JP6463353B2 - セラミックにおける細孔形成のための架橋澱粉 - Google Patents
セラミックにおける細孔形成のための架橋澱粉 Download PDFInfo
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- JP6463353B2 JP6463353B2 JP2016522780A JP2016522780A JP6463353B2 JP 6463353 B2 JP6463353 B2 JP 6463353B2 JP 2016522780 A JP2016522780 A JP 2016522780A JP 2016522780 A JP2016522780 A JP 2016522780A JP 6463353 B2 JP6463353 B2 JP 6463353B2
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- green body
- starch
- drying
- cross
- porous ceramic
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- 235000019698 starch Nutrition 0.000 title claims description 89
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Classifications
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0087—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by generating pores in the ceramic material while in the molten state
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
- C04B38/0635—Compounding ingredients
- C04B38/0645—Burnable, meltable, sublimable materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
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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
- C04B35/185—Mullite 3Al2O3-2SiO2
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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
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- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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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
- C04B35/46—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
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- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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- C04B35/638—Removal thereof
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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Description
本明細書において、多孔質セラミック体を作製するための細孔形成剤としての架橋澱粉の使用を開示する。特定の実施形態では、少なくとも1つの架橋澱粉は、例えば追加添加として少なくとも約20重量%等の比較的高濃度でバッチ組成物中に存在してよい。特定の実施形態では、少なくとも1つの架橋澱粉は、追加添加として約20重量%〜約40重量%、例えば約20重量%〜約35重量%、約20重量%〜約30重量%、又は約28重量%〜約32重量%の範囲の量でバッチ組成物中に存在してよい。本明細書において使用される場合、用語「追加添加(super addition)」は、追加の成分又は材料を、バッチ組成物又は処方に、100重量パーセントベース処方を超過して又はこれに加えて添加することを指す。
本明細書において開示する架橋澱粉は、コージエライト形成用粉末、ムライト形成用粉末、及びチタン酸アルミニウム形成用粉末を含む、当該技術分野において公知のいずれのセラミック形成用粉末を用いて、バッチ組成物を形成できることが想定される。本明細書において使用される場合、用語「粉末(powder)」、例えばセラミック形成用粉末は、いずれの好都合な粒子サイズを指す。特定の実施形態では、粒子サイズは、約50nm〜約5000マイクロメートル、例えば約200nm〜約5000マイクロメートルの範囲であってよい。
バッチ組成物を生成した後、バッチ組成物を押出成形して未焼成体を形成し、続いて乾燥させる。乾燥後、未焼成体を、多孔質セラミック体を得るために焼成するまでの期間保管してよい。
また、本明細書において、許容可能な孔形成剤処方のために未焼成体をスクリーニングする方法を開示する。この方法は、特に大規模な材料の混合、液体との混合、並びにダイを通した押出成形、それに続く乾燥及び焼成を伴う従来のプロセスに比べて、コスト効率が良く迅速な評価を可能とし得る。本明細書において開示するように、ダイから押し出された後の乾燥時の未焼成体の収縮を、乾燥状態から焼成状態までの未焼成体の収縮と合わせて追跡してよい。乾燥時の収縮が特定の閾値未満、例えば約5%未満、又は特定の実施形態では、約4%未満、約3%未満、約2%未満、又は約1%未満である場合に、この未焼成体を、多孔性セラミック体を作製するために選択してよい。特定の実施形態では、未焼成体の乾燥時の収縮が約5%未満である場合に、未焼成体は実質的に割れのない多孔質セラミック体をもたらすことができる。本明細書において使用される場合、用語「収縮(shrinkage)」は、本体の初期押出成形寸法と比較して、パーセンテージで表した、相対的部分径方向又は軸方向寸法減少である。
コージエライトムライト‐チタン酸アルミニウム無機体パッケージをベースとして、複数の組成物を調製した。これらを以下の図1に示す。表1に示したように、細孔形成剤として添加される澱粉の量は、約30%を超え、乾燥体積ベースで約35%超に到達する。表1はまた、湿潤‐乾燥間収縮、膨張、24時間後の重量増加、及び完全な時効処理(例えば10日後)における重量増加を含む試験された実験条件に関する、選択された関心対象の特性を列挙する。
24時間の時効処理後の乾燥材料の増大及び重量増加を、様々な澱粉細孔形成剤を含む、複数のバッチ組成物に関して測定した。図1は、使用される澱粉細孔形成剤のタイプに応じた、24時間の時効処理後の重量増加に対する乾燥材料増大を示す。ジャガイモ、エンドウ、トウモロコシ及びサゴを含む異なる源からの架橋澱粉及び高架橋澱粉を評価した。加工澱粉、及び高アミロペクチン澱粉又は高アミロースレベルを有する澱粉も評価した。
材料の3つの異なるステージ:完全に乾燥した、24時間の時効処理後、及び完全な時効処理(例えば10日)後の、様々な澱粉細孔形成剤を含む未焼成体に関して、MORを測定した。未架橋のジャガイモ澱粉、架橋ジャガイモ澱粉及び架橋エンドウ澱粉を評価した。図3は、各未焼成体に関する、3つの異なるステージにおけるMORを示す。最大膨張は、試験された各澱粉細孔形成剤に関して、一貫して約24時間後に得られることに留意されたい。
マイクロ波乾燥プロセスの代表的な3つの温度における乾燥後に、未架橋のジャガイモ澱粉を含む破砕された未焼成体の走査電子顕微鏡(SEM)画像を撮影した。これを図4A〜Cに示す。図4A、図4B及び図4Cにそれぞれ示したように、未焼成体を80℃、105℃及び120℃で、100%まで乾燥させた。120℃のオーブン乾燥温度において、澱粉顆粒は中空形状を呈し、放出されたアミロースによって周囲の無機マトリクスに結合し、劣化により、より低い温度においてよりも脆弱となることが観察される。図4Cを参照のこと。
Claims (6)
- 多孔質セラミック体を作製する方法であって、
前記方法は:
少なくとも1つのチタン酸アルミニウム形成用粉末、少なくとも1つの溶媒、少なくとも1つのバインダ、及び追加添加として30重量%を超えかつ40重量%以下の量で存在する少なくとも1つの架橋澱粉を混合してバッチ組成物を形成するステップ;
前記バッチ組成物を押出成形して未焼成体を形成するステップ;
前記未焼成体を乾燥させるステップ;並びに
前記未焼成体を焼成してチタン酸アルミニウムを含む多孔質セラミック体を形成するステップ
を有してなり、
35℃及び85%の湿度における前記未焼成体の増大は、前記未焼成体の完全な乾燥後少なくとも24時間でかつ焼成前において、0.8%未満である、方法。 - 前記多孔質セラミック体の多孔率が50%超である、請求項1に記載の多孔質セラミック体を作製する方法。
- 前記多孔性セラミック体の多孔率が50%〜65%の範囲である、請求項1又は2に記載の多孔質セラミック体を作製する方法。
- 35℃で85%の湿度下の前記未焼成体の増大が、乾燥後少なくとも24時間において、0.5%未満である、請求項1〜3のいずれか1項に記載の多孔質セラミック体を作製する方法。
- 前記未焼成体の乾燥時の収縮が5%未満である、請求項1〜4のいずれか1項に記載の多孔質セラミック体を作製する方法。
- 少なくとも1つのチタン酸アルミニウム形成用粉末;
少なくとも1つのバインダ;及び
追加添加として30重量%を超えかつ40重量%以下の量で存在する少なくとも1つの架橋澱粉
を含む未焼成体であって、
35℃及び85%の湿度における前記未焼成体の増大は、完全な乾燥後少なくとも24時間において、0.8%未満である、未焼成体。
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US61/891,079 | 2013-10-15 | ||
PCT/US2014/060641 WO2015057805A2 (en) | 2013-10-15 | 2014-10-15 | Crosslinked starches for pore forming in ceramics |
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FR1301843A (fr) | 1961-06-12 | 1962-08-24 | Commissariat Energie Atomique | Céramique poreuse à très faible conductibilité thermique et procédé pour sa fabrication |
JPS5385850A (en) | 1976-12-30 | 1978-07-28 | Matsushita Electric Works Ltd | Production of fiberboard |
JP4266103B2 (ja) | 2001-12-07 | 2009-05-20 | 日本碍子株式会社 | 多孔質セラミック体の製造方法 |
US6620751B1 (en) * | 2002-03-14 | 2003-09-16 | Corning Incorporated | Strontium feldspar aluminum titanate for high temperature applications |
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US7442425B2 (en) | 2003-09-30 | 2008-10-28 | Corning Incorporated | High porosity honeycomb and method |
US20060021308A1 (en) | 2004-07-29 | 2006-02-02 | Merkel Gregory A | Mullite-aluminum titanate body and method for making same |
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US7575618B2 (en) | 2006-03-30 | 2009-08-18 | Corning Incorporated | Reactive binders for porous wall-flow filters |
US8956436B2 (en) | 2006-06-30 | 2015-02-17 | Corning Incorporated | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
US8394167B2 (en) | 2006-06-30 | 2013-03-12 | Corning Incorporated | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
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