Ceramic clay, ceramic formed article, ceramic structure, and manufacturing methods thereof
AssigneeNGK Insulators, Ltd.
InventorTakahiro Tomita
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Abstract
There is disclosed a ceramic clay obtained by kneading a forming material containing a ceramic forming material, wherein the forming material contains layered double hydroxide, in addition to the ceramic forming material, at a ratio of 0.5 to 50% by mass with respect to a total with the ceramic forming material, and hardness measured by an NGK clay hardness meter is set to 4 to 18 mm. A high-strength honeycomb structure can be obtained capable of preventing or inhibiting pollution and global warming when used in manufacturing a ceramic structure, and having few defects such as cracks.
Claims20
A ceramic-forming green clay obtained by kneading a mixture comprising:
- a ceramic-forming material selected from the group consisting of silicon carbide, aluminum titanate, and cordierite;
- and
- a layered double hydroxide shown by formula (I):
- [M2+1-xM3+x(OH)2][An−x/n·yH2O] (I)
- wherein M2+, M3+, and An− denote a bivalent cation, tervalent cation, and an anion, respectively, n denotes anion valence (1≦n≦3), x denotes a composition ratio of tervalent cation (M3+) with respect to the sum of bivalent cation (M2+) and tervalent cation (M3+) and a value in a range of 0.1≦x≦0.4 and y denotes a molar number of water in the layered double hydroxide;
- wherein a ratio of a mass of the layered double hydroxide with respect to a total mass of the ceramic-forming material and the layered double hydroxide is 0.5 to 10%;
- and
- wherein the clay has a hardness, measured by an NGK clay hardness meter, in a range of 4 to 18 mm.
A method of manufacturing a ceramic forming green clay, comprising the steps of:
- kneading a forming material containing a ceramic-forming material and a layered double hydroxide to obtain a ceramic forming green clay;
- wherein the ceramic-forming material is selected from the group consisting of silicon carbide, aluminum titanate and cordierite;
- and
- wherein the layered double hydroxide is shown by the following formula (I):
- [M2+1-xM3+x(OH)2][An−x/n·yH2O] (I)
- wherein M2+, M3+, and An− denote a bivalent cation, tervalent cation, and an anion, respectively, n denotes anion valence (1≦n≦3), x denotes a composition ratio of tervalent cation (M3+) with respect to the sum of bivalent cation (M2+) and tervalent cation (M3+) and a value in a range of 0.1≦x≦0.4, and y denotes a molar number of water in the layered double hydroxide;
- wherein a ratio of a mass of the layered double hydroxide with respect to a total mass of the ceramic-forming material and the layered double hydroxide is 0.5 to 10%;
- and
- wherein a hardness of the ceramic clay, measured by an NGK clay hardness meter, is in a range of 4 to 18 mm.
Dependencies are inferred from the claim text.