Transparent Calcium Phosphate Structure With Low-Temperature Densification
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Solution Overview
Problem
Existing sintering methods for producing inorganic ceramic members require high temperatures, leading to high energy consumption and costs, and the resulting calcium phosphate transparent bodies may lack sufficient mechanical strength.
Innovation Solution
A structure composed of calcium phosphate crystal particles with an average size of 60 nm or less, coupled by a calcium phosphate compound, is produced under low-temperature conditions through pressurization and heating, achieving a relative density of 80% or more and a total light transmittance of 45% or more at 589 nm, with a Vickers hardness of 1 GPa or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sintering method is used to produce calcium phosphate transparent body, then mechanical strength is improved, but energy consumption and production cost increase due to high temperature heating
Solution Approach 1:
The invention changes the temperature parameter from high temperature sintering to low temperature drying process, and changes the state parameter from solid aggregate to gel structure, thereby reducing energy consumption while maintaining mechanical strength through the unique gel network formation
Solution Approach 2:
The invention utilizes phase transition of water from liquid to vapor during drying process, and the gelation process where sol transitions to gel, to form a dense structure without high temperature sintering, thus reducing energy consumption while achieving sufficient mechanical strength
2Strength
If sintering method is used to produce calcium phosphate transparent body, then mechanical strength is improved, but production cost increases due to high temperature heating
Solution Approach 1:
The invention changes the temperature parameter from high temperature sintering to low temperature drying process, and changes the state parameter from solid aggregate to gel structure, thereby reducing production cost while maintaining mechanical strength through the unique gel network formation
Solution Approach 2:
The invention uses inexpensive gelatin as a temporary binding agent that is removed during drying, replacing expensive high-temperature sintering processes, thereby reducing production cost while achieving sufficient mechanical strength
3Use of energy by moving object
If calcium phosphate transparent body is produced by drying dispersion at low temperature, then energy consumption is reduced, but mechanical strength may be insufficient
Solution Approach 1:
The invention uses gelatin as an intermediary substance that forms a gel network between calcium phosphate particles during low temperature drying, providing mechanical strength support without requiring high temperature sintering, thus achieving both low energy consumption and sufficient mechanical strength
Solution Approach 2:
The invention creates a composite structure where gelatin and calcium phosphate form a gel network together, combining the mechanical properties of gelatin with the structural integrity of calcium phosphate, achieving sufficient strength at low temperature
4Illumination intensity
If crystal particle size is reduced to 60 nm or less, then translucency is improved, but manufacturing complexity increases
Solution Approach 1:
The invention uses self-assembly of calcium phosphate particles within the gel network during drying, where particles automatically arrange themselves into a dense, uniform structure without requiring complex external control, achieving fine particle size distribution and high translucency with simple manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting structure exhibits excellent mechanical strength, translucency, and bioactivity, with enhanced light transmission and infrared shielding capabilities, while being produced at lower temperatures, reducing energy consumption and production costs.
Implementation Method 1
a step of pressurizing and heating a mixture for 20 minutes or longer and 12 hours or shorter under conditions where a pressure is 3000 MPa or less, and a temperature is 300°C or lower
Implementation Method 2
an aqueous solution containing calcium and phosphorus and having a pH of 4.0 or more
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A structure (1) includes: a plurality of crystal particles (2) including a calcium phosphate compound; and a coupling portion (3) that couples each of the crystal particles (2) and includes a calcium phosphate compound. An average particle size of the crystal particles (2) is 60 nm or less. A relative density of the structure (1) is 80% or more. When a thickness of the structure (1) is 1 mm, a total light transmittance of light having a wavelength of 589 nm is 45% or more. A Vickers hardness of the structure (1) is 1 GPa or more.