JP5785471B2 - 封口材及びセラミックスハニカム焼成体の製造方法 - Google Patents
封口材及びセラミックスハニカム焼成体の製造方法 Download PDFInfo
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- JP5785471B2 JP5785471B2 JP2011227106A JP2011227106A JP5785471B2 JP 5785471 B2 JP5785471 B2 JP 5785471B2 JP 2011227106 A JP2011227106 A JP 2011227106A JP 2011227106 A JP2011227106 A JP 2011227106A JP 5785471 B2 JP5785471 B2 JP 5785471B2
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- Prior art keywords
- fired body
- honeycomb fired
- sealing material
- ceramic
- inorganic
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Classifications
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- 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
- 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
- C04B35/46—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 titanium oxides or titanates
- C04B35/462—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 titanium oxides or titanates based on titanates
- C04B35/478—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 titanium oxides or titanates based on titanates based on aluminium titanates
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J1/00—Adhesives based on inorganic constituents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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Description
本実施形態の封口材は、水系の無機接着剤と、チタン酸アルミニウム系セラミックス粒子(粉末)と、を含有するものである。以下、封口材の各構成材料について説明する。
本実施形態のセラミックスハニカム焼成体の製造方法は、原料混合物を押出成形して、隔壁により区画された複数の流路を有するグリーンハニカム成形体を得る押出成形工程と、上記グリーンハニカム成形体を焼成して未封口ハニカム焼成体を得る焼成工程と、上記未封口ハニカム焼成体における上記流路の一方の端部を、上記本実施形態の封口材を用いて封口し、封口ハニカム焼成体を得る封口工程と、上記封口ハニカム焼成体を100〜300℃で加熱してセラミックスハニカム焼成体を得る加熱工程と、を有する方法である。また、本発明は、セラミックスハニカム焼成体にカケや亀裂等の欠陥や封口不足箇所が存在する場合、それらの欠陥部位を上記本実施形態の封口材により補修する方法を含む。
(封口材の調製)
水系無機接着剤としてスミセラムS−10A(商品名、朝日化学工業社製、特性は下記表1に示す)を75質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)25質量%とを混合し、封口材を調製した。なお、チタン酸アルミニウムマグネシウムとアルミノシリケートガラスの複合相をもつ粉末は、本発明のチタン酸アルミニウム系セラミックス粒子に相当する。このときの固形分質量比は、S−10A:チタン酸アルミニウムマグネシウム系セラミックス粉末=55:45であった。
グリーンハニカム成形体を形成するために、チタン酸アルミニウムマグネシウムの原料粉末(Al2O3,TiO2,MgO)、SiO2、チタン酸アルミニウムマグネシウムとアルミナとアルミノシリケートガラスとの複合相をもつセラミックス粉末(仕込み時の組成式:41.4Al2O3−49.9TiO2−5.4MgO−3.3SiO2、式中の数値はモル比を表す。)、有機バインダ、潤滑剤、造孔剤、可塑剤、分散剤及び水(溶媒)を含む原料混合物を調製した。原料混合物中の各成分の含有量は下記の値に調整した。
Al2O3:37.3質量部。
TiO2:37.0質量部。
MgO:1.9質量部。
SiO2:3.0質量部。
セラミックス粉末:8.8質量部。
造孔剤:馬鈴薯(potato)から得た平均粒径25μmの澱粉12.0質量部。
有機バインダ:メチルセルロース(SM−4000、信越化学工業社製)5.5質量部、ヒドロキシプロピルメチルセルロース(60SH−4000、信越化学工業社製)2.3質量部、合計7.8質量部。
可塑剤:グリセリンDG(日本油脂社製)0.4質量部。
分散剤:ユニルーブ(50MB−72、日本油脂社製)4.6質量部。
水:28.3質量部。
水系無機接着剤としてスミセラムS−18D(商品名、朝日化学工業社製、特性は下記表1に示す)を75質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)25質量%とを混合し、封口材を調製した。このときの固形分質量比は、S−18D:チタン酸アルミニウムマグネシウム系セラミックス粉末=57:43であった。この封口材を用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤としてスミセラムS−30A(商品名、朝日化学工業社製、特性は下記表1に示す)を75質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)25質量%とを混合し、封口材を調製した。このときの固形分質量比は、S−30A:チタン酸アルミニウムマグネシウム系セラミックス粉末=53:47であった。この封口材を用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤としてスミセラムS−208A(商品名、朝日化学工業社製、特性は下記表1に示す)を75質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)25質量%とを混合し、封口材を調製した。このときの固形分質量比は、S−208A:チタン酸アルミニウムマグネシウム系セラミックス粉末=57:43であった。この封口材を用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤としてスミセラムS−30A(商品名、朝日化学工業社製、特性は下記表1に示す)を50質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)50質量%とを混合し、封口材を調製した。このときの固形分質量比は、S−30A:チタン酸アルミニウムマグネシウム系セラミックス粉末=27:73であった。この封口材を用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤としてスミセラムS−208A(商品名、朝日化学工業社製、特性は下記表1に示す)を50質量%と、チタン酸アルミニウムマグネシウム(Al1.76Mg0.12Ti1.12O5)とアルミノシリケートガラスの複合相を持つ粉末(Al1.82Mg0.12Ti1.12O6.09−0.1SiO2、平均粒径D50:23μm)50質量%とを混合し、封口材を調製した。このときの固形分質量比は、S−208A:チタン酸アルミニウムマグネシウム系セラミックス粉末=31:69であった。この封口材を用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤であるスミセラムS−18D(商品名、朝日化学工業社製、特性は下記表1に示す)を単独で封口材として用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤であるスミセラムS−30A(商品名、朝日化学工業社製、特性は下記表1に示す)を単独で封口材として用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
水系無機接着剤であるスミセラムS−208A(商品名、朝日化学工業社製、特性は下記表1に示す)を単独で封口材として用いた以外は実施例1と同様にして、セラミックスハニカム焼成体を得た。
上記の実施例及び比較例で得られたセラミックスハニカム焼成体について、封口の状態を観察し、密着性を評価した。密着性は、硬化後の封口材とハニカム焼成体の隔壁との間に隙間がなく、両者の密着性が良好である場合を「良好」とし、硬化後の封口材とハニカム焼成体の隔壁との間に隙間がある場合を「不可」として評価した。結果を表2に示す。
上記の実施例及び比較例で得られたセラミックスハニカム焼成体を、空気雰囲気中、1200℃で1時間加熱することにより、硬化した封口材の耐熱性を評価した。耐熱性は、上記加熱条件での耐熱試験後、封口材の融解の有無、封口材と隔壁との密着性、及び、封口材の膨張による隔壁破壊の有無を確認することにより評価した。結果を表2に示す。
Claims (4)
- 水系の無機接着剤と、チタン酸アルミニウムマグネシウム系セラミックス粒子と、を含有し、
前記チタン酸アルミニウムマグネシウム系セラミックス粒子におけるマグネシウムの含有量が、アルミニウム及びチタンの合計量に対して、モル比で0.03〜0.15である、封口材。 - 前記無機接着剤と前記チタン酸アルミニウムマグネシウム系セラミックス粒子との固形分質量比が、99:1〜25:75である、請求項1記載の封口材。
- 前記無機接着剤が、コロイド状無機酸化物、無機高分子、耐火物粒子及び水を含む、請求項1又は2記載の封口材。
- 原料混合物を押出成形して、隔壁により区画された複数の流路を有するグリーンハニカム成形体を得る押出成形工程と、
前記グリーンハニカム成形体を焼成して未封口ハニカム焼成体を得る焼成工程と、
前記未封口ハニカム焼成体における前記流路の一方の端部を、請求項1〜3のいずれか一項に記載の封口材を用いて封口し、封口ハニカム焼成体を得る封口工程と、
前記封口ハニカム焼成体を100〜300℃で加熱してセラミックスハニカム焼成体を得る加熱工程と、
を有するセラミックスハニカム焼成体の製造方法。
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WO2020112379A1 (en) * | 2018-11-30 | 2020-06-04 | Corning Incorporated | Honeycomb body manufacturing methods |
WO2022046399A1 (en) * | 2020-08-25 | 2022-03-03 | Corning Incorporated | Cement mixtures for plugging honeycomb bodies and methods of making the same |
JP2023544991A (ja) * | 2020-09-30 | 2023-10-26 | マテリオン プレシジョン オプティクス (シャンハイ) リミテッド | 耐高温バインダ |
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KR101123173B1 (ko) * | 2003-09-29 | 2012-03-19 | 히타치 긴조쿠 가부시키가이샤 | 세라믹 허니컴 필터 및 그 제조 방법 |
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US20060280905A1 (en) * | 2005-06-14 | 2006-12-14 | Ngk Insulators, Ltd. | Honeycomb structure |
DE102005045666A1 (de) * | 2005-09-14 | 2007-03-15 | Itn Nanovation Gmbh | Schicht oder Beschichtung sowie Zusammensetzung zu ihrer Herstellung |
JP2007105622A (ja) * | 2005-10-13 | 2007-04-26 | Ohcera Co Ltd | 排ガス浄化ハニカムフィルタ及びその製造方法 |
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WO2007097000A1 (ja) | 2006-02-24 | 2007-08-30 | Ibiden Co., Ltd. | ハニカム成形体用封口装置、封止材ペーストの充填方法、及び、ハニカム構造体の製造方法 |
WO2008087783A1 (ja) * | 2007-01-18 | 2008-07-24 | Ngk Insulators, Ltd. | 目封止ハニカム構造体の製造方法 |
WO2009017642A1 (en) * | 2007-07-31 | 2009-02-05 | Corning Incorporated | Compositions for applying to ceramic honeycomb bodies |
WO2010072971A1 (fr) * | 2008-12-23 | 2010-07-01 | Saint-Gobain Centre De Recherches Et D'etudes Europeen | Structure filtrante dont les faces d'entree et de sortie presentent un materiau de bouchage different |
US20110151181A1 (en) * | 2009-12-21 | 2011-06-23 | Geo2 Technologies, Inc. | Fiber Enhanced Porous Substrate |
JP4825309B2 (ja) * | 2010-01-19 | 2011-11-30 | 住友化学株式会社 | ハニカム構造体 |
FR2957529B1 (fr) * | 2010-03-19 | 2012-04-06 | Saint Gobain Ct Recherches | Structure filtrante comprenant un materiau de bouchage ameliore |
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- 2011-10-14 JP JP2011227106A patent/JP5785471B2/ja not_active Expired - Fee Related
- 2011-10-14 CN CN2011800519408A patent/CN103153914A/zh active Pending
- 2011-10-14 EP EP11836044.5A patent/EP2634163A4/en not_active Withdrawn
- 2011-10-14 WO PCT/JP2011/073700 patent/WO2012056905A1/ja active Application Filing
- 2011-10-14 US US13/881,297 patent/US20130207323A1/en not_active Abandoned
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN116082020A (zh) * | 2022-11-21 | 2023-05-09 | 景德镇陶瓷大学 | 一种Si3N4纤维涂层表面改性氧化铝基蜂窝陶瓷的低温原位制备方法及其制得的产品 |
CN116082020B (zh) * | 2022-11-21 | 2023-10-13 | 景德镇陶瓷大学 | 一种Si3N4纤维涂层表面改性氧化铝基蜂窝陶瓷的低温原位制备方法及其制得的产品 |
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EP2634163A1 (en) | 2013-09-04 |
KR20140000696A (ko) | 2014-01-03 |
JP2012106913A (ja) | 2012-06-07 |
EP2634163A4 (en) | 2014-04-16 |
US20130207323A1 (en) | 2013-08-15 |
WO2012056905A1 (ja) | 2012-05-03 |
CN103153914A (zh) | 2013-06-12 |
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