JP2008545611A - 低熱膨張係数のコージエライト体およびその製造方法 - Google Patents
低熱膨張係数のコージエライト体およびその製造方法 Download PDFInfo
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- JP2008545611A JP2008545611A JP2008514670A JP2008514670A JP2008545611A JP 2008545611 A JP2008545611 A JP 2008545611A JP 2008514670 A JP2008514670 A JP 2008514670A JP 2008514670 A JP2008514670 A JP 2008514670A JP 2008545611 A JP2008545611 A JP 2008545611A
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- cordierite
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- 229910052878 cordierite Inorganic materials 0.000 title claims abstract description 101
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 title claims abstract description 101
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- 239000000203 mixture Substances 0.000 claims abstract description 85
- 239000000919 ceramic Substances 0.000 claims abstract description 49
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims abstract description 6
- 229910004298 SiO 2 Inorganic materials 0.000 claims abstract description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 45
- 239000002243 precursor Substances 0.000 claims description 36
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 31
- 239000000454 talc Substances 0.000 claims description 27
- 229910052623 talc Inorganic materials 0.000 claims description 27
- 239000002002 slurry Substances 0.000 claims description 26
- 239000002904 solvent Substances 0.000 claims description 22
- 238000010304 firing Methods 0.000 claims description 20
- 239000011230 binding agent Substances 0.000 claims description 19
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 19
- 239000000377 silicon dioxide Substances 0.000 claims description 19
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- 239000004927 clay Substances 0.000 claims description 15
- 238000002156 mixing Methods 0.000 claims description 13
- 229910001593 boehmite Inorganic materials 0.000 claims description 12
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 12
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 11
- 238000001694 spray drying Methods 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 229910052570 clay Inorganic materials 0.000 claims description 2
- 239000013078 crystal Substances 0.000 abstract description 10
- 241000264877 Hippospongia communis Species 0.000 description 21
- 239000002994 raw material Substances 0.000 description 8
- 239000000758 substrate Substances 0.000 description 8
- 238000001125 extrusion Methods 0.000 description 7
- 239000002245 particle Substances 0.000 description 7
- 230000035939 shock Effects 0.000 description 7
- 238000005259 measurement Methods 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 5
- 238000009472 formulation Methods 0.000 description 5
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 5
- 238000002441 X-ray diffraction Methods 0.000 description 4
- 210000004027 cell Anatomy 0.000 description 4
- 235000012239 silicon dioxide Nutrition 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 3
- 230000003197 catalytic effect Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229930195733 hydrocarbon Natural products 0.000 description 3
- 150000002430 hydrocarbons Chemical class 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000000877 morphologic effect Effects 0.000 description 3
- 239000004215 Carbon black (E152) Substances 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000002585 base Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000003344 environmental pollutant Substances 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 229920000609 methyl cellulose Polymers 0.000 description 2
- 239000001923 methylcellulose Substances 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 231100000719 pollutant Toxicity 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- RNAMYOYQYRYFQY-UHFFFAOYSA-N 2-(4,4-difluoropiperidin-1-yl)-6-methoxy-n-(1-propan-2-ylpiperidin-4-yl)-7-(3-pyrrolidin-1-ylpropoxy)quinazolin-4-amine Chemical compound N1=C(N2CCC(F)(F)CC2)N=C2C=C(OCCCN3CCCC3)C(OC)=CC2=C1NC1CCN(C(C)C)CC1 RNAMYOYQYRYFQY-UHFFFAOYSA-N 0.000 description 1
- 229910002706 AlOOH Inorganic materials 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 241000640882 Condea Species 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229920003091 Methocel™ Polymers 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- MHCAFGMQMCSRGH-UHFFFAOYSA-N aluminum;hydrate Chemical compound O.[Al] MHCAFGMQMCSRGH-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 210000005056 cell body Anatomy 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 229920003086 cellulose ether Polymers 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 239000008119 colloidal silica Substances 0.000 description 1
- 230000002301 combined effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 229910002026 crystalline silica Inorganic materials 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 238000007571 dilatometry Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 238000007580 dry-mixing Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000003502 gasoline Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 description 1
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 description 1
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 description 1
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- 238000000643 oven drying Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- -1 silicon organometallic compound Chemical class 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000007569 slipcasting Methods 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
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- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
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Abstract
Description
軸I比および横断I比は、X線ビームでのコージエライトハニカム試料の異なる配向を指す。X線ビームはある角度で平面に当たる。具体的に横断I比の測定に関して言えば、この測定は、X線が当たる平面がハニカムの形成壁表面で構成される平面である場合の試料の平面に関して行う。別の言い方をすれば、この横断I比の測定は、コージエライトハニカム基材を薄く切って、ハニカムのウェブの平らな部分を露出させ、そのウェブに対してX線回折を実施し、観察される回折ピークの強度を計算することによって行う。得られた値が、完全なランダム配向の結晶(すなわち、粉末)物体のI比である0.65より大きい場合、コージエライト結晶子は好ましい配向を有していると判断できる。すなわち、コージエライト結晶子の大部分は、c軸がウェブの平面内にあるように配向していると判断できる。I比が1.00の場合、すべてのコージエライト結晶子は負膨張軸(negative expansion axis)がウェブの平面内にあるように配向していることを意味しているであろう。それゆえに、横断I比(IT)が値1.00に近いほど、平面配向の度合いは高くなる。ここで軸I比の測定について具体的に述べると、この測定は、X線が当たる平面がハニカムウェブの断面端(cross-sectional ends)から構成されているセルのチャネルの長さに対して垂直(それゆえに、横断I比のそれに対しても垂直)である平面に対して行われる。別の言い方をすれば、このX線測定は、押出し方向に対して垂直なコージエライトハニカムの表面に対して行う。軸I比(IA)が0.65未満である場合、コージエライト結晶子が好ましい配向であることを前と同様に判断できる。具体的に言えば、コージエライト結晶子はそのc軸がウェブの平面内にあるように優先的に配向しているので、平面からの反射強度は完全なランダム配向のコージエライト結晶子の物体のそれよりも大きいと予想される。
Claims (10)
- 少なくとも約93重量%のコージエライトを含んでいる焼結相組成物を含むセラミック物品であって、前記コージエライトが約49〜約53重量%のSiO2、約33〜約38重量%のAl2O3、および約12〜約16重量%のMgOから実質的になり、前記焼結相組成物の軸方向の熱膨張係数が25℃〜800℃の温度範囲にわたって−0.6×10−7/℃と等しいかそれよりさらに負であることを特徴とするセラミック物品。
- 前記焼結相組成物の熱膨張係数が25℃〜800℃の温度範囲にわたって−1.0×10−7/℃と等しいかそれよりもさらに負であることを特徴とする請求項1に記載のセラミック物品。
- 前記焼結相組成物の熱膨張係数が25℃〜800℃の温度範囲にわたって−0.6×10−7/℃〜−2.0×10−7/℃であることを特徴とする請求項1に記載のセラミック物品。
- 前記焼結相組成物の熱膨張係数が25℃〜800℃の温度範囲にわたって−1.0×10−7/℃〜−2.0×10−7/℃であることを特徴とする請求項1に記載のセラミック物品。
- 焼結相コージエライト組成物を含むセラミック物品の製造方法であって、
分散性アルミナ源と酸化マグネシウム源を溶媒中で混合してスラリープレミックスを得る工程と、
前記スラリープレミックスから前記溶媒を実質的に除去して第1乾燥プレミックスを得る工程と、
少なくとも1種のシリカ源を前記第1乾燥プレミックスと一緒に混合してコージエライト前駆体バッチ組成物を得る工程と、
前記コージエライト前駆体バッチ組成物を結合剤系と一緒に混合して軟質のコージエライト前駆体組成物を形成する工程と、
前記軟質のコージエライト前駆体組成物から未焼成体を形成する工程と、
前記焼結相組成物を含むセラミック物品を得るのに十分な温度で十分な時間、前記未焼成体を焼成する工程と
を有してなるセラミック物品の製造方法。 - 前記酸化マグネシウム源が滑石を含み、前記分散性アルミナ源がベーマイトを含み、前記溶媒が水を含むことを特徴とする請求項5に記載の方法。
- 前記分散性アルミナ源がおよそ15〜およそ45重量%の前記コージエライト前駆体バッチ組成物を含むことを特徴とする請求項5に記載の方法。
- 前記焼結相コージエライト組成物が、約49〜約53重量%のSiO2、約33〜約38重量%のAl2O3、および約12〜約16重量%のMgOから実質的になる少なくとも約93重量%のコージエライトを含み、前記焼結相コージエライト組成物の熱膨張係数が25℃〜800℃の温度範囲にわたって−0.6×10−7/℃と等しいかそれよりもさらに負であることを特徴とする請求項5に記載の方法。
- 前記溶媒が噴霧乾燥によって前記スラリープレミックスから除去されることを特徴とする請求項5に記載の方法。
- 少なくとも1種のシリカ源を前記第1乾燥プレミックスと一緒に混合してコージエライト前駆体バッチ組成物を得るステップが、少なくとも1種の追加無機バッチ材料を前記第1乾燥プレミックスと混合することをさらに含み、前記少なくとも1種の追加無機バッチ材料が原料粘土、火焼粘土、滑石、シリカ、アルミナ、ベーマイト、またはそれらの混合物を含むことを特徴とする請求項5に記載の方法。
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US11/141,784 US7300898B2 (en) | 2005-05-31 | 2005-05-31 | Low CTE cordierite body |
PCT/US2006/018232 WO2006130321A2 (en) | 2005-05-31 | 2006-05-12 | Low cte cordierite body and methods of manufacturing same |
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