JP2010535147A - 繊維ベースセラミック基材およびその製造方法 - Google Patents
繊維ベースセラミック基材およびその製造方法 Download PDFInfo
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Abstract
【解決手段】
基材が高温に曝露されても結晶シリカすなわちクリストバライトを形成しない安定した化合物の形成を促進する無機バインダーを使用することで、安価なアルミノシリケート繊維からセラミック基材物質が形成される。このアルミノシリケート繊維は有機バインダー、無機バインダーおよび液体を含む添加物と混合され、可塑性混合物を形成する。この可塑性混合物は素地基材に形成され、その後にセラミック基材に硬化される。繊維ベース組成は、濾過、断熱、および高温処理並びに化学反応に利用できる堅牢な多孔質構造物を形成させる。
Description
Claims (23)
- セラミック基材の製造方法であって、
15重量%から72重量%の範囲のアルミナを含有するアルミノシリケート繊維を準備するステップと、
該アルミノシリケート繊維を、無機バインダー、有機バインダー、および液体(流体)で成る添加物と混合して可塑性混合物を形成するステップと、
該可塑性混合物を素地基材に成型するステップと、
該素地基材を加熱して前記液体と前記有機バインダーとを除去するステップと、
前記素地基材を焼結させ、前記アルミノシリケート繊維と前記無機バインダーとで、安定した非結晶ガラスによって結合されたムライト構造物を形成させるステップと、
を含んで成る製造方法。 - ムライト構造物はアルミノシリケート繊維間の空間によって提供される空孔を有していることを特徴とする請求項1記載の製造方法。
- 添加物は空孔形成剤を含んでおり、該空孔形成剤は加熱ステップによって除去されることを特徴とする請求項2記載の製造方法。
- 有機バインダーはセリアを含んでいることを特徴とする請求項1記載の製造方法。
- 有機バインダーはコロイド状セリウムを含んでいることを特徴とする請求項1記載の製造方法。
- 無機バインダーはマグネシウムアルミナシリケートを含んでいることを特徴とする請求項1記載の製造方法。
- 無機バインダーはビーガムを含んでいることを特徴とする請求項6記載の製造方法。
- 無機バインダーは酸化カルシウムを含んでいることを特徴とする請求項1記載の製造方法。
- 無機バインダーはベントナイトを含んでいることを特徴とする請求項8記載の製造方法。
- 無機バインダーは、非結晶ガラスの熱膨張率をムライトの熱膨張率にほぼ対応させるように選択されることを特徴とする請求項1記載の製造方法。
- 無機バインダーは、非結晶ガラスの熱膨張率をアルミノシリケートの熱膨張率に対応して低下させるように選択されることを特徴とする請求項1記載の製造方法。
- 無機バインダーは酸化チタンを含んでいることを特徴とする請求項11記載の製造方法。
- 無機バインダーは繊維であることを特徴とする請求項1記載の製造方法。
- 焼結ステップは1000℃を超える温度で実施されることを特徴とする請求項1記載の製造方法。
- 可塑性混合物を素地基材に成型するステップは押出成型を含んでいることを特徴とする請求項1記載の製造方法。
- 素地基材はハニカム形態であることを特徴とする請求項15記載の製造方法。
- セラミック基材であって、アルミノシリケート繊維から形成された多結晶ムライト繊維を含んでおり、前記アルミノシリケート繊維は15重量%から72重量%の範囲のアルミナを含有しており、前記多結晶ムライト繊維は前記アルミノシリケート繊維と無機バインダーとから形成された安定した非結晶ガラスで結合されて堅牢構造物を形成しており、該堅牢構造物は1000℃を超える温度に曝露されてもクリストバライトを形成しないことを特徴とするセラミック基材。
- 多結晶ムライト繊維間の空間によって提供される空孔をさらに含んでいることを特徴とする請求項17記載のセラミック基材。
- 堅牢構造物は押出成型によって提供されたハニカム形態を有していることを特徴とする請求項18記載のセラミック基材。
- 無機バインダーは、酸化カルシウム、マグネシア、酸化セリウム、および酸化チタンから選択される少なくとも1種であることを特徴とする請求項18記載のセラミック基材。
- 無機バインダーは繊維であることを特徴とする請求項20記載のセラミック基材。
- 安定した非結晶ガラスは、多結晶ムライトの熱膨張率にほぼ対応する熱膨張率を有していることを特徴とする請求項17記載のセラミック基材。
- 堅牢構造物は、アルミノシリケート繊維の熱膨張率よりも小さい熱膨張率を有していることを特徴とする請求項17記載のセラミック基材。
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Also Published As
Publication number | Publication date |
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US7781372B2 (en) | 2010-08-24 |
US20090035511A1 (en) | 2009-02-05 |
EP2173683A4 (en) | 2011-08-03 |
CN101765570A (zh) | 2010-06-30 |
EP2173683A1 (en) | 2010-04-14 |
WO2009017865A1 (en) | 2009-02-05 |
ZA201000686B (en) | 2010-10-27 |
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