Manufacturing method of ceramic body

Patent metadata

Field	Value
Publication number	US-2018243942-A1
Application number	US-201715855044-A
Country	US
Kind code	A1
Filing date	Dec 27, 2017
Priority date	Feb 24, 2017
Publication date	Aug 30, 2018
Grant date	—

Abstract

A manufacturing method of a ceramic body which includes a firing step of firing a ceramic formed body in a firing kiln,
wherein in the firing step, a temperature rise process until reaching a firing temperature of the ceramic formed body is divided into a plurality of temperature regions including a first temperature region, a second temperature region, and a third temperature region, the manufacturing method of the ceramic body further including an oxygen concentration adjustment step of adjusting a first oxygen concentration in the first temperature region in a range of 7 to 21 vol %, a maximum value of a second oxygen concentration in the second temperature region in a range of 3 to 11 vol %, and a maximum value of a third oxygen concentration in the third temperature region in a range of 3 to 11 vol %.

First claim

What is claimed is:

1 . A manufacturing method of a ceramic body which comprises a firing step of firing a ceramic formed body in a firing kiln,
wherein in the firing step, a temperature rise process until reaching a firing temperature of the ceramic formed body is divided into a plurality of temperature regions including a first temperature region including a temperature rise start point, a second temperature region having a higher temperature than the first temperature region, and a third temperature region having a higher temperature than the second temperature region, the manufacturing method of the ceramic body further comprising an oxygen concentration adjustment step of adjusting a first oxygen concentration in the first temperature region in a range of 7 to 21 vol %, adjusting a maximum value of a second oxygen concentration in the second temperature region in a range of 3 to 11 vol % which is smaller than a maximum value of the first oxygen concentration, and adjusting a maximum value of a third oxygen concentration in the third temperature region in a range of 3 to 11 vol % which is smaller than the maximum value of the first oxygen concentration.

2 . The manufacturing method of the ceramic body according to claim 1 ,
wherein as the firing kiln, a continuous firing kiln is used which has an inlet and an outlet and is configured to fire the ceramic formed body while conveying the ceramic formed body in a kiln space between the inlet and the outlet, the first temperature region includes the inlet as the temperature rise start point, the second temperature region is positioned on a downstream side of the conveyance of the ceramic formed body from the first temperature region, and the third temperature region is positioned on the downstream side of the conveyance of the ceramic formed body from the second temperature region.

3 . The manufacturing method of the ceramic body according to claim 1 ,
wherein in the oxygen concentration adjustment step, a minimum value of the first oxygen concentration is adjusted to 8 vol % or more and the maximum value of the second oxygen concentration is adjusted to 8 vol % or less.

4 . The manufacturing method of the ceramic body according to claim 1 ,
wherein in the oxygen concentration adjustment step, the maximum value of the third oxygen concentration is adjusted in a range of 6 to 10 vol %.

5 . The manufacturing method of the ceramic body according to claim 1 ,
wherein an upper limit value of the first temperature region is adjusted to a temperature range of 250° C.±50° C.

6 . The manufacturing method of the ceramic body according to claim 1 ,
wherein in the oxygen concentration adjustment step, the maximum value of the third oxygen concentration in the third temperature region is adjusted to be smaller than the maximum value of the second oxygen concentration, and a lower limit value of the third temperature region is adjusted to a temperature range of 400° C.±50° C.

7 . The manufacturing method of the ceramic body according to claim 1 ,
wherein in the oxygen concentration adjustment step, the maximum value of the third oxygen concentration in the third temperature region is adjusted to be larger than the maximum value of the second oxygen concentration, and a lower limit value of the third temperature region is adjusted to a temperature range of 400° C.±50° C.

8 . The manufacturing method of the ceramic body according to claim 1 ,
wherein in the oxygen concentration adjustment step, the first oxygen concentration is adjusted to gradually or stepwisely lower, as the process is close to the second temperature region.

9 . The manufacturing method of the ceramic body according to claim 1 ,
wherein the ceramic body is a honeycomb structure.

Assignees

• Ngk Insulators Ltd

Inventors

• Kitaguchi Daniel Yukichi

Classifications

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B2235/6583

  Oxygen containing atmosphere, e.g. with changing oxygen pressures · CPC title

• B28B11/243 Primary

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• C04B35/195

  Alkaline earth aluminosilicates, e.g. cordierite {or anorthite} · CPC title

• C04B38/0006

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title