CN1200909C - 制造堇青石陶瓷蜂窝结构的方法 - Google Patents
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Abstract
本发明涉及一种制造堇青石陶瓷蜂窝结构的方法,它包括下列步骤:制备合适的堇青石原料和成形剂;将成形剂加入到合适的堇青石的原料中;混合成形剂和原料以得到原料配料;挤压原料配料以得到成形体;干燥成形体;烧结干燥后的成形体;从而得到的以堇青石晶相作为主成分的蜂窝结构体,其中,在烧结步骤中,至少从最大温度1300℃开始的温度下降速率不大于100℃/小时。
Description
技术领域
本发明涉及用于制造以堇青石作为晶相主成分的堇青石陶瓷蜂窝结构的方法。
背景技术
通常,堇青石陶瓷蜂窝结构体是以下列步骤制造的:制备合适的堇青石原料和成形剂;将成形剂加入到原堇青石的原料中;混合成形剂和合适的堇青石原料以得到原料配料;挤压原料配料以得到成形体;干燥成形体;烧结干燥后的成形体。在上述的堇青石陶瓷蜂窝结构体中,对于制造有低的热膨胀系数的堇青石陶瓷蜂窝结构的方法已公开在日本专利公开件No.5-82343中,例如使用平均粒度为5-100μm的滑石粉、平均粒度不大于2μm的氧化铝和平均粒度不大于15μm的高纯度无定形二氧化硅可制得孔隙度为30~42%、沿A-轴的热膨胀系数不大于0.3×10-6/℃和沿B-轴的热膨胀系数不大于0.5×10-6/℃的堇青石陶瓷蜂窝结构。此外,在日本专利公开件No.4-70053中还公开了一种堇青石陶瓷蜂窝结构,其孔隙度为30%、沿A-轴的热膨胀系数不大于0.8×10-6/℃和沿B-轴的热膨胀系数不大于1.0×10-6/℃。
近年,对生产肋厚不大于100μm的薄壁蜂窝结构有很高的需求。在这种情况下,为了容易载带催化剂,优选蜂窝结构的孔隙度不小于30%。此外,为了防止肋失效,必须排除粒度大于原料压模缝宽的粗颗粒。但是,在上述已知技术中,出现了下列问题。即用作原料之一的平均粒度不大于2μm的细氧化铝有降低热膨胀系数的优点。但另一方面,由于上述的氧化铝有强的颗粒结块特性,并且难以进行分粒,因此,不可能消除细氧化铝的粗颗粒。因此,在细氧化铝中残存在的氧化铝粗颗粒在利用压模的蜂窝结构成形步骤中会堵塞压模的缝。此外,因为细氧化铝有上述的细颗粒,就出现细氧化铝降低堇青石陶瓷蜂窝结构的孔隙度。另外,作为原料的高纯无定形二氧化硅有降低热膨胀系数的优点。但另一方面,与石英二氧化硅相比,高纯无定形二氧化硅有降低堇青石陶瓷蜂窝结构的孔隙度的缺点,并且价格也贵。
发明内容
本发明的目的是消除上述缺点,并提供一种制造堇青石陶瓷蜂窝结构的方法,该方法可廉价得到无肋失效和有低的热膨胀系数的薄壁蜂窝结构体。
按照本发明,制造堇青石陶瓷蜂窝结构的方法包括下列步骤:制备合适的堇青石原料和成形剂;将成形剂加入到合适的堇青石的原料中;混合成形剂和原料以得到原料配料;挤压原料配料以得到成形体;干燥成形体;烧结干燥后的成形体;从而得到的以堇青石晶相作为主成分的蜂窝结构体,其中,在烧结步骤中,至少从最大温度1300℃开始的温度下降速率不大于100℃/小时。
在本发明中,因为在烧结步骤中,至少从最大温度1300℃开始的温度下降速率不大于100℃/小时,所以可能廉价得到无肋失效和有低的膨胀系数的堇青石陶瓷蜂窝结构。
在本发明的优选实施方案中,在合适的堇青石的原料配料中采用石英,并且所用氧化铝的平均粒度大于2μm。在这种情况下,与按已知的制造方法得到的蜂窝结构体相比,可廉价得到蜂窝结构体。所制得的堇青石陶瓷蜂窝结构的特性为在40~800℃范围内,其沿A-轴的热膨胀系数不大于0.4×10-6/℃,沿B-轴的热膨胀系数不大于0.6×10-6/℃。在该优选实施方案中,由此所得的堇青石陶瓷蜂窝结构的特性为沿A-轴的热膨胀系数不大于0.3×10-6/℃,沿B-轴的热膨胀系数不大于0.5×10-6/℃。再则,该堇青石陶瓷蜂窝结构的孔隙度大于30%。此外,当采用月桂酸钾皂作为成形剂,并且从最大温度为1250℃开始的温度下降速率不大于50℃/时或在最大温度下的温度保持时间不小于6小时时,本发明可达更优选的方案。
附图简介
图1为按照本发明制造堇青石陶瓷蜂窝结构的方法的一种实施方案流程图。
本发明的最佳实施模式
图1为按照本发明制造堇青石陶瓷蜂窝结构的方法的一种实施方案流程图。将参照图1对按本发明的制造堇青石陶瓷蜂窝结构的方法进行描述。首先制备合适的堇青石的原料配料。该原料配料是由将成形剂如水溶性纤维素、表面活性剂和水加到包括如滑石粉、高岭土、煅烧高岭土、氧化铝、氢氧化铝、石英的合适的堇青石原料中,并将它们混合。然后,所得的原料配料用压模挤压,以得到有堇青石组合物的蜂窝成形体。之后,干燥所得的蜂窝成形体以得到干燥的蜂窝成形体。最后,烧结所得的干燥的蜂窝成形体以得到堇青石陶瓷蜂窝结构。
本发明的特征是,在烧结步骤中,至少从最大温度1300℃开始的温度下降速率不大于100℃/时。在本发明中,对在烧结步骤中从最大温度开始的温度下降速率进行平缓控制,以使其不大于100℃/时。所以,增加了堇青石晶相,并由此可制造有低的热膨胀系数的堇青石陶瓷蜂窝结构。
在上述实施方案中,在原料配料中采用石英来形成堇青石,并采用粒度大于2μm的氧化铝。在本发明中,可使用石英二氧化硅来代替在已知方法中采用的高纯无定形二氧化硅。在这种情况下,可增加蜂窝结构的孔隙度,与采用高纯无定形二氧化硅的已知实施方案相比,又可达到低的价格。此外,采用粒度大于2μm的氧化铝可使孔隙度达到大于30%,并防止包括难以分粒的粗颗粒。再则,采用月桂酸钾皂作为成形剂可达到低的热膨胀系数,因此这也是有利的。此外,当从最大温度1250℃开始的温度下降速率不大于50℃/时及在最大温度下的温度保持时间不小于6小时时,本发明可更优选地实施,因为其为优选的实施方案。
按本发明所得的堇青石陶瓷蜂窝结构有如此优异的低的热膨胀系数,即在40~800℃范围内沿堇青石陶瓷蜂窝结构的A-轴的热膨胀系数不大于0.4×10-6/℃,沿堇青石陶瓷蜂窝结构的B-轴的热膨胀系数不大于0.6×10-6/℃,再则,沿堇青石陶瓷蜂窝结构的A-轴的热膨胀系数不大于0.3×10-6/℃,沿堇青石陶瓷蜂窝结构的B-轴的热膨胀系数不大于0.5×10-6/℃。此外,由此得到的堇青石陶瓷蜂窝结构的孔隙度可大于30%,因此达到了优异的催化剂载带特性,催化剂能容易地载带其上。
下面将描述一个实际的实施方案。
按上述的制造方法,将表1所示的原料以给定速率混合,并在其中加入水溶性纤维、表面活性剂和水,以制得原料的配料。然后,原料配料经捏和、捣拌、挤压和干燥以制造有堇青石组合物的干燥的蜂窝结构体。
表1 所采用的原料和混合速率
原料 | 平均颗度(μm) | +45μm剩余部分(ppm) | 混合速率(wt%) |
滑石灰 | 9 | 12 | 40 |
高岭土 | 8 | 5 | 18 |
煅烧高岭土 | 3 | 8 | 16 |
氧化铝 | 5 | 14 | 10 |
氢氧化铝 | 1.8 | 13 | 10 |
石英 | 4 | 7 | 6 |
然后,烧结所得的干燥体。干燥的蜂窝结构体在基于下述表2的烧结条件下,采用带有程序功能的市售电炉于1425℃的最大温度下进行烧结。得到按本发明实施方案1-9和对比实施方案21-24的烧结的蜂窝结构体。分别测定各烧结的蜂窝结构体的孔隙度和热膨胀系数。该烧结的蜂窝结构体的孔隙度是以汞注入法测定其总的小孔体积,并基于所测的总小孔体积计算而得的。在这种情况下,堇青石的真密度假设为2.52g/cm3。这种测量是采用测微学公司的Autopore9405进行的。此外,烧结的蜂窝结构体的热膨胀系数是在下述条件下测定的,即蜂窝结构的挤压方向为A-轴方向,垂直于蜂窝结构的挤压方向和平行于蜂窝结构的晶格线的方向为B-轴方向。热膨胀系数是在40~800℃范围内沿A-轴和B-轴方向分别测定的。结果列于表2。
表2实施方案
编号 | 烧结条件 | 孔隙度(%) | 热膨胀系数(×10-6/℃) | |||
在最大温度下维持的时间(hr) | 温度下降速率(℃/hr) | 冷却温度(℃) | A-轴 | B-轴 | ||
1 | 12 | 100 | 1250 | 32.0 | 0.30 | 0.60 |
2 | 12 | 75 | 1250 | 32.3 | 0.27 | 0.57 |
3 | 12 | 50 | 1250 | 31.7 | 0.22 | 0.50 |
4 | 12 | 25 | 1250 | 31.9 | 0.24 | 0.52 |
5 | 12 | 25 | 1200 | 31.6 | 0.17 | 0.43 |
6 | 12 | 25 | 1000 | 31.3 | 0.20 | 0.48 |
7 | 6 | 25 | 1200 | 32.5 | 0.31 | 0.57 |
8 | 4 | 75 | 1200 | 33.1 | 0.40 | 0.61 |
9 | 12 | 100 | 1300 | 32.4 | 0.37 | 0.61 |
21 | 2 | 300 | 1250 | 31.7 | 0.57 | 0.77 |
22 | 12 | 150 | 1250 | 32.1 | 0.38 | 0.62 |
23 | 12 | 300 | 1250 | 31.7 | 0.46 | 0.65 |
24 | 12 | 100 | 1350 | 32.3 | 0.42 | 0.63 |
从表2的结果可理解下列的阐述。当从最大温度开始的冷却变慢时,热膨胀系数相应降低。温度下降速率不大于50℃/时可足以满足降低热膨胀系数的效果(参看实施例1-4,特别是实施例3和4有相同的值)。另一方面,如果温度下降更快如不小于150℃/时,则热膨胀系数变得较高(参看对比实施方案21-23)。如果从最大温度1300℃开始降温(参看实施方案9),则从最大温度的慢冷却是有效的。此外,如果慢冷却是在1200℃时进行,则可达更有效的优点(参看实施方案5、7和8)。如果慢冷却是在低于1200℃时进行,不能达到比上述情况更大的优点(参看实施方案6)。另一方面,如果慢冷却不仅在1350℃时进行,其优点是小的(参看实施方案24)。当在最大温度下维持的时间更长时,其热膨胀系数相应降低。如果温度维持时间至少是4小时或更长,则可述低的热膨胀系数(参看实施例2、5、7和8)。如果在最大温度下的维持时间变短,并且冷却速率更快时(如对比实施方案21),所得的热膨胀系数特别高。
工业应用性
从上述可理解,按照本发明在烧焙步骤中,因为从最大温度1300℃开始的温度下降速率不大于100℃/时,所以就可廉价得到无肋失效和有低的热膨胀系数的堇青石陶瓷蜂窝结构。
Claims (6)
1.一种制造堇青石陶瓷蜂窝结构的方法,其包括下列步骤:
制备堇青石原料和成形剂;将成形剂加入到堇青石的原料中;混合成形剂和原料以得到原料配料;挤压原料配料以得到成形体;干燥成形体;烧结干燥后的成形体;从而得到的以堇青石晶相作为主成分的蜂窝结构体,其中,在烧结步骤中,从最大温度1300℃开始的温度下降速率不大于100℃/小时。
2.权利要求1的制造堇青石陶瓷蜂窝结构的方法,其中在堇青石的原料配料中采用石英,并采用平均粒度大于2μm的氧化铝。
3.权利要求1的制造堇青石陶瓷蜂窝结构的方法,其中堇青石陶瓷蜂窝结构的孔隙度大于30%。
4.权利要求1的制造堇青石陶瓷蜂窝结构的方法,其中采用月桂酸钾皂作为成形剂。
5.权利要求1的制造堇青石陶瓷蜂窝结构的方法,其中从最大温度1250℃开始的温度下降速率不大于50℃/时。
6.权利要求1的制造堇青石陶瓷蜂窝结构的方法,其中在最大温度下的温度维持时间不小于6小时。
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Application Number | Priority Date | Filing Date | Title |
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JP2000105869 | 2000-04-07 | ||
JP105869/2000 | 2000-04-07 | ||
JP105869/00 | 2000-04-07 |
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CN1383421A CN1383421A (zh) | 2002-12-04 |
CN1200909C true CN1200909C (zh) | 2005-05-11 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CNB018016308A Expired - Lifetime CN1200909C (zh) | 2000-04-07 | 2001-04-06 | 制造堇青石陶瓷蜂窝结构的方法 |
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US (1) | US6783724B2 (zh) |
EP (1) | EP1201620B1 (zh) |
KR (1) | KR100447300B1 (zh) |
CN (1) | CN1200909C (zh) |
AU (1) | AU4685901A (zh) |
BR (1) | BR0105790A (zh) |
CA (1) | CA2372368C (zh) |
DE (1) | DE60126218T2 (zh) |
WO (1) | WO2001077043A1 (zh) |
ZA (1) | ZA200110067B (zh) |
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BR0108502A (pt) * | 2000-04-07 | 2003-03-18 | Ngk Insulators Ltd | Alvéolo cerâmico de cordierita de expansão térmica baixa e processo de produção do mesmo |
WO2003014041A2 (en) * | 2001-08-08 | 2003-02-20 | Showa Denko K.K. | $g(a)-alumina for cordierite ceramics, production method of the $g(a)-alumina and structures of cordierite ceramics using the $g(a)-alumina |
US6864198B2 (en) * | 2003-01-30 | 2005-03-08 | Corning Incorporated | Cordierite ceramic body and method |
JP4358662B2 (ja) * | 2004-03-23 | 2009-11-04 | 日本碍子株式会社 | コーディエライト質ハニカム構造体の製造方法 |
US8663545B2 (en) * | 2004-03-31 | 2014-03-04 | Ngk Insulators, Ltd. | Method of manufacturing honeycomb structure and honeycomb structure |
JPWO2006006667A1 (ja) | 2004-07-14 | 2008-05-01 | 日本碍子株式会社 | 多孔質ハニカム構造体の製造方法 |
EP1890983B1 (en) * | 2005-05-31 | 2012-12-12 | Corning Incorporated | Aluminum titanate ceramic forming batch mixtures and green bodies including pore former combinations and methods of manufacturing and firing same |
CN101233090B (zh) * | 2005-08-01 | 2012-07-04 | 日立金属株式会社 | 蜂窝陶瓷构造体的制造方法 |
DE102005042056A1 (de) * | 2005-09-05 | 2007-03-08 | Robert Bosch Gmbh | Filterelement und Rußfilter mit reduzierten Temperaturspannungen |
US7744980B2 (en) * | 2005-12-20 | 2010-06-29 | Corning Incorporated | Low CTE cordierite honeycomb article and method of manufacturing same |
JP5313658B2 (ja) * | 2006-03-07 | 2013-10-09 | 日本碍子株式会社 | セラミック構造体及びその製造方法 |
US20070281127A1 (en) * | 2006-05-30 | 2007-12-06 | Monika Backhaus-Ricoult | Cordierite formation |
JP2008108976A (ja) * | 2006-10-26 | 2008-05-08 | Ube Ind Ltd | 熱電変換モジュール及びその製造方法 |
DE102006058800A1 (de) * | 2006-12-13 | 2008-06-19 | Wacker Chemie Ag | Verfahren zur Herstellung von Katalysatoren und deren Verwendung für die Gasphasenoxidation von Olefinen |
WO2008076231A2 (en) | 2006-12-13 | 2008-06-26 | Strutt Peter R | Electrode assembly for a solid oxide fuel cell and method for making the same |
JP2009067628A (ja) | 2007-09-13 | 2009-04-02 | Ngk Insulators Ltd | ハニカム構造体 |
JP4842986B2 (ja) * | 2008-03-19 | 2011-12-21 | 日本碍子株式会社 | セラミックス成形体の乾燥方法 |
US8696962B2 (en) * | 2011-09-16 | 2014-04-15 | Corning Incorporated | Methods for reducing defects in ceramic articles and precursors |
US10399909B1 (en) | 2015-06-23 | 2019-09-03 | Hrl Laboratories, Llc | Ordered cellular structures and methods of manufacturing the same |
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US3950175A (en) * | 1973-11-05 | 1976-04-13 | Corning Glass Works | Pore size control in cordierite ceramic |
US4869944A (en) * | 1987-02-12 | 1989-09-26 | Ngk Insulators, Ltd. | Cordierite honeycomb-structural body and a method for producing the same |
JPH0733013B2 (ja) * | 1988-09-20 | 1995-04-12 | 日本碍子株式会社 | セラミックハニカム構造体の製造法 |
JPH064507B2 (ja) * | 1988-10-21 | 1994-01-19 | 三井造船株式会社 | 低熱膨張コージェライトの製造方法 |
JPH0651596B2 (ja) * | 1991-03-29 | 1994-07-06 | 日本碍子株式会社 | コージェライト質ハニカム構造体の製造法 |
JP2981034B2 (ja) | 1991-09-30 | 1999-11-22 | 日本碍子株式会社 | セラミックハニカム構造体の焼成方法 |
JP3130979B2 (ja) * | 1991-09-30 | 2001-01-31 | 京セラ株式会社 | コージライト質セラミックスの製造法 |
US5258150A (en) * | 1991-12-06 | 1993-11-02 | Corning Incorporated | Fabrication of low thermal expansion, high porosity cordierite body |
US5183608A (en) * | 1992-01-03 | 1993-02-02 | Corning Incorporated | Method of making diesel particulate filters |
JP3227038B2 (ja) * | 1993-11-10 | 2001-11-12 | 日本碍子株式会社 | セラミックス構造体の製造方法 |
CN1210835A (zh) | 1997-07-28 | 1999-03-17 | 康宁股份有限公司 | 烧成时间显著缩短的堇青石物体的制备方法 |
JP3150928B2 (ja) | 1997-08-29 | 2001-03-26 | 日本碍子株式会社 | 薄壁コージェライト質ハニカム構造体の製造方法 |
JPH11236262A (ja) * | 1998-02-23 | 1999-08-31 | Kyocera Corp | 低熱膨張セラミックス構造部材およびそれを用いた半導体素子製造装置用部材 |
DE69840728D1 (de) * | 1997-12-02 | 2009-05-20 | Corning Inc | Verfahren zur herstellung honigwabenkörper aus cordierit niedriger expansion |
JPH11309380A (ja) * | 1998-02-26 | 1999-11-09 | Nippon Soken Inc | コーディエライトハニカム構造体の製造方法 |
KR20010078396A (ko) * | 1998-11-20 | 2001-08-20 | 알프레드 엘. 미첼슨 | 저열팽창, 고강도 코디어라이트 구조물의 제조방법 |
WO2000040521A1 (en) * | 1998-12-31 | 2000-07-13 | Corning Incorporated | Low sintering temperature cordierite batch and cordierite ceramic produced therefrom |
-
2001
- 2001-04-06 EP EP01919818A patent/EP1201620B1/en not_active Expired - Lifetime
- 2001-04-06 AU AU46859/01A patent/AU4685901A/en not_active Abandoned
- 2001-04-06 US US09/980,940 patent/US6783724B2/en not_active Expired - Lifetime
- 2001-04-06 KR KR10-2001-7015685A patent/KR100447300B1/ko not_active IP Right Cessation
- 2001-04-06 WO PCT/JP2001/003006 patent/WO2001077043A1/ja active IP Right Grant
- 2001-04-06 DE DE60126218T patent/DE60126218T2/de not_active Expired - Lifetime
- 2001-04-06 CA CA002372368A patent/CA2372368C/en not_active Expired - Fee Related
- 2001-04-06 BR BR0105790-1A patent/BR0105790A/pt not_active Application Discontinuation
- 2001-04-06 CN CNB018016308A patent/CN1200909C/zh not_active Expired - Lifetime
- 2001-12-06 ZA ZA200110067A patent/ZA200110067B/xx unknown
Also Published As
Publication number | Publication date |
---|---|
KR20020026176A (ko) | 2002-04-06 |
WO2001077043A1 (en) | 2001-10-18 |
ZA200110067B (en) | 2002-12-06 |
US20030102606A1 (en) | 2003-06-05 |
CN1383421A (zh) | 2002-12-04 |
DE60126218D1 (de) | 2007-03-15 |
BR0105790A (pt) | 2002-03-19 |
AU4685901A (en) | 2001-10-23 |
KR100447300B1 (ko) | 2004-09-07 |
DE60126218T2 (de) | 2007-10-31 |
CA2372368A1 (en) | 2001-10-18 |
EP1201620A1 (en) | 2002-05-02 |
US6783724B2 (en) | 2004-08-31 |
EP1201620B1 (en) | 2007-01-24 |
EP1201620A4 (en) | 2004-11-17 |
CA2372368C (en) | 2007-06-12 |
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