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US4925816A
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Novel solid solution, heat-resistant sintered body and method of producing the same
Assignee: NGK Insulators Ltd
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Filing: 1988-08-16
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Granted: 1990-05-15
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Expires: 2008-08-16
Abstract
Abstract A novel solid solution has a composition of R y Zr 4 Si x P 6-x O 24 (R is at least one forming bivalent or trivalent element 0≦x≦2, 2/3≦y≦2). Furthermore, a heat-resistant sintered body and heat-resistant phosphate based compound sintered body comprises the above solid solution and has excellent heat resistance and high temperature stability. And also, a method of producing such sintered bodies is disclosed.
Inventors
- 👤 Keiichiro Watanabe
- 👤 Tsuneaki Ohashi
- 👤 Tadaaki Matsuhisa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 15:27
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/01; C04B35/48; C04B35/481
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
61 words
A solid solution having a composition of R y Zr 4 Si x P 6-x O 24 , wherein R is at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 2
Dependent Claim
61 words
A solid solution having a composition of R y Zr 4 Si x P 6-x O 24 , wherein R is at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 3
Dependent Claim
90 words
A heat-resistant sintered body consisting essentially of a solid solution of the R y Zr 4 Si x P 6-x O 24 system, wherein R is at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula; wherein said sintered body has a self-weight softening percentage of not more than 0.3% after a heat treatment at 1400° C. for 5 hours.
Claim 4
Dependent Claim
90 words
A heat-resistant sintered body consisting essentially of a solid solution of the R y Zr 4 Si x P 6-x O 24 system, wherein R is at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula; wherein said sintered body has a self-weight softening percentage of not more than 0.3% after a heat treatment at 1400° C. for 5 hours.
Claim 5
Dependent Claim
123 words
A heat-resistant phosphate based compound sintered body consisting essentially of at least 10% by weight of a solid solution of the R y Zr 4 Si x P 6-x O 24 system, wherein R is at least one bivalent or trivalent element, x is a numerical value of 0 to 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula; and zirconyl phosphate (Zr 2 P 2 O 9 ); wherein said sintered body has a weight-reduced percentage of not more than 10% after a heat treatment at 1400° C. for 100 hours and a self-weight softening percentage of not more than 0.3% after a heat treatment at 1400° C. for 5 hours.
Claim 6
Dependent Claim
123 words
A heat-resistant phosphate based compound sintered body consisting essentially of at least 10% by weight of a solid solution of the R y Zr 4 Si x P 6-x O 24 system, wherein R is at least one bivalent or trivalent element, x is a numerical value of 0 to 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula; and zirconyl phosphate (Zr 2 P 2 O 9 ); wherein said sintered body has a weight-reduced percentage of not more than 10% after a heat treatment at 1400° C. for 100 hours and a self-weight softening percentage of not more than 0.3% after a heat treatment at 1400° C. for 5 hours.
Claim 7
Independent Claim
184 words
A method of producing a heat-resistant sintered body, comprising: molding a batch mixture selected from the group consisting of: (A) ZrP 2 O 7 , Zr 2 P 2 O 9 , and/or ZrO 2 , SiO 2 or a compound thereof, and one or more RO and/or a phosphate of R; (B) ZrP 2 O 7 , Zr 2 P 2 O 9 , SiO 2 and one or more RO; and (C) ZrP 2 O 7 , ZrSiO 4 and one or more RO; wherein R includes one or more bivalent or trivalent elements; and firing the molded batch mixture at a temperature of not lower than 1400° C. in air to precipitate a solid solution of the R y Zr 4 Si x P 6-x O 24 system as a main crystalline phase of the sintered body, wherein R is said at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 8
Independent Claim
184 words
A method of producing a heat-resistant sintered body, comprising: molding a batch mixture selected from the group consisting of: (A) ZrP 2 O 7 , Zr 2 P 2 O 9 , and/or ZrO 2 , SiO 2 or a compound thereof, and one or more RO and/or a phosphate of R; (B) ZrP 2 O 7 , Zr 2 P 2 O 9 , SiO 2 and one or more RO; and (C) ZrP 2 O 7 , ZrSiO 4 and one or more RO; wherein R includes one or more bivalent or trivalent elements; and firing the molded batch mixture at a temperature of not lower than 1400° C. in air to precipitate a solid solution of the R y Zr 4 Si x P 6-x O 24 system as a main crystalline phase of the sintered body, wherein R is said at least one bivalent or trivalent element, x is a numerical value of greater than 0 but not greater than 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 9
Independent Claim
130 words
A method of producing a heat-resistant phosphate based compound sintered body, comprising: molding a batch mixture of Zr 2 P 2 O 9 , ZrSiO 4 and one or more RO, wherein R includes one or more bivalent or trivalent elements; firing the molded batch mixture at 1500°-1600° C. in air to form a sintered body consisting essentially of at least 10% by weight of a solid solution of the R y Zr 4 Si x P 6-x O 24 system and zirconyl phosphate (Zr 2 P 2 O 9 ), wherein R is said at least one bivalent or trivalent element, x is a numerical value of 0 to 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 10
Independent Claim
130 words
A method of producing a heat-resistant phosphate based compound sintered body, comprising: molding a batch mixture of Zr 2 P 2 O 9 , ZrSiO 4 and one or more RO, wherein R includes one or more bivalent or trivalent elements; firing the molded batch mixture at 1500°-1600° C. in air to form a sintered body consisting essentially of at least 10% by weight of a solid solution of the R y Zr 4 Si x P 6-x O 24 system and zirconyl phosphate (Zr 2 P 2 O 9 ), wherein R is said at least one bivalent or trivalent element, x is a numerical value of 0 to 2, and y is a numerical value of 2/3 to 2 satisfying an electrically neutral condition of the chemical formula.
Claim 11
Dependent Claim
25 words
The method of claim 4, wherein said firing is carried out at a temperature of 1400°-1800° C. for a time of 1 to 24 hours.
Claim 12
Dependent Claim
25 words
The method of claim 4, wherein said R is at least one element selected from the group consisting of Ca, Sr, Ba, Y and Ni.
Claim 13
Dependent Claim
25 words
The method of claim 5, wherein said R is at least one element selected from the group consisting of Ca, Sr, Ba, Y and Ni.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-05-14 | 1993-11-13 | 1994-05-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-05-14 | 1997-11-13 | 1998-05-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-05-14 | 2001-11-13 | 2002-05-15 | $7700.00 | Window Closed / Lapsed |