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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- earth metal
- oxide
- wall
- rare earth
- aluminum titanate
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- 239000000919 ceramic Substances 0.000 title claims description 46
- 229910000505 Al2TiO5 Inorganic materials 0.000 title claims description 32
- 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 title claims description 32
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 239000000203 mixture Substances 0.000 claims description 49
- 239000002994 raw material Substances 0.000 claims description 27
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 24
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 22
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 21
- 229910021193 La 2 O 3 Inorganic materials 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 18
- 239000011148 porous material Substances 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 17
- 229910052791 calcium Inorganic materials 0.000 claims description 14
- 239000011575 calcium Substances 0.000 claims description 14
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 14
- 229910052712 strontium Inorganic materials 0.000 claims description 14
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 13
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 11
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims description 11
- 239000000463 material Substances 0.000 claims description 10
- 239000006057 Non-nutritive feed additive Substances 0.000 claims description 9
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 9
- 239000000377 silicon dioxide Substances 0.000 claims description 9
- 238000001125 extrusion Methods 0.000 claims description 8
- 239000000314 lubricant Substances 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 7
- 150000002910 rare earth metals Chemical class 0.000 claims description 7
- 239000011230 binding agent Substances 0.000 claims description 6
- 239000013078 crystal Substances 0.000 claims description 6
- 229910052746 lanthanum Inorganic materials 0.000 claims description 5
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 5
- 229910052710 silicon Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- 239000002904 solvent Substances 0.000 claims description 5
- 229910052719 titanium Inorganic materials 0.000 claims description 5
- 239000010936 titanium Substances 0.000 claims description 5
- 229910052727 yttrium Inorganic materials 0.000 claims description 5
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- 239000004014 plasticizer Substances 0.000 claims description 3
- -1 of 2 to 10% Inorganic materials 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 230000014759 maintenance of location Effects 0.000 claims 2
- 238000010438 heat treatment Methods 0.000 claims 1
- 210000004027 cell Anatomy 0.000 description 47
- 238000002347 injection Methods 0.000 description 26
- 239000007924 injection Substances 0.000 description 26
- 239000012071 phase Substances 0.000 description 24
- 238000010304 firing Methods 0.000 description 18
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 12
- 150000001342 alkaline earth metals Chemical class 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 11
- 239000002245 particle Substances 0.000 description 10
- 229910052788 barium Inorganic materials 0.000 description 8
- 239000010433 feldspar Substances 0.000 description 8
- 210000002421 cell wall Anatomy 0.000 description 7
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 6
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 6
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 5
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 description 5
- 238000005245 sintering Methods 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229920003091 Methocel™ Polymers 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
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- 239000003981 vehicle Substances 0.000 description 3
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 2
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 2
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 239000005642 Oleic acid Substances 0.000 description 2
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 2
- SIWVEOZUMHYXCS-UHFFFAOYSA-N oxo(oxoyttriooxy)yttrium Chemical compound O=[Y]O[Y]=O SIWVEOZUMHYXCS-UHFFFAOYSA-N 0.000 description 2
- 239000004071 soot Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 1
- 241001085205 Prenanthella exigua Species 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000003125 aqueous solvent Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- ZJRXSAYFZMGQFP-UHFFFAOYSA-N barium peroxide Chemical compound [Ba+2].[O-][O-] ZJRXSAYFZMGQFP-UHFFFAOYSA-N 0.000 description 1
- AYJRCSIUFZENHW-DEQYMQKBSA-L barium(2+);oxomethanediolate Chemical compound [Ba+2].[O-][14C]([O-])=O AYJRCSIUFZENHW-DEQYMQKBSA-L 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 238000009924 canning Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000004814 ceramic processing Methods 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 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 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 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 1
- 230000000694 effects Effects 0.000 description 1
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- 239000005350 fused silica glass Substances 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
- BDAGIHXWWSANSR-NJFSPNSNSA-N hydroxyformaldehyde Chemical group O[14CH]=O BDAGIHXWWSANSR-NJFSPNSNSA-N 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 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
- 229910052622 kaolinite Inorganic materials 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 125000002524 organometallic group Chemical group 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
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- Porous Artificial Stone Or Porous Ceramic Products (AREA)
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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2005
- 2005-02-22 US US11/064,347 patent/US7259120B2/en active Active
- 2005-03-22 KR KR1020067024422A patent/KR101192916B1/ko active IP Right Grant
- 2005-03-22 WO PCT/US2005/009596 patent/WO2006028506A2/en active Application Filing
- 2005-03-22 JP JP2007509475A patent/JP2007533591A/ja active Pending
- 2005-03-22 PL PL05812348T patent/PL1737554T3/pl unknown
- 2005-03-22 CN CNB2005800117527A patent/CN100512919C/zh active Active
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Publication number | Publication date |
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CN1942228A (zh) | 2007-04-04 |
EP1737554A2 (en) | 2007-01-03 |
PL1737554T3 (pl) | 2015-03-31 |
US20060281627A1 (en) | 2006-12-14 |
US7259120B2 (en) | 2007-08-21 |
JP2007533591A (ja) | 2007-11-22 |
KR20070012506A (ko) | 2007-01-25 |
CN100512919C (zh) | 2009-07-15 |
KR101192916B1 (ko) | 2012-10-18 |
WO2006028506A2 (en) | 2006-03-16 |
WO2006028506A3 (en) | 2006-10-12 |
EP1737554A4 (en) | 2008-05-07 |
JP2013199424A (ja) | 2013-10-03 |
EP1737554B1 (en) | 2014-10-29 |
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