Method of preparing a superconductive material

Abstract: A superconductive material including a substrate and a superconductive layer of a double oxide of metals provided on the substrate is produced by a method which comprises the steps of: (a) providing a solution containing a blend of metal compounds having a composition corresponding to that of the double oxide; (b) applying the solution on the substrate to form a liquid film; (c) drying the liquid film; and (d) calcining the dried film to convert the metal compounds into the superconductive double oxide of the metals.

Description: This invention relates to a method of preparing a superconductive material. There are now increasing reports concerning metal oxides exhibiting superconductivity. Examples of such oxides include (La 0.9 Sr 0.1 )₂CuO₄, (La 0.9 Ba 0.1 )₂CuO₄ and YBa₂Cu₃O₇. These superconductive metal oxides of a ceramic type have thus far been prepared by a vapor phase method or a tape cast method. The former method requires the use of a large, elaborate apparatus. Further, the vapor phase method cannot prepare a superconductive material having a large surface area. The latter method fails to give films with a thin, uniform thickness of less than 20 µm (micrometer). Additionally, the tape cast method requires a high sintering temperature. From the stand point of actual industrial applications, it is highly desirous to provide superconductive materials having various shapes such as thin films, thin wires, tubes and rods. With the known methods, however, it is impossible or extremely difficult to produce ceramic type superconductive materials with such shapes. With the foregoing problems in view the present invention provides a method of preparing a superconductive material having a superconductive metal oxide layer provided on a substrate, said method comprising the steps of: (a) providing a non-aqueous solution containing a blend of metal compounds having a composition corresponding to that of the metals in the superconductive metal oxide, said metal compounds being selected from salts, chelates, halides, hydroxides, peroxides and oxides of said metals; (b) applying said solution on the substrate to form a liquid film; (c) drying said liquid film; and (d) calcining said dried film to convert said metal compounds into a superconductive metal oxide layer. The present invention provides a superconductive material including a substrate and a superconductive metal oxide layer provided over at least a portion of the surface of the substrate. The superconductive material is produced by a method including the following steps. (a) Preparation of Coating Solution: In this step a coating solution containing a blend of metal compounds is prepared. The metal compounds are salts, chelates, halides, hydroxides, peroxides and oxides of the selected metals. The contents of the metal compounds in the blend are so determined as to provide the desired superconductive oxide of the metals. That is, the molar ratios of the metal compounds in the blend are equivalent to those of the metals in the superconductive oxide. For example, if a superconductive metal oxide having a formula (La 0.9 Sr 0.1 )₂CuO₄ is intended, a coating solution containing La, Sr and Cu compounds and having contents of the La and Sr compounds of 1.8 and 0.2 moles, respectively, per mole of the Cu compound is used. Any metal compound of the above-defined kind may be used as long as it gives an oxide upon calcination. A metal compound which is decomposed at a temperature of preferably 1000°C or below, more preferably 200-900°C is suitably used. Examples of suitable metal compounds include metal salts of organic or inorganic acids such as naphthenic acid, 2-ethyl hexanoic acid, caprylic acid, stearic acid, lauric acid, butyric acid, propionic acid, oxalic acid, citric acid, lactic acid, phenol, cathechol, benzoic acid, salicilic acid, ethylenediaminetetracetic acid, nitric acid, carbonic acid, and hydrochloric acid; and chelate compounds such as metal acetylacetonates. Above all, metal compounds having an oxygen atom directly bonded to the metal, such as organic acid salts, acetylacetonates and nitrates, are preferably used because of the ease in which they may be converted into metal oxides upon calcination. Organic or inorganic metal compounds used as starting metal compounds and containing no oxygen directly bonded to the metals may be converted into such preferred metal compounds when used in conjunction with a suitable solvent such as an organic acid, an alcohol, acetylacetone or nitric acid. Any non-aqueous solvent may be used as long as it can dissolve the metal compounds. Examples of suitable solvents include hydrocarbons such as hexane, octane, benzene, toluene and tetralin; alcohols such as methanol, ethanol, propanol, butanol and amyl alcohol; ketones such as acetone, methyl ethyl ketone and acetylacetone; ethers such as dibutyl ether; aldehydes such as acetoaldehyde and benzaldehyde; organic acids such as formic acid, acetic acid, propionic acid, butylic acid, caprilic acid, lauric acid, stearic acid, naphthenic acid, linoleic acid, oleic acid, oxalic acid, citric acid, lactic acid, phenol and p-toluic acid; esters such as butylbutylate; amines such as dimethylamine and aniline; amides such as N-methylacetamide and formamide; sulfur compounds such as dimethylsulfoxide; and heterocyclic compounds such as pyridine and furfural. These solvents may be used singly or in combination of two or more and suitably selected according to the metal compounds to be dissolved. The coating solution may be prepared by, for example, dissolving a blend of metal compounds in a non-aqueous solvent. Alternatively, each metal compound is first dissolved in a suitable solvent and, then, the resultant solutions are mixed in suitable proportions. The concentration of the coating solution is not specifically limited but is, generally, 3-40 % by weight. The coating solution may further contain suitable additives such as a viscosity controlling agent, e.g. polyvinyl alcohol. (b) Liquid Film Forming Step: The coating solution obtained in the above step (a) is applied on at least a portion of the surface of a substrate to form a liquid film over that surface. The substrate may be formed of a metal or a metal alloy such as copper, titanium, lead or a stainless steel, a metal oxide such as alumina, zirconia or titania, or a ceramic material such as silicon carbide or graphite. The shape of the substrate is not specifically limited. Substrates having curved or flat surfaces, such as plates, wires, coils, fibers, fabrics, tubes, blocks and rods may be used. Porous substrate may also be used. Coating of the coating solution may be performed by any suitably way such as by a dip coating, spray coating or brush coating method. (c) Drying of Liquid Film: The substrate having a coated liquid film is then dried at room or an elevated temperature under ambient or a reduced pressure. It is not necessary to completely dry the film since the drying step is followed by a calcination step at an early stage of which drying may be completed. (d) Calcination Step: The dried (or semidried) film containing the metal compounds and formed on the substrate is subjected to calcination to convert the metal compounds into the desired superconductive oxide of the metals. The calcination temperature varies with the kind of the superconductive oxide, but generally in the range of 500-1000 °C. When the metal compounds are organic compounds, they are decomposed or oxidized at temperatures of 200-500 °C and crystallization or superconductive metal oxide forming reaction takes place at temperatures of 500-1000 °C. Inorganic metal compounds such as metal nitrates, hydroxides, carbonates or halides are decomposed and oxidized to form superconductive metal oxides at temperatures of 1000 °C or below. The calcination is preferably performed for 0.5 hour or more, more preferably 1-72 hours. The calcination step and the above-described drying step may be conducted separately or continuously. The atmosphere in which the calcination is performed may be, for example, air, oxygen, nitrogen or argon. Calcination in an oxygen-free atmosphere should be followed by calcination in oxygen-containing atmosphere at 500-1000 °C. In the calcination step, pressurized condition, ambient pressure or reduced pressure may be used. The calcination product is then allowed to be cooled to room temperature to obtain a superconductive composite material having a superconductive metal oxide layer provided over the surface of the substrate. The method of the present invention can form superconductive composite materials having a superconductive layer with a thickness of 0.01-20 µm, especially 0.1-10 µm. The thickness of the superconductive layer may be controlled by adjusting the concentration of the metal compounds in the coating solution or by repeating the coating and calcination steps suitable times. The method of the present invention is particularly suited for the production of superconductive materials having a superconductive layer of the following oxides. However, the present invention is applicable to any other superconductive metal oxides. AB₂Cu₃O 7+x (La 1-y Z y )₂CuO 4-z In the above formulae: A : Y, La, Nd, Sm, Eu, Gd, Dy, Ho, Er, Yb, Lu, or a mixture of two or more thereof; B : Ba, Sr, Ca or a mixture of two or more thereof; x : a number greater than -1 but less than +1; Z : Ba, Sr, Ca or a mixture of two or more thereof, y : a number greater than 0 but not greater than 0.2; and z : a number less than 1 but not less than 0. The following examples will further illustrate the present invention. Example 1 The metal compounds shown above were mixed with each other and the mixture dissolved in the above solvent to give a coating solution having the total metal compounds concentration shown above and having the molar ratio of the metals as shown above. The coating solution was applied on the substrate shown above by immersing the substrate in the coating solution and the coat was dried in the air. Then the substrate having the dried coat was calcined under the conditions shown above. The immersing, drying and calcining steps were repeated 10 times to give a superconductive material whose electrical resistivity was abruptly decreased at the temperature (on set) shown above and which exhibited perfect superconductivity at the temperature shown above. The above procedure was repeated in the same manner as described using an alumina bar (diameter 1 mm) in place of the alumina plate as a substrate. The resultant superconductive composite materials showed similar critical temperature. The electrical conductivity was measured by the four termini method in which four spaced apart electrodes with about 2 mm distance were provided on the superconductive layer by coating a silver paste thereon. Examples 2-17 were conducted to prepare various superconductive materials under conditions as summarized below. In each of Examples 2-17, the procedure including coating, drying and 1st stage calcination steps was repeated in the number indicated below. Thereafter, the 2nd stage calcination was performed in an oxygen-containing atmosphere. The calcined product was then gradually cooled to room temperature. Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Example 9 Example 10 Example 11 Example 12 Example 13 Example 14 Example 15 Example 16 Example 17

Claims: A method of preparing a superconductive material having a superconductive metal oxide layer provided on a substrate, said method comprising the steps of: (a) providing a non-aqueous solution containing a blend of metal compounds having a composition corresponding to that of the metals in the superconductive metal oxide, said metal compounds being selected from salts, chelates, halides, hydroxides, peroxides and oxides of said metals; (b) applying said solution on the substrate to form a liquid film; (c) drying said liquid film; and (d) calcining said dried film to convert said metal compounds into a superconductive metal oxide layer. A method as claimed in Claim 1, wherein said substrate is in the form of a wire or a plate. A method as claimed in Claim 1 or Claim 2, wherein said metal compounds are compounds capable of forming oxides upon calcination at 1000°C or less. A method as claimed in Claim 3, wherein said metal compounds are naphthenates, octylates, caprylates, stearates, laurates, butyrates, propionates, oxalates, citrates, lactates, benzoates, salcilates, ethylenediaminetetracetates, nitrates, carbonates, hydrochlorides or acetylacetonates of said metals. A method as claimed in Claim 3 or Claim 4, wherein step (d) is performed at a temperature of 500-1000°C. A method as claimed in Claim 5, wherein step (d) is performed in an oxygen-containing atmosphere for from 0.5 hour or more. A method as claimed in Claim 6, wherein the calcination in the oxygen-containing atmosphere is preceded by calcination in an oxygen-free atmosphere. A method as claimed in any preceding claim, wherein steps (a) to (d) are repeated until said superconductive layer has a thickness of 0.01-20 µm. A method as claimed in any preceding claim, wherein said solution contains a first compound selected from Y compounds, La compounds, Nd compounds, Sm compounds, Eu compounds, Gd compounds, Dy compounds, Ho compounds, Er compounds, Yb compounds, Lu compounds and mixtures thereof, a second compound selected from Ba compounds, Sr compounds, Ca compounds and mixtures thereof and a Cu compound so that said superconductive metal oxide has the formula: AB₂Cu₃O 7+x wherein A stands for Y, La, Nd, Sm, Eu, Gd, Dy, Ho, Er, Yb, Lu, or a mixture of two or more thereof, B stands for Ba, Sr, Ca or a mixture of two or more thereof, and x stands for a number greater than -1 but less than +1. A method as claimed in any one of Claims 1-8, wherein said solution contains a La compound, a compound selected from Ba compounds, Sr compounds, Ca compounds and mixtures thereof and a Cu compound, so that said superconductive metal oxide has the formula: (La 1-y Z y )₂CuO 4-z wherein Z stands for Ba, Sr, Ca or a mixture of two or more thereof, y is greater than 0 but not greater than 0.2 and z is a number less than 1 but not less than 0. A method as claimed in any preceding claim, wherein said substrate is formed of a metal, metal oxide or a ceramic.

Inventors: KAWAGUCHI KENJI, KONDO WAKICHI, KUMAGAI TOSHIYA, MIZUTA SUSUMU, SHIN SHIGEMITSU, YOKOTA HIROSHI, KAWAGUCHI, KENJI, KONDO, WAKICHI, KUMAGAI, TOSHIYA, MIZUTA, SUSUMU, SHIN, SHIGEMITSU, YOKOTA, HIROSHI
Applicants: AGENCY IND SCIENCE TECHN, DIRECTOR-GENERAL OF THE AGENCY OF INDUSTRIAL SCIENCE AND TECHNOLOGY
Application year: 1988
Main classification: H01L39
IPC codes: H01L39, C01G3