Superconducting ceramics and methods of manufacturing the same

Abstract: A high Tc superconducting ceramics material is produced by mixing ceramic constituents with an alcohol or a freon before firing. The alcohol or freon functions as a reducing agent during firing so that excess oxygen can be eliminated from the superconducting structure. The formed superconducting ceramics is coated with a protective organic resin film in order to avoid the degrading influence of exposure to the air.

Description: BACKGROUND OF THE INVENTION This invention generally relates to the field of superconducting ceramics. It has long been known that metals such as mercury and lead, intermetallics such as NbNd, Nb 3 Ge and NbGa and ternary materials such as Nb 3 (Al 0.8 Ge 0.2 ) demonstrate superconductivity. However, the transition temperature of such long known conventional superconducting materials cannot exceed 25°K. In more recent years, superconducting ceramics have attracted widespread interest. A new material was first reported by researchers at the Zurich laboratory of IBM Corp. as Ba-La-Cu-O-type high temperature superconducting oxides. Subsequently, La-Sr-Cu(II)-O-type superconducting oxides were also proposed. Another type of superconducting material that has been found is (YBa 2 )Cu 3 0 6-8 . By virtue of the fact that these superconducting ceramics form a quasi-molecular atomic unit in a crystalline structure whose unit cell is constructed with one layer in which electrons have essentially one-dimensional motion, whereas three dimensional electron motion conditions occurs in the long known materials mentioned above, higher transition temperatures were achieved. Much work has been undertaken by researchers in the field who have endeavoured to elevate Tco, the temperature at which resistance vanishes, above the levels previously obtained and preferably above the boiling point of liquid nitrogen (77°K) or even higher. As described in our European Patent Application No. 87309081.5 (EP-A-0283620), we have investigated superconducting ceramic materials having the stoichiometric formulae (A 1-x B x ) y Cu z O w , where A represents one or more elements of Group IIIa of the Japanese Periodic Table, e.g. the rare earth elements, and B represents one or more elements of Group IIa of the Japanese Periodic Table, e.g. the alkaline earth elements including beryllium and magnesium, and in the continuation of these investigations we have discovered that contact of the external surfaces of superconductors with air makes it difficult to obtain a stabilized high Tco. SUMMARY OF THE INVENTION According to the present invention there is provided a method of manufacturing a superconductive ceramics material comprising: mixing chemical constituents of the superconductive ceramics material; firing the mixture in order to produce the superconductive material; and coating the fired superconductive material on its external surface with a protective layer such that the superconductive material does not collect water from the atmosphere; the method being characterised in that prior to firing the mixture, said chemical constituents of the superconductive material are compacted with a reducing, water-free liquid in order to substantially reduce excess oxygen in said superconductive material. Whereas in previous attempts to find commercially attractive superconducting materials, attention has been focused upon the elevation of Tc by modifying the composition of molar ratios of the constituent elements of the materials, in accordance with the present invention there is provided an improved process for the manufacture of superconductive ceramics in accordance with which, immediately after the formation of the superconducting structure, the superconducting body is coated with a protecting film such as an organic resin film for example in order that the superconducting body does not collect water from the surrounding atmosphere and particularly from the air, during cooling of the superconducting body to liquid nitrogen temperatures for initiating the transition to the superconducting phase. If water is absorbed into the superconducting material, the superconducting properties of the superconducting ceramics can be degraded. The article "Water interaction with the superconducting YBa 2 Cu 3 O 7 phase" by M.F. Yan et al published in Applied Physics Letters, Vol.51, No. 7, 17 August 1987 on pages 532-534 discusses the sensitivity to water and water vapour of the superconducting ceramic material YBa 2 Cu 3 O 7 and concludes that this material is subject to decomposition in water and exhibits degraded superconductivity by the interaction of the material with water and humid air. There is a suggestion in the article that this effect need not preclude practical application of the material since it should be possible to protect it with coatings of metal, glass or plastic. There is however no suggestion in the article of compacting the constituents of the superconductive material with a reducing, water-free liquid in order to substantially reduce excess oxygen in the superconductive material. In accordance with a preferred embodiment of the invention, the starting chemicals required for constituting a superconducting ceramics material are ground, compressed and fired. After repeating this procedure one or more times in order to obtain a uniform composition, the fine powder that results is mixed with a reducing, water-free liquid and compressed into a compact containing the liquid therein. The compact is gradually heated so as not to cause flash reduction, and is fired at 500-1400°C. The fired compact is then coated with an organic resin film immediately after its removal from the oven. Examples of such organic resins are epoxy resins, fluorine resins, silicone resins and polyimide resins. In accordance with experimental results that have been obtained, the critical temperature of the resulting superconductor was elevated to 150-400K. Superconducting materials in accordance with the present invention have a modified perovskite-like triple-layered structure as shown in Fig. 1 of the accompanying drawing. Each layer of the structure predominately comprises copper atoms 2 and oxygen atoms 5 located around the copper atoms 2. Oxygen vacancies 7 are considered to play an important role in superconduction. In order to eliminate excess oxygen from superconducting ceramics, a reducing water-free liquid is introduced into the ceramics material before firing. Examples of such reducing liquids are methyl alcohol, ethyl alcohol and fluorinated hydrocarbons such as Freon 113™. The reducing liquids react with oxygen contained in the ceramics material so as to produce water vapour and carbon dioxide which is eliminated during the firing of the ceramics. Because of the elimination of oxygen by this technique, the atomic distance along the C axis can be reduced and therefore very high critical temperatures can be obtained. Other features of the invention are set forth with particularity in the appended claims and will become clear to those possessed of the relevant skills from consideration of the following description of the exemplary embodiments. BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a diagram showing the modified perovskite-like structure of superconducting ceramics in accordance with the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS Described hereinafter are a couple of examples illustrating the manufacture of superconducting ceramics conforming to the stoichiometric formulae (A 1-x B x ) y Cu z O w ,where A is one or more elements of Group IIIa of the Japanese Periodic Table, e.g. the rare earth element, B is one or more elements of Group IIa of the Japanese Periodic Table, e.g. the alkaline earth metals including beryllium and magnesium, and 0 < x < 1; y = 2.0 - 4.0, preferably 2.5 - 3.5; z = 1.0 - 4.0, preferably 1.5 - 3.5; and w = 4.0 - 10.0, preferably 6.0 - 8.0. Examples of such materials are YBa 2 Cu 3 0 7-x and YCa 2 Cu 3 O 7-x . For the avoidance of doubt it is to be noted that all references herein and in the appended claims to the Periodic Table and to specific Groups of the Periodic Table are to be understood to refer to the Japanese Periodic Table and to the Groups thereof as described in the Iwanami "Physics and Chemistry Dictionary". As compared with the Group designations of the Periodic Table as described in "The Penguin Dictionary of Science" for example, which are the Group designations commonly accepted throughout Europe, Groups Ia, IIa, VIII, Ib, IIb and 0 are the same in the Japanese and European Periodic Tables, Groups IIIa, IVa, Va, VIA and VIIa of the Japanese Periodic Table correspond respectively to Groups IIIb, IVb, Vb, VIb and VIIb of the European Periodic Table, and Groups IIIb, IVb, Vb, VIb and VIIb of the Japanese Periodic Table correspond respectively to Groups IIIa, IVa, Va, VIa and VIIa of the European Periodic Table. Example 1: Prescribed amounts of BaCO 3 , CaCO 3 , CuO and Y 2 O 3 (High Purity Chemical Industries Co. Ltd. 99.95% or higher) were used for preparing a superconducting ceramic material of the above formula where x=0.67, y=3, z=3 and w=6-8. i.e. in consistence with (YBa 2 )-Cu 3 O 6-8 or (YBaCa)Cu 3 O 6-8 . The factor "W" was controlled by adjusting the sintering conditions. After being mixed in a ball mill, the high purity chemicals were pressed in a capsule at 500KN/m 2 (500Kg/cm 2 ) and formed into a cylindrical tablet of 10mm diameter and 3mm height. The tablet was heated (fired) and oxidized at 500-1100°C, e.g. 950°C, for 8 hours in an oxidizing atmosphere such as in air, this step being called pre-firing hereinafter. Next, the tablet was finely ground in a ball mill so that the average grain diameter was 20-0.003 µm, e.g. 0.5 µm or smaller. This step is repeated 3-5 times. In this step, it is desired to take care to avoid the occurrence of Y 2 BaCuO 5 or a copper oxide phase in the product. Then, the powder of 20-0.003 µm average diameter was sufficiently mixed with methyl alcohol in a ball mill, and was pressed in a capsule at a pressure of 1000KN/m 2 (1 t/cm 2 ) so as to be formed into tablets. The tablets were then fired, hereinafter called main firing, for 10 - 50 hours at 500-1400°C, for example 15 hours at 930°C, in an oxidizing atmosphere such as in air. This firing was carried out by elevating the temperature from room temperature to the prescribed temperature at 10 - 1000°C per hour, e.g. at 100°C per hour. While the temperature was being elevated, the ceramic material was partially reduced by virtue of the alcohol. Thereafter, the temperature was reduced to 400°C at 100°C per minute. By virtue of this procedure, a dense perovskite-like structure was obtained. Next, the tablet was covered with a resin coating by immersion in a silicone resin solution followed by thermal setting at 150°C for two hours or 30 minutes in dehumidified air. Alternatively the tablets could be coated with an epoxy resin, in which case thermal setting is carried out at 150°C for 30 minutes or 240°C for 5 minutes in air. The relationship between temperature and the resistivity of the resultant material was investigated. When the temperature was lowered from 250K, the resistivity started to drop at around 250K and disappeared at 248K. This critical temperature of 248K was repeatedly observed when the temperature was repeatedly raised and lowered between room temperature and the critical temperature. For comparison, the same superconducting ceramic material was fabricated without provision of the resin coating and upon examination was found to have a critical temperature which dropped to 93K when the temperature was repeatedly raised and lowered. The organic resin used for covering the superconducting materials of the invention is preferably selected from soft resins, because local stress in superconducting materials caused by contraction or expansion of the resin during curing is undesirable. Example 2 . The procedure of Example 1 was repeated but with 50% of Y substituted by Yb and Ca substituted by Sr, and with a fluorinated hydrocarbon in place of methyl alcohol. The Y and Yb were introduced as oxides or fluorides. As a result, Tc onset was measured to be 300°K and Tco was 297°K, which were maintained for a week or long term. The foregoing Examples are merely illustrative of the invention, and do not include all of the combinations of elements and process variations which may be used to produce superconducting ceramics materials in accordance with the invention, other combinations also being effective to provide improved superconducting materials. Superconducting ceramics for use in accordance with the present invention also may be prepared so as to be consistent with the stoichiometric formulae (A 1-x b x ) y Cu z O w X v , where A is one or more elements of Group IIIa of the Japanese Periodic Table, e.g. the rare earth elements, B is one or more elements of Group IIA of the Japanese Periodic Table e.g. the alkaline earth metals including beryllium and magnesium, X is one or more elements of the group consisting of Ge, Sn, Pb, F or Cl, and 0 < x <1; y = 2.0 - 4.0, preferably 2.5 - 3.5; z = 1.0 - 4.0, preferably 1.5 - 3.5; w = 4.0 - 10.0, preferably 6.0 - 8.0; and v = 0 - 3. An example of such a material is YBa 2 Cu 3 O 6-8 . Also, superconducting ceramics for use in accordance with the present invention may be prepared so as to be consistent with the stoichiometric formulae (A 1-x B x ) y Cu z O w , where A is one or more elements of Group Vb of the Japanese Periodic Table such as Bi, Sb and As, B is one or more elements of Group IIa of the Japanese Periodic Table, e.g. the alkaline earth metals, and x = 0.3 - 1; y = 2.0 - 4.0, preferably 2.5 - 3.5; z = 1.0 - 4.0, preferably 1.5 - 3.5; and w = 4.0 - 10.0, preferably 6.0 - 8.0. An example of such a material is BiCaSrCu 3 O 6-8 . While several embodiments have been specifically described, it is to be appreciated that the present invention is not limited to the particular examples described. For example, diamond-like carbon can be used for protecting the surface of superconducting ceramic films. A suitable process for the formation of carbon materials can be seen in our European Patent Application No. 88301364.1(EP-A-0284190). Also, the application of a magnetic field during main-firing is effective for aligning the crystalline axis of the resultant material.

Claims: A method of manufacturing a superconductive ceramics material comprising: mixing chemical constituents of the superconductive ceramics material; firing the mixture in order to produce the superconductive material; and coating the fired superconductive material on its external surface with a protective layer such that the superconductive material does not collect water from the atmosphere; the method being characterised in that prior to firing the mixture, said chemical constituents of the superconductive material are compacted with a reducing, water-free liquid in order to substantially reduce excess oxygen from said superconductive material. A method as claimed in claim 1 wherein the reducing liquid is an alcohol, such as methyl alcohol or ethyl alcohol, or a fluorinated hydrocarbon. A method as claimed in claim 1 or 2 wherein the protective layer comprises an organic resin or a diamond-like carbon film. A method as claimed in claim 3 wherein said organic resin comprises an epoxy resin, a fluorine resin, a polyimide resin or a silicone resin. A method as claimed in any of the preceding claims wherein said chemical constituents are mixed in accordance with the stoichiometric formula (A 1-x B x ) y Cu z O w , where A is one or more elements from Group IIIa of the Japanese Periodic Table or Group Vb of the Japanese Periodic Table such as Bi, Sb and As, B is one or more elements of Group IIa of the Japanese Periodic Table, and x = 0.3 - 1; y = 2.0 - 4.0, z = 1.0 - 4.0 and w = 4.0 - 10.0. A method as claimed in any of claims 1 to 4 wherein the chemical constituents are mixed in accordance with the stoichiometric formula (A 1-x B x ) y Cu z O w X v , where A is one or more elements of IIIa of the Japanese Periodic Table, B is one or more elements of Group IIa of the Japanese Periodic Table, X is one or more elements of the group consisting of Ge, Sn, Pb, F or Cl, and O<x<1, y = 2.0 - 4.0, z = 1.0 - 4.0, w = 4.0 - 10.0, and v = 0-3. A method as claimed in any of the preceding claims wherein said chemical constituents are subjected to prefiring after a first mixing step, and then are finely ground prior to said compacting step. A method as claimed in any of the preceding claims and including a thermal setting step following the coating of the superconductive material with the protective layer. A method as claimed in any of the preceding claims wherein a magnetic field is applied to the material during its firing for aligning the crystalline axis of the resultant material.

Inventors: YAMAZAKI SHUNPEI, YAMAZAKI, SHUNPEI
Applicants: SEMICONDUCTOR ENERGY LAB, SEMICONDUCTOR ENERGY LABORATORY CO., LTD.
Application year: 1988
Main classification: C04B41
IPC codes: C04B35, C04B41, H01L39, H01B12, C01G1, H01B13