JP2017178655A - 成形体密度の予測方法、及びセラミックス焼成体の製造方法 - Google Patents
成形体密度の予測方法、及びセラミックス焼成体の製造方法 Download PDFInfo
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Abstract
【解決手段】成形体についての成形体密度と、焼成体についての気孔率との相関関係を求める相関関係算出工程と、坏土の作製に用いたセラミックス原料と略同一組成のセラミックス原料から坏土Aを作製し、坏土Aを成形して成形体Bを作製し、成形体Bを乾燥して乾燥体C、さらに乾燥体Cを焼成して所望の気孔率を有する焼成体Dを作製する場合に、相関関係を用いて焼成体Dの所望の気孔率に対応する成形体Bの成形体密度の予測値を算出する成形体密度予測工程と、を含む成形体密度の予測方法。
【選択図】図1
Description
図1に本発明の一実施形態のセラミックス成形体の成形体密度の予測方法を示す。成形体密度の予測方法は、所望の気孔率を有するセラミックス焼成体を作製するために用いられるものであり、成形体についての成形体密度と、焼成体についての気孔率との相関関係を求める相関関係算出工程と、その相関関係を用いて焼成体の所望の気孔率に対応する成形体の成形体密度の予測値を算出する成形体密度予測工程と、を含む。相関関係算出工程は、まず、無機粉末と、バインダーと、造孔材と、水とを含むセラミックス原料を混練して坏土を作製し、その坏土を成形して成形体を作製し、その成形体についての成形体密度を測定する。さらに、その成形体を乾燥して乾燥体を作製し、乾燥体を焼成して焼成体を作製し、その焼成体についての気孔率を測定する。そして、測定した成形体についての成形体密度と、焼成体についての気孔率との相関関係を求める。また、成形体密度予測工程は、相関関係を用いて焼成体の所望の気孔率に対応する成形体の成形体密度の予測値を算出する工程である。具体的には、成形体密度予測工程は、坏土の作製に用いたセラミックス原料と略同一組成のセラミックス原料から坏土Aを作製し、坏土Aを成形して成形体Bを作製し、成形体Bを乾燥して乾燥体C、さらに乾燥体Cを焼成して所望の気孔率を有する焼成体Dを作製する場合に、求めた相関関係を用いて焼成体Dの所望の気孔率に対応する成形体Bの成形体密度の予測値を算出する工程である。
本発明の相関関係算出工程は、図1に示されるように、無機粉末と、バインダーと、造孔材と、水とを含むセラミックス原料を混練して坏土を作製し、坏土を成形して成形体を作製し、成形体についての成形体密度を測定し、さらに、成形体を乾燥して乾燥体を作製し、乾燥体を焼成して焼成体を作製し、焼成体についての気孔率を測定して、成形体についての成形体密度と、焼成体についての気孔率との相関関係を求める工程である。この工程では、複数の坏土を作製し、その坏土一つ一つに対してそれぞれ成形体密度と焼成体の気孔率を測定する。
さらに、本発明の成形体密度の予測方法では、坏土の作製に用いたセラミックス原料と略同一組成のセラミックス原料から坏土Aを作製し、その坏土Aを成形して成形体Bを作製し、成形体Bを乾燥して乾燥体C、さらに乾燥体Cを焼成して所望の気孔率を有する焼成体Dを作製する場合に、相関関係を用いて焼成体Dの前記所望の気孔率に対応する成形体Bの成形体密度の予測値を算出する成形体密度予測工程を含む。
次に、上述の成形体密度の予測方法を利用したセラミックス焼成体の製造方法について説明する。図4に、本発明のセラミックス焼成体の製造方法の概略構成の図を示す。セラミックス焼成体の製造方法は、成形体密度の予測方法を用いて、坏土Aから所望の気孔率を有する焼成体Dを作製するセラミックス焼成体の製造方法である。具体的には、無機粉末と、バインダーと、造孔材と、水とを含むセラミックス原料を混練して坏土Aを作製する坏土作製工程と、坏土Aを押出成形して成形体Bを成形する成形工程と、成形体Bを焼成して焼成体Dを作製する焼成工程と、を有する。そして、さらに、成形体Bの成形体密度の予測値となるように、坏土Aに含まれる水の量を調整する水添加量調整工程を含む。
坏土調整工程は、乾式混合工程、湿式混合工程、混練工程をそれぞれ実施可能な構成を有するセラミックス成形体製造装置を使用して実施されることが好ましい。また、セラミックス成形体製造装置は、その機能的構成として、バッチ式の乾式混合部と、バッチ式または連続式の湿式混合部と、混練部と、押出成形部とを主に有し、混練部はその構成要素内に水を更に添加する機能を備えていることが好ましい。加えて、混練部における水の添加量を調整する機能を備えていることが好ましい。以下、坏土調整工程の流れについて説明する。
乾式混合工程は、バッチ式の乾式混合部(バッチミキサー)を用いて実施されることが好ましい。所定の配合比率で計量された複数種類の粉末状または粉体状のセラミックス粉体、造孔材及びバインダーを含む原料が乾式混合部に投入され、撹拌機構(図示しない)によってセラミックス粉体、造孔材及びバインダーが互いに均一に混じり合うように撹拌混合を行う。これにより、原料が複数種類のセラミックス粉体等が均一に分散した乾式混合物に変換される。
得られた乾式混合物は、湿式混合工程に送られることが好ましい。ここで、湿式混合工程は、乾式混合物をバッチ処理または連続処理によって湿式混合を行うバッチ式または連続式の湿式混合部(バッチミキサーまたは連続ミキサー)を用いて行われることが好ましい。バッチ式の湿式混合部を用いた場合、乾式混合を行った乾式混合部をそのまま利用することができ、規定の添加量の液体を投入した後、上記撹拌機構を利用して乾式混合物と液体の混合が行われる。
その後、混練機を使用して混練工程が実施されることが好ましい。本実施形態の製造方法において、混練工程及び次工程の成形工程は、連続一体的に実施されることが好ましい。すなわち、セラミックス成形体製造装置において、湿式混合部から送られた湿式混合物を、混練部は混練し、更に当該混練部と連続一体的に構成された押出成形部に、処理された混練物(成形原料)が直接送り出される。そして、押出成形部の押出ダイ(口金)を通じて成形原料が押出成形される。これにより、セラミックス成形体が形成される。
試料1〜3を作製した。まず、焼成後にコージェライト組成となる組成にてアルミナ、カオリン、タルク、およびシリカを配合した無機粉末[平均粒度(算術平均径)200μm]500kgに対し、有機バインダーを25kg、造孔材(松本油脂製薬株式会社製、マツモトマイクロスフェアー)25kg、水をそれぞれ148kg、162kg、162kgずつ混ぜ合わせ、坏土を作製した。試料1〜3の坏土のバッチミキサーでの湿粉含水率はそれぞれ22.8%、22.0%、20.0%であった。
Claims (6)
- 無機粉末と、バインダーと、造孔材と、水とを含むセラミックス原料を混練して坏土を作製し、前記坏土を成形して成形体を作製し、前記成形体についての成形体密度を測定し、さらに、前記成形体を乾燥して乾燥体を作製し、前記乾燥体を焼成して焼成体を作製し、前記焼成体についての気孔率を測定して、
前記成形体についての前記成形体密度と、前記焼成体についての前記気孔率との相関関係を求める相関関係算出工程と、
前記坏土の作製に用いた前記セラミックス原料と略同一組成のセラミックス原料から坏土Aを作製し、前記坏土Aを成形して成形体Bを作製し、成形体Bを乾燥して乾燥体C、さらに前記乾燥体Cを焼成して所望の気孔率を有する焼成体Dを作製する場合に、
前記相関関係を用いて前記焼成体Dの前記所望の気孔率に対応する前記成形体Bの前記成形体密度の予測値を算出する成形体密度予測工程と、を含む成形体密度の予測方法。 - 前記相関関係を、一次関数[焼成体の気孔率=係数A×(成形体密度)+係数B]に近似して求める請求項1に記載の成形体密度の予測方法。
- 前記造孔材は前記水と混練されることにより破壊される発泡樹脂を含む請求項1または2に記載の成形体密度の予測方法。
- 請求項1〜3のいずれか一項に記載の成形体密度の予測方法を用いて、前記坏土Aから前記所望の気孔率を有する前記焼成体Dを作製するセラミックス焼成体の製造方法であって、
無機粉末と、バインダーと、造孔材と、水とを含むセラミックス原料を混練して前記坏土Aを作製する坏土作製工程と、
前記坏土Aを押出成形して前記成形体Bを成形する成形工程と、
前記成形体Bを焼成して焼成体Dを作製する焼成工程と、を有し、
さらに、前記成形体Bの前記成形体密度の前記予測値となるように、前記坏土Aに含まれる水の量を調整する水添加量調整工程と、を含むセラミックス焼成体の製造方法。 - 前記成形体Bの前記成形体密度を測定する成形体密度測定工程と、
前記成形体密度測定工程により測定された前記成形体密度を用い、前記相関関係に基づいて焼成体Dについての気孔率を予測する気孔率予測工程と、をさらに含み、
前記気孔率予測工程により予測された気孔率が前記所望の気孔率と異なる場合に、前記水添加量調整工程において前記水の量を調整する請求項4に記載のセラミックス焼成体の製造方法。 - 前記坏土作製工程は、
前記セラミックス原料のうち、前記無機粉末と、前記バインダーと、前記造孔材と、を含む原料をバッチ処理により乾式混合する乾式混合工程と、
前記乾式混合工程によって得られた乾式混合物に、前記水を含む液体を添加し、湿式混合する湿式混合工程と、
前記湿式混合工程によって得られた湿式混合物を混練する混練工程と、を含み、
前記水添加量調整工程は、前記混練工程で前記湿式混合物を混練する過程において、前記坏土Aに前記水を加えて調整する請求項4または5に記載のセラミックス焼成体の製造方法。
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