JP5734335B2 - チタン酸アルミニウムセラミックおよびその製造方法 - Google Patents
チタン酸アルミニウムセラミックおよびその製造方法 Download PDFInfo
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- JP5734335B2 JP5734335B2 JP2013086408A JP2013086408A JP5734335B2 JP 5734335 B2 JP5734335 B2 JP 5734335B2 JP 2013086408 A JP2013086408 A JP 2013086408A JP 2013086408 A JP2013086408 A JP 2013086408A JP 5734335 B2 JP5734335 B2 JP 5734335B2
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Description
La2O3を含むことである。このような添加により、広範囲の焼成温度に亘って安定した特性を得ることもできる。
La2O3・4TiO2・6Al2O3)+k(LaAlO3)を含み、ここで、a,b,c,d,e,f,g,h,i.jおよびkは、(a+b+c+d+e+f+g+h+i+j+k=1.000)とする各構成要素の重量比率であり、かつ0.5≦a≦0.95,
0.0≦b≦0.5, 0.0≦c≦0.5, 0.0≦d≦0.5, 0.0≦e≦0.5, 0.0≦f≦0.25, 0.0≦g≦0.1, 0.0≦h≦0.03,i+j+k>0.001,b+c+d>0.001である。
Kronos 3200 であった。実施例2〜5においては、気孔形成剤は使用されていない。これらのバッチのためのバインダは A4M Methocel であった。滑剤としてオレイン酸が用いられ、溶媒は水であった。認識されるように、組成の大多数は30体積%を超える、中には40体積%を超える多孔度を示しており、1425℃で焼成されたものは、気孔形成剤を用いなくとも40%を超える多孔度を示している。これら組成物は、室温(RT)と1000℃の間で25×107/℃未満のCTEを示し、大多数の組成物は15×107/℃以下、中には10×107/℃以下のCTEを示し、或る実施例は5×107/℃未満のCTEを示している。実施例2〜5に関するMPSは10μm以上であり、或るものは15μm以上のMPSを示し、20μm以上を示すものさえある。優れたCTE,多孔度およびMPSは、1500℃未満あるいは1450℃よりも低い最高温度で焼成した間に得られる。いくつかの実施例は、室温(RT)と1000℃の間のCTEが10×107/℃以下であるのと組み合わせて、30体積%を超える多孔度を得ている。上記の実施例2〜5および下記の実施例6,7は、直径2.54cm(1インチ)、セル密度31セル/cm2(200/平方インチ)、壁厚406μm(0.016インチ)であった。
11 注入端
12 注入セル
14 排出セル
16,19 栓
17 排出端
20 ディーゼル微粒子フィルタ
Claims (18)
- チタン酸アルミニウムからなる壁通過型フィルタの製造方法であって、
(a)シリカ、アルミナおよびチタニアの供給源と、ストロンチウムおよびカルシウムの組合せの供給源とを含む無機原材料のバッチを形成し、
(b)該無機原材料のバッチに、酸化物基準で0.01〜10重量%の量の希土類金属酸化物を添加し、
(c)前記無機原材料のバッチと前記希土類金属酸化物とを、可塑剤、滑剤、バインダ、気孔形成剤および溶媒からなる群から選ばれた加工助剤とともに混合して可塑化混合物を形成し、
(d)該可塑化混合物を成形して未焼成体にし、
(e)該未焼成体を1500℃未満の最高温度に加熱し、チタン酸アルミニウムからなる主相が形成されるのに十分な時間保持する、
各ステップを含み、
前記無機原材料のバッチが、酸化物基準の重量%で表して、40〜65%のAl 2 O 3 と,25〜40%のTiO 2 と,3〜12%のSiO 2 と、2〜10%の、SrOおよびCaOの組合せとを含むことを特徴とする方法。 - 前記可塑化混合物の成形ステップが、ダイを通す押出成形によって行なわれることを特徴とする請求項1記載の方法。
- 前記希土類金属酸化物の金属が、イットリウム、ランタンおよびこれらの組合せからなる群から選ばれることを特徴とする請求項1または2記載の方法。
- 前記希土類金属酸化物が、酸化物基準の重量%で表して、0.01%と2.0%との間の量で添加されることを特徴とする請求項1から3いずれか1項記載の方法。
- 前記希土類金属酸化物がLa2O3であることを特徴とする請求項1または2記載の方法。
- 前記La2O3は、酸化物基準の重量%で表して、0.01%と2.0%との間の量が添加されることを特徴とする請求項5記載の方法。
- 前記未焼成体が、8時間未満の保持時間をもって焼成されることを特徴とする請求項1から6いずれか1項記載の方法。
- 前記最高温度が1400℃と1450℃の間の温度であることを特徴とする請求項1から7いずれか1項記載の方法。
- 前記最高温度が1450℃未満であることを特徴とする請求項1から7いずれか1記載の方法。
- 前記保持時間が6時間と8時間の間の時間であることを特徴とする請求項1から9いずれか1記載の方法。
- チタン酸アルミニウムからなる主結晶相を有すると共に、
(i)アルミニウム、(ii)チタン、(iii)珪素、(iv)ストロンチウムおよびカルシウムの組合せ、および(v)希土類金属を含む材料組成を有するチタン酸アルミニウムセラミックからなり、
前記組成が、酸化物基準の重量%で表して、40〜65%のAl 2 O 3 と,25〜40%のTiO 2 と,3〜12%のSiO 2 と、2〜10%の、SrOおよびCaOの組合せと、0.01〜10%の、La 2 O 3 ,Y 2 O 3 およびこれらの組合せからなる群から選ばれた少なくとも一種類の希土類金属酸化物とを含む、
壁通過型フィルタ。 - 酸化物基準の重量%で表して、0.01%と0.35%との間のFe2O3をさらに含むことを特徴とする請求項11記載の壁通過型フィルタ。
- 酸化物基準の重量%で計算して、6.0%以上のLa2O3を含むことを特徴とする請求項11記載の壁通過型フィルタ。
- 40体積%を超える多孔度を有することを特徴とする請求項11から13いずれか1項記載の壁通過型フィルタ。
- 気孔サイズの中央値が10μmを超えていることを特徴とする請求項11から14いずれか1項記載の壁通過型フィルタ。
- 室温〜1000℃間で測定した熱膨張係数が15×10−7/℃以下であることを特徴とする請求項11から15いずれか1項記載の壁通過型フィルタ。
- 室温〜1000℃間で測定した熱膨張係数が10×10−7/℃以下であり、40体積%を超える多孔度を有することを特徴とする請求項11から15いずれか1項記載の壁通過型フィルタ。
- チタン酸アルミニウムからなる主結晶相を有すると共に、
(i)アルミニウム、(ii)チタン、(iii)珪素、(iv)ストロンチウムおよびカルシウムの組合せ、および(v)希土類金属を含む材料組成を有するチタン酸アルミニウムセラミックからなり、
酸化物基準の重量%で計算して、45〜60%のAl2O3,28〜36%のTiO2,5〜12%のSiO2、3〜8%のSrO、0.1〜5%のCaO、および1〜9%の
La2O3から実質的になる酸化物組成を有する、壁通過型フィルタ。
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JP2007533591A (ja) | 2007-11-22 |
CN100512919C (zh) | 2009-07-15 |
KR20070012506A (ko) | 2007-01-25 |
CN1942228A (zh) | 2007-04-04 |
EP1737554A2 (en) | 2007-01-03 |
WO2006028506A2 (en) | 2006-03-16 |
KR101192916B1 (ko) | 2012-10-18 |
US20060281627A1 (en) | 2006-12-14 |
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