Porous material, manufacturing method of the same, and honeycomb structure

Patent metadata

Field	Value
Publication number	US-9289707-B2
Application number	US-201313849695-A
Country	US
Kind code	B2
Filing date	Mar 25, 2013
Priority date	Mar 28, 2012
Publication date	Mar 22, 2016
Grant date	Mar 22, 2016

Abstract

There are disclosed a porous material having excellent heat resisting properties and an excellent resistance to heat shock. A porous material contains aggregates and an amorphous binding agent to bind the aggregates to one another in a state where pores are formed among the aggregates, the binding agent contains a rare earth element, the amorphous binding agent preferably contains magnesium, aluminum, silicon, the rare earth element and oxygen, and the amorphous binding agent preferably contains 8.0 to 15.0 mass % of MgO, 30.0 to 60.0 mass % of Al 2 O 3 , 30.0 to 55.0 mass % of SiO 2 , and 1.5 to 10.0 mass % of the rare earth oxide.

First claim

What is claimed is:

1. A porous material which contains aggregates, and an amorphous binding agent to bind the aggregates to one another in a state where pores are formed among the aggregates,
wherein the amorphous binding agent contains 8.0 to 15.0 mass % of MgO, 30.0 to 60.0 mass % of Al 2 O 3 , 30.0 to 55.0 mass % of SiO 2 , and 1.5 to 10.0 mass % of a rare earth oxide in the whole binding agent.

2. The porous material according to claim 1 ,
wherein a rare earth element of the rare earth oxide is at least one selected from the group consisting of yttrium, lanthanum, cerium, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium and lutetium.

3. The porous material according to claim 1 ,
wherein a ratio of a mass of the binding agent to a total mass of the aggregates and the binding agent is from 7 to 45 mass %.

4. The porous material according to claim 1 , wherein the aggregates are silicon carbide particles or silicon nitride particles.

5. The porous material according to claim 1 , wherein a porosity is from 52 to 70%.

6. The porous material according to claim 1 ,
wherein a bending strength is 10 MPa or more, and a bending strength/Young's modulus ratio is 1.7×10 −3 or more.

7. The porous material according to claim 1 , wherein a coefficient of thermal expansion is 4.3×10 −6 /K or less.

8. A manufacturing method of the porous material according to claim 1 , comprising:
firing a raw material for the porous material according to claim 1 which contains aggregate powder and a raw material for the amorphous binding agent including a rare earth element, at 1400 to 1480° C. to prepare the porous material.

9. A honeycomb structure comprising:
partition walls which are constituted of the porous material according to claim 1 and with which a plurality of cells extending from one end surface to the other end surface are formed.

10. The honeycomb structure according to claim 9 , comprising:
plugged portions arranged in open frontal areas of the predetermined cells in the one end surface and open frontal areas of the remaining cells in the other end surface.

Assignees

• Ngk Insulators Ltd

Inventors

• Izumi Yunie
• Kobayashi Yoshimasa

Classifications

• C04B2235/663

  Oxidative annealing · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title

• C04B2235/3225

  Yttrium oxide or oxide-forming salts thereof · CPC title

• C04B2235/9607

  Thermal properties, e.g. thermal expansion coefficient · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title