JP6273007B2 - 多孔質セラミックスのための迅速な焼成方法 - Google Patents
多孔質セラミックスのための迅速な焼成方法 Download PDFInfo
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- 239000000919 ceramic Substances 0.000 title claims description 126
- 238000000034 method Methods 0.000 title claims description 38
- 238000010304 firing Methods 0.000 title claims description 34
- 238000010438 heat treatment Methods 0.000 claims description 153
- 239000000758 substrate Substances 0.000 claims description 61
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 33
- 229910052760 oxygen Inorganic materials 0.000 claims description 33
- 239000001301 oxygen Substances 0.000 claims description 33
- 239000011148 porous material Substances 0.000 claims description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 11
- 239000000203 mixture Substances 0.000 claims description 10
- 229910052878 cordierite Inorganic materials 0.000 claims description 7
- 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 description 7
- 229920002472 Starch Polymers 0.000 claims description 6
- 239000010439 graphite Substances 0.000 claims description 6
- 229910002804 graphite Inorganic materials 0.000 claims description 6
- 235000019698 starch Nutrition 0.000 claims description 6
- 239000008107 starch Substances 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 239000003575 carbonaceous material Substances 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims description 2
- 241000264877 Hippospongia communis Species 0.000 description 84
- 238000005336 cracking Methods 0.000 description 13
- 238000006243 chemical reaction Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- 239000011230 binding agent Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000005259 measurement Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 230000035484 reaction time Effects 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- -1 etc.) Substances 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D24/00—Producing articles with hollow walls
- B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
- B29D24/005—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having joined ribs, e.g. honeycomb
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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
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- 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
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- C04B38/0006—Honeycomb structures
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- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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Description
実施形態では、焼成方法の第1のステージは、セラミックハニカム素地を室温から約300℃の第1の温度まで加熱するステップを含んでよい。本明細書において使用される場合、室温は特に制限されておらず、焼成方法の第1のステージの開始前のセラミック本体及び/又は加熱装置のいずれの周囲温度を含んでよいことが理解されるべきである。
実施形態では、焼成方法の第2のステージは、セラミックハニカム素地を、第1のステージにおいて到達した最高温度から約800℃以上の第2の温度まで加熱するステップを含んでよい。いくつかの実施形態では、本焼成方法の第2のステージは、セラミックハニカム素地を、第1のステージにおいて到達した最高温度から約1000℃以下の第2の温度まで加熱するステップを含んでよい。いくつかの実施形態では、本方法の第2のステージは、セラミックハニカム素地を、第1のステージにおいて到達した最高温度から約900℃の温度まで加熱するステップを含んでよい。
実施形態では、本明細書に記載される焼成方法の第3のステージは、セラミックハニカム素地を、第2のステージにおいて到達した最高温度から第3の温度まで加熱するステップを含んでよい。第3の温度は、1050℃以上、又は約1100℃以上でさえあってよい。実施形態では、第3の温度は約1200℃であってよい。
実施形態では、焼成方法の第4のステージは、セラミックハニカム本体を、第3のステージにおける最高温度から最高ソーク温度まで加熱するステップを含む。最高ソーク温度は、約1200℃超、又は約1300℃超でさえあってよい。いくつかの実施形態では、最高ソーク温度は約1400℃超であってよい。セラミックハニカム本体を、所定の長さの時間に亘って、最高ソーク温度に保持してよい。最高ソーク温度に保持する期間は特に制限されず、適切な特性を形成するのに必要な長さであってよい。セラミックハニカム本体が最高ソーク温度まで加熱された後、セラミックハニカム本体を周囲条件において室温まで冷却してよい。この冷却は、加熱装置からセラミックハニカム本体を取り外すことによって、又は周囲空気が炉内に流入する及び/若しくは炉を通って流れることができるようにすることによって実施してよい。
以下の実施例では、以下の表1に示した直径を有する円筒形セラミックハニカム本体を、炉内において図1に示した加熱速度で加熱する。更に、各ステージにおいて使用される酸素の量、及び使用される細孔形成剤の量を表1に列挙する。実施例1〜6はそれぞれ、コージエライト組成物である。
本明細書に記載される様々な実施形態の修正例及び変形例を包含することが意図されている。
Claims (10)
- コージェライトセラミックハニカム素地を焼成する方法であって、
前記セラミックハニカム素地を、室温から290℃〜310℃の第1の温度まで加熱するステップ;及び
前記セラミックハニカム素地を、前記第1の温度から800℃以上の第2の温度まで、90℃/hr以上の加熱速度で加熱するステップ
を有してなり、
前記セラミックハニカム素地は、4.0インチ(10.16cm)以上〜9.0インチ(22.86cm)以下の直径を有し、
前記セラミックハニカム素地は、デンプン、グラファイトおよびそれらの混合物から選択される炭素系細孔形成剤を10重量%以上〜45重量%以下の濃度で含む、方法。 - 前記セラミックハニカム素地を室温から前記第1の温度まで加熱する前記ステップは:
前記セラミックハニカム素地を、室温から215℃〜250℃の温度まで加熱するステップ;及び
前記セラミックハニカム素地を、前記215℃〜250℃の温度から前記第1の温度まで、90℃/hr以上の加熱速度で加熱するステップ
を含む、請求項1に記載の方法。 - 前記セラミックハニカム素地を、室温から前記215℃〜250℃の温度まで加熱する前記ステップは:
前記セラミックハニカム素地を、室温から150℃〜205℃の温度まで、60℃/hr以上〜80℃/hr以下の加熱速度で加熱するステップ;及び
前記セラミックハニカム素地を、前記150℃〜205℃の温度から前記215℃〜250℃の温度まで、20℃/hr以下の加熱速度で加熱するステップ
を含む、請求項2に記載の方法。 - 前記セラミックハニカム素地を室温から前記第1の温度まで加熱する前記ステップは、90℃/hr以上の加熱速度で加熱するステップを含む、請求項1〜3のいずれか1項に記載の方法。
- 前記セラミックハニカム素地を前記第1の温度から前記第2の温度まで加熱する前記ステップは、150℃/hr以下の加熱速度で加熱するステップを含む、請求項1〜4のいずれか1項に記載の方法。
- 前記第2の温度は1000℃以下であり、
前記方法は更に、前記セラミックハニカム素地が前記第2の温度まで加熱された後に、前記セラミックハニカム素地を前記第2の温度から1050℃以上の第3の温度まで加熱して、前記セラミックハニカム素地中に残っている炭素質材料を除去するステップを含む、請求項1〜5のいずれか1項に記載の方法。 - 前記セラミックハニカム素地は、前記第2の温度から前記第3の温度まで、20℃/hr以下の加熱速度で加熱される、請求項6に記載の方法。
- 前記セラミックハニカム素地は、前記第2の温度から前記第3の温度まで、60℃/hr以上の加熱速度で加熱される、請求項6に記載の方法。
- 室温から前記第1の温度まで前記セラミックハニカム素地を加熱する間に存在する雰囲気の酸素含有量は、5%〜8%である、請求項1〜8のいずれか1項に記載の方法。
- 前記第1の温度から前記第2の温度まで前記セラミックハニカム素地を加熱する間に存在する雰囲気の酸素含有量は、7%〜13%である、請求項1〜9のいずれか1項に記載の方法。
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US13/951,802 | 2013-07-26 | ||
US13/951,802 US9446560B2 (en) | 2013-07-26 | 2013-07-26 | Fast firing method for high porosity ceramics |
PCT/US2014/047713 WO2015013346A1 (en) | 2013-07-26 | 2014-07-23 | Fast firing method for high porosity ceramics |
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JP6273007B2 true JP6273007B2 (ja) | 2018-01-31 |
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EP (1) | EP3024798B1 (ja) |
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CN110475599B (zh) | 2017-01-31 | 2022-01-25 | 康宁股份有限公司 | 图案堵塞的蜂窝体、微粒过滤器及用于其的挤出模头 |
EP3676483B1 (en) | 2017-08-28 | 2021-05-26 | Corning Incorporated | Honeycomb body with radial honeycomb structure having transition structural component and extrusion die therefor |
US11536176B2 (en) | 2017-11-21 | 2022-12-27 | Corning Incorporated | High ash storage, pattern-plugged, honeycomb bodies and particulate filters |
WO2019125830A1 (en) | 2017-12-22 | 2019-06-27 | Corning Incorporated | Extrusion dies |
JP7022593B2 (ja) * | 2018-01-15 | 2022-02-18 | 日本碍子株式会社 | セラミックス焼成体の製造方法、及びセラミックス成形体の焼成方法 |
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CN112236210A (zh) | 2018-05-31 | 2021-01-15 | 康宁股份有限公司 | 具有蜂窝结构强化特征的蜂窝体及用于其的挤出模头 |
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EP3801826A1 (en) | 2018-05-31 | 2021-04-14 | Corning Incorporated | Honeycomb bodies with triangular cell honeycomb structures and manufacturing methods thereof |
WO2020101911A1 (en) | 2018-11-15 | 2020-05-22 | Corning Incorporated | Tilted cell honeycomb body, extrusion die and method of manufacture thereof |
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CN103517885B (zh) | 2012-01-06 | 2016-09-28 | 康宁股份有限公司 | 陶瓷加工烧制 |
WO2014138015A1 (en) | 2013-03-08 | 2014-09-12 | Corning Incorporated | Fast firing method for ceramics |
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