JP5411851B2 - 希土類酸化物を含む高孔隙率のセラミック・ハニカム物品およびその製造方法 - Google Patents
希土類酸化物を含む高孔隙率のセラミック・ハニカム物品およびその製造方法 Download PDFInfo
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- JP5411851B2 JP5411851B2 JP2010514808A JP2010514808A JP5411851B2 JP 5411851 B2 JP5411851 B2 JP 5411851B2 JP 2010514808 A JP2010514808 A JP 2010514808A JP 2010514808 A JP2010514808 A JP 2010514808A JP 5411851 B2 JP5411851 B2 JP 5411851B2
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- honeycomb
- rare earth
- cordierite
- ceramic honeycomb
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- 239000000919 ceramic Substances 0.000 title claims description 58
- 229910001404 rare earth metal oxide Inorganic materials 0.000 title claims description 27
- 238000004519 manufacturing process Methods 0.000 title description 6
- 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 description 31
- 229910052878 cordierite Inorganic materials 0.000 claims description 30
- 239000011148 porous material Substances 0.000 claims description 26
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 claims description 23
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 claims description 9
- 229910052749 magnesium Inorganic materials 0.000 claims description 6
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- 239000003054 catalyst Substances 0.000 description 8
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- 238000000034 method Methods 0.000 description 7
- 238000009826 distribution Methods 0.000 description 6
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- 229910052727 yttrium Inorganic materials 0.000 description 4
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- 208000005189 Embolism Diseases 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
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- PGZIKUPSQINGKT-UHFFFAOYSA-N dialuminum;dioxido(oxo)silane Chemical compound [Al+3].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O PGZIKUPSQINGKT-UHFFFAOYSA-N 0.000 description 2
- 239000010432 diamond Substances 0.000 description 2
- 239000004205 dimethyl polysiloxane Substances 0.000 description 2
- 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 2
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- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
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- 229910018068 Li 2 O Inorganic materials 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
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- 239000003513 alkali Substances 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 150000008064 anhydrides Chemical class 0.000 description 1
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- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
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- 230000003197 catalytic effect Effects 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 229910001919 chlorite Inorganic materials 0.000 description 1
- 229910052619 chlorite group Inorganic materials 0.000 description 1
- QBWCMBCROVPCKQ-UHFFFAOYSA-N chlorous acid Chemical compound OCl=O QBWCMBCROVPCKQ-UHFFFAOYSA-N 0.000 description 1
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
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- 229910010272 inorganic material Inorganic materials 0.000 description 1
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- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
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- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
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- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
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- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
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- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/52—Constituents or additives characterised by their shapes
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5445—Particle size related information expressed by the size of the particles or aggregates thereof submicron sized, i.e. from 0,1 to 1 micron
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/252—Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
Description
コージエライト形成無機材料、希土類酸化物源、および孔隙形成剤を液体溶媒と混合して可塑化バッチを形成し、
可塑化バッチを未焼成のハニカム物品へと成形し、
前記未焼成のハニカム物品を焼成して、Mg2Al4Si5O18および0.1重量%〜5.0重量%の希土類酸化物を含むコージエライト型の相、および%P≧45%を含む、多孔質のセラミック・ハニカム物品を形成する、
各工程を含む。
Nb3=(9/16)[(E°RT/ERT)−1]
ここでERTは、試料を加熱する前の室温で測定した弾性率であり、E°RTは仮定上の微小亀裂のない状態における同一試料の弾性率の室温の値である。E°RTの値は、試料を1200℃まで加熱することにより微小亀裂を閉じてアニーリングし;サンプルを室温まで冷却し;冷却の間のT曲線に対するEの直線に近い部分、典型的には約600〜900℃における接線を構築し、ここで試料は、なお大部分が微小亀裂のない状態にあり;室温に戻る接線を外挿する、ことによって決定される。E°RTの値は、25℃で見積もった接線の値とされる接線の傾きΔE/ΔTおよびE°RTの値は、次の関係も満たさなければならない:
ΔE/ΔT =−7.5×10-5(E°RT)
Δαmc=[76.8(IA)3−129.5(IA)2+97.9(IA)−12.8]
+0.6(%Mu+Sp+Sa+Al)−CTE
ここで%(Mu+Sp+Sa+Al)はハニカム内に存在する、ムライト、スピネル、サフィリン、およびコランダムの重量%の合計であり、ここで、IAは軸I比である。Δαmcの値は、基体が所定のIAおよび%二次結晶相について微小亀裂のない状態を示すであろうCTEの値と比較して、セラミック体のCTEが微小亀裂に起因して低くくなるような範囲の尺度である。約4.5未満のΔαmcの値は、微小亀裂の程度が低いことを表す。約2.0未満のΔαmcを有する実施の形態についても記載され、さらに低い微小亀裂の程度を表す。
TSL(℃)=500℃+TSP
ここで、
TSP(℃)=MOR/[(E)(CTE500-900)]
であり、ここでMORは室温で測定した破壊応力であり、Eは室温で測定した弾性率であり、CTE500-900は、加熱の際の500℃〜900℃における平均熱膨張率である。予測される熱衝撃限界(TSL)は、物品の表面温度が約500℃である場合に、物品が破砕することなくその中央内部で耐えうる、最高温度の相対的表示である。一部の実施例では、熱衝撃パラメータ
TSP*=MOR/[(E)(CTE200-1000℃)]
および
TSL*=TSP*+200
も提供される。
PCF=%P/db
ここでdb=(d90−d10)/d50である。
Claims (4)
- セラミック・ハニカム物品であって、
該物品が、少なくとも80重量%のコージエライト・セラミック相、および該セラミックの微細構造内に含まれる0.1から5重量%の希土類酸化物を含み、
%P≧45%である全孔隙率(%P)、
ERatio 1000≦1.05、ここでERatio 1000=E1000℃/ERTである、および
CTE(25〜800℃)≦15×10-7/℃
を有することを特徴とするセラミック・ハニカム物品。 - 1〜40μmのメジアン孔隙径をさらに含むことを特徴とする請求項1記載のセラミック・ハニカム物品。
- 50%≦%P≦70%である全孔隙率(%P)と、
3〜30μmのメジアン孔隙径と、
を有するセラミック・ハニカム物品であって、
該物品が、少なくとも80重量%の、Mg2Al4Si5O18を含むコージエライト型の相、および
0.1〜5.0重量%の希土類酸化物を含み、さらに
ERatio 1000≦1.05、ここでERatio 1000=E1000℃/ERTである、を有するセラミック・ハニカム物品。 - 前記希土類酸化物が、酸化イットリウム、酸化ランタンおよびそれらの組合せからなる群より選択されることを特徴とする請求項3記載のセラミック・ハニカム物品。
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US11/823,580 US8709577B2 (en) | 2007-06-28 | 2007-06-28 | High porosity ceramic honeycomb article containing rare earth oxide and method of manufacturing same |
PCT/US2008/007940 WO2009005679A1 (en) | 2007-06-28 | 2008-06-26 | High porosity ceramic honeycomb article containing rare earth oxide and method of manufacturing same |
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