Method of hydrothermal liquid phase sintering of ceramic materials and products derived therefrom

• US 8,709,960 B2
• Filed: 01/04/2011
• Issued: 04/29/2014
• Est. Priority Date: 11/15/2007
• Status: Active Grant

• Current Assignee: Rutgers University
• Original Assignee: Rutgers University
• Inventors: Riman, Richard E., Atakan, Vahit
• Primary Examiner(s): GROUP, KARL E
• Application Number:
  US12/984,299
• Publication Number:
  US 20110104469A1
• Time in Patent Office: 1,211 Days
• Field of Search: 501102-139, 501/1, 501/94, 501/151, 501/152, 264/643, 264/646, 264/648, 428/307.3, 428/307.7, 428/701, 428/702
• US Class Current: 501/1
• CPC Class Codes: C04B 2235/3208 Calcium oxide or oxide-forming salts thereof, e.g. lime
• CPC Class Codes: C04B 2235/3213 Strontium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3215 Barium oxides or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3256 Molybdenum oxides, molybdates or oxide forming salts thereof, e.g. cadmium molybdate
• CPC Class Codes: C04B 2235/3262 Manganese oxides, manganates, rhenium oxides or oxide-forming salts thereof, e.g. MnO
• CPC Class Codes: C04B 2235/3275 Cobalt oxides, cobaltates or cobaltites or oxide forming salts thereof, e.g. bismuth cobaltate, zinc cobaltite
• CPC Class Codes: C04B 2235/3279 Nickel oxides, nickalates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3296 Lead oxides, plumbates or oxide forming salts thereof, e.g. silver plumbate
• CPC Class Codes: C04B 2235/608 Green bodies or pre-forms with well-defined density
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 35/2658 Other ferrites containing manganese or zinc, e.g. Mn-Zn ferrites
• CPC Class Codes: C04B 35/2666 Other ferrites containing nickel, copper or cobalt
• CPC Class Codes: C04B 35/2683 Other ferrites containing alkaline earth metals or lead
• CPC Class Codes: C04B 35/42 based on chromites C04B35/047 and C04B35/105 take precedence
• CPC Class Codes: C04B 35/447 based on phosphates , e.g. hydroxyapatite
• CPC Class Codes: C04B 35/457 based on tin oxides or stannates
• CPC Class Codes: C04B 35/4682 based on BaTiO3 perovskite phase
• CPC Class Codes: C04B 35/47 based on strontium titanates
• CPC Class Codes: C04B 35/49 containing also titanium oxides or titanates
• CPC Class Codes: C04B 35/491 based on lead zirconates and lead titanates , e.g. PZT
• CPC Class Codes: C04B 35/495 : based on vanadium, niobium, tantalum, molybdenum or tungsten oxides or solid solutions thereof with other oxides, e.g. vanadates, niobates, tantalates, molybdates or tungstates
• CPC Class Codes: C04B 35/64 : Burning or sintering processes C04B33/32 takes precedence ; powder metallurgy B22F
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249956 : Void-containing component is inorganic
• CPC Class Codes: Y10T 428/249957 : Inorganic impregnant
• CPC Class Codes: Y10T 428/24999 : Inorganic

Abstract

Provided here is a method of producing a monolithic body from a porous matrix, comprising: (i) providing a porous matrix having interstitial spaces and comprising at least a first reactant; (ii) contacting the porous matrix with an infiltrating medium that carries at least a second reactant; (iii) allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product; and (iv) allowing the at least first product to form and fill at least a portion of the interstitial spaces of the porous matrix, thereby producing a monolithic body, wherein the monolithic body does not comprise barium titanate.

Claims

1. A sintered composition produced by a hydrothermal liquid phase sintering process, which process comprises allowing a portion of a porous matrix, wherein the porous matrix has a predetermined shape and size, to undergo a reaction with a first reactant carried by a liquid to provide at least a first product, during which reaction a remaining portion of the porous matrix acts as a scaffold for facilitating the formation of the first product from the liquid, thereby producing a hydrothermal liquid phase sintered composition

wherein the sintered composition substantially maintains the predetermined shape and size of the porous matrix, and

wherein the first product comprises carbonate, sulfate, oxalate, fluoride, fluorophosphate, or a mixture thereof.

2. The sintered composition of claim 1, wherein the first product has substantially the same molar volume as the porous matrix.

3. The sintered composition of claim 1, wherein the first product has a larger molar volume than the porous matrix.

4. The sintered composition of claim 1, wherein the first product has a smaller molar volume than the porous matrix.

5. The sintered composition of claim 1, wherein the porous matrix comprises a metal oxide, metal hydroxide, metal sulfate, metal fluoride, metal titanate, or a combination thereof.

6. The sintered composition of claim 1, wherein the first reactant comprises an oxalate, a carbonate, a sulfate, or a combination thereof.

7. The sintered composition of claim 1, wherein the porous matrix comprises calcium, magnesium, strontium, titanium, zirconium, chromium, manganese, iron, nickel, copper, aluminum, beryllium, barium, scandium, vanadium, cobalt, zinc, lead, rhodium, yttrium, ruthenium, technetium, molybdenum, neodymium, zirconium, lanthanum, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, mercury, thallium, palladium, lathanides, actinides, or a combination thereof.

8. The sintered composition of claim 1, wherein the porous matrix further comprises a material that decomposes before it is able to sinter if a conventional sintering method is used.

9. The sintered composition of claim 1, wherein the composition comprises a structural, electrical, chemical, ceramic, magnetic, superconducting, mechanical, biological material, or a combination thereof.

10. The sintered composition of claim 1, wherein the sintered composition has an interconnecting microstructure.

11. The sintered composition of claim 1, wherein the sintered composition has a composite microstructure.

18. The sintered composition produced of claim 1, wherein the sintered composition comprises carbonate, sulfate, oxalate, or a mixture thereof.

19. The sintered composition produced of claim 1, wherein the sintered composition comprises carbonate.

20. The sintered composition produced of claim 1, wherein the sintered composition comprises sulfate.

21. The sintered composition produced of claim 1, wherein the sintered composition comprises oxalate.

12. A sintered monolithic body comprising:

a first product, wherein the first product is formed from a reaction between a first reactant and a portion of a porous matrix, wherein the porous matrix has a predetermined shape and size and the first product and porous matrix form the sintered monolithic body; and

a microstructure,

wherein the microstructure comprises an interconnecting network;

wherein the sintered monolithic body has a porosity of less than 40%,

wherein the sintered monolithic body substantially maintains the predetermined shape and size of the porous matrix, and

wherein the first product comprises carbonate, sulfate, oxalate, fluoride, fluorophosphate, or a mixture thereof.

13. The sintered monolithic body of claim 12, wherein the sintered monolithic body is a ceramic.

14. The sintered monolithic body of claim 12, wherein the sintered monolithic body is substantially fully dense.

15. The sintered monolithic body of claim 12, wherein the sintered monolithic body has a residual porosity of about 15 percent or less by volume.

16. The sintered monolithic body of claim 12, wherein the sintered monolithic body comprises covalent bonding, ionic bonding, metallic bonding or combination thereof.

17. The sintered monolithic body of claim 12, wherein the microstructure is homogenous.

22. The sintered monolithic body of claim 12, wherein the sintered composition comprises carbonate, sulfate, oxalate, or a mixture thereof.

23. The sintered monolithic body of claim 12, wherein the sintered composition comprises carbonate.

24. The sintered monolithic body of claim 12, wherein the sintered composition comprises sulfate.

25. The sintered monolithic body of claim 12, wherein the sintered composition comprises oxalate.

26. The sintered monolithic body of claim 12, wherein the sintered composition is substantially free of hydraulic bonds.