JP5144256B2 - 多孔質セラミック物体の強度の増大方法及びこの方法から製造された物体 - Google Patents
多孔質セラミック物体の強度の増大方法及びこの方法から製造された物体 Download PDFInfo
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- JP5144256B2 JP5144256B2 JP2007509596A JP2007509596A JP5144256B2 JP 5144256 B2 JP5144256 B2 JP 5144256B2 JP 2007509596 A JP2007509596 A JP 2007509596A JP 2007509596 A JP2007509596 A JP 2007509596A JP 5144256 B2 JP5144256 B2 JP 5144256B2
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Description
(a)一緒に本質的に化学的に結合されたセラミック粒子を含む多孔質セラミック物体を、ホウ素源に露出する工程及び
(b)この多孔質物体を、酸素含有雰囲気中で、増大した強度を有する多孔質セラミック物体を形成するために十分な温度に加熱する工程
を含んでなる多孔質セラミック物体の強度の増大方法である。
TSF=MOR/(E×α)
(式中、MORは、(Pa)によって与えられる破壊係数であり、Eは、(Pa)によって与えられる弾性率であり、そしてαは、(1/℃)によって与えられる線熱膨張率である)
によって与えられる熱衝撃係数(TSF)によって計算することができる。この係数は、℃の単位を有し、この値が高いほど、熱衝撃に対する耐性が大きい。
曲げ試験片2セル×5セル×40〜75mmを、国際出願公開第WO03/082773A1号明細書の実施例4に記載されているのと同じ方法で製造した、公称175cpsi(セル/平方インチ)針状ムライトハニカムから切断した。形成した後のハニカムを、また、国際出願公開第WO03/082773A1号明細書の実施例4に記載されているようにして、1400℃で2時間熱処理した。4〜6個の試験片の組に、4重量%〜10重量%の範囲内のB2O3の90℃の水溶液を含浸させた。過剰の溶液をチャンネルから吹き出し、そしてこの部品を、0℃に冷却し、その後、室温で乾燥窒素を流しながら乾燥させた。乾燥後、試験片を、覆ったアルミナトレー内で、空気中で1400℃で2時間加熱した。1組を2回処理した。23個の試験片の一組は、未処理のままであり、ここで比較例1として参照する。これらの例の結果を表Iに示す。
ハニカムの上にB2O3の均一な皮膜を作るために、上記のものと同じ方法で製造した、5.66インチ直径×6インチ長さ、公称175cpsiの針状ムライトハニカムの壁に、90℃の8重量%B2O3水溶液を充填した。このハニカムを断熱容器内に入れ、1℃に冷却し、そこでこれを、乾燥N2をゆっくり流しながら、14日間ゆっくり乾燥させた。次いで、乾燥した部品を、空気中で1400℃で2時間加熱した。全質量は4%ほど増加した。
B2O3の不均一皮膜を有するハニカムを、下記のようにして作った。上記のものと同じ方法で製造した、5.66インチ直径×6インチ長さ、公称175cpsiの針状ムライトハニカムの壁に、90℃の8重量%B2O3水溶液を充填した。この含浸されたハニカムを、オーブン内で110℃で乾燥させた。次いで、乾燥した部品を、空気中で1400℃で2時間加熱した。質量は4%ほど増加した。この部品は、熱応力試験に於いて、第二サイクルの間に390℃で破壊した。ハニカムの外側四分の一及び中心部から切断した機械的試験片は、それぞれ、56.1MPa及び314℃並びに31.6MPa及び209℃の平均強度及び熱衝撃係数を示した。内側試験片の、より低い強度及び熱衝撃係数は、乾燥の間に、B2O3溶液がハニカムの外側に吐出し、従って内部試験内には、より少ないB2O3が残ることに起因すると考えられた。
この実施例に於いて、公称175cpsiセリアドープした針状ムライトハニカム(4重量%のCeO2)を使用した。セリアドープしたハニカムは、4重量%のCeO2含有量を有する針状ムライトを製造するために十分な酢酸セリウム(III)を押出ミックスに添加した以外は、国際出願公開第WO03/082773A1号明細書の実施例4に記載されているのと同じ方法で製造した。曲げ試験片は、実施例1〜5について記載したのと同じ方法で製造し、ここで、8重量%B2O3水溶液を使用して、曲げ試験片を処理した。1400℃に2時間加熱した後、試験片質量は2.9%ほど増加した。これらのB2O3処理した試験片は、64.0MPaの平均強度及び344℃の平均TSFを有しており、他方、同じハニカムからの未処理の試験片(即ち比較例2)は、39.9MPaの平均強度及び240℃の平均TSFを有していた。
含浸のために、8重量%のB2O3及び6重量%のNd(NO3)3・6H2Oを含有する水溶液を使用した以外は、実施例1〜5に記載したようにして、曲げ試験片を製造し、そして処理した。1400℃で2時間熱処理した後に測定した質量増加は、7.1%であった。この試験片は、36.0MPaの平均強度及び340℃の平均TSFを有していた。同じハニカムからの処理しなかった試験片(即ち比較例3)は、22.6MPaの平均強度及び266℃の平均TSFを有していた。
イビデン株式会社、日本国大垣市から入手可能な、公称200cpsiの炭化ケイ素、ディーゼル粒子フィルター及び8重量%のB2O3水溶液を使用した以外は、実施例1〜5に記載したようにして、曲げ試験片を製造し、そして処理した。B2O3処理した試験片は、90.6MPaの平均強度及び176℃の平均TSFを有しており、他方、同じハニカムからの処理しなかった試験片(比較例4)は、59.8MPaの平均強度及び128℃の平均TSFを有していた。
公称200cpsiのコーディエライトディーゼル粒子フィルター(コーニング社(Corning Incorporated)、ニューヨーク州コーニング)及び10重量%のB2O3水溶液を使用した以外は、実施例1〜5に記載したようにして、曲げ試験片を製造し、そして処理した。B2O3処理した試験片は、17.8MPaの平均強度及び703℃の平均TSFを有しており、他方、同じハニカムからの処理しなかった試験片(比較例5)は、9.2MPaの平均強度及び671℃の平均TSFを有していた。
曲げ試験片を、実施例1〜5について記載したようにして製造し、そしてそれぞれの試験片を前駆体中に浸漬し、過剰物を吹き飛ばし、次いで110℃で乾燥することによって、ポリマーSiC前駆体(アリルヒドリドポリカルボシラン)(スターファイヤー・システムズ社(Starfire Systems Inc.)、ニューヨーク州Watervliet、SP−マトリックス・ポリマー(SP-Matrix Polymer))で被覆した。乾燥した試験片を、窒素下で1000℃まで1時間ゆっくり加熱し、次いで5℃/分で室温にまで冷却した。この方法によって、それぞれの試験片の重量が約8%ほど増加した、SiC皮膜になった。次いで、SiC被覆した試験片を、90℃の8重量%B2O3水溶液で含浸させ、冷却し、乾燥し、そして実施例1〜5について記載したようにして空気中で熱処理した。試験片全質量は、SiC及びB2O3処理後に約11.6%ほど増加した。この試験片は、58.3MPaの平均強度及び314℃の平均TSFを有していた。
以下に、本発明及びその関連態様を記載する。
態様1.(a)一緒に本質的に化学的に結合されたセラミック粒子を含む多孔質セラミック物体を、ホウ素源に露出する工程及び
(b)この多孔質物体を、酸素含有雰囲気中で、増大した強度を有する多孔質セラミック物体を形成するために十分な温度に加熱する工程
を含んでなる、多孔質セラミック物体の強度の増大方法。
態様2.その中に溶解したホウ素源を有する液体を含浸させ、そしてこの液体を除去して、ホウ素源が、多孔質セラミック物体のセラミック粒子の少なくとも一部の上に堆積するようにすることによって、多孔質セラミック物体をホウ素源に露出する態様1に記載の方法。
態様3.ホウ素源を、液体から沈殿させ、そして続いてこの液体を除去する態様2に記載の方法。
態様4.pH、温度又はこれらの組合せを変えることによって、ホウ素源を沈殿させる態様3に記載の方法。
態様5.ホウ素源が酸化ホウ素、ホウ酸、有機ホウ酸エステル、炭化ホウ素、窒化ホウ素、o−カルボラン、五ホウ酸アンモニウム、ホウ酸テトラフェニルアンモニウム、金属ホウ化物、金属ホウ酸塩又はこれらの組合せである態様1に記載の方法。
態様6.ホウ素源が炭化ホウ素、酸化ホウ素、ホウ酸、有機ホウ酸エステル又はこれらの組合せである態様5に記載の方法。
態様7.別個に与えられたホウ素源を多孔質セラミック物体と共に同時に加熱することによって、多孔質セラミック物体をホウ素源に露出する態様1に記載の方法。
態様8.加熱を空気中で行う態様1に記載の方法。
態様9.加熱を少なくとも1000℃で最高1450℃までの温度で行う態様1に記載の方法。
態様10.多孔質セラミック物体が窒化ケイ素、チタン酸アルミニウム、炭化ケイ素、コーディエライト及びムライト又はこれらの組合せである態様1に記載の方法。
態様11.多孔質セラミック物体が炭化ケイ素、コーディエライト及びムライト又はこれらの組合せである態様10に記載の方法。
態様12.多孔質セラミック物体がムライトである態様11に記載の方法。
態様13.多孔質セラミック物体が針状ムライトである態様12に記載の方法。
態様14.多孔質セラミック物体がディーゼル粒子フィルターである態様1に記載の方法。
態様15.一緒に融合されているセラミック粒子からなる多孔質セラミック物体であって、セラミック粒子の少なくとも一部の上に、ホウ素を含有する酸化物ガラス相が存在する多孔質セラミック物体。
態様16.多孔質セラミック物体がムライト、炭化ケイ素、コーディエライト、チタン酸アルミニウム又はこれらの組合せである態様15に記載の多孔質セラミック物体。
態様17.セラミック物体がムライト又は炭化ケイ素である態様16に記載の多孔質セラミック物体。
態様18.多孔質セラミック物体がムライトである態様17に記載の多孔質セラミック物体。
態様19.セラミック物体が針状ムライトである態様18に記載の多孔質セラミック物体。
態様20.ホウ素を含有する酸化物ガラス相が希土類金属、Zr、Hf、Sn、Si、N、C、Al又はこれらの組合せからなる態様15に記載の多孔質セラミック物体。
態様21.ホウ素を含有する酸化物ガラス相がNd、Ce、Zr、Sn、Si、N、C、Al又はこれらの組合せからなる態様20に記載の多孔質セラミック物体。
態様22.多孔質セラミック物体がホウ素を含有する酸化物ガラス相を欠いている類似の多孔質セラミック物体よりも少なくとも10%大きい強度を有する態様15に記載の多孔質セラミック物体。
態様23.多孔質セラミック物体がホウ素を含有する酸化物ガラス相を欠いている類似の多孔質セラミック物体よりも少なくとも20%大きい熱衝撃係数を有する態様22に記載の多孔質セラミック物体。
態様24.多孔質セラミック物体が多孔質セラミック物体の少なくとも0.01重量%のホウ素の量を有する態様15に記載の多孔質セラミック物体。
態様25.多孔質セラミック物体がムライトである態様24に記載の多孔質セラミック物体。
態様26.態様15に記載の多孔質セラミック物体を含んでなるフィルター。
態様27.フィルターがディーゼル粒子フィルターである態様26に記載のフィルター。
態様28.フィルターがその上に触媒を有する態様27に記載のフィルター。
態様29.多孔質セラミック物体がホウ素を含有する酸化物ガラス相を欠いている類似の多孔質セラミック物体よりも少なくとも10%大きい熱衝撃係数を有する態様22に記載の多孔質セラミック物体。
Claims (14)
- (a)一緒に本質的に化学的に結合されたセラミック粒子を含む多孔質セラミック物体を、ホウ素源に露出し(ここでホウ素源は多孔質セラミック物体内に均一に分布されている)、そして
(b)前記多孔質物体を、酸素含有雰囲気中で、増大した強度を有する多孔質セラミック物体を形成するために十分な温度に加熱する
ことを含んでなる、多孔質セラミック物体の強度の増大方法。 - ホウ素源を含む液体を多孔質セラミック物体に含浸させ、そしてこの液体を除去して、ホウ素源が、多孔質セラミック物体のセラミック粒子の少なくとも一部の上に堆積するようにすることによって、多孔質セラミック物体をホウ素源に露出する請求項1に記載の方法。
- ホウ素源を、液体から沈殿させ、そして続いてこの液体を除去する請求項2に記載の方法。
- ホウ素源が酸化ホウ素、ホウ酸、有機ホウ酸エステル、炭化ホウ素、窒化ホウ素、o−カルボラン、五ホウ酸アンモニウム、ホウ酸テトラフェニルアンモニウム、金属ホウ化物、金属ホウ酸塩又はこれらの組合せである請求項1に記載の方法。
- 別個に与えられたホウ素源を多孔質セラミック物体と共に同時に加熱することによって、多孔質セラミック物体をホウ素源に露出する請求項1に記載の方法。
- 加熱を空気中で行う請求項1に記載の方法。
- 加熱を少なくとも1000℃で最高1450℃までの温度で行う請求項1に記載の方法。
- 多孔質セラミック物体が窒化ケイ素、チタン酸アルミニウム、炭化ケイ素、コーディエライト及びムライト又はこれらの組合せである請求項1に記載の方法。
- 多孔質セラミック物体が針状ムライトである請求項8に記載の方法。
- 多孔質セラミック物体がディーゼル粒子フィルターである請求項1に記載の方法。
- 一緒に融合されているセラミック粒子からなる多孔質セラミック物体を含むフィルターであって、セラミック粒子の少なくとも一部の上に、ホウ素を含有する酸化物ガラス相が存在し、前記酸化物ガラス相が希土類金属、Zr、Hf、Sn、Si、Al又はこれらの組合せを含むフィルター。
- 多孔質セラミック物体がムライト、炭化ケイ素、コーディエライト、チタン酸アルミニウム又はこれらの組合せである請求項11に記載のフィルター。
- セラミック物体が針状ムライトである請求項12に記載のフィルター。
- フィルターがディーゼル粒子フィルターである請求項11に記載のフィルター。
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2005
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EP2253603A1 (en) | 2010-11-24 |
RU2006141000A (ru) | 2008-05-27 |
CN101628824B (zh) | 2012-05-16 |
CN100564316C (zh) | 2009-12-02 |
WO2005102959A1 (en) | 2005-11-03 |
JP2007533594A (ja) | 2007-11-22 |
CA2562671C (en) | 2013-04-16 |
ATE496876T1 (de) | 2011-02-15 |
US20070021291A1 (en) | 2007-01-25 |
ZA200609457B (en) | 2008-11-26 |
DE602005026114D1 (de) | 2011-03-10 |
KR20070008701A (ko) | 2007-01-17 |
CA2562671A1 (en) | 2005-11-03 |
US7381681B2 (en) | 2008-06-03 |
EP1740515B1 (en) | 2011-01-26 |
CN1942413A (zh) | 2007-04-04 |
BRPI0510875A (pt) | 2007-12-26 |
US20050239640A1 (en) | 2005-10-27 |
KR101250674B1 (ko) | 2013-04-03 |
PL1740515T3 (pl) | 2011-07-29 |
RU2401821C2 (ru) | 2010-10-20 |
PL2253603T3 (pl) | 2013-01-31 |
EP2253603B1 (en) | 2012-08-29 |
EP1740515A1 (en) | 2007-01-10 |
CN101628824A (zh) | 2010-01-20 |
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