JP4612415B2 - シリコン組成物 - Google Patents
シリコン組成物 Download PDFInfo
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- JP4612415B2 JP4612415B2 JP2004507485A JP2004507485A JP4612415B2 JP 4612415 B2 JP4612415 B2 JP 4612415B2 JP 2004507485 A JP2004507485 A JP 2004507485A JP 2004507485 A JP2004507485 A JP 2004507485A JP 4612415 B2 JP4612415 B2 JP 4612415B2
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Description
本発明は、シリコーンゲルを含有するシリコン組成物、及びセラミックの製造におけるその使用に関する。
オルガノハロシラン、アルコキシシラン、ハロシラン、及び特にメチルクロロシランは、シリコーンポリマーを製造する基本的要素である。オルガノハロシラン及びハロシランは、金属シリコンを有機ハロゲン化物又は塩化水素と、任意に触媒の存在下で反応させる、「直接法」と一般に呼ばれる方法により商業的に生産されている。直接法は、当該技術分野において既知であり、例えば、米国特許第2380995号に記載されている。例えば、直接法によるメチルクロロシランの商業的生産では、200℃〜500℃の温度で流動床に塩化メチルガスを通過させて流動床中でシリコン粉末を流動化させることにより、微細に粉砕した金属シリコン粉末を、触媒の存在下で塩化メチルと反応させる。
本発明の第1の態様によれば、25〜95重量%の、主成分が加水分解ジシランであるシリコーンゲル、及び5〜75重量%の、クレイ及び金属水酸化物からなる群から選択されるバインダー物質を含有するシリコン組成物が提供される。
本明細書で使用する場合、「クレイ」には、その辞書の定義が与えられる。すなわち、種々の形態の水和ケイ酸アルミニウム、例えば、一般式nAl2O3mSiO2・xH2O(式中、xは水和度である)の水和ケイ酸アルミニウムを示す。
(i)例えば、シリコン組成物の押出成形(extrusion)を補助し、必要とされる圧力を低減する加圧助剤(pressing aid)。有用な加圧助剤としては、潤滑性固体物質、例えば、黒鉛、脂肪酸又はステアリン酸アルミニウムが挙げられる。加圧助剤は、好適には、シリコン組成物中に0.01〜0.5重量%の量で存在する。
(ii)シリコン組成物から製造されるセラミック物品の乾燥を助長する「開放(opening)」剤。アルミナなどの固体試薬は、この性質を一般的に有するが、シリコン組成物は、非反応性の開放剤を代用として又は追加として含む。有用な開放剤としては、例えば、ヒュームドシリカ又は沈降シリカなどのシリカ、及び石英が挙げられる。かかる開放剤は、好適には、シリコン組成物中に1〜10重量%の量で、好ましくは1〜6重量%の量で存在する。例えば、シリカは、4〜5重量%のレベルで有用な開放剤であることがわかった。
(iii)「増量剤(volumiser)」、すなわち、シリコン組成物から製造されるセラミック物品の多孔質容積を増加させ、密度を低下させる充填剤。有用な増量剤としては、おがくず、ポリスチレン、pvc、真珠岩及びポリウレタンが挙げられる。増量剤は、その密度(低密度の充填剤ほど、低重量%で必要とされる)に応じて、例えばシリコン組成物の0.5〜15重量%で使用することができる。
(iv)組成物の共融温度を低下させ、それにより焼成温度を下げるための、煉瓦の製造に有用な「焼結剤」。有用な焼結剤としては、ホウ酸、ホウ酸ナトリウム及び炭酸カルシウムが挙げられ、好適には、シリコン組成物の1.0重量%まで、好ましくは0.5重量%までの量で存在し得る。
(i)良好な熱(高温及び低温)強度などの良好な強度、
(ii)良好な断熱性、
(iii)良好な熱安定性(すなわち、良好な耐火性)、
(iv)高耐酸性、及び/又は
(v)軽量だが強固な材料をもたらす良好な多孔性/密度特性
を典型的に有する。
金属シリコンを塩化メチルと反応させる直接法によるメチルクロロシランの製造で生成した高沸点オルガノクロロシランを加水分解して生成した、水分量45〜50重量%のシリコーンゲル45%を予備磨砕(preground)した。Alを多く含むクレイ10%を固体状でバインダーとしてシリコーンゲルに添加して混合し、均質な塊を形成した。アルミナ粉末45%を添加し、組成物を再度混合して均質なシリコン組成物とした。
実施例1のシリコーンゲル70%を予備磨砕し、ヒュームドシリカ5%及びボールクレイ25%と混合し、加圧成形し、実施例1の手順を用いて乾燥させた。硬い乾燥成形体を8時間1300℃で焼成した。焼成成形体は、約1.0の比重を有し、これを30%HNO3水溶液と接触させた状態を3ヶ月より長い間維持し、また50%H2SO4水溶液と接触させた状態を3ヶ月より長い間維持したが、目視による劣化はなく、酸作用に対して高耐久性であった。焼成品の融解温度は約1470℃であった。
直接法によるメチルクロロシランの製造で生成した高沸点オルガノクロロシランを濾過し、金属シリコン、銅及び鉄などの固形物質を除去した。濾過したオルガノクロロシランを石灰溶液で加水分解し、シリコーンゲルを生成した。シリコーンゲルを遠心分離機内にて脱イオン水で洗浄し、重鉱物相から分離した。得られた改質シリコーンゲル20%を予備磨砕し、クレイ35%及びアルミナ粉末45%と混合し、加圧成形し、実施例1の手順を用いて乾燥させた。クレイは、Fuch製のアルミナを多く含むクレイであった。アルミナ(Al2O3)は、以下の粒径分布(重量%)を有した:10%>90μm;30%>63μm;60%>45μm;80%>32μm。硬い乾燥成形体を4時間1450℃で焼成した。焼成品は、1670℃までの温度でその形状を保持し、焼成中にセラミック物品を支持する棚として適当であった。また、焼成品は、溶融アルミナに対して耐久性があり、アルミニウムのインゴット又は鋳物の鋳型として使用することができた。
実施例3の改質シリコーンゲル25%を予備磨砕し、アルミナ40%及びクレイ35%と混合した。使用したアルミナ及びクレイは、実施例3に記載のものであった。混合物を加圧成形し、実施例1の手順を用いて乾燥させた。硬い乾燥成形体を4時間1450℃で焼成した。1100℃でDIN EN 993−15により試験すると、焼成品は1.07W/(mK)という断熱性の値を有し、耐火断熱材料として特に好適であった。
Claims (14)
- 25〜95重量%の、主成分が加水分解ジシランであるシリコーンゲル、及び5〜75重量%の、クレイ及び金属水酸化物からなる群から選択されるバインダー物質を含むシリコン組成物。
- 15〜80重量%の、主成分が加水分解ジシランであるシリコーンゲル、3〜75重量%の、クレイ及び金属水酸化物からなる群から選択されるバインダー物質、及び10〜70重量%の、アルミナ、酸化ジルコニウム、酸化チタン、酸化マグネシウム、炭酸ジルコニウム、硝酸ジルコニウム及び炭酸マグネシウムからなる群から選択される固体試薬を含むシリコン組成物。
- 少なくとも25重量%の前記シリコーンゲル、少なくとも10重量%の前記バインダー物質、及び少なくとも20重量%の前記固体試薬を含む請求項2に記載のシリコン組成物。
- 前記シリコーンゲルが、シルメチレンをさらに含むことを特徴とする請求項2又は3に記載のシリコン組成物。
- 前記シリコーンゲルが、オルガノシリコン物質又はハロシランの製造において生成するオルガノハロシランの加水分解生成物であることを特徴とする請求項1又は4に記載のシリコン組成物。
- 前記シリコーンゲルが、金属シリコンを有機ハロゲン化物又は塩化水素と反応させる直接法によるオルガノハロシラン又はハロシランの製造において生成する高沸点オルガノハロシランを加水分解することにより生成するゲルであることを特徴とする請求項5に記載のシリコン組成物。
- 前記ゲルが、水洗により改質されることを特徴とする請求項6に記載のシリコン組成物。
- 前記バインダー物質が、クレイ及び水酸化アルミニウムから選択される請求項1〜7のいずれか一項に記載のシリコン組成物。
- 前記固体試薬がアルミナである請求項2〜8のいずれか一項に記載のシリコン組成物。
- 請求項1〜9のいずれか一項に記載のシリコン組成物を成形してプレセラミック物品を形成すること、及び前記物品を1100〜1900℃の範囲の温度でベーキングすることを含むセラミック物品の製造方法。
- 前記シリコン組成物が、請求項2又は3で定義されたものであり、前記物品が1400〜1900℃の範囲の温度でベーキングされることを特徴とする請求項10に記載の方法。
- 前記シリコン組成物が、窯の備品に成形されることを特徴とする請求項11に記載の方法。
- 請求項10〜12のいずれか一項に記載の方法により製造されたセラミック物品。
- クレイ及びアルミナを含み、焼成すると、1450℃の温度でその形状を保持できるセラミック物品が形成される、主成分が加水分解ジシランであるシリコーンゲルをプレセラミック組成物に使用する方法。
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GBGB0212324.8A GB0212324D0 (en) | 2002-05-29 | 2002-05-29 | Silicon composition |
PCT/EP2003/006268 WO2003099828A1 (en) | 2002-05-29 | 2003-05-27 | Silicon composition |
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JP2005527460A JP2005527460A (ja) | 2005-09-15 |
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EP (1) | EP1513850B1 (ja) |
JP (1) | JP4612415B2 (ja) |
CN (2) | CN100402469C (ja) |
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AU (1) | AU2003238503A1 (ja) |
DE (1) | DE60333633D1 (ja) |
ES (1) | ES2349693T3 (ja) |
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2002
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- 2003-05-27 DE DE60333633T patent/DE60333633D1/de not_active Expired - Lifetime
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DE60333633D1 (de) | 2010-09-16 |
WO2003099828A1 (en) | 2003-12-04 |
ES2349693T3 (es) | 2011-01-10 |
EP1513850B1 (en) | 2010-08-04 |
ATE476435T1 (de) | 2010-08-15 |
JP2005527460A (ja) | 2005-09-15 |
EP1513850A1 (en) | 2005-03-16 |
CN100402469C (zh) | 2008-07-16 |
US7101821B2 (en) | 2006-09-05 |
CN1872795A (zh) | 2006-12-06 |
GB0212324D0 (en) | 2002-07-10 |
AU2003238503A1 (en) | 2003-12-12 |
CN1656106A (zh) | 2005-08-17 |
CN1321998C (zh) | 2007-06-20 |
US20050176864A1 (en) | 2005-08-11 |
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