JP5345502B2 - セラミックスハニカム構造体の製造方法およびセラミックスハニカム構造体用のコート材 - Google Patents
セラミックスハニカム構造体の製造方法およびセラミックスハニカム構造体用のコート材 Download PDFInfo
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- JP5345502B2 JP5345502B2 JP2009246412A JP2009246412A JP5345502B2 JP 5345502 B2 JP5345502 B2 JP 5345502B2 JP 2009246412 A JP2009246412 A JP 2009246412A JP 2009246412 A JP2009246412 A JP 2009246412A JP 5345502 B2 JP5345502 B2 JP 5345502B2
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- 239000000463 material Substances 0.000 title claims description 120
- 239000011248 coating agent Substances 0.000 title claims description 117
- 238000000576 coating method Methods 0.000 title claims description 117
- 239000000919 ceramic Substances 0.000 title claims description 84
- 238000000034 method Methods 0.000 title claims description 22
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 239000002245 particle Substances 0.000 claims description 164
- 238000009826 distribution Methods 0.000 claims description 97
- 239000000843 powder Substances 0.000 claims description 72
- 238000001035 drying Methods 0.000 claims description 30
- 238000002156 mixing Methods 0.000 claims description 29
- 238000005192 partition Methods 0.000 claims description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 238000010438 heat treatment Methods 0.000 claims description 7
- 239000011362 coarse particle Substances 0.000 claims description 5
- 210000000988 bone and bone Anatomy 0.000 claims 1
- 230000000052 comparative effect Effects 0.000 description 26
- 238000010298 pulverizing process Methods 0.000 description 19
- 238000012360 testing method Methods 0.000 description 10
- 238000000227 grinding Methods 0.000 description 9
- 230000002093 peripheral effect Effects 0.000 description 8
- 238000005520 cutting process Methods 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 6
- 238000010586 diagram Methods 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- 238000012937 correction Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 239000008119 colloidal silica Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 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 compound [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 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000009499 grossing Methods 0.000 description 2
- 239000010954 inorganic particle Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000006259 organic additive Substances 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- 229910002060 Fe-Cr-Al alloy Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- JFBZPFYRPYOZCQ-UHFFFAOYSA-N [Li].[Al] Chemical compound [Li].[Al] JFBZPFYRPYOZCQ-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000012615 aggregate Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound 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 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000002612 dispersion medium Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- SBEQWOXEGHQIMW-UHFFFAOYSA-N silicon Chemical compound [Si].[Si] SBEQWOXEGHQIMW-UHFFFAOYSA-N 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 230000001502 supplementing effect Effects 0.000 description 1
- 238000001132 ultrasonic dispersion Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- C04B2235/54—Particle size related information
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- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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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
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5463—Particle size distributions
- C04B2235/5481—Monomodal
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Description
粉末骨材として、セルベン、セラミックスファイバー、無機添加剤、有機添加剤、分散媒として水、結合材としてコロイダルシリカを用いて、コート材を調合した。なお、コート材の塗工性を一定にするため、追加で水を0〜4%添加し、所望の粘度(例えば220±30dPa・s)に調節し、添加水を合わせて約100%となるようにした。コート材の調合割合を表1に示す。実施例および比較例において使用した骨材の調整方法については下記に記す。
所望の平均粒径、粒度分布を得るため適宜混合比率を変えて調整し、表2に示すような各比較例、実施例の微粒骨材、粗粒骨材、混合骨材、粉末骨材等を得た。粒度分布の測定は、「湿式法」に基づき、測定機器は、レーザ回折/散乱式粒度分布測定装置(型番:LA−920、HORIBA社製)を使用し、設定条件として横軸の分解能は、0.02〜2000μmを対数スケールで85分割して測定した。その他の測定条件は、超音波分散時間を1分、被測定各骨材の量を0.05gとして測定した。
本発明のコート材塗布工程は、セラミックスからなる多孔質の隔壁によって区画された複数のセルを有するハニカム構造体の外周を被覆するようにコート材を塗布するものである。表面条件を厳しくし、観察を容易とするため、コート材塗布工程、コート材加熱乾燥工程は、以下に示す板状物である試験片への塗布および乾燥とした。図4Aに示すように、気孔率48%のコージェライトのセラミックスハニカム構造体1をセル4に対し45°方向に切断した板状物1a(250mm×250mmの正方形)を試験に用いた。実際に外壁を形成する試験は時間を要するためである。板状物1aであっても、外壁に塗布した場合と同様な結果が得られる。試験に用いたのは、図4Aの切断位置2に示すセル4の隔壁5に対し45°方向に切断した板状物1aである。隔壁5に対し斜め方向に切断したのは、よりクラックの発生しやすい条件(塗工面の凹凸が大きい状態)で、試験を行うためであるが、最もクラックが発生しやすい条件(切断位置1)は、板状物1aを作製する際に凹凸自体が脆く、高さを一定にする事が困難であるため、隔壁5に対し斜めに切断した板状物(切断位置2)を試験に使用した(なお、切断位置3では、クラックが発生しにくい)。
コート材塗布工程、およびコート材加熱乾燥工程で得られたコート材7に対し、目視で確認できるクラックの発生を確認し、図6に示すように、クラックの分岐点から分岐点までを1本として数えて評価を行った。
Claims (2)
- セラミックスからなる多孔質の隔壁によって区画された複数のセルを有したセラミックスハニカム構造体の外周を、コート材にて被覆して外壁を形成するセラミックスハニカム構造体の製造方法であって、
平均粒径が16〜20.1μmで粒度分布広さが5〜11である微粒骨材と、平均粒径が39.6〜47μmで粒度分布広さが10.9〜13.2である粗粒骨材と、を混合してなる混合骨材からなり、前記混合骨材の平均粒径が22.6〜39μmであり、粒度分布広さが14.6〜33であるセラミックス粉末骨材を使用し、前記粒度分布広さの定義は、粒径ごとの頻度をプロットした粒度分布曲線におけるピーク高さの半値幅を、前記ピーク高さで除算した値であり、前記粒度分布曲線のピークが一本であり、少なくとも前記セラミックス粉末骨材と、水とを混合して前記コート材を得るコート材調整工程と、
前記セラミックスハニカム構造体の外周を被覆するように前記コート材を塗布するコート材塗布工程と、
前記コート材塗布工程の後で前記コート材を加熱乾燥させることによって前記外壁を形成するコート材加熱乾燥工程と、を含むセラミックスハニカム構造体の製造方法。 - セラミックスからなる多孔質の隔壁によって区画された複数のセルを有したセラミックスハニカム構造体用コート材であって、
粉末の粒度分布広さの定義を、粒径ごとの頻度をプロットした粒度分布曲線におけるピーク高さの半値幅を前記ピーク高さで除算した値とした場合に、前記粒度分布曲線のピークが一本であり、平均粒径が16〜20.1μmで粒度分布広さが5〜11である微粒骨材と、平均粒径が39.6〜47μmで粒度分布広さが10.9〜13.2である粗粒骨材と、を混合してなる混合骨材からなり、前記混合骨材の平均粒径が22.6〜39μmで粒度分布広さが14.6〜33であるセラミックス粉末骨材と、水とを少なくとも含むセラミックスハニカム構造体用のコート材。
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US12/613,900 US8277895B2 (en) | 2008-11-10 | 2009-11-06 | Method for manufacturing ceramic honeycomb structure and coating material for the ceramic honeycomb structure |
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DE102018203435A1 (de) | 2017-03-22 | 2018-09-27 | Ngk Insulators, Ltd. | Umfangsbeschichtungsmaterial, umfangsbeschichtete wabenstruktur |
US10633297B2 (en) | 2018-03-16 | 2020-04-28 | Ngk Insulators, Ltd. | Method of manufacturing honeycomb structure |
US11266942B2 (en) | 2018-09-20 | 2022-03-08 | Ngk Insulators, Ltd. | Outer periphery coating material, outer periphery coated honeycomb structure and dust collecting filter |
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US11142485B2 (en) | 2017-03-22 | 2021-10-12 | Ngk Insulators, Ltd. | Circumferential coating material, circumferential coated honeycomb structure |
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DE102019001621B4 (de) | 2018-03-16 | 2024-06-13 | NGK lnsulators, Ltd. | Verfahren zur Herstellung einer Wabenstruktur |
US11578001B2 (en) | 2018-03-30 | 2023-02-14 | Ngk Insulators, Ltd. | Coating material, outer periphery-coated silicon carbide-based honeycomb structure, and method for coating outer periphery of silicon carbide-based honeycomb structure |
US11266942B2 (en) | 2018-09-20 | 2022-03-08 | Ngk Insulators, Ltd. | Outer periphery coating material, outer periphery coated honeycomb structure and dust collecting filter |
DE102019005854B4 (de) | 2018-09-20 | 2022-12-22 | NGK lnsulators, Ltd. | Außenumfangsbeschichtungsmaterial, Wabenstruktur mit beschichtetem Außenumfang und Staubauffangfilter |
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US8277895B2 (en) | 2012-10-02 |
DE102009052192A1 (de) | 2010-10-14 |
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US20120225768A1 (en) | 2012-09-06 |
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