Sintered objects and processes for producing same

Patent metadata

Field	Value
Publication number	US-9403722-B2
Application number	US-201113577585-A
Country	US
Kind code	B2
Filing date	Feb 8, 2011
Priority date	Feb 9, 2010
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

Abstract

Provided is a sintered object which has excellent resistance to corrosion by corrosive halogen gases and by the plasmas thereof and has excellent thermal conductivity and excellent electrical conductivity. The sintered object has few limitations on design, is usable in a wide range of applications, and is highly versatile. The sintered object has no frequency dependence when a high-frequency voltage is applied thereto and with which it is possible to actualize the stability of a plasma. Also provided is a method for producing the sintered object. Furthermore provided is a high-frequency transmission material which has direct-current electrical conductivity for reducing fluctuations in plasma potential and has capacitive properties that enable the material to transmit high-frequency power necessary for plasma excitation, and which has no fear of causing contamination of a sample with a metal and has resistance to corrosion by plasmas.

First claim

The invention claimed is:

1. A sintered object containing yttrium oxide and fibrous carbon,
wherein a relative density of the sintered object is 97% or more, and a volume resistivity value of the sintered object upon which a corrosion test has not been performed is 0.5 Ω·cm or more and 10 Ω·cm or less,
wherein the fibrous carbon is three-dimensionally dispersed, and an aggregation diameter of the fibrous carbon is 5 μm or less,
wherein a content of the fibrous carbon is 0.5 volume % or more and 5 volume % or less with respect to a total amount of the fibrous carbon and yttrium oxide, and
wherein the diameter of the fibrous carbon is 30 nm or less, and the length of the fibrous carbon is 10 μm or less.

2. The sintered object according to claim 1 ,
wherein the fibrous carbon is one type or two types or more selected from a group consisting of single-walled carbon nanotubes, two-walled carbon nanotubes and multi-walled carbon nanotubes.

3. A method of producing the sintered object according to claim 1 , comprising:
a mixed slurry preparing process of mixing a yttrium oxide slurry with a fibrous carbon slurry to form a mixed slurry, wherein the fibrous slurry is subjected to dispersion processing for 4 to 10 hours and wherein an average secondary particle diameter of fibrous carbon in the fibrous carbon slurry is 400 nm or less;
a granule forming process of spray-drying the mixed slurry to form granules; and
a sintering process of the granules under a pressure of 1 MPa or more and 20 MPa or less to form a sintered object.

4. The sintered object according to claim 1 ,
wherein said sintered object is produced by a method comprising:
a mixed slurry preparing process of mixing a yttrium oxide slurry with a fibrous carbon slurry to form a mixed slurry;
a granule forming process of spray-drying the mixed slurry to form granules; and
a sintering process of the granules under a pressure of 1 MPa or more and 20 MPa or less,

wherein an average secondary particle diameter of fibrous carbon in the fibrous carbon slurry is 400 nm or less.

5. A high frequency transmission material formed of a composite material in which fibrous carbon is dispersed in yttrium oxide,
wherein the material contains fibrous carbon at 1 volume % or more and 10 volume % or less with respect to a total amount of the fibrous carbon and the yttrium oxide,
wherein the length of the fibrous carbon is from 0.1 μm to 10 μm, and
wherein a volume resistivity value during application of a direct-current voltage is 30 Ω·cm or less, and an impedance angle at a frequency of 10 MHz is a negative value.

6. The high frequency transmission material according to claim 5 ,
wherein the fibrous carbon is carbon nanotubes.

7. The high frequency transmission material according to claim 5 ,
wherein the fibrous carbon is dispersed in a grain boundary of the yttrium oxide.

8. The high frequency transmission material according to claim 5 ,
wherein said high frequency transmission material is produced by a method comprising mixing the yttrium oxide slurry with the fibrous carbon slurry to form the mixed slurry, spray-drying the mixed slurry, and sintering the mixed slurry under an reducing atmosphere,
wherein an average secondary particle diameter of fibrous carbon in the fibrous carbon slurry is 400 nm or less.

9. A sintered object which contains yttrium oxide and a fibrous carbon,
wherein a relative density of the sintered object is 95% or more, and a volume resistivity value of the sintered object is 30 Ω·cm or more and 1000 Ω·cm or less,
wherein the fibrous carbon is three-dimensionally dispersed in a grain boundary of the yttrium oxide, and an aggregation diameter of the fibrous carbon is 1 μm or less,
wherein the length of the fibrous carbon is 10 μm or less,
wherein a content of the fibrous carbon is 0.5 volume % to 1.5 volume % with respect to a total amount of the fibrous carbon and the yttrium oxide, and
wherein an impedance angle at a frequency of 10 MHz is a negative value.

10. The sintered object according to claim 9 ,
wherein the fibrous carbon is one kind or two kinds or more selected from a group consisting of single-walled carbon nanotubes, two-walled carbon nanotubes and multi-walled carbon nanotubes.

11. The sintered object according to claim 9 ,
wherein an average particle diameter of the yttrium oxide is 0.1 μm or more and 10 μm or less.

12. The sintered object according to claim 9 ,
wherein an impedance angle at a frequency of 10 MHz is in a range of −90° or more and −70° or less.

13. The sintered object according to claim 9 ,
wherein said sintered object is produced by a method comprising:
a mixed slurry preparing process of mixing a yttrium oxide slurry with a fibrous carbon slurry to form a mixed slurry;
a granule forming process of spray-drying the mixed slurry to form granules; and
a sintering process of the granules under a pressure of 1 MPa or more and 20 MPa or less,

wherein an average secondary particle diameter of fibrous carbon in the fibrous carbon slurry is 200 nm or less.

14. A method of producing the sintered object according to claim 9 , comprising:
a mixed slurry preparing process of mixing a yttrium oxide slurry with a fibrous carbon slurry to form a mixed slurry, wherein the fibrous slurry is subjected to dispersion processing for 4 to 10 hours and wherein an average secondary particle diameter of fibrous carbon in the fibrous carbon slurry is 400 nm or less;
a granule forming process of spray-drying the mixed slurry to form granules; and
a sintering process of the granules under a pressure of 1 MPa or more and 20 MPa or less to form a sintered object.

15. The method of producing the sintered object according to claim 14 ,
wherein an average secondary particle diameter of the fibrous carbon in the fibrous carbon slurry is 200 nm or less.

Assignees

• Ando Kazuto
• Hayashi Shintaro
• Kugimoto Hirokuni
• Ishizuka Masayuki
• Sumitomo Osaka Cement Co Ltd

Inventors

• Ando Kazuto
• Hayashi Shintaro
• Kugimoto Hirokuni
• Ishizuka Masayuki

Classifications

• C04B35/50 Primary

  based on rare-earth compounds {(non-oxide rare earth compounds C04B35/5156)} · CPC title

• C04B2235/5248

  Carbon, e.g. graphite · CPC title

• C04B2235/9692

  Acid, alkali or halogen resistance · CPC title

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title

• C04B2235/85

  Intergranular or grain boundary phases · CPC title