JP2009517326A - 細孔径分布の狭いコージエライトセラミックハニカム物品およびその製造方法 - Google Patents
細孔径分布の狭いコージエライトセラミックハニカム物品およびその製造方法 Download PDFInfo
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- 239000011148 porous material Substances 0.000 title claims abstract description 128
- 239000000919 ceramic Substances 0.000 title claims abstract description 121
- 238000009826 distribution Methods 0.000 title claims abstract description 41
- 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 39
- 229910052878 cordierite Inorganic materials 0.000 title claims abstract description 38
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 30
- 239000002245 particle Substances 0.000 claims abstract description 21
- 229920001592 potato starch Polymers 0.000 claims abstract description 13
- 238000010304 firing Methods 0.000 claims description 30
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 26
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 20
- 239000007788 liquid Substances 0.000 claims description 14
- 238000002791 soaking Methods 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 239000011230 binding agent Substances 0.000 claims description 7
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 6
- 239000000395 magnesium oxide Substances 0.000 claims description 5
- 239000002243 precursor Substances 0.000 claims description 4
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 3
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 2
- 238000001914 filtration Methods 0.000 abstract description 22
- 210000004027 cell Anatomy 0.000 description 27
- 239000004071 soot Substances 0.000 description 27
- 239000000454 talc Substances 0.000 description 15
- 229910052623 talc Inorganic materials 0.000 description 15
- 239000012700 ceramic precursor Substances 0.000 description 9
- 238000007654 immersion Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 230000035699 permeability Effects 0.000 description 9
- 238000001125 extrusion Methods 0.000 description 7
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 7
- 229910052753 mercury Inorganic materials 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- 230000004044 response Effects 0.000 description 7
- 229920002472 Starch Polymers 0.000 description 5
- 239000004927 clay Substances 0.000 description 5
- 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 5
- 230000035939 shock Effects 0.000 description 5
- 235000019698 starch Nutrition 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 4
- 210000002421 cell wall Anatomy 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 230000000877 morphologic effect Effects 0.000 description 4
- 238000002459 porosimetry Methods 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000008107 starch Substances 0.000 description 4
- 239000005995 Aluminium silicate Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 235000012211 aluminium silicate Nutrition 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000001413 cellular effect Effects 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 239000000314 lubricant Substances 0.000 description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 230000000630 rising effect Effects 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 2
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 2
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 2
- 239000005642 Oleic acid Substances 0.000 description 2
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 2
- 238000002441 X-ray diffraction Methods 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
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical class [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910001593 boehmite Inorganic materials 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 2
- 229910010272 inorganic material Inorganic materials 0.000 description 2
- 239000011147 inorganic material Substances 0.000 description 2
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 2
- 229910052622 kaolinite Inorganic materials 0.000 description 2
- 229920000609 methyl cellulose Polymers 0.000 description 2
- 239000001923 methylcellulose Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 2
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910002706 AlOOH Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- SMZOGRDCAXLAAR-UHFFFAOYSA-N aluminium isopropoxide Chemical compound [Al+3].CC(C)[O-].CC(C)[O-].CC(C)[O-] SMZOGRDCAXLAAR-UHFFFAOYSA-N 0.000 description 1
- MHCAFGMQMCSRGH-UHFFFAOYSA-N aluminum;hydrate Chemical compound O.[Al] MHCAFGMQMCSRGH-UHFFFAOYSA-N 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 229910001680 bayerite Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000009924 canning Methods 0.000 description 1
- 150000001721 carbon Chemical class 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
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 229910002026 crystalline silica Inorganic materials 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 229910001648 diaspore Inorganic materials 0.000 description 1
- 238000002276 dielectric drying Methods 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
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000007572 expansion measurement Methods 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 230000009931 harmful effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 125000004356 hydroxy functional group Chemical group 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
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 230000002688 persistence Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- -1 silicon organometallic compound Chemical class 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/0615—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
- C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
- Y10S264/48—Processes of making filters
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S55/00—Gas separation
- Y10S55/05—Methods of making filter
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S55/00—Gas separation
- Y10S55/10—Residue burned
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S55/00—Gas separation
- Y10S55/30—Exhaust treatment
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Filtering Materials (AREA)
- Exhaust Gas After Treatment (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
Description
102 入口端
104 出口端
106 多孔質壁
108,110 セル
112 栓
Claims (36)
- セラミックハニカム物品において、
総気孔率(%P)、42%<%P<56%、および
前記総気孔率の15%未満しか10μm未満の細孔径を有さず、該総気孔率の20%未満しか30μmより大きい細孔径を有さず、d幅=(d90−d10)/d50であるd幅≦1.50を有する細孔径分布、
を有する、コージエライトを含有する多孔質セラミックからなるセラミックハニカム物品。 - %P<54%をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。
- %P<52%をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。
- 44%<%P<52%をさらに含むことを特徴とする請求項3記載のセラミックハニカム物品。
- 前記総気孔率の10%未満しか10μm未満の細孔径を有さないことを特徴とする請求項1記載のセラミックハニカム物品。
- 前記総気孔率の25%未満しか30μmより大きい細孔径を有さないことを特徴とする請求項1記載のセラミックハニカム物品。
- 前記総気孔率の60%より多くが、10μm以上かつ30μm以下の細孔径を有することを特徴とする請求項1記載のセラミックハニカム物品。
- 前記総気孔率の70%より多くが、10μm以上かつ30μm以下の細孔径を有することを特徴とする請求項7記載のセラミックハニカム物品。
- 前記総気孔率の80%より多くが、10μm以上かつ30μm以下の細孔径を有することを特徴とする請求項7記載のセラミックハニカム物品。
- 前記総気孔率が、13μm≦d50≦22μmのメジアン細孔径(d50)を含むことを特徴とする請求項1記載のセラミックハニカム物品。
- 14μm≦d50≦21μmであることを特徴とする請求項10記載のセラミックハニカム物品。
- 25℃から800℃の温度範囲に亘りCTE≦8.0×10-7/℃の熱膨張係数(CTE)をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。
- CTE≦6.0×10-7/℃(25℃から800℃)であることを特徴とする請求項12記載のセラミックハニカム物品。
- CTE≦5.0×10-7/℃(25℃から800℃)であることを特徴とする請求項12記載のセラミックハニカム物品。
- CTE≦4.0×10-7/℃(25℃から800℃)であることを特徴とする請求項12記載のセラミックハニカム物品。
- CTE≦3.0×10-7/℃(25℃から800℃)であることを特徴とする請求項12記載のセラミックハニカム物品。
- 前記細孔径分布が、d因子=(d50−d10)/d50であるd因子≦0.45をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。
- d因子≦0.40であることを特徴とする請求項17記載のセラミックハニカム物品。
- d因子≦0.35であることを特徴とする請求項17記載のセラミックハニカム物品。
- d因子≦0.33であることを特徴とする請求項17記載のセラミックハニカム物品
- 前記細孔径分布が、d幅=(d90−d10)/d50であるd幅≦1.35をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。
- d幅≦1.20であることを特徴とする請求項21記載のセラミックハニカム物品。
- d幅≦1.10であることを特徴とする請求項21記載のセラミックハニカム物品。
- 44%<%P<52%、
14μm≦d50≦21μm、
CTE≦6.0×10-7/℃(25℃から800℃)、および
d因子=(d50−d10)/d50であるd因子≦0.45
をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。 - 42%<%P<56%、
13μm≦d50≦22μm、
CTE≦6.0×10-7/℃(25℃から800℃)、および
d幅≦1.35
をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。 - d因子=(d50−d10)/d50であるd因子≦0.45、および
d幅≦1.35
をさらに含むことを特徴とする請求項1記載のセラミックハニカム物品。 - セラミックハニカム物品を製造する方法であって、
酸化マグネシウム源、アルミナ形成源、およびシリカ形成源から選択される無機バッチ成分、
40μmより大きいメジアン粒径を有する細孔形成剤、
液体ビヒクル、および
結合剤、
を含有する可塑化コージエライト前駆体バッチ組成物を提供し、
前記可塑化コージエライト前駆体バッチ組成物からハニカム未焼成体を成形し、
前記ハニカム未焼成体を、コージエライトを含有し、42%より大きくかつ56%未満の総気孔率および該総気孔率の15%未満しか10μm未満の細孔径を有さずかつ該総気孔率の20%未満しか30μmより大きい細孔径を有さない細孔径分布を有するセラミックハニカム物品に転化するのに効果的な焼成条件下で、前記ハニカム未焼成体を焼成する、
各工程を有してなる方法。 - 前記細孔形成剤がバレイショデンプンを含むことを特徴とする請求項27記載の方法。
- 前記細孔形成剤が、前記無機バッチ成分の総質量に対して5質量%から20質量%の量で存在することを特徴とする請求項27記載の方法。
- 前記細孔形成剤が、45μmから55μmの範囲のメジアン粒径を有するバレイショデンプンを含むことを特徴とする請求項27記載の方法。
- 前記無機バッチ成分が、
酸化物の質量基準で、
約49から約53質量パーセントのSiO2、
約33から約38質量パーセントのAl2O3、および
約12から約16質量パーセントのMgO、
からなる群より選択される焼結相コージエライト組成を提供するように選択されることを特徴とする請求項27記載の方法。 - 前記効果的な焼成条件が、前記ハニカム未焼成体を1350℃から1450℃の範囲の最高浸漬温度で焼成し、続いて、該最高浸漬温度を、前記ハニカム未焼成体を、コージエライトを含有するセラミックハニカム物品に転化するのに十分な期間に亘り保持することを含むことを特徴とする請求項27記載の方法。
- 前記最高浸漬温度が約1415℃から約1435℃の範囲にあることを特徴とする請求項32記載の方法。
- 前記最高浸漬温度が、温度を、60℃/時以下の平均上昇速度で、約1300℃より高くから該最高浸漬温度に上昇させることにより達成されることを特徴とする請求項32記載の方法。
- 前記最高浸漬温度が、温度を、10℃/時から70℃/時の間の平均上昇速度で、約1300℃に上昇させることにより達成されることを特徴とする請求項32記載の方法。
- セラミックハニカム物品において、
総気孔率(%P)、42%<%P<56%、および
d幅=(d90−d10)/d50であるd幅≦1.50とd因子=(d50−d10)/d50であるd因子≦0.45を有する細孔径分布、
を有する、コージエライトを含有する多孔質セラミックからなるセラミックハニカム物品。
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US11/291,831 | 2005-11-30 | ||
US11/291,831 US7485170B2 (en) | 2005-11-30 | 2005-11-30 | Narrow pore size distribution cordierite ceramic honeycomb articles and methods for manufacturing same |
PCT/US2006/042384 WO2007064433A2 (en) | 2005-11-30 | 2006-10-31 | Narrow pore size distribution cordierite ceramic honeycomb articles and methods for manufacturing same |
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JP2009517326A true JP2009517326A (ja) | 2009-04-30 |
JP2009517326A5 JP2009517326A5 (ja) | 2010-04-02 |
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US (1) | US7485170B2 (ja) |
EP (1) | EP1968913B1 (ja) |
JP (1) | JP5199111B2 (ja) |
CN (1) | CN101316805B (ja) |
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JP5199111B2 (ja) | 2013-05-15 |
US7485170B2 (en) | 2009-02-03 |
EP1968913B1 (en) | 2011-12-07 |
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