JP2009541187A - コージエライトの形成 - Google Patents
コージエライトの形成 Download PDFInfo
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- JP2009541187A JP2009541187A JP2009513236A JP2009513236A JP2009541187A JP 2009541187 A JP2009541187 A JP 2009541187A JP 2009513236 A JP2009513236 A JP 2009513236A JP 2009513236 A JP2009513236 A JP 2009513236A JP 2009541187 A JP2009541187 A JP 2009541187A
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- cordierite
- boron oxide
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- 229910052878 cordierite Inorganic materials 0.000 title claims abstract description 50
- 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 50
- 230000015572 biosynthetic process Effects 0.000 title description 6
- 239000011148 porous material Substances 0.000 claims abstract description 74
- 238000005245 sintering Methods 0.000 claims abstract description 54
- 238000010304 firing Methods 0.000 claims abstract description 35
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 31
- 239000000919 ceramic Substances 0.000 claims abstract description 29
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 28
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 15
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 15
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 14
- 239000011230 binding agent Substances 0.000 claims abstract description 10
- 238000004519 manufacturing process Methods 0.000 claims abstract description 8
- 238000002156 mixing Methods 0.000 claims abstract description 6
- 239000002904 solvent Substances 0.000 claims abstract description 6
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical group O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims description 51
- 229910052810 boron oxide Inorganic materials 0.000 claims description 50
- 239000000203 mixture Substances 0.000 claims description 32
- 229910052796 boron Inorganic materials 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 20
- 239000004033 plastic Substances 0.000 claims description 14
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 239000010439 graphite Substances 0.000 claims description 5
- 229910002804 graphite Inorganic materials 0.000 claims description 5
- 229920002472 Starch Polymers 0.000 claims description 2
- 238000004458 analytical method Methods 0.000 claims description 2
- 239000002243 precursor Substances 0.000 claims description 2
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- 239000008107 starch Substances 0.000 claims description 2
- 238000009826 distribution Methods 0.000 abstract description 21
- 230000035939 shock Effects 0.000 abstract description 6
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- 239000011521 glass Substances 0.000 description 27
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- 239000000047 product Substances 0.000 description 14
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- 239000000454 talc Substances 0.000 description 8
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- 239000002245 particle Substances 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 239000013078 crystal Substances 0.000 description 5
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- 239000004927 clay Substances 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
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- 239000002244 precipitate Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 239000005388 borosilicate glass Substances 0.000 description 3
- 230000003197 catalytic effect Effects 0.000 description 3
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000000543 intermediate Substances 0.000 description 2
- 239000013067 intermediate product Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 238000003746 solid phase reaction Methods 0.000 description 2
- 229910052596 spinel Inorganic materials 0.000 description 2
- 239000011029 spinel Substances 0.000 description 2
- 238000005382 thermal cycling Methods 0.000 description 2
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- RPZANUYHRMRTTE-UHFFFAOYSA-N 2,3,4-trimethoxy-6-(methoxymethyl)-5-[3,4,5-trimethoxy-6-(methoxymethyl)oxan-2-yl]oxyoxane;1-[[3,4,5-tris(2-hydroxybutoxy)-6-[4,5,6-tris(2-hydroxybutoxy)-2-(2-hydroxybutoxymethyl)oxan-3-yl]oxyoxan-2-yl]methoxy]butan-2-ol Chemical compound COC1C(OC)C(OC)C(COC)OC1OC1C(OC)C(OC)C(OC)OC1COC.CCC(O)COC1C(OCC(O)CC)C(OCC(O)CC)C(COCC(O)CC)OC1OC1C(OCC(O)CC)C(OCC(O)CC)C(OCC(O)CC)OC1COCC(O)CC RPZANUYHRMRTTE-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229920000896 Ethulose Polymers 0.000 description 1
- 239000001859 Ethyl hydroxyethyl cellulose Substances 0.000 description 1
- 241000422980 Marietta Species 0.000 description 1
- 229920003091 Methocel™ Polymers 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000004814 ceramic processing Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- PBAYDYUZOSNJGU-UHFFFAOYSA-N chelidonic acid Natural products OC(=O)C1=CC(=O)C=C(C(O)=O)O1 PBAYDYUZOSNJGU-UHFFFAOYSA-N 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000001186 cumulative effect Effects 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
- 239000012153 distilled water Substances 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
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- 239000012467 final product Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 230000014509 gene expression Effects 0.000 description 1
- 238000007496 glass forming Methods 0.000 description 1
- 239000000017 hydrogel Substances 0.000 description 1
- 229920003063 hydroxymethyl cellulose Polymers 0.000 description 1
- 229940031574 hydroxymethyl cellulose Drugs 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
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- 238000007569 slipcasting Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 230000001052 transient effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000004627 transmission electron microscopy Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- 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
- C04B35/18—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 rich in aluminium oxide
- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3409—Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
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Abstract
Description
溶媒に完全に、またはある程度溶解させた焼結促進剤を含む溶液を調製し、
マグネシア源、アルミナ源、及びシリカ源を含むコージエライト形成バッチを調製し、
前記溶液、コージエライト形成バッチ、及び有機結合剤を混合して可塑性の混合物を提供し、
前記可塑性の混合物を成形して成形された物品を形成し、
前記成形された物品を結晶質のコージエライトに転換するのに効果的な温度及び時間で、前記成形された物品を乾燥及び加熱する、
各工程を有してなる。本方法は、有利なことに、加熱温度が低く、及び/または加熱時間が短くて済む。本発明の別の態様は、改善された特性、すなわち、1μm未満、たいていの場合は3μm未満の大きさの孔隙の大きな影響を受けずに、所望のCTE、非常に高いMOR、高孔隙率、及び幅の狭い孔隙径分布を有するセラミックのマイクロ構造を生じさせる焼結助剤を含む、バッチ組成物を提供する。
本発明のコージエライト・セラミック物品を製造するために成形し、乾燥し、加熱した可塑性の混合物は、溶解させた焼結促進剤を含む溶液、マグネシア源、アルミナ源、シリカ源、及び有機結合剤を含む。「マグネシア源」、「アルミナ源」、及び「シリカ源」という表現は、マグネシア、アルミナ、及びシリカ自体、または、焼成の際にマグネシア、アルミナ、及び/またはシリカの発生源となる、他の材料のことをいう。適切なコージエライト形成マグネシア源、アルミナ源、及びシリカ源は周知であるので、ここでは特に記載しない。混合物には、随意的に、孔隙形成剤を含めてもよい。孔隙形成剤は、未焼成体の乾燥及び加熱の間に、蒸発または燃焼によって気化し、他の方法で得られるよりも高い孔隙率及び/または粗いメジアン孔隙径をもたらす、一過性の粒子物質である。孔隙形成剤は、原料に基づいて、10重量%〜50重量%の量で用いられる。典型的には、グラファイト孔隙形成剤を、可塑性の混合物の重量に基づいて、10〜40%の量で用いて差し支えない。別の方法としては、デンプン孔隙形成剤を、可塑性の混合物の重量に基づいて、典型的には約10%〜20%の量で用いて構わない。少なくとも10μmで50μmを超えない粒径を有する孔隙形成剤が、典型的に用いられる。
セラミックペーストは、射出成形法、スリップキャスト法、乾式プレス法など、当技術分野で既知の任意のセラミック形成方法で成形して差し支えないが、好ましい成形技法として、ダイに通した押出成形法が挙げられる。このような技法は、自動車用触媒コンバータ及び微粒子フィルタの製造に極めて有用な、薄壁ハニカム・モノリスの形成に使用して差し支えない。適切な押出成形法及び他の成形技法は当技術分野で周知であり、ここでは特に記載しない。
Claims (9)
- コージエライト・セラミック物品の製造方法であって、
溶媒に溶解させた焼結促進剤を含む溶液を調製する工程、
前記溶液、マグネシア源、アルミナ源、シリカ源、及び有機結合剤を混合して可塑性の混合物を提供する工程であって、前記焼結促進剤が均一に分散されている工程、
前記可塑性の混合物を成形して、成形物品を形成する工程、および
前記成形物品を結晶質のコージエライトに転化するのに効果的な温度及び時間で、前記成形物品を加熱する工程、
を有してなる方法。 - 前記焼結促進剤が、乾燥ベースで、前記可塑性の混合物の約0.3〜約0.5%を構成することを特徴とする請求項1記載の方法。
- 前記可塑性の混合物を成形する前に、該可塑性の混合物に孔隙形成剤を分散させることを特徴とする請求項1記載の方法。
- 前記孔隙形成剤が、前記可塑性の混合物の約10〜40重量%の量で存在するグラファイト微粒子であることを特徴とする請求項3記載の方法。
- 前記孔隙形成剤が、前記可塑性の混合物の約10〜20重量%の量で存在するデンプンであることを特徴とする請求項4記載の方法。
- 前記溶媒が水であり、前記焼結促進剤が酸化ホウ素であることを特徴とする請求項1記載の方法。
- マグネシア源、アルミナ源、シリカ源、有機結合剤、及び、溶媒中に溶解させた焼結粗促進剤を含む溶液、を含む混合物
を含む、可塑性のコージエライト前駆体組成物。 - 前記焼結促進剤が酸化ホウ素であることを特徴とする請求項7記載の組成物。
- 前記組成物を成形し、焼成した後、ICP分析によって決定される残留ホウ素含量が0.05〜1.8%の範囲であることを特徴とする請求項8記載の方法。
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US11/443,807 | 2006-05-30 | ||
US11/443,807 US20070281127A1 (en) | 2006-05-30 | 2006-05-30 | Cordierite formation |
PCT/US2007/012653 WO2007142921A1 (en) | 2006-05-30 | 2007-05-29 | Cordierite formation |
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EP (1) | EP2029496A1 (ja) |
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US7960009B2 (en) * | 2008-02-29 | 2011-06-14 | Corning Incorporated | Dispersion-toughened cordierite for filter and substrate applications |
US8148297B2 (en) * | 2009-11-30 | 2012-04-03 | Corning Incorporated | Reticular cordierite composition, article and manufacture thereof |
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CN101460418A (zh) | 2009-06-17 |
EP2029496A1 (en) | 2009-03-04 |
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