US4902457A
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Method for manufacturing a porous material or a composite sintered product comprising zirconium oxide and a carbide
Assignee: Panasonic Holdings Corp
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Filing: 1987-04-07
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Granted: 1990-02-20
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Expires: 2007-04-07
Abstract
Abstract A method for manufacturing a porous body comprising zirconium oxide and a metal carbide is described. The method comprises mixing a metallic zirconium powder, a metal oxide, and a carbon powder, shaping the mixture in a desired form, and igniting a part or portion of the shaped mixture in an atmosphere inert to a combustion reaction of the shaped mixture. The combustion reaction is caused to continue by the heat of the reaction, so that the zirconium is converted to zirconium oxide, and the metal oxide is reduced with zirconium and converted to a metal carbide to obtain a porous body. This body may be readily divided into fine pieces. If the above procedure is effected under a molding compression pressure, a composite sintered product comprising zirconium oxide and the metal carbide is obtained.
Inventors
- 👤 Takahiro Wada
- 👤 Seiji Adachi
- 👤 Toshihiro Mihara
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 09:51
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/48; C04B35/486; C04B35/49; C04B35/622; C04B35/64; C04B35/65; C04B35/651
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
139 words
A method for manufacturing a porous material comprising zirconium oxide and a metal carbide, comprising mixing a zirconium alloy powder, a metal oxide powder and a carbon powder, wherein the zirconium alloy is an alloy of zirconium and aluminum, yttrium or magnesium; shaping the mixture in a desired form; and igniting a portion of the shaped mixture in an atmosphere which is inert to a combustion reaction of the shaped mixture so that the combustion reaction starts in said portion of said mixture and continues throughout the shaped mixture by the heat of the reaction, wherey the zirconium alloy powder is converted to a solid solution comprising zirconia and the metal oxide powder is converted to a metal carbide throughout the shaped mixture to attain a porous body substantially made of the zirconia solid solution and the metal carbide.
Claim 2
Independent Claim
139 words
A method for manufacturing a porous material comprising zirconium oxide and a metal carbide, comprising mixing a zirconium alloy powder, a metal oxide powder and a carbon powder, wherein the zirconium alloy is an alloy of zirconium and aluminum, yttrium or magnesium; shaping the mixture in a desired form; and igniting a portion of the shaped mixture in an atmosphere which is inert to a combustion reaction of the shaped mixture so that the combustion reaction starts in said portion of said mixture and continues throughout the shaped mixture by the heat of the reaction, wherey the zirconium alloy powder is converted to a solid solution comprising zirconia and the metal oxide powder is converted to a metal carbide throughout the shaped mixture to attain a porous body substantially made of the zirconia solid solution and the metal carbide.
Claim 3
Dependent Claim
31 words
The method according to claim 1, further comprising adding a binder in the mixing step in an amount of about 1 to 5 wt% of the total amount of the powders.
Claim 4
Dependent Claim
22 words
The method according to claim 2, wherein said binder is polyvinyl alcohol and is provided in the form of an aqueous solution.
Claim 5
Dependent Claim
35 words
The method according to claim 1, wherein the metal oxide powder is mixed with the zirconium alloy powder and is selected from the group consisting of titanium oxides/niobium oxide and the carbon powder silicon oxide.
Claim 6
Dependent Claim
14 words
The method according to claim 4, wherein said metal oxide is a titanium oxide.
Claim 7
Dependent Claim
13 words
The method according to claim 5, wherein said titanium oxide is titanium dioxide.
Claim 8
Dependent Claim
13 words
The method according to claim 5, wherein said titanium oxide is dititanium trioxide.
Claim 9
Dependent Claim
13 words
The method according to claim 4, wherein said metal oxide is niobium pentaoxide.
Claim 10
Dependent Claim
13 words
The method according to claim 4, wherein said metal oxide is silicon dioxide.
Claim 11
Dependent Claim
14 words
The method according to claim 1, wherein said zirconium alloy powder further comprises magnesium.
Claim 12
Dependent Claim
19 words
The method according to claim 1, wherein the powder mixture further comprises an element for stabilizing the zirconium oxide.
Claim 13
Dependent Claim
11 words
The method according to claim 11, wherein said element is yttrium.
Claim 14
Dependent Claim
16 words
The method according to claim 1, wherein said mixture further comprises zirconium oxide stabilized with yttrium.
Claim 15
Dependent Claim
24 words
The method according to claim 1, further comprising adding to the mixture an aluminum powder, whereby aluminum oxide is contained in the porous body.
Claim 16
Dependent Claim
29 words
The method according to claim 1, wherein said porous body is divided into fine pieces in the form of a mixture of said zirconium oxide and said metal carbide.
Claim 17
Dependent Claim
16 words
The method according to claim 1, wherein said carbon powder is carbon black obtained from acetylene.
Claim 18
Independent Claim
142 words
A method for manufacturing a composite sintered product comprising zirconium oxide and a metal carbide, comprising mixing a zirconium alloy powder, a metal oxide powder and a carbon powder, wherein the zirconium alloy is an alloy or zirconium and aluminum, yttrium or magnesium; shaping the mixture in a desired form; and igniting, under molding compression pressure, a portion of the shaped mixture in an atmosphere which is inert to the combustion of the shaped mixture so that the combustion reaction starts in the portion of the mixture and continues throughout the shaped mixture by the heat of the reaction, whereby the zirconium alloy powder is converted to a solution comprising zirconia and the metal oxide powder is converted to a metal carbide throughout the shaped mixture to attain a sintered product substantially made of the zirconia solid solution and the metal carbide.
Claim 19
Independent Claim
142 words
A method for manufacturing a composite sintered product comprising zirconium oxide and a metal carbide, comprising mixing a zirconium alloy powder, a metal oxide powder and a carbon powder, wherein the zirconium alloy is an alloy or zirconium and aluminum, yttrium or magnesium; shaping the mixture in a desired form; and igniting, under molding compression pressure, a portion of the shaped mixture in an atmosphere which is inert to the combustion of the shaped mixture so that the combustion reaction starts in the portion of the mixture and continues throughout the shaped mixture by the heat of the reaction, whereby the zirconium alloy powder is converted to a solution comprising zirconia and the metal oxide powder is converted to a metal carbide throughout the shaped mixture to attain a sintered product substantially made of the zirconia solid solution and the metal carbide.
Claim 20
Dependent Claim
31 words
The method according to claim 17, further comprising adding a binder in the mixing step in an amount of about 1 to 5 wt% of the total amount of the powders.
Claim 21
Dependent Claim
22 words
The method according to claim 18, wherein the binder is polyvinyl alcohol and is provided in the form of an aqueous solution.
Claim 22
Dependent Claim
25 words
The method according to claim 17, wherein the metal oxide powder is selected from the group consisting of titanium oxides, niobium oxide and silicon oxide.
Claim 23
Dependent Claim
14 words
The method according to claim 20, wherein said metal oxide is a titanium oxide.
Claim 24
Dependent Claim
13 words
The method according to claim 21, wherein said titanium oxide is titanium dioxide.
Claim 25
Dependent Claim
13 words
The method according to claim 21, wherein said titanium oxide is dititanium trioxide.
Claim 26
Dependent Claim
13 words
The method according to claim 20, wherein said metal oxide is niobium pentaoxide.
Claim 27
Dependent Claim
13 words
The method according to claim 20, wherein said metal oxide is silicon dioxide.
Claim 28
Dependent Claim
14 words
The method according to claim 17, wherein said metallic zirconium powder further comprises magnesium.
Claim 29
Dependent Claim
18 words
The method according to claim 17, wherein said mixture further comprises an element for stabilizing the zirconium oxide.
Claim 30
Dependent Claim
11 words
The method according to claim 27, wherein said element is yttrium.
Claim 31
Dependent Claim
16 words
The method according to claim 17, wherein said mixture further comprises zirconium oxide stabilized with yttrium.
Claim 32
Dependent Claim
24 words
The method according to claim 17, further comprising adding to said mixture an aluminum powder, whereby aluminum oxide is contained in the porous body.
Claim 33
Dependent Claim
16 words
The method according to claim 17, wherein said carbon powder is carbon black obtained from acetylene.
References Cited (Backward Citations)
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