JP3130979B2 - Manufacturing method of cordierite ceramics - Google Patents

Manufacturing method of cordierite ceramics

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Publication number
JP3130979B2
JP3130979B2 JP03252110A JP25211091A JP3130979B2 JP 3130979 B2 JP3130979 B2 JP 3130979B2 JP 03252110 A JP03252110 A JP 03252110A JP 25211091 A JP25211091 A JP 25211091A JP 3130979 B2 JP3130979 B2 JP 3130979B2
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JP
Japan
Prior art keywords
water absorption
temperature
firing
shrinkage
cordierite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP03252110A
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Japanese (ja)
Other versions
JPH0585813A (en
Inventor
純司 大江
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kyocera Corp
Original Assignee
Kyocera Corp
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Priority to JP03252110A priority Critical patent/JP3130979B2/en
Publication of JPH0585813A publication Critical patent/JPH0585813A/en
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Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【産業上の利用分野】本発明は、主にハニカム構造体と
して用いられるコージライト質セラミックスの製造法に
関するものである。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing cordierite ceramics mainly used as a honeycomb structure.

【0002】[0002]

【従来の技術】コージライト(2MgO・2Al2 3
・5SiO2 )質セラミックスは 熱膨張係数が11×
10-7/℃と低いため熱衝撃に強く、また多孔体である
ため、ハニカム構造体に成形して自動車排ガス浄化用触
媒担体等として広く使用されている。このような触媒担
体として用いる場合には、吸水率が高い方が触媒を担持
しやすく、触媒の活性も高いものが得られる。したがっ
て、高吸水率の担体が求められている。
2. Description of the Related Art Cordierite (2MgO.2Al 2 O 3)
・ 5SiO 2 ) ceramics has a thermal expansion coefficient of 11 ×
Since it is as low as 10 -7 / ° C, it is resistant to thermal shock, and because it is porous, it is widely used as a catalyst carrier for purifying automobile exhaust gas by being formed into a honeycomb structure. When used as such a catalyst carrier, a catalyst having a higher water absorption rate can easily carry a catalyst and has a higher activity of the catalyst. Therefore, a carrier having a high water absorption is required.

【0003】また、コージライト質セラミックスは焼成
工程において1〜3%収縮するが、この収縮率のばらつ
きは原料組成、粒子径、セラミックス粉末を成形するた
めに添加されるメチルセルロース、ポリビニルアルコー
ルなどの結合剤の種類と量、焼成前密度、焼成温度であ
ると考えられ、焼成収縮率のばらつきを小さくする為こ
れらの要因の変動を小さくする努力が払われてきた。
In addition, cordierite ceramics shrink by 1 to 3% in the firing step, and the variation in the shrinkage is caused by the combination of the raw material composition, the particle size, and the binding of methylcellulose, polyvinyl alcohol, etc. added to form the ceramic powder. It is considered to be the type and amount of the agent, the density before firing, and the firing temperature, and efforts have been made to reduce the fluctuations of these factors in order to reduce the fluctuation in the firing shrinkage.

【0004】[0004]

【発明が解決しようとする課題】従来、コージライト質
セラミックスの吸水率を高めるためには、例えばセラミ
ックス原料に、焼成時に焼失して空隙を生成させる様な
小麦粉や米粉を混合したり(特公昭63−27303号
公報参照)、あるいはセラミックス原料100重量部に
対しグラファイトやカーボン粉末を1〜30重量部加え
ることによって調節してきた。しかし、これらのいわゆ
るポア剤を添加することは、製造コストの高騰につなが
るだけでなく、ポア剤を焼失させるために600℃以上
の温度で長時間保持する必要があった。
Conventionally, in order to increase the water absorption of cordierite-based ceramics, for example, a wheat flour or a rice flour which is burned during firing to form voids is mixed with a ceramic raw material (Japanese Patent Publication No. No. 63-27303) or by adding 1 to 30 parts by weight of graphite or carbon powder to 100 parts by weight of a ceramic raw material. However, the addition of these so-called pore agents not only leads to an increase in the production cost, but also requires that the pore agents be kept at a temperature of 600 ° C. or higher for a long time in order to burn them off.

【0005】また、コージライト質セラミックスの焼成
収縮率を調整するために、原料組成や粒子径、成形助剤
の種類と添加量及び焼成前密度などの管理を行なってき
たが、これらを充分に管理することは困難であった。例
えばバッチ式焼成炉とトンネル型の連続式焼成炉では得
られたコージライト質セラミックスの吸水率や収縮率が
異なるといった不具合があった。
In order to adjust the firing shrinkage of cordierite ceramics, the composition of the raw materials, the particle size, the type and amount of the molding aid and the density before firing have been managed. It was difficult to manage. For example, a batch type firing furnace and a tunnel type continuous firing furnace have a problem that the obtained cordierite ceramics have different water absorption and shrinkage.

【0006】そこで、本発明はコージライト質セラミッ
クスの吸水率および焼成収縮を高めるとともに、これら
の値を自由にコントロールすることを可能ならしめるも
のである。
Therefore, the present invention increases the water absorption and firing shrinkage of cordierite ceramics, and enables these values to be freely controlled.

【0007】[0007]

【課題を解決するための手段】上記に鑑みて本発明は、
化学組成がMgO10〜18重量%、SiO242〜5
2重量%、Al2334〜48重量%よりなるセラミッ
ク原料を所定形状に成形した後、得られた成形体を11
60〜1290℃の温度域における昇温速度を300℃
/時間未満他の温度域よりも遅くするか、または11
60〜1290℃の温度域で0.5時間以上一定温度で
保持し、さらに1300〜1440℃の温度で0.5〜
24時間保持して焼成する工程によりコージライト質セ
ラミックスを製造するようにしたものである。
In view of the above, the present invention provides
Chemical composition of MgO 10-18% by weight, SiO 2 42-5
After forming a ceramic raw material comprising 2 % by weight and 34 to 48% by weight of Al 2 O 3 into a predetermined shape, the obtained formed body is
300 ° C in the temperature range of 60 to 1290 ° C
/ Hour less than other temperature range , or 11
The temperature is maintained at a constant temperature in a temperature range of 60 to 1290 ° C. for 0.5 hour or more, and further, at a temperature of 1300 to 1440 ° C.
Cordierite ceramics are manufactured by a process of firing for 24 hours.

【0008】本発明の製造方法では、1160〜129
0℃の温度域で保持するか、または昇温速度を小さくす
ることによって、コージライト質セラミックスの吸水率
と収縮率を高くすることができる。また、上記保持時間
や昇温速度を変化させることによって自由に吸水率と収
縮率の値調整することができる。
In the manufacturing method of the present invention, 1160 to 129
By maintaining the temperature in the temperature range of 0 ° C. or decreasing the rate of temperature rise, the water absorption and shrinkage of the cordierite ceramic can be increased. Further, the values of the water absorption rate and the shrinkage rate can be freely adjusted by changing the holding time and the heating rate.

【0009】例えば、従来の製造方法では、吸水率2
5.4%、収縮率96.7%であるコージライト質セラ
ミックスに対し、1210℃で1.5時間保持するだけ
で吸水率を28.0%とできる。さらに、上記保持時間
を11時間とすると吸水率29.5%、収縮率97.9
7%まで高くすることができる。
For example, in the conventional manufacturing method, the water absorption rate is 2
With respect to cordierite ceramics having 5.4% and shrinkage of 96.7%, the water absorption can be made 28.0% only by holding at 1210 ° C. for 1.5 hours. Further, when the holding time is 11 hours, the water absorption is 29.5% and the shrinkage is 97.9.
It can be as high as 7%.

【0010】本発明の方法により焼成収縮率、吸水率を
変化させ得る理由は、完全には解明されていないが、本
発明の現象を説明しうるメカニズムは 以下のように推
定される。
The reason why the firing shrinkage and the water absorption can be changed by the method of the present invention has not been completely elucidated, but the mechanism that can explain the phenomenon of the present invention is presumed as follows.

【0011】まず、本発明のようにAl2 3 、Mg
O、SiO2 源をカオリン、タルクに求めるような固相
合成反応において、焼成工程の途中1000℃前後でβ
-Quartz が発生するすることは知られている(T.I.Barr
y,J.M.Cox and R.Morrel:J.Mat.Sci.,13,pp594-610(197
8)参照) 。そして、1200℃以降このβ-Quartz が消
滅し、コージライト結晶が析出してくる。この系ではコ
ージライトは高温ほどよく生成する。
First, as in the present invention, Al 2 O 3 , Mg
In a solid-phase synthesis reaction in which O and SiO 2 sources are required for kaolin and talc, β
-Quartz is known to occur (TIBarr
y, JMCox and R. Morrel: J. Mat.Sci., 13, pp 594-610 (197
8)). After 1200 ° C., the β-Quartz disappears, and cordierite crystals precipitate. In this system, cordierite forms better at higher temperatures.

【0012】本発明の1160〜1290℃の温度域で
もコージライト化が起こっており、従来の製造方法では
この反応を進行させずに高温に加熱するため、未反応の
成分が一次的に溶融し、液相焼結することにより緻密化
して吸水率を低くすると考えられる。これに対し、本発
明のように1160〜1290℃の温度域にて保持また
は昇温速度を遅くしてコージライト化を進行させた場合
には、液相焼結を起こさせるような成分の残量が少な
く、また低温にて結晶化したコージライトが核となり一
層コージライト化を促進し、液相成分による焼結が起こ
りにくくなるため、焼成収縮率・吸水率を高くすること
ができると考えられる。
In the present invention, cordierite is formed even in the temperature range of 1160 to 1290 ° C., and in the conventional production method, since this reaction is heated to a high temperature without proceeding, unreacted components are temporarily melted. It is considered that liquid phase sintering densifies and lowers the water absorption. On the other hand, when the cordierite is formed by holding or slowing down the heating rate in the temperature range of 1160 to 1290 ° C. as in the present invention, the residual component that causes liquid phase sintering is left. It is thought that since the amount is small and cordierite crystallized at low temperature becomes a nucleus and further promotes cordierite, sintering due to liquid phase components is less likely to occur, so that firing shrinkage and water absorption can be increased. Can be

【0013】なお、本発明において焼成条件をコントロ
ールする温度域を1160℃〜1290℃とした理由は
1160℃以下ではコージライト化が効率的に行なわれ
ず、結果的に焼成収縮率、吸水率を高める効果が顕著で
ないからである。また、1290℃以上ではコージライ
ト化反応のスピードより液相生成による収縮のスピード
の方が早く、実質的にその効果が見られないからであ
る。
In the present invention, the reason for setting the temperature range for controlling the firing conditions to 1160 ° C. to 1290 ° C. is that cordierite cannot be efficiently formed below 1160 ° C., and as a result, the firing shrinkage and water absorption are increased. This is because the effect is not remarkable. Also, at 1290 ° C. or higher, the speed of shrinkage due to liquid phase generation is faster than the speed of the cordierite-forming reaction, and the effect is not substantially observed.

【0014】また、本発明において出発原料の化学組成
をMgO10〜18重量%、SiO2 42〜52重量
%、Al2 3 34〜48重量%としたのは、この範囲
外であると、求めるコージライト(2MgO・2Al2
3 ・5SiO2 )質セラミックスを得られないためで
ある。
In the present invention, the chemical compositions of the starting materials of 10 to 18% by weight of MgO, 42 to 52% by weight of SiO 2 , and 34 to 48% by weight of Al 2 O 3 are determined to be outside these ranges. Cordierite (2MgO.2Al 2
This is because an O 3 · 5SiO 2 ) ceramic cannot be obtained.

【0015】[0015]

【実施例】実験例1 表1に示す原料粉末を、化学組成がMgO13.5重量
%、SiO2 49.1重量%、Al2 3 37.4重量
%となるよう混合し、成形助剤としてメチルセルロー
ス、水を混合、混練してセラミックス可塑性組成物を調
整し、この組成物を公知のハニカム成形用押出しダイス
内を通してハニカム形状に成形し、ついで乾燥し、焼成
した。
EXPERIMENTAL EXAMPLE 1 The raw material powders shown in Table 1 were mixed so as to have a chemical composition of 13.5% by weight of MgO, 49.1% by weight of SiO 2 and 37.4% by weight of Al 2 O 3 , and a molding aid. Was prepared by mixing and kneading methyl cellulose and water to prepare a ceramic plastic composition. The composition was formed into a honeycomb shape through a known extrusion die for honeycomb molding, and then dried and fired.

【0016】[0016]

【表1】 [Table 1]

【0017】焼成スケジュールは図1に示すように、成
形助剤を焼失させるために350℃で1時間保持(KE
EP1)し、1150〜1360℃の間で3時間保持
(KEEP2)する以外は300℃/時間の速度で昇温
し、最高焼成温度1425℃で1時間保持(KEEP
3)して焼成した。上記KEEP2の温度を変化させ、
得られた焼成体の収縮率、吸水率を測定した結果を表2
および図2に示す。
As shown in FIG. 1, the firing schedule is maintained at 350 ° C. for one hour to burn off the molding aid (KE
EP1), and the temperature was raised at a rate of 300 ° C./hour except for holding for 3 hours between 1150 ° C. and 1360 ° C. (KEEP 2), and held for 1 hour at a maximum firing temperature of 1425 ° C. (KEEP).
3) and fired. Changing the temperature of KEEP2,
Table 2 shows the results of measuring the shrinkage and water absorption of the obtained fired body.
And FIG.

【0018】[0018]

【表2】 [Table 2]

【0019】この結果より明らかに、KEEP2の温度
が本発明の範囲外である比較例1、2、3、4では収縮
率97%以下、吸水率26%以下であるのに対し、本発
明実施例のNo.1−1〜1−4は明らかに収縮率97
%以上、吸水率26%以上とともに高い値を示した。し
たがって、1160〜1290℃の温度域で保持するこ
とによって、収縮率、吸水率を高くできることがわか
る。また、最も効果的であるのは上記保持温度が121
0℃前後であることもわかる。
The results clearly show that in Comparative Examples 1, 2, 3, and 4 in which the temperature of KEEP2 is out of the range of the present invention, the shrinkage is 97% or less and the water absorption is 26% or less. No. of the example. 1-1 to 1-4 clearly have a shrinkage rate of 97
% And a water absorption of 26% or more. Therefore, it can be seen that the shrinkage and the water absorption can be increased by maintaining the temperature in the temperature range of 1160 to 1290 ° C. The most effective is that the holding temperature is 121
It can also be seen that it is around 0 ° C.

【0020】実験例2 実験例1と同様にハニカム形状に成形し、ついで乾燥
し、焼成した。焼成スケジュールを図3に示すように、
成形助剤を焼き出すために350℃で1時間保持(KE
EP1)し、1210℃で0〜12時間保持(KEEP
2)する以外は300℃/時間の速度で昇温し、最高焼
成温度1425℃で1時間保持(KEEP3)して焼成
した。上記KEEP2の保持時間を変化させ、得られた
焼成体の収縮率、吸水率を測定した結果を表3および図
4に示す。
EXPERIMENTAL EXAMPLE 2 A honeycomb shape was formed in the same manner as in Experimental Example 1, and then dried and fired. The firing schedule is shown in FIG.
Hold at 350 ° C for 1 hour to bake out the molding aid (KE
EP1) and hold at 1210 ° C. for 0 to 12 hours (KEEP
Except for 2), the temperature was raised at a rate of 300 ° C./hour, and firing was performed at a maximum firing temperature of 1425 ° C. for 1 hour (KEEP3). Table 3 and FIG. 4 show the results of measuring the shrinkage and water absorption of the obtained fired body while changing the holding time of KEEP2.

【0021】[0021]

【表3】 [Table 3]

【0022】この結果より明らかに、KEEP2の保持
時間が0時間である比較例では収縮率97%以下、吸水
率26%以下であるのに対し、本発明実施例のNo.2
−1〜2−4は収縮率97%以上、吸水率27%以上と
ともに高い値を示した。また、KEEP2の保持時間が
0.5時間以上になると大幅に収縮率、吸水率の上昇が
見られ、それから徐々に上昇率は下がるものの最大12
時間で収縮率は98%、吸水率は29.5%まで上昇
し、それ以降はほとんど変化ないことがわかる。したが
って、上記KEEP2の保持時間は0.5時間以上とす
ることによって、収縮率、吸水率を高くできることがわ
かる。
The results clearly show that the comparative example in which the retention time of KEEP2 is 0 hour has a shrinkage rate of 97% or less and a water absorption rate of 26% or less, whereas the comparative example No. 2
-1 to 2-4 showed high values with a shrinkage of 97% or more and a water absorption of 27% or more. Further, when the holding time of KEEP2 becomes 0.5 hours or more, the contraction rate and the water absorption rate increase significantly, and then the rate of increase gradually decreases, but the maximum is 12%.
It can be seen that the shrinkage rate increases to 98% and the water absorption rate rises to 29.5% with time, and hardly changes thereafter. Therefore, it can be seen that the shrinkage and water absorption can be increased by setting the holding time of KEEP2 to 0.5 hours or more.

【0023】実施例3 実験例1と同様にハニカム形状に成形し、ついで乾燥
し、焼成した。焼成スケジュールを図5に示すように、
1160〜1290℃の昇温時間を変化させて焼成し、
得られた焼成体の収縮率、吸水率を測定した結果を表4
に示す。
Example 3 A honeycomb was formed in the same manner as in Experimental Example 1, and then dried and fired. The firing schedule is shown in FIG.
Firing by changing the temperature rise time of 1160 to 1290 ° C,
Table 4 shows the results of measuring the shrinkage and water absorption of the obtained fired body.
Shown in

【0024】[0024]

【表4】 [Table 4]

【0025】この結果から1160〜1290℃の温度
域で一定温度で保持するのではなく、昇温速度を300
℃/時間未満とすることによっても、上記実験例1、2
と同様に収縮率、吸水率を高くできることがわかる。
[0025] Rather than holding at a constant temperature in a temperature range of 1,160 to 1,290 ° C. From this result, the Atsushi Nobori rate of 300
° C. / even by less than time, the Experimental Examples 1 and 2
It can be seen that the shrinkage rate and the water absorption rate can be increased in the same manner as in the above.

【0026】[0026]

【発明の効果】このように本発明によれば、コージライ
ト質セラミックスの焼成条件中、1160〜1290℃
の温度域において昇温速度を300℃/時間未満他の
温度域よりも遅くするか、または1160〜1290℃
の温度域で0.5時間以上一定温度で保持し、さらに1
300〜1440℃の温度で0.5〜24時間保持し
て、焼成することによって、焼結体の焼成収縮率、吸水
率を高くする効果を奏することができる。加えるに、1
160〜1290℃の温度域における昇温速度または保
持時間を調節することによって、自由に焼成体の焼成収
縮率と吸水率をコントロールできるという効果を奏する
ことができる。
As described above, according to the present invention, the firing conditions for cordierite ceramics are 1160-1290 ° C.
The heating rate of less than 300 ° C. / time in a temperature range and other
Slower than the temperature range or 1160-1290 ° C
At a constant temperature for at least 0.5 hour in the temperature range of
By holding and firing at a temperature of 300 to 1440C for 0.5 to 24 hours, an effect of increasing the firing shrinkage and water absorption of the sintered body can be obtained. In addition, 1
By adjusting the heating rate or the holding time in the temperature range of 160 to 1290 ° C., the effect of freely controlling the firing shrinkage and the water absorption of the fired body can be obtained.

【図面の簡単な説明】[Brief description of the drawings]

【図1】本発明のコージライト質セラミックスの製造方
法における焼成スケジュールを示すグラフである。
FIG. 1 is a graph showing a firing schedule in a method for producing cordierite ceramics of the present invention.

【図2】焼成中の保持温度と、得られた焼成体の収縮
率、吸水率との関係を示すグラフである。
FIG. 2 is a graph showing the relationship between the holding temperature during firing and the shrinkage and water absorption of the obtained fired body.

【図3】本発明のコージライト質セラミックスの製造方
法における焼成スケジュールを示すグラフである。
FIG. 3 is a graph showing a firing schedule in the method for producing cordierite ceramics of the present invention.

【図4】焼成中の保持時間と、得られた焼成体の収縮
率、吸水率との関係を示すグラフである。
FIG. 4 is a graph showing the relationship between the holding time during firing and the shrinkage and water absorption of the obtained fired body.

【図5】本発明の他の実施例における焼成スケジュール
を示すグラフである。
FIG. 5 is a graph showing a firing schedule according to another embodiment of the present invention.

Claims (1)

(57)【特許請求の範囲】(57) [Claims] 【請求項1】MgO10〜18重量%、SiO242〜
52重量%、Al2334〜48重量%の組成よりなる
セラミック原料を所定形状に成形した後、得られた成形
体を1160〜1290℃の温度域における昇温速度を
300℃/時間未満他の温度域よりも遅くするか、ま
たは同温度域で0.5時間以上一定温度で保持し、さら
に1300〜1440℃の温度で0.5〜24時間保持
して焼成することにより吸水率を26%以上とすること
を特徴とするコージライト質セラミックスの製造法。
(1) MgO of 10 to 18% by weight, SiO 2 of 42 to
After forming a ceramic raw material having a composition of 52% by weight and 34 to 48% by weight of Al 2 O 3 into a predetermined shape, the obtained molded body is heated at a temperature rising rate of less than 300 ° C./hour in a temperature range of 1160 to 1290 ° C. water absorption by the or slower than the other temperature range, or held at a constant temperature over 0.5 hours at the same temperature range, then retained and fired for further 0.5 to 24 hours at a temperature of 1,300 to 1,440 ° C. To be 26% or more
The process of cordierite ceramics said.
JP03252110A 1991-09-30 1991-09-30 Manufacturing method of cordierite ceramics Expired - Fee Related JP3130979B2 (en)

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CN1210835A (en) 1997-07-28 1999-03-17 康宁股份有限公司 Method of producing cordierite bodies utilizing substantially reduced firing times
EP0894776B1 (en) * 1997-07-28 2003-09-10 Corning Incorporated Method of producing fast-fired cordierite bodies
AU2001246856A1 (en) * 2000-04-07 2001-10-23 Ngk Insulators, Ltd. Cordierite ceramic honeycomb of low thermal expansion and method for manufacturing the same
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WO2005068396A1 (en) * 2004-01-13 2005-07-28 Ngk Insulators, Ltd. Honeycomb structure and method for producing the same
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JP6002813B1 (en) * 2015-05-29 2016-10-05 株式会社大島造船所 Ship
CN107349968A (en) * 2017-06-12 2017-11-17 中国汽车技术研究中心 Pretreatment method of ceramic carrier for SCR molecular sieve catalyst and preparation method of SCR molecular sieve catalyst

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