Ceramic clay, ceramic formed article, ceramic structure, and manufacturing methods thereof

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 system hardness scale is set to 10 to 35 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.

1 . 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 system hardness scale is in a range of 10 to 35 mm.    
     
     
         2 . The ceramic clay according to  claim 1 , wherein the layered double hydroxide is hydrotalcite represented by the following formula (II):  
         Mg 1-x Al x (OH) 2 (CO 3 ) x/2 .mH 2 O   (II),  
       (where x denotes a value in a range of 0.2≦x≦0.33, and m denotes an arbitrary value corresponding to the value of x).  
     
     
         3 . The ceramic clay according to  claim 1 , wherein the layered double hydroxide is hydrotalcite represented by the following formula (III):  
         Mg 6 Al 2 (OH) 16 CO 3 .4H 2 O   (III).  
     
     
         4 . A ceramic formed article obtained by forming the ceramic clay according to  claim 1 .  
     
     
         5 . The ceramic formed article according to claim  4 , comprising: a honeycomb formed article formed into a honeycomb shape.  
     
     
         6 . A ceramic structure obtained by firing the ceramic formed article according to  claim 4 .  
     
     
         7 . A method of manufacturing a ceramic clay, comprising the steps of: kneading a forming material containing a ceramic forming material to obtain the ceramic clay, 
 wherein the forming material containing layered double hydroxide, in addition to the ceramic forming material, is used at a ratio of 0.5 to 50% by mass with respect to a total with the ceramic forming material.    
     
     
         8 . The method of manufacturing the ceramic clay according to  claim 7 , wherein hydrotalcite represented by the following formula (II) is used as the layered double hydroxide:  
         Mg 1-x Al x (OH) 2 (CO 3 ) x/2 .mH 2 O   (II),  
       (where x denotes a value in a range of 0.2≦x≦0.33, and m denotes an arbitrary value corresponding to the value of x).  
     
     
         9 . The method of manufacturing the ceramic clay according to  claim 7 , wherein hydrotalcite represented by the following formula (III) is used as the layered double hydroxide:  
         Mg 6 Al 2 (OH) 16 CO 3 .4H 2 O   (III).  
     
     
         10 . The method of manufacturing the ceramic clay according to  claim 7 , wherein hardness of the obtained ceramic clay, measured by an NGK system hardness scale, is in a range of 10 to 35 mm.  
     
     
         11 . A method of manufacturing a ceramic formed article, comprising the steps of: further forming the ceramic clay obtained by the method according to  claim 7  to obtain the ceramic formed article.  
     
     
         12 . The method of manufacturing the ceramic formed article according to  claim 11 , further comprising the steps of: forming the ceramic clay into a honeycomb shape to obtain a honeycomb formed article.  
     
     
         13 . A method of manufacturing a ceramic structure, comprising the steps of: further firing the ceramic formed article obtained by the method according to  claim 11  to obtain a ceramic structure.