# US 12,767,600 B2 · Powder for ceramic shaping, method of manufacturing ceramic shaped object, ceramic shaped object, and device

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- Number: US 12,767,600 B2
- Document ID: US12767600B2
- Status: Granted
- Kind: B2
- Application number: 18/636,418
- Filed: 2024-04-16
- Published: 2024-10-31
- Granted: 2026-10-20
- Earliest claimed: 2023-04-28
- Assignees: Canon Kabushiki Kaisha
- Applicants: Canon Kabushiki Kaisha
- Inventors: Naoyuki Koketsu; Nobuhiro Yasui; Takuya Yoshioka; Chiaki Arii; Yasuhiro Sekine
- Web page: https://patentgrep.com/patent/US12767600B2

## CPC

- C04B 35/4885: {with aluminium oxide}
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- C04B 35/488: Composites
- C04B 35/62813: {Alumina or aluminates}
- C04B 35/62892: {with a coating layer consisting of particles}
- C04B 35/64: Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F})
- C04B 35/653: Processes involving a melting step
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3246: Stabilised zirconias, e.g. YSZ or cerium stabilised zirconia
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/6026: Computer aided shaping, e.g. rapid prototyping
- C04B 2235/616: Liquid infiltration of green bodies or pre-forms
- C04B 2235/656: characterised by specific heating conditions during heat treatment
- C04B 2235/661: Multi-step sintering
- C04B 2235/665: Local sintering, e.g. laser sintering
- C04B 2235/94: Products characterised by their shape
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

## Abstract

Provided is a powder for ceramic shaping including oxide particles, wherein the oxide particles each contain a plurality of kinds of elements including at least Zr, Y, Si, and optionally Al, and contain at least silicon monoxide particles, and wherein when a content of the Zr is converted into a mass of ZrO2, a content of the Y is converted into a mass of Y2O3, a content of the Si is converted into a mass of SiO2, and a content of the Al is converted into a mass of Al2O3, the mass of ZrO2, the mass of Y2O3, and the mass of SiO2 with respect to a total amount of the mass of ZrO2, the mass of Y2O3, the mass of SiO2, and the mass of Al2O3 are represented by α (mass %), β (mass %), and γ (mass %), respectively, α, β, and γ satisfy the following expressions. 7 ⁢ 7 . 6 ⁢ 4 ≤ α ≤ 93.06 4.42 ≤ β ≤ 6.49 0.72 ≤ γ < ¯ 1 ⁢ 7 . 2 ⁢ 9

## Claims

### Claim 1

A powder for ceramic shaping to be used in an additive manufacturing method involving performing shaping through irradiation with laser light, the powder for ceramic shaping comprising oxide particles,
wherein the oxide particles each contain a plurality of elements including at least Zr, Y, Si, and optionally Al, and contain at least silicon monoxide particles, and
wherein when a content of the Zr is converted into a mass of ZrO2, a content of the Y is converted into a mass of Y2O3, a content of the Si is converted into a mass of SiO2, and a content of the Al is converted into a mass of Al2O3, the mass of ZrO2, the mass of Y2O3, and the mass of SiO2 with respect to a total amount of the mass of ZrO2, the mass of Y2O3, the mass of SiO2, and the mass of Al2O3 are represented by α (mass %), β (mass %), and γ (mass %), respectively, α, β, and γ satisfy expressions:
7
⁢
7
.
6
⁢
4
≤
α
≤
93.06
4.42
≤
β
≤
6
.
4
⁢
9
0.72
≤
γ
<
¯
1
⁢
7
⁢
.29
.

### Claim 2 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the oxide particles contain silicon dioxide particles.

### Claim 3 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the oxide particles contain yttria-stabilized zirconia particles.

### Claim 4 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein when the silicon monoxide particles each do not contain a region except for silicon monoxide, an average particle size of particles except for the silicon monoxide particles out of the oxide particles is 10 μm to 200 μm, and is larger than an average particle size of the silicon monoxide particles.

### Claim 5 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein when the silicon monoxide particles each do not contain a region except for silicon monoxide, an average particle size of the silicon monoxide particles is 1 μm to 10 μm, and is ⅕ or less of an average particle size of particles except for the silicon monoxide particles out of the oxide particles.

### Claim 6 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein when the silicon monoxide particles each include a region except for silicon monoxide, an average particle size of the silicon monoxide particles is 5 μm to 200 μm.

### Claim 7 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the oxide particles contain alumina-added yttria-stabilized zirconia particles.

### Claim 8 (depends on 1)

The powder for ceramic shaping according to claim 1,
wherein the oxide particles each contain Al, and
wherein when the mass of Al2O3 with respect to the total amount of the mass of ZrO2, the mass of Y2O3, the mass of SiO2, and the mass of Al2O3 is represented by δ (mass %), δ satisfies expressions:
0.21
≤
δ
≤
9
⁢
.17
.

### Claim 9 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein a content of the silicon monoxide particles in the oxide particles is 0.5 vol % to 53 vol %.

### Claim 10 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the powder for ceramic shaping has a fluidity index of 40 (sec/50 g) or less.

### Claim 11 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the powder for ceramic shaping does not contain a resin binder.

### Claim 12 (depends on 1)

The powder for ceramic shaping according to claim 1, wherein the powder for ceramic shaping does not contain elemental carbon.