RU2017144428A - Способ изготовления пористых тел с улучшенными свойствами - Google Patents

Способ изготовления пористых тел с улучшенными свойствами Download PDF

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RU2017144428A
RU2017144428A RU2017144428A RU2017144428A RU2017144428A RU 2017144428 A RU2017144428 A RU 2017144428A RU 2017144428 A RU2017144428 A RU 2017144428A RU 2017144428 A RU2017144428 A RU 2017144428A RU 2017144428 A RU2017144428 A RU 2017144428A
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powder
mixture
precursors
alumina
particle size
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RU2017144428A
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English (en)
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Войцех Л. СУХАНЕК
Мэттью ДЖУЛИАН
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Сайентифик Дизайн Компани, Инк.
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    • 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
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Claims (48)

1. Смесь предшественников для изготовления пористого тела, причем данная смесь предшественников включает: (i) по меньшей мере, один порошок измельченного α-оксида алюминия, имеющий размер частиц от 0,1 до 6 мкм, (ii) порошок бемита, который действует как связующее вещество для порошка α-оксида алюминия, и (iii) по меньшей мере, один выгорающий материал, имеющий размер частиц от 1 до 10 мкм.
2. Смесь предшественников по п. 1, дополнительно включающая порошок неизмельченного α-оксида алюминия, имеющий размер частиц от 10 до 100 мкм.
3. Смесь предшественников по п. 2, в которой массовое соотношение порошка измельченного и неизмельченного α-оксида алюминия находится в интервале от 0,25:1 до приблизительно 5:1.
4. Смесь предшественников по п. 1, в которой порошок неизмельченного α-оксида алюминия исключается из смеси предшественников.
5. Смесь предшественников по п. 1, дополнительно включающая добавку, выбранную из растворителей и смазочных материалов.
6. Смесь предшественников по п. 1, в которой в качестве вышеупомянутого выгорающего материала выбирается, по меньшей мере, один материал из полиолефинового порошка и графитового порошка.
7. Смесь предшественников по п. 1, в которой в качестве вышеупомянутого выгорающего материала выбираются одновременно полиолефиновый порошок и графитовый порошок.
8. Смесь предшественников по п. 7, в которой массовое соотношение полиолефинового порошка и графитового порошка находится в интервале от 0,25:1 до приблизительно 5:1.
9. Смесь предшественников по п. 1, в которой бемит присутствует в количестве, составляющем, по меньшей мере, 10 мас.% полного содержания оксида алюминия.
10. Смесь предшественников по п. 1, в которой бемит присутствует в количестве, составляющем, по меньшей мере, 25 мас.% полного содержания оксида алюминия.
11. Смесь предшественников по п. 1, в которой бемит представляет собой наноразмерный порошок с размером диспергированных частиц менее 100 нм.
12. Смесь предшественников по п. 1, в которой вышеупомянутый порошок измельченного α-оксида алюминия имеет размер частиц/кристаллитов от 0,25 до 4 мкм.
13. Смесь предшественников по п. 1, в которой содержащее кремний вещество практически исключается из смеси предшественников.
14. Смесь предшественников по п. 1, в которой содержащее натрий вещество практически исключается из смеси предшественников.
15. Способ изготовления пористого тела, причем данный способ включает
изготовление смеси предшественников, включающей (i) порошок измельченного α-оксида алюминия, имеющий размер частиц от 0,1 до 6 мкм, (ii) порошок бемита, который действует как связующее вещество для порошка α-оксида алюминия, и (iii) выгорающий материал, имеющий размер частиц от 1 до 10 мкм;
формирование заданной формы; и
направление формы на стадию термической обработки, в процессе которой форму спекают, получая пористое тело.
16. Способ по п. 15, дополнительно включающий порошок неизмельченного α-оксида алюминия, имеющий размер частиц от 10 до 100 мкм, в вышеупомянутой смеси предшественников.
17. Способ по п. 16, в котором массовое соотношение порошка измельченного и неизмельченного α-оксида алюминия находится в интервале от 0,25:1 до приблизительно 5:1.
18. Способ по п. 15, в котором порошок неизмельченного α-оксида алюминия исключается из смеси предшественников.
19. Способ по п. 15, причем данный способ включает
диспергирование бемита в воде с образованием дисперсии бемита;
добавление порошка измельченного α-оксида алюминия, имеющего размер частиц от 0,1 до 6 мкм, в дисперсию бемита и перемешивание до тех пор, пока не получится первая гомогенная смесь, в которой вышеупомянутый бемит действует как связующее вещество для порошка α-оксида алюминия;
добавление выгорающих материалов, имеющих размер частиц от 1 до 10 мкм, и перемешивание до тех пор, пока не получится вторая гомогенная смесь;
формование второй гомогенной смеси с получением формы вышеупомянутой второй гомогенной смеси; и
направление полученной формы на стадию термической обработки, в процессе которой полученную форму спекают, получая пористое тело.
20. Способ по п. 15, в котором вышеупомянутая стадия термической обработки включает
направление полученной формы на стадию термической обработки при температуре в интервале от 35 до 900°C для удаления воды и выжигания выгорающего материала с получением предварительно обожженного пористого тела; и
направление предварительно обожженного пористого тела на стадию спекания при температуре в интервале от 900 до 2000°C для получения вышеупомянутого пористого тела.
21. Способ по п. 15, в котором вышеупомянутое пористое тело обладает, по меньшей мере, одним из следующих свойств: водопоглощение, составляющее, по меньшей мере, 30%, прочность при раздавливании, составляющую, по меньшей мере, 40 Н, и удельную поверхность по BET, составляющую, по меньшей мере, 0,3 м2/г.
22. Способ по п. 15, в котором вышеупомянутое пористое тело имеет архитектуру пор, которая обеспечивает, по меньшей мере, одно из следующих свойств: извилистость, составляющую 7 или менее, сжатие, составляющее 4 или менее, и проницаемость, составляющую 30 мДарси или более.
23. Способ по п. 15, в котором вышеупомянутый выгорающий материал выбирается из полиолефинового порошка и графитового порошка.
24. Способ по п. 19, в котором вышеупомянутый выгорающий материал включает полиолефиновый порошок, и вышеупомянутая стадия (iii) включает добавление вышеупомянутого полиолефинового порошка, имеющего размер частиц от 1 до 10 мкм, и перемешивание до тех пор, пока не получится вторая гомогенная смесь.
25. Способ по п. 24, в котором вышеупомянутая стадия (iii) дополнительно включает, во время или после добавления и перемешивания полиолефинового порошка, добавление графитового порошка в качестве дополнительного выгорающего материала и перемешивание до тех пор, пока не получится вышеупомянутая вторая гомогенная смесь, которая включает графитовый порошок.
26. Способ по п. 25, в котором массовое соотношение полиолефинового порошка и графитового порошка находится в интервале от 0,25:1 до приблизительно 5:1.
27. Способ по п. 25, в котором вышеупомянутый графитовый порошок имеет размер частиц от 3 до 10 мкм.
28. Способ по п. 19, в котором вышеупомянутая стадия (ii) включает, во время или после добавления и перемешивания порошка измельченного α-оксида алюминия, добавление порошка неизмельченного α-оксида алюминия, имеющего размер частиц в интервале от 10 до 100 мкм, и перемешивание до тех пор, пока не получается вышеупомянутая первая гомогенная смесь.
29. Способ по п. 28, в котором массовое соотношение порошка измельченного и неизмельченного α-оксида алюминия находится в интервале от 0,25:1 до приблизительно 5:1.
30. Способ по п. 15, в котором бемит присутствует в количестве, составляющем, по меньшей мере, 10 мас.% полного содержания оксида алюминия.
31. Способ по п. 15, в котором бемит присутствует в количестве, составляющем, по меньшей мере, 25 мас.% полного содержания оксида алюминия.
32. Способ по п. 15, в котором бемит представляет собой наноразмерный порошок с размером диспергированных частиц менее 100 нм.
33. Способ по п. 15, в котором порошок неизмельченного α-оксида алюминия исключается из способа получения пористого тела.
34. Способ по п. 15, в котором содержащее кремний вещество практически исключается из способа получения пористого тела.
35. Способ по п. 15, в котором содержащее натрий вещество практически исключается из смеси предшественников.
36. Способ по п. 15, в котором, после вышеупомянутой стадии термической обработки с образованием пористого тела, вышеупомянутый способ дополнительно включает осаждение серебра на поверхности и/или в объеме вышеупомянутого пористого тела.
37. Способ по п. 15, в котором вышеупомянутый порошок измельченного α-оксида алюминия имеет размер частиц от 0,25 до 4 мкм.
38. Способ по п. 15, в котором указанную смесь предшественников формируют одним из следующих способов: экструзия или прессование.
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