JP2010519169A - 4ウェイおよび窒素酸化物吸着剤用のセラミック材およびその製造方法 - Google Patents
4ウェイおよび窒素酸化物吸着剤用のセラミック材およびその製造方法 Download PDFInfo
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Abstract
Description
より厳しい規制により、ディーゼル排気の軽減のための後処理技術の改善が依然として推進されている。HC、NOx、CO、およびPMの排気を同時に制御する排気量削減システムは、本業界において4ウェイシステムと呼ばれるが、多数のOEM(相手先ブランド製造)メーカーが望む未来の技術である。現在の4ウェイ排気量削減技術では、微細な多孔質のセラミックフィルター上にコーティングする窒素酸化物吸着剤(貯蔵)材料の使用が提案されている。使用の際、エンジンはリッチ運転モードとリーン運転モードを繰り返す。エンジンがリーン運転モードになっている間、粒子状物質は窒素酸化物吸着剤から放出される活性酸素および排気からの過剰酸素により酸化される。リッチモードの間は、粒子状物質も吸着されたNOxの低減の間に放出される活性酸素によっても酸化される一方で、窒素酸化物は削減される。
a(Al2TiO5)+ b(ZrTiO4)+ c(Y2O3)+ d(YPO4)
を含む、焼結相セラミック組成物であり、
ここで、a、b、c、およびdが(a + b + c + d)= 1.00であるような各成分の重量画分であり、0.5 < a ≦ 0.95、0 ≦ b ≦ 0.5、0.0 ≦ c ≦ 0.10、および0 ≦ d ≦ 0.5である。そのセラミック物品は、例えばカリウム系の触媒組成を含む、アルカリ系またはアルカリ土類系の触媒組成をさらに含みうる。本セラミック物品におけるシリカの欠如は、1つの態様においては、本セラミック物品をカリウム移動に対して耐性を持たせることができる。またさらなる態様においては、本発明のセラミック物品は、比較的低い熱膨張係数を伴う、比較的高い熱容量を示す。触媒した場合、その結果得られるセラミック体は依然として耐久性を有し、低いCTEおよび高い耐熱衝撃性を維持している。
a(Al2TiO5)+ b(ZrTiO4)+ c(Y2O3)+ d(YPO4)
を含む、焼結相セラミック酸化物組成からなり、
ここで、a、b、c、およびdが(a + b + c + d)= 1.00となる各成分の重量画分であり、
0.5 < a ≦ 0.95、0 ≦ b ≦ 0.5、0.0 ≦ c ≦ 0.10、および0 ≦ d ≦ 0.5である。
チタン酸ジルコニウムおよびチタン酸アルミニウム(ZT-AT)から実質的に構成される、本発明の4つの焼結相セラミック酸化物組成物は、様々な相対酸化物重量画分で、下記の表1に規定される典型的なバッチ組成物から調製された。
本発明に従ったチタン酸アルミニウムのセラミック物品について、非ケイ酸塩型添加物および強化剤としてのリン酸イットリウムの適合性についても、3種類の押出成形バッチを使用して評価した。それに関して、リン酸イットリウムおよびチタン酸アルミニウム(YP-AT)を含む、3種類の本発明の焼結相セラミック酸化物組成物を、下記の表3に規定する典型的なバッチ組成物から調製した。
Claims (22)
- 酸化物重量パーセント基準表示で、
a(Al2TiO5)+ b(ZrTiO4)+ c(Y2O3)+ d(YPO4)
を含む、焼結相セラミック組成物を含むセラミック物品であって、
ここで、
a、b、c、およびdは、(a + b + c + d)= 1.00になる、各成分の重量画分であり、
0.5 < a ≦ 0.95、0 ≦ b ≦ 0.5、0.0 ≦ c ≦ 0.10、および0 ≦ d ≦ 0.5である、
セラミック物品。 - 前記焼結相セラミック組成物が、チタン酸アルミニウム、チタン酸ジルコニウム、および酸化イットリウムから実質的に構成され、
0.60 ≦ a ≦ 0.80および0.20 ≦ b ≦ 0.40および0.00 ≦ c ≦ 0.05であることを特徴とする請求項1記載のセラミック物品。 - 前記焼結相セラミック組成物が、チタン酸アルミニウムおよびリン酸イットリウムから実質的に構成され、
0.5 ≦ a ≦ 0.95および0.05 ≦ d ≦ 0.5であることを特徴とする請求項1記載のセラミック物品。 - 前記焼結相セラミック組成物の全孔隙率が45%以上であることを特徴とする請求項1記載のセラミック物品。
- 前記焼結相セラミック組成物の全孔隙率が50%以上であることを特徴とする請求項4記載のセラミック物品。
- 前記焼結相セラミック組成物の全孔隙率が50%から60%の範囲であることを特徴とする請求項4記載のセラミック物品。
- 前記焼結相セラミック組成物の少なくとも一方向の熱膨張係数が、25℃から1000℃の温度範囲にわたって15.0×10-7/℃以下であることを特徴とする請求項1記載のセラミック物品。
- 前記焼結相セラミック組成物の少なくとも一方向の熱膨張係数が、25℃から1000℃の温度範囲にわたって12.0×10-7/℃以下であることを特徴とする請求項1記載のセラミック物品。
- 前記焼結相セラミック組成物の少なくとも一方向の熱膨張係数が、25℃から1000℃の温度範囲にわたって10.0×10-7/℃以下であることを特徴とする請求項1記載のセラミック物品。
- 前記焼結相セラミック組成物の少なくとも一方向の熱膨張係数が、蒸気中、850℃で10時間劣化処理した後、25℃から1000℃の温度範囲にわたって20.0×10-7/℃以下であることを特徴とする請求項1記載のセラミック物品。
- アルカリ触媒ウォッシュコーティングをさらに含むことを特徴とする請求項1記載のセラミック物品。
- 前記アルカリ触媒ウォッシュコーティングがカリウムを含むことを特徴とする請求項1記載のセラミック物品。
- 前記セラミック物品がハニカム体であることを特徴とする請求項1記載のセラミック物品。
- セラミック物品の製造方法であって、
アルミナ源、チタニア源、および少なくとも1つのジルコニア源、イットリア源、リン酸塩源、およびリン酸イットリウム源を含む可塑化セラミック前駆体バッチ組成物、
有機結合剤、および
液体溶媒、
を提供する工程と、
前記可塑化セラミック前駆体バッチ組成物から押出成形された未焼成体を形成する工程と、
前記セラミック前駆体バッチ組成物を焼結相セラミック組成物に変換するために有効な条件下で、前記形成された未焼成体を焼成する工程と、
を有してなる方法。 - 前記セラミック前駆体バッチ組成物が、アルミナ源、チタニア源、およびジルコニア源を含むことを特徴とする請求項14記載の方法。
- 前記セラミック前駆体バッチ組成物が、酸化イットリウム焼結助剤をさらに含むことを特徴とする請求項15記載の方法。
- 前記セラミック前駆体バッチ組成物が、アルミナ源、チタニア源、およびリン酸イットリウム源をさらに含むことを特徴とする請求項14記載の方法。
- 前記形成された未焼成体を焼成する前に、前記未焼成体を乾燥させる工程をさらに含むことを特徴とする請求項14記載の方法。
- 前記セラミック前駆体バッチ組成物を焼結相セラミック組成物に変換するために有効な焼成条件が、前記形成された未焼成体を1400℃から1600℃までの範囲の温度で焼成することを含むことを特徴とする請求項14記載の方法。
- 前記セラミック前駆体バッチ組成物を焼結相セラミック組成物に変換するために有効な焼成条件が、前記形成された未焼成体を1450℃から1550℃までの範囲の温度で焼成することを含むことを特徴とする請求項19記載の方法。
- 焼成後に、未反応のチタニアが実質的に残らないことを特徴とする請求項18記載の方法。
- 前記押出成形された未焼成体がハニカム体であることを特徴とする請求項14記載の方法。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US11/711,336 | 2007-02-27 | ||
US11/711,336 US7713897B2 (en) | 2007-02-27 | 2007-02-27 | Ceramic materials for 4-way and NOx adsorber and method for making same |
PCT/US2008/001918 WO2008106014A2 (en) | 2007-02-27 | 2008-02-13 | Ceramic materials for 4-way and nox adsorber and method for making same |
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JP2010519169A true JP2010519169A (ja) | 2010-06-03 |
JP5335699B2 JP5335699B2 (ja) | 2013-11-06 |
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JP5344930B2 (ja) * | 2007-01-30 | 2013-11-20 | 京セラ株式会社 | ハニカム構造体および浄化装置 |
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US9221192B2 (en) * | 2010-11-30 | 2015-12-29 | Corning Incorporated | Ceramic processing firing |
FR2973368B1 (fr) * | 2011-03-31 | 2013-11-08 | Saint Gobain Ct Recherches | Grains fondus atz |
BR112013030870A2 (pt) * | 2011-06-01 | 2017-02-21 | Centre De Rech De L'industrie Belge De La Céramique | mistura de partículas de cerâmica, e um método para a fabricação de peças de cerâmica a partir de tal mistura |
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US10526249B2 (en) * | 2012-11-30 | 2020-01-07 | Corning Incorporated | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
US9102114B1 (en) * | 2013-03-15 | 2015-08-11 | Ibiden Co., Ltd. | Method for manufacturing aluminum-titanate-based ceramic honeycomb structure |
US9339791B2 (en) | 2013-06-18 | 2016-05-17 | Corning Incorporated | Low thermal expansion aluminum titanate zirconium tin titanate ceramics |
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JP6633192B2 (ja) | 2015-09-28 | 2020-01-22 | コーニング インコーポレイテッド | チタン酸ジルコニウムスズ組成物、それを含むセラミック体、およびそれを製造する方法 |
JP6756530B2 (ja) * | 2016-07-05 | 2020-09-16 | イビデン株式会社 | ハニカム構造体及びハニカム構造体の製造方法 |
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Also Published As
Publication number | Publication date |
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CN101622053A (zh) | 2010-01-06 |
CN101622053B (zh) | 2013-02-06 |
EP2117680A4 (en) | 2014-01-15 |
CN103058650A (zh) | 2013-04-24 |
US20100234216A1 (en) | 2010-09-16 |
CN103058650B (zh) | 2015-03-11 |
US7932201B2 (en) | 2011-04-26 |
US7713897B2 (en) | 2010-05-11 |
EP2117680B1 (en) | 2017-05-10 |
EP2117680A2 (en) | 2009-11-18 |
US20080203627A1 (en) | 2008-08-28 |
JP5335699B2 (ja) | 2013-11-06 |
WO2008106014A3 (en) | 2008-11-13 |
WO2008106014A2 (en) | 2008-09-04 |
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