JP4498727B2 - アルミナ焼結体及びその製造方法 - Google Patents
アルミナ焼結体及びその製造方法 Download PDFInfo
- Publication number
- JP4498727B2 JP4498727B2 JP2003398206A JP2003398206A JP4498727B2 JP 4498727 B2 JP4498727 B2 JP 4498727B2 JP 2003398206 A JP2003398206 A JP 2003398206A JP 2003398206 A JP2003398206 A JP 2003398206A JP 4498727 B2 JP4498727 B2 JP 4498727B2
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- Prior art keywords
- alumina
- sintered body
- alumina sintered
- pore
- alumina particles
- 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.)
- Expired - Lifetime
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims description 197
- 238000004519 manufacturing process Methods 0.000 title claims description 58
- 239000002245 particle Substances 0.000 claims description 129
- 239000011148 porous material Substances 0.000 claims description 101
- 238000009826 distribution Methods 0.000 claims description 48
- 238000005245 sintering Methods 0.000 claims description 27
- 239000002131 composite material Substances 0.000 claims description 18
- 239000000395 magnesium oxide Substances 0.000 claims description 11
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 11
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 235000012239 silicon dioxide Nutrition 0.000 claims description 4
- 238000009423 ventilation Methods 0.000 claims description 4
- 239000007789 gas Substances 0.000 description 36
- 238000000034 method Methods 0.000 description 23
- 238000005259 measurement Methods 0.000 description 17
- 239000011241 protective layer Substances 0.000 description 16
- 230000000052 comparative effect Effects 0.000 description 14
- 238000002156 mixing Methods 0.000 description 13
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 10
- 239000010410 layer Substances 0.000 description 9
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 8
- 239000011230 binding agent Substances 0.000 description 8
- 239000002994 raw material Substances 0.000 description 7
- 239000007788 liquid Substances 0.000 description 6
- 239000002002 slurry Substances 0.000 description 6
- 239000002612 dispersion medium Substances 0.000 description 5
- 239000000428 dust Substances 0.000 description 5
- 238000010304 firing Methods 0.000 description 5
- 239000012770 industrial material Substances 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- 239000007784 solid electrolyte Substances 0.000 description 5
- 239000002270 dispersing agent Substances 0.000 description 4
- 239000003254 gasoline additive Substances 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 235000009508 confectionery Nutrition 0.000 description 3
- 239000003344 environmental pollutant Substances 0.000 description 3
- 239000010408 film Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 3
- 229910052753 mercury Inorganic materials 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 231100000719 pollutant Toxicity 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 239000011812 mixed powder Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 239000001856 Ethyl cellulose Substances 0.000 description 1
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- WUOACPNHFRMFPN-UHFFFAOYSA-N alpha-terpineol Chemical compound CC1=CCC(C(C)(C)O)CC1 WUOACPNHFRMFPN-UHFFFAOYSA-N 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical class [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- SQIFACVGCPWBQZ-UHFFFAOYSA-N delta-terpineol Natural products CC(C)(O)C1CCC(=C)CC1 SQIFACVGCPWBQZ-UHFFFAOYSA-N 0.000 description 1
- 230000000368 destabilizing effect Effects 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 229920001249 ethyl cellulose Polymers 0.000 description 1
- 235000019325 ethyl cellulose Nutrition 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- UEGPKNKPLBYCNK-UHFFFAOYSA-L magnesium acetate Chemical compound [Mg+2].CC([O-])=O.CC([O-])=O UEGPKNKPLBYCNK-UHFFFAOYSA-L 0.000 description 1
- 235000011285 magnesium acetate Nutrition 0.000 description 1
- 239000011654 magnesium acetate Substances 0.000 description 1
- 229940069446 magnesium acetate Drugs 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000010705 motor oil Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 231100000572 poisoning Toxicity 0.000 description 1
- 230000000607 poisoning effect Effects 0.000 description 1
- 230000004043 responsiveness Effects 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 230000002123 temporal effect Effects 0.000 description 1
- 229940116411 terpineol Drugs 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
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- 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
- C04B35/10—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 aluminium oxide
- C04B35/111—Fine ceramics
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Description
粒径(レーザー回折式粒度分布測定装置使用)
球形度(SEMにて粒子の長径、短径を測定)
平均気孔径(水銀圧入式細孔分布測定装置使用)
気孔率(水銀圧入式細孔分布測定装置使用)
気孔分布(気孔径の分布幅)(水銀圧入式細孔分布測定装置使用)
第1の製造方法の実施例
第1のアルミナ粒子1からなる原料粉末に、分散媒(例えば、エタノール)、分散剤、第2のアルミナ粒子2を含むスラリーを添加し、予備混合した後、予め、溶剤(例えばターピネオール)に有機バインダー(例えばエチルセルロース)及び可塑剤を溶かした液(以下「有機バインダー液」という)を追加して更に混合後、分散媒の除去及び溶剤の追加により粘度を調整することにより得られたペーストを塗布または印刷により膜状成形体を作製し、これを焼成する。
第2の製造方法の実施例
第3のアルミナ粒子4からなる原料粉末に、分散媒(例えば、エタノール)、分散剤、SiO2源(例えばシリカゾル)、MgO源(例えば、酢酸マグネシウム)を添加し、以下上記の第1の製造方法と同じ方法で焼結体を得る。
第3の製造方法の実施例
第4のアルミナ粒子8からなる原料粉末と、第5のアルミナ粒子9からなる原料粉末との混合粉末に分散媒(例えば、エタノール)、分散剤を添加し、以下上記の第1の製造方法と同じ方法で焼結体を得る。
従来の製造方法の比較例
従来のアルミナ粒子からなる原料粉末と、アルミニウム塩(例えば水酸化アルミニウム)との混合粉末に分散媒(例えば、エタノール)、分散剤を添加し、以下上記の第1の製造方法と同じ方法で焼結体を得る。
実施例1〜3及び比較例1で用いた材料(骨材及び造孔材)の粒径、形状、混合割合、焼結温度並びに得られたアルミナ焼結体の気孔径、気孔率及び気孔分布(気孔径の分布幅)を表1に示す。表1に示すように、実施例1〜3で得られたアルミナ焼結体の方が、比較例1で得られたアルミナ焼結体よりも、気孔径、気孔率及び気孔分布(気孔径の分布幅)において精密に制御されていることがわかる。
次に、印刷後のジルコニア(固体電解質)シートS1とジルコニア(固体電解質)シートS3との間に空間を設けるためパンチングを施したジルコニア(固体電解質)シートS2を挟み込むように積層し、切断加工後、焼成する。ただし、シートS2の一部分に有機ペースト(バインダー液)を塗布・乾燥した後、焼成工程で、本有機ペーストを除去することにより、シートS1とシートS2の間およびシートS2とS3の間にガス経路が形成される。
Claims (10)
- 骨材としてのアルミナ粒子を造孔材の存在下で焼結することによって得られる、複数の連通気孔を有する気体透過性のアルミナ焼結体であって、
前記連通気孔の平均気孔径が、400〜1100Åで、気孔率が、4〜16%であり、
前記連通気孔の気孔分布(気孔径の分布幅)が、300〜1100Åであるアルミナ焼結体。 - 複数の連通気孔を有する気体透過性のアルミナ焼結体を製造する方法であって、
粒径が0.2〜0.7μmで球形度が0.7〜1.0の骨材としての第1のアルミナ粒子と、粒径が0.01〜0.1μmの造孔材としての第2のアルミナ粒子とを混合し、前記第1のアルミナ粒子の相互間の空隙に前記第2のアルミナ粒子の複数を埋め込むようにして、1200〜1400℃の温度で焼結することによって、前記連通気孔の平均気孔径が、400〜1100Åで、気孔率が、4〜16%であるアルミナ焼結体を得るアルミナ焼結体の製造方法。 - 得られる前記アルミナ焼結体の気孔分布(気孔径の分布幅)が、300〜1100Åである請求項2に記載のアルミナ焼結体の製造方法。
- 前記第2のアルミナ粒子を、前記第1のアルミナ粒子に対して0.2〜1.5質量%の割合で混合する請求項3に記載のアルミナ焼結体の製造方法。
- 複数の連通気孔を有する気体透過性のアルミナ焼結体を製造する方法であって、
粒径が0.2〜0.7μmで球形度が0.7〜1.0の骨材としての第3のアルミナ粒子を、二酸化ケイ素(SiO2)及び酸化マグネシウム(MgO)を含む造孔材としての複合材の存在下で、1200〜1400℃の温度で焼結することによって、前記第3のアルミナ粒子の相互間を前記複合材の層によって結合させて、前記連通気孔の平均気孔径が、400〜1100Åで、気孔率が、4〜16%であるアルミナ焼結体を得るアルミナ焼結体の製造方法。 - 前記複合材を、前記第3のアルミナ粒子に対して0.02〜2質量%の割合で混合する請求項5に記載のアルミナ焼結体の製造方法。
- 得られる前記アルミナ焼結体の気孔分布(気孔径の分布幅)が、300〜1100Åである請求項5又は6に記載のアルミナ焼結体の製造方法。
- 複数の連通気孔を有する気体透過性のアルミナ焼結体を製造する方法であって、
粒径が0.3〜1.0μmで球形度が0.7〜1.0の骨材としての第4のアルミナ粒子と、粒径が0.2〜0.8μmの造孔材としての第5のアルミナ粒子とを混合し、前記第4のアルミナ粒子間の空隙に前記第5のアルミナ粒子を嵌め込むようにして、前記1200〜1400℃の温度で焼結することによって、前記連通気孔の平均気孔径が、400〜1100Åで、気孔率が、4〜16%であるアルミナ焼結体を得るアルミナ焼結体の製造方法。 - 得られる前記アルミナ焼結体の気孔分布(気孔径の分布幅)が、300〜1100Åである請求項8に記載のアルミナ焼結体の製造方法。
- 前記第5のアルミナ粒子を、前記第4のアルミナ粒子に対して50〜95質量%の割合で混合する請求項8又は9に記載のアルミナ焼結体の製造方法。
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JP5593264B2 (ja) * | 2010-03-31 | 2014-09-17 | 日本碍子株式会社 | アルミナ多孔体の製法 |
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