JP5907943B2 - 粉末成形体の製造方法 - Google Patents
粉末成形体の製造方法 Download PDFInfo
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- JP5907943B2 JP5907943B2 JP2013500939A JP2013500939A JP5907943B2 JP 5907943 B2 JP5907943 B2 JP 5907943B2 JP 2013500939 A JP2013500939 A JP 2013500939A JP 2013500939 A JP2013500939 A JP 2013500939A JP 5907943 B2 JP5907943 B2 JP 5907943B2
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Description
前記成形原料と、前記分散媒と、前記分散助剤と、前記バインダ前駆体と、前記反応進行剤と、を含む前記スラリーを調製する、スラリー調製工程と、
調製された前記スラリーを所定形状に成形することで一次粉末成形体を得る、成形工程と、
前記一次粉末成形体にて、前記化学反応を進行させて前記スラリーを固化させるとともに前記一次粉末成形体から前記分散媒を揮発除去する、乾燥固化工程(固化にはゲル化と硬化とが含まれる)と、
を含むものである。なお、前記成形原料は、第一の成形原料と、この第一の成形原料とは異なる第二の成形原料と、を含むものであってもよい。
せん断速度が1sec−1以下(静置時)にて粘度が5000cP以上で、
せん断速度が20sec−1以上(成形時)にて粘度が1000cP以下
に調製されていることが好適である。この場合、具体的には、前記成形原料の添加量を100重量部とした場合に、前記擬塑性付与剤が1重量部以上3重量部未満添加される。
せん断速度が1sec−1以下にて粘度が20000cP以上で、
せん断速度が20sec−1以上にて粘度が1000cP以下
に調製されていることがさらに好適である。この場合、具体的には、前記成形原料の添加量を100重量部とした場合に、前記擬塑性付与剤が2重量部以上3重量部未満添加される。
図1は、本実施形態の製造方法の一例を示す概略図である。図2Aは、図1に示されているスラリーSの概略構成を示す断面図である。図1及び図2Aを参照すると、本実施形態においては、以下の手順に従って、粉末成形体(セラミックグリーン体)PCが製造される。
粉末状のセラミック原料1(図2Aに示されているように2種以上のセラミック原料1a,1b…が含まれることがあり得る)と、バインダ前駆体であるイソシアネート2a及びポリオール2bと、触媒3と、分散媒4と、を少なくとも含むスラリーSを調製する。セラミック原料1は、分散媒4中に分散される。イソシアネート2a及びポリオール2b、並びに触媒3は、分散媒4に溶解される。このとき、セラミック原料1(1a,1b)を分散媒4中に安定的かつ均一に分散させるために、分散助剤5が添加される。
工程1にて調製されたスラリーSを、周知の成形法により任意の形状に成形することで、一次粉末成形体PC1を得る(図1における(ii)参照)。このとき、スラリーSは、成形時に加えられるせん断速度によって、複雑な形状の成形にも適した良好な流動性を示す。よって、一次粉末成形体PC1の成形が良好に行われる。
上述の成形法により得られた一次粉末成形体PC1を、常温にて放置する(図1における(iii)参照)。これにより、イソシアネート2aとポリオール2bとの化学反応(ウレタン反応:図2B参照)が進行して、有機バインダとしてのウレタン樹脂2が生じ、一次粉末成形体PC1を構成するスラリーSが固化(ゲル化)する。このとき、一次粉末成形体PC1を構成するスラリーSは、ゲル化開始時点にて、静置時であるために高粘度を示す。よって、ゲル化中のセラミック原料1の沈降が、良好に抑制され得る。特に、2種以上のセラミック原料1a,1b…が含まれている場合に、相互の比重の違いによる偏析が、良好に抑制され得る。
本発明の「成形原料」に相当するセラミック原料1(1a,1b)としては、酸化物系セラミックが使用されてもよいし、非酸化物系セラミックが使用されてもよい。例えば、焼成により所望組成のセラミックを構成するための金属化合物粉末(ZrO2、Al2O3、NiO、ZnO、MgO、CaO、SnO2、SiO2、Y2O3、Fe2O3、Co3O4、BaTiO3、SrTiO3、PZT、SiC、TiC、Si3N4、TiN、AlN、等)が用いられ得る。セラミック原料1(1a,1b)の粒子径については、スラリーSを調製可能(すなわち分散媒4中に安定的に分散可能)な限りにおいて、特に限定はない。
図1における(ii)には、代表例として、スラリーSを金型Dにおける上型D1と下型D2との間に設けられたキャビティ内に注入する工程が示されている。この工程によって得られる一次粉末成形体PC1には、少なくとも、セラミック原料1(1a,1b)、イソシアネート2a、ポリオール2b、触媒3、分散媒4、分散助剤5、及び擬塑性付与剤6が含まれているが、イソシアネート2a及びポリオール2bの一部が反応することで生じたウレタン樹脂2が含まれている可能性もある。すなわち、工程1及び/又は工程2の間に、ウレタン反応が部分的に進行していることがあり得る。
ゲル化の進行に伴って、隣接するウレタン樹脂2の分子間において、同分子中にそれぞれ生成されているウレタン基(−O−CO−NH−)同士を連結するように架橋が発生する。この架橋により、ウレタン樹脂2の分子間で強固なネットワークが形成される。この結果、一次粉末成形体PC1中に残存する分散媒4の加熱による揮発が進行しても、ウレタン樹脂2の分子間距離の収縮の発生が、可及的に抑制される。これにより、工程3によって一次粉末成形体PC1から粉末成形体PCを得る際の、乾燥収縮率及びそのばらつきを、可及的に抑制することができる。
次に、上述の製造方法の一具体例について、その評価結果とともに説明する。
なお、上述の実施形態や具体例は、上述した通り、出願人が取り敢えず本願の出願時点において最良であると考えた本発明の具現化の一例を単に示したものにすぎないのであって、本発明はもとより上述の実施形態や具体例によって何ら限定されるべきものではない。よって、上述の実施形態や具体例に対して、本発明の本質的部分を変更しない範囲内において、種々の変形が施され得ることは、当然である。
Claims (6)
- 粉末状の成形原料と、これを分散させるための分散媒と、前記成形原料を前記分散媒中に均一に分散させるための分散助剤と、化学反応によって合成樹脂である有機バインダを生成させるためのバインダ前駆体と、前記化学反応を進行させるための反応進行剤と、を含むスラリーを調製する、スラリー調製工程と、
調製された前記スラリーを所定形状に成形することで一次粉末成形体を得る、成形工程と、
前記一次粉末成形体にて、前記化学反応を進行させて前記スラリーを固化させるとともに前記一次粉末成形体から前記分散媒を揮発除去する、乾燥固化工程と、
を含む、粉末成形体の製造方法において、
前記スラリーは、当該スラリーに擬塑性を付与するための擬塑性付与剤を含み、せん断速度が1sec -1 以下にて粘度が5000cP以上で、せん断速度が20sec -1 以上にて粘度が1000cP以下に調製されたことを特徴とする、
粉末成形体の製造方法。 - 請求項1に記載の、粉末成形体の製造方法であって、
前記スラリーは、
前記成形原料の添加量を100重量部とした場合に、前記擬塑性付与剤を1重量部以上3重量部未満含むことを特徴とする、
粉末成形体の製造方法。 - 請求項1又は請求項2に記載の、粉末成形体の製造方法であって、
前記スラリーは、
せん断速度が1sec-1以下にて粘度が20000cP以上に調製されたことを特徴とする、
粉末成形体の製造方法。 - 請求項3に記載の、粉末成形体の製造方法であって、
前記スラリーは、
前記成形原料の添加量を100重量部とした場合に、前記擬塑性付与剤を2重量部以上3重量部未満含むことを特徴とする、
粉末成形体の製造方法。 - 請求項1〜請求項4のうちのいずれか1項に記載の、粉末成形体の製造方法であって、
前記乾燥固化工程にて、ウレタン反応によって前記有機バインダとしてのウレタン樹脂を生成させることを特徴とする、
粉末成形体の製造方法。 - 請求項1〜請求項5のうちのいずれか1項に記載の、粉末成形体の製造方法であって、
前記成形原料は、
第一の成形原料と、
前記第一の成形原料とは異なる第二の成形原料と、
を含むことを特徴とする、
粉末成形体の製造方法。
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JP4536943B2 (ja) * | 2000-03-22 | 2010-09-01 | 日本碍子株式会社 | 粉体成形体の製造方法 |
US6953503B2 (en) * | 2001-04-17 | 2005-10-11 | Ngk Insulators, Ltd. | Method of manufacturing molded body, slurry for molding, core for molding, method of manufacturing core for molding, hollow ceramic molded body, and light emitting container |
WO2009016698A1 (ja) * | 2007-07-27 | 2009-02-05 | Ngk Insulators, Ltd. | セラミック粉末成形体、セラミック焼成体及びセラミック粉末成形体の製造方法 |
US8962749B2 (en) | 2008-02-19 | 2015-02-24 | Ngk Insulators, Ltd. | Ceramic green sheet and method for producing the same |
JP5281592B2 (ja) * | 2009-01-22 | 2013-09-04 | 日本碍子株式会社 | 金属コイルを内部に有するセラミック焼成体の製造方法 |
JP2010241129A (ja) | 2009-03-19 | 2010-10-28 | Ngk Insulators Ltd | 粉体成形体の製造方法 |
EP2233449B1 (de) * | 2009-03-27 | 2014-12-17 | Ivoclar Vivadent AG | Verwendung eines Schlickers für die Herstellung von Dentalkeramiken mittels Hot-Melt-Inkjet-Druckverfahren |
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Publication number | Priority date | Publication date | Assignee | Title |
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JPH07186116A (ja) * | 1993-12-24 | 1995-07-25 | Toshiba Ceramics Co Ltd | セラミックスの成形法 |
JPH10130076A (ja) * | 1996-10-28 | 1998-05-19 | Toshiba Ceramics Co Ltd | 多孔質セラミックスの製造方法 |
JPH1148222A (ja) * | 1997-08-06 | 1999-02-23 | Ngk Insulators Ltd | 粉体成形方法 |
JP2003147495A (ja) * | 2001-11-05 | 2003-05-21 | Taiheiyo Cement Corp | 金属−セラミックス複合材料用プリフォームの作製方法 |
JP2005193573A (ja) * | 2004-01-08 | 2005-07-21 | Fujikura Kasei Co Ltd | セラミックグリーンシート並びにその製造方法 |
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