上に形成され、ペロブスカイト型酸化物相を45体積%より多く含む酸化物層と、
を備えた複合体。 - 第1部材と、
第2部材と、
前記第1部材と前記第2部材とを接合する接合部と、
を備え、
前記第1部材及び前記第2部材のうちの少なくとも一方が前記基材であり、前記接合部が前記酸化物層である、請求項1に記載の複合体。 - 前記接合部は、前記第1部材側の表面の一部及び前記第2部材側の表面の一部のうちの少なくとも一方が露出している、請求項2に記載の複合体。
- 前記基材と、
前記基材の一部又は全部の表面を被覆する被覆部と、
を備え、
前記被覆部が前記酸化物層である、請求項1に記載の複合体。 - 前記ペロブスカイト型酸化物は、LaとCuとを含む酸化物及びSrとFeとを含む酸化物のうちの少なくとも一方である、請求項1〜4のいずれか1項に記載の複合体。
- 前記ペロブスカイト型酸化物は、La2CuO4及びSrFeO3のうちの少なくとも一方である、請求項1〜5のいずれか1項に記載の複合体。
- 前記酸化物層は、ペロブスカイト型酸化物相単相である、請求項1〜6のいずれか1項に記載の複合体。
- 前記基材は、Siを含有するセラミックス及びFeを含有する合金のうちの少なくとも一方である、請求項1〜7のいずれか1項に記載の複合体。
- 前記酸化物層の電気伝導率は0.1S/cm以上である、請求項1〜8のいずれか1項に記載の複合体。
- 前記基材と前記酸化物層との付着強度が3.0MPa以上である、請求項1〜9のいずれか1項に記載の複合体。
- 請求項1〜10のいずれか1項に記載の複合体を備えたハニカム構造体。
- 基材上に酸化物層原料を配置した積層体を焼成し、前記基材上にペロブスカイト型酸化物相を45体積%より多く含む酸化物層を形成する工程、
を含む、複合体の製造方法。 - 第1部材と第2部材との間に接合部原料を配置した積層体を焼成して、前記第1部材と前記第2部材とを接合する接合部を形成する工程、
を含み、
前記第1部材及び前記第2部材のうちの少なくとも一方として前記基材を用い、前記接合部原料として前記酸化物層原料を用いる、請求項12に記載の複合体の製造方法。 - 前記基材の表面に被覆部原料を配置した積層体を焼成して、前記基材の一部又は全部の表面を被覆する被覆部を形成する工程、
を含み、
前記被覆部原料として前記酸化物層原料を用いる、請求項12に記載の複合体の製造方法。 - 前記酸化物層原料は、金属粉末と化合物粉末とを含む、請求項12〜14のいずれか1項に記載の複合体の製造方法。
- 前記化合物粉末は、酸化物粉末、炭酸塩粉末、水酸化物塩粉末、塩化物塩粉末からなる群より選ばれる1種以上である請求項15に記載の複合体の製造方法。
- 前記酸化物層原料は、前記金属粉末としてCuを含み前記化合物粉末としてLa(OH)3を含むか、前記金属粉末としてFeを含み前記化合物粉末としてSrCO3を含む、請求項15又は16に記載の複合体の製造方法。
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