JPH02199076A - Production of porous ceramic material - Google Patents

Production of porous ceramic material

Info

Publication number
JPH02199076A
JPH02199076A JP1834689A JP1834689A JPH02199076A JP H02199076 A JPH02199076 A JP H02199076A JP 1834689 A JP1834689 A JP 1834689A JP 1834689 A JP1834689 A JP 1834689A JP H02199076 A JPH02199076 A JP H02199076A
Authority
JP
Japan
Prior art keywords
ceramic material
ceramic
pore
organic binder
oxide
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.)
Pending
Application number
JP1834689A
Other languages
Japanese (ja)
Inventor
Kenji Futaki
二木 賢治
Osamu Murayama
修 村山
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kanebo Ltd
Original Assignee
Kanebo Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Kanebo Ltd filed Critical Kanebo Ltd
Priority to JP1834689A priority Critical patent/JPH02199076A/en
Publication of JPH02199076A publication Critical patent/JPH02199076A/en
Pending legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/063Preparing or treating the raw materials individually or as batches
    • C04B38/0635Compounding ingredients
    • C04B38/0645Burnable, meltable, sublimable materials
    • C04B38/0675Vegetable refuse; Cellulosic materials, e.g. wood chips, cork, peat, paper

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Abstract

PURPOSE:To obtain a porous ceramic material having high strength and excellent impact resistance and toughness by mixing a ceramic material with specific amounts of a non-oxide whisker, an organic binder and a pore-forming material and calcining the mixture in an oxidizing atmosphere. CONSTITUTION:An oxide ceramic material such as Al2O3, ZrO2 or SiO2 is mixed with 1-10wt.% of a non-oxide whisker (based on the above ceramic material), an organic binder and a pore-forming material. The non-oxide whisker is preferably SiC whisker, the organic binder is e.g. starch or methylcellulose and the pore-forming material is e.g. crushed rice hull or wood flour. The above mixture is thoroughly stirred, added with water and kneaded. The obtained slurry is poured into a prescribed forming mold and dried to obtain a green ceramic. The green ceramic is degreased preferably at 250-500 deg.C to remove the organic binder and the pore-forming material and then calcined by heating in an oxidizing atmosphere e.g. at 1400-1700 deg.C to obtain the objective porous ceramic material.

Description

【発明の詳細な説明】 (産業上の利用分野) 本発明は、ウィスカーで強化した酸化物系セラミックス
多孔体の製造方法に関する。
DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing a whisker-reinforced oxide-based ceramic porous body.

(従来の技術) アルミナ、ジルコニア、シリカ等の焼結体は、高強度か
つ高硬度であり、更に寸法安定性が良好で、耐熱性、耐
薬品性に優れた素材として汎用されている。また、これ
らの素材を用いた多孔体は、その優れた特性より濾過材
、触媒担体、センサー等にその利用が試みられつつある
。しかしながら、アルミナ、ジルコニア等の酸化物系焼
結体は、耐衝撃性や靭性が悪いという欠点があり、割れ
たり欠けたりし易すく、その用途は限られたものであっ
た。
(Prior Art) Sintered bodies such as alumina, zirconia, and silica have high strength and hardness, and also have good dimensional stability and are widely used as materials with excellent heat resistance and chemical resistance. In addition, porous bodies made of these materials are being used for filtering materials, catalyst carriers, sensors, etc. due to their excellent properties. However, oxide-based sintered bodies such as alumina and zirconia have drawbacks such as poor impact resistance and toughness, and are easily cracked or chipped, so that their uses have been limited.

従来、酸化物系焼結体に靭性を賦与する方法として、非
酸化物ウィスカーによる強化が試みられているが、焼成
は窒素中、アルゴン中あるいは真空中等の非酸化性雰囲
気で行われており、ウィスカーが酸化物に変化し補強効
果が発現しにくい酸化性雰囲気では行われていなかった
。また、その焼結法として母相マトリックスとウィスカ
ーとの密着性を確保するため、一般にはホットプレス法
あるいはHIP(熱間等方加圧)法が採用されており、
これらの方法は、マトリックスを高密度化させるもので
あって、多孔体の製造には適しておらず、耐衝撃性や靭
性に優れたセラミックス多孔体は、今だ満足すべきもの
が得られていないのが現状である。
Conventionally, strengthening with non-oxide whiskers has been attempted as a method of imparting toughness to oxide-based sintered bodies, but sintering is performed in a non-oxidizing atmosphere such as nitrogen, argon, or vacuum. This has not been done in an oxidizing atmosphere where the whiskers change into oxides and the reinforcing effect is difficult to develop. In addition, in order to ensure the adhesion between the matrix matrix and the whiskers, the sintering method generally uses the hot press method or the HIP (hot isostatic pressing) method.
These methods increase the density of the matrix and are not suitable for manufacturing porous bodies, and ceramic porous bodies with excellent impact resistance and toughness have not yet been produced. is the current situation.

(発明が解決しようとする課題) 本発明者らは鋭意研究した結果、酸化物系セラ撃性に優
れたセラミックス多孔体を製造できることを見出し本発
明を完成したものであり、本発明の目的は、高強度且つ
耐衝撃性、靭性に優れたセラミックス多孔体の製造方法
を提供するにある。
(Problems to be Solved by the Invention) As a result of intensive research, the present inventors have completed the present invention by discovering that it is possible to produce a ceramic porous body with excellent oxide-based ceramic properties.The purpose of the present invention is to An object of the present invention is to provide a method for manufacturing a porous ceramic body having high strength, excellent impact resistance, and toughness.

(課題を解決するための手段) 上述の目的は、アルミナ、ジルコニア;シリカ。(Means for solving problems) The above objects are alumina, zirconia; silica.

ムライト、およびコーディエライトよりなる群から選ば
れた少なくとも1[1からなるセラミックス原料と、該
セラミックス材料に対して1〜10重量%の非酸化物ウ
ィスカーと、有機質バインダー及び気孔形成材とからな
る混合物を、酸化性雰囲気で焼成することを特徴とする
セラミックス多孔体の製造方法忙よって達成される。
A ceramic raw material consisting of at least one selected from the group consisting of mullite and cordierite, a non-oxide whisker of 1 to 10% by weight based on the ceramic material, an organic binder and a pore-forming material. This is achieved by a method for producing a porous ceramic body, which is characterized by firing a mixture in an oxidizing atmosphere.

本発明に用いるセラミックス通、料は酸化物系のもので
あり、具体的にはアルミナ、ジルコニア。
The ceramic materials used in the present invention are oxide-based materials, specifically alumina and zirconia.

シリカ、ムライト、およびコーディエライトで、これら
を単独で用いても2種以上を併用してもよく、好ましく
はアルミナおよびジルコニアで、より好ましくはアルミ
ナとジルコニアとの混合物である。
Silica, mullite, and cordierite may be used alone or in combination of two or more, preferably alumina and zirconia, and more preferably a mixture of alumina and zirconia.

を併用してもよく、好ましくは8i0ウイスカーが用い
られる。また、その形状は特に限定されるものではなく
、例えば平均直径0.3〜3μm 、平均長さ6〜60
μmのものが用いられる。
may be used in combination, and preferably 8i0 whiskers are used. Further, the shape is not particularly limited, and for example, the average diameter is 0.3 to 3 μm, and the average length is 6 to 60 μm.
μm is used.

本発明に用いる有機質バインダーとしては、通常使用さ
れているものから適宜選定して使用すればよく、特に限
定されるものではないが、例えば澱粉、メチルセルロー
ス、カルボキシメチルセルロース、メチルヒドロキシエ
チルセルロースおよびアクリル樹脂等が挙げられ、好ま
しくは澱粉が用い−られる。
The organic binder used in the present invention may be appropriately selected from commonly used binders, and is not particularly limited. For example, starch, methylcellulose, carboxymethylcellulose, methylhydroxyethylcellulose, acrylic resin, etc. Starch is preferably used.

本発明において気孔形成材としては、例えば籾殻の粉砕
品、木粉、澱粉および樹脂の微粉末等の有機質微粉末が
用いられるが、好ましくは平均粒径1000μm以下に
粉砕された籾殻の微粉末が用いられる。
In the present invention, as the pore-forming material, organic fine powder such as crushed rice husk, wood flour, starch, and resin fine powder is used, but preferably fine rice husk powder crushed to an average particle size of 1000 μm or less is used. used.

上記のセラミックス材料の微粉末、非酸化物ウィスカー
、有機質バインダー及び気孔形成材を用いて、セラミッ
クス多孔体を製造するKは、まず特定組成のセラミック
ス材料に1該セラミツクス材料に対し1〜10重量−の
非酸化物ウィスカーを上記有機質バインダー及び気孔形
成材とともに混合し、充分撹拌したのち水を加え、更に
混線しスラリーとする。これを所望の型枠に注型し、乾
燥してグリーン体とする。
To produce a ceramic porous body using the fine powder of the ceramic material, non-oxide whiskers, organic binder and pore-forming material, first mix the ceramic material with a specific composition by 1 to 10% by weight based on the ceramic material. The non-oxide whiskers are mixed with the above-mentioned organic binder and pore-forming material, and after thorough stirring, water is added and mixed to form a slurry. This is poured into a desired mold and dried to form a green body.

上記の方法において非酸化物ウィスカーの量がセラミッ
クス材料に対し1重量%より少ない場合は、ウィスカー
による補強材としての効果が発現せず、10重量−より
多い場合には高強度のセラミックス多孔体を得るのが困
難となり、いずれも好ましくない。また、非酸化物ウィ
スカーの量が増える程、後述の焼成工程での収縮率が小
さくなる傾向にある。
In the above method, if the amount of non-oxide whiskers is less than 1% by weight based on the ceramic material, the effect of the whiskers as a reinforcing material will not be expressed, and if the amount is more than 10% by weight, a high strength porous ceramic material will be used. Both are undesirable because they are difficult to obtain. Furthermore, as the amount of non-oxide whiskers increases, the shrinkage rate in the firing step described below tends to decrease.

次に得られたグリーン体を、好ましくは250〜500
℃、より好ましくはsoo〜400℃で脱脂し、有機質
バインダー及び気孔形成材を焼尽除去する。脱脂工程は
ゆるやかな昇温によって行なうのが好ましく、急激な昇
温を行なうとウィスカーの形態が失なわれる傾向にあり
、補強材としての効果が発現くにくいものとなる。引き
続き、酸化性雰囲気下で、例えば1400〜1700°
Cに加熱し焼成する。焼成温度及び時間はセラミックス
材料の組成に応じて焼結を行なうのに最適になるよう適
宜選定する。
Next, the obtained green body is preferably 250 to 500
Degreasing is carried out at a temperature of 0.degree. C., more preferably 400.degree. C., to burn out and remove the organic binder and pore-forming material. It is preferable that the degreasing step be carried out by slowly increasing the temperature; if the temperature is rapidly increased, the whiskers tend to lose their shape and become less effective as a reinforcing material. Subsequently, under an oxidizing atmosphere, e.g.
Heat to C and bake. The firing temperature and time are appropriately selected depending on the composition of the ceramic material so as to be optimal for sintering.

以上の方法に従って製造されたセラミックス多孔体は、
通常平均気孔径5〜100μm、気孔率50〜75%の
連通気孔を有する構造物であり、高強度且つ靭性、耐衝
撃性に優れたものである。
The ceramic porous body manufactured according to the above method is
Usually, it is a structure having continuous pores with an average pore diameter of 5 to 100 μm and a porosity of 50 to 75%, and has high strength, excellent toughness, and impact resistance.

(効果) 本発明の方法によれば、セラミックス多孔体の非酸化物
ウィスカーによる強化が酸化性雰囲気での焼成によって
行うことができ、混入したウィスカーにより焼成収縮率
が小さくなるため、気孔率の高い多孔体および大型の多
孔体を製造することができる。
(Effects) According to the method of the present invention, the porous ceramic body can be strengthened by non-oxide whiskers by firing in an oxidizing atmosphere, and the mixed whiskers reduce the firing shrinkage rate, resulting in high porosity. Porous bodies and large porous bodies can be produced.

本発明の方法によって得られたセラミックス多孔体は、
連通気、孔を有するものであり、高強度且つ耐衝撃性、
靭性に優れたものであり、濾過材。
The ceramic porous body obtained by the method of the present invention is
It has continuous ventilation and holes, and has high strength and impact resistance.
It has excellent toughness and is a filter material.

触媒担体等に好適に用いられる。Suitable for use as catalyst carriers, etc.

(実施例) セラミックス材料として平均粒径0.6μmのアルミナ
微粉末と平均粒径10μmのジルコニア微粉末を用意し
、これにSiCウィスカーおよび籾殻と馬鈴薯澱粉を第
1表に示す如き配合量で混合し、充分に撹拌したのち水
を加え、更に充分混練してスラリーを得た。用いたSi
Cウィスカーは直径0.3〜3μm、長さ3〜100μ
mのもので、籾殻は平均粒径約500μmの平板状をし
たものである。
(Example) A fine alumina powder with an average particle size of 0.6 μm and a fine zirconia powder with an average particle size of 10 μm were prepared as ceramic materials, and SiC whiskers, rice husks, and potato starch were mixed in the amounts shown in Table 1. After thorough stirring, water was added and the mixture was thoroughly kneaded to obtain a slurry. Si used
C whiskers have a diameter of 0.3 to 3 μm and a length of 3 to 100 μm.
The rice husks are plate-shaped with an average grain size of about 500 μm.

上記スラリーを外径120mm、内径80mm。The above slurry had an outer diameter of 120 mm and an inner diameter of 80 mm.

高さ150mmの円筒形型枠に注型し、70°Cで6時
間放置して澱粉を糊化させ粘土状物質とした。
It was poured into a cylindrical mold with a height of 150 mm and left at 70°C for 6 hours to gelatinize the starch and form a clay-like substance.

次に1得られた粘土状物質を型枠から取り出し、50℃
に設定した乾燥機中に入れて3日間放置し、乾燥を行い
グリーン体を得た。このグリーン体を電気炉に入れ、3
00℃までゆっくりと昇温し脱脂を行ったのち、更に昇
温しで1580″Cで3時間焼成をし、セラミックス多
孔体を作成した。
Next, the clay-like material obtained in 1 was taken out of the mold and heated to 50°C.
The sample was placed in a dryer set to 3 days and left to dry to obtain a green body. Put this green body in an electric furnace and
After degreasing by slowly increasing the temperature to 00°C, the temperature was further increased and firing was performed at 1580''C for 3 hours to create a porous ceramic body.

上述の方法で得られた実施例に対し、比較例として8に
ウィスカーを用いないで製造したもの、およびSiCウ
ィスカーをセラミックス材料に対し20mm%配合して
製造したものを作成した。
In contrast to the examples obtained by the above method, Comparative Examples 8 were manufactured without using whiskers and in which SiC whiskers were mixed at 20 mm% with respect to the ceramic material.

上記実施例および比較例のセラミックス多孔体はいずれ
も連通気孔を有し、その物性は第1表に示す通りであっ
た。尚、耐衝撃性の評価は下記の方法で行なった。
The ceramic porous bodies of the above Examples and Comparative Examples all had continuous pores, and their physical properties were as shown in Table 1. Note that impact resistance was evaluated using the following method.

く耐衝撃性評価法〉 得られたセラミックス多孔体を外径95 mm内径75
mm5高さ18mmのリング状に成形加工し、これを厚
さ1mmのシリコンゴムバッキングで上下から挾んでス
テンレス族の容器内に既定し収納する。次に、この容器
を厚さ1インチの鉄板上に0.8mの高さから落下して
、容器内の試料の割れ方により下記の様に評価した。
Impact resistance evaluation method> The obtained ceramic porous body has an outer diameter of 95 mm and an inner diameter of 75 mm.
It is molded into a ring shape of mm5 and height of 18 mm, which is sandwiched from above and below with silicone rubber backing having a thickness of 1 mm, and stored in a stainless steel container. Next, this container was dropped from a height of 0.8 m onto a 1-inch-thick iron plate, and the sample inside the container was evaluated as follows based on how it cracked.

○:割れなかった △:1〜2ケ所で割れた○: Not broken △: Broken in 1 or 2 places

Claims (1)

【特許請求の範囲】[Claims] アルミナ、ジルコニア、シリカ、ムライト、およびコー
ディエライトよりなる群から選ばれた少なくとも1種か
らなるセラミックス材料と、該セラミックス材料に対し
て1〜10重量%の非酸化物ウィスカーと、有機質バイ
ンダー及び気孔形成材とからなる混合物を、酸化性雰囲
気で焼成することを特徴とするセラミックス多孔体の製
造方法。
A ceramic material made of at least one member selected from the group consisting of alumina, zirconia, silica, mullite, and cordierite, 1 to 10% by weight of non-oxide whiskers based on the ceramic material, an organic binder, and pores. 1. A method for producing a porous ceramic body, comprising firing a mixture comprising a forming material and a forming material in an oxidizing atmosphere.
JP1834689A 1989-01-28 1989-01-28 Production of porous ceramic material Pending JPH02199076A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP1834689A JPH02199076A (en) 1989-01-28 1989-01-28 Production of porous ceramic material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP1834689A JPH02199076A (en) 1989-01-28 1989-01-28 Production of porous ceramic material

Publications (1)

Publication Number Publication Date
JPH02199076A true JPH02199076A (en) 1990-08-07

Family

ID=11969104

Family Applications (1)

Application Number Title Priority Date Filing Date
JP1834689A Pending JPH02199076A (en) 1989-01-28 1989-01-28 Production of porous ceramic material

Country Status (1)

Country Link
JP (1) JPH02199076A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0927709A1 (en) * 1997-12-22 1999-07-07 Sandvik Aktiebolag Method of manufacturing whisker-reinforced ceramics
CN1063543C (en) * 1992-05-05 2001-03-21 广州市国营白云机电厂 Porous ceramics piece used in LPG stove
WO2005091946A3 (en) * 2004-03-12 2006-12-21 Tran Ionics Corp Thin film composite electrolyte
CN102491778A (en) * 2011-11-25 2012-06-13 中原工学院 Method for preparing SiC porous material by using paper pulp carbon source stent
CN107698276A (en) * 2017-09-19 2018-02-16 常州朋悦纺织品有限公司 A kind of porous silicon carbide ceramic and preparation method thereof

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1063543C (en) * 1992-05-05 2001-03-21 广州市国营白云机电厂 Porous ceramics piece used in LPG stove
EP0927709A1 (en) * 1997-12-22 1999-07-07 Sandvik Aktiebolag Method of manufacturing whisker-reinforced ceramics
US6169048B1 (en) 1997-12-22 2001-01-02 Sandvik Ab Method of manufacturing whisker-reinforced ceramics
WO2005091946A3 (en) * 2004-03-12 2006-12-21 Tran Ionics Corp Thin film composite electrolyte
US7255961B2 (en) * 2004-03-12 2007-08-14 Trans Ionics Corporation Thin film composite electrolyte
CN102491778A (en) * 2011-11-25 2012-06-13 中原工学院 Method for preparing SiC porous material by using paper pulp carbon source stent
CN107698276A (en) * 2017-09-19 2018-02-16 常州朋悦纺织品有限公司 A kind of porous silicon carbide ceramic and preparation method thereof

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