Ceramic clay, ceramic formed article, and ceramic structure, and manufacturing methods thereof
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C04B-033/00
C04B-033/24
C04B-035/03
C04B-035/04
출원번호
US-0069888
(2011-03-23)
등록번호
US-8679997
(2014-03-25)
우선권정보
JP-2010-078244 (2010-03-30)
발명자
/ 주소
Tomita, Takahiro
Morimoto, Kenji
출원인 / 주소
NGK Insulators, Ltd.
대리인 / 주소
Burr & Brown, PLLC
인용정보
피인용 횟수 :
0인용 특허 :
4
초록▼
The ceramic clay is provided by kneading a forming raw material containing a ceramic forming material. The forming raw material contains, in addition to the ceramic forming material, a layered double hydroxide represented by a predetermined chemical formula in an amount of from 0.01 to 5 mass % base
The ceramic clay is provided by kneading a forming raw material containing a ceramic forming material. The forming raw material contains, in addition to the ceramic forming material, a layered double hydroxide represented by a predetermined chemical formula in an amount of from 0.01 to 5 mass % based on the total amount of the layered double hydroxide and the ceramic forming material. The layered double hydroxide turns into a gel when dispersed in water, and when the layered double hydroxide is dispersed in water at a concentration of 6 mass %, the layered double hydroxide has a viscosity of from 1000 to 20000 mPa·s.
대표청구항▼
1. A ceramic clay obtained by kneading a forming raw material containing a ceramic forming material comprising, in addition to the ceramic forming material, a layered double hydroxide in flake form in an amount of from 0.01 to 5 mass % based on the total amount of the layered double hydroxide and th
1. A ceramic clay obtained by kneading a forming raw material containing a ceramic forming material comprising, in addition to the ceramic forming material, a layered double hydroxide in flake form in an amount of from 0.01 to 5 mass % based on the total amount of the layered double hydroxide and the ceramic forming material; wherein the layered double hydroxide is represented by the following formula (I): [M2+1−xM3+x(OH)2][Aan−x/n.yH2O] (I),wherein M2+, M3+, and Aan− represent a divalent cation, a trivalent cation, and an anion other than a carbonate ion, respectively, n stands for a valence of the anion (1≦n≦3), x represents a composition ratio of the trivalent cation (M3+) in the sum of the divalent cation (M2+) and the trivalent cation (M3+) and satisfies the following range: 0.1≦x≦0.4, and y stands for the number of moles of water;wherein the layered double hydroxide in flake form turns into a gel when dispersed in water; andwherein the layered double hydroxide has a viscosity of from 1000 to 20000 mPa·s when dispersed in water at a concentration of 6 mass %. 2. The ceramic clay according to claim 1, which shows a sheet extrusion pressure of 5 MPa or less. 3. The ceramic clay according to claim 1, which has a true stress of 20 kPa or greater at a true strain of 0.05 as measured in a uniaxial compression test. 4. The ceramic clay according to claim 1, which comprises an organic binder at a content of 2 mass % or less as a superaddition based on the total amount of the ceramic forming material and the layered double hydroxide. 5. The ceramic clay according to claim 1, wherein the layered double hydroxide is a hydrotalcite represented by the following formula (II): Mg1−xAlx(OH)2Abn−x/n.mH2O (II), wherein Abn− represents a carboxylate ion, n stands for a valence (1≦n≦3) of the carboxylate ion, x stands for a composition ratio of Al in the sum of Mg and Al and satisfies the following range: 0.1≦x≦0.4, and m stands for the number of moles of water in the hydrotalcite. 6. The ceramic clay according to claim 1, wherein the layered double hydroxide is a hydrotalcite represented by the following formula (III): Mg0.75Al0.25(OH)2Aan−2/n.0.5H2O (III), wherein Acn− represents any of an acetate ion, a propionate ion, and a lactate ion, and n stands for a valence (1≦n≦3) of the ion. 7. The ceramic clay according to claim 1, further comprising a hydrophilic polymer. 8. The ceramic clay according to claim 7, wherein the hydrophilic polymer is a methacrylic acid polymer. 9. A ceramic formed article obtained by molding or forming the ceramic clay as claimed in claim 1. 10. The ceramic formed article as claimed in claim 9, which is a honeycomb formed article having a honeycomb form. 11. A ceramic structure obtained by forming the ceramic formed article as claimed in claim 9. 12. A manufacturing method of a ceramic clay comprising a step of kneading a forming raw material containing a ceramic forming material; wherein the forming raw material comprises, in addition to the ceramic forming material, a layered double hydroxide in flake form in an amount of from 0.01 to 5 mass % based on the total amount of the ceramic forming material and the layered double hydroxide;wherein the layered double hydroxide is represented by the following formula (I): [M2+1−xM3+x(OH)2][Aan−x/n.yH2O] (I), wherein M2+, M3+, and Aan− represent a divalent cation, a trivalent cation, and an anion other than a carboxylate ion, respectively, n stands for a valence of the anion (1≦n≦3), x stands for a composition ratio of the trivalent cation (M3+) in the sum of the divalent cation (M2+) and the trivalent cation (M3+) and satisfies the following range: 0.1≦x≦0.4, and y stands for the number of moles of water; wherein the layered double hydroxide in flake form turns into a gel when dispersed in water andwherein the layered double hydroxide has a viscosity of from 1000 to 20000 mPa·s when dispersed in water at a concentration of 6 mass %. 13. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the ceramic clay shows a sheet extrusion pressure of 5 MPa or less. 14. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the ceramic clay has a true stress of 20 kPa or greater at a true strain of 0.05 as measured in a uniaxial compression test. 15. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the forming raw material comprises an organic binder and a content thereof as a superaddition is 2 mass % or less based on the total amount of the ceramic forming material and the layered double hydroxide. 16. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the layered double hydroxide is a hydrotalcite represented by the following formula (II): Mg1−xAlx(OH)2Abn−x/n.mH2O (II), wherein Abn− represents a carboxylate ion, n stands for a valence (1≦n≦3) of the carboxylate ion, x stands for a composition ratio of Al in the sum of Mg and Al and satisfies the following range: 0.1≦x≦0.4, and m stands for the number of moles of water in the hydrotalcite. 17. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the layered double hydroxide is a hydrotalcite represented by the following formula (III): Mg0.75Al0.25(OH)2Aan−2/n.0.5H2O (III), wherein Acn− represents any of an acetate ion, a propionate ion, and a lactate ion, and n stands for a valence (1≦n≦3) of the ion. 18. The manufacturing method of a ceramic clay as claimed in claim 12, wherein the forming raw material further comprises a hydrophilic polymer. 19. The manufacturing method of a ceramic clay as claimed in claim 18, wherein the hydrophilic polymer is a methacrylic acid polymer. 20. A manufacturing method of a ceramic formed article, comprising a step of molding or forming the ceramic clay obtained using the method as claimed in claim 12 into the ceramic formed article.
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이 특허에 인용된 특허 (4)
Schutz Alain A. (Penn Township PA) Cullo Leonard A. (Hempfield Township ; both of Westmoreland County PA) Kelkar Chandrashekhar P. (Plum Boro ; Allegheny County PA), Hydrotalcite-like materials having a sheet-like morphology and process for production thereof.
Kawasaki Shinji,JPX ; Ito Shigenori,JPX ; Okumura Kiyoshi,JPX, Sintered laminated structures, electrochemical cells and process for producing such sintered laminated structures.
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