JP5567465B2 - 少なくとも二つの焼結体を結合する方法及び該方法によって調製した複合構造物 - Google Patents
少なくとも二つの焼結体を結合する方法及び該方法によって調製した複合構造物 Download PDFInfo
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Description
(a)第一の金属酸化物を含む第一の焼結体を提供すること;
(b)第二の金属酸化物を含む第二の焼結体を提供すること;
(c)第一の焼結体と第二の焼結体の結合表面間の結合材料を提供すること、ここで該結合材料は少なくとも一つの有機成分及びセラミック粒子を含み、ここで該セラミック粒子は:
(i)該結合材料の少なくとも40体積%そして75体積%以下を構成し;そして
(ii)第一の焼結体及び第二の焼結体の少なくとも一つに含まれる元素を少なくとも一つ含むこと;
(d)結合表面に少なくとも1kPaかつ5MPa未満の圧力を適用し、第一の焼結体、第二の焼結体及び結合材料の組立物を提供すること;
(e)該結合材料が結合表面に適合することを可能にするために十分な適合温度まで該組立物を加熱すること;そして
(f)第一の及び第二の焼結体の最小焼結温度未満である結合温度まで該組立物をさらに加熱すること、
それによって該少なくとも二つの焼結体は結合材料によって結合され複合構造体を形成する。
第一の金属酸化物を含む第一の焼結体;
第二の金属酸化物を含む第二の焼結体;及び
少なくとも一つの有機成分及びセラミック粒子を含む第一の焼結体と第二の焼結体の間の結合、ここで該セラミック粒子は:
(i)該結合材料の少なくとも40体積%そして75体積%以下を構成し;そして
(ii)第一の焼結体及び第二の焼結体の少なくとも一つに含まれる元素を少なくとも一つ含む。
b. 分散剤(B−79 PVB)
c. バインダー(B−98 PVB)
d. 可塑剤(S−160 BBP)
e. 2.0m2/g La0.9Ca0.1FeO3−d粉末
f. 6.0m2/g (La0.9Ca0.1)1.005FeO3−d粉末
b. エタノール、PM−509
c. 分散剤(B−79 PVB)
d. バインダー(B−98 PVB)
e. 可塑剤(S−160 BBP)
HSY3.0)を添加することによって調製した。このスリップを30分間ペイントシェーカーにかけ、その後68.8gのバインダー(B−98 PVB)、35.7gの可塑剤(S−160 BBP)を添加しそしてさらに1時間ペイントシェークした。それを68時間ボールミルで混合し、その後脱気しそしてキャスティングして250μm厚のテープを作った。
Claims (15)
- 少なくとも二つの焼結体を結合し複合構造物を形成する方法であって、前記方法は以下を含み:
(a)第一の金属酸化物を含む第一の焼結体を提供すること;
(b)第二の金属酸化物を含む第二の焼結体を提供すること;
(c)第一の焼結体と第二の焼結体の結合表面間に結合材料を提供すること、
ここで該結合材料は少なくとも一つの有機成分とセラミック粒子の複合混合物であり、
ここで該少なくとも一つの有機成分は、該結合材料が加熱前に適合を生じない重合性の成分を含み、かつ、該少なくとも一つの有機成分は重合性バインダー、可塑剤、及び分散剤からなる群から選択した少なくとも一つの成分であり、
ここで該セラミック粒子は:
(i)該結合材料の40体積%〜75体積%を構成し;
(ii)第一の焼結体及び第二の焼結体の少なくとも一つに含まれる元素を少なくとも一つ含み;そして
(iii)2〜10m2/gの範囲の表面積を有すること
(d)結合表面に少なくとも1kPaかつ5MPa未満の圧力を適用し、第一の焼結体、第二の焼結体及び結合材料の組立物を提供すること;
(e)該結合材料が結合表面に適合することを可能にするために十分な適合温度まで該組立物を加熱すること;そして
(f)第一の及び第二の焼結体の最低焼結温度未満である結合温度まで該組立物をさらに加熱すること、
それによって該少なくとも二つの焼結体は結合材料によって結合され複合構造体を形成し、
ここで該セラミック粒子が本方法の間に液相を形成しない、方法。 - 第一の金属酸化物がペロブスカイト型結晶構造及び蛍石型結晶構造からなる群から選択した第一の結晶質構造を有する第一の多成分金属酸化物であり、そして第二の金属酸化物が第一の結晶質構造と同一の第二の結晶質構造を有する第二の多成分金属酸化物である、請求項1に記載された方法。
- 第一の焼結体及び第二の焼結体が同一の組成物を有する、請求項2に記載された方法。
- 第一の焼結体及び第二の焼結体の少なくとも一つがアルミナ、ジルコニア、セリア、1>x>0、1.1>y>1、且つδが化合物の電荷を中立にするLa1-xSrxCoyO3-δセラミック、又は1>x>0.5、1.1≧y>1、且つδが化合物の電荷を中立にする(La1-xCax)yFeO3-δセラミックを含んでなる、請求項1に記載された方法。
- 第一の及び第二の焼結体がイオン輸送膜、イオン輸送膜の相互接続物(interconnect)、イオン輸送膜の支持体、イオン輸送膜のセラミックのチューブ、イオン輸送膜のシール又はイオン輸送膜の導管の構成要素である、請求項1に記載された方法。
- 結合材料は化学的にそして機械的に第一の焼結体及び第二の焼結体と両立する、請求項1に記載された方法。
- セラミック粒子が第一の焼結体及び第二の焼結体の少なくとも一つに含まれた全ての元素を含んでなる、請求項1に記載された方法。
- 少なくとも一つの有機成分がバインダー及び可塑剤を少なくとも0.25:1のバインダー対可塑剤の質量比率で含んでなる、請求項1に記載された方法。
- 結合表面の平坦さからの外れ具合(out of flatness)が500μm未満であるように結合表面が提供される、請求項1に記載された方法。
- 適合温度が300℃未満である、請求項1に記載された方法。
- 結合温度が第一の及び第二の焼結体の焼結温度より少なくとも100℃低い、請求項1に記載された方法。
- 結合表面に対して実質的に法線の角度で圧力が適用される、請求項1に記載された方法。
- 複合構造物は第一の焼結体と第二の焼結体との間に区別できる界面(interfacial)相がない、請求項1に記載された方法。
- 結合が熱サイクルを通して安定している、請求項1に記載された方法。
- 重合性バインダーが、ポリビニルブチラール、ポリプロピレンカーボネート、ポリビニルアルコール、ポリビニルクロライド、ポリアクリレートエステル、ポリメチルメタクリレート、ポリイソブチレン、ポリウレタン、メチルセルロース、及びラテックスからなる群から選択され、可塑剤が、ブチルベンジルフタレート、ジメチルフタレート、ポリエチレングリコール、ポリアルキレングリコール、トリエチレングリコール、グリセロール、ブチルステアレート、プロピレンカーボネート、及びブチルステアレートからなる群から選択される、請求項1に記載された方法。
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