METHOD OF MANUFACTURING CERAMIC PRODUCTS

Abstract: A method for manufacturing a product of ceramics in which a green body (31) is formed by isostatic pressing and an outer surface of the green body (31) is polished by a buffing member (33) before sintering, so that the utilization coefficient of a starting material of the product can be improved but the smoothness of the outer surface of the final product is the same as the smoothness of the outer surface of the conventional product.

Description: The present invention relates to a method for manufacturing products of ceramics, particularly relates to a method for manufacturing products having a cylindrical outer surface such as translucent alumina tube for use in a high-voltage electric discharge lamp and a valve for use in automobile parts. In a manufacturing process of the products of ceramics having a cylindrical shape or a columnar shape, granulated powder is molded by the isostatic pressing such as hydrostatic pressing to obtain a green body and an outer surface of the green body is ground before sintering in order to make the surface smooth. In a grinding process of the green body, the outer surface thereof is generally ground by using a bite or a wheel around which an abrasive is provided. By grinding the outer surface of the green body with the bite or the wheel, a final product having a uniformity in thickness and a smoothness on the outer surface thereof can be obtained. Particularly, in a manufacturing process of a translucent alumina tube for use in a high-voltage electric discharge lamp, it is necessary to make the outer surface of the green body smooth in order to obtain an alumina tube as the final product having a predetermined translucency. For this purpose, the grinding with the bite or the wheel was generally conducted to finish the green body of the alumina tube. Figs. 1A and 1B are cross- and longitudinal-sectional views showing a green body 1 of the translucent alumina tube which has a cylindrical shape. According to the known grinding method for grinding the outer surface of the green body 1, in order to obtain a high roundness of the cylindrical body and a uniformity of thickness, the outer surface 1a of the green body 1 is ground by using the bite or the wheel to the degree that an unevenness formed on the outer surface is completely removed. That is to say, the outer surface of the green body 1 should be ground not only upto the minimum outer diameter of the cylindrical body but also upto the line shown by the reference D₂ in Figs. 1A and 1B under taking a margin for grinding into consideration. However, such high roundness and uniformity of the thickness are not required to manufacture the product such as the translucent alumina tube for the high-voltage electric discharge lamp. Because, in such tubes, if the sufficient translucency is obtained, the roundness of the body and the uniformity of the thickness do not matter to the efficiency of the tube. Therefore, only a smoothness of the outer surface 1a of the green body 1 is required to finish the green body. If the outer surface of the product such as the translucent alumina tube for use in the high-voltage electric discharge lamp is ground by the bite or the wheel, the utilization coefficient of the material of the product would be decreased. Further, when the product is made by a brittle material such as ceramics, the grinding with the bite or the wheel would cause a crack on the outer surface 1a of the green body 1 and then the molded body 1 would be broken before or after sintering. The starting material of the translucent alumina tube is so expensive that the problem of the cracking was very serious in manufacturing the translucent alumina tube. The present invention aims to overcome these disadvantages and provides for example a method in which the outer surface of the product is polished by a buffing member to obtain a necessary smoothness. According to the invention, the utilization coefficient of the starting material for the product is not decreased, but the product whose outer surface has the same smoothness as that of the product ground by the known method can be obtained. Specifically, the present invention provides a method for manufacturing a ceramic product comprising: isostatically pressing a body of granulated powder to obtain a shaped green body having an unevenness at an outer surface thereof; polishing the uneven outer surface to smooth it without removing the unevenness, and sintering the green body to obtain the product. In order to make the outer surface of the green body smooth without regard to the unevenness thereon, it may be sufficient to remove only an outermost surface layer of the green body. Therefore, in the present invention, only a little of the outermost surface layer of the green body is removed by buffing with a non woven fabric or a brush wheel having a contour along the unevenness instead of by grinding with the bite or the wheel which have a high stiffness. Thus, it is possible to obtain a smooth outer surface on the green body without reducing the utilization coefficient of the starting material. Fig. 2 is a schematic view showing the outer surface layer of the green body 1 in a large scale. The outermost surface layer of the green body 1 is constituted by a granulated particle layer 11. The granulated particle layer 11 is formed on a compacted particle layer 12 as shown in Fig. 2. Particles constituting of the granulated particle layer 11 are granulated by using a spray dryer. The thicknesses of the granulated particle layer 11 is about 50∼100 µm. In order to obtain a smoothness on the outer surface of the green body 1, it is enough to remove only the granulated particle layer 12 formed on the compacted layer 12 along the unevenness of the outer surface of the green body 1. It should be noted that it is not necessary to remove all of the granulated particles 11 formed on the compacted layer 12, but about 10∼30 µm of the particles should be removed in order to obtain the smooth outer surface. According to the method of the invention, a margin for grinding the outer surface of the green body is not necessary to be taken into consideration and it is possible to form the shape of the green body similar to the shape of the final product. Therefore, the utilization coefficient of the starting material is greatly increased. Figs. 1A and 1B are cross- and longitudinal-sectional views of a cylindrical tube; Fig. 2 is a schematic view depicting the outermost surface layer of the cylindrical tube shown in Figs. 1A and 1B; Fig. 3 is a schematic view illustrating a centerless grinder to which the present invention is applied; and Fig. 4 is a schematic view representing a valve. Fig. 3 is a schematic view illustrating a centerless grinder by which an outer surface of a product having a cylindrical shape is polished under the application of the present invention. In Fig. 3, the numerical number 31 denotes a green body to be polished, 32 a supporting portion for supporting the green body 31, 33 a buff wheel to polish the outer surface of the molded body 31, and 34 an adjustable wheel for urging the green body 31 against the buff wheel 33. Example 1 To alumina powder of 100 weight percent having an average particle diameter of 0.3 µm, is added magnesium oxide (MgO) of 0.10 weight percent as a sintering assistant. Thereafter the alumina powder and the magnesium oxide are mixed with a binder in a mixing attrition mill for one hour. The thus obtained mixture is granulated by a spray dryer to obtain granular powder having an average particle diameter of 80 µm. The thus obtained granular powder is hydrostatic-pressed by using a rubber mold having its thickness of 5 mm and a core under a pressure of 2 ton/cm² to obtain a green body 31 having a cylindrical shape. The molded body 31 is placed on the supporting portion 32 and the outer surface thereof is polished by rotating the buff wheel 33 under the adjustment of the adjustable wheel 34. A buffing condition is in the following. The buff wheel 33 comprises a round body 33a made by an alloy of aluminum and a buffing member 33b made by nylon (Scotch Bright - trade mark) having a thickness of 5 mm. The buffing member 33b is arranged around the outer circumference of the round body 33a. Buffing is conducted under the condition that the rotational frequency of the buff wheel 33 is 1200 rpm, the peripheral speed of the buff wheel 33 is 940 m/min, the feeding speed for feeding the molded body 31 is 40 mm/sec, the distance between the buff wheel 33 and the adjustable wheel 34 is set for 5∼20 mm. After polishing, the molded body is preliminarily sintered in an air and then primarily sintered for one hour in an ammonia decomposited atmosphere of 70∼80 Aq under the temperature of 1900°C to obtain the final product. The thus obtained translucent alumina tube, a comparative alumina tube to which no buffing is applied, and a conventional alumina tube whose outer surface is ground by using a bite are prepared, and a linear transparency, a white light transparency and a maximum surface roughness of these alumina tubes were measured. The measurement result is mentioned in the following Table 1. From the result mentioned in Table 1, it is proved that the linear transparency, total light transparency and smoothness of the alumina tube manufactured according to the present invention are the same as those of the conventional example tube the outer surface of which was ground by the bite. Example 2 Fig. 4 is a schematic view showing a valve 35 which is manufactured under the application of the present invention. Ten kilograms of a starting material consisting of silicon nitride powder of 93 weight percent having an average particle diameter of 0.5 µm, aluminum oxide (Al₂O₃) of 4 weight percent, and Y₂O₃ of 3 weight percent is prepared. The starting material is mixed with 15 Kg of water in a wet-type mixing attrition mill for one hour to obtain a slurry. To the thus obtained slurry is added and mixed a polyvinyl alcohol of 3 weight percent, and then the slurry is granulated by a spray dryer to obtain granular particles having an average particle diameter of 60 µm. The thus obtained granular particles are hydrostatic-pressed by using a rubber mold having a thickness of 5 mm under a pressure of 2.0 ton/cm² to form a green body. The outer surface of the green body is polished by the buff wheel 33 under the same condition of the first example. Thereafter, the green body is preliminarily sintered in an air at the temperature of 500°C for 5 hours, in order to remove the polyvinyl alcohol included in the green body. Then, the preliminarily sintered body is primarily sintered in a nitride atmosphere of 20 atm at the temperature of 1800°C for one hour to obtain a valve 35 as a final product. The valve whose surface polished in accordance with the method of the present invention, a comparison example valve which is sintered without being ground, and a conventional valve whose outer surface is ground by using a bite are prepared and the maximum surface roughnesses of the respective valves are compared to each other. The comparison result is mentioned in Table 2. From Table 2, it is proved that the valve manufactured by the method of the present invention has the same smoothness as that of the conventional example valve. The present invention is not limited to the embodiments stated in the above but many alternations and variations can be applied. For instance, if the method of the present invention is applied to a general machine for making a cylindrical shape such as a cylindrical grinder, etc., the utilization coefficient of the starting material can be greatly increased. Further, it would be possible to prevent to cause a crack on the surface of the product and thus it is expected to increase the yield. It should be noted that by dropping a wetting agent to the buff wheel 33 depending upon the kind of the work to be ground, the surface of the final product would become more smooth.

Claims: A method for manufacturing a ceramic product comprising: isostatically pressing a body of granulated powder to obtain a shaped green body (1) having an unevenness at an outer surface (1a) thereof; polishing the uneven outer surface (1a) to smooth it without removing the unevenness, and sintering the green body (1) to obtain the product. A method according to claim 1 in which the outer surface (1a) is not ground before the polishing. A method according to claim 1 in which the polishing removes 10 to 30 µm from the uneven surface (1a). A method according to claim 1 in which the outer surface (1a) has an outermost, granular layer (11) on an inner, compacted layer (12), and the polishing smooths but does not remove entirely the granular layer (11). A method according to any one of the preceding claims in which the polishing is done using a buffing member (3). A method according to claim 5 in which the buffing member (33) comprises non-woven nylon fabric. A method according to claim 5 in which the buffing member (33) comprises a wheel with a nylon brush around the wheel. A method according to claim 6 or claim 7 in which, during the polishing step, a wetting agent is used between the buffing member (33) and the green body (1). A method according to any one of the preceding claims in which the green body (1) is cylindrical. A method according to any one of the preceding claims in which the product is a translucent alumina lamp tube.

Inventors: DOI, JYUNICHI, HANZAWA, SHIGERU, SUZUKI, MITSUGU, TSUJI, AKIHIRO
Applicants: NGK INSULATORS, LTD.
Application year: 1990
Main classification: B28B3
IPC codes: C04B35, B24B29, B24B5, B28B11