JPH0575717B2 - - Google Patents
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- Publication number
- JPH0575717B2 JPH0575717B2 JP59244632A JP24463284A JPH0575717B2 JP H0575717 B2 JPH0575717 B2 JP H0575717B2 JP 59244632 A JP59244632 A JP 59244632A JP 24463284 A JP24463284 A JP 24463284A JP H0575717 B2 JPH0575717 B2 JP H0575717B2
- Authority
- JP
- Japan
- Prior art keywords
- ceramic
- lithium
- synthetic resin
- dimensional network
- raw material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000000919 ceramic Substances 0.000 claims description 57
- 239000002002 slurry Substances 0.000 claims description 29
- 230000035939 shock Effects 0.000 claims description 18
- 239000006260 foam Substances 0.000 claims description 17
- 239000002994 raw material Substances 0.000 claims description 16
- 229920003002 synthetic resin Polymers 0.000 claims description 15
- 239000000057 synthetic resin Substances 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 13
- 229910000502 Li-aluminosilicate Inorganic materials 0.000 claims description 12
- 239000004927 clay Substances 0.000 claims description 11
- 238000004891 communication Methods 0.000 claims description 11
- 238000004519 manufacturing process Methods 0.000 claims description 8
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 claims description 6
- 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 6
- 229910052622 kaolinite Inorganic materials 0.000 claims description 6
- 229910052901 montmorillonite Inorganic materials 0.000 claims description 6
- 239000002689 soil Substances 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 5
- 238000010304 firing Methods 0.000 claims description 5
- -1 sericite Chemical compound 0.000 claims description 4
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052744 lithium Inorganic materials 0.000 claims description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 2
- 229910018068 Li 2 O Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 239000003054 catalyst Substances 0.000 description 9
- 229910052878 cordierite Inorganic materials 0.000 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 description 7
- 239000000969 carrier Substances 0.000 description 5
- 238000000746 purification Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 229920005830 Polyurethane Foam Polymers 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- 239000011496 polyurethane foam Substances 0.000 description 4
- 210000004027 cell Anatomy 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- 239000004115 Sodium Silicate Substances 0.000 description 2
- 238000005273 aeration Methods 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 210000000170 cell membrane Anatomy 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 229910052911 sodium silicate Inorganic materials 0.000 description 2
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- FCVHBUFELUXTLR-UHFFFAOYSA-N [Li].[AlH3] Chemical compound [Li].[AlH3] FCVHBUFELUXTLR-UHFFFAOYSA-N 0.000 description 1
- HEHRHMRHPUNLIR-UHFFFAOYSA-N aluminum;hydroxy-[hydroxy(oxo)silyl]oxy-oxosilane;lithium Chemical compound [Li].[Al].O[Si](=O)O[Si](O)=O.O[Si](=O)O[Si](O)=O HEHRHMRHPUNLIR-UHFFFAOYSA-N 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229910052670 petalite Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- 229910002027 silica gel Inorganic materials 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
Landscapes
- Catalysts (AREA)
Description
産業上の利用分野
本発明は自動車排ガス中のパーテイキユレート
捕捉材、自動車排ガスの浄化触媒担体、その他の
触媒担体、通気性断熱材などに好適に使用される
内部連通空間を有する三次元網状構造をなした低
圧力損失の耐熱衝撃性に優れたセラミツク多孔体
を製造する方法に関するものである。
従来技術及びその問題点
従来より、内部連通空間を有する三次元網状構
造の合成樹脂発泡体、例えば軟質ポリウレタンフ
オームにセラミツク泥漿を付着し、これを乾燥焼
成することにより得られたセラミツク多孔体を自
動車排ガス中のパーテイキユレート捕捉材、自動
車排ガス浄化触媒担体、その他の触媒担体、通気
性を有する熱輻射材（通気性断熱材）などの用途
に用いることが知られている。しかしながら、こ
れらの用途に使用するにあたつては、通気抵抗性
が小さいことと同時に耐熱性及び耐熱衝撃性が重
要な物性として要求される。例えばデイーゼル車
排ガスのパーテイキユレート捕捉材の場合、捕捉
したパーテイキユレートを燃焼除去するにあたつ
ては、急激な温度上昇があり、通常のテイーゼル
車排ガスの温度が約250℃から１〜２分の間に
1200℃あるいはそれ以上の温度に達する場合があ
る。またガソリン車排ガスの温度も時として1000
℃あるいはそれ以上に上昇する場合もあり、十分
な耐熱性と耐熱衝撃性が要求される。
従来、ガソリン車排ガス浄化触媒担体の用途に
は、コーデイエライト質セラミツクスが耐熱性も
あり、熱膨張係数が小さく、耐熱衝撃性も良いた
め利用されてきたが、デイーゼル車排ガスのパー
テイキユレート捕捉材等の用途には耐熱衝撃性不
足に基づく割れや剥離が起こりやすいため、信頼
性にかけるという問題がある。即ち、コーデイエ
ライト質セラミツクスは1300℃乃至1350℃程度の
耐熱性はあるにもかかわらず、耐熱衝撃性として
は900℃乃至950℃程度が限度であり、実用上の最
高使用温度をこの付近の温度に制限せざるを得な
い。特に内部連通空間を有する三次元網状構造の
合成樹脂発泡体にセラミツク泥漿を付着し、これ
を乾燥焼成することにより得られるセラミツク多
孔体の場合は、押出し成形の過程でセラミツク粒
子を配向させることによい望ましい方向の熱膨張
係数を低減することのできるハニカム製造品とは
異なり、熱膨張係数が等方性であるため耐熱衝撃
性に及ぼす熱膨張係数の影響は大きい。ガソリン
車排ガス浄化触媒担体としてはコーデイエライト
質ハニカム構造品がほぼ問題のない品質レベルに
あるのに対し、三次元網状構造のセラミツク多孔
体の場合には達熱衝撃性の点でハニカム構造品に
比べて劣り、実用上問題が残る。
この点を改良するため、本発明者らはコーデイ
エライトより熱膨張係数が小さく、耐熱衝撃性が
良いと考えられるリチウム−アルミン珪酸塩を原
料として内部連通空間を有する三次元網状構造セ
ラミツク多孔体を作成した。しかしながら、リチ
ウム−アルミノ珪酸塩にバインダー、解膠剤など
の副原料を添加し、水を加えて作成したセラミツ
ク泥漿に内部連通空間を有する三次元網状構造の
合成樹脂発泡体を浸漬してセラミツク泥漿を付着
し、余剰の泥漿を遠心力、あるいは通気により除
去し、乾燥焼成する通常のセラミツク多孔体作成
法では、セラミツク泥漿が合成樹脂発泡体に対し
付着むらを起こして目づまりを生じやすく、同一
嵩密度において圧力損失が高く、機械的強度は低
いものしか得られないという問題点があつた。
発明の概要
本発明者らは、上記事情に鑑み、コーデイエラ
イト材質の内部連通空間を有する三次元網状構造
セラミツク多孔体の自動車排ガス中のパーテイキ
ユレート捕捉材や自動車排ガス浄化触媒担体等へ
の応用について検討した結果、これら用途の要求
特性に対し、耐熱性を多少犠牲にしても耐熱衝撃
性を向上することが製品特性としてバランスが取
れ、総合的な性能向上につながると見出し、この
ため更に前記構造のセラミツク多孔体について研
究を重ねた結果、コーデイエライトより耐熱性は
多少劣るものの、熱膨張係数が小さく、耐熱衝撃
性に優れたリチウム−アルミノ珪酸塩を主原料と
するセラミツク材料を用いる場合は耐熱衝撃性を
200℃も改良できることを見出した。
また、リチウム−アルミノ珪酸塩を原料として
前記構造のセラミツク多孔体を製造する場合、合
成樹脂発泡体へのセラミツクの付着むらが生成
し、内部連通空間部にめ目づまりを発生して圧力
損失を増大し、一方において機械的強度を低下す
るという問題が生じたが、この点を解決すべく鋭
意検討をすすめた結果、カオリナイト、セリサイ
ト、モンモリロナイト、トスダイトなどを主原料
とする粘土をリチウム−アルミノ珪酸塩を添加し
たセラミツク泥漿を使用することにより改良でき
ることを見出し、本発明をなすに至つたものであ
る。
発明の構成
以下、本発明につき更に詳しく説明する。
本発明に係るセラミツク多孔体の製造方法は、
内部連通空間を有する三次元網状構造の合成樹脂
発泡体を基材とし、これをセラミツクの泥漿に浸
漬して、前記合成樹脂発泡体にセラミツクを付着
せしめたのち、乾燥し焼成して三次元網状構造の
セラミツク多孔体を製造する方法において、前記
セラミツク泥漿の原料としてリチウム−アルミノ
珪酸塩75〜95重量部にカオリナイト、セリサイ
ト、モンモリロナイト、トスダイトなどから選ば
れる少なくとも１種を主成分とする粘土25〜５重
量部を配合したセラミツク原料を使用するように
したものである。
ここで、セラミツク多孔体原料となる合成樹脂
発泡体としては、内部連通空間を有する三次元網
状構造のものであればいずれのものでもよく、例
えば軟質ポリウレタンフオーム、特にセル膜のな
い軟質ポリウレタンフオームを好適に使用し得
る。
本発明は、この合成樹脂発泡体をセラミツク泥
漿に浸漬し、発泡体にセラミツク泥漿を付着せる
ものであるが、この場合セラミツク泥漿の組成と
して、リチウム−アルミノ珪酸塩75〜95重量部に
カオリナイト、セリサイト、モンモリロナイト、
トスダイトなどを主成分とする粘土25〜５重量部
を添加して作成したセラミツク原料土を用いるも
のである。このセラミツク泥漿は、このセラミツ
ク原料土を水に分散させるものであるが、セラミ
ツク泥漿中にはポリビニルアルコール、カルボキ
シメチルセルロースなどのバインダー、ケイ酸ナ
トリウムなど解膠剤を配合することができる。セ
ラミツク泥漿の粘度は、目的とするセラミツク多
孔体のセルの大きさ等に応じ、水の添加量を加減
して調整することができる。
次いでこのセラミツク泥漿に三次元網状構造の
合成樹脂発泡体を浸漬し引き上げた後、余剰の泥
漿を遠心力または通気などにより除去し、乾燥す
る。この場合、所定量のセラミツク泥漿が三次元
網状構造の合成樹脂発泡体に付着するまでのこの
操作を繰り返すことができる。次に、所定量のセ
ラミツク泥漿が付着した合成樹脂発泡体を乾燥し
た後これを炉に入れ、1220〜1380℃の間の好適な
焼成温度で焼成することにより、前記合成樹脂発
泡体に対応したセル構造の内部連通空間を有する
三次元網状構造のセラミツク多孔体を得ることが
できる。
ここでリチウム−アルミノ珪酸塩としては、リ
チウムに対するアルミニウムの割合が酸化物換算
の重量比としてAl2O3／Li2O＝3.0〜4.0、またシ
リカの量が45％〜75％のものが好ましく、リチウ
ム−アルミノ珪酸塩としてペタライト、リチウム
−フエスパー、スポジユメンなどが使用できる。
また、カオリナイト、セリサイト、モンモリロ
ナイト、トスダイトなを主成分とする粘土として
は木節粘土、蛙目粘土、あるいは各種陶石あるい
はそれらの水簸物（水で洗つて可溶成分を除去し
たもの）などが使用できる。
発明の効果
本発明のセラミツク多孔体の製造方法によれ
ば、上述したようにセラミツク泥漿のセラミツク
原料としてリチウム−アルミノ珪酸塩75〜95重量
部に粘土、好適にはカオリナイト、セリサイト、
モンモリロナイト、トスダイトなどを主原料とす
る粘土25〜５重量部を添加して作成したセラミツ
ク原料土を用いたことにより、目づまりが少なく
圧力損失及び機械的強度が改良され、しかも低熱
膨張性で耐熱衝撃性に優れたセラミツク多孔体を
製造することができ、このため本発明によつて得
られたセラミツク多孔体は、特にデイーゼル車排
ガス中のパーテイキユレート捕捉材あるいはガソ
リン車排ガス浄化触媒担体としての用途に好適に
使用でき、また同様の温度変化速度の大きき条件
で使用されるその他の触媒担体や通気性を有する
熱輻射材などの用途に用いることができる。
以下、本発明の実施例と比較例を示すが、本発
明は下記の実施例に制限されるものではない。
実施例、比較例
第１表に示すセラミツク原料土100重量部に対
し、ポリビニルアルコール4.5重量部、珪酸ナト
リウム0.2重量部、シリカゲル4.5重量部および適
量の水を添加して低粘性のセラミツク泥漿を作成
した。１インチあたりセル数が20個の一辺が10cm
の立方体形状を有するセル膜のない三次元網状構
造の軟質ポリウレタンフオームのこの泥漿に含浸
した。
余分な泥漿を遠心分離機により除去し、十分に
乾燥した。適量のセラミツクが付着するまでこの
操作を繰り返した。次いで、上下両面を除く側面
にセラミツク泥漿を塗布し、乾燥した。乾燥品は
1280℃で１時間焼成を行なつてセラミツク多孔体
を得た。焼成品から一辺が５cmの立方体を切り出
して、風速３ｍ／秒での圧力損失を測定したの
ち、圧縮強度を測定した。さらに一辺が10cmの焼
成品を一定温度に保つた電気炉に一時間放置した
のち取り出し、室温に放置する試験法により耐熱
衝撃性試験を実施した。その結果、クラツクが入
らなかつた場合には温度を50℃引き上げて同様な
方法で耐熱衝撃性試験を行なつた。これらの結果
を第１表に示す。
また比較のため、前記と同様にして、セラミツ
ク原料土としてコーデイエライトを用い、試験サ
ンプルを作成し、同様な評価を行なつた。結果を
第２表に示す。
第１、２表の結果から、リチウム−アルミノ珪
酸塩と粘土を主原料とすることにより耐熱衝撃性
が200℃も向上することがわかつた。また、リチ
ウム−アルミノ珪酸塩を原料とする場合、セラミ
ツク泥漿の付着むらが生じやすく、このため所定
の嵩比重を得るためにセラミツク泥漿の付着回数
を重ねるに従つて目づまりが激しくなり、圧力損
失が増大するが、粘土を添加することにより目づ
まりが改善され、圧力損失が顕著に改善されるこ
とがわかつた。更に、粘土の配合量が多くなると
機械的強度が改善されるが、配合量が多くなりす
ぎると耐熱衝撃性が不良になる傾向がみられた。
Industrial Application Field The present invention is a three-dimensional network structure having an internal communication space, which is suitably used as a particulate capture material in automobile exhaust gas, a catalyst carrier for purifying automobile exhaust gas, other catalyst carriers, and a breathable heat insulating material. The present invention relates to a method for producing a porous ceramic body with low pressure loss and excellent thermal shock resistance. Prior art and its problems Conventionally, ceramic porous bodies obtained by adhering ceramic slurry to a three-dimensional network-structured synthetic resin foam having internal communication spaces, such as soft polyurethane foam, and drying and firing the slurry have been used in automobiles. It is known to be used for applications such as a particulate capture material in exhaust gas, a catalyst carrier for automobile exhaust gas purification, other catalyst carriers, and a breathable heat radiating material (breathable heat insulating material). However, when used in these applications, heat resistance and thermal shock resistance are required as important physical properties, as well as low airflow resistance. For example, in the case of a particulate capture material for diesel vehicle exhaust gas, there is a rapid temperature rise when burning and removing the captured particulate, and the temperature of normal diesel vehicle exhaust gas increases from about 250℃ to 1 to 2 degrees Celsius. in minutes
Temperatures can reach 1200°C or more. Also, the temperature of gasoline vehicle exhaust gas sometimes reaches 1000
The temperature may rise to ℃ or even higher, so sufficient heat resistance and thermal shock resistance are required. Conventionally, cordierite ceramics have been used for gasoline vehicle exhaust gas purification catalyst carriers because they are heat resistant, have a small coefficient of thermal expansion, and have good thermal shock resistance. In applications such as materials, cracking and peeling are likely to occur due to insufficient thermal shock resistance, which poses a problem in terms of reliability. In other words, although cordierite ceramics have heat resistance of about 1300°C to 1350°C, their thermal shock resistance is limited to about 900°C to 950°C, and the maximum practical operating temperature is around this range. We have no choice but to limit the temperature. In particular, in the case of ceramic porous bodies obtained by adhering ceramic slurry to a three-dimensional network-structured synthetic resin foam having internal communication spaces and drying and firing it, the ceramic particles are oriented during the extrusion process. Unlike honeycomb products, which can reduce the coefficient of thermal expansion in a desired direction, the influence of the coefficient of thermal expansion on thermal shock resistance is large because the coefficient of thermal expansion is isotropic. Cordierite honeycomb structure products have almost acceptable quality as exhaust gas purification catalyst carriers for gasoline vehicles, but in the case of porous ceramic materials with a three-dimensional network structure, honeycomb structure products are inferior in terms of thermal shock resistance. is inferior to that of , and there remain practical problems. In order to improve this point, the present inventors created a porous ceramic material with a three-dimensional network structure having internal communication spaces using lithium-alumin silicate, which is thought to have a smaller coefficient of thermal expansion and better thermal shock resistance than cordierite, as a raw material. It was created. However, ceramic slurry is produced by immersing a synthetic resin foam with a three-dimensional network structure with internal communication spaces in a ceramic slurry made by adding auxiliary materials such as a binder and a deflocculant to lithium-aluminosilicate and adding water. In the usual ceramic porous material production method, in which the excess slurry is removed by centrifugal force or aeration, and then dried and fired, the ceramic slurry adheres unevenly to the synthetic resin foam, which tends to cause clogging, and the same bulk. There were problems in that pressure loss was high due to density and only low mechanical strength could be obtained. SUMMARY OF THE INVENTION In view of the above circumstances, the present inventors have developed a three-dimensional network structure ceramic porous body made of cordierite material having an internal communication space as a particulate capture material in automobile exhaust gas, an automobile exhaust gas purification catalyst carrier, etc. As a result of considering the applications, we found that improving thermal shock resistance, even at the expense of some heat resistance, would provide a balanced product characteristic and lead to improved overall performance. As a result of repeated research on ceramic porous bodies with the above structure, we have found that although the heat resistance is somewhat inferior to that of cordierite, we use a ceramic material whose main raw material is lithium-aluminosilicate, which has a small coefficient of thermal expansion and excellent thermal shock resistance. In case of thermal shock resistance
It was discovered that the temperature could be improved by as much as 200℃. Furthermore, when producing a ceramic porous body with the above structure using lithium-aluminosilicate as a raw material, uneven adhesion of the ceramic to the synthetic resin foam occurs, causing clogging in the internal communication space and increasing pressure loss. However, on the other hand, there was a problem that the mechanical strength decreased, but as a result of intensive studies to solve this problem, we found that clays mainly made of kaolinite, sericite, montmorillonite, tosudite, etc. It was discovered that improvements could be made by using a ceramic slurry to which silicate was added, leading to the present invention. Structure of the Invention The present invention will be explained in more detail below. The method for producing a ceramic porous body according to the present invention includes:
A synthetic resin foam with a three-dimensional network structure having internal communication spaces is used as a base material, and this is immersed in ceramic slurry to adhere the ceramic to the synthetic resin foam, which is then dried and fired to form a three-dimensional network structure. In the method for producing a ceramic porous body having a structure, the raw material for the ceramic slurry is a clay whose main component is 75 to 95 parts by weight of lithium-aluminosilicate and at least one selected from kaolinite, sericite, montmorillonite, tosudite, etc. A ceramic raw material containing 25 to 5 parts by weight is used. Here, the synthetic resin foam serving as the raw material for the porous ceramic material may be any material as long as it has a three-dimensional network structure with internal communication spaces, such as soft polyurethane foam, especially soft polyurethane foam without a cell membrane. It can be suitably used. In the present invention, this synthetic resin foam is immersed in ceramic slurry to adhere the ceramic slurry to the foam. In this case, the composition of the ceramic slurry is 75 to 95 parts by weight of lithium-aluminosilicate and kaolinite. , sericite, montmorillonite,
Ceramic raw material soil prepared by adding 25 to 5 parts by weight of clay whose main component is tosudite or the like is used. This ceramic slurry is made by dispersing the ceramic raw material soil in water, and a binder such as polyvinyl alcohol or carboxymethyl cellulose, or a deflocculant such as sodium silicate may be added to the ceramic slurry. The viscosity of the ceramic slurry can be adjusted by adjusting the amount of water added depending on the size of the cells of the intended ceramic porous body. Next, a synthetic resin foam having a three-dimensional network structure is immersed in this ceramic slurry and pulled up, after which excess slurry is removed by centrifugal force or aeration, and the foam is dried. In this case, this operation can be repeated until a predetermined amount of ceramic slurry adheres to the synthetic resin foam having a three-dimensional network structure. Next, after drying the synthetic resin foam to which a predetermined amount of ceramic slurry has adhered, it is placed in a furnace and fired at a suitable firing temperature between 1220 and 1380°C, thereby forming a mold corresponding to the synthetic resin foam. A ceramic porous body having a three-dimensional network structure having an internal communication space of a cell structure can be obtained. Here, the lithium-aluminosilicate is preferably one in which the ratio of aluminum to lithium is Al 2 O 3 /Li 2 O = 3.0 to 4.0 as a weight ratio in terms of oxide, and the amount of silica is 45% to 75%. As the lithium aluminosilicate, petalite, lithium fesper, spodiumen, etc. can be used. In addition, clays whose main components are kaolinite, sericite, montmorillonite, and tosudite include Kibushi clay, Frogme clay, various pottery stones, and their elutriated products (washed with water to remove soluble components). ) etc. can be used. Effects of the Invention According to the method for producing a ceramic porous body of the present invention, as described above, 75 to 95 parts by weight of lithium-aluminosilicate, clay, preferably kaolinite, sericite, etc. are added as the ceramic raw material of the ceramic slurry.
By using ceramic raw material soil made by adding 25 to 5 parts by weight of clay mainly composed of montmorillonite, tosudite, etc., it has less clogging and improved pressure loss and mechanical strength, and has low thermal expansion and thermal shock resistance. Therefore, the ceramic porous body obtained by the present invention is particularly suitable for use as a particulate capture material in diesel vehicle exhaust gas or as a gasoline vehicle exhaust gas purification catalyst carrier. It can also be suitably used for applications such as other catalyst carriers used under similar conditions with large temperature change rates and air-permeable heat radiating materials. Examples and comparative examples of the present invention will be shown below, but the present invention is not limited to the following examples. Examples and Comparative Examples Low-viscosity ceramic slurry was prepared by adding 4.5 parts by weight of polyvinyl alcohol, 0.2 parts by weight of sodium silicate, 4.5 parts by weight of silica gel, and an appropriate amount of water to 100 parts by weight of the ceramic raw material soil shown in Table 1. did. 20 cells per inch, 10cm on a side
Impregnated into this slurry is a flexible polyurethane foam in a three-dimensional network structure without a cell membrane with a cubic shape. Excess slurry was removed using a centrifuge and thoroughly dried. This operation was repeated until a suitable amount of ceramic was attached. Ceramic slurry was then applied to the sides except the top and bottom and allowed to dry. Dry products
Firing was performed at 1280°C for 1 hour to obtain a ceramic porous body. A cube with a side of 5 cm was cut out from the fired product, and the pressure loss at a wind speed of 3 m/sec was measured, and then the compressive strength was measured. Furthermore, a thermal shock resistance test was conducted using a test method in which a fired product measuring 10 cm on a side was left in an electric furnace kept at a constant temperature for one hour, then taken out and left at room temperature. As a result, if no cracks were found, the temperature was raised by 50°C and a thermal shock resistance test was conducted in the same manner. These results are shown in Table 1. For comparison, a test sample was prepared using cordierite as the ceramic raw material soil in the same manner as described above, and the same evaluation was performed. The results are shown in Table 2. From the results in Tables 1 and 2, it was found that by using lithium-aluminosilicate and clay as the main raw materials, the thermal shock resistance was improved by as much as 200°C. In addition, when lithium-aluminosilicate is used as a raw material, uneven adhesion of ceramic slurry tends to occur, and as a result, as the number of times of adhesion of ceramic slurry increases to obtain a predetermined bulk specific gravity, clogging becomes more severe and pressure loss increases. However, it was found that by adding clay, clogging was improved and pressure loss was significantly improved. Furthermore, as the amount of clay added increases, the mechanical strength improves, but when the amount added too much, there is a tendency for thermal shock resistance to become poor.
【表】【table】
Claims (1)
樹脂発泡体を基材とし、これをセラミツクの泥漿
に浸漬して、前記合成樹脂発泡体にセラミツクを
付着せしめたのち、乾燥して、焼成して、三次元
網状構造のセラミツク多孔体を製造する方法にお
いて、前記セラミツク泥奨の原料として、リチウ
ム−アルミノ珪酸塩75〜95重量部に粘土25〜５重
量部を添加して作成したセラミツク原料土を用い
ることを特徴とする低圧力損失の耐熱衝撃性に優
れたセラミツクの多孔体の製造方法。 ２ リチウム−アルミノ珪酸塩として、リチウム
に対するアルミニウムの割合がAl2O3／Li2O＝
3.0〜4.0であり、かつシリカの含有量が45〜75％
であるものを用いた特許請求の範囲第１項記載の
セラミツク多孔体の製造方法。 ３ 粘土として主成分がカオリナイト、セリサイ
ト、モンモリロナイト、トスダイトから選ばれる
少なくとも１種であるものを用いた特許請求の範
囲第１項又は第２項記載のセラミツク多孔体の製
造方法。[Scope of Claims] 1. A synthetic resin foam having a three-dimensional network structure having internal communication spaces is used as a base material, and this is immersed in a ceramic slurry to adhere the ceramic to the synthetic resin foam, and then dried. and firing to produce a ceramic porous body having a three-dimensional network structure, in which 25 to 5 parts by weight of clay is added to 75 to 95 parts by weight of lithium-aluminosilicate as a raw material for the ceramic slurry. A method for producing a ceramic porous body having low pressure loss and excellent thermal shock resistance, which is characterized by using the prepared ceramic raw material soil. 2 As a lithium-aluminosilicate, the ratio of aluminum to lithium is Al 2 O 3 /Li 2 O=
3.0-4.0 and silica content 45-75%
A method for producing a porous ceramic body according to claim 1, using the following. 3. The method for producing a ceramic porous body according to claim 1 or 2, using clay whose main component is at least one selected from kaolinite, sericite, montmorillonite, and tosudite.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59244632A JPS61127678A (en) | 1984-11-21 | 1984-11-21 | Manufacture of ceramic porous body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59244632A JPS61127678A (en) | 1984-11-21 | 1984-11-21 | Manufacture of ceramic porous body |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS61127678A JPS61127678A (en) | 1986-06-14 |
| JPH0575717B2 true JPH0575717B2 (en) | 1993-10-21 |
Family
ID=17121637
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP59244632A Granted JPS61127678A (en) | 1984-11-21 | 1984-11-21 | Manufacture of ceramic porous body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS61127678A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2759147B2 (en) * | 1987-02-25 | 1998-05-28 | 住友化学工業株式会社 | Method for producing porous ceramic body |
-
1984
- 1984-11-21 JP JP59244632A patent/JPS61127678A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS61127678A (en) | 1986-06-14 |
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