JP2019515859A - 高空隙率のセラミックハニカム構造及び製造方法 - Google Patents
高空隙率のセラミックハニカム構造及び製造方法 Download PDFInfo
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Abstract
Description
df=(d50−d10)/d50
ここで、d50及びd10は、先に定められたとおりである。本明細書に記載される実施形態では、多孔質セラミックハニカム構造の多孔質壁の開放された相互接続した空隙率の細孔径分布は、dfが、約0.35以下など、約0.45以下になるように、比較的狭い。他の実施形態では、dfは、約0.25以下など、約0.3以下である。幾つかの実施形態では、dfは、約0.05以上である。したがって、実施形態では、dfは、約0.05以上〜約0.35以下など、約0.05以上〜約0.45以下である。他の実施形態では、dfは、約0.05以上〜約0.25以下など、約0.05以上〜約0.3以下である。
別段の定めがない限り、指定された温度範囲における、構造の少なくとも1つの方向における熱膨張係数であることが理解されるべきである。
TSL=TSP+500℃
式中、TSPは、:
CFA=(w)(N)[2N−0.5−w]
式中、wは、インチ単位の多孔質セラミックハニカム構造の壁厚であり、Nは、in−2単位のセル密度である。
比較例1〜6は、スピネルなしに製造され、したがって、本明細書に記載される実施形態に従って作られた多孔質セラミックハニカム構造よりも多くの微少亀裂を有する、多孔質セラミックハニカム構造である。比較例1〜6の前駆体バッチ組成物及び焼成サイクルは、表2に示されるとおりである。表2の焼成サイクルの行には、1200℃から浸漬温度までの℃/時間でのランプ速度、浸漬温度、及び多孔質セラミックハニカム構造が浸漬温度で保持される時間(時間)を示す、「ランプ>1200℃/浸漬T/浸漬時間」が記載されている。加えて、MOR、正規化MOR、歪み耐性、TSP等の比較例の多孔質セラミックハニカム構造の物性が、表2に提供されている。
比較例7〜10は、スピネルの量を低下させて製造した多孔質セラミックハニカム構造である。より少ないスピネルを有する多孔質セラミックハニカム構造は、より高いスピネル含量を有する多孔質セラミックハニカム構造よりも多くの微少亀裂を含む。比較例7〜10の前駆体バッチ組成物及び焼成サイクルは、表3に示されるとおりである。表3の焼成サイクルの行には、1200℃から浸漬温度までの℃/時間でのランプ速度、浸漬温度、及び多孔質セラミックハニカム構造が浸漬温度で保持される時間(時間)を示す、「ランプ>1200℃/浸漬T/浸漬時間」が記載されている。加えて、MOR、正規化MOR、歪み耐性、TSP等の比較例の多孔質セラミックハニカム構造の物性が、表3に提供されている。
セラミックハニカム構造であって、
チャネルを形成する複数の交差するチャネル壁を含み、かつ、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含むセラミック材料からなる
ウェブマトリクスを有する、セラミックハニカム構造。
前記平均チャネル壁厚が、約130μm以下であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記メジアン細孔径が、約10μm超〜約50μm以下であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記メジアン細孔径が、約13μm以上〜約30μm以下であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約12.2セル/cm2(約200cpsi)以上のセル密度を有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、単峰型の細孔分布を有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記dfが、約0.35以下であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記dfが、約0.16以上であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記dfが、約0.16以上であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記dfが、約0.20以上かつ約0.45以下であることを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約0.5(d50−5.0)以上の軸CTEを有することを特徴とする、ここで、d50はμmで表され、CTEは10−7/℃で表される、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、d50>25μm及び約0.5(d50−5.0)以上の軸CTEを有することを特徴とし、ここで、d50はμmで表され、CTEは10−7/℃で表される、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約10×10−7/℃以上の軸CTEを有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約15×10−7/℃以上の軸CTEを有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造の細孔構造が、チャネル壁厚より大きい内接円を有する個々の細孔を含まないことを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約6.89MPa(約1000psi)以上の強度(MOR/CFA)を含むことを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約1000℃超の熱衝撃限界(TSL)、幾つかの実施形態では約1000℃〜約1550℃の範囲の熱衝撃限界(TSL)を有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
前記セラミックハニカム構造が、約1000℃〜約1550℃の範囲の熱衝撃限界(TSL)を有することを特徴とする、実施形態1に記載のセラミックハニカム構造。
セラミックハニカム物品であって、
ウェブ構造を有するセラミックハニカム構造;
前記ウェブ構造内に形成される複数のチャネル;及び
前記セラミックハニカム構造の細孔容積の少なくとも約50%を満たす、前記セラミックハニカム構造上のウォッシュコート材料
を含み、前記セラミックハニカム構造が、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含む、
セラミックハニカム物品。
前記ウォッシュコート材料が、前記セラミックハニカム構造の前記細孔容積の少なくとも約60%を満たすことを特徴とする、実施形態19に記載のセラミックハニカム物品。
前記セラミックハニカム構造が、約0.5(d50−5.0)以上の軸CTEを有することを特徴とし、ここで、d50はμmで表され、CTEは10−7/℃で表される、実施形態19に記載のセラミックハニカム物品。
前記セラミックハニカム構造が、単峰型の細孔分布を有することを特徴とする、実施形態19に記載のセラミックハニカム物品。
前記セラミックハニカム構造が、約6.89MPa(約1000psi)以上の強度(MOR/CFA)を含むことを特徴とする、実施形態19に記載のセラミックハニカム物品。
前記セラミックハニカム構造が、d50<40μmを有し、前記ウォッシュコート材料が、前記セラミックハニカム構造の細孔容積の少なくとも50%を満たすことを特徴とする、実施形態19に記載のセラミックハニカム物品。
セラミックハニカム構造の製造方法であって、
約10μm以下のメジアン粒径を有するセラミック前駆体バッチ組成物と約10μm以上のメジアン粒径を有する少なくとも1つのデンプン系細孔形成剤とを混合する工程;
前記セラミック前駆体バッチ組成物と少なくとも1つのデンプン系細孔形成剤との混合物を、ウェブ構造を有する未焼成のセラミック構造へと成形する工程;及び
前記未焼成のセラミック構造を焼成して、ウェブ構造を有する前記セラミックハニカム構造を生成する工程であって、該セラミックハニカム構造が、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含む、工程
を含む、方法。
前記バッチ組成物が、約20質量%以上のスピネルを含むことを特徴とする、実施形態25に記載の方法。
前記少なくとも1つのデンプン系細孔形成剤の前記メジアン粒径が、約10μm超〜約50μm以下であることを特徴とする、実施形態25に記載の方法。
前記平均チャネル壁厚が、約130μm以下であることを特徴とする、実施形態25に記載の方法。
101,201 セルチャネル
102 第1の端部
104 第2の端部
106,206 多孔質ウェブ
108,208 入口セル
110,210 出口セル
112,212 プラグ
202 入口端
204 出口端
214 フロースルーチャネル
Claims (5)
- セラミックハニカム構造であって、
チャネルを形成する複数の交差するチャネル壁を含み、かつ、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含むセラミック材料からなる
ウェブマトリクスを有する、セラミックハニカム構造。 - 前記メジアン細孔径が、約10μm超〜約50μm以下であることを特徴とする、請求項1に記載のセラミックハニカム構造。
- セラミックハニカム物品であって、
ウェブ構造を有するセラミックハニカム構造;
前記ウェブ構造内に形成される複数のチャネル;及び
前記セラミックハニカム構造の細孔容積の少なくとも約50%を満たす、前記セラミックハニカム構造上のウォッシュコート材料
を含み、前記セラミックハニカム構造が、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含む、
セラミックハニカム物品。 - セラミックハニカム構造の製造方法であって、
約10μm以下のメジアン粒径を有するセラミック前駆体バッチ組成物と約10μm以上のメジアン粒径を有する少なくとも1つのデンプン系細孔形成剤とを混合する工程;
前記セラミック前駆体バッチ組成物と少なくとも1つのデンプン系細孔形成剤との混合物を、ウェブ構造を有する未焼成のセラミック構造へと成形する工程;及び
前記未焼成のセラミック構造を焼成して、ウェブ構造を有する前記セラミックハニカム構造を生成する工程であって、前記セラミックハニカム構造が、
約55%以上の全空隙率;
約150μm以下の平均チャネル壁厚;
約10μm以上のメジアン細孔径;
約0.45以下のdf、ここで、df=(d50−d10)/d50である;及び
約6.21MPa(約900psi)以上の強度(MOR/CFA)
を含む、工程
を含む、方法。 - 前記バッチ組成物が、約20質量%以上のスピネルを含むことを特徴とする、請求項4に記載の方法。
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