JP4216174B2 - コート材、セラミックスハニカム構造体及びその製造方法 - Google Patents
コート材、セラミックスハニカム構造体及びその製造方法 Download PDFInfo
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- JP4216174B2 JP4216174B2 JP2003421079A JP2003421079A JP4216174B2 JP 4216174 B2 JP4216174 B2 JP 4216174B2 JP 2003421079 A JP2003421079 A JP 2003421079A JP 2003421079 A JP2003421079 A JP 2003421079A JP 4216174 B2 JP4216174 B2 JP 4216174B2
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- powder
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- honeycomb structure
- ceramic
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- 239000000919 ceramic Substances 0.000 title claims abstract description 157
- 239000011248 coating agent Substances 0.000 title claims abstract description 145
- 238000000576 coating method Methods 0.000 title claims abstract description 145
- 239000000463 material Substances 0.000 title claims abstract description 136
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 62
- 239000000843 powder Substances 0.000 claims abstract description 157
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 74
- 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 74
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000002245 particle Substances 0.000 claims description 57
- 238000000034 method Methods 0.000 claims description 28
- 238000001035 drying Methods 0.000 claims description 23
- 238000005192 partition Methods 0.000 claims description 18
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 17
- 238000010304 firing Methods 0.000 claims description 13
- 239000000835 fiber Substances 0.000 claims description 10
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 10
- 230000003746 surface roughness Effects 0.000 claims description 10
- 239000012530 fluid Substances 0.000 claims description 9
- 238000001354 calcination Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 28
- 239000010410 layer Substances 0.000 description 36
- 239000011247 coating layer Substances 0.000 description 21
- 230000035939 shock Effects 0.000 description 16
- 230000000052 comparative effect Effects 0.000 description 15
- 230000000694 effects Effects 0.000 description 15
- 239000003054 catalyst Substances 0.000 description 13
- 239000007789 gas Substances 0.000 description 13
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 12
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 12
- 238000010521 absorption reaction Methods 0.000 description 10
- 230000002093 peripheral effect Effects 0.000 description 8
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 8
- 229910010271 silicon carbide Inorganic materials 0.000 description 8
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 6
- 229910052581 Si3N4 Inorganic materials 0.000 description 6
- 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 description 6
- 239000010419 fine particle Substances 0.000 description 6
- 229910052863 mullite Inorganic materials 0.000 description 6
- 239000011148 porous material Substances 0.000 description 6
- 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 description 6
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 6
- 229910000166 zirconium phosphate Inorganic materials 0.000 description 6
- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 6
- 238000000227 grinding Methods 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000002360 preparation method Methods 0.000 description 5
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- 239000011362 coarse particle Substances 0.000 description 4
- 230000006866 deterioration Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 230000002427 irreversible effect Effects 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 238000000638 solvent extraction Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000001788 irregular Effects 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
- 238000007561 laser diffraction method Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
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- Compositions Of Oxide Ceramics (AREA)
Description
タルク、カオリン、アルミナ、シリカ等を、焼成後の組成がコージェライトの理論組成(2MgO・2Al2O3・5SiO2)となるように混合したコージェライト原料粉末に、成形助剤、造孔剤、及び水を加え、混合・混練してなる坏土を押出成形し、乾燥することによって、ハニカム構造の乾燥体を製造した。この乾燥体については、複数のセル3の開口部に目封じ材を導入し、再度乾燥することによって、複数のセル3の入口側端面Bと出口側端面Cとを互い違いに目封じ部10によって目封じした構造の目封じ乾燥体とした(図3参照)。この目封じ乾燥体を焼成して焼結体とした後、外周部を研削加工により除去して外径を調整し、外径265mmのセル構造体1を製造した。なお、このセル構造体1の長さ(BC間距離)は178mm、隔壁厚さは0.43mm、セルピッチは2.5mmである。
タップかさ密度、平均粒子径、及び44μm以下粉末成分含有割合(A,B)が異なるコージェライト粉末を主成分として、コート材(実施例1〜9、比較例1,2)を調製した。コート材に含まれる成分、及び各成分の配合割合(質量%)を表1に示す。また、コージェライト粉末のタップかさ密度(g/cm3)、平均粒子径(μm)、及び44μm以下粉末成分含有割合(A,B)(質量%)を表2に示す。なお、使用したコージェライト粉末の各種物性値の測定方法を以下に示す。
所定の外周コート機を使用して、前述のセル構造体の外周を被覆するようにコート材(実施例1〜9、比較例1,2)を塗布した後、室温条件下で約20時間乾燥することにより、塗布したコート材を硬化させて外壁を形成し、外径266.6mm×長さ178mm、外壁厚0.8mmのセラミックスハニカム構造体(実施例10〜18、比較例3,4(n=3))を製造した。
実施例10〜18、比較例3,4(n=3(No.1〜3))のセラミックスハニカム構造体について、外周コート機を使用してコート材を塗布するに際して生じた、目視で確認できる剥れ部の数(剥れ部発生数(箇所))を測定した。結果を表3に示す。
実施例10〜18、比較例3,4(n=5)のセラミックスハニカム構造体の表面粗さRa(μm)を、JIS B0601「表面粗さ−定義及び表示」に従って測定した。結果を表3に示す。
製造した実施例10〜18、比較例3,4のセラミックスハニカム構造体の外壁に生じた、目視で確認できるクラック数(本)を測定した。結果を表3(「初期」の欄)に示す。また、各セラミックスハニカム構造体について所定の耐熱衝撃性試験を500〜650℃の温度で実施し、試験後における外壁に生じたクラック数(本)を測定した。結果を表3に示す。なお、耐熱衝撃性試験の実施方法を以下に示す。
その外周を被覆するようにコート材を塗布したセル構造体の乾燥を、80℃で約1時間熱風乾燥すること以外は、前述の実施例10〜18、比較例3,4の場合と同様の操作により、外径266.6mm×長さ178mm、外壁厚0.8mmのセラミックスハニカム構造体(実施例19〜27、比較例5,6)を製造した。また、上述した「表面粗さの測定」に従って、各セラミックスハニカム構造体の外壁の表面粗さを測定した。結果を表4に示す。なお、上述した「クラック数の測定」に従って、各セラミックスハニカム構造体の外壁に生じた、目視で確認できるクラック数(本)を測定した。結果を表4(「初期」の欄)に示す。また、各セラミックスハニカム構造体について上述の耐熱衝撃性試験を500〜650℃の温度で実施し、試験後における外壁に生じたクラック数(本)を測定した。結果を表4に示す。
Claims (8)
- タップかさ密度が1.3g/cm3以上である主成分としてのコージェライト粉末と、水とを含んでなるとともに、
前記コージェライト粉末の平均粒子径が20〜55μmであり、かつ、粒子径が44μm以下である粉末成分の、前記コージェライト粉末全体に対する含有割合が80質量%以下であるコート材。 - 前記コージェライト粉末の平均粒子径が25〜55μmである請求項1に記載のコート材。
- セラミックスファイバ、シリカゾル、及びアルミナゾルからなる群より選択される少なくとも一種を更に含んでなる請求項1又は2に記載のコート材。
- セラミックスからなる、所定形状を有する多孔質体の表面に塗布した後、乾燥及び/又は焼成することにより、前記多孔質体の表面に外壁を形成するために用いられる請求項1〜3のいずれか一項に記載のコート材。
- 隔壁によって区画された流体の流路となる複数のセルを有する、多孔質体からなるセル構造体と、前記セル構造体の外周部を被覆するように配設された、セラミックス粉末を主成分とする多孔質体からなる外壁とを備えてなるセラミックスハニカム構造体であって、
前記外壁の表面粗さRaが5〜50μmであり、
前記外壁を構成する前記セラミックス粉末が、タップかさ密度が1.3g/cm 3 以上であるとともに、平均粒子径が20〜55μmであり、かつ、粒子径が44μm以下である粉末成分の、前記セラミックス粉末全体に対する含有割合が80質量%以下のコージェライト粉末であるセラミックスハニカム構造体。 - 隔壁によって区画された流体の流路となる複数のセルを有する、多孔質体からなるセル構造体の外周を被覆するように、主成分としてのコージェライト粉末と、水とを含んでなるコート材を塗布し、塗布した前記コート材を乾燥及び/又は焼成することにより外壁を形成するセラミックスハニカム構造体の製造方法であって、
前記コージェライト粉末のタップかさ密度が1.3g/cm3以上であるとともに、平均粒子径が20〜55μmであり、かつ、粒子径が44μm以下である粉末成分の、前記コージェライト粉末全体に対する含有割合が80質量%以下であるセラミックスハニカム構造体の製造方法。 - 前記コージェライト粉末の平均粒子径が25〜55μmである請求項6に記載のセラミックスハニカム構造体の製造方法。
- 前記コート材が、セラミックスファイバ、シリカゾル、及びアルミナゾルからなる群より選択される少なくとも一種を更に含んでなる請求項6又は7に記載のセラミックスハニカム構造体の製造方法。
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US10/541,065 US20060121240A1 (en) | 2003-01-09 | 2003-12-25 | Coating material, ceramic honeycomb structure and method for production thereof |
PCT/JP2003/016714 WO2004063125A1 (ja) | 2003-01-09 | 2003-12-25 | コート材、セラミックスハニカム構造体及びその製造方法 |
EP03786306A EP1586547A4 (en) | 2003-01-09 | 2003-12-25 | COATING MATERIAL, CERAMIC WAVE STRUCTURE AND MANUFACTURING METHOD THEREFOR |
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- 2003-12-25 EP EP03786306A patent/EP1586547A4/en not_active Withdrawn
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JP2005199179A (ja) * | 2004-01-15 | 2005-07-28 | Ngk Insulators Ltd | セル構造体及びその製造方法 |
JP4550434B2 (ja) * | 2004-01-15 | 2010-09-22 | 日本碍子株式会社 | セル構造体及びその製造方法 |
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