CN104350026B - 通过水合氧化铝的量对陶瓷结构进行尺度控制 - Google Patents
通过水合氧化铝的量对陶瓷结构进行尺度控制 Download PDFInfo
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- CN104350026B CN104350026B CN201380021443.2A CN201380021443A CN104350026B CN 104350026 B CN104350026 B CN 104350026B CN 201380021443 A CN201380021443 A CN 201380021443A CN 104350026 B CN104350026 B CN 104350026B
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Abstract
本文揭示了通过调节批料组合物的水合氧化铝含量,对陶瓷蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长进行控制和/或预测的方法。还揭示了根据此类方法生产的基本不含粘土的堇青石蜂窝体。
Description
发明领域
本申请根据35 U.S.C.§119,要求2012年2月29日提交的美国临时申请系列第61/604715号的优先权,本文以该申请为基础并将其全文通过引用结合于此。
本发明涉及对陶瓷结构,例如生坯体状态和经烧制的状态之间的收缩和/或生长进行控制的方法。示例性方法可包括调节批料组合物的水合氧化铝的含量。还揭示了使用此类方法获得的组合物和产物。
背景
陶瓷结构,包括基材,可用于各种应用。作为非限制性例子,陶瓷蜂窝结构或陶瓷蜂窝体可选择性地堵塞并用于柴油颗粒过滤器(“DPF”)、膜分离和流通式催化转化器。但是,可靠地生产挤出-成形陶瓷蜂窝结构的能力通常取决于使得生产变化性最小化的能力,例如在烧制和/或干燥过程中,陶瓷蜂窝结构收缩或生长的程度。因为可以将陶瓷蜂窝结构放置在外壳中,例如当用作DPF时,因此对于蜂窝体的形状和/或尺寸具有各种规格。例如,某些应用可能要求蜂窝结构在烧制和/或干燥之后的收缩或生长相对于目标值变化不超过±0.5%,从而确保能够将最终产物装入特定的外壳中。在其他示例性应用中,相对于目标值变化不能超过约±0.3%。
已经采用了数种不同的方法来控制烧制过程中陶瓷的收缩和/或生长,例如,批料组成变化、原材料选矿、烧制工艺变化以及烧制的成品切割结合人工长皮。但是,工业中仍然需要提供额外的方法来控制陶瓷结构(例如陶瓷体)的收缩和/或生长,特别是在生坯体状态和经烧制的状态之间。具体来说,需要方法来控制组成并非常规堇青石的陶瓷结构(例如,基本不含粘土的堇青石蜂窝体)的收缩和/或生长。
概述
在各个实施方式中,本发明涉及通过调节批料组合物的水合氧化铝含量来对陶瓷蜂窝结构的收缩和/或生长进行预测和/或控制的方法。在某些实施方式中,所揭示的方法可用于对基本不含粘土的堇青石蜂窝体的收缩和/或生长进行控制和/或预测。
在某些实施方式中,对生坯体状态和经烧制的状态之间的陶瓷蜂窝结构的收缩和/或生长进行控制的方法包括以下步骤:(a)提供适合制造陶瓷蜂窝结构的批料组合物;(b)将批料组合物挤出成生坯蜂窝结构;(c)测量生坯蜂窝结构的尺度;(d)对生坯蜂窝结构进行烧制;(e)测量烧制的蜂窝结构的尺度;(f)确定烧制的蜂窝结构相比于生坯蜂窝结构的收缩或生长;(g)通过向批料组合物中加入选定量的至少一种水合氧化铝,来调节组合物的水合氧化铝的含量;以及(h)根据需要重复步骤(a)至(g),以获得生坯体和经烧制的状态之间的所需水平的收缩或生长。
在其他实施方式中,对生坯体状态和经烧制的状态之间的陶瓷蜂窝结构的收缩和/或生长进行控制的方法包括以下步骤:(a)提供适合制造陶瓷蜂窝结构的批料组合物;(b)分析批料组合物的水合氧化铝含量;(c)通过向批料组合物中加入预定量的至少一种水合氧化铝,来调节批料组合物的水合氧化铝的含量;(d)将经调节的批料组合物挤出成生坯蜂窝结构;(e)测量生坯蜂窝结构的尺度;(f)对生坯蜂窝结构进行烧制;(g)测量烧制的蜂窝结构的尺度;(h)确定烧制的蜂窝结构相比于生坯蜂窝结构的收缩或生长;以及(i)根据需要重复步骤(b)至(h),以获得生坯体和经烧制的状态之间的所需水平的收缩或生长。
在其他实施方式中,制造陶瓷蜂窝结构的方法包括以下步骤:(a)提供适合制造陶瓷蜂窝结构的批料组合物;(b)通过加入至少一种水合氧化铝,来调节批料组合物的水合氧化铝的含量,相对于批料组合物的总重量,所述至少一种水合氧化铝的添加量最高至约50重量%;(c)将经调节的批料组合物挤出成生坯蜂窝结构;以及(d)对生坯蜂窝结构进行烧制。根据各个实施方式,可以调节批料组合物的水合氧化铝的含量,使得以批料组合物的总重量计,水合氧化铝贡献最高至约50%的总化学计量的氧化铝。
本发明的其他实施方式还涉及用于陶瓷蜂窝结构的组合物,其中所述组合物包含添加的水合氧化铝。作为非限制性的例子,本文所揭示的是这样一种堇青石蜂窝体,使得以批料组合物的总重量计,所述堇青石蜂窝体的水合氧化铝含量贡献了最高至约32%的总化学计量的氧化铝,其中所述批料组合物基本不含粘土。
附图简要说明
可单独通过以下详述或通过以下详述并结合附图理解本发明。包括的附图提供了对本发明的进一步理解,附图被结合在本说明书中并构成说明书的一部分。附图显示了一个或多个示例性的实施方式,与描述一起用来解释各种原理和操作。
图1显示根据本发明的示例性实施方式,两种基本不含粘土的堇青石组合物从生坯体(模)状态到经烧制的状态的轮廓收缩与水合氧化铝含量的关系。
具体实施方式
在各个实施方式中,本发明涉及通过调节批料组合物的水合氧化铝含量,对陶瓷蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长进行控制的方法。
根据各个实施方式,可以通过调节批料组合物的水合氧化铝含量,对基本不含粘土的堇青石蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长进行控制和/预测。例如,需要的话,可以增加或降低批料组合物中存在的水合氧化铝(如勃姆石或三水合铝)的量,以实现所需的收缩或生长水平。
术语“生坯体状态”、“生坯蜂窝体”、“生坯蜂窝结构”以及它们的其他变形在本文中可互换地使用,以表示未烧制的、未反应的前体组合物,所述未烧制的、未反应的前体组合物经过混合和/或塑化和/或挤出。生坯体可任选地干燥,但是没有经过煅烧、烧结或任意其他反应性烧制过程。
术语“经烧制的状态”、“经烧制的蜂窝体”、“经烧制的蜂窝结构”以及它们的其他变形在本文中可互换地使用,以表示这样一种陶瓷制品,其在有效地将前体组合物转变成包含烧结相的陶瓷组合物的条件下进行过烧制。陶瓷制品在烧制过程中可任选地经受煅烧。
可以从蜂窝体挤出的时间到蜂窝体烧制以产生陶瓷的时间来测量蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长。或者,可以从蜂窝体挤出且基本干燥的时间到蜂窝体烧制以产生陶瓷的时间来测量蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长。
术语“批料组合物”、“前体组合物”以及它们的变形在本文中可互换地使用,以表示包含至少一种无机陶瓷成形组分的基本均质的混合物。在本发明的各个示例性实施方式中,所述至少一种无机陶瓷成形组分可选自适合形成所需的陶瓷组合物的任意组分,例如,氧化铝源、氧化硅源和氧化镁源。在某些实施方式中,至少一种无机陶瓷成形组分可以是反应性粉末的形式。
示例性的氧化铝源包括但不限于,在单独存在或存在其他材料的情况下,当加热至足够高的温度时,会产生氧化铝的材料。合适的氧化铝源的非限制性例子包括α-氧化铝;过渡型氧化铝,例如γ-氧化铝、θ-氧化铝、-氧化铝和ρ-氧化铝;水合氧化铝;水铝矿;刚玉;勃姆石;假勃姆石;氢氧化铝;羟基氧化铝;水铝石;及其混合物。
示例性的氧化硅源包括但不限于,非晶体氧化硅,例如稠合氧化硅和溶胶凝胶氧化硅;晶体氧化硅,例如沸石、石英和方石英;硅酮树脂;硅藻土;高岭土;滑石;以及多铝红柱石。在其他实施方式中,氧化硅源可选自包含至少一种当加热时形成游离氧化硅的化合物的氧化硅形成源,所述化合物是例如,硅酸和硅酮有机金属化合物。
氧化镁源包括但不限于,滑石、菱镁矿(MgCO3)以及在单独存在或者在存在其他材料的情况下,当加热至足够高的温度时,会产生氧化镁的任意材料。
在各个实施方式中,可以对批料组合物进行选择,从而基本不含粘土。在此类实施方式中,批料组合物可基本不含粘土,如高岭土。基本不含粘土的堇青石结构的制备参见例如美国专利第7,704,296号以及美国专利申请公开第2009/0220736号所述,其全文通过引用结合入本文。根据各个示例性实施方式,批料组合物可包含小于约1重量%的粘土,例如小于约0.5重量%的粘土,或者小于约0.1重量%的粘土。
根据本发明的各个示例性实施方式,批料混合物还可包含至少一种额外的无机材料,例如氧化物(如氧化镧)、碳酸盐(如碳酸钙和碳酸锶)、硝酸盐和氢氧化物。在至少一个实施方式中,所述至少一种额外的无机材料可选自形成玻璃的金属氧化物,例如氧化钇、氧化镧、氧化钡、氧化钠、氧化钾、氧化锂、氧化钙、铁氧化物、氧化硼和磷氧化物。这些氧化物可作为氧化物、碳酸盐、硝酸盐、氢氧化物或者具有一种其他或具有至少一种氧化物(其选自二氧化钛、铝氧化物、二氧化硅、氧化钙、氧化锶和氧化镧)的多组分化合物添加。在某些实施方式中,形成玻璃的金属氧化物可以是能够在溶剂中形成胶状悬浮物的胶状金属氧化物。根据一个实施方式,批料组合物中存在的形成玻璃的金属氧化物的量可以是至少约3重量%,例如至少约5重量%,至少约10重量%,或者约3-50重量%,例如约10-50重量%。
在各个示例性实施方式中,批料组合物可包含至少一种其他已知的可用于制造批料材料的组分。例如,批料组合物还可包含至少一种选自粘结剂、溶剂、表面活性剂、润滑剂和成孔剂的额外组分。
如果需要的话,本领域技术人员能够选择一种或多种合适的粘结剂。仅举例来说,所述至少一种粘结剂可以选自有机粘结剂(如含纤维素的组分),例如甲基纤维素、羟基丙基甲基纤维素、甲基纤维素衍生物,及其组合。在某些非限制性实施方式中,批料组合物中存在的粘结剂的量可以是约为1-10重量%,例如约2-6重量%,或者约3-5重量%。
如果需要的话,本领域技术人员也能够选择合适的溶剂。溶剂可用于,例如对无机陶瓷成形粉末进行润湿和/或提供使得粘结剂溶解的介质,从而为批料组合物提供塑性。在各个示例性实施方式中,所述至少一种溶剂可以是水性的,例如水或者水可混溶溶剂,或者无机的,或其部分组合。在至少一个示例性实施方式中,溶剂包括水,例如去离子水。根据各个非限制性实施方式,批料组合物中存在的溶剂的量约为20-50重量%,例如约25-40重量%,或者约30-35重量%。
批料组合物还可任选地包含至少一种表面活性剂。可用于根据本发明的各个实施方式的表面活性剂的非限制性例子包括C8-C22脂肪酸及其衍生物;C8-C22脂肪酯及其衍生物;C8-C22脂肪醇及其衍生物;及其组合。在某些示例性实施方式中,所述至少一种表面活性剂可选自:硬脂酸、月桂酸、油酸、亚油酸、棕榈油酸、月桂基硫酸铵,以及它们的衍生物,及其组合。根据某些非限制性实施方式,批料组合物中存在的至少一种表面活性剂的量约为0.5-2重量%,例如约1重量%。
批料组合物还可任选地包含至少一种润滑剂。例如,批料组合物可包含至少一种油性润滑剂,其选自:轻质矿物油、玉米油、高分子量聚丁烯、多元醇酯、轻质矿物油和蜡乳液的掺混物、石蜡的玉米油的掺混物,及其组合。在某些实施方式中,批料组合物中存在的至少一种润滑剂的量可以是约为1-10重量%,例如约3-6重量%,或者约4-5重量%。
根据各个实施方式,批料组合物还可包含至少一种成孔剂。合适的成孔剂包括任意颗粒物质,其在烧制过程中从生坯体烧掉,以在经烧制的陶瓷中产生孔。成孔剂的例子包括但不限于,碳成孔剂,例如石墨、活性碳、石油焦炭和炭黑;淀粉成孔剂,例如玉米、大麦、豆、土豆米、木薯、豌豆、西谷叶纤维、小麦、美人蕉和胡桃壳粉;聚合物成孔剂,例如聚丁烯、聚甲基戊烯、聚乙烯、聚丙烯、聚苯乙烯、聚酰胺(尼龙)、环氧化物、ABS、丙烯酸类和聚酯(PET),及其组合。根据至少一个实施方式,所述至少一种成孔剂选自碳成孔剂(例如石墨)和淀粉成孔剂(例如稻米、西谷叶纤维和土豆)。在各个非限制性实施方式中,批料组合物中存在的至少一种成孔剂的量约为5-30重量%,例如约15-30重量%,或者约20-25重量%。
可以采用本领域已知的任意方法对批料材料进行混合以获得基本均质的批料组合物。例如,所述至少一种无机陶瓷成形材料可以是用如下至少一种组分进行润湿的粉末,所述至少一种组分选自溶剂、粘结剂及其组合。溶剂和/或粘结剂可以以适合对批料进行润湿和/或塑化的任意量加入。可以在任意合适的混合机中对批料进行混合和/或塑化,在所述混合机中批料会发生塑化。例如,可以使用螺条混合机、双螺杆挤出机/混合机、螺旋混合机、研磨混合机或者双臂混合机。
根据本发明的各个实施方式,水合氧化铝可选自勃姆石(AlOOH)和三水合铝(Al(OH)3)。可以通过向批料材料中加入选定量的水合氧化铝来调节批料材料的水合氧化铝含量,例如在进行了水合氧化铝含量的分析之后和/或确定了蜂窝体从生坯状态到经烧制的状态的收缩之后。对于任意给定的批料材料,可以构建收缩与水合氧化铝含量的关系图。可以通过实验地操纵批料材料的水合氧化铝的含量,以在图上产生变化间隔的数据点,来产生该图。对于各数据点,批料材料可以挤出以形成蜂窝结构,在生坯体状态进行测量,采用选定的烧制循环进行烧制,并在经烧制的状态进行测量。因此,对于任意给定的水合氧化铝含量可以得到收缩值,并可采用这些数据点产生图。此类图的非限制性例子如图1所示。一旦对于给定的批料材料和烧制循环获得了收缩和水合氧化铝含量之间的线性关系,则可以产生出于预测建模目的的调整系数。使用这些系数,可以在烧制之前和/或之后调节批料的水合氧化铝的含量,以实现所需的收缩水平。
例如,在一个示例性实施方式中,采用从例如图1的图所产生的系数,可以对用于形成批料组合物的原材料进行预先分析,以确定批料组合物的水合氧化铝的含量。使用该分析结果,然后可以基于预测建模,将水合氧化铝的含量向上或向下调节至所需的量,以实现所需的水合氧化铝含量和/或收缩水平。然后可以从经调节的批料组合物产生生坯蜂窝体,并烧制以产生陶瓷蜂窝体。然后可以对所得到的陶瓷蜂窝体进行测量,以证实获得了预定的收缩量。如果收缩过高或高低,则需要的话可以通过增加或降低水合氧化铝的量,来对批料组合物进行进一步调节,以实现所需的收缩量。
在另一个示例性实施方式中,可以将批料组合物挤出成生坯蜂窝体、烧制,并分析收缩。随后,可以采用预测建模向上或向下调节批料组合物的水合氧化铝含量,以实现所需的收缩水平。然后可以对从经调节的批料组合物产生的陶瓷蜂窝体的尺度进行测量,以证实获得了适当的收缩。如果收缩过高或高低,则需要的话可以通过增加或降低水合氧化铝的量,来对批料组合物进行进一步调节,以实现所需的收缩量。
可以通过例如,向组合物加入额外的水合氧化铝,来增加批料组合物的水合氧化铝的含量。例如,可以向批料组合物中加入勃姆石或三水合铝,直至实现了所需的水合氧化铝含量。在另一个实施方式中,可以向批料组合物中加入具有高水合氧化铝含量的材料,直至实现了所需的水合氧化铝含量。类似地,可以通过例如,加入具有低水合氧化铝含量的材料,直至实现了所需的水合氧化铝含量,来降低批料的水合氧化铝的含量。本领域技术人员能够做出此类调节同时对批料组合物中存在的其他组分进行适当补偿。
根据至少某些示例性实施方式,可以对水合氧化铝含量进行调节,从而使得组合物中的所有水合氧化铝的量最高至约为50重量%,例如约1-32重量%,或者约2-16重量%。例如,可以对批料组合物进行调节,从而使得水合氧化铝贡献最高至约50%的总化学计量的氧化铝,以批料组合物的总重量计,例如约为1-32%,或者约为2-16%。在一个非限制性例子中,可以对基本不含粘土的堇青石组合物进行调节,从而使得水合氧化铝贡献最高至约32%的总化学计量的氧化铝,以批料组合物的总重量计。在另一个示例性实施方式中,可以对基本不含粘土的堇青石批料组合物进行调节,从而使得批料组合物中存在的基本所有的氧化铝都是由水合氧化铝贡献的。
在各个实施方式中,可以通过本领域技术人员已知的用于成形塑化混合物的任意方法,将批料组合物成形为生坯蜂窝体。例如,批料组合物可以经受注塑、挤出、粉浆浇铸、离心浇铸、压力浇铸或者干压制。
可以对批料组合物进行垂直或水平挤出,并且挤出机可任选地采用模头。在一些示例性的实施方式中,挤出可以使用液压油缸挤出压机,或两段排气单钻挤出机或双螺杆混合机(在出料端连接有模头组件)进行。可以根据批料材料和其他工艺条件来选择合适的螺杆元件,从而积累足够的压力,以迫使批料组合物通过模头。
通过挤出批料组合物,可以获得具有多个被分隔或壁相互分开的孔道的蜂窝体。在各个实施方式中,可以选择特定的模头,从而使得蜂窝体具有所需的孔道形状、壁厚和/或孔道密度。
可任选地通过本领域技术人员已知的任意常规方法对生坯蜂窝体进行干燥,以形成生坯蜂窝体。例如,可以采用热空气干燥、介电干燥、微波干燥、减压干燥、真空干燥或者冷冻干燥,对生坯蜂窝体进行干燥。
在各种示例性实施方式中,随后可以对生坯蜂窝体进行烧制,以形成陶瓷蜂窝体。本领域技术人员能够确定用于形成陶瓷蜂窝体的合适的方法和条件,例如烧制条件,包括设备、温度和持续时间。此类方法和条件可取决于,例如,生坯体的尺寸和组成,以及陶瓷蜂窝体所需的性质。
生坯蜂窝体可以在选定的温度下,在合适的气氛中烧制一段时间,这取决于生坯蜂窝体的组成、尺寸和几何形貌。例如,进行烧制的温度范围可以约为1300℃至1450℃,烧制时间可以约为1-200小时,例如约3-100小时,或者约20-50小时。
任选地,可以对生坯蜂窝体进行煅烧以烧掉任选的成孔剂、粘结剂和/或表面活性剂,这可以在烧制之前或者在烧制期间的温度上升过程中。例如,粘结剂可具有约200℃的燃烧温度,成孔剂可具有约300-1000℃的燃烧温度。因此,进行煅烧的温度范围可以约为200-1000℃,煅烧时间可以约为10-100小时。
可以使用本领域已知的任意常规方法对生坯蜂窝体和/或经烧制的蜂窝体的尺度进行测量。例如,在一些实施方式中,可以测量蜂窝体的直径。在其他实施方式中,可以测量蜂窝体的半径、高度和/或总体积。
可以采用例如如下等式,来确定蜂窝体从生坯状态到经烧制的状态的收缩和/或生长:
收缩%=([生坯尺寸]-[经烧制的尺寸])/(生坯尺寸)
其中,“尺寸”是上述测量的尺度之一,例如蜂窝体直径或高度。
应理解,上文的描述和下文的实施例只是示例性和说明性的,不构成对要求保护的本发明的限制。此外,还应理解的是,本文的不同实施方式的各个特征和/或特性可相互结合。因此,应当理解,在不背离本发明的范围的前提下,可以对列举的实施方式进行各种修改,并且可以设计其他实现形式。本领域的技术人员通过考虑说明书和实施本文所述的各种示例性实施方式,可以显而易见地想到其他的实施方式。
还应理解的是,本文所用的冠词“该”、“一个”或“一种”表示“至少一个(一种)”,不应局限为“仅一个(一种)”,除非明确有相反的说明。因此,例如,“一种成孔剂”的用法意指至少一种成孔剂。
除非另有说明,否则,本说明书和权利要求书中使用的所有数字均应理解为在所有情况下都受“约”字修饰,而不管有没有这样表述。还应理解,本说明书和权利要求书中使用的精确数值构成本发明另外的实施方式,并用于包括可通过提供的示例范围和值之中公开的任意两个端点窄化的任意范围。发明人已尽力确保实施例中所披露的数值的精确度。然而,由于相应的测量技术中存在标准偏差,任何测得的数值都可能不可避免地包含一定的误差。
实施例
采用包含勃姆石以及(a)细的滑石、不含粘土堇青石或者(b)粗的滑石、不含粘土的堇青石的批料材料来制备数种生坯蜂窝体。对生坯蜂窝体进行测量,然后干燥和烧制,从而将生坯蜂窝体转化成陶瓷蜂窝体。测量并记录生坯体在干燥和烧制过程中的收缩。结果示于下表I中。
表I
细的滑石和粗的滑石蜂窝体的轮廓收缩(模头至经烧制)与水合氧化铝(勃姆石)含量的关系图如图1所示。令人惊讶的发现,蜂窝体在生坯体和经烧制的状态之间的轮廓收缩线性地对应于批料材料中存在的水合氧化铝的量。具体地,随着批料材料中存在的勃姆石的量的增加,轮廓的收缩量也增加。
采用例如如图1所示的附图,可以产生用于给定批料组合物和烧制循环的调整系数。使用这些系数,可以通过对由批料组合物产生的陶瓷蜂窝体进行尺度测量来进行过程测量。如果收缩过低(即,蜂窝体大于所需的情况),则可以调节水合氧化铝的含量(即增加),以增加收缩量。例如,可以向批料组合物中加入额外的勃姆石和/或三水合铝,同时对于其他组分进行适当的补偿。如果收缩过高(即,蜂窝体小于所需的情况),则可以调节水合氧化铝的含量(即降低),以降低收缩量。然后可以对从经调节的批料组合物产生的陶瓷蜂窝体的尺度进行测量,以证实获得了适当的收缩。或者,采用例如图1的图所产生的系数,可以对批料组合物的水合氧化铝含量进行预先分析,并根据需要进行调节以实现所需的收缩水平。然后可以从经调节的批料组合物产生生坯蜂窝体,并烧制以产生陶瓷蜂窝体。然后可以对所得到的陶瓷蜂窝体进行测量,以证实获得了预测的收缩量。如果收缩过高或高低,则需要的话可以通过增加或降低水合氧化铝的量,来对批料组合物进行进一步调节,以实现所需的收缩量。
Claims (21)
1.一种对陶瓷蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长进行控制的方法,所述方法包括:
(a)提供包含水合氧化铝含量并适合制造陶瓷蜂窝结构的批料组合物;
(b)将所述批料混合物挤出成生坯蜂窝结构;
(c)测量生坯蜂窝结构的尺度;
(d)对生坯蜂窝结构进行烧制;
(e)测量烧制的蜂窝结构的尺度;
(f)确定烧制的蜂窝结构相比于生坯蜂窝结构的收缩或生长,并基于所述收缩或生长与所述批料组合物的水合氧化铝含量之间的关联来选择所述批料组合物所需的水合氧化铝含量;
(g)通过向批料组合物中加入选定量的至少一种水合氧化铝,来调节组合物的水合氧化铝的含量;以及
(h)根据需要重复步骤(a)至(g),以获得生坯体和经烧制的状态之间的所需水平的收缩或生长。
2.如权利要求1所述的方法,其特征在于,所述批料组合物是基本不含粘土的堇青石组合物。
3.如权利要求2所述的方法,其特征在于,所述批料组合物包括氧化硅源、氧化铝源、镁源或其组合中的至少一种。
4.如权利要求3所述的方法,其特征在于,所述批料组合物还包含至少一种形成玻璃的金属氧化物源。
5.如权利要求4所述的方法,其特征在于,所述至少一种形成玻璃的金属氧化物源包括钇源、镧源或其组合。
6.如权利要求4所述的方法,其特征在于,所述至少一种形成玻璃的金属氧化物源包括钙源、钾源、钠源、锂源、铁源或其组合中的至少一种。
7.如权利要求1所述的方法,其特征在于,所述至少一种水合氧化铝选自勃姆石和三水合铝。
8.如权利要求1所述的方法,其特征在于,加入到批料组合物中的所述至少一种水合氧化铝的量最高至约为50重量%,相对于批料组合物的总重量。
9.如权利要求1所述的方法,其特征在于,所述调节组合物的水合氧化铝的含量包括:
通过加入至少一种水合氧化铝,来调节批料组合物的水合氧化铝的含量以实现所需的收缩水平,相对于批料组合物的总重量,所述至少一种水合氧化铝的添加量为1-32重量%。
10.一种对陶瓷蜂窝结构在生坯体状态和经烧制的状态之间的收缩和/或生长进行控制的方法,所述方法包括:
(a)提供包含水合氧化铝含量并适合制造陶瓷蜂窝结构的批料组合物;
(b)分析批料组合物的水合氧化铝含量;
(c)通过向批料组合物中加入预定量的至少一种水合氧化铝,来调节批料组合物的水合氧化铝的含量;
(d)将经调节的批料组合物挤出成生坯蜂窝结构;
(e)测量生坯蜂窝结构的尺度;
(f)对生坯蜂窝结构进行烧制;
(g)测量烧制的蜂窝结构的尺度;
(h)确定烧制的蜂窝结构相比于生坯蜂窝结构的收缩或生长,并基于所述收缩或生长与所述批料组合物的水合氧化铝含量之间的关联来选择所述批料组合物所需的水合氧化铝含量;以及
(i)根据需要重复步骤(b)至(h),以获得生坯体和经烧制的状态之间的所需水平的收缩或生长。
11.如权利要求10所述的方法,其特征在于,所述批料组合物是基本不含粘土的堇青石组合物。
12.如权利要求11所述的方法,其特征在于,所述批料组合物包括氧化硅源、氧化铝源、镁源或其组合中的至少一种。
13.如权利要求10所述的方法,其特征在于,所述批料组合物还包含至少一种形成玻璃的金属氧化物源。
14.如权利要求13所述的方法,其特征在于,所述至少一种形成玻璃的金属氧化物源包括钇源、镧源或其组合。
15.如权利要求13所述的方法,其特征在于,所述至少一种形成玻璃的金属氧化物源包括钙源、钾源、钠源、锂源、铁源或其组合中的至少一种。
16.如权利要求10所述的方法,其特征在于,所述水合氧化铝选自勃姆石和三水合铝。
17.如权利要求10所述的方法,其特征在于,加入到批料组合物中的所述至少一种水合氧化铝的量最高至约为50重量%,相对于批料组合物的总重量。
18.一种通过权利要求9的方法制备的堇青石蜂窝体,以批料组合物的总重量计,所述堇青石蜂窝体的水合氧化铝含量为1-32重量%以实现所需的收缩水平,从而贡献了最高至约32%的总化学计量的氧化铝,其中所述批料组合物基本不含粘土。
19.如权利要求18所述的堇青石蜂窝体,其特征在于,所述批料组合物包括氧化硅源、氧化铝源、镁源或其组合中的至少一种。
20.如权利要求18所述的堇青石蜂窝体,其特征在于,所述批料组合物还包含至少一种形成玻璃的金属氧化物源。
21.如权利要求18所述的堇青石蜂窝体,其特征在于,所述水合氧化铝选自勃姆石和三水合铝。
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- 2013-02-27 EP EP13709652.5A patent/EP2819972B1/en active Active
- 2013-02-27 JP JP2014559983A patent/JP6173356B2/ja active Active
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CN100410206C (zh) * | 2005-03-17 | 2008-08-13 | 日本碍子株式会社 | 蜂窝结构体及其制造方法 |
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PL2819972T3 (pl) | 2021-12-27 |
CN104350026A (zh) | 2015-02-11 |
EP2819972B1 (en) | 2021-07-21 |
EP2819972A1 (en) | 2015-01-07 |
US20130224431A1 (en) | 2013-08-29 |
JP6173356B2 (ja) | 2017-08-02 |
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US9878958B2 (en) | 2018-01-30 |
JP2015513517A (ja) | 2015-05-14 |
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