Zirconium oxide-based composite material

Patent metadata

Field	Value
Publication number	US-9783459-B2
Application number	US-201314422541-A
Country	US
Kind code	B2
Filing date	Aug 20, 2013
Priority date	Aug 20, 2012
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

A ceramic composite material and a method for producing same. The ceramic composite material has a ceramic matrix comprising zirconium oxide and at least one secondary phase dispersed therein. The matrix is composed of zirconium oxide as at least 51 vol.-% of composite material, and the secondary phase is in a proportion of 1 to 49 vol.-% of composite material, wherein 90 to 99% of the zirconium oxide is present in the tetragonal phase based on the total zirconium oxide portion. The tetragonal phase of the zirconium oxide is stabilized by at least one member selected from the group consisting of chemical stabilization and mechanical stabilization. The ceramic composite is damage-tolerant.

First claim

It is claimed:

1. A composite material comprising:
a ceramic matrix, said ceramic matrix comprising zirconium oxide and at least one secondary phase dispersed therein, wherein the matrix composed of zirconium oxide has a proportion of at least 51 vol.-% of composite material, and wherein the secondary phase has a proportion of from 4 to 6 vol.-% of composite material, wherein 95 to 99% of the zirconium oxide is present in the tetragonal phase based on the total zirconium oxide portion;
wherein the tetragonal phase of the zirconium oxide is stabilized by at least one member selected from the group consisting of chemical stabilization and mechanical stabilization;
wherein the secondary phase comprises at least one member selected from the group consisting of: strontium hexaaluminate, lanthanum aluminate, hydroxyapatite, fluorapatite, tricalcium phosphate, spinel, aluminum oxide, yttrium aluminum garnet, mullite, zircon, quartz, talc, kaolinite, pyrophyllite, potassium feldspar, leucite and lithium metasilicate, and
wherein the chemical stabilization is via addition of a chemical stabilizer selected from the group consisting of Y 2 O 3 , CeO 2 , Gd 2 O 3 , Sm 2 O 3 , and Er 2 O 3 ; wherein a total content of chemical stabilizer is <12 mol-% based on a zirconium oxide content.

2. A composite material according to claim 1 , wherein the matrix composed of zirconium oxide has an average grain size of 0.1 to 2.0 μm.

3. A composite material according to claim 1 , wherein the chemical stabilizer is Y 2 O 3 .

4. A composite material according to claim 3 , wherein a content of Y 2 O 3 is ≦3 mol, based on the zirconium oxide content.

5. A composite material according to claim 1 , wherein at least one of the zirconium oxide or the secondary phase contain a soluble substituent.

6. A composite material according to claim 5 , wherein the soluble substituent is selected from the group consisting of Cr, Fe, Mg, Ca, Ti, Y, Ce, a lanthanide and V.

7. A composite material according to claim 6 , wherein the soluble substituent is an oxide.

8. A composite material according to claim 1 , wherein the secondary phase includes a dispersoid which, due to crystal structure of the dispersoid, allows at least one of shear deformation on the microscopic level or reduces the hardness of the composite material.

9. A composite material according to claim 1 , wherein particles of the secondary phase have a particle size of less than or equal to a grain size of the zirconium oxide.

10. A composite material according to claim 1 , wherein the particles of the secondary phase have a particle size of from 0.2 to 2.0 μm.

11. A composite material comprising:
a ceramic matrix, said ceramic matrix comprising zirconium oxide and at least one secondary phase dispersed therein, wherein the matrix composed of zirconium oxide has a proportion of at least 51 vol.-% of composite material, and wherein the secondary phase has a proportion of 1 vol.-% of composite material, wherein 90 to 99% of the zirconium oxide is present in the tetragonal phase based on the total zirconium oxide portion; and
wherein the tetragonal phase of the zirconium oxide is stabilized by at least one member selected from the group consisting of chemical stabilization and mechanical stabilization.

12. A composite material according to claim 1 , wherein the secondary phase comprises said aluminum oxide.

13. A composite material according to claim 1 , wherein the composite material has a hardness<1350.

14. A composite material according to claim 13 , wherein the composite material has a hardness of <1200.

15. A composite material according to claim 1 , wherein the composite material has a hardness of <1000.

16. A composite material according to claim 1 , wherein the composite material has a breaking strength≧800 MPa.

17. A composite material according to claim 1 , wherein the damage tolerance or residual strength following an HV50 indentation is >400 MPa.

18. An article of manufacture comprising the composite material of claim 1 , wherein the article of manufacture is a member selected from a dental prostheses, a dental restoration, a dental root pin, a dental implant, an abutment and a spinal implant.

19. A method for producing a sintered molded body made of a composite material according to claim 1 , comprising the steps of:
a) placing a powder mixture of the ceramic matrix into water,
b) homogenizing in a dissolver;
c) grinding in an agitator ball mill;
d) spray drying to form a granulate;
e) moistening the granulate with water;
f) axially pressing the granulate to form a block;
g) machine cutting a block to form pre-sintered state;
h) sintering the pre-sintered state block to form a sintered block; and
i) hard machining the sintered block.

20. A composite material according to claim 1 , wherein the content of CeO 2 is ≦12 mol-%, based on the zirconium oxide content.

21. A composite material according to claim 1 , wherein the content of Gd 2 O 3 is ≦3 mol-%, based on the zirconium oxide content.

22. A composite material according to claim 1 , wherein the content of Sm 2 O 3 is ≦3 mol-%, based on the zirconium oxide content.

23. A composite material according to claim 1 , wherein the content of Er 2 O 3 is ≦3 mol-%, based on the zirconium oxide content.

24. A composite material comprising:
a ceramic matrix, said ceramic matrix comprising zirconium oxide and a secondary phase dispersed therein, wherein the matrix composed of zirconium oxide has a proportion of at least 51 vol.-% of composite material, and that the secondary phase has a proportion of from 4 to 6 vol.-% of composite material, wherein 95 to 99% of the zirconium oxide is present in the tetragonal phase based on the total zirconium oxide portion; and
wherein the tetragonal phase of the zirconium oxide is stabilized by at least one member selected from the group consisting of chemical stabilization and mechanical stabilization.

25. A method for producing a sintered molded body made of a composite material according to claim 24 , comprising the steps of:
a) placing powder mixture of the zirconium oxide and the secondary phase into water to form an aqueous mixture
b) homogenizing the aqueous mixture in a dissolver to form a homogenized aqueous mixture;
c) grinding the homogenized aqueous mixture in an agitator ball mill to form a ground homogenized aqueous mixture;
d) spray drying to form a granulate;
e) moistening the granulate with water;
f) axially pressing a block;
g) machine cutting a block in a green or pre-sintered state;
h) sintering; and
i) hard machining.

26. A composite material comprising:
a ceramic matrix, said ceramic matrix comprising zirconium oxide and at least one secondary phase dispersed therein, wherein the matrix composed of zirconium oxide has a proportion of at least 51 vol.-% of composite material, and wherein the secondary phase has a proportion of 1 to 10 vol.-% of composite material, wherein 90 to 99% of the zirconium oxide is present in the tetragonal phase based on the total zirconium oxide portion;
wherein the tetragonal phase of the zirconium oxide is stabilized by at least one member selected from the group consisting of chemical stabilization and mechanical stabilization; and
wherein the secondary phase comprises zircon.

Assignees

• Ceram Gmbh

Inventors

• Gottwik Lukas
• Kuntz Meinhard
• Porporati Alessandro Alan
• Ehrlich Juliane
• Morhardt Andreas
• Friederich Kilian

Classifications

• A61K6/822

  comprising rare earth metal oxides · CPC title

• A61K6/802

  comprising ceramics · CPC title

• A61K6/824

  comprising transition metal oxides · CPC title

• A61F2/3094

  Designing or manufacturing processes · CPC title

• A61K6/818

  comprising zirconium oxide · CPC title