JP2019527181A - セラミック粉末を製造するためのシステム及び方法 - Google Patents
セラミック粉末を製造するためのシステム及び方法 Download PDFInfo
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- JP2019527181A JP2019527181A JP2018568261A JP2018568261A JP2019527181A JP 2019527181 A JP2019527181 A JP 2019527181A JP 2018568261 A JP2018568261 A JP 2018568261A JP 2018568261 A JP2018568261 A JP 2018568261A JP 2019527181 A JP2019527181 A JP 2019527181A
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Abstract
Description
本出願は、2016年7月8日に出願された米国仮出願第62/360,079号の利益を主張し、その全体が参照により本明細書に組み込まれる。
広義において、本発明はセラミック粉末を製造するためのシステム及び方法に関する。より具体的には、本開示は、連続式反応器の中で様々なセラミック粉末を炭素熱合成することにより、一貫した特徴及び/又は特性を有するよう調整されたセラミック粉末製品を得るものである。
前記方法は、スイープガスを導入して、前記スイープガスを、前記第1端部から、前記少なくとも1つのプリフォームの中を通って前記第2端部に流すことと、これと同時に、前記少なくとも1つのプリフォームを前記反応器本体内で炭素熱反応させることと、均一な特性を有するセラミック粉末製品を形成することと、を含む。
本発明は、添付の図面を参照してさらに説明するが、同様の構造については、幾つかの図を通して同じ参照番号が付されている。示された図は必ずしも縮尺とおりではなく、本発明の原理を説明することに重点が置かれている。さらに、幾つかの特徴については、特定の構成要素の詳細を示すために誇張されている場合がある。
Claims (36)
- 第1端部及び第2端部を有する反応器本体であって、前記第1端部から前記第2端部に延びて反応チャンバーを構成する内側側壁を有し、前記反応チャンバーに沿って高温ゾーンを提供するための熱源が配備された、反応器本体と、
前記第1端部に隣接し、前記反応チャンバーにスイープガスを導入できるよう構成されたスイープガス入口と、前記第2端部に隣接し、前記反応チャンバーから排出ガスを排出できるように構成されたスイープガス出口と、
反応器本体の内部に連続的に配列された複数の容器であって、各容器が少なくとも1つのプリフォームを保持できるように構成され、スイープガスを通過させることができるように構成された、容器と、を具え、
各プリフォームは炭素熱反応する前駆体材料の混合物で構成され、スイープガスがその内部を通過可能であり、
前記前駆体混合物が高温ゾーンで反応が行われことにより、均一な特性を有するセラミック粉末製品を形成することができる、システム。 - 反応器本体は垂直又は水平に構成される、請求項1のシステム。
- 反応器本体は、傾斜して形成され、前記第1端部と前記第2端部とは異なる高さである、請求項1のシステム。
- 反応器入口と第1シールとの間にて、前記第1端部に隣接して前記第1端部に連通するよう構成されたステージング領域をさらに含み、
前記ステージング領域は、少なくとも1つの容器を受け入れられるように構成され、さらに、前記ステージング領域にはバルブが配備されており、ステージング領域全体に圧力差が形成され、ステージング領域から気体種を除去及び/又は追加することができる、請求項1のシステム。 - ステージング領域は、容器及びプリフォームを予熱できるように構成された熱源を含む、請求項4のシステム。
- 反応器本体の第1端部に配備され、前記第1端部に隣接する反応チャンバーを密封するよう構成された第1シールと、
反応器本体の第2端部に配備され、前記第2端部に隣接する反応チャンバーを密封するよう構成された第2シールと、をさらに含む、請求項1のシステム。 - 前記容器の外径は反応器本体の内径より小さい、請求項1のシステム。
- 複数の容器の各々は、プリフォームが配備された複数の積み重ねられた容器の重量を支持できるように構成される、請求項1のシステム。
- 複数の容器の各々は、少なくとも1つの端部と、前記端部の外周を取り囲んで前記端部から延在する側壁と、を含む,請求項1のシステム。
- 前記端部の少なくとも1つと容器には、容器の側壁を前記端部に取り付けられるように構成された機械的装置が配備される、請求項1のシステム。
- 容器の側壁又は容器の端部の少なくとも1つには孔が形成されている、請求項1のシステム。
- システムは、容器の反応器本体への挿入及び反応器本体からの除去を繰り返すことができるように構成されている、請求項1のシステム。
- プリフォームは、球体、ロッド、プレート、レンガ状塊、ブロック、四面体、トーラス、管体、及びそれらの組合せからなる群から選択される形態である、請求項1のシステム。
- プリフォームは、圧密された固体形態、押し出された形態、成型された形態、注型された形態、及びそれらの組合せからなる群から選択される、請求項1のシステム。
- プリフォームは容器の高さに合わせて形成される、請求項1のシステム。
- プリフォームは、容器内で垂直方向に積み重ねられた構成である、請求項1のシステム。
- プリフォームは、多孔質剛性体として形成され、スイープガスがプリフォーム本体を通過することができる孔隙部を有する、請求項1のシステム。
- セラミック粉末を製造する方法であって、
少なくとも1つのプリフォームを反応器に供給することを含み、前記反応器が、第1端部と、第2端部と、前記第1端部から前記第2端部に延びて反応チャンバーを構成する内側側壁と、前記反応チャンバーに沿って高温ゾーンを提供するための熱源と、を有する反応器本体を含み、前記反応器本体内に複数の容器が連続的に配列され、各容器が少なくとも1つのプリフォームを保持すると共に、スイープガスが前記容器を通過することができるように構成され、各プリフォームが、炭素熱反応する前駆体材料の混合物から形成されており、前記方法は、
スイープガスを、前記第1端部から、前記少なくとも1つのプリフォームの中を通って前記第2端部に送給することと、
これと同時に、前記少なくとも1つのプリフォームを前記反応器本体の中で炭素熱反応させることと、
均一な特性を有するセラミック粉末製品を形成することと、を含む、方法。 - 前駆体混合物を調製することをさらに含む、請求項18の方法。
- 前駆体混合物からプリフォームを形成することをさらに含む、請求項19の方法。
- 前記形成する工程は、プリフォーム混合物を圧密すること、前駆体混合物を成型すること、前駆体混合物を注型すること、前駆体混合物を押し出すこと、及びそれらを組み合わせて行うこと、の少なくとも1つを含む、請求項20の方法。
- 前記前駆体混合物を調製することは、(a)内部に前記試剤を有する湿潤凝集体を形成すること、又は(b)適合性材料及び/又は結合剤を用いて前記試剤を乾式処理すること、の1つをさらに含む、請求項19の方法。
- 前記前駆体混合物をプリフォームに処理することをさらに含む、請求項22の方法。
- 前記処理工程は、プリフォームを脱水すること、プリフォームを硬化させること、プリフォームを型から除去すること、及びそれらを組み合わせて行うこと、の少なくとも1つを含む、請求項23の方法。
- プリフォームは、均一な熱伝達を促進し、オフガスとプリフォームとの連通を促進するための物体として構成される、請求項18の方法。
- スイープガスを、(i)プリフォーム本体の中を通して流すこと、 (ii)プリフォーム本体の周りを流すこと、並びに、プリフォーム本体の中及び周りを流すこと、をさらに含む、請求項18の方法。
- 第1端部及び第2端部を有する反応器本体であって、前記第1端部から前記第2端部に延びて反応チャンバーを構成する内側側壁を有し、前記反応チャンバーに沿って高温ゾーンを提供するための熱源が配備された、反応器本体と、
前記第1端部に隣接し、スイープガスを反応チャンバーに導入できるように構成されたスイープガス入口と、前記第2端部に隣接し、排出ガスを反応チャンバーから排出できるように構成されたスイープガス出口と、
前記反応器本体の中に連続的に配列された複数のプリフォームと、を具え、
各プリフォームには、(1)プリフォームのトップ部からボトム部に延在し、ガスの流れに平行な少なくとも1つのガス通路、及び(2)プリフォーム本体内部の多孔質を構成し、スイープガスが、プリフォーム本体内を十分に流れることができる複数の空所が設けられ、
各プリフォームは、炭素熱反応する前駆体材料の混合物から形成され、
前記前駆体混合物が高温ゾーンで反応が行われことにより、均一な特性を有するセラミック粉末製品を形成することができる、システム。 - ガス通路は、反応チャンバーの横断面積に対する面積率が0.05面積率〜0.8面積率として構成される、請求項27のシステム。
- プリフォームは複数の粒子から構成され、各粒子は前駆体混合物から構成される、請求項27のシステム。
- 空所は、プリフォーム内の粒内孔隙部として構成される、請求項27のシステム。
- 粒内孔隙部は、プリフォームの横断面積に対する面積率が、0〜0.6面積率として構成される、請求項30のシステム。
- 空所は、プリフォーム内の粒間孔隙部として構成される、請求項27のシステム。
- 粒間孔隙部は、プリフォームのガス通路を除く横断面積に対する面積率が0〜0.6面積率として構成される、請求項32のシステム。
- 空所は、プリフォームの粒間孔隙部と粒内孔隙部との組合せとして構成される、請求項27のシステム。
- 少なくとも1つのプリフォームが、容器の内部に配置され、前記容器はスイープガスがその内部を通過することができるように構成される、請求項27のシステム。
- 第1端部及び第2端部を有する反応器本体であって、前記第1端部から前記第2端部に延びて反応チャンバーを構成する内側側壁を有し、前記反応チャンバーに沿って高温ゾーンを提供するための熱源が配備された、反応器本体と、
前記第1端部に隣接し、前記反応チャンバーにスイープガスを導入できるように構成されたスイープガス入口と、前記第2端部に隣接し、前記反応チャンバーから排出ガスを排出できるように構成されたスイープガス出口と、
炭素熱反応する前駆体材料の混合物から形成された粉末であって、その内部をスイープガスが流れることができるように前記反応チャンバーの中に配備された、粉末と、を含み、
前記前駆体混合物が前記高温ゾーンの中での反応によって、均一な特性を有するセラミック粉末製品を作製することができる、システム。
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