Ceramic member

Patent metadata

Field	Value
Publication number	US-9776380-B2
Application number	US-201113876466-A
Country	US
Kind code	B2
Filing date	Sep 26, 2011
Priority date	Sep 29, 2010
Publication date	Oct 3, 2017
Grant date	Oct 3, 2017

Abstract

Provided is a ceramic member in which the difference in thermal expansion coefficient between an insulating ceramic material and an electrically conductive ceramic material is extremely small and therefore any mismatch caused in association with this difference in thermal expansion coefficient does not occur, and which does not undergo any failure such as breakage, cracking, detachment or destruction. The ceramic member ( 1 ) includes an electrically conductive ceramic material ( 2 ) which contains yttrium oxide as the main component and additionally contains a fibrous electrically conductive substance such as carbon nanotubes in an amount of 0.1 to 3 vol % inclusive and an insulation ceramic material ( 3 ) which contains yttrium oxide as the main component, wherein the electrically conductive ceramic material ( 2 ) and the insulation ceramic material ( 3 ) are adhered to each other in an integrated manner through an adhesive layer ( 4 ) which includes an inorganic adhesive material.

First claim

We claim:

1. A ceramic member comprising:
a conductive ceramic consisting essentially of yttrium oxide and a fibrous conductive substance, wherein the conductive ceramic includes the yttrium oxide as a main component and includes the fibrous conductive substance in an amount of 0.1 vol % to 3 vol % with respect to the yttrium oxide; and
an insulating ceramic consisting essentially of yttrium oxide;
wherein the conductive ceramic and the insulating ceramic are adhered or joined through an adhesive layer made of an inorganic adhesive material selected from alkali metal silicate-based adhesive materials, silica sol-based adhesive materials, and metal alkoxide-based adhesive materials,
the conductive ceramic has a volume resistivity value ranging 0.5 Ω·cm to 10 Ω·cm, and
thermal expansion coefficients of the conductive ceramic and the insulating ceramic and a thermal expansion coefficient of the adhesive layer match in a range of ±10%.

2. The ceramic member according to claim 1 , wherein the fibrous conductive substance is a nanofiber having an aspect ratio of 10 or more.

3. The ceramic member according to claim 2 , wherein the nanofiber is a carbon nanotube.

4. The ceramic member according to claim 1 , wherein the conductive ceramic and the insulating ceramic are joined through heating.

5. The ceramic member according to claim 1 , wherein the yttrium has an average particle diameter of 0.1 μm to 10 μm.

6. The ceramic member according to claim 1 , wherein the fibrous conductive substance is three-dimensionally dispersed.

7. The ceramic member according to claim 1 , wherein the fibrous conductive substance is one or more carbon nanotube selected from the group consisting of a Single Walled Carbon Nanotube (SWCNT), a Double Walled Carbon Nanotube (DWCNT) and a Multi Walled Carbon Nanotube (MWCNT) having an aspect ratio (length/diameter) of 10 or more, a diameter of 30 nm or less, and a length of 10 μm or less.

8. The ceramic member according to claim 1 , wherein the fibrous conductive substance is present as a single body or an aggregate in which a plurality of single bodies of the fibrous conductive substance is aggregated in the matrix made of yttrium oxide particles, and the aggregation diameter of the aggregate (the diameter of the aggregate) is 5 μm or less.

9. The ceramic member according to claim 1 , wherein the fibrous conductive substance has a content rate ranging from 0.5 volume % to 2 volume %.

10. The ceramic member according to claim 1 , wherein the volume intrinsic resistance value of the insulating ceramic is 10 8 Ω·cm or more.

11. A ceramic member comprising:
a conductive ceramic consisting essentially of yttrium oxide and a fibrous conductive substance, wherein the conductive ceramic includes the yttrium oxide as a main component and includes the fibrous conductive substance in an amount of 0.1 vol % to 3 vol % with respect to the yttrium oxide; and
an insulating ceramic consisting essentially of yttrium oxide;
wherein the conductive ceramic and the insulating ceramic are adhered or joined through an adhesive layer made of an inorganic adhesive material selected from alkali metal silicate-based adhesive materials, silica sol-based adhesive materials, and metal alkoxide-based adhesive materials,
the fibrous conductive substance is a carbon nanotube having aspect ratio of 10 or more,
the conductive ceramics has a relative density of 95% or more and a volume resistivity ranging from 0.5 Ω·cm to 10 Ω·cm,
the yttrium oxide contained in the conductive ceramics is yttrium oxide particle having an average particle diameter ranging from 0.1 μm to 10 μm, and
the fibrous conductive substance is present in the conductive ceramics as a single body or an aggregate having a diameter of 5 μm or less.

12. The ceramic member according to claim 11 , wherein
the conductive ceramics is a conductive ceramics produced by a method comprising the steps of:
preparing yttrium oxide slurry containing water and yttrium oxide particles in an amount ranging from 30 mass % to 50 mass %, and fibrous conductive substance slurry containing water and fibrous conductive substance having an average secondary particle diameter of 2 μm or less in the slurry in an amount ranging from 0.5 mass % to 2 mass %,
mixing the yttrium oxide slurry with the fibrous conductive substance slurry so that the fibrous conductive substance becomes 0.1 volume % to 3 volume % with respect to yttrium oxide to obtain a mixed slurry,
spray-drying the resultant mixed slurry to obtain a granulated powder having average granulated powder diameter ranging from 30 μm to 100 μm,
molding the resultant granulated powder using a mold to produce a compact, and
sintering the resultant compact in an inert atmosphere at a temperature of 1600° C. to 1850° C. for 1 to 6 hours;

wherein the insulating ceramics is an insulating ceramics produced by a method comprising the steps of:
preparing yttrium oxide slurry containing water and yttrium oxide particles in an amount ranging from 30 mass % to 50 mass %,
spray-drying the resultant slurry to obtain a granulated powder having average granulated powder diameter ranging from 30 μm to 100 μm,
molding the resultant granulated powder using a mold to produce a compact, and
sintering the resultant compact in an inert atmosphere at a temperature of 1600° C. to 1850° C. for 1 to 6 hours.

13. The ceramic member according to claim 11 , wherein the volume intrinsic resistance value of the insulating ceramic is 10 8 Ω·cm or more.

Assignees

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

Inventors

• Hayashi Shintaro
• Ishizuka Masayuki
• Ando Kazuto

Classifications

• B32B18/00 Primary

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• Y10T428/249928

  Fiber embedded in a ceramic, glass, or carbon matrix · CPC title

• C04B2237/04

  Ceramic interlayers · CPC title

• C04B2235/5296

  with a defined aspect ratio, e.g. indicating sphericity · CPC title

• C04B2235/5288

  Carbon nanotubes · CPC title