JP5346284B2 - 耐亀裂性セラミック・ハニカム物品及びその製造方法 - Google Patents
耐亀裂性セラミック・ハニカム物品及びその製造方法 Download PDFInfo
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- JP5346284B2 JP5346284B2 JP2009513253A JP2009513253A JP5346284B2 JP 5346284 B2 JP5346284 B2 JP 5346284B2 JP 2009513253 A JP2009513253 A JP 2009513253A JP 2009513253 A JP2009513253 A JP 2009513253A JP 5346284 B2 JP5346284 B2 JP 5346284B2
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- 239000000919 ceramic Substances 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 239000011148 porous material Substances 0.000 claims abstract description 51
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 37
- 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 claims abstract description 37
- 238000009826 distribution Methods 0.000 claims abstract description 29
- 238000000034 method Methods 0.000 claims abstract description 22
- 210000003491 skin Anatomy 0.000 claims description 65
- 239000000454 talc Substances 0.000 claims description 22
- 229910052623 talc Inorganic materials 0.000 claims description 22
- 239000000463 material Substances 0.000 claims description 18
- 210000002615 epidermis Anatomy 0.000 claims description 11
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 6
- 238000010304 firing Methods 0.000 claims description 5
- 239000005995 Aluminium silicate Substances 0.000 claims description 4
- 235000012211 aluminium silicate Nutrition 0.000 claims description 4
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 229910001593 boehmite Inorganic materials 0.000 claims description 3
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 3
- 230000002093 peripheral effect Effects 0.000 claims description 3
- 230000008569 process Effects 0.000 claims description 3
- 238000005245 sintering Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 5
- 241000264877 Hippospongia communis Species 0.000 description 66
- 235000012222 talc Nutrition 0.000 description 23
- 239000000203 mixture Substances 0.000 description 13
- 239000002245 particle Substances 0.000 description 13
- 239000003054 catalyst Substances 0.000 description 9
- 230000000977 initiatory effect Effects 0.000 description 9
- 230000008859 change Effects 0.000 description 8
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- 230000007423 decrease Effects 0.000 description 7
- 239000007789 gas Substances 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 6
- 238000005336 cracking Methods 0.000 description 6
- 238000001125 extrusion Methods 0.000 description 6
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- 229930195733 hydrocarbon Natural products 0.000 description 4
- 150000002430 hydrocarbons Chemical class 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 238000000746 purification Methods 0.000 description 4
- 230000008646 thermal stress Effects 0.000 description 4
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 3
- 229910002091 carbon monoxide Inorganic materials 0.000 description 3
- 229920000609 methyl cellulose Polymers 0.000 description 3
- 239000001923 methylcellulose Substances 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000000969 carrier Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 210000003038 endothelium Anatomy 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 230000014509 gene expression Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
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- 239000012467 final product Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000000116 mitigating effect Effects 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
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- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 1
- 239000008117 stearic acid Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000003784 tall oil Substances 0.000 description 1
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Description
アルミナ、カオリン、ベーマイト、シリカ、及びタルクを含む、セラミック形成材料の可塑化バッチを調製する工程であって、前記タルクは1.50よりも大きい、関係(D90−D10)/D50によって与えられる孔隙径分布を有するものである工程、
前記セラミック形成材料を押出成形して、ウェブ及び周囲表皮(peripheral skin)を有するハニカム未焼成体を形成する工程、
前記未焼成体を焼成して、305μm(12ミル)の厚さ未満の表皮を有するセラミック・ハニカム物品を形成する工程、
を有してなる方法を提供する。タルクは、2.2μm〜4.0μmのメジアン粒径(セディグラフによる)を有することが好ましい。単一のタルク源を用いることが最も好ましい。
表2は、それぞれ方程式(6)及び(7)に基づいて算出した亀裂発生の相対抵抗の%変化(Rpi/Rp25)及び亀裂拡大の相対抵抗の%変化((R''')pi/(R''')p25)を示しており、ここで、指数「Pi」は25%以外の孔隙率における特徴を表しており、指数「P25」は孔隙率25%における特徴を表している。
亀裂拡大の相対抵抗は約118%も増大した。表皮の孔隙率は約25%から最大で約45%まで、好ましくは約25%から約35%まで増大する。この範囲では、Rpi/Rp25の低下は約7%未満であり、(R''')pi/(R''')p25の上昇は、約40%よりも大きい。
Claims (12)
- ハニカム・セラミック物品であって、
孔隙率Ps及び305μm(12ミル)未満の厚さを有する外周皮と、
前記外周皮内に配置された複数のウェブ部分であって、孔隙率Pw及び76.2μm(3.0ミル)未満の厚さを有する前記ウェブ部分と、
前記ウェブ部分によって形成された複数の貫通孔と、
を含み、
PsがPwよりも大きいことを特徴とするハニカム・セラミック物品。 - 前記Ps/Pwの比が1.12〜1.6であることを特徴とする請求項1記載のセラミック物品。
- 前記Ps/Pwの比が1.20よりも大きいことを特徴とする請求項2記載のセラミック物品。
- 前記Ps/Pwの比が1.28よりも大きいことを特徴とする請求項2記載のセラミック物品。
- 前記ハニカム・セラミック物品の前記外皮が、前記ウェブ部分の厚さの2〜4倍の表皮厚を有することを特徴とする請求項1記載のセラミック物品。
- 前記ハニカム・セラミック物品の前記外皮が、前記ウェブ部分の厚さの3〜3.5倍の表皮厚を有することを特徴とする請求項1記載のセラミック物品。
- 前記ハニカム・セラミック物品の前記表皮の孔隙率(Ps)が35%よりも大きいことを特徴とする請求項1記載のセラミック物品。
- 前記ハニカム・セラミック物品の前記表皮の孔隙率(Ps)が35%〜45%であることを特徴とする請求項7記載のセラミック物品。
- 前記ウェブの孔隙率(Pw)が約28%未満であることを特徴とする請求項1記載のセラミック物品。
- ハニカム・セラミック物品であって、
孔隙率(Ps)及び305μm(12ミル)未満の厚さを有する外周皮と、
前記外周皮内に配置された複数のウェブ部分であって、孔隙径(Pw)及び正規化された孔隙径分布(PSDw=(D90−D10)/D50)、及び76.2μm(3.0ミル)未満の厚さを有する前記ウェブ部分と、
前記ウェブ部分によって形成された複数の貫通孔と、
を含み、
PsがPwよりも大きく、PSDwが約1.5〜4.5の間であることを特徴とするハニカム・セラミック物品。 - コージエライト・ハニカム物品における表皮の亀裂を低減させる方法であって、
セラミック形成材料の可塑化されたバッチを調製し、
前記セラミック形成材料を押出成形してウェブ及び周囲表皮を有するハニカム未焼成体を形成し、
前記未焼成体を焼成してセラミック・ハニカム物品を形成する、
各工程を有してなり、
前記表皮が、前記焼成工程の後に、Ps/Pw≧1.12の孔隙比を示し、ここで、Psは前記表皮の孔隙率であり、Pwは前記ウェブの孔隙率である、方法。 - コージエライト・ハニカム物品における表皮の亀裂を低減させる方法であって、
アルミナ、カオリン、ベーマイト、シリカ、及びタルクを含むセラミック形成材料の可塑化されたバッチを調製する工程であって、前記タルクが1.50よりも大きい(D90−D10)/D50の関係によって与えられる孔隙径分布を有するものである工程、
前記セラミック形成材料を押出成形してウェブ及び周囲表皮を有するハニカム未焼成体を形成する工程、
前記未焼成体を焼成して、305μm(12ミル)未満の厚さを有するセラミック・ハニカム物品を形成する工程、
を有してなる方法。
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US81009306P | 2006-05-31 | 2006-05-31 | |
US60/810,093 | 2006-05-31 | ||
PCT/US2007/012741 WO2007142971A2 (en) | 2006-05-31 | 2007-05-30 | Crack-resistant ceramic honeycomb articles and methods of manufacturing same |
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JP2009538759A JP2009538759A (ja) | 2009-11-12 |
JP2009538759A5 JP2009538759A5 (ja) | 2013-05-23 |
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US (1) | US7780755B2 (ja) |
EP (1) | EP2024299A2 (ja) |
JP (1) | JP5346284B2 (ja) |
CN (1) | CN101460424B (ja) |
WO (1) | WO2007142971A2 (ja) |
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US20100126222A1 (en) * | 2008-11-25 | 2010-05-27 | Thierry Luc Alain Dannoux | Method and apparatus for forming and cutting a shaped article from a sheet of material |
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CN102500423B (zh) * | 2011-11-09 | 2013-07-31 | 萍乡市安发冶化环保填料有限公司 | 蜂窝陶瓷脉冲保护剂 |
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JP7029221B2 (ja) * | 2016-02-17 | 2022-03-03 | 日本碍子株式会社 | 目封止ハニカム構造体、及び目封止ハニカム構造体の製造方法 |
CN113573794B (zh) * | 2019-03-12 | 2023-06-16 | 康宁股份有限公司 | 具有表皮的陶瓷蜂窝体 |
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- 2007-05-30 WO PCT/US2007/012741 patent/WO2007142971A2/en active Application Filing
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US7780755B2 (en) | 2010-08-24 |
WO2007142971A3 (en) | 2008-07-03 |
CN101460424B (zh) | 2013-09-25 |
WO2007142971A2 (en) | 2007-12-13 |
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