JP7362144B2 - 再生ケイ酸アルミニウム材及び、再生ケイ酸アルミニウム材を含む粒子状混合物 - Google Patents
再生ケイ酸アルミニウム材及び、再生ケイ酸アルミニウム材を含む粒子状混合物 Download PDFInfo
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Description
(i)粒子径d50が10μm~30μmであり;
(ii)粒子径d70が40μm未満であり;及び
(iii)粒子径d98が60μm未満である。
本発明は、セラミック物品の製造において使用するのに適した、上記再生ケイ酸アルミニウム材を含む粒子状混合物にも関する。
典型的には、粒子状混合物は、セラミック物品の製造に使用するのに適しており、特にセラミック磁器質床タイル製造に使用するのに適している。典型的には、セラミック製造プロセスは、粒子状混合物を液圧プレス等のプレス機に運ぶこと、粒子状混合物をグリーン物品へと加圧することを含む。グリーン物品はその後、乾燥機、次に窯(キルン)に運ばれ、焼結又は焼成されてセラミック物品を形成する。当該分野で知られている標準的なセラミック製造プロセスが適切である。
(i)10μm~30μmの粒子径d50;
(ii)50μm未満の粒子径d70;及び
(iii)70μm未満の粒子径d98
(i)10μm~25μmの粒子径d50;
(ii)30μm未満の粒子径d70;及び
(iii)55μm未満の粒子径d98
典型的には、再生ケイ酸アルミニウム材は、石炭燃焼生成物に由来する。
(i)10μm~30μmの粒子径d50;
(ii)40μm未満の粒子径d70;及び
(iii)60μm未満の粒子径d98
(i)10μm~25μmの粒子径d50;
(ii)30μm未満の粒子径d70;及び
(iii)55μm未満の粒子径d98
(a)任意で、1.0%~5.0%の可燃性炭素;及び
(b)任意で、0.5%~3.0%の酸化鉄
を含んでもよい。
可燃性炭素レベルをコントロールするこのようなプロセスは、当該分野で十分に知られている。
(a)1.0%~3.0%の可燃性炭素;及び
(b)0.5%~2.0%の酸化鉄
を含む。
一般的に、可燃性炭素は、強熱減量(LOI:loss on ignition)法によって測定できる炭素である。この可燃性炭素は、粒子状混合物中で注意深く制御される必要がある。再生ケイ酸アルミニウム材は、不燃性炭化物等の不燃性炭素を、一般的には非常に低濃度(微量)で含んでもよい。
典型的には、酸化鉄含量は、蛍光X線分光法(XRF)によって測定される。
適切な任意のバインダーは、有機バインダーである。適切な有機バインダーとして、ポリビニルアルコール、流動化剤(superplasticizer)、メチルセルロース、カルボメトキシセルロース、又はデキストリンが挙げられる。他のバインダーは、当業者に周知である。有機バインダーは液状であってもよい。
可燃性炭素のレベルは、ASTM D7348による強熱減量(LOI)試験によって測定される。この試験では、サンプルを乾燥するために、まず1gのフライアッシュを150℃で乾燥する。このサンプルをその後冷却し、秤量する。次に、サンプルを2時間かけて段階的に500℃に達するまで加熱する。
酸化鉄のレベルは、蛍光X線によって測定される。再生ケイ酸アルミニウムの典型的な粒径は十分に小さく、この技術は精密測定に適している。この技術は、高エネルギーガンマ線又はX線を使用してサンプルを励起することで機能する。これは、存在する原子のイオン化を引き起こし、これは次いで原子の種類によって決まる固有周波数EM放射線を放射する。異なる周波数の強度分析は、元素分析を行うことを可能にする。適切な装置は、オリンパスによって供給されているXRF分析計のVartaシリーズである。この装置は、元素鉄を検出し、結果は最も一般的には、対応するFe2O3レベルに換算される。
粒度分布は、レーザー回析によって測定される。レーザー回析による粒径分析の望ましい基準は、ISO 8130-13の「Coating powders - Part 13. Particle size analysis by laser diffraction」に示されている。この基準に適合している適切な分析機は、米国、カリフォルニア州、アーバインのHoriba Instruments社;英国、ウースターシャーのMalvern Instruments社;ドイツ、クラウスタール・ツェラーフェルトのSympatec社;米国、カリフォルニア州、フラートンのBeckman-Coulter社によって製造されている。適切な粒径分析機は、Malvern Instruments社のMastersizer 2000である。典型的には、試験物質が初めに液体に分散されるウェット法ではなく、物質が粉末流として試験される「ドライ」分析技術が使用される。測定は、通常、製造者の取扱説明書及び試験手順に従って行われる。
同量の再生ケイ酸アルミニウム材、クレイ及び長石を含むが、粒度分布の異なる3つのセラミック組成物を準備し、同じ寸法と重量を有するグリーンセラミック試験物品を形成した。
Claims (7)
- セラミック物品の製造において使用するのに適した粒子状混合物であって、当該粒子状混合物が、
40wt%~70wt%の再生ケイ酸アルミニウム材、及び
30wt%~60wt%の、クレイ(パイロフィライトクレイを除く)、頁岩(シェール)、長石、及びそれらの任意の組み合わせから選択される物質
を含むものであり、
ここで、前記再生ケイ酸アルミニウム材が、以下の粒度分布を有するものである:
(i)10μm~30μmの粒子径d50;
(ii)40μm未満の粒子径d70;及び
(iii)60μm未満の粒子径d98
粒子状混合物。 - 前記再生ケイ酸アルミニウム材が、再生材料の少なくとも99wt%が75μm未満の粒径を有する粒度分布を有する、請求項1に記載の粒子状混合物。
- 前記再生ケイ酸アルミニウムが、
(a)1.0%~5.0%の可燃性炭素;及び
(b)0.5%~3.0%の酸化鉄
を含む、請求項1又は2に記載の粒子状混合物。 - 前記再生ケイ酸アルミニウム材が、以下の粒度分布:
(i)10μm~25μmの範囲の粒子径d50;
(ii)30μm未満の粒子径d70;及び
(iii)55μm未満の粒子径d98
を有する、請求項1~3のいずれか1項に記載の粒子状混合物。 - 前記再生ケイ酸アルミニウム材が、石炭燃焼生成物に由来する、請求項1~4のいずれか1項に記載の粒子状混合物。
- 前記粒子状混合物が、以下の粒度分布:
(i)10μm~30μmの粒子径d50;
(ii)50μm未満の粒子径d70;及び
(iii)75μm未満の粒子径d98
を有する、請求項1~5のいずれか1項に記載の粒子状混合物。 - 前記粒子状混合物が、さらにガラスを含み、
ここで、クレイ(パイロフィライトクレイを除く)、頁岩、長石、及びガラスの合計量が、60wt%以下である、請求項1~6のいずれか1項に記載の粒子状混合物。
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