JPWO2013147321A1 - 炭化珪素質多孔体、ハニカム構造体及び電気加熱式触媒担体 - Google Patents
炭化珪素質多孔体、ハニカム構造体及び電気加熱式触媒担体 Download PDFInfo
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- JPWO2013147321A1 JPWO2013147321A1 JP2014508263A JP2014508263A JPWO2013147321A1 JP WO2013147321 A1 JPWO2013147321 A1 JP WO2013147321A1 JP 2014508263 A JP2014508263 A JP 2014508263A JP 2014508263 A JP2014508263 A JP 2014508263A JP WO2013147321 A1 JPWO2013147321 A1 JP WO2013147321A1
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- silicon carbide
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims abstract description 102
- 229910010271 silicon carbide Inorganic materials 0.000 title claims abstract description 91
- 239000003054 catalyst Substances 0.000 title claims description 17
- 239000011148 porous material Substances 0.000 claims abstract description 89
- 239000002245 particle Substances 0.000 claims abstract description 35
- 229910052751 metal Inorganic materials 0.000 claims abstract description 30
- 239000002184 metal Substances 0.000 claims abstract description 30
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 27
- 239000010703 silicon Substances 0.000 claims abstract description 27
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 16
- 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 group [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 claims abstract description 16
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical group O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 34
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 10
- 150000001342 alkaline earth metals Chemical class 0.000 claims description 10
- 230000003647 oxidation Effects 0.000 claims description 8
- 238000007254 oxidation reaction Methods 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 239000000835 fiber Substances 0.000 claims description 2
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- 239000000203 mixture Substances 0.000 description 12
- 239000011863 silicon-based powder Substances 0.000 description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 9
- 238000001035 drying Methods 0.000 description 8
- 238000010304 firing Methods 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
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- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 5
- 239000004927 clay Substances 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- 238000005485 electric heating Methods 0.000 description 4
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 4
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- 229910052661 anorthite Inorganic materials 0.000 description 3
- GWWPLLOVYSCJIO-UHFFFAOYSA-N dialuminum;calcium;disilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])([O-])[O-].[O-][Si]([O-])([O-])[O-] GWWPLLOVYSCJIO-UHFFFAOYSA-N 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
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- 238000007561 laser diffraction method Methods 0.000 description 3
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- 229910052712 strontium Inorganic materials 0.000 description 3
- 229910000018 strontium carbonate Inorganic materials 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 229910000323 aluminium silicate Inorganic materials 0.000 description 2
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 2
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- 229910000510 noble metal Inorganic materials 0.000 description 2
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- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
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- 229910020068 MgAl Inorganic materials 0.000 description 1
- 229910017625 MgSiO Inorganic materials 0.000 description 1
- 235000006508 Nelumbo nucifera Nutrition 0.000 description 1
- 240000002853 Nelumbo nucifera Species 0.000 description 1
- DFPAKSUCGFBDDF-UHFFFAOYSA-N Nicotinamide Chemical group NC(=O)C1=CC=CN=C1 DFPAKSUCGFBDDF-UHFFFAOYSA-N 0.000 description 1
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- 229910004283 SiO 4 Inorganic materials 0.000 description 1
- 229910003668 SrAl Inorganic materials 0.000 description 1
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- 238000002441 X-ray diffraction Methods 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
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- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910002090 carbon oxide Inorganic materials 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
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- 229910052839 forsterite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
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- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 description 1
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- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 description 1
- 238000010813 internal standard method Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
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- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
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- 150000005846 sugar alcohols Polymers 0.000 description 1
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Abstract
Description
R’=σ・(1−ν)・κ/E・α
で表される。このため、耐熱衝撃性の向上には、強度を高く、ポアソン比を低く、熱伝導率を高く、ヤング率を低く、熱膨張係数を低くすることが求められており、これらのいずれかを向上させる必要がある。
強度=ハニカム構造体の曲げ強度/{1−(開口率/100)}
ヤング率=ハニカム構造体のヤング率/{1−(開口率/100)}
開気孔率[%]=全細孔容積/{(1/見掛け密度)+全細孔容積} ×100
炭化珪素粉末、金属珪素粉末、タルク(3MgO・4SiO2・H2O)、水酸化アルミニウム、シリカを表2に示す質量割合で混合した。ここで、タルク、水酸化アルミニウム、シリカが酸化物相を形成する材料である。なお、後述のX線回折測定によれば、実施例1では、母相がコーディエライト、分散相がムライトとなることが確認できた。これに、バインダーとしてヒドロキシプロピルメチルセルロース、造孔材として吸水性樹脂を添加すると共に、水を添加して成形原料とし、成形原料を混練し、土練して円柱状の坏土を作製した。バインダーの含有量は炭化珪素(SiC)粉末と金属珪素(金属Si)粉末の合計に対し7質量%であり、造孔材の含有量は炭化珪素粉末と金属珪素粉末の合計に対し2質量%であり、水の含有量は炭化珪素粉末と金属珪素粉末の合計に対し35質量%であった。炭化珪素粉末の平均粒子径は30μmであり、金属珪素粉末の平均粒子径は6μmであった。また、造孔材の平均粒子径は、20μmであった。なお、炭化珪素、金属珪素及び造孔材の平均粒子径は、レーザー回折法で測定した値である。
・組成
ハニカム構造体の炭化珪素質多孔体の組成は、粉末X線回折の内部標準法により測定した。なお、原料の組成比と炭化珪素質多孔体の組成比とのズレは1%程度であった。
・開気孔率
水銀圧入法(JIS R 1655準拠)による全細孔容積[cm3/g]と気相置換法による乾式自動密度測定機による見掛密度[g/cm3]から、下記式にて算出した。
開気孔率[%]=全細孔容積/{(1/見掛密度)+全細孔容積}×100
・平均気孔径
水銀圧入法(JIS R 1655準拠)により測定した。
・強度
ハニカム構造体をセルが貫通する方向を長手方向とした試験片(縦5セル×横10セル×長さ40mm)に加工し、JIS R1601に準拠した曲げ試験によりハニカム構造体の曲げ強度を算出した。その後、別途計測した上記ハニカム構造体の開口率を用いて、下記式にて算出した。
強度=ハニカム構造体の曲げ強度/{1−(開口率/100)}
・ヤング率
ハニカム構造体をセルが貫通する方向を長手方向とした試験片(縦5セル×横10セル×長さ70mm)に加工し、吊り下げスパンを50mmとした共振法にてヤング率を測定した。
・熱伝導率
比熱と熱拡散率と嵩密度の積として算出した。なお、比熱はDSC法、熱拡散率は光交流法により測定した。また、嵩密度は下記式から算出した。
嵩密度=1/{(1/見掛密度)+全細孔容積}
・平均線熱膨張係数
JIS R1618に準拠して、室温〜800℃の平均線熱膨張係数を測定した。
・電気炉スポーリング試験(急速冷却試験)
ハニカム構造体を電気炉にて所定温度で2時間加熱し、均一な温度にした後、室温に取り出し、クラックの発生の有無を目視で観察した。このとき、所定温度を700℃としたときにクラックが発生しなかったものを「○」、所定温度を700℃としたときにクラックが発生したものを「△」、それ以下の温度でクラックが発生したものを「×」とした。クラックが発生する温度が高いものほど耐熱衝撃性が高いことを示す。
原料組成を表2に示すものとした以外は実施例1に準じて実施例2〜10の炭化珪素質多孔体を製造した。
タルクの代わりに炭酸カルシウムを用い、原料組成を表2に示すものとした以外は実施例1に準じて実施例11の炭化珪素質多孔体を製造した。
タルクの代わりに炭酸ストロンチウムを用い、原料組成を表2に示すものとした以外は実施例1に準じて比較例1,2の炭化珪素質多孔体を製造した。
原料組成を表2に示すものとした以外は実施例1に準じて比較例3,4の炭化珪素質多孔体を製造した。
タルクとともに炭酸ストロンチウムを用い、原料組成を表2に示すものとした以外は実施例1に準じて比較例5の炭化珪素質多孔体を製造した。
Claims (10)
- 炭化珪素粒子と、金属珪素と、酸化物相とを含み、前記炭化珪素粒子どうしが前記金属珪素及び前記酸化物相の少なくとも一方を介して結合されている炭化珪素質多孔体であって、
前記酸化物相は、母相と、該母相中に分散し該母相より熱膨張率の高い分散相とを備えた、
炭化珪素質多孔体。 - 前記酸化物相中の前記分散相の含有率の下限値は1質量%であり、上限値は40質量%である、請求項1に記載の炭化珪素質多孔体。
- 前記分散相の平均粒径の下限値が0.1μmであり、上限値が5μmである、請求項1又は2に記載の炭化珪素質多孔体。
- 前記分散相は、板状、針状、繊維状である、請求項1〜3のいずれか1項に記載の炭化珪素質多孔体。
- 炭化珪素粒子の含有率の下限値が50質量%であり、上限値が80質量%であり、金属珪素の含有率の下限値が15質量%であり、上限値が45質量%であり、酸化物の含有率の下限値が1質量%であり、上限値が25質量%である、請求項1〜4のいずれか1項に記載の炭化珪素質多孔体。
- 前記母相は、アルカリ土類金属、アルミニウム、及び、珪素を含む酸化物であり、前記分散相は、アルカリ土類金属、アルミニウム、及び、珪素のうちの1種以上を含む酸化物である、請求項1〜5のいずれか1項に記載の炭化珪素質多孔体。
- 前記母相は、コーディエライトである、請求項1〜6のいずれか1項に記載の炭化珪素質多孔体。
- 前記分散相は、ムライトである、請求項1〜7のいずれか1項に記載の炭化珪素質多孔体。
- 請求項1〜8のいずれか1項に記載の炭化珪素質多孔体で構成される、ハニカム構造体。
- 請求項1〜8のいずれか1項に記載の炭化珪素質多孔体を利用した、電気加熱式触媒担体。
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