JP5746690B2 - コージライト形成バッチ材料及びその使用方法 - Google Patents
コージライト形成バッチ材料及びその使用方法 Download PDFInfo
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- JP5746690B2 JP5746690B2 JP2012513911A JP2012513911A JP5746690B2 JP 5746690 B2 JP5746690 B2 JP 5746690B2 JP 2012513911 A JP2012513911 A JP 2012513911A JP 2012513911 A JP2012513911 A JP 2012513911A JP 5746690 B2 JP5746690 B2 JP 5746690B2
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- kaolin clay
- cordierite
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- 239000000463 material Substances 0.000 title claims description 73
- 229910052878 cordierite Inorganic materials 0.000 title claims description 54
- 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 title claims description 54
- 238000000034 method Methods 0.000 title claims description 16
- 239000005995 Aluminium silicate Substances 0.000 claims description 77
- 235000012211 aluminium silicate Nutrition 0.000 claims description 77
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 77
- 239000004927 clay Substances 0.000 claims description 69
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 48
- 239000000203 mixture Substances 0.000 claims description 33
- 239000000919 ceramic Substances 0.000 claims description 32
- 239000000377 silicon dioxide Substances 0.000 claims description 21
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 20
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 15
- 238000010304 firing Methods 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 10
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 8
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 7
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 7
- 230000015572 biosynthetic process Effects 0.000 claims description 5
- HDWRPIXRVRDTQW-UHFFFAOYSA-N aluminan-2-one Chemical compound O=C1CCCC[AlH]1 HDWRPIXRVRDTQW-UHFFFAOYSA-N 0.000 claims 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 20
- 239000011230 binding agent Substances 0.000 description 10
- 239000011777 magnesium Substances 0.000 description 9
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 8
- 229910052749 magnesium Inorganic materials 0.000 description 8
- 239000011148 porous material Substances 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- 229910052623 talc Inorganic materials 0.000 description 6
- 238000005259 measurement Methods 0.000 description 5
- 239000000454 talc Substances 0.000 description 5
- 239000011362 coarse particle Substances 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- -1 silicon organometallic compounds Chemical class 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229920002472 Starch Polymers 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 239000008107 starch Substances 0.000 description 3
- 235000019698 starch Nutrition 0.000 description 3
- 239000011324 bead Substances 0.000 description 2
- 229910001593 boehmite Inorganic materials 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000013001 point bending Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- 235000005273 Canna coccinea Nutrition 0.000 description 1
- 240000008555 Canna flaccida Species 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 240000005979 Hordeum vulgare Species 0.000 description 1
- 235000007340 Hordeum vulgare Nutrition 0.000 description 1
- 240000007049 Juglans regia Species 0.000 description 1
- 235000009496 Juglans regia Nutrition 0.000 description 1
- 240000003183 Manihot esculenta Species 0.000 description 1
- 235000016735 Manihot esculenta subsp esculenta Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 244000046052 Phaseolus vulgaris Species 0.000 description 1
- 235000010627 Phaseolus vulgaris Nutrition 0.000 description 1
- 240000004713 Pisum sativum Species 0.000 description 1
- 235000010582 Pisum sativum Nutrition 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 235000021307 Triticum Nutrition 0.000 description 1
- 244000098338 Triticum aestivum Species 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000003463 adsorbent Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- UIEATEWHFDRYRU-UHFFFAOYSA-N bepridil Chemical compound C1CCCN1C(COCC(C)C)CN(C=1C=CC=CC=1)CC1=CC=CC=C1 UIEATEWHFDRYRU-UHFFFAOYSA-N 0.000 description 1
- 229960003665 bepridil Drugs 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 229910002026 crystalline silica Inorganic materials 0.000 description 1
- 229910052571 earthenware Inorganic materials 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000005350 fused silica glass Substances 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 230000009545 invasion Effects 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000000691 measurement method Methods 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
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000002006 petroleum coke Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001748 polybutylene Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000002195 soluble material Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 235000020234 walnut Nutrition 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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Description
様々な実施の形態において、コージライト形成バッチ材料の全体組成が、酸化物基準で、5〜25重量パーセントのMgO、35〜60重量パーセントのSiO2、及び25〜50重量パーセントのAl2O3から成っている。別の実施の形態において、少なくとも1つのアルミナ源及び少なくとも1つのシリカ源がカオリン粘土ではない。更に別の例示的な実施の形態において、生及びか焼カオリン粘土が、無機バッチ成分の30重量パーセント未満、例えば、20重量パーセント未満を占めている。
本開示の様々な例示的実施の形態において、少なくとも1つの生カオリン粘土をThiele Kaolin社(ジョージア州、サンダースビル)がKaofine90(商標)という商品名で販売しているFine No.1のような市販の製品から選択することができる。
様々な例示的実施の形態において、生及びか焼カオリン粘土が含まれている場合、それ等を含むカオリン粘土の総量が、コージライト形成バッチ材料を成す無機バッチ成分の30重量パーセント未満を占めるようにすることができる。例えば、カオリン粘土の総量がコージライト形成バッチ材料を成す無機バッチ成分の20重量パーセント未満又は15重量パーセント未満、例えば、コージライト形成バッチ材料を成す無機バッチ成分の12重量パーセントを占めるようにすることができる。
本開示によるコージライト含有セラミック体は、例えば、ハニカム体のようなセル状体を含む任意の有益な大きさ及び形状を有することができる。
本明細書において、「中間焼成強度」という用語及びその変形は、400℃〜1000℃での焼成中におけるセラミック体の強度を意味し、本明細書において、「中火焼成した」コージライト形成体とも言う。例えば、本開示の少なくとも1つの実施の形態において、中間焼成強度は少なくとも1つの有機バインダーを除去した後であって焼結前のセラミック体の強度である。当業者は中火焼成したコージライト形成体の強度を測定するための適切な方法及び条件を決定することができる。例えば、1つの実施の形態において、支持スパン2.5インチ(63.5mm)、荷重スパン0.75インチ(19.05mm)のMTSアライアンスRT5、4点屈曲MOR装置によってコージライト形成体の強度を測定することができる。
本明細書において、「中間焼成強度が向上する」という用語及びその変形は、本開示で説明した高BET比表面積を有する生カオリン粘土を含むコージライト形成バッチ材料から形成されたものではない中火焼成コージライト形成体と比較して、中火焼成コージライト形成体の強度が向上することを意味する。様々な実施の形態において、少なくとも10%、例えば、少なくとも20%、少なくとも40%、少なくとも60%、少なくとも80%、少なくとも100%、あるいはそれ以上コージライト形成体の中間焼成強度を向上させることができる。
No.2剥離・加工カオリン粘土及びFine No.1カオリン粘土を使用して、生カオリン粘土の混合物を11種類調製した。80重量パーセントのNo.2カオリン粘土の粒径は2μm未満であり、粘土のBET比表面積は13.4m2/gであった。Fine No.1カオリン粘土のBET比表面積は24.6m2/gであった。
表1に示すように、No.2カオリン粘土を10%ずつ増加させてFine No.1カオリン粘土に混合した。測定したエンドメンバー及び混合物のBET比表面積を下表1及び図1に示す。
タルク、アルミナ、シリカ、細孔剤、潤滑剤、有機バインダー、及び(前記実施例1同様)13.4m2/gのBET比表面積を有するNo.2カオリン粘土から成るバッチ材料を調製した。そのコージライト形成バッチ材料を下表2に示す。
生カオリン粘土の組成を除き、実施例2の手順によって実施例3〜7を調製した。生カオリンとして、実施例1同様、Fine No.1及びNo.2カオリン粘土を使用し、下表3に示すように、20%ずつ増加させて混合物を調製した。
タルク、アルミナ、シリカ、細孔剤、潤滑剤、有機バインダー、及び(前記実施例1同様)13.4m2/gのBET比表面積を有するNo.2カオリン粘土から成るバッチ材料を調製した。バッチ組成を上表2に示す。
生カオリン粘土組成を除き、実施例8の手順によって実施例9〜13を調製した。生カオリンとして、実施例1同様、Fine No.1及びNo.2カオリン粘土を使用し、下表4に示すように、20%ずつ増加させて混合物を調製した。
Claims (5)
- 少なくとも1つの酸化マグネシウム源、
少なくとも1つのアルミナ非カオリン粘土源、
少なくとも1つのシリカ非カオリン粘土源、及び
生カオリン粘土、
を含む無機バッチ成分から成るコージライト形成バッチ材料であって、
前記生カオリン粘土が、22m2/gより大きいBET比表面積を有し、
全体組成が、酸化物基準で、5〜25重量パーセントのMgO、35〜60重量パーセントのSiO2、及び25〜50重量パーセントのAl2O3を有してなることを特徴とするコージライト形成バッチ材料。 - か焼カオリン粘土をさらに含み、前記生カオリン粘土およびか焼カオリン粘土の総量が、前記無機バッチ成分の30重量パーセント未満であることを特徴とする請求項1記載のコージライト形成バッチ材料。
- コージライト含有セラミック体を製造する方法であって、
少なくとも1つの酸化マグネシウム源、
少なくとも1つのアルミナ非カオリン粘土源、
少なくとも1つのシリカ非カオリン粘土源、及び
生カオリン粘土、
を含む無機バッチ成分から成るコージライト形成バッチ材料であって、
前記生カオリン粘土が、22m2/gより大きいBET比表面積を有し、
全体組成が、酸化物基準で、5〜25重量パーセントのMgO、35〜60重量パーセントのSiO2、及び25〜50重量パーセントのAl2O3を有してなるバッチ材料から未焼成体を形成するステップと、
前記未焼成体を焼成してコージライト含有セラミック体を得るステップと、
を有して成ることを特徴とする方法。 - メジアン粒径が10μmより大きい少なくとも1つの酸化マグネシウム源、
少なくとも1つのアルミナ非カオリン粘土源、
メジアン粒径が10μmより大きい少なくとも1つのシリカ非カオリン粘土源、及び
生カオリン粘土、
を含む無機バッチ成分から成るコージライト形成バッチ材料であって、
前記生カオリン粘土が、17.9m2/g以上のBET比表面積を有し、
全体組成が、酸化物基準で、5〜25重量パーセントのMgO、35〜60重量パーセントのSiO2、及び25〜50重量パーセントのAl2O3を有してなることを特徴とするコージライト形成バッチ材料。 - コージライト含有セラミック体を製造する方法であって、
メジアン粒径が10μmより大きい少なくとも1つの酸化マグネシウム源、
少なくとも1つのアルミナ非カオリン粘土源、
メジアン粒径が10μmより大きい少なくとも1つのシリカ非カオリン粘土源、及び
生カオリン粘土、
を含む無機バッチ成分から成るコージライト形成バッチ材料であって、
前記生カオリン粘土全体が、17.9m2/g以上のBET比表面積を有し、
全体組成が、酸化物基準で、5〜25重量パーセントのMgO、35〜60重量パーセントのSiO2、及び25〜50重量パーセントのAl2O3を有してなるバッチ材料から未焼成体を形成するステップと、
前記未焼成体を焼成してコージライト含有セラミック体を得るステップと、
を有して成ることを特徴とする方法。
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