EP0134136A2
Expired / Lapsed
EP
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A method of producing ceramics
Assignee: NGK Insulators Ltd
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Filing: 1984-08-09
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Granted: —
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Expires: 2004-08-09
Abstract
Abstract Zirconia powder is formed by dry grinding, and a slurry of the zirconia powder with nonaqueous solvent is shaped and first at above 1100°C, preferably at 1200 - 1400°C. By dry grinding and the use of a non-aqueous slurry, a lower sintering temperature and improved avoidance of pinholes and cracks can be achieved. A metal layer can be fired with the ceramics. The invention can be applied in the production of oxygen sensors, for example.
Inventors
- 👤 Syunzo Mase
- 👤 Shigeo Soejima
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-05 01:24
CPC Classifications
G; G01; G01N; G01N27/00; G01N27/26; G01N27/403; G01N27/406; G01N27/407; G01N27/4073; C; C04; C04B; C04B35/00; C04B35/01; C04B35/48; C04B35/486; C04B41/00; C04B41/009; C04B41/45; C04B41/50; C04B41/51; C04B41/80; C04B41/81; C04B41/85; C04B41/88
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
49 words
A method of producing ceramics, comprising steps of preparing powder mainly consisting of zirconia by dry grinding, making a slurry of the thus dry ground powder by using a nonaqueous solvent, forming a shaped body from the slurry, and firing the shaped body at a temperature higher than 1,100°C.
Claim 2
Independent Claim
49 words
A method of producing ceramics, comprising steps of preparing powder mainly consisting of zirconia by dry grinding, making a slurry of the thus dry ground powder by using a nonaqueous solvent, forming a shaped body from the slurry, and firing the shaped body at a temperature higher than 1,100°C.
Claim 3
Dependent Claim
40 words
A method as set forth in claim 1, wherein a layer of paste containing metallic powder is overlaid at least on one side surface of said shaped body, and then the shaped body having the layer of paste is fired.
Claim 4
Dependent Claim
45 words
A method as set forth in claim 1, wherein a layer of paste containing a compound capable of generating metal upon heating is overlaid at least.on one side surface of said shaped body, and then the shaped body having the layer of paste is fired.
Claim 5
Dependent Claim
65 words
A method as set forth in claim 1, wherein a layer of paste containing metallic powder is overlaid at least on one side surface of said shaped body, and the shaped body having the layer of paste is overlaid on a green layer mainly consisting of ceramics material so as to form a laminated body, and the laminated body is fired into a unitary ware.
Claim 6
Dependent Claim
65 words
A method as set forth in claim 1, wherein a layer of paste containing metallic powder is overlaid at least on one side surface of said shaped body, and the shaped body having the layer of paste is overlaid on a fired layer mainly consisting of ceramics material so as to form a laminated body, and the laminated body is fired into a unitary ware.
Claim 7
Dependent Claim
71 words
A method as set forth in claim 1, wherein a layer of paste containing a compound capable of generating metal upon heating is overlaid at least on one side surface of said shaped body, and the shaped body having the layer of paste is overlaid on a green layer mainly consisting of ceramics material so as to form a laminated body, and the laminated body is fired into a unitary ware.
Claim 8
Dependent Claim
71 words
A method as set forth in claim 1, wherein a layer of paste containing a compound capable of producing metal upon heating is overlaid at least on one side surface of said shaped body, and the shaped body having the layer of paste is overlaid on a fired layer mainly consisting of ceramics material so as to form a laminated body, and the laiminated body is fired into a unitary ware.
Claim 9
Independent Claim
127 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, overlaying a first electrode layer on said substrate, said first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, heating said substrate with the first electrode layer so as to generate a first electrode, overlaying said heated substrate on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics, and forming a second electrode on said zirconia ceramics to form an oxygen sensor element.
Claim 10
Independent Claim
127 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, overlaying a first electrode layer on said substrate, said first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, heating said substrate with the first electrode layer so as to generate a first electrode, overlaying said heated substrate on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics, and forming a second electrode on said zirconia ceramics to form an oxygen sensor element.
Claim 11
Independent Claim
126 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, overlaying a first electrode layer on said substrate, said first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, heating said substrate with the first electrode layer so as to generate a first electrode, overlaying said heated substrate on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics, and forming a second electrode on said substrate to form an oxygen sensor element.
Claim 12
Independent Claim
126 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, overlaying a first electrode layer on said substrate, said first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, heating said substrate with the first electrode layer so as to generate a first electrode, overlaying said heated substrate on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics, and forming a second electrode on said substrate to form an oxygen sensor element.
Claim 13
Independent Claim
115 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, preparing a first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, overlaying said substrate and said first electrode layer on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics with a first electrode formed thereunder, and forming a second electrode on said zirconia ceramics to form an oxygen sensor element.
Claim 14
Independent Claim
115 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, preparing a first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, overlaying said substrate and said first electrode layer on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics with a first electrode formed thereunder, and forming a second electrode on said zirconia ceramics to form an oxygen sensor element.
Claim 15
Independent Claim
114 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, preparing a first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, overlaying said substrate and said first electrode layer on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics with a first electrode formed thereunder, and forming a second electrode on said substrate to form an oxygen sensor element.
Claim 16
Independent Claim
114 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, preparing a first electrode layer mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, overlaying said substrate and said first electrode layer on a shaped body formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia so as to form a laminated body, firing said laminated body at a temperature higher than 1,100°C so as to generate zirconia ceramics with a first electrode formed thereunder, and forming a second electrode on said substrate to form an oxygen sensor element.
Claim 17
Independent Claim
114 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, preparing a first electrode layer and a second electrode layer, both said electrode layers mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, preparing a green zirconia layer formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia, overlaying said substrate, said first and second electrode layers, and said zirconia layers so as to form a laminated body with said zirconia layer placed between said first and second electrode, firing said laminated body to form an oxygen sensor element.
Claim 18
Independent Claim
114 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of ceramics material, preparing a first electrode layer and a second electrode layer, both said electrode layers mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, preparing a green zirconia layer formed of a nonaqueous slurry of dry ground powder mainly consisting of zirconia, overlaying said substrate, said first and second electrode layers, and said zirconia layers so as to form a laminated body with said zirconia layer placed between said first and second electrode, firing said laminated body to form an oxygen sensor element.
Claim 19
Independent Claim
129 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, preparing a first electrode layer and a second electrode layer, both said electrode layers mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, preparing a green zirconia layer formed of a nonaquous slurry of dry ground powder mainly consisting of zirconia, overlaying said substrate, said first and second electrode layers, and said zirconia layers so as to form a laminated body with said substrate placed between said first and second electrode and at least one electrode covered by said zirconia layer, firing said laminated body at a temperature higher than 1,100°C to form an oxygen sensor element.
Claim 20
Independent Claim
129 words
A method of producing a ceramics, comprising steps of preparing a substrate mainly consisting of zirconia ceramics, preparing a first electrode layer and a second electrode layer, both said electrode layers mainly consisting of at least one material selected from the group consisting of metallic powder and a compound capable of generating metal upon heating, preparing a green zirconia layer formed of a nonaquous slurry of dry ground powder mainly consisting of zirconia, overlaying said substrate, said first and second electrode layers, and said zirconia layers so as to form a laminated body with said substrate placed between said first and second electrode and at least one electrode covered by said zirconia layer, firing said laminated body at a temperature higher than 1,100°C to form an oxygen sensor element.
Claim 21
Independent Claim
37 words
A method of producing ceramics as set forth in claims 1, 2, 3, 4, 5, 6, or 7, wherein said dry ground powder has a specific surface area of larger than 5 m 2 / g .
Claim 22
Dependent Claim
37 words
A method of producing an oxygen sensor element as set forth in claim 8, 9, 10, 11, 12, or 13, wherein said dry ground powder has a specific surface area of larger than 5 m 2 /g.
References Cited (Backward Citations)
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