Method for producing ceramic sintered body, and method and device for producing ceramic molded body

Patent metadata

Field	Value
Publication number	US-11724415-B2
Application number	US-202117206717-A
Country	US
Kind code	B2
Filing date	Mar 19, 2021
Priority date	Feb 5, 2016
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

The present invention is a sintering method of a ceramic for sintering characterized by forming a layer containing a carbon powder on a surface of an article consisting of a ceramic for sintering, and then irradiating with laser a surface of the carbon powder-containing layer of a lamination obtained.

First claim

What is claimed is:

1. A method for sintering a ceramic, the method comprising:
forming a layer comprising a carbon powder on a surface of a ceramic article consisting of a non-sintered ceramic to thereby prepare a carbon powder-containing laminated layer, and
irradiating with a laser a surface of the carbon powder-containing laminated layer to sinter the non-sintered ceramic located under an irradiated area of the carbon powder-containing laminated layer,
wherein the carbon powder in the carbon powder-containing laminated layer at an irradiated part is removed after irradiating, and
wherein the carbon powder is of graphite, and a thickness of the carbon powder-containing laminated layer is in a range from 100 nm to 10 μm.

2. The method according to claim 1 ,
wherein the non-sintered ceramic is of at least one compound selected from a group consisting of an oxide, a nitride, and an oxynitride.

3. A method for producing a ceramic article having a sintered ceramic part, the method comprising:
forming a layer comprising a carbon powder on a surface of a non-sintered ceramic part comprising a non-sintered ceramic to thereby prepare a carbon powder-containing laminated layer over the non-sintered ceramic part, and
irradiating with a laser a surface of the carbon powder-containing laminated layer to sinter a non-sintered ceramic containing part that is located under an irradiated part of the carbon-powder containing laminated layer to thereby form the ceramic article having the sintered ceramic part,
wherein the carbon powder in the carbon powder-containing laminated layer at an irradiated part is removed after irradiating, and
wherein the carbon powder is of graphite, and a thickness of the carbon powder-containing laminated layer is in a range from 100 nm to 10 μm.

4. The method according to claim 3 ,
wherein the non-sintered ceramic is of at least one compound selected from a group consisting of an oxide, a nitride, and an oxynitride.

5. A method for producing a ceramic article having a three-dimensional sintered ceramic part, the method comprising:
preparing a first non-sintered ceramic part comprising a non-sintered ceramic,
forming a layer comprising a carbon powder on a surface of the first non-sintered ceramic part to thereby prepare a first carbon powder-containing laminated layer over the first non-sintered ceramic part,
irradiating with a laser a surface of the first carbon powder-containing laminated layer to sinter the non-sintered ceramic of the first non-sintered ceramic part located under an irradiated part to form a first sintered part,
forming a second non-sintered ceramic part comprising a non-sintered ceramic on the first sintered part,
forming a layer comprising a carbon powder on a surface of the second non-sintered ceramic part to thereby prepare a second carbon powder-containing laminated layer over the second non-sintered ceramic part, and
irradiating with a laser a surface of the second carbon powder-containing laminated layer to sinter the non-sintered ceramic of the second non-sintered ceramic part located under an irradiated part to thereby form a second sintered ceramic part that is integrated with the first sintered ceramic part,
wherein the carbon powder in the first carbon powder-containing laminated layer or the second carbon powder-containing laminated layer at an irradiated part is removed after irradiating, and
wherein the carbon powder is of graphite, and a thickness of the first carbon powder-containing laminated layer or the second carbon powder-containing laminated layer is in a range from 100 nm to 10 μm.

6. The production method according to claim 5 ,
wherein the first carbon powder-containing laminated layer or the second carbon powder-containing laminated layer is irradiated with the laser while scanning the laser or changing an optical path via a light diffusion lens with the first non-sintered ceramic part secured during the applying of the laser, or
the first carbon powder-containing laminated layer or the second carbon powder-containing laminated layer is irradiated with the laser with an optical path secured while moving the first non-sintered ceramic part during the applying of the laser.

7. The production method according to claim 5 ,
wherein the second non-sintered ceramic part is formed by a method comprising spraying a slurry comprising a non-sintered ceramic particle and a dispersion medium on the surface of the first sintered ceramic part in a state where the first sintered ceramic part is heated.

8. The method according to claim 1 ,
wherein the ceramic article is consisting of a particle aggregate of non-sintered ceramic particles.

9. The method according to claim 1 ,
wherein the laser output is in a range from 50 to 2000 W/cm 2 .

10. The method according to claim 3 , wherein the non-sintered ceramic part is consisting of a particle aggregate of non-sintered ceramic particles.

11. The method according to claim 3 ,
wherein the laser output is in a range from 50 to 2000 W/cm 2 .

12. The method according to claim 5 , wherein the first non-sintered ceramic part is consisting of a particle aggregate of non-sintered ceramic particles.

13. The method according to claim 5 , wherein the second non-sintered ceramic part is consisting of a particle aggregate of non-sintered ceramic particles.

14. The method according to claim 5 , wherein the laser output is in a range from 50 to 2000 W/cm 2 .

Assignees

• Japan Fine Ceramics Ct
• Noritake Co Ltd
• Toto Ltd
• Ngk Insulators Ltd
• Ngk Spark Plug Co

Inventors

• Kimura Teiichi
• Suehiro Satoshi

Classifications

• Y02P10/25

  Process efficiency · CPC title

• C04B35/64 Primary

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B35/62218

  obtaining ceramic films, e.g. by using temporary supports · CPC title

• C04B35/638 Primary

  Removal thereof · CPC title

• C04B2235/665

  Local sintering, e.g. laser sintering · CPC title