JP7022593B2 - 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 - Google Patents
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 Download PDFInfo
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- C04B35/63—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 using additives specially adapted for forming the products, e.g.. binder binders
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- 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
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
- C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
- C04B2235/3481—Alkaline earth metal alumino-silicates other than clay, e.g. cordierite, beryl, micas such as margarite, plagioclase feldspars such as anorthite, zeolites such as chabazite
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6562—Heating rate
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
- C04B2235/6584—Oxygen containing atmosphere, e.g. with changing oxygen pressures at an oxygen percentage below that of air
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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
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
- C04B2235/6585—Oxygen containing atmosphere, e.g. with changing oxygen pressures at an oxygen percentage above that of air
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/04—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity adapted for treating the charge in vacuum or special atmosphere
- F27B9/045—Furnaces with controlled atmosphere
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/06—Forming or maintaining special atmospheres or vacuum within heating chambers
- F27D2007/063—Special atmospheres, e.g. high pressure atmospheres
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0006—Monitoring the characteristics (composition, quantities, temperature, pressure) of at least one of the gases of the kiln atmosphere and using it as a controlling value
- F27D2019/0012—Monitoring the composition of the atmosphere or of one of their components
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0006—Monitoring the characteristics (composition, quantities, temperature, pressure) of at least one of the gases of the kiln atmosphere and using it as a controlling value
- F27D2019/0018—Monitoring the temperature of the atmosphere of the kiln
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D19/00—Arrangements of controlling devices
- F27D2019/0028—Regulation
- F27D2019/0068—Regulation involving a measured inflow of a particular gas in the enclosure
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Description
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含む。
前記第2ガスの前記第2酸素濃度と1サイクルにおける前記第2ガスの供給時間の掛け算から算出される第2供給量をFとし、
1サイクルの時間をRとし、
1サイクルにおける酸素の平均供給量が((E+F)/R)により表される時、
3<((E+F)/R)<13
を満足する。
焼成炉内においてセラミックス成形体を加熱する工程と、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含む。
実施例1~7では、焼成されるセラミックス成形体は、図5に示したハニカム構造を有するセラミックス成形体であり、直径、高さ、隔壁厚、1平方インチ当たりのセルの数(cpsi(cells per square inches))が、それぞれ、330mm、152mm、4mil、400cpsiである。セラミックス成形体に含まれるセラミックス材料は、コージェライト化原料である。セラミックス成形体は、有機バインダーのメチルセルロースと、水を更に含む。表1に記載の条件にて図1と同様の加熱条件で焼成を行った。なお、第1ガスの酸素濃度は、大気中の酸素濃度に等しく、ここではその変動を無視し、21VOL%と仮定している。脱バイ工程と加熱工程に続いて、通常の条件に従い、焼成工程と冷却工程も行った。
6 :焼成炉
90 :セラミックス成形体
93 :開口セル
94 :外周壁
C1 :供給サイクル
CH :第1酸素濃度
CL :第2酸素濃度
P1 :温度ピーク
P2 :温度ピーク
R1 :供給時間
R2 :供給時間
T1 :雰囲気温度
Z1 :脱バイ帯
Z2 :焼成帯
Z3 :冷却帯
Claims (14)
- セラミックス焼成体の製造方法であって、
焼成炉内においてセラミックス成形体を加熱する工程と、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含み、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程は、前記焼成炉の雰囲気温度が300℃以下において行われる、セラミックス焼成体の製造方法。 - セラミックス焼成体の製造方法であって、
焼成炉内においてセラミックス成形体を加熱する工程と、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含み、
前記焼成炉内において前記セラミックス成形体を加熱する工程は、180℃以上の温度範囲において目標温度まで第1昇温速度で昇温する第1昇温工程と、前記焼成炉内の温度が前記目標温度に到達した後、前記第1昇温速度よりも大きい第2昇温速度で昇温する第2昇温工程を含み、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程は、前記第1昇温工程で行われる、セラミックス焼成体の製造方法。 - 前記目標温度は、300℃以下の温度である、請求項2に記載のセラミックス焼成体の製造方法。
- 前記焼成炉の雰囲気温度が前記目標温度に到達するに同期して、前記焼成炉の雰囲気が、低酸素雰囲気から大気雰囲気に変えられる、請求項2又は3に記載のセラミックス焼成体の製造方法。
- 前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程は、前記焼成炉に供給されるガスの酸素濃度を変えることに基づいて行われる、請求項1乃至4のいずれか一項に記載のセラミックス焼成体の製造方法。
- 前記焼成炉に供給されるガスの酸素濃度を変えることは、少なくとも第1酸素濃度の第1ガスと、前記第1酸素濃度よりも低い第2酸素濃度の第2ガスの間で前記焼成炉に供給するガスを変えることを含む、請求項5に記載のセラミックス焼成体の製造方法。
- 前記焼成炉に供給されるガスの酸素濃度を変えることは、第1酸素濃度の第1ガスと、前記第1酸素濃度よりも低い第2酸素濃度の第2ガスを交互に前記焼成炉に供給するサイクルを繰り返すことを含む、請求項5に記載のセラミックス焼成体の製造方法。
- 前記第1酸素濃度は、21VOL%以下である、請求項6又は7に記載のセラミックス焼成体の製造方法。
- 前記第1酸素濃度は、15VOL%以上である、請求項8に記載のセラミックス焼成体の製造方法。
- 前記第2酸素濃度は、5VOL%以下である、請求項6乃至9のいずれか一項に記載のセラミックス焼成体の製造方法。
- 1サイクルにおける前記第1ガスの供給時間が、1サイクルにおける前記第2ガスの供給時間よりも短い、請求項7に記載のセラミックス焼成体の製造方法。
- セラミックス焼成体の製造方法であって、
焼成炉内においてセラミックス成形体を加熱する工程と、
前記焼成炉に供給されるガスの酸素濃度を変えることに基づいて、前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含み、
前記焼成炉に供給されるガスの酸素濃度を変えることは、第1酸素濃度の第1ガスと、前記第1酸素濃度よりも低い第2酸素濃度の第2ガスを交互に前記焼成炉に供給するサイクルを繰り返すことを含み、
前記第1ガスの前記第1酸素濃度と1サイクルにおける前記第1ガスの供給時間の掛け算から算出される第1供給量をEとし、
前記第2ガスの前記第2酸素濃度と1サイクルにおける前記第2ガスの供給時間の掛け算から算出される第2供給量をFとし、
1サイクルの時間をRとし、
1サイクルにおける酸素の平均供給量が((E+F)/R)により表される時、
3<((E+F)/R)<13
を満足する、セラミックス焼成体の製造方法。 - 前記セラミックス成形体は、開口セルを規定する隔壁から構築されたハニカム構造を有する、請求項1乃至12のいずれか一項に記載のセラミックス焼成体の製造方法。
- セラミックス成形体の焼成方法であって、
焼成炉内においてセラミックス成形体を加熱する工程と、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程を含み、
前記セラミックス成形体の加熱中に前記焼成炉内の酸素濃度が振幅するように酸素濃度を制御する工程は、前記焼成炉の雰囲気温度が300℃以下において行われる、セラミックス成形体の焼成方法。
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US16/196,057 US11136272B2 (en) | 2018-01-15 | 2018-11-20 | Method of producing fired ceramic article and method of firing ceramic green body |
DE102018009197.0A DE102018009197B4 (de) | 2018-01-15 | 2018-11-22 | Verfahren zur Herstellung eines gebrannten Keramikgegenstandes |
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