JP2014519470A - チタン酸アルミニウムセラミックフィルタ特性を制御する方法 - Google Patents
チタン酸アルミニウムセラミックフィルタ特性を制御する方法 Download PDFInfo
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- JP2014519470A JP2014519470A JP2014513501A JP2014513501A JP2014519470A JP 2014519470 A JP2014519470 A JP 2014519470A JP 2014513501 A JP2014513501 A JP 2014513501A JP 2014513501 A JP2014513501 A JP 2014513501A JP 2014519470 A JP2014519470 A JP 2014519470A
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- Prior art keywords
- glass
- aluminum titanate
- composite
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- Prior art date
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Links
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 title claims abstract description 114
- 229910000505 Al2TiO5 Inorganic materials 0.000 title claims abstract description 113
- 238000000034 method Methods 0.000 title claims abstract description 46
- 239000000919 ceramic Substances 0.000 title abstract description 78
- 239000011521 glass Substances 0.000 claims abstract description 173
- 239000002131 composite material Substances 0.000 claims abstract description 65
- 239000010433 feldspar Substances 0.000 claims abstract description 60
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims abstract description 56
- 239000000203 mixture Substances 0.000 claims abstract description 40
- 238000010304 firing Methods 0.000 claims abstract description 34
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims abstract description 28
- 230000000930 thermomechanical effect Effects 0.000 claims abstract description 16
- 229910052712 strontium Inorganic materials 0.000 claims abstract description 15
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 11
- 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 claims abstract description 11
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 8
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims abstract description 7
- 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 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 75
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 45
- 238000000137 annealing Methods 0.000 claims description 26
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 24
- 229910052698 phosphorus Inorganic materials 0.000 claims description 24
- 239000011574 phosphorus Substances 0.000 claims description 23
- 229910052810 boron oxide Inorganic materials 0.000 claims description 21
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims description 21
- 239000000377 silicon dioxide Substances 0.000 claims description 20
- FUJCRWPEOMXPAD-UHFFFAOYSA-N lithium oxide Chemical compound [Li+].[Li+].[O-2] FUJCRWPEOMXPAD-UHFFFAOYSA-N 0.000 claims description 11
- 229910001947 lithium oxide Inorganic materials 0.000 claims description 11
- 239000002241 glass-ceramic Substances 0.000 claims description 8
- 229910001392 phosphorus oxide Inorganic materials 0.000 claims description 8
- VSAISIQCTGDGPU-UHFFFAOYSA-N tetraphosphorus hexaoxide Chemical compound O1P(O2)OP3OP1OP2O3 VSAISIQCTGDGPU-UHFFFAOYSA-N 0.000 claims description 8
- 238000010348 incorporation Methods 0.000 claims description 6
- 239000002243 precursor Substances 0.000 claims description 4
- 229910000272 alkali metal oxide Inorganic materials 0.000 claims description 2
- 239000008187 granular material Substances 0.000 abstract description 3
- 239000000463 material Substances 0.000 description 163
- 239000011148 porous material Substances 0.000 description 102
- 238000009826 distribution Methods 0.000 description 51
- 229910052744 lithium Inorganic materials 0.000 description 37
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 34
- 241000264877 Hippospongia communis Species 0.000 description 29
- 238000007654 immersion Methods 0.000 description 29
- 238000001816 cooling Methods 0.000 description 24
- 238000001878 scanning electron micrograph Methods 0.000 description 20
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 19
- 238000010438 heat treatment Methods 0.000 description 19
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 18
- 239000000654 additive Substances 0.000 description 18
- 229910052782 aluminium Inorganic materials 0.000 description 16
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 15
- 229910017119 AlPO Inorganic materials 0.000 description 14
- 230000015572 biosynthetic process Effects 0.000 description 14
- 229910010293 ceramic material Inorganic materials 0.000 description 14
- 239000000047 product Substances 0.000 description 13
- 230000035939 shock Effects 0.000 description 12
- 238000005245 sintering Methods 0.000 description 12
- 229910019142 PO4 Inorganic materials 0.000 description 11
- 238000001354 calcination Methods 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 11
- 239000010452 phosphate Substances 0.000 description 11
- 239000012925 reference material Substances 0.000 description 11
- 230000035882 stress Effects 0.000 description 11
- 230000007423 decrease Effects 0.000 description 10
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 10
- 230000002829 reductive effect Effects 0.000 description 10
- 238000007496 glass forming Methods 0.000 description 9
- 230000009467 reduction Effects 0.000 description 9
- 230000000996 additive effect Effects 0.000 description 8
- 230000008859 change Effects 0.000 description 8
- 230000012010 growth Effects 0.000 description 8
- 238000002844 melting Methods 0.000 description 8
- 230000008018 melting Effects 0.000 description 8
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 8
- 229910052753 mercury Inorganic materials 0.000 description 8
- 239000002994 raw material Substances 0.000 description 8
- 238000000113 differential scanning calorimetry Methods 0.000 description 7
- 229910010272 inorganic material Inorganic materials 0.000 description 7
- 239000011147 inorganic material Substances 0.000 description 7
- 230000003993 interaction Effects 0.000 description 7
- 238000005382 thermal cycling Methods 0.000 description 7
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 6
- 238000001887 electron backscatter diffraction Methods 0.000 description 6
- 238000009472 formulation Methods 0.000 description 6
- 239000004615 ingredient Substances 0.000 description 6
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 description 6
- 238000005259 measurement Methods 0.000 description 6
- 230000000704 physical effect Effects 0.000 description 6
- 238000004626 scanning electron microscopy Methods 0.000 description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 5
- 230000008901 benefit Effects 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 238000001914 filtration Methods 0.000 description 5
- 238000002459 porosimetry Methods 0.000 description 5
- 239000010421 standard material Substances 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 229910018068 Li 2 O Inorganic materials 0.000 description 4
- 239000002585 base Substances 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 238000002425 crystallisation Methods 0.000 description 4
- 230000008025 crystallization Effects 0.000 description 4
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 4
- 230000006872 improvement Effects 0.000 description 4
- -1 oxides (eg Chemical compound 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 230000001902 propagating effect Effects 0.000 description 4
- 238000002791 soaking Methods 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- 238000005728 strengthening Methods 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 239000010936 titanium Substances 0.000 description 4
- 238000012512 characterization method Methods 0.000 description 3
- 230000001276 controlling effect Effects 0.000 description 3
- 239000010432 diamond Substances 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 239000007789 gas 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
- 238000013001 point bending Methods 0.000 description 3
- 239000005368 silicate glass Substances 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 239000002419 bulk glass Substances 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000012937 correction Methods 0.000 description 2
- 230000001351 cycling effect Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000001934 delay Effects 0.000 description 2
- 230000008034 disappearance Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 150000004679 hydroxides Chemical class 0.000 description 2
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 238000013507 mapping Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 239000000075 oxide glass Substances 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000009827 uniform distribution Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 241001391944 Commicarpus scandens Species 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 241000316887 Saissetia oleae Species 0.000 description 1
- 229910003668 SrAl Inorganic materials 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- GNKTZDSRQHMHLZ-UHFFFAOYSA-N [Si].[Si].[Si].[Ti].[Ti].[Ti].[Ti].[Ti] Chemical compound [Si].[Si].[Si].[Ti].[Ti].[Ti].[Ti].[Ti] GNKTZDSRQHMHLZ-UHFFFAOYSA-N 0.000 description 1
- KHIHIHNAFRNJFC-UHFFFAOYSA-N [Ti].[Sr].[La] Chemical compound [Ti].[Sr].[La] KHIHIHNAFRNJFC-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 1
- 239000012491 analyte Substances 0.000 description 1
- 239000005347 annealed glass Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 238000009924 canning Methods 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 230000000875 corresponding effect Effects 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
- 238000013480 data collection Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 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
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000013213 extrapolation Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000003546 flue gas Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- BDAGIHXWWSANSR-NJFSPNSNSA-N hydroxyformaldehyde Chemical compound O[14CH]=O BDAGIHXWWSANSR-NJFSPNSNSA-N 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000005764 inhibitory process Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 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 1
- 230000000670 limiting effect Effects 0.000 description 1
- XIXADJRWDQXREU-UHFFFAOYSA-M lithium acetate Chemical compound [Li+].CC([O-])=O XIXADJRWDQXREU-UHFFFAOYSA-M 0.000 description 1
- 239000011855 lithium-based material Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 238000010606 normalization Methods 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 238000003921 particle size analysis Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000005325 percolation Methods 0.000 description 1
- 239000005365 phosphate glass Substances 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000000644 propagated effect Effects 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 238000001953 recrystallisation Methods 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 230000000717 retained effect Effects 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
- 229920002050 silicone resin Polymers 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 229910000018 strontium carbonate Inorganic materials 0.000 description 1
- VEALVRVVWBQVSL-UHFFFAOYSA-N strontium titanate Chemical compound [Sr+2].[O-][Ti]([O-])=O VEALVRVVWBQVSL-UHFFFAOYSA-N 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- ISIJQEHRDSCQIU-UHFFFAOYSA-N tert-butyl 2,7-diazaspiro[4.5]decane-7-carboxylate Chemical compound C1N(C(=O)OC(C)(C)C)CCCC11CNCC1 ISIJQEHRDSCQIU-UHFFFAOYSA-N 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 230000004222 uncontrolled growth Effects 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
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
- C04B38/0006—Honeycomb structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
- B01J21/063—Titanium; Oxides or hydroxides thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C10/00—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
- C03C10/0036—Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition containing SiO2, Al2O3 and a divalent metal oxide as main constituents
-
- 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
- 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
- C04B35/46—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 titanium oxides or titanates
- C04B35/462—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 titanium oxides or titanates based on titanates
- C04B35/478—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 titanium oxides or titanates based on titanates based on aluminium titanates
-
- 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
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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Abstract
Description
定義
「多孔度」および類似の用語は、一般に、空隙、または同義語として、ハニカム材料の壁内の細孔を指す。肉眼で見えるチャネル(macroscopic channel)が占める、ハニカムにおける空隙は除外される。「多孔度」および類似の用語は、一般に、細孔の存在に起因し得、ハニカムの肉眼で見えるチャネルまたはビア(via)の存在に起因し得る、ハニカム材料における空隙を除外する、ハニカム材料における全空隙、あるいは粉状の固体材料の全容積に対する細孔容積の比率を指し、多孔度パーセント(%P)として表され得る。多孔度、およびセラミック体の類似の態様が、同一出願人が所有し、同一譲受人に譲渡された米国特許第6,864,198号明細書に記載されている。d10、d50およびd90などのパラメータは、細孔径分布に関する。量d50は、細孔容積に基づいた中央細孔径(MPS)であり、マイクロメートル単位で測定され;したがって、d50は、セラミックの開放気孔率の50%に水銀が圧入された細孔径である(水銀ポロシメトリー)。量d90は、細孔容積の90%が、直径がd90の値より小さい細孔から構成される細孔径であり;したがって、d90は、セラミックの開放気孔率の10容積%に水銀が圧入された細孔径に等しい。量d10は、細孔容積の10%が、直径がd10の値より小さい細孔から構成される細孔径であり;したがって、d10は、セラミックの開放気孔率の90容積%に水銀が圧入された細孔径に等しい。d10およびd90の値も、マイクロメートルの単位である。量(d50−d10/d50)は、中央細孔径、d50より細かい細孔径の分布の幅を表す。
1.材料のチタン酸アルミニウム粒度が、減少されて、材料のより低い微小亀裂密度および材料の強度の増加が得られる。この考えは、微細構造および繊維AT材料において得られるチタン酸アルミニウム粒度が約3〜7マイクロメートルである微細な無機アルミナ繊維から作製されるチタン酸アルミニウムベースの材料において実施された(「Acicular Porous Ceramic Article and Manufacture Thereof」という発明の名称の、2008年2月29日に出願された、同一出願人が所有し、同一譲受人に譲渡された同時係属中の出願である米国仮特許出願第61/067,615号明細書を参照)。
ガラス源およびチタン酸アルミニウム源を組み合わせてバッチ組成物にする工程と;
組み合わされたバッチ組成物を焼成して、チタン酸アルミニウム複合体を生成する工程と
を含み、
ガラス源が、複合体のセラミック顆粒間に、ガラスフィルム、ガラス−セラミックフィルム、またはその両方を提供する方法を提供する。
シリカと、酸化リチウム、酸化ナトリウム、酸化カリウムなどのアルカリ酸化物源、または水酸化物、ハロゲン化物、および類似の源などのそれらの前駆体との組合せを、0.3〜5重量%、好ましくは0.3〜3重量%、またはより好ましくは0.4〜1重量%の量でバッチに加える工程;
酸化リン源を、0.1〜3重量%、好ましくは0.1〜1%の量でバッチに加える工程;
酸化ホウ素源を、0.1〜2重量%、好ましくは0.1〜1%の量でバッチに加える工程;
またはそれらの組合せ
のうちの少なくとも1つによって行うことができ、重量%は、バッチ組成物の総重量に対する超過添加に基づき得る。
部分的なガラスまたはガラス−セラミック相の蒸発;
ガラスまたはガラス−セラミック相の結晶化;
複合相へのガラスまたはガラス−セラミック相の組み込み;
またはそれらの組合せ
のうちの少なくとも1つを含む。
焼成温度が、例えば、少なくとも25℃だけ低下され得;
焼成時間が、例えば、少なくとも10%だけ減少され得;
または焼成温度の低下および焼成時間の減少の組合せにより、ガラス源なしで実施された方法と比較して同じ有用な生成物が提供される。
完全に焼成されたチタン酸アルミニウムベースの複合体を、0.5〜10重量%のリン酸水溶液中に浸漬する工程と;
浸漬された複合体をアニールして、0.5〜2重量%の、得られる複合体へのリンの組み込みを得る工程とを含み、重量%が、浸漬されていない複合体の総重量に対する超過添加に基づく方法を提供する。
セラミック内に粒界ガラスフィルムを形成する工程を含み、フィルムが、約20nm〜500nmの厚さを有し、微小亀裂と相互作用し、微小亀裂の制御されない成長を抑制する方法を提供する。
ガラス源およびチタン酸アルミニウム源を組み合わせてバッチ組成物にする工程と;
組み合わされたバッチ複合組成物を焼成して、チタン酸アルミニウム複合体を生成する工程と
を含むか、それらから実質的になるか、またはそれらからなり、
ガラス源が、複合体のセラミック顆粒間に、ガラスフィルム、ガラス−セラミックフィルム、またはその両方を提供する方法を提供する。
完全に焼成されたチタン酸アルミニウムベースの複合体を、0.5〜10重量%のリン酸水溶液中に浸漬する工程と;
浸漬された複合体をアニールして、0.5〜2重量%の、得られる複合体へのリンの組み込みを得る工程とを含むか、それらから実質的になるか、またはそれらからなり、重量%が、浸漬されていない複合体の総重量に対する超過添加に基づく方法を提供する。
1.薄い粒界ガラスフィルムの存在が、チタン酸アルミニウム−長石複合体における好ましい亀裂の伝播を誘導し、長期の亀裂の伝播を遅延させて、それ以外は物理的特性が変更されない材料に向上した強度/破壊靱性を与える。(例えば、Corningの現行のDuratrap AT(登録商標)材料およびその多孔度が改変された(porosity−engineered)誘導体と比較して)向上した材料の強度および靱性が、例えば、統合SCR用途のための向上した薄壁および高い多孔度のフィルタを得るのに必要とされる。
実施例1
バッチへの酸化リチウムガラス形成添加剤の添加。表1に列挙される0、0.5および1重量%のLi2O超過添加を有する別々にバッチされた組成物A、B、Cを、300/14セル形状を有する1インチ(25.4mm)の直径のハニカムへとラム押し出しした(ram−extrude)。無機原料、細孔形成剤、および結合剤を、乾燥した状態で予め混合した。乾燥した混合原料を、鍋の中で組み合わせて、好適なペースト生地が達成されるまでバッチ水を加えながら温めた。リチウムを、バッチ水に溶解された酢酸リチウムとしてバッチに加えた。バッチ組成物AAは、表1に示される異なる細孔形成剤レベルを有する別の基準バッチである。
実施例2
酸化リンガラス形成剤。酸化リンは、様々な酸化物におけるガラスの形成を促進することが知られているため、1〜5%の酸化リンレベルを有するATタイプのバッチを作製した。酸化リンを、リン酸アルミニウムの形態でバッチに加えた。バッチ組成物が、表3にまとめられている。
実施例3
完全に焼成されたハニカムをリン酸中に浸漬することによるガラスの形成。A、G、およびHの完全に焼成された部分を、リン酸(10重量%、水溶液)中に浸漬し、次に、アニールした(1400℃)。これらのバッチ組成物が、表5に列挙される。
0、1、2、および5%のチタン−ストロンチウム−ランタンシリケートガラスを得るために、追加のチタニア、ストロンチア、酸化ランタン、およびシリカと残留アルミナとともにチタン酸アルミニウムおよびストロンチウム長石を含有するように材料I、J、K、およびLをバッチした。さらなるバッチMを、過剰なアルミナおよび5%の同じガラスを用いずに作製した。
実施例5
ATにおけるガラスの形成のための酸化ホウ素の添加。表12は、6重量%のMgO、バッチNを有するコージエライト−ムライト−チタン酸アルミニウム複合体にガラス形成剤として加えられた低いレベル(例えば、0.5〜2重量%)の酸化ホウ素を列挙している。バッチOは、0.5%、バッチPは1%を含有し、バッチQは2%の酸化ホウ素を有する。
特性評価の技術
微細構造の特性評価。標準的な走査電子顕微鏡法(SEM)の特性評価を、ハニカム壁表面および研磨されたハニカム断面(ハニカムチャネルに垂直に切断された)について行った。研磨された断面の観察では、焼成された製品を、エポキシに浸透し、薄く切り、研磨した。顕微鏡的レベルで存在する多孔度および相の空間分布を、研磨された試料断面について視覚化した。材料多孔度PSEM(%)、平均細孔径d平均、SEMを、画像分析技術と組み合わせたSEMによって評価した。
Claims (5)
- ストロンチウム長石、ムライト、コージエライト、またはそれらの組合せのうちの少なくとも1つを含むチタン酸アルミニウム複合体の熱機械特性を向上させる方法であって:
ガラス源およびチタン酸アルミニウム源を組み合わせてバッチ組成物にする工程と;
前記組み合わされたバッチ複合組成物を、1340〜1460℃で焼成して、前記チタン酸アルミニウム複合体を生成する工程と
を含み、ここで、
前記ガラス源が、前記複合体の粒子間で、粒界ガラスフィルム、粒界ガラス−セラミックフィルム、またはそれらの組合せを提供し;
前記粒界フィルムが、20nm〜500nmの厚さを有し、
前記複合体の機械的強度が、前記ガラス源の非存在下で作製される前記複合体と比較して向上されることを特徴とする方法。 - 前記ガラス源が、酸化リチウム、酸化ホウ素、シリカ、酸化リン、上記のいずれかの前駆体または源、あるいはそれらの混合物のうちの少なくとも1つを含むことを特徴とする、請求項1に記載の方法。
- 前記ガラス源を組み合わせる工程が:
シリカとアルカリ酸化物源との組合せを、0.3〜5重量%の量で前記バッチに加える工程;
酸化リン源を、0.1〜3重量%の量で前記バッチに加える工程;
酸化ホウ素源を、0.1〜2重量%の量で前記バッチに加える工程;
またはそれらの組合せ
のうちの少なくとも1つを含み、前記重量%が、前記バッチ組成物の重量に対するガラス源の超過添加に基づくことを特徴とする、請求項1に記載の方法。 - 組み合わせる工程および焼成する工程が、前記ガラス源の非存在下で作製される前記複合体と比較して、50%の多孔度で、10×10−7K−1未満のCTEで、5〜25%だけ前記複合体の強度を向上させることを特徴とする、請求項1に記載の方法。
- チタン酸アルミニウムベースの複合体の熱機械特性を向上させる方法であって:
完全に焼成されたチタン酸アルミニウムベースの複合体を、0.5〜10重量%のリン酸水溶液中に浸漬する工程と;
前記浸漬された複合体をアニールして、0.5〜2重量%の、得られる複合体へのリンの組み込みを得る工程と
を含み、前記重量%が、前記浸漬されていない複合体の重量に対する超過添加に基づくことを特徴とする方法。
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US13/117,510 US9272956B2 (en) | 2011-05-27 | 2011-05-27 | Method for controlling aluminum titanate ceramic filter properties |
PCT/US2012/026724 WO2012166222A1 (en) | 2011-05-27 | 2012-02-27 | Method for controlling aluminum titanate ceramic filter properties |
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- 2012-02-27 CN CN201280025734.4A patent/CN103562155B/zh not_active Expired - Fee Related
- 2012-02-27 PL PL12709204T patent/PL2714619T3/pl unknown
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- 2012-02-27 WO PCT/US2012/026724 patent/WO2012166222A1/en active Application Filing
- 2012-02-27 CN CN201610546193.XA patent/CN106220167A/zh active Pending
- 2012-02-27 EP EP12709204.7A patent/EP2714619B1/en not_active Not-in-force
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Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2007533591A (ja) * | 2004-04-21 | 2007-11-22 | コーニング インコーポレイテッド | チタン酸アルミニウムセラミックおよびその製造方法 |
JP2008508185A (ja) * | 2004-07-29 | 2008-03-21 | コーニング インコーポレイテッド | 細孔サイズ分布の狭いチタン酸アルミニウム物体およびその製造方法 |
JP2009542566A (ja) * | 2006-06-30 | 2009-12-03 | コーニング インコーポレイテッド | コージェライトチタン酸アルミニウムマグネシウム組成物及びこの組成物を含むセラミック製品 |
WO2009063997A1 (ja) * | 2007-11-14 | 2009-05-22 | Hitachi Metals, Ltd. | チタン酸アルミニウム質セラミックハニカム構造体、その製造方法、及びそれを製造するための原料粉末 |
JP2011516371A (ja) * | 2008-02-29 | 2011-05-26 | コーニング インコーポレイテッド | 異方性多孔質セラミック物品およびその製造 |
Also Published As
Publication number | Publication date |
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EP2714619A1 (en) | 2014-04-09 |
CN103562155A (zh) | 2014-02-05 |
EP2714619B1 (en) | 2018-05-23 |
WO2012166222A1 (en) | 2012-12-06 |
PL2714619T3 (pl) | 2018-11-30 |
US20120297830A1 (en) | 2012-11-29 |
CN106220167A (zh) | 2016-12-14 |
JP6148668B2 (ja) | 2017-06-21 |
US9272956B2 (en) | 2016-03-01 |
CN103562155B (zh) | 2016-08-17 |
US20160122855A1 (en) | 2016-05-05 |
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