JP4991636B2 - 炭化ケイ素質多孔体の製造方法 - Google Patents
炭化ケイ素質多孔体の製造方法 Download PDFInfo
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- JP4991636B2 JP4991636B2 JP2008150924A JP2008150924A JP4991636B2 JP 4991636 B2 JP4991636 B2 JP 4991636B2 JP 2008150924 A JP2008150924 A JP 2008150924A JP 2008150924 A JP2008150924 A JP 2008150924A JP 4991636 B2 JP4991636 B2 JP 4991636B2
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- silicon carbide
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims description 105
- 229910010271 silicon carbide Inorganic materials 0.000 title claims description 86
- 239000011148 porous material Substances 0.000 title claims description 81
- 238000004519 manufacturing process Methods 0.000 title claims description 25
- 239000000843 powder Substances 0.000 claims description 67
- 239000002245 particle Substances 0.000 claims description 49
- 238000010304 firing Methods 0.000 claims description 44
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 41
- 239000007787 solid Substances 0.000 claims description 31
- 229910052799 carbon Inorganic materials 0.000 claims description 27
- 238000010438 heat treatment Methods 0.000 claims description 23
- 238000005261 decarburization Methods 0.000 claims description 17
- 238000006243 chemical reaction Methods 0.000 claims description 16
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 15
- 239000012298 atmosphere Substances 0.000 claims description 15
- 229910052710 silicon Inorganic materials 0.000 claims description 14
- 239000010703 silicon Substances 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 13
- 230000001590 oxidative effect Effects 0.000 claims description 13
- 229910052581 Si3N4 Inorganic materials 0.000 claims description 11
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 11
- 239000000853 adhesive Substances 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 8
- 230000001070 adhesive effect Effects 0.000 claims description 7
- 238000005304 joining Methods 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 5
- 238000005192 partition Methods 0.000 claims description 3
- 238000013007 heat curing Methods 0.000 claims 1
- 150000004767 nitrides Chemical class 0.000 claims 1
- 239000011863 silicon-based powder Substances 0.000 claims 1
- 238000000034 method Methods 0.000 description 30
- 238000013001 point bending Methods 0.000 description 24
- 210000003739 neck Anatomy 0.000 description 21
- 239000000758 substrate Substances 0.000 description 14
- 230000035939 shock Effects 0.000 description 11
- 238000001035 drying Methods 0.000 description 9
- 239000011230 binding agent Substances 0.000 description 8
- 229910002804 graphite Inorganic materials 0.000 description 8
- 239000010439 graphite Substances 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 7
- 230000007423 decrease Effects 0.000 description 6
- 238000001878 scanning electron micrograph Methods 0.000 description 6
- 239000000654 additive Substances 0.000 description 5
- 238000007796 conventional method Methods 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 239000004071 soot Substances 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 4
- 239000013618 particulate matter Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 3
- 239000006229 carbon black Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 3
- 229910052753 mercury Inorganic materials 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 239000003575 carbonaceous material Substances 0.000 description 2
- 239000011247 coating layer Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000008929 regeneration Effects 0.000 description 2
- 238000011069 regeneration method Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910021383 artificial graphite Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003610 charcoal Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000007429 general method Methods 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 230000001172 regenerating effect Effects 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
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- Ceramic Products (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Filtering Materials (AREA)
Description
<平均気孔直径> 水銀ポロシメータ(micromeritics社製, オートポアIV9500)を使用して水銀圧入法により測定した気孔径分布から、メディアン径(累積気孔体積が全気孔体積の50%のときの直径)として求めた。
<見掛け気孔率> 平均気孔径の測定に際し、試料に圧入された水銀体積と試料体積とから算出した。
<常温での三点曲げ強度> JIS R1601に準拠し、支点間距離40mm、クロスヘッドスピード0.5mm/minで測定した。
<電子顕微鏡観察> 走査型電子顕微鏡(日本電子株式会社製、JXA−840型)を使用し、円管状の焼結体の端面の観察を行った。
<耐熱衝撃性試験(SML:Soot Mass Limit)> DPFをディーゼルエンジン(NISSAN製QD32型)に取り付け、エンジンを回転数1400rpm、トルク200Nmで動作させ、所定量のススを堆積させる。その後、エンジンを回転数3000rpm、トルク180Nmで動作させ、約680℃に達した時点で一気にアイドリング状態とし、酸素過剰状態でススを燃焼させて、熱衝撃によるDPFの破損の有無を確認する。ススの堆積量を変化させて上記の操作を行い、DPFが破損することなくDPFに堆積させることができるススの量を、フィルタ体積1L(リットル)当たりで表示した数値を、耐熱衝撃性の指標とした。
S3 焼成工程
S4 接合工程
S5 脱炭・接合部熱処理工程
Claims (3)
- 骨材としての炭化ケイ素粉末65〜95質量%に、ケイ素及び炭素のモル比(Si/C)が0.5〜1.5である窒化ケイ素粉末及び炭素質固体粉末を混合し、単一の方向に延びて列設された複数の隔壁により区画された複数のセルを備えるハニカム構造に成形する成形工程と、
該成形工程で得られた成形体を1800〜2200℃の非酸化性雰囲気で一度のみ焼成する焼成工程と、
該焼成工程を経て得られたハニカム構造の焼結体の複数を接着剤で接合する接合工程と、
該接合工程後に酸化性雰囲気で行われ、残留する炭素質固体粉末を燃焼させると共に接着剤を加熱硬化させる脱炭・接合部熱処理工程とを具備し、
前記炭素質固体粉末は、平均粒子径が10〜50μmであり、前記焼成工程で反応生成させる炭化ケイ素の炭素源であると共に、前記焼成工程で気孔を形成させる造孔剤として用いられる
ことを特徴とする炭化ケイ素質多孔体の製造方法。 - 骨材としての前記炭化ケイ素粉末は、平均粒子径が10〜20μmの粗粒粉末と、該粗粒粉末の1/5〜1/40の平均粒子径の微粒粉末とから構成されることを特徴とする請求項1に記載の炭化ケイ素質多孔体の製造方法。
- 前記炭素質固体粉末の配合量は、骨材としての前記炭化ケイ素粉末、前記窒化ケイ素粉末、及び前記炭素質固体粉末の総質量に対して1〜10質量%であることを特徴とする請求項1または請求項2に記載の炭化ケイ素質多孔体の製造方法。
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JP2009292708A JP2009292708A (ja) | 2009-12-17 |
JP4991636B2 true JP4991636B2 (ja) | 2012-08-01 |
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Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
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JP5281666B2 (ja) * | 2011-02-28 | 2013-09-04 | 東京窯業株式会社 | 導電性セラミックス焼結体 |
JP5350426B2 (ja) * | 2011-03-31 | 2013-11-27 | 東京窯業株式会社 | 導電性セラミックス焼結体の製造方法 |
KR101980938B1 (ko) * | 2012-09-06 | 2019-05-21 | 아우디 아게 | 다공성 물품의 가공 방법 |
JP2014136185A (ja) * | 2013-01-16 | 2014-07-28 | Tokyo Yogyo Co Ltd | ガス吸着再生機能を有する炭化ケイ素質基材 |
CN110698215A (zh) * | 2019-10-29 | 2020-01-17 | 中国科学院上海硅酸盐研究所苏州研究院 | 一种耐高温耐腐蚀反应烧结碳化硅膜支撑体及其制备方法 |
CN111533572B (zh) * | 2020-05-08 | 2022-03-15 | 武汉工程大学 | 一种多孔碳化硅陶瓷支撑体的制备方法 |
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JP4246802B2 (ja) * | 1995-08-22 | 2009-04-02 | 東京窯業株式会社 | ハニカム構造体とその製造方法及び用途、並びに加熱装置 |
JP4381011B2 (ja) * | 2003-03-14 | 2009-12-09 | 東京窯業株式会社 | 炭化珪素質ハニカム構造体とそれを用いたセラミックフィルター |
JP5073209B2 (ja) * | 2006-01-17 | 2012-11-14 | 東京窯業株式会社 | SiC系接合材 |
PL1900709T3 (pl) * | 2006-09-14 | 2010-11-30 | Ibiden Co Ltd | Sposób wytwarzania korpusu o strukturze plastra miodu i kompozycja materiałowa do wypalanego korpusu o strukturze plastra miodu |
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