JP2018520970A - セラミックハニカム体を焼成する方法 - Google Patents
セラミックハニカム体を焼成する方法 Download PDFInfo
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- JP2018520970A JP2018520970A JP2017558009A JP2017558009A JP2018520970A JP 2018520970 A JP2018520970 A JP 2018520970A JP 2017558009 A JP2017558009 A JP 2017558009A JP 2017558009 A JP2017558009 A JP 2017558009A JP 2018520970 A JP2018520970 A JP 2018520970A
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Images
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
- 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
- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- 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
- C04B38/0006—Honeycomb structures
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- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
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- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
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- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
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Abstract
Description
11.5インチ(29.21cm)×9.4インチ(23.88cm)、14.3インチ(36.32cm)×7.9インチ(20.07cm)、10.5インチ(26.67cm)×6.5インチ(16.51cm)、及び13.9インチ(35.30インチ)×6.5インチ(16.51cm)の寸法を有する多数のコージエライト形成未焼結ハニカム体を形成した。各上記未焼結ハニカム体を、200℃である第1の温度まで、約30℃/時間で加熱した。続いて、上記未焼結ハニカム体を、200℃である上記第1の温度から450℃である第2の温度まで、以下の表3に記載した加熱速度で加熱した。上記第1の温度から上記第2の温度までの加熱ステージ内で、釜内の酸素レベルを、有機揮発物放出のピーク付近である280℃において、追加の酸素を上記釜に導入する前に測定した。続いて酸素を、上記第2の温度(450℃)に達するまで、上記釜に導入した。上記第2の温度に達すると、上記釜を、上記第2の温度から600℃である第3の温度まで、以下の表3に記載した加熱速度で加熱した。上記第2の温度から上記第3の温度までの記加熱ステージ内で、上記釜内の酸素レベルを480℃において測定した。表3に示した各サンプルにおいて、平均割れ率は11%以下であった。
11.5インチ(29.21cm)×9.4インチ(23.88cm)、14.3インチ(36.32cm)×7.9インチ(20.07cm)、10.5インチ(26.67cm)×6.5インチ(16.51cm)、及び13.9インチ(35.30インチ)×6.5インチ(16.51cm)の寸法を有する多数の未焼結コージエライトセラミックハニカム体を形成した。各上記未焼結コージエライトセラミックハニカム体を、200℃の第1の温度まで加熱した。続いて、上記未焼結コージエライトセラミック体を、200℃である上記第1の温度から450℃である第2の温度まで、以下の表4に記載した加熱速度で加熱した。上記第1の温度から上記第2の温度までの加熱ステージ内で、釜内の酸素レベルを、有機揮発物放出のピーク付近である280℃において、追加の酸素を上記釜に導入する前に測定した。続いて酸素を、上記第2の温度(450℃)に達するまで、上記釜に導入した。上記第2の温度に達すると、上記釜を、上記第2の温度から600℃である第3の温度まで、以下の表4に記載した加熱速度で加熱した。上記第2の温度から上記第3の温度まで加熱する上記加熱ステージ内で、上記釜内の酸素レベルを480℃において測定した。表4に示した各サンプルにおいて、平均割れ率は18%以上であった。
窯内で未焼結ハニカム体を焼成するための方法であって、
上記方法は:
上記未焼結ハニカム体を、第1の温度から第2の温度まで、第1の加熱速度で、及び第1の酸素レベルで加熱するステップ;並びに
その後、上記未焼結ハニカム体を、上記第2の温度から第3の温度まで、第2の加熱速度で、及び第2の酸素レベルで加熱するステップ
を含み、
上記第2の加熱速度は上記第1の加熱速度より大きく、
上記第2の酸素レベルは上記第1の酸素レベルより高く、
上記未焼結ハニカム体からの有機揮発物放出のピーク付近において、酸素を上記釜に導入して、上記釜の酸素レベルを、上記第1の酸素レベルから上記第2の酸素レベルまで上昇させる、方法。
上記釜の上記酸素レベルは、上記揮発性有機物放出のピークの間、上記第1の酸素レベルに維持される、実施形態1に記載の方法。
上記第1の酸素レベルは、約5体積%〜約13体積%である、実施形態1に記載の方法。
上記第1の酸素レベルは、約8体積%〜約11体積%である、実施形態1に記載の方法。
上記第2の酸素レベルは、約12体積%〜約20体積%である、実施形態1に記載の方法。
上記第2の酸素レベルは、約13体積%〜約17体積%である、実施形態1に記載の方法。
上記第1の加熱速度は、約20℃/時間〜約45℃/時間である、実施形態1に記載の方法。
上記第1の加熱速度は、約30℃/時間〜約42℃/時間である、実施形態1に記載の方法。
上記第2の加熱速度は、約35℃/時間〜約90℃/時間である、実施形態1に記載の方法。
上記第2の加熱速度は、約40℃/時間〜約70℃/時間である、実施形態1に記載の方法。
上記第1の温度は、約180℃〜約220℃である、実施形態1に記載の方法。
上記第2の温度は、約430℃〜約470℃である、実施形態1に記載の方法。
上記第3の温度は、約580℃〜約620℃である、実施形態1に記載の方法。
上記未焼結ハニカム体の直径は約8インチ(20.32cm)〜約15インチ(38.10cm)であり、アスペクト比は約0.4〜約1.5である、実施形態1に記載の方法。
約260℃〜約300℃の釜温度において、酸素を上記釜に導入して、上記釜の上記酸素レベルを、上記第1の酸素レベルから上記第2の酸素レベルまで上昇させる、実施形態1に記載の方法。
窯内で未焼結ハニカム体を焼成するための方法であって、
上記方法は:
未焼結セラミックハニカム体を、約180℃〜約220℃である第1の温度から約430℃〜約470℃である第2の温度まで、約20℃/時間〜約45℃/時間である第1の加熱速度で、及び約5体積%〜約13体積%である第1の酸素レベルで加熱するステップ;並びに
上記未焼結セラミックハニカム体を、上記第2の温度から約580℃〜約620℃である第3の温度まで、約35℃/時間〜約90℃/時間である第2の加熱速度で、及び約12体積%〜約20体積%である第2の酸素レベルで加熱するステップ
を含み、
上記第2の加熱速度は上記第1の加熱速度より大きく、
上記第2の酸素レベルは上記第1の酸素レベルより高く、
上記未焼結セラミックハニカム体からの有機揮発物放出のピーク付近において、酸素を上記釜に導入して、上記釜の酸素レベルを、上記第1の酸素レベルから上記第2の酸素レベルまで上昇させ、
上記未焼結セラミックハニカム体の直径は約8インチ(20.32cm)〜約15インチ(38.10cm)であり、アスペクト比は約0.4〜約1.5である、方法。
上記釜の上記酸素レベルは、上記揮発性有機物放出のピークの間、上記第1の酸素レベルに維持される、実施形態16に記載の方法。
上記第1の酸素レベルは、約8体積%〜約11体積%である、実施形態16に記載の方法。
上記第2の酸素レベルは、約13体積%〜約17体積%である、実施形態16に記載の方法。
約260℃〜約300℃の釜温度において、酸素を上記釜に導入して、上記釜の上記酸素レベルを、上記第1の酸素レベルから上記第2の酸素レベルまで上昇させる、実施形態16に記載の方法。
窯内で未焼結体を焼成するための方法であって、
上記方法は:
上記未焼結体を、有機揮発物放出のピークまで、第1の酸素レベルO1未満で、T1(200℃)からT2(280℃)まで加熱するステップ;
その後、上記未焼結体を、上記T2(280℃)からT3(450℃)まで加熱し、酸素レベルを上記O1からO2まで上昇させる、ステップ;
その後、上記未焼結体を、上記T3(450℃)からT4(580℃)まで加熱するステップ[[このステージの間、酸素は消費されるが、追加されないため、上記O2からO3まで減少する−この酸素の減少を従属クレームとする]]
を含み、
上記T1(200℃)から上記T3(450℃)まで加熱する上記ステップは、第1の加熱速度におけるものであり、上記T3(450℃)から上記T4(580℃)まで加熱する上記ステップは、上記第1の加熱速度より大きい第2の加熱速度におけるものである、方法。
その後上記未焼結体を、上記未焼結体をセラミック体へと変えるのに十分な温度及び時間で、加熱するステップを更に含む、実施形態21に記載の方法。
105 ハニカム構造
110 平行チャネル
115 交差チャネル壁
130 入口端
135 出口端
Claims (5)
- 窯内で未焼結ハニカム体を焼成するための方法であって、
前記方法は:
前記未焼結セラミックハニカム体を、約180℃〜約220℃である第1の温度から約430℃〜約470℃である第2の温度まで、約20℃/時間〜約45℃/時間である第1の加熱速度で、及び約5体積%〜約13体積%である第1の酸素レベルで加熱するステップ;並びに
前記未焼結セラミックハニカム体を、前記第2の温度から約580℃〜約620℃である第3の温度まで、約35℃/時間〜約90℃/時間である第2の加熱速度で、及び約12体積%〜約20体積%である第2の酸素レベルで加熱するステップ
を含み、
前記第2の加熱速度は前記第1の加熱速度より大きく、
前記第2の酸素レベルは前記第1の酸素レベルより高く、
前記未焼結セラミックハニカム体からの有機揮発物放出のピーク付近において、酸素を前記釜に導入して、前記釜の酸素レベルを、前記第1の酸素レベルから前記第2の酸素レベルまで上昇させ、
前記未焼結セラミックハニカム体の直径は約8インチ(20.32cm)〜約15インチ(38.10cm)であり、アスペクト比は約0.4〜約1.5である、方法。 - 前記釜の前記酸素レベルは、前記揮発性有機物放出のピークの間、前記第1の酸素レベルに維持される、請求項1に記載の方法。
- 前記第1の酸素レベルは、約8体積%〜約11体積%である、請求項1に記載の方法。
- 前記第2の酸素レベルは、約13体積%〜約17体積%である、請求項1に記載の方法。
- 約260℃〜約300℃の釜温度において、酸素を前記釜に導入して、前記釜の前記酸素レベルを、前記第1の酸素レベルから前記第2の酸素レベルまで上昇させる、請求項1に記載の方法。
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