CN1323981C - 以钛酸铝为基的陶瓷制品 - Google Patents

以钛酸铝为基的陶瓷制品 Download PDF

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Publication number
CN1323981C
CN1323981C CNB038229404A CN03822940A CN1323981C CN 1323981 C CN1323981 C CN 1323981C CN B038229404 A CNB038229404 A CN B038229404A CN 03822940 A CN03822940 A CN 03822940A CN 1323981 C CN1323981 C CN 1323981C
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tio
particulate filter
diesel particulate
2sio
passage
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CN1684924A (zh
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G·H·比尔
S·B·奥古米
D·J·圣朱利恩
P·D·特珀谢
C·J·沃伦
I·M·梅尔斯科特
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Corning Inc
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Corning Inc
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    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
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Abstract

本发明提供了一种以钛酸铝为基的陶瓷制品，它具有如下组成，包括u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1，5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1和0.5。

Description

以钛酸铝为基的陶瓷制品
发明背景
本发明涉及用于高温的以钛酸铝为基的陶瓷制品。本发明特别涉及具有渗透率高、兼备热膨胀性低和热抗震性高、适用于汽车排放控制(automotiveemissions control)的以钛酸铝为基的陶瓷制品。
工业上，堇青石(2MgO·2Al2O3·5SiO2)由于其在大多数操作条件下兼有良好的热抗震性、过滤效率和耐久性，业已成为汽车排放控制应用，如柴油机中的排气后处理系统中作为成本-有效材料的选择。但是，在某些情况下，堇青石过滤器容易被损伤，甚至会骤然破坏。在不受控制的再生期间会发生偶然的热失控，导致堇青石局部熔化。
当来自发动机油、催化剂添加剂、或排气口管道衬里中被腐蚀金属的金属杂质在操作时引入了过滤器时，这是使堇青石破坏的另一个因素。典型的是，在超过1300℃温度下，这些金属形成了与堇青石结构反应的氧化物。破坏的堇青石材料通常使过滤器上形成小孔，在此金属开始沉积并反应产生材料和熔融的现象。
最近，用作柴油机排气过滤的碳化硅(SiC)壁流(wall-flow)过滤器已投放市场。但是，SiC过滤器的制造成本很高，由于其内在的热膨胀系数TE)高，且热抗震性不良，它必须分割拼装使用
因此，需要适合高温下使用，如汽车排放控制系统中使用且能克服目前存在缺陷的陶瓷制品。本发明提供了这类陶瓷制品和其制备方法及其应用。
发明概述
本发明基于这样的发现：以钛酸铝为基的陶瓷制品具有高的互相连通的孔隙率和大的中值孔径，且渗透率高，能用于高温，如汽车排放的控制，包括，但不限于汽车催化转化器和柴油机排气后处理系统，如柴油机颗粒过滤器。
本发明的一个方面提供了一种陶瓷制品，它具有包含如下物质的组成：u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，0.5＜u≤0.95，0.01＜v≤0.5，0.01＜w≤0.5，0＜x≤0.5，0＜y≤0.1，0＜z≤0.5，0＜a≤0.3，0＜b≤0.3。通过X-射线衍射和电子探针微分析对本发明陶瓷进行的检查观察到钛酸铝(Al2O·TiO2)、锶长石(SrO·Al2O3·2SiO2)、富铝红柱石(3Al2O3·2SiO2)、矾土(Al2O3)和/或玻璃等各相。这些相在最终产物不一定是完美的化学计量或也不一定是完美的晶体、
加入硅石和玻璃提高强度，降低孔隙率、降低热膨胀和烧结温度，并能使陶瓷抵抗分解。加入矾土会增加孔隙率。硅石的加入量可最高达到10％重量(基于批料的总重量)，矾土的加入量，可最高达50％重量。具有由1.1SrO-1.5Al2O3-13.6SiO2-TiO2代表的组成的玻璃的加入量最高达50％重量。钛酸铁和/或钛酸镁可代替最高到30％重量的钛酸铝相。这些替代能提高800-1200℃温度下钛酸铝相的抗分解性。
本发明的另一方面，本发明的陶瓷制品的热膨胀系数(CTE)在通道温到800-1000℃下测量为低于45×10-7/℃，优选的是低于25×10-7/℃，更好的是低于5×10-7/℃；其孔隙率最高达60％体积，优选的是最高达55％体积，更好的是最高达45％体积；中值孔径最高达25微米，较好的是最高达20微米，更好的是最高达15微米；在横截面为圆形的固体棒上测得的断裂模数大于400磅/平方英寸(psi)，优选的是大于700psi。
本发明的另一方面提供了一种制备以钛酸铝为基的陶瓷体的方法，该方法包括：(a)配制包含硅石、矾土、氧化锶、二氧化钛和/或氧化铁的无机原料，以及用包括增塑剂、润滑剂、粘合剂等有机处理溶剂和水作为溶剂进行处理，混合形成均匀并增塑的混合物；(b)将增塑的混合物成形为坯体；(c)以20-40℃/小时的升温速度，在各个温度间隔，最终在1100-1650℃，优选的是1100-1500℃的保持温度下对坯体加热30-50小时，形成烧结的钛酸铝体。1100-1650℃，优选的是1100-1500℃的明显低的烧结温度能明显降低制造成本，同时保留本发明陶瓷低的热膨胀、高的热抗震性和高的机械强度。
本发明的另一方面提供了一种柴油机颗粒过滤器。成功地使用柴油机排气过滤器需要低的压力降和低的逆着发动机的反压力，以及在热循环期间具有高的耐用性。柴油机颗粒过滤器包括一个堵住的壁流的蜂窝体，它具有一入口端和一出口端，以及从入口端到出口端延伸出来的多个通道，所述的通道具有多孔的壁，其中入口端处所有通道中的一部分被沿着其长度的一部分堵住，在入口端开口的剩余通道在出口处被沿着其长度的部分堵住，结果发动机的排气流通过蜂窝体从入口流动到出口，通过通道的壁，并在出口端的开放通道从结构中流出去。
在优选的实施方案中，柴油机颗粒过滤器包括一个蜂窝体，它由本发明的以钛酸铝为基的陶瓷组成，所述的以钛酸铝为基的陶瓷具有如下组成，包括u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，u＝0.6965，v＝0.225，w＝0.075，x＝0，y＝0，z＝0，z＝0.0035，b＝0。
在另一个实施方案中，柴油机颗粒过滤器具有下列性质：CTE(通道温到800-1000℃)低于15×10-7/℃，优选的是低于5×10-7/℃；孔隙率为30-50％体积，优选的是35-45％体积；中值孔径为5-20微米，优选的是10-15微米；在平行于通道密度为200通道/平方英寸(cpsi)、壁厚度为0.016英寸的蜂窝体的通道方向切得的蜂窝棒上，用四点法测得的断裂模数为150-400psi，优选的是150-300psi；渗透率为至少0.20×10-12m2，优选的是0.33-1.00×10-12m2；在通道密度为273cpsi、通道壁厚度为0.015英寸的5.66″×6″样品中，人工碳烟尘以210scfm流量负载到最高达5克/升下，压力降为5kPa或低于5kPa。
附图简述
在阅读下面的详细描述时，通过结合所附的附图可完全理解本发明。
图1是热膨胀系数随0＜w＜0.30(3Al2O3-2SiO2)变化的关系图，组成中u＝0.7(Al2O3-TiO2)，剩余的是(SrO-Al2O3-2SiO2)；该组成在1500℃下烧结了4小时。
图2是孔隙率随0＜w＜0.30(3Al2O3-2SiO2)变化的关系图，组成中u＝0.7(Al2O3-TiO2)，剩余的是(SrO-Al2O3-2SiO2)；该组成在1500℃下烧结了4小时。
图3对热膨胀系数(CTE)(10-7/℃)，孔隙率(％体积)和中值孔径(MPS)(微米)进行比较，以y轴代表0＜z＜0.30(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)、x轴代表0＜v＜0.30(11.2SrO-10.9Al2O3-24.1SiO2-TiO2)；该组成中u＝0.6965(Al2O3-TiO2)，a＝0.0045(Fe2O3-TiO2)，剩余的是Al2O3；该组成在1495℃下烧结8小时；
图4是入口端和出口端之间的压降图(即，压差，单位为KPa)，与气体流量为210scfm的烟尘负载(g/L)的关系图，它是对于包括有实施例5表1提供的组成的本发明陶瓷的柴油机颗粒过滤器，是大小为5.66英寸×6英寸、通道密度为273通道/平方英寸(cpsi)，通道壁厚度为0.015英寸的样品上进行的。
发明详述
本发明提供了一种以钛酸铝为基的陶瓷，包含u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，0.5＜u≤0.95，0.01＜v≤0.5，0.01＜w≤0.5，0＜x≤0.5，0＜y≤0.1，0＜z≤0.5，0＜a≤0.3，0＜b≤0.3。
本发明的陶瓷是高熔点的，其热膨胀系数(CTE)低，热耐用性高，这使它适合用于高温场合，包括，但不限于，汽车排放控制系统。因此，在通道温到800-1000℃温度下用膨胀计测定的热膨胀(热膨胀系数)低于45×10-7/℃，优选的是低于25×10-7/℃，更优选的是低于5×10-7/℃。本发明结构体的低膨胀性是由各向异性的热膨胀产生的微破坏的结果。
因此，本发明结构体的一个优点是热膨胀滞后现象(即加热和冷却曲线之间的差异)很低。这保证了高的热抗震性。现参见图1，它提供了热膨胀系数随0＜w＜0.30(3Al2O3-2SiO2)变化的图，组成中u＝0.7(Al2O3-TiO2)，剩余的是(SrO-Al2O3-2SiO2)；该组成在1500℃下烧结4小时。为了得到CTE低于5×10-7/℃的值，w范围优选的是0.05-0.15。在w的低端值和高端值上，热膨胀性增加。
除了热膨胀性外，本发明的陶瓷特别适合于高度相互连通的孔隙率和大的中值孔径。因此，由水银孔隙计测得的孔隙率最高达60％体积，优选的是最高达55％体积，更好是最高达45％体积。中值孔径最高达25微米，优选的是最高达20微米，更好的是最高达15微米。
现参见图2，它提供了孔隙率随0＜w＜0.30(3Al2O3-2SiO2)变化的关系图，组成中u＝0.7(Al2O3-TiO2)，剩余的是(SrO-Al2O3-2SiO2)；该组成在1500℃下烧结4小时。在w为0.08-0.11处得到孔隙率的峰值。在w的低端值和高端值处，孔隙率都降低，最低孔隙率在w＞0.25处。
现参见图3，它提供了热膨胀系数(CTE)(10-7/℃)，孔隙率(％体积)和中值孔径(MPS)(微米)进行比较的图，以y轴代表0＜z＜0.30(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)、x轴代表0＜v＜0.30(11.2SrO-10.9Al2O3-24.1SiO2-TiO2)；该组成中u＝0.6965(Al2O3-TiO2)，a＝0.0045(Fe2O3-TiO2)，剩余的是Al2O3；该组成在1495℃下烧结8小时。通过改变z和v的两个重量分数，可以控制在所需应用中本发明陶瓷体的CTE、孔隙率和MPS。本发明陶瓷体也显示了高的断裂模数(在圆形横截面的固体棒上测量)大于400磅/平方英寸(psi)，优选的是大于700psi。
本发明陶瓷特别适合用于柴油机排气过滤。在优选的实施方案中，柴油机颗粒过滤器包括一个堵住的(plugged)壁流动(wall-flow)的过滤器体，由本发明的陶瓷构成，所述的陶瓷具有如下组成，优选地包括u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，u＝0.6965，v＝0.225，w＝0.075，x＝0，y＝0，z＝0，z＝0.0035，b＝0。
蜂窝状过滤器体具有一入口端和一出口端，以及从入口端到出口端延伸出来的多个通道，所述的通道具有多孔的壁，其中入口端处所有通道中的一部分沿着其一部分长度被堵住，在入口端开口的剩余通道在出口处则沿着其长度的部分堵住，该堵住的结构体使发动机的排气流通过蜂窝体从入口流到出口，通过通道壁进入开放通道，并通过出口端的开放通道从结构中出去。柴油机颗粒过滤器的合适的通道密度范围为70通道/m2(10.9通道/cm2)到800通道/m2(124通道/cm2)。
在另一个实施方案中，本发明柴油机颗粒过滤器具有下列性质：CTE(通道温到800-1000℃)低于15×10-7/℃，优选的是低于5×10-7/℃；孔隙率为30-50％体积，优选的是35-45％体积；中值孔径为5-20微米，优选的是10-15微米；在平行于通道密度为200通道/平方英寸(cpsi)、壁厚度为0.016英寸的蜂窝体的通道方向切得的蜂窝状棒上用四点法测得的断裂模数为150-400psi，优选的是150-300psi；渗透率为至少0.20×10-12m2，优选的是0.33-1.00×10-12m2；在通道密度为273cisi、通道壁厚度为0.015英寸的5.66″×6″样品中，人工碳烟尘以210scfm流量负载到最高达5克/升下，压力降为5kPa或低于5kPa。进一步的是，具有本发明结构的过滤器在200-1000℃温度下热循环200次(每次循环18分钟，顶端温度处保持3分钟)后，其直线尺寸的增加率小于0.05％。
本发明也涉及制造本发明以钛酸铝为基的陶瓷的方法，包括形成来自某些无机粉末原料的混合物，所述的无机粉末原料包括硅石、矾土、氧化锶、氧化钛和/或氧化铁来原料。使该原料与可包括增塑剂、润滑剂、粘合剂和水作为溶剂的有机加工助剂混合。然后使混合物成形成坯体。孔形成物，如石墨或聚乙烯颗粒，可以用来提高孔隙率和中值孔径。孔形成物是容易气化的颗粒材料，它在干燥或加热坯体期间蒸发或燃烧而气化，得到所需的、通常是较高孔隙率和/或较大的中值孔径。不适宜使用粒径大的原料。
矾土原料是一种粉末，在没有其它原料情况下，加热到足够高的温度会得到基本纯的氧化铝，包括α-氧化铝、过渡态氧化铝，如γ-氧化铝或ρ(rho)-氧化铝、水合氧化铝、水铝矿、勃姆石、氢氧化铝和它们的混合物。矾土原料的粒径最高达25微米。硅石原料包括方英石、非结晶硅石、诸如熔凝硅石或溶胶-凝胶法硅石、有机硅树脂、沸石、硅藻土硅石、高岭土、和石英。硅石原料的中值粒径最高达30微米。
二氧化钛原料优选，但非限制性的是金红石。二氧化钛原料的中值粒径对于避免由于结构中的核芯成长过快而包入未反应的氧化物是重要的。氧化锶原料是碳酸锶，其中值粒径最高达20微米。氧化铁原料的中值粒径最高达0.5微米。
使无机粉末化的原料与有机加工组分，如甲基纤维素粘合剂、油酸/三已醇胺表面活性剂混合，形成增塑的和均匀的混合物。增塑的混合物通过常规方法，优选的是用蜂窝状模头挤压来成形。所得的坯体还可以进行干燥，然后以20-40℃/小时升温速率的各种温度下，最终在1100-1650℃，优选的是1100-1500℃的保持温度下对坯体加热30-50小时，形成最终的产品结构体。
为了得到壁流过滤器，如现有技术那样，在入口端或入口面堵住蜂窝结构体的多个通道的一部分。堵塞仅仅发生在通道末端处，虽然深度有所不同，典型的是堵入深度约1-20毫米。在出口端上堵住的通道部分并不相应于入口端堵住的通道部分。因此，每个通道只在一端堵住。优选的排列是在给定面上的每隔一个通道以隔子状形堵住。
为了更清楚地描述本发明，现给出下列非限定性的实施例。除非另作说明，其中所有的份数、比例和百分数都是以重量为基的。
实施例
这样制备本发明的样品：称出干燥的各组分，将它们与有机组分和水混合，并在不锈钢研磨机中捏合进行混合，形成可塑性的物料。表I提供了粉末化原料和成形助剂的分数和比例。具体是，将三乙醇胺(TEA)先与水混合，然后再与油酸和/或松浆油(tall oil，分散剂)混合。使用前，所得的溶液在通道温下放置24小时，然后冷藏过夜。各无水组分，包括硅石、氧化钛、碳酸锶、氧化钛、矾土、氢氧化铝、有机硅树脂、石墨、聚乙烯颗粒和/或甲基纤维素粘合剂在研磨机中干混。在连续混合中慢慢加入松浆油/TEA/水溶液进行均匀化和增塑。
被增塑的混合物通过模头挤压成形为具有大致100-400cpsi的蜂窝体，其通道壁厚度为约0.010到0.025英寸。这样形成的蜂窝体被切割成所需的长度，在85℃的烘箱中加热至干燥。将样品在电炉中烧结，以20-40℃/小时升温速率在各种温度间隔下，最终在1200℃的第一保持温度下保持4小时，在1500℃的第二保持温度保持6小时，以形成最终产品结构体，关闭炉子的电源进行冷却。
测量下列性质，数据列于表II：断裂模数(单位为psi，每平方英寸磅)(除非另作说明，在平行于通道密度为200通道/平方英寸(cpsi)、壁厚度为0.016英寸的蜂窝体的通道方向切得的蜂窝棒上测定)，孔隙率(％体积)，中值孔径(微米)，热膨胀系数10-7/℃，渗透率10-12m2。实施例5给出了就性质而言较为优选的组合物。该组合物尤为适合用于制造包括堵住的壁流的蜂窝体的柴油机颗粒过滤器。
因此，实施例5陶瓷的挤压的蜂窝体在入口端和出口端用钛酸铝粉末制成的冷结糊剂(cold-set paste)堵上。样品的尺寸包括直径5.66英寸，长度6英寸，通道密度为273cpsi，通道壁厚度为0.015英寸。这样进行反压力(back pressure)试验：用人工煤灰(类似于复印机调色剂)以210scfm的流速负载到样品上，最高达5g/L，并测量入口和出口端的压力降(kPa)。所得的数据如图4所示，它表明其压力降很优良，为2kPa到5kPa。
实施例2和3对本发明陶瓷的热处理效果进行了检查，结果如表III所示，具体是，显示了烧结条件可用来改变强度、孔隙率、中值孔径和渗透率，以便适合特定使用时的需求。
本发明提供了一种以钛酸铝为基的陶瓷，用于汽车发散控制系统中，特别是用于柴油机排气过滤器中，这种系统中的用途需要热膨胀低，热耐用性大，压力降和发动机的反压力都很低。本发明的陶瓷可在1100-1650℃，优选的是1100-1500℃的相对低的烧结温度形成所需的性质，这可明显降低其制造成本。
应当明白，虽然本发明参照特定的描述和特定的实施方案作了揭示，但不应只限于这类手段，还可采用不背离本发明精神和权利要求范围的其它手段实施本发明。
表I  实施例1-9的原料
实施例序号    1   2   3   4   5   6   7   8   9
原料(重量％)
SiO2 Silverbond200(UniminCorp)   10.11   10.11   2.11   10.0   10.0   10.0   10.0   10.1   11.4
Al2O3 RMA(-325目)(Alcan)    49.77   42.77   49.77   0   47.46   0   0   49.77   49.07
Al2O3A10(-325目)Alcoa)    0   0   0   47.46   0   47.46   47.46   0   0
Al(OH)3Gibbsite(Alcan)    0   5.00   -   3.04   3.04   3.04   3.04   0   0
SrCO3(-325目)(ChemicalProducts)    9.90   9.90   9.90   9.8   9.8   9.8   9.8   9.9   9.25
PezO3Hematite(Fisher Scientific) 0.45 0.45   0.45   0.22   0.22   0.22   0.22   0.45   0.45
TIO2 3020(-325目)(Kronos)   29.77   29.77   29.77   29.48   29.48   29.48   0   29.77   29.83
TiO2 Ti-pure(DuPont)    0   0   0   0   0   0   29.48   0   0
硅烷树脂(Dow Coming)    0   0   5.0   0   0   0   0   0   0
孔形成物
石墨(A625)(Asbury)    0   0   0   0   0   20   20   0   0
聚乙烯颗粒(Equistar)    0   0   0   10.0   0   0   0   0   0
粘合剂，润滑剂和溶剂
Methocel A4Ms(Dow Coming)    4.50   4.50   4.5   0   0   0   0   0   0
Methocel Aqualon 334(Hercules) 0   0   0   4.5   4.5   4.5   4.5   6   6
油酸(Fisher Scientific)    1.00   1.00   1.0   1.0   1.0   0   0   2   2
Tall Oil(Sand S Chemical)    0   0   0   0   0   1.0   1.0   0   1.0
TnEthanol Amine99(DowComing)    0.15   0.15   0.15   0.15   0.15   0.15   0.15   0.0   0.0
水    17   17   17   17   17   17   17   17   17
表II.实施例1-9的烧结条件和性质
 实施例序号   1   2   3   4   5   6   7   8   9
 炉子类型   电炉   电炉   电炉   电炉   电炉   电炉   电炉   电炉   电炉
 第一保持温度(℃)/时间(小时)   1200/4   1200/4   1200/4   1200/4   1200/4   1200/4   1200/4   -   -
 第二保持温度(℃)/时间(小时)   1500/6   1500/6   1500/6   1500/6   1500/6   1500/6   1500/6   1500/4   1500/4
 性质
 断裂模数(psi)   191   361   270   187   206   208   220   487*   784*
 孔隙率(体积％)   42.24   34.41   33.96   46   40.8   46.0   43.9   54   36
 平均孔径(微米)   13.78   8.40   10.52   13.8   16.8   12.6   17.8   20   19
 CIE(通道温到800-1000℃)(10-7/℃)   5.4/9.6   0.9/5.1   1.9/6.3   11.2   4.6   9.4   10.7   12   11
 渗透率(10-12m2)   -   0.243   -   -   -   -   -   -   -
*MOR是在圆形横截面的固体棒上测得的。
表II  I实施例2和3的样品性质随热处理的变化
  实施例   2   3   3   3
  烧结条件
  第一保持温度(℃)/时间(小时)   1300/4   1350/4   1300/4   1100/4
  第二保持温度(℃)/时间(小时)   1490/6   1490/4   1490/6   1300/4
  第三保持温度(℃)/时间(小时)   --   1475/4   --   1485/6
  性质
  断裂模数(psi)   354   255   269   250
  孔隙率(体积％)   39.13   38.31   37.88   36
  平均孔径(微米)   6.77   10.37   9.73   12
  CTE(通道温到800-1000℃)(10-7/℃)   4.8/8.8   3.7/5.1   4.9/8.9   2.0/6.0
  渗透率(10-12m2)   0.219   0.409   0.483   0.500

Claims (12)

1.一种陶瓷制品，它具有包含如下物质的组成：u(Al2O3-TiO2)+v(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，0.5＜u≤0.95，0.01＜v≤0.5，0.01＜w≤0.5，0＜x≤0.5，0＜y≤0.1，0＜z≤0.5，0＜a≤0.3，0＜b≤0.3。
2.一种柴油机颗粒过滤器，包括权利要求1所述的陶瓷制品和塞住的壁流蜂窝状过滤器体，所述的过滤器体包括多个端塞住的平行管道，所述的管道从前面的入口端延伸到其出口端。
3.根据权利要求2所述的柴油机颗粒过滤器，它在通道温到800-1000℃温度下测得的CTE低于15×10-7/℃。
4.根据权利要求2所述的柴油机颗粒过滤器，其孔隙率为30-50％体积。
5.根据权利要求2所述的柴油机颗粒过滤器，它的中值孔径为5-25微米。
6.根据权利要求2所述的柴油机颗粒过滤器，它在通道密度为200通道/平方英寸和壁厚度为0.016英寸的圆形棒上测得的断裂模数为150-400磅/平方英寸。
7.根据权利要求2所述的柴油机颗粒过滤器，其渗透率为至少0.20×10-12m2。
8.根据权利要求2所述的柴油机颗粒过滤器，它的通道密度为273通道/平方英寸、通道壁厚度为0.015英寸，以210标准立方英尺/分钟流量将人工碳烟尘负载其上，最高达5克/升，所述柴油机颗粒过滤器的压力降为5kPa或低于5kPa。
9.一种制备以钛酸铝为基的陶瓷体的方法，包括：
(a)配制包含硅石、矾土、氧化锶、二氧化钛和/或氧化铁的无机原料，以及包含包括增塑剂、润滑剂、粘合剂和水作为溶剂的有机处理剂的批料，混合形成均匀并增塑的混合物；
(b)将增塑的混合物成形为坯体；
(c)以20-40℃/小时的升温速率在各个温度间隔下，最终在1100-1650℃的保持温度下对坯体加热30-50小时，形成陶瓷，所述的陶瓷具有包含如下物质的组成：u(Al2O3-TiO2)+(R)+w(3Al2O3-2SiO2)+x(Al2O3)+y(SiO2)+z(1.1SrO-1.5Al2O3-13.6SiO2-TiO2)+a(Fe2O3-TiO2)+b(MgO-2TiO2)，其中，R是SrO-Al2O3-2SiO2或11.2SrO-10.9Al2O3-24.1SiO2-TiO2，其中u，v，w，x，y，z，a和b是每个组分的重量分数，u+v+w+x+y+z+a+b＝1，0.5＜u≤0.95，0.01＜v≤0.5，0.01＜w≤0.5，0＜x≤0.5，0＜y≤0.1，0＜z≤0.5，0＜a≤0.3，0＜b≤0.3。
10.根据权利要求9所述的方法，其中加热在1100-1500℃下进行。
11.根据权利要求9所述的方法，其中通过挤压成形。
12.根据权利要求11所述的方法，其中增塑的混合物被挤压成蜂窝状坯体。
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