JP2010516621A - 押出成形した繊維状炭化ケイ素基材およびその製造方法 - Google Patents
押出成形した繊維状炭化ケイ素基材およびその製造方法 Download PDFInfo
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Abstract
【選択図】図1
Description
本発明の例に関する詳細説明をここに示す。ただし、本発明はさまざまな形で例示される場合があることを理解すべきである。そのため、ここに開示する特定の詳細は制限的なものとして解釈されるべきではなく、むしろ実質的にすべての詳述したシステム、構造または様式において本発明を使用する方法を当業者に教示するための代表的な基本として捉えられるべきである。
C + Si → SiC
ただし、ケイ素系成分がシリカである場合は、反応は次式で描写することができる。
3C + SiO2 → SiC +2CO2
この反応では、安定したSiCが形成される前に中間体である移行的な化合物が形成される場合があることを理解すべきである。
3C + SiO2 → SiC +2CO2
2C+ 2SiO → 2SiC + O2
C + Si → SiC
ただし、ケイ素系成分がシリカである場合は、反応は次式で描写することができる。
C + SiO2 → SiC + O2
この反応は構造が不活性環境下で、少なくとも1400°C以上の温度で長期間、例えば4時間加熱したときに発生する。不活性環境は、炭素が二酸化炭素に酸化されることを阻止するべく、酸素の不在を確保するために必要である。結果的に生じる構造を一般的に図5に示すが、ここで炭化ケイ素繊維430は、絡み合い重複した関係で表示され、開放細孔網440を形成している。
短炭素繊維 17.9%
コロイド状シリカ(50%水溶液) 59.7%
hpmc 10.0%
脱イオン水 12.4%
短炭素繊維 16.7%
コロイド状シリカ(50%水溶液) 32.4%
hpmc 9.3%
脱イオン水 41.6%
短炭素繊維 17.6%
金属ケイ素粉末(約45 μm) 41.2%
hpmc 11.8%
脱イオン水 29.4%
短炭素繊維 16.3%
金属ケイ素粉末(約45 μm) 45.7%
hpmc 10.9%
脱イオン水 27.2%
短炭素繊維 16.2%
金属ケイ素粉末(約45 μm) 37.8%
ベントナイト 2.7%
hpmc 10.8%
脱イオン水 32.4%
短炭素繊維 14.7%
金属ケイ素粉末(約45 μm) 34.3%
金属チタン粉末(約45 μm) 11.8%
hpmc 9.8%
脱イオン水 29.4%
短炭素繊維 15.9%
金属ケイ素粉末(約45 μm) 37.1%
金属アルミニウム粉末(約45 μm) 7.2%
hpmc 10.6%
脱イオン水 29.2%
短炭素繊維 18.8%
金属ケイ素粉末(約45 μm) 43.8%
SMP-10 SiC前駆物質ポリマー溶液 6.3%
エチルセルロース 12.5%
トルエン 18.8%
West Systems 403 Microfibers 16.7%
金属ケイ素粉末(約45 μm) 38.9%
Hpmc 11.1%
脱イオン水 33.3%
Claims (27)
- 繊維状炭化ケイ素基材を製造する方法であって、
押出成形可能な混合物を提供するために、炭素繊維を、ケイ素および結合剤で構成される添加物、および流体と混合し、
前記押出成形可能な混合物を未焼成基材として押出成形し、
前記炭素繊維および前記添加物を用いて炭化ケイ素繊維を形成すべく、前記未焼成基材を加熱する、ことを特徴とする繊維状炭化ケイ素基材の製造方法。 - 前記加熱ステップがさらに、
前記未焼成基材を第一の温度に加熱して、実質的にすべての流体を除去し、
前記未焼成基材を第二の温度に加熱して、添加物の結合剤部分を除去し、
前記未焼成基材を第三の温度に加熱して、炭化ケイ素を形成する、
ことから構成される、請求項1に記載の製造方法。 - 第三の温度が少なくとも1400℃である、請求項2に記載の製造方法。
- 前記添加物がさらに金属ケイ素粒子を備える、請求項1に記載の製造方法。
- 前記添加物がさらにシリカ粒子を備える、請求項1に記載の製造方法。
- 炭素繊維とシリカ粒子の比が、炭素繊維1に対してシリカが約2〜5である、請求項5に記載の製造方法。
- 前記添加物がさらにメチルセルロースを備える、請求項1に記載の製造方法。
- 前記炭素繊維がさらに、ポリアクリルニトリジル炭素繊維、石油ピッチ炭素繊維および炭化した有機繊維のうち少なくとも一つを備えてなる、請求項1に記載の製造方法。
- 前記添加物がさらに、細孔形成剤、可塑剤および分散剤のうち少なくとも一つを備えてなる、請求項1に記載の製造方法。
- 繊維状炭化ケイ素基材を製造する方法であって、
押出成形可能な混合物を提供するために、炭素繊維を、コロイド状シリカ、有機結合剤、および流体と混合し、
前記押出成形可能な混合物を未焼成基材として押出成形し、
前記未焼成基材から流体を除去し、
有機結合剤を分解し、
前記炭素繊維および前記コロイド状シリカを用いて炭化ケイ素を形成する反応をさせる、ことを特徴とする繊維状炭化ケイ素基材の製造方法。 - 前記混合ステップがさらに結合剤を含み、
前記形成ステップがさらに、前記結合剤を用いた結合の形成を含んでなる、請求項10に記載の製造方法。 - 前記炭素繊維が、ポリアクリルニトリジル炭素繊維、石油ピッチ炭素繊維および炭化した有機繊維のうち少なくとも一つを備えてなる、請求項10に記載の製造方法。
- 前記炭素繊維が1〜1000のアスペクト比を持つ、請求項12に記載の製造方法。
- 多孔質セラミック基材であって、
開放細孔網を形成する炭化ケイ素繊維から成る構造と、
その構造内にて少なくとも部分的に形成された複数の経路と、
入口経路として構成された、前記複数の経路のうちの少なくとも一つと、
出口経路として構成された、前記複数の経路のうちの他の少なくとも一つと、
を備えてなる多孔質セラミック基材。 - 前記構造がさらに、隣接する炭化ケイ素繊維間での金属結合、セラミック結合およびガラス結合のうち少なくとも一つを備える、請求項14に記載の多孔質セラミック基材。
- 前記炭化ケイ素繊維が、炭素繊維およびケイ素系添加物の混合物の反応から形成される、請求項14に記載の多孔質セラミック基材。
- 前記複数の経路が押出により形成される、請求項14に記載の多孔質セラミック基材。
- 押出成形されたハニカム基材であって、
隣接した経路間で多孔性の壁を形成するハニカムアレイの経路を備え、
前記多孔性の壁は、絡み合った炭化ケイ素繊維から形成される開放細孔網からなる構造を有してなる、ことを特徴とするハニカム基材。 - 前記絡み合った炭化ケイ素繊維が少なくとも部分的に金属結合で結合されている、請求項18に記載のハニカム基材。
- 前記金属結合がケイ素からなる、請求項19に記載のハニカム基材。
- 前記絡み合った炭化ケイ素繊維が少なくとも部分的にガラス結合またはセラミック結合で結合されている、請求項18に記載のハニカム基材。
- 前記ガラス結合またはセラミック結合がシリカからなる、請求項21に記載のハニカム基材。
- 前記絡み合った炭化ケイ素繊維が少なくとも部分的にポリマー結合で結合されている、請求項18に記載のハニカム基材。
- 入口および出口を有するハウジングと、
前記ハウジング内に設けられた押出成形したハニカム基材と
を具備したフィルタであって、
前記ハニカム基材は、隣接した経路間で多孔性の壁を形成するハニカムアレイの経路を備え、
前記多孔性の壁は、絡み合った炭化ケイ素繊維から形成される開放細孔網からなる構造を有しており、
前記ハニカムアレイの経路は、入口経路のセットおよび出口経路のセットとして構成されており、
フィルタハウジング内の流れは、前記入口から入口経路を通過し、多孔性の壁を通って出口経路に入り、出口に向かって出る、ことを特徴とするフィルタ。 - 前記絡み合った炭化ケイ素繊維が少なくとも部分的に金属結合で結合されている、請求項24に記載のフィルタ。
- 前記絡み合った炭化ケイ素繊維が少なくとも部分的にガラス結合またはセラミック結合で結合されている、請求項24に記載のフィルタ。
- 前記絡み合った炭化ケイ素繊維が少なくとも部分的にポリマー結合で結合されている、請求項24に記載のフィルタ。
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US11/669,671 US20080179782A1 (en) | 2007-01-31 | 2007-01-31 | Extruded Fibrous Silicon Carbide Substrate and Methods for Producing the Same |
PCT/US2008/052372 WO2008094955A2 (en) | 2007-01-31 | 2008-01-30 | An extruded fibrous silicon carbide substrate and methods for producing the same |
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US (1) | US20080179782A1 (ja) |
EP (1) | EP2129624A4 (ja) |
JP (1) | JP2010516621A (ja) |
TW (1) | TW200844048A (ja) |
WO (1) | WO2008094955A2 (ja) |
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