JP2011526576A - チタン酸アルミニウム型の多孔質構造体 - Google Patents
チタン酸アルミニウム型の多孔質構造体 Download PDFInfo
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Abstract
(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z
このセラミック材料は、酸化物(Al2O3、TiO2、MgO及びZrO2)だけに基づくmol%で、次の組成を満たす:90<2a+3m<110;100+a<3t<210−a;且つa+t+m+zr=100(ここで、aは、Al2O3のモル分率であり;tは、TiO2のモル分率であり;mは、MgOのモル分率であり;zrは、ZrO2のモル分率である)。
【選択図】なし
Description
(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z
この材料は、次の組成を満たす(酸化物Al2O3、TiO2、MgO及びZrO2に基づくmol%で):
90<2a+3m<110;
100+a<3t<210−a;及び
a+t+m+zr=100
(ここで、aは、Al2O3のモル分率であり;tは、TiO2のモル分率であり;mは、MgOのモル分率であり;zrは、ZrO2のモル分率である)。
−25%超であるが55%未満のAl2O3;
−35%超であるが60%未満のTiO2;
−1%超であるが8%未満のMgO;
−0.7%超であるが7%未満のZrO2;及び
−20%未満のSiO2。
(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z
(−xは0.45〜0.94;
−yは0.05〜0.50;
−zは0.005〜0.06;且つ
−x+y+z=1)。
−xは0.65〜0.90;
−yは0.09〜0.40;
−zは0.005〜0.05;且つ
−x+y+z=1。
a)開始分量を形成するようにして原料を混合するステップ;
b)溶融液を得るようにして開始分量を溶融するステップ;
c)溶融液を冷却して、それにより溶融液を完全に固化するステップ(この冷却は、例えば三分未満で素早く行うことができる);及び
d)任意的に、その固形体を、粒子混合体を得るようにして粉砕するステップ。
第一に、初期反応体、焼結により得られた粒子、又は溶融キャストにより得られた粒子を、上述のように又はこれらの混合体として、所望の組成を得るために適切な割合で混合する。
−98%超のTiO2を含有するアナターゼ(Altichem社から販売されている)、又は95wt%のTiO2を含有し、且つ約120μmのメジアン径d50を有するルチル(Europe Minerals社により販売されている);
−98%超のAl2O3を含有し、且つ約85μmのメジアン径d50を有するアルミナ(AR75(商標)、Alcan社により販売されている);
−99.5%超の純度、及び208μmのメジアン径d50を有するSiO2(SIFRACO社により販売されている);
−98%超の純度、及び80%超の粒子が0.25〜1mmの直径を有するMgO(Nedmag社により販売されている);
−約97%のCaOを含有し、80%の粒子が80μm未満の直径を有するライム;
−99.5%超のK2CO3を含有し、80%超の粒子が0.25〜1mmの直径を有する炭酸カリウム(Albemarle社により販売されている);
−98.5%超の純度、及び3.5μmのメジアン径d50を有するジルコニウム(Saint-Gobain ZirPro社により参照番号CC10に下に販売されている)
1)酸化物に基づいてwt%で示した化学組成は、蛍光X線によって測定された;
2)耐熱生成品中に存在する結晶相は、X線回折及びマイクロプローブ分析によって特性化した。表1において、AMTZは(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z型の固溶体を示し、P2は第二の副相の存在を示し、且つPSはケイ酸塩の第二相に対応し、「M」は主相に対応し、且つ「〜」は微量の形態で存在する相を意味する;
3)初期に存在する結晶相と、1100℃で100時間の熱処理後に存在する結晶相とを、X線回折によって比較することからなる試験によって、存在する結晶相の安定性を測定した。この処理後のルチルTiO2の存在に対応する主なピークの最大強度が、AMTZ相の3つの主なピークの最大強度の平均の50%未満を保持した場合に、生成体を安定とみなした。表1に与えた値は、ルチル相の主なピークの最大強度の、AMTZ相の3つの主なピークの最大強度の平均に対するパーセント比に対応し、次の式による:
TiO2/AMTZ=
(主なルチルピークの最大強度)/(3つの最大のAMTZピークの最大強度の平均)
上述したような50%未満の強度の比は、材料の良好な安定性を特徴付け、且つそれを使用可能とするとみなされる。
4)熱膨張係数(TEC:thermal expansion coefficient)は、メジアン径d50が50μm未満である、同じ粒径分布を有する粉体から形成されたディスクについて、膨張測定(dilatrometry)によって25℃〜1000℃で通常得られる値の平均に対応する。そのディスクは、圧縮し、そして表1に示された温度で焼結することによって、調製された;且つ
5)曲げ破壊係数(MOR:module of rupture)は、粉体を等方性加圧(isostatic pressing)し、続いて焼結することによって得られた45mm×4mm×3mmの寸法の棒について、通常の方法での4点曲げ試験において、室温で測定された。
−90wt%の、上述の電気炉−溶融キャスト(electric−furnace−fused−cast)粒子;
−最終組成において10酸化物等量wt%の、上述の原料。
(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z
−第1の比較例1では、材料を、ジルコニウム源を初期反応物に導入しないで溶融キャスト粒子から初めに調製した;
−第2の比較例2では、材料を、ジルコニウム源を初期反応物に導入しないで上述の原料の粉体を反応焼結することにより得られた粒子から合成した;
−第3の比較例3では、材料を、初期混合体に3t<100+a且つ2a+3m>110となる非常に少量のチタンを用いて合成した;
−第4及び第5の比較例4及び5では、材料を、少量のアルミニウムを含有する溶融キャスト粒子から最初に調整した;
−第6の比較例6では、材料を、高いジルコニウム含量により特徴付けられた溶融キャスト粒子から合成した;
−第7の比較例7では、溶融キャスト粒子を、3t<100+aとなる量のAl2O3及びTiO2を用いて合成した。
−比較例1、2、4及び5の材料は、SiCのTECよりも高いことさえある、高すぎるTEC値を有している;
−本発明によらない比較例3及び7の材料は、明白に不十分な安定性である;
−比較例6の材料は、粒子フィルター型のフィルター構造体での使用に関して許容できない。これは、ジルコニウムの特異的な膨張を特徴付けるものと類似の不連続性が存在するTEC曲線を有することが、観察されたからである。ここで、この不連続の前では0.73の平均TECが測定された一方で、この不連続の後では4.99の平均TECが測定された。このような特性は、材料を破壊する亀裂を生成しやすい。
特に粒子フィルターとしての用途向けの、本発明により得られた材料から形成した部品の特性を調査するために、試験片2及び5を製造するために前に使用したものと同じ粉体から、本発明による多孔質の試験片を調製した。その化学組成を、表4で与える。
Claims (11)
- チタン、アルミニウム、マグネシウム、及びジルコニウムを含有する擬板チタン石型の酸化物相を主に含むセラミック材料、又は前記酸化物相からなるセラミック材料を有する多孔質構造体であって、前記擬板チタン石型の相が、次の式を実質的に満たし:
(Al2TiO5)x(MgTi2O5)y(MgTiZrO5)z
前記材料が、酸化物(Al2O3、TiO2、MgO及びZrO2)に基づくmol%で、次の組成を満たす、多孔質構造体:
90<2a+3m<110;
100+a<3t<210−a;且つ
a+t+m+zr=100
(ここで、aは、Al2O3のモル分率であり;tは、TiO2のモル分率であり;mは、MgOのモル分率であり;zrは、ZrO2のモル分率である)。 - 次の関係を満たす、請求項1に記載の多孔質構造体:
xが0.45〜0.94;
yが0.05〜0.50;
zが0.005〜0.06;且つ
x+y+z=1。 - 次の関係を満たす、請求項2に記載の多孔質構造体:
xが0.65〜0.90;
yが0.09〜0.40;
zが0.005〜0.05;且つ
x+y+z=1。 - 前記材料が、酸化物に基づくwt%で次の化学組成を有する、請求項1〜3のいずれか一項に記載の多孔質構造体:
−25%超であるが55%未満のAl2O3;
−35%超であるが60%未満のTiO2;
−1%超であるが8%未満のMgO;
−0.7%超であるが7%未満のZrO2;及び
−20%未満のSiO2。 - 前記材料が、酸化物に基づくwt%で次の化学組成を有する、請求項4に記載の多孔質構造体:
−35%超であるが50%未満のAl2O3;
−40%超であるが55%未満のTiO2;
−1.5%超であるが6%未満のMgO;
−1.5%超であるが6%未満のZrO2;及び
−0.5%超であるが10%未満のSiO2。 - 前記ZrO2の少なくとも一部が、元素Zrのモル分率と、元素Ce及び/又は元素Hfのモル分率とを置き換えることに基づいて、Ce2O3及びHfO2からなる群より選択される少なくとも一つの酸化物で置き換えられている、請求項1〜5のいずれか一項に記載の多孔質構造体。
- 前記材料が、擬板チタン石型の相からなる主相、及び少なくとも一つの第二相を有し、前記第二相が、ケイ酸塩相、並びに/又は酸化チタンTiO2及び/若しくは酸化ジルコニウムZrO2から本質的になる相である、請求項1〜6のいずれか一項に記載の多孔質構造体。
- 前記第二相が、前記材料の総重量の0〜40%の範囲となる割合のケイ酸塩相からなる、請求項7に記載の多孔質構造体。
- 前記ケイ酸塩相が、主にシリカ及びアルミナからなり、前記ケイ酸塩相中のシリカの重量による割合が50%超である、請求項8に記載の多孔質構造体。
- 前記第二相が、酸化チタンTiO-2及び/又は酸化ジルコニウムZrO2を本質的に含有する、請求項7〜9のいずれか一項に記載の多孔質構造体。
- 前記セラミック材料が、10%超の気孔率及び5〜60μmを中心とする気孔径を有する前記構造体を構成する、ハニカム型構造を有する請求項1〜10のいずれか一項に記載の多孔質構造体、特に自動車用途向けのフィルター又は触媒担体。
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CN102083768A (zh) | 2011-06-01 |
EP2303798A2 (fr) | 2011-04-06 |
KR20110028331A (ko) | 2011-03-17 |
US20110152075A1 (en) | 2011-06-23 |
JP5406286B2 (ja) | 2014-02-05 |
US8551910B2 (en) | 2013-10-08 |
WO2010001066A2 (fr) | 2010-01-07 |
CN102083768B (zh) | 2013-09-11 |
FR2933401A1 (fr) | 2010-01-08 |
FR2933401B1 (fr) | 2010-07-30 |
WO2010001066A3 (fr) | 2010-02-25 |
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