Aluminum-containing oxide and process for producing aluminum-con

Details Aluminum-containing oxide and process for producing aluminum-con Aluminum-containing oxide and process for producing aluminum-con

1991-11-22

1995-05-09

Lieberman, Paul

Compositions: ceramic

Ceramic compositions

Aluminum compound containing

501154, 501127, 501128, 502354, 502205, 502202, 502249, 502324, 502352, 502242, 502335, 502336, 423600, 423593, C04B 3510, C04B 3560, B01J 2104, B01J 2318

Patent

active

054139740

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to an aluminum-containing oxide for use as a machine part, an electronic part such as an electronic circuit substrate or a cerdip package, a catalyst, a catalyst support, a sensor, an adsorbent, and a filler for chromatography, a molded article obtained by molding the aluminum-containing oxide, an article obtained by subjecting the molded article to heat treatment, and a process for producing the aluminum-containing oxide.


TECHNICAL BACKGROUND

A conventional molded article of an aluminum-containing oxide is obtained by adding an organic compound or an inorganic compound as a binder to an alumina powder and molding the resultant mixture. A machine part or an electronic part of aluminum-containing oxide is produced by further subjecting the molded article to a sintering treatment at a high temperature of 1,400.degree. C. or higher (For example, see the Supplement to Kogyo Zairyo (Industrial Materials), November 1987, on a process for producing an alumina substrate as one example of molded articles of an aluminum-containing oxide, issued by Nikkan Kogyo Shinbunsha). As a conventional process for producing an aluminum oxide powder, there is available a method in which alumina produced by a Bayer method is milled, a method in which aluminum hydroxide obtained from an aluminum compound by a coprecipitation method is ignited and then milled, a CVD method (gaseous phase reaction deposition method) in which an alumina oxide powder is synthesized in a gaseous phase from a special aluminum compound having a volatility.
In a conventional method for producing a molded article from an aluminum oxide powder, an article obtained by adding an organic compound or an inorganic compound as a binder to an aluminum oxide powder and molding the resultant mixture is required to be treated at a high temperature of 1,400.degree. C. or higher as described above. On the other hand, when an aluminum powder is molded without a binder, it is required to mold it at a high temperature of 1,100.degree. C. or higher, or to employ a means such as a hot-press, etc.
In other conventional methods for producing aluminum oxides, such as the Bayer method, the method of igniting aluminum hydroxide, etc., it is burdensome to remove harmful impurities, and the finely milling step is complicated. Furthermore, aluminum oxides obtained by these methods are usually crystalline. A sputtering method of a CVD method is known to be a method for obtaining an amorphous aluminum oxide. However, the handling of a raw material or the production process according to that method is complicated and troublesome.


DISCLOSURE OF THE INVENTION

With regard to a process for producing a molded article from an aluminum oxide powder, the present inventors have made a diligent study for a process for producing a molded article at a low temperature. As a result, it has been found that a novel aluminum-containing oxide powder having a composition containing a trace amount of bismuth is effective for producing a molded article at a low temperature, and that the above novel powder can be easily produced by rapidly cooling a melt of an aluminum metal to which a trace amount of bismuth metal has been incorporated to coagulate the melt and then oxidizing the coagulation product. On the basis of this finding, the present invention has been completed. That is, it is an object of the present invention to provide a substantially amorphous, aluminum-containing oxide having a composition Al.sub.1-x-y1-y2 Bi.sub.x M.sub.1y1 M.sub.2y2 O.sub.z (wherein x is defined by 0.0001.ltoreq.x.ltoreq.0.10, M.sub.1 is at least one selected from Si, P, B, Sb, Se, Te, Sn, Zn, In, Cr, Nb, Sc, Y, Sr, Ba, Ca, Na, Li, Mg, Mn, W, Ti, Zr, Hf, Be and rare earth metals, M.sub.2 is at least one selected from Fe, Ni, Co, Rh, Ru, Re, Cu and Pb, y1 is defined by 0.ltoreq.y1.ltoreq.0.1, y2 is defined by 0.ltoreq.y2.ltoreq.0.01, z is defined by 1.2.ltoreq.z.ltoreq.1.5, and x, y1, y2 and z are each an atomic ratio), a metal composition containing a trace amount of bis

REFERENCES:
patent: 4344926 (1982-08-01), Petty et al.
Chemical Abstracts, CA 110(14):126938v (1988) no month available.
Chemical Abstracts, CA 90(8):61943q (1978) no month available.
Chemical Abstracts, CA 88(22):162169f (1978) no month available.
Chemical Abstracts, CA 83(10):89325u (1975) no month available.

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