JP6263198B2 - 菫青石チタン酸アルミニウムマグネシウム組成物、およびこれを含んでなるセラミック物品 - Google Patents
菫青石チタン酸アルミニウムマグネシウム組成物、およびこれを含んでなるセラミック物品 Download PDFInfo
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- JP6263198B2 JP6263198B2 JP2015545146A JP2015545146A JP6263198B2 JP 6263198 B2 JP6263198 B2 JP 6263198B2 JP 2015545146 A JP2015545146 A JP 2015545146A JP 2015545146 A JP2015545146 A JP 2015545146A JP 6263198 B2 JP6263198 B2 JP 6263198B2
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Description
1.チタン酸アルミニウムおよび二チタン酸マグネシウムの固溶体から主に構成される第1結晶相と、菫青石を含む第2結晶相と、を含んでなるセラミック物品であって、
該セラミック物品は、酸化物基準の重量%で表して、4〜10%のMgO;40〜55%のAl 2 O 3 ;25〜44%のTiO 2 ;5〜25%のSiO 2 ;ならびに焼結助剤を含む組成を有し、前記焼結助剤は、酸化カルシウムおよび酸化ストロンチウムのうちの少なくとも1種を含む、セラミック物品。
2.前記焼結助剤が酸化セリウムをさらに含む、実施態様1に記載のセラミック物品。
3.前記焼結助剤が、酸化イットリウムおよび酸化ランタンのうちの少なくとも1種をさらに含む、実施態様1または2に記載のセラミック物品。
4.酸化物基準で表して、a(Al 2 TiO 5 )+b(MgTi 2 O 5 )+c(2MgO・2Al 2 O 3 ・5SiO 2 )+d(3Al 2 O 3 ・2SiO 2 )+e(MgO・Al 2 O 3 )+f(2MgO・TiO 2 )+g(CaO)+h(SrO)+i(X)+j(Fe 2 O 3 ・TiO 2 )+k(TiO 2 )+l(Al 2 O 3 )(式中、Xは、CeO 2 、Y 2 O 3 およびLa 2 O 3 の少なくとも1種であり、かつa、b、c、d、e、f、g、h、i、j、kおよびlは、(a+b+c+d+e+f+g+h+i+j+k+l)=1.00となるような各成分の重量分率であり、かつ0.3≦a≦0.75、0.075≦b≦0.3、0.02≦c≦0.5、0.0≦d≦0.4、0.0≦e≦0.25、0.0≦f≦0.1、0.0≦g≦0.01、0.0≦h≦0.02、0.0015≦(g+h)、0.0≦i≦0.05、0.0≦j≦0.05、0.0≦k≦0.2、および0.0≦l≦0.1である)で表される組成を有する、実施態様1から3のいずれか記載のセラミック物品。
5.0.0025≦g≦0.0075である、実施態様4に記載のセラミック物品。
6.0.005≦h≦0.015である、請求項4または5に記載のセラミック物品。
7.前記焼結助剤が酸化セリウムをさらに含む、実施態様4から6のいずれかに記載のセラミック物品。
8.前記焼結助剤が、酸化イットリウムおよび酸化ランタンのうちの少なくとも1種をさらに含む、実施態様4から7のいずれかに記載のセラミック物品。
9.40体積%超の全間隙率(%P)を有する、実施態様1から8のいずれかに記載のセラミック物品。
10.25℃〜1000℃の温度範囲で、14×10 −7 /℃以下の熱膨張係数(CTE)を有する、実施態様1から9いずれかに記載のセラミック物品。
11.前記焼結助剤は、酸化物基準の重量%で表して、無機バッチ組成物の全重量に対して0.15〜2重量%の範囲の量で存在する、実施態様1から10のいずれかに記載のセラミック物品。
12.酸化物基準の重量%で表して、5〜10%のMgO;40〜50%のAl 2 O 3 ;30〜35%のTiO 2 ;および10〜20%のSiO 2 ;を含む組成を有する、実施態様1から11のいずれかに記載のセラミック物品。
13.10μm〜30μmの範囲の中央細孔径d 50 を有する、実施態様1から12のいずれかに記載のセラミック物品。
14.15μm〜25μmの範囲の中央細孔径d 50 を有する、実施態様1から13のいずれかに記載のセラミック物品。
15.実施態様1から14のいずれかに記載のセラミック物品を含むディーゼル粒子フィルターであって、軸方向に延在し、末端が閉塞された複数の入口および出口セルを有するハニカム構造を含んでなる、ディーゼル粒子フィルター。
16.アルミナ、マグネシアおよびチタニアを主に含んでなる擬板チタン石相と、
菫青石を含んでなる第2相と、
酸化カルシウムおよび酸化ストロンチウムのうちの少なくとも1種を含んでなる焼結助剤と、を含んでなるセラミック物品。
17.酸化ランタニドおよび酸化イットリウムのうちの少なくとも1種をさらに含む、実施態様16に記載のセラミック物品。
18.前記酸化ランタニドが酸化セリウムを含む、実施態様17に記載のセラミック物品。
19.前記焼結助剤が、酸化セリウムと、酸化イットリウムおよび酸化ランタンのうちの少なくとも1種とを含む、実施態様16から18のいずれかに記載のセラミック物品。
20.セラミック物品を製造する方法であって、
マグネシア源、シリカ源、アルミナ源、チタニア源、および少なくとも1種の焼結助剤を含んでなる無機バッチ組成物を提供するステップ;
前記無機バッチ組成物を、可塑剤、潤滑剤、結合剤、細孔形成剤および溶媒からなる群より選択される1種以上のプロセス助剤と混合して、可塑化セラミック前駆体バッチ組成物を形成するステップ;
前記可塑化セラミック前駆体バッチ組成物を、未焼成体へと成形するステップ;および
前記未焼成体を、アルミナ、マグネシアおよびチタニアを主に含んでなる擬板チタン石相と菫青石を含んでなる第2相とを含むセラミック物品に転化させるのに有効な条件下で焼成するステップ;
を有してなり、前記焼成助剤が、酸化カルシウムおよび酸化ストロンチウムのうちの少なくとも1種を含む、方法。
21.前記焼結助剤が、酸化ランタニドおよび酸化イットリウムのうちの少なくとも1種をさらに含む、実施態様20に記載の方法。
22.前記酸化ランタニドが酸化セリウムを含む、実施態様21に記載の方法。
23.前記焼結助剤が、酸化セリウムと、酸化イットリウムおよび酸化ランタンのうちの少なくとも1種とを含む、実施態様20から22のいずれかに記載の方法。
24.少なくとも1つの焼結助剤が、酸化物基準の重量%で表して、前記無機バッチ組成物の全重量に対して0.15〜2重量%の範囲の量で存在する、実施態様20から23のいずれかに記載の方法。
25.前記可塑化セラミック前駆体バッチ組成物が押出成形される、実施態様20から24のいずれかに記載の方法。
26.前記未焼成体をセラミック物品に転化させるのに有効な焼成条件が、1250℃〜1450℃の範囲の第1の保持温度で前記未焼成体を加熱し、前記未焼成体をセラミック物品に転化させるのに十分な第1の保持時間の間、前記第1の保持温度を維持することを含む、実施態様20から25のいずれかに記載の方法。
27.前記第1の保持温度が、1330℃〜1380℃の範囲であり、かつ前記第1の保持時間が2〜24時間の範囲である、実施態様26記載の方法。
28.前記焼成条件が、
前記焼成されたセミック体を、第2の保持時間の間、前記第1の保持温度より低い第2の保持温度に冷却し;
前記セラミック体を、第3の保持時間の間、閾値温度より高くかつ前記第1の保持温度より低い第3の保持温度であって、前記第2の保持温度より高い第3の保持温度に加熱し;および
前記セラミック体を室温(RT)まで冷却する;ことをさらに含む、実施態様20から27のいずれかに記載の方法。
29.前記第2の保持温度が、25℃〜500℃の範囲であり、前記第2の保持時間が、1時間〜48時間の範囲であり、前記第3の保持温度が850℃〜1350℃の範囲であり、および前記第3の保持時間が1時間〜24時間の範囲である、実施態様20から28のいずれかに記載の方法。
Claims (8)
- チタン酸アルミニウムおよび二チタン酸マグネシウムの固溶体を主に含んでなる擬板チタン石相と、菫青石を含んでなる第2相と、を含んでなるセラミック物品であって、該セラミック物品は、酸化物基準の重量%で表して、4〜10%のMgO;40〜55%のAl 2 O 3 ;25〜44%のTiO 2 ;5〜25%のSiO 2 ;ならびに焼結助剤を含む組成を有し、前記焼結助剤は、(i)0.15〜1.0重量%のCaOおよび(ii)0.1〜2.0重量%のSrOのうちの少なくとも1種を含む、セラミック物品。
- 前記焼結助剤が酸化セリウムをさらに含むことを特徴とする、請求項1に記載のセラミック物品。
- 前記焼結助剤が、酸化イットリウムおよび酸化ランタンの少なくとも1種をさらに含むことを特徴とする、請求項1または2に記載のセラミック物品。
- 酸化物基準で表して、a(Al2TiO5)+b(MgTi2O5)+c(2MgO・2Al2O3・5SiO2)+d(3Al2O3・2SiO2)+e(MgO・Al2O3)+f(2MgO・TiO2)+g(CaO)+h(SrO)+i(X)+j(Fe2O3・TiO2)+k(TiO2)+l(Al2O3)(式中、Xは、CeO2、Y2O3およびLa2O3の少なくとも1種であり、かつa、b、c、d、e、f、g、h、i、j、kおよびlは、(a+b+c+d+e+f+g+h+i+j+k+l)=1.00となるような各成分の重量分率であり、かつ0.3≦a≦0.75、0.075≦b≦0.3、0.02≦c≦0.5、0.0≦d≦0.4、0.0≦e≦0.25、0.0≦f≦0.1、0.0≦g≦0.01、0.0≦h≦0.02、0.0015≦(g+h)、0.0≦i≦0.05、0.0≦j≦0.05、0.0≦k≦0.2、および0.0≦l≦0.1である)で表される組成を有することを特徴とする、請求項1から3のいずれか一項に記載のセラミック物品。
- 0.0025≦g≦0.0075および0.005≦h≦0.015であることを特徴とする、請求項4に記載のセラミック物品。
- 少なくとも40%の全間隙率(%P)を有する、請求項1から5いずれか1項記載のセラミック物品。
- 25℃〜1000℃の温度範囲で、25.0×10 −7 /℃以下の熱膨張係数(CTE)を有する、請求項1から6いずれか1項記載のセラミック物品。
- 10μm〜30μmの範囲の中央細孔径d 50 を有する、請求項1から7いずれか1項記載のセラミック物品。
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