Silicon carbide material, honeycomb structure, and electric heating type catalyst carrier

Abstract

A silicon carbide material according to the present invention includes a substrate containing, as a main component, silicon carbide or containing, as main components, silicon carbide and metallic silicon, and a film covering at least a portion of the surface of the substrate. The film contains, as a main component, a phase including at least four elements: lithium (Li), aluminum (Al), silicon (Si), and oxygen (O). One example of such a silicon carbide material includes a substrate having a structure in which silicon carbide particles are bonded by metallic silicon, and a lithium aluminosilicate film covering at least a portion of the surface of the silicon carbide particles. Such a silicon carbide material can be used for a DPF, an electric heating type catalytic converter, or the like.

1 . A silicon carbide material, including:
 a substrate containing, as a main component, silicon carbide or containing, as main components, silicon carbide and metallic silicon, and   a film covering at least a portion of the surface of the substrate,   wherein the film contains, as a main component, a phase including at least four elements: lithium (Li), aluminum (Al), silicon (Si), and oxygen (O).   
     
     
         2 . The silicon carbide material according to  claim 1 , wherein the film does not contain potassium. 
     
     
         3 . The silicon carbide material according to  claim 1 , wherein the film contains a lithium aluminosilicate. 
     
     
         4 . The silicon carbide material according to  claim 3 , wherein the lithium aluminosilicate is spodumene. 
     
     
         5 . The silicon carbide material according to  claim 1 , wherein the substrate has a structure in which silicon carbide particles are bonded by metallic silicon. 
     
     
         6 . The silicon carbide material according to  claim 1 , wherein the substrate has a porosity of 20% to 70%. 
     
     
         7 . The silicon carbide material according to  claim 1 , wherein the film has the maximum thickness of 2 to 102 μm. 
     
     
         8 . The silicon carbide material according to  claim 1 , wherein the film has the film weight ratio of 4.1% to 58.3% by weight. 
     
     
         9 . The silicon carbide material according to  claim 1 , wherein the film has a composition including 1% to 37% by weight of lithium oxide (Li 2 O), 3% to 49% by weight of aluminum oxide (Al 2 O 3 ), and 48% to 96% by weight of silicon oxide (SiO 2 ). 
     
     
         10 . A honeycomb structure which includes the silicon carbide material according to  claim 1 . 
     
     
         11 . An electric heating type catalyst carrier which uses the silicon carbide material according to  claim 1 . 
     
     
         12 . The silicon carbide material according to  claim 4 , wherein the substrate has a structure in which silicon carbide particles are bonded by metallic silicon. 
     
     
         13 . The silicon carbide material according to  claim 4 , wherein the substrate has a porosity of 20% to 70%. 
     
     
         14 . The silicon carbide material according to  claim 4 , wherein the film has the maximum thickness of 2 to 102 
     
     
         15 . The silicon carbide material according to  claim 4 , wherein the film has the film weight ratio of 4.1% to 58.3% by weight. 
     
     
         16 . The silicon carbide material according to  claim 4 , wherein the film has a composition including 1% to 37% by weight of lithium oxide (Li 2 O), 3% to 49% by weight of aluminum oxide (Al 2 O 3 ), and 48% to 96% by weight of silicon oxide (SiO 2 ). 
     
     
         17 . A honeycomb structure which includes the silicon carbide material according to  claim 4 . 
     
     
         18 . An electric heating type catalyst carrier which uses the silicon carbide material according to  claim 4 .