WO2011111624A1 - 赤色透光性ジルコニア焼結体、その製造方法、その焼結体からなる部材、及びその部材を用いる宝飾品及び外装部品 - Google Patents
赤色透光性ジルコニア焼結体、その製造方法、その焼結体からなる部材、及びその部材を用いる宝飾品及び外装部品 Download PDFInfo
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Definitions
- the present invention relates to a colored translucent zirconia sintered body having not only a red color but also high translucency, a manufacturing method thereof, a member made of the sintered body, and a jewelry and an exterior part using the member.
- Zirconia sintered body is an excellent ceramic material with high strength and pearly luster. Furthermore, a further high-class feeling can be provided by providing translucency. In recent years, not only conventional structural member applications but also applications as jewelry members and exterior members of electronic devices have been expanded.
- Patent Document 1 Conventionally, in a zirconia sintered body (Patent Document 1) with improved translucency, the color tone is colorless or light yellow. With the expansion of applications of transparent zirconia sintered bodies, there has been a demand for more colorfully colored sintered bodies, so-called colored translucent zirconia sintered bodies, while maintaining the translucency of the zirconia sintered bodies. . Among such colored translucent zirconia sintered bodies, there is a strong demand for colored translucent zirconia sintered bodies exhibiting red as a translucent zirconia sintered body having a clear coloring that gives a particularly rich decoration. ing.
- the present invention provides a colored translucent zirconia sintered body that not only exhibits red color but also has high translucency.
- the present inventors diligently studied a colored translucent zirconia sintered body exhibiting a red color. As a result, translucent zirconia sintered body colored in red without impairing translucency by containing translucent zirconia sintered body containing yttria (Y 2 O 3 ) as a colorant. It was found that a knot was obtained. That is, the present invention contains 6 mol% to 30 mol% yttria and 0.1 mol% to 5 mol% cerium oxide in terms of CeO 2 , and the cerium oxide contains a trivalent cerium oxide. It is a zirconia sintered body.
- the gist of the present invention resides in the following (1) to (11).
- the maximum value of the linear transmittance for visible light having a wavelength of 400 nm to 500 nm is 3% or less, and the maximum value of the linear transmittance for visible light having a wavelength of 600 nm to 800 nm is It is 40% or more,
- the lightness L * and the hues a * and b * are 20 ⁇ L * ⁇ 50, 40 ⁇ a * ⁇ 60, and 30 ⁇ b * ⁇ 70.
- the zirconia sintered body according to any one of (3).
- Zirconia powder containing 6 mol% to 30 mol% yttria and 0.1 mol% to 5 mol% cerium oxide in terms of CeO 2 is formed, subjected to primary sintering, hot isostatic pressing (HIP) treatment and annealing.
- the primary sintered body is disposed in a breathable container and subjected to HIP treatment, wherein the manufacturing method according to (5) above.
- a member comprising the zirconia sintered body according to any one of (1) to (4).
- a deep red and transparent zirconia sintered body having transparency in addition to diamond luster based on a high refractive index peculiar to zirconia, a deep red and transparent zirconia sintered body having transparency can be obtained.
- FIG. 1 is a graph showing the linear transmittance ((a) Example 1 (b) Example 3) of the zirconia sintered body of the present invention with respect to light having a wavelength of 200 nm to 800 nm.
- FIG. 2 is a graph showing an X-ray diffraction pattern ((a) Example 1 (b) Example 3) of the zirconia sintered body of the present invention.
- FIG. 3 is a graph showing the fluorescence spectrum of Example 3.
- FIG. 4 is a graph showing the linear transmittance of Comparative Example 1 with respect to light having a wavelength of 200 nm to 800 nm.
- the zirconia sintered body of the present invention contains 6-30 mol% of yttria, preferably 7-30 mol%, more preferably 8-15 mol%.
- Yttria is a zirconia stabilizer. By containing yttria, the crystal structure of the zirconia sintered body is stabilized. Furthermore, by setting the yttria content within this range, the crystal phase of the zirconia sintered body can be made only cubic (fluorite structure). If the yttria content is less than 6 mol%, tetragonal crystals are likely to be mixed in addition to cubic crystals, and the translucency tends to be lowered.
- the yttria content is 7 mol% or more, tetragonal crystals are less likely to be generated, and the crystal phase can be made only cubic.
- the yttria content is determined by Y 2 O 3 / (ZrO 2 + Y 2 O 3 ).
- the zirconia sintered body of the present invention contains 0.1 mol% to 5 mol% of cerium oxide in terms of CeO 2 .
- the content of cerium oxide is preferably 0.5 mol% to 2 mol%, more preferably 0.5 mol% to 1 mol%, and even more preferably 0.5 mol% to 0.75 mol%.
- Cerium oxide functions as a colorant for developing a red color. By containing the cerium oxide in the above range, it becomes possible for the zirconia sintered body to develop a red color having an excellent color tone. On the other hand, if the cerium oxide content is less than 0.1 mol%, the red coloring of the present invention cannot be obtained.
- the translucency of the zirconia sintered body is lowered by the precipitation of cerium oxide.
- the content of cerium oxide is obtained by CeO 2 / (ZrO 2 + Y 2 O 3 + CeO 2).
- the cerium oxide needs to contain trivalent cerium.
- Trivalent cerium is contained in the zirconia sintered body as an oxide of trivalent cerium.
- the zirconia sintered body exhibits a particularly bright red color.
- the ratio (%) of trivalent cerium here is the molar fraction (mol%) occupied by trivalent cerium with respect to the cerium oxide contained in the zirconia sintered body.
- the proportion of trivalent cerium can be determined from CeO 1.5 / (CeO 1.5 + CeO 2 ). Therefore, the trivalent cerium oxide also has the same ratio (mol%).
- the colored translucent zirconia sintered body of the present invention is a colored translucent zirconia sintered body utilizing the color developed by the existing colorant (cerium oxide (CeO 2 )), that is, the color developed by tetravalent cerium. It is different from the union.
- the zirconia sintered body of the present invention preferably has a cubic fluorite structure. Since cubic crystals have no optical anisotropy, particularly high transparency can be obtained when the individual crystals of the polycrystalline body of the zirconia sintered body are cubic.
- the zirconia sintered body of the present invention has a cubic fluorite type crystal structure.
- the zirconia sintered body of the present invention is a polycrystalline body composed of many crystal grains, and is different from a single crystal zirconia sintered body.
- the zirconia sintered body of the present invention contains a stabilizer other than yttria in a range that does not deteriorate translucency and does not impair the color tone, such as lanthanoid rare earth oxides, Ca, Mg and oxides thereof. It may be. Moreover, you may contain the coloring agent for adjusting the color tone of red. Examples of the colorant for adjusting the red color tone include lanthanoid rare earth oxides such as neodymium oxide and transition metal oxides such as cobalt oxide. The colorant for adjusting the red color tone is preferably neodymium oxide or cobalt oxide, or both.
- the total content of these stabilizers and colorants for adjusting the color tone of red is preferably 2 mol% or less, more preferably 1 mol% or less, and 0.1 mol% or less. Is more preferable, and it is still more preferable that it is 0.05 mol% or less (500 ppm or less). When the content is 2 mol% or less, these compounds do not precipitate and can be dissolved in the zirconia sintered body.
- the content of the stabilizer other than yttria and the colorant for adjusting the red color tone is a ratio to the zirconia sintered body, and is obtained by X / (ZrO 2 + Y 2 O 3 + CeO 2 + X) ( X is a stabilizer other than yttria and a colorant for adjusting the red color tone).
- the maximum value of linear transmittance for visible light having a wavelength of 600 nm to 800 nm is preferably 40% or more, more preferably 50% or more, More preferably, it is 60% or more.
- the maximum value of the linear transmittance for visible light having a wavelength of 600 nm to 800 nm is less than 40%, the translucency is low and the aesthetic property is inferior.
- the zirconia sintered body of the present invention has a high maximum value of linear transmittance with respect to visible light having a wavelength of 600 nm to 800 nm. Therefore, the zirconia sintered body of the present invention is a translucent zirconia sintered body having high transparency equivalent to the transparent zirconia sintered body.
- the maximum value of the linear transmittance for visible light having a wavelength of 400 nm to 500 nm is preferably 3% or less, more preferably 1% or less, in a sample having a thickness of 1 mm. preferable. Visible light having a wavelength of 400 nm to 500 nm is absorbed based on red. Therefore, the zirconia sintered body of the present invention has a visible light linear transmittance of substantially 0% at a wavelength of 400 nm to 500 nm. In consideration of variation in measurement, it is preferably 3% or less, more preferably 1% or less, and further preferably 0.5%.
- the translucent zirconia sintered body exhibiting red color according to the present invention easily transmits visible light having a wavelength of 600 nm to 800 nm. However, visible light having a wavelength of 400 nm to 500 nm is hardly transmitted due to absorption based on red.
- the conventional colored translucent zirconia sintered bodies exhibiting pink or purple also absorb visible light of about 400 nm to 500 nm, but the absorption of these sintered bodies is different from the absorption of the zirconia sintered body of the present invention. .
- a colored translucent zirconia sintered body having a maximum linear transmittance of 40% or more for visible light having a wavelength of 600 nm to 800 nm or more and exhibiting pink or purple has a linear transmittance of 5% or more at 400 nm to 500 nm. Become.
- the color tone of the colored zirconia sintered body is defined by lightness L * and hues a * and b * .
- the hue a * indicates a color tone from red to green.
- the larger the a * value the stronger the red tone, and the smaller the value, the stronger the green tone.
- b * values indicate the color blue from yellow
- b * values of yellow color tone is stronger the larger, color tone of blue becomes stronger as the b * value is small.
- the zirconia sintered body of the present invention is a translucent zirconia sintered body, a so-called translucent zirconia sintered body. Therefore, the color tone of the zirconia sintered body of the present invention changes depending on the translucency. For example, as the linear transmittance increases, the lightness L * and the hues a * and b * all increase. On the other hand, when the linear transmittance decreases, the lightness L * and the hues a * and b * all decrease.
- Examples of the color tone that can be achieved in the translucent range of the zirconia sintered body of the present invention include 20 ⁇ L * ⁇ 50, 40 ⁇ a * ⁇ 60, and 30 ⁇ b * ⁇ 70. Particularly, 30 ⁇ L * ⁇ 45, 50 ⁇ a * ⁇ 60, 50 ⁇ b * ⁇ 70 as bright bright red, and 20 ⁇ L * ⁇ 30, 40 ⁇ a * ⁇ 50, 30 ⁇ for particularly deep crimson color.
- An example of a preferable color tone is b * ⁇ 50.
- the average particle size of the crystal particles in the zirconia sintered body of the present invention is preferably 10 ⁇ m or more and 50 ⁇ m or less. When the average particle diameter exceeds 50 ⁇ m, the bending strength of the zirconia sintered body tends to be lowered.
- the zirconia sintered body of the present invention forms zirconia powder containing 6 mol% to 30 mol% yttria and 0.1 mol% to 5 mol% cerium oxide in terms of CeO 2, and performs primary sintering and hot isostatic pressing. It can be manufactured by forming trivalent cerium in the sintered body by press (HIP) treatment and further annealing.
- HIP press
- the method of the present invention forms a raw material powder containing zirconia, yttria, and cerium oxide.
- the zirconia powder used for the raw material is preferably easily sinterable.
- an easily sinterable powder in which 8 mol% yttria or 10 mol% yttria produced by a hydrolysis method is dissolved can be used.
- the method for adding cerium oxide may be mixed with the above zirconia powder so as to be within the composition range of the present invention, and the addition method is not limited.
- the mixing method of the powder is not limited as long as these components are uniformly mixed, and a normal wet mixing method such as a ball mill or a stirring mill can be used.
- a normal wet mixing method such as a ball mill or a stirring mill
- the raw material powder can be formed into a desired shape, and it can be performed by a conventional ceramic forming method such as a die press, cold isostatic pressing, slip casting, injection molding or the like.
- the obtained molded body is then sintered at normal pressure and in the atmosphere to obtain a primary sintered body.
- the primary sintering can be performed in the atmosphere using a normal sintering furnace.
- the primary sintering temperature is preferably 1250 ° C. or higher and 1400 ° C. or lower. If the temperature is lower than 1250 ° C., the relative density of the obtained primary sintered body tends to be as low as 95% or less, so that the density of the zirconia sintered body after the HIP treatment is hardly increased. Moreover, when it exceeds 1400 degreeC, the crystal grain diameter of a primary sintered compact will become large too much, and the translucency of the zirconia sintered compact after a HIP process will fall easily.
- the average crystal grain size of the primary sintered body is preferably 5 ⁇ m or less, more preferably 2 ⁇ m or less, and even more preferably 1.5 ⁇ m or less. If the average crystal grain size exceeds 5 ⁇ m, the density of the zirconia sintered body after the HIP treatment tends to be low.
- the primary sintered body is subjected to HIP treatment.
- HIP treatment tetravalent cerium in the primary sintered body is reduced to produce trivalent cerium.
- the sintered body is colored red.
- the HIP treatment is preferably performed by placing the primary sintered body in a breathable container. This promotes the production of trivalent cerium.
- the air permeable container is not particularly limited as long as it is other than a sealed container, but open containers such as a lidded container having a vent and a container without a lid can be exemplified.
- the HIP treatment is preferably performed in a strong reducing atmosphere, and a non-oxidizing gas such as argon or nitrogen is preferably used as the pressure medium. Moreover, it is preferable to use an apparatus in which the heat source and the heat insulating material are made of graphite.
- the HIP treatment temperature is preferably 1400 ° C. or higher and 1800 ° C. or lower, and more preferably 1500 ° C. or higher and 1700 ° C. or lower. Below 1400 ° C., trivalent cerium is hardly generated. On the other hand, when the HIP processing temperature exceeds 1800 ° C., the growth of crystal grains becomes remarkable, so that the strength of the obtained zirconia sintered body tends to decrease. In addition, as the HIP processing temperature is higher, the brightness L * value, hue a * value, and b * value of the obtained zirconia sintered body are increased, and a bright red color tends to be obtained.
- the HIP processing pressure is preferably 50 MPa or more and 200 MPa or less.
- the HIP-treated body after the HIP treatment is annealed (heat treatment in an oxidizing atmosphere).
- annealing the blackness of the zirconia sintered body is removed, and the translucency is improved.
- the annealing is preferably performed in an oxidizing atmosphere such as normal air or a gas atmosphere containing oxygen. Since it is the simplest to carry out in air
- the annealing temperature is preferably 800 ° C. or higher and 1000 ° C. or lower.
- annealing When annealing is performed at a temperature exceeding 1000 ° C., trivalent cerium generated by the HIP process is re-oxidized to become tetravalent cerium, so that the sintered body easily changes from red to light yellow.
- the annealing temperature is less than 800 ° C., the sintered body is not removed from the black color and the translucency is lowered.
- the annealing holding time is preferably 1 hour or more and 5 hours or less.
- the color tone was measured using a color difference meter (Color Analyzer TC-1800MK-II, manufactured by Tokyo Denshoku Co., Ltd.) under the conditions of a D65 light source and a 10 ° viewing angle in accordance with JISZ8722.
- the transmittance was measured based on JISK7105 “Testing method for optical properties of plastics” and JISK7361-1 “Testing method for total light transmittance of plastics and transparent materials”.
- a double beam type spectrophotometer manufactured by JASCO Corporation, Model V-650
- the light generated from the light source deuterium lamp and halogen lamp
- the total light transmission amount and the diffuse transmission amount were measured.
- the linear transmittance was derived from equation (2).
- the measurement wavelength range was 200 nm to 800 nm.
- Ti Tt ⁇ Td (2)
- Td diffuse transmittance (%)
- the fluorescence spectrum of the sintered body was measured, and the presence or absence of trivalent cerium in the sintered body was confirmed. Measurement was performed using a FP-6500 apparatus manufactured by JASCO Corporation, using a xenon lamp (248 nm) as an excitation light source, and measuring light emission with a wavelength of 300 nm to 700 nm by a reflection method. The sample used for the measurement of the linear transmittance was used. Trivalent cerium was confirmed by the presence of a peak near 570 nm to 600 nm.
- Examples 1-6 Predetermined amounts of zirconia powder and cerium oxide powder were weighed, mixed in a ball mill made of zirconia having a diameter of 10 mm in an ethanol solvent for 72 hours, and then dried to prepare raw material powders having different amounts of cerium.
- zirconia powder 8 mol% yttria-containing zirconia powder (manufactured by Tosoh, TZ-8Y; specific surface area 13 m 2 / g, crystallite diameter 40 nm) produced by a hydrolysis method is used.
- As the cerium oxide powder A 99.9% pure reagent was used.
- HIP treatment and annealing Using the primary sintered bodies of sample numbers 1 to 3, HIP treatment was performed at a temperature of 1650 ° C., a pressure of 150 MPa, and a holding time of 1 hour. Argon gas having a purity of 99.9% was used as the pressure medium.
- the HIP apparatus was an apparatus equipped with a carbon heater and a carbon heat insulating material. Further, an alumina lid crucible having a vent hole was used as a container for installing the sample.
- the zirconia sintered body obtained by the HIP treatment exhibited a blackish red translucent color. The zirconia sintered body was further heated in the atmosphere at a heating rate of 250 ° C./h, and kept at 1000 ° C. for 1 hour for annealing treatment. All the sintered bodies after the annealing treatment were red and transparent. Table 2 shows the characteristics of the obtained zirconia sintered body.
- the obtained zirconia sintered body did not transmit light having a wavelength of 500 nm or less due to absorption based on red, and the linear transmittance from 500 nm to 400 nm was 0%. All the zirconia sintered bodies had a cubic fluorite structure.
- the linear transmittances of Examples 1 and 3 are shown in FIG. 1, and the XRD is shown in FIG.
- Examples 4-6 Zirconia sintered bodies were obtained in the same manner as in Examples 1 to 3, except that the primary sintered bodies of sample numbers 1 to 3 were used and the HIP treatment temperature was set to 1500 ° C.
- the properties of the obtained zirconia sintered body are shown in Table 3.
- the obtained zirconia sintered body was a transparent zirconia sintered body having a low brightness and a deep red color as compared with the zirconia sintered bodies of Examples 1 to 3.
- the crystal phase of any sintered body had a cubic fluorite structure.
- Examples 7 and 8 (Powder preparation) In addition to zirconia powder and cerium oxide powder, neodymium oxide and cobalt oxide were weighed in predetermined amounts, mixed in a ball mill made of zirconia having a diameter of 10 mm in ethanol solvent for 72 hours, and dried powder was used as raw material powder.
- the raw material powder was molded at a pressure of 50 MPa by a die press and then processed at a pressure of 200 MPa using a cold isostatic press to obtain a cylindrical molded body having a diameter of 20 mm and a thickness of 3 mm.
- Primary sintering was performed in the air at a heating rate of 100 ° C./h, a sintering temperature of 1325 ° C., and a sintering time of 2 hours to obtain primary sintered bodies of sample numbers 7 and 8.
- the composition of the primary sintered body was the same as that of the raw material powder.
- the characteristics of the obtained primary sintered body are shown in Table 4.
- HIP treatment and annealing Using a primary sintered body of sample number 7 or 8, HIP treatment was performed in the same manner as in Examples 1 to 3 at a temperature of 1650 ° C., a pressure of 150 MPa, and a holding time of 1 hour, and then the sintered body was heated in the atmosphere. Annealing treatment was performed by maintaining the temperature at 1000 ° C. for 1 hour at a rate of 250 ° C./h. The properties of the obtained zirconia sintered body are shown in Table 5.
- Example 9 The fluorescence spectra of the zirconia sintered bodies of Examples 3 and 6 were measured. In any of the zirconia sintered bodies, light emission having a peak at 590 nm attributed to trivalent cerium was observed, and the presence of cerium trivalent was confirmed. The fluorescence spectrum of Example 3 is shown in FIG.
- any of the zirconia sintered bodies of Examples 3 and 6 0.06% by weight decreased before and after the HIP treatment. This corresponded to the weight loss (0.06 wt%) calculated from the reduction of cerium oxide (CeO 2 ⁇ 1 / 2Ce 2 O 3 + 1 / 4O 2 ) shown in the above formula (1).
- the ratio of trivalent cerium to the cerium oxide contained in the sintered zirconia was calculated from the formula CeO 1.5 / (CeO 1.5 + CeO 2 ).
- the zirconia sintered body of No. 6 is 100 mol%.
- the zirconia sintered compact which does not contain cerium since the weight reduction before and after HIP processing was not confirmed, it can be said that the said weight reduction is due to reduction
- Comparative Examples 1 and 2 About the zirconia sintered compact obtained by carrying out similarly to Example 3 and 6, it annealed by hold
- the zirconia sintered body of the present invention has a deep red color and transparency in addition to diamond luster based on a high refractive index peculiar to zirconia.
- it since it has a high hardness, it can be used for various members such as high-quality jewelry and decorative members that are not damaged, such as watch parts and exterior parts of portable electronic devices. Therefore, the industrial value of the present invention is remarkable.
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Abstract
Description
しかしながら、これまで透光性が高く、なおかつ鮮やかな赤色を呈する透光性ジルコニア焼結体は得られていなかった。
すなわち、本発明は6mol%~30mol%のイットリア及びCeO2換算で0.1mol%~5mol%のセリウム酸化物を含有し、該セリウム酸化物が3価セリウムの酸化物を含有することを特徴とするジルコニア焼結体である。
(1)6mol%~30mol%のイットリア及びCeO2換算で0.1mol%~5mol%のセリウム酸化物を含有し、該セリウム酸化物が3価セリウムの酸化物を含有することを特徴とするジルコニア焼結体。
(2)好ましくは、結晶相が立方晶蛍石型構造であることを特徴とする上記(1)に記載のジルコニア焼結体。
(3)好ましくは、試料厚さ1mmにおいて、波長400nm~500nmの可視光に対する直線透過率の最大値が3%以下であり、かつ、波長600nm~800nmの可視光に対する直線透過率の最大値が40%以上であることを特徴とする上記(1)又は(2)に記載のジルコニア焼結体。
(4)好ましくは、明度L*、色相a*およびb*が、20≦L*≦50、40≦a*≦60および30≦b*≦70であることを特徴とする上記(1)乃至(3)のいずれかに記載のジルコニア焼結体。
(6)好ましくは、一次焼結体を通気性のある容器に配してHIP処理を行うことを特徴とする上記(5)に記載の製造方法。
(7)好ましくは、アニールを800℃以上1000℃以下で行うことを特徴とする上記(5)又は(6)に記載のジルコニア焼結体の製造方法。
(8)好ましくは、HIP処理に供する一次焼結体の平均粒径が5μm以下であることを特徴とする上記(5)乃至(7)のいずれかに記載の製造方法。
(10)上記(9)に記載の部材を用いることを特徴とする宝飾品。
(11)上記(9)に記載の部材を用いることを特徴とする外装部品。
本発明のジルコニア焼結体は、イットリアを6~30mol%含有し、好ましくは7~30mol%を含有し、より好ましくは8~15mol%含有する。イットリアはジルコニアの安定化剤である。イットリアを含有することでジルコニア焼結体の結晶構造が安定化される。さらに、イットリア含有量をこの範囲とすることで、ジルコニア焼結体の結晶相を立方晶(蛍石型構造)のみとすることができる。イットリア含量が6mol%未満では立方晶の他に正方晶が混在しやすくなり、透光性が低下し易い。イットリア含有量が7mol%以上であれば正方晶がより生成しにくくなり、結晶相を立方晶のみとすることができる。
なお、イットリア含有量は、Y2O3/(ZrO2+Y2O3)で求められる。
なお、セリウム酸化物の含有量は、CeO2/(ZrO2+Y2O3+CeO2)で求められる。
3価セリウムが多いほど、ジルコニア焼結体がより鮮明な赤色を呈する。そのため、3価セリウムは、セリウム酸化物中のセリウムの50%以上であることが好ましく、80%以上であることがより好ましく、90%以上であることがさらに好ましく、100%に近づくほどより好ましい。
このように、本発明の着色透光性ジルコニア焼結体は、存在する着色剤(酸化セリウム(CeO2))そのものが呈する発色、即ち4価セリウムが呈する発色を利用した着色透光性ジルコニア焼結体とは異なる。
なお、本発明のジルコニア焼結体は立方晶蛍石型結晶構造を有する。また、本発明のジルコニア焼結体は多くの結晶粒子からなる多結晶体であり、単結晶のジルコニア焼結体とは異なる。
また、赤色の色調を調節するための着色剤を含有していてもよい。赤色の色調を調節するための着色剤として酸化ネオジウム等のランタノイド系希土類酸化物、酸化コバルト等の遷移金属酸化物が例示できる。赤色の色調を調節するための着色剤としては、酸化ネオジウム又は酸化コバルト、若しくはその両者であることが好ましい。
なお、イットリア以外の安定化剤や赤色の色調を調節するための着色剤の含有量は、ジルコニア焼結体に対する割合であり、X/(ZrO2+Y2O3+CeO2+X)で求められる(Xはイットリア以外の安定化剤や赤色の色調を調節するための着色剤)。
この様に、本発明のジルコニア焼結体は、波長600nm~800nmの可視光に対する直線透過率の最大値が高い。そのため、本発明のジルコニア焼結体は、透明ジルコニア焼結体と同等の高い透明性を有する透光性ジルコニア焼結体である。
本発明のジルコニア焼結体は、6mol%~30mol%イットリア及びCeO2換算で0.1mol%~5mol%のセリウム酸化物を含有するジルコニア粉末を成形し、これを一次焼結、熱間静水圧プレス(HIP)処理し、さらにアニールすることにより焼結体中に3価セリウムを生成させることによって製造することができる。
原料に使用するジルコニア粉末は易焼結性であることが好ましい。例えば、比表面積5m2/g~20m2/g、結晶子径10nm~100nmの微細粒子からなる粉末を用いることが好ましい。また、あらかじめジルコニアに対して6mol%~30mol%イットリアが固溶した粉末を用いることがより好ましい。このような粉末としては、加水分解法で製造された8mol%のイットリア若しくは10mol%のイットリアを固溶した易焼結性粉末を用いることができる。
原料粉末の成形は、所望の形状に成形できれば特に制限はなく、金型プレス、冷間静水圧プレス、スリップキャスティング、インジェクションモールディング等の通常のセラミックス成形方法で行うことができる。
一次焼結温度は1250℃以上1400℃以下が好ましい。1250℃未満では得られる一次焼結体の相対密度が95%以下と密度が低くなりやすいため、HIP処理後のジルコニア焼結体の密度が上がりにくくなる。また、1400℃を超えると一次焼結体の結晶粒径が大きくなり過ぎ、HIP処理後のジルコニア焼結体の透光性が低下しやすくなる。
HIP処理では一次焼結体中の4価セリウムが還元され、3価セリウムが生成する。3価セリウムを含有することによって、焼結体が赤色に発色する。
HIP処理は、通気性のある容器に一次焼結体を配して行うことが好ましい。これにより3価セリウムの生成が促進される。通気性のある容器としては、密閉容器以外のものであれば特に限定されないが、通気孔を有する蓋付容器、蓋なし容器等の開放容器が例示できる。
CeO2 → 1/2Ce2O3 + 1/4O2↑ (1)
上記の反応で生成する酸素が密閉容器中で滞留すると、一次焼結体が酸化される。これにより、3価セリウムの生成が抑制される。通気性のある容器を用いることにより、一次焼結体近傍に存在する酸素が取り除かれ、3価セリウムの生成が促進される。
HIP処理圧力は50MPa以上200MPa以下であることが好ましい。50MPa未満では加圧効果が得られず、ジルコニア焼結体の密度が向上しにくい。一方、200MPaであればジルコニア焼結体の緻密化が促進しやすい。
アニール温度は800℃以上1000℃以下とすることが好ましい。1000℃を超える温度でアニールすると、HIP処理で生成した3価セリウムが再酸化されて4価セリウムとなるため、焼結体が赤色から薄黄色に変化しやすい。一方、アニール温度が800℃未満では、焼結体は黒味が除かれず透光性が低くなる。アニールの保持時間は、1時間以上5時間以下とすることが好ましい。
本発明の焼結体及び粉末の特性測定方法を以下に説明する。
色調は、JISZ8722に準拠し、D65光源、10°視野角の条件において色差計(カラーアナライザーTC-1800MK-II、東京電色社製)を用いて測定を行った。
透過率はJISK7105「プラスティックスの光学特性試験方法」およびJISK7361-1「プラスティック・透明材料の全光線透過率の試験方法」に基づいて測定した。測定試料は焼結体厚みを1mmに加工し、表面粗さRa=0.02μm以下に両面鏡面研磨したものを用いた。測定にはダブルビーム方式の分光光度計(日本分光株式会社製、V-650型)を用い、光源(重水素ランプおよびハロゲンランプ)より発生した光を試料に透過および散乱させ積分球を用いて全光線透過量、拡散透過量を測定した。直線透過率は(2)式から導いた。測定波長領域は200nm~800nmの領域とした。
Ti=Tt-Td ・・・(2)
Tt:全光線透過率(%)
Td:拡散透過率(%)
Ti:直線透過率(%)
焼結体の蛍光スペクトルを測定し、焼結体中の3価セリウムの有無を確認した。測定は日本分光(株)製FP-6500装置を用い、励起光源としてキセノンランプ(248nm)を用い、反射法によって波長300nm~700nmの発光を測定した。測定試料は直線透過率の測定に用いたものを用いた。570nm~600nm付近のピークの存在によって3価セリウムを確認した。
(原料粉末の調製)
ジルコニア粉末及び酸化セリウム粉末を所定量秤量し、エタノール溶媒中直径10mmのジルコニア製ボールで72時間ボールミル混合した後、乾燥してセリウム量の異なる原料粉末を調製した。
なお、ジルコニア粉末としては、加水分解法で製造された8mol%イットリア含有ジルコニア粉末(東ソー製、TZ-8Y;比表面積13m2/g、結晶子径40nm)を使用し、酸化セリウム粉末としては、純度99.9%の試薬を使用した。
各原料粉末を金型プレスによって圧力50MPaで成形した後、冷間静水圧プレス装置を用い圧力200MPaで処理し、直径20mm、厚さ3mmの円柱状の成形体を得た。
得られた成形体は、大気中において昇温速度を100℃/h、焼結温度1350℃、焼結時間2時間で焼結し、自然放冷して試料番号1~3の一次焼結体を得た。得られた一次焼結体の特性を表1に示した。いずれの一次焼結体の組成も原料粉末の組成と同一であった。また、いずれもの一次焼結体も相対密度は95%以上、平均粒径は5μm以下であった。
試料番号1~3の一次焼結体を用い、温度1650℃、圧力150MPa、保持時間1時間でHIP処理した。圧力媒体には純度99.9%のアルゴンガスを用いた。HIP装置はカーボンヒーター及びカーボン断熱材を備えた装置であった。また、試料を設置する容器として通気孔のあるアルミナ製蓋付きルツボを用いた。
HIP処理によって得られたジルコニア焼結体は、黒味を帯びた赤色半透明を呈していた。このジルコニア焼結体をさらに大気中で昇温速度250℃/hで昇温し、1000℃で1時間保持してアニール処理した。アニール処理後の焼結体は全て赤色透明を呈した。得られたジルコニア焼結体の特性を表2に示した。
試料番号1~3の一次焼結体を用い、HIP処理温度を1500℃にした以外は実施例1~3と同様にしてジルコニア焼結体を得た。得られたジルコニア焼結体の特性を表3に示した。
得られたジルコニア焼結体は、実施例1~3のジルコニア焼結体と比較して明度が低く、濃い赤色を呈する透明ジルコニア焼結体であった。また、いずれの焼結体の結晶相も、立方晶蛍石型構造であった。
(粉末調製)
ジルコニア粉末、酸化セリウム粉末の他、酸化ネオジウム、酸化コバルトを、それぞれ所定量を秤量し、エタノール溶媒中直径10mmのジルコニア製ボールで72時間ボールミル混合し、乾燥した粉末を原料粉末とした。
原料粉末を金型プレスによって圧力50MPaで成形した後、冷間静水圧プレス装置を用い圧力200MPaで処理し、直径20mm、厚さ3mmの円柱成形体を得た。
大気中で昇温速度を100℃/h、焼結温度1325℃、焼結時間2時間で一次焼結して試料番号7及び8の一次焼結体を得た。一次焼結体の組成は原料粉末の組成と同一であった。
得られた一次焼結体の特性を表4に示した。
試料番号7又は8の一次焼結体を用い、温度1650℃、圧力150MPa、保持時間1時間で、実施例1~3と同様の方法でHIP処理した後、焼結体を大気中、昇温速度250℃/hで1000℃に1時間保持してアニール処理した。
得られたジルコニア焼結体の特性を表5に示した。
実施例3及び6のジルコニア焼結体の蛍光スペクトルを測定した。いずれのジルコニア焼結体も3価セリウムに帰属される590nmにピークを有する発光が観察され、セリウム3価の存在が確認された。実施例3の蛍光スペクトルを図3に示した。
なお、セリウムを含有しないジルコニア焼結体ではHIP処理前後の重量減少は確認されなかったため、当該重量減少はセリウムの還元によるものであるといえる。
実施例3及び6と同様にして得られたジルコニア焼結体について、大気中、昇温速度250℃/h、温度1200℃で1時間保持してアニール処理した。いずれのジルコニア焼結体も、ごく薄い黄色味を帯びた透明体であった。
ジルコニア焼結体の特性を表6に、比較例1の直線透過率を図4に示した。
比較例1の蛍光スペクトルは400nm付近にメインピークがあり、590nm付近のピークは観察されなかった。これにより、比較例1のジルコニア焼結体は3価セリウムを含有していないことが分かった。
本出願は、2010年3月9日出願の日本国特許出願(特願2010-051627)に基づくものであり、その内容はここに参照として取込まれる。
Claims (11)
- 6mol%~30mol%のイットリア及びCeO2換算で0.1mol%~5mol%のセリウム酸化物を含有し、該セリウム酸化物が3価セリウムの酸化物を含有することを特徴とするジルコニア焼結体。
- 結晶相が立方晶蛍石型構造であることを特徴とする請求項1に記載のジルコニア焼結体。
- 試料厚さ1mmにおいて、波長400nm~500nmの可視光に対する直線透過率の最大値が3%以下であり、かつ、波長600nm~800nmの可視光に対する直線透過率の最大値が40%以上であることを特徴とする請求項1又は2に記載のジルコニア焼結体。
- 明度L*、色相a*およびb*が、20≦L*≦50、40≦a*≦60および30≦b*≦70であることを特徴とする請求項1乃至3のいずれかに記載のジルコニア焼結体。
- 6mol%~30mol%イットリア及びCeO2換算で0.1mol%~5mol%のセリウム酸化物を含有するジルコニア粉末を成形し、一次焼結、熱間静水圧プレス処理およびアニールし、焼結体中に3価セリウムを生成させることを特徴するジルコニア焼結体の製造方法。
- 一次焼結体を通気性のある容器に配してHIP処理を行うことを特徴とする請求項5に記載の製造方法。
- アニールを800℃以上1000℃以下で行うことを特徴とする請求項5又は6に記載のジルコニア焼結体の製造方法。
- HIP処理に供する一次焼結体の平均粒径が5μm以下であることを特徴とする請求項5乃至7のいずれかに記載の製造方法。
- 請求項1乃至4のいずれかに記載のジルコニア焼結体からなる部材。
- 請求項9に記載の部材を用いることを特徴とする宝飾品。
- 請求項9に記載の部材を用いることを特徴とする外装部品。
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