WO2006046542A1 - ハニカム構造体の製造方法及びハニカム構造体 - Google Patents
ハニカム構造体の製造方法及びハニカム構造体 Download PDFInfo
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- WO2006046542A1 WO2006046542A1 PCT/JP2005/019567 JP2005019567W WO2006046542A1 WO 2006046542 A1 WO2006046542 A1 WO 2006046542A1 JP 2005019567 W JP2005019567 W JP 2005019567W WO 2006046542 A1 WO2006046542 A1 WO 2006046542A1
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- magnesium
- honeycomb
- containing substance
- talc
- honeycomb structure
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- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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Definitions
- the present invention relates to a method of manufacturing a her cam structure and a her cam structure. More specifically, a method of manufacturing a hard cam structure capable of obtaining a well-formed her cam structure even if the organic matter content in the clay is small, and a hard cam obtained by this manufacturing method. -Concerning the cam structure.
- a ceramic material formation preparation
- water an organic binder, etc.
- a method for producing a ceramic structure that is dried and fired is disclosed (for example, see Patent Document 3).
- the organic binder is contained in the clay because the ceramic raw material powder and water alone do not provide sufficient plasticity and shape retention necessary for these moldings! Etc. to improve moldability.
- Patent Document 1 Japanese Patent Laid-Open No. 11-92214
- Patent Document 2 JP-A-11-100259
- Patent Document 3 Japanese Patent No. 3227039
- the formability of the cordierite hard cam structure increases as the amount of the organic binder added that imparts plasticity and shape retention increases.
- the organic binder is burned off during firing, if the amount of the organic binder added is large, the space occupied by the organic noinder at the time of molding becomes a defect. For this reason, with the increase in the amount of organic binder added, the hard cam structure There was a problem that the number of defects in the body increased and the mechanical strength of the honeycomb structure decreased.
- the organic binder burns during firing, the internal temperature of the hard cam structure becomes higher than the outside due to the heat of combustion. As a result, a large thermal stress is generated, which causes many defects such as cracks.
- the present invention has been made in view of the above-mentioned problems, and can obtain a well-shaped knot-cam structure even if the content of organic matter in the kneaded material, particularly organic noinda, is small. It is possible to provide a method for manufacturing a honeycomb structure and a honeycomb structure obtained by the manufacturing method.
- a honeycomb structure is produced by forming a clay containing a molding composition made of cordierite forming material and an organic binder into a honeycomb shape, and firing the honeycomb formed body to form a honeycomb structure.
- the second magnesium-containing substance is 40 masses with respect to the total amount of the first magnesium-containing substance and the second magnesium-containing substance.
- the second magnesium-containing material strength Magnesium hydroxide, magnesium oxide, magnesium carbonate, magnesium silicate and magnesium aluminate other than talc
- the method for producing a Hercam structure according to any one of [1] to [3], wherein at least one kind of force and group force is selected.
- talc first magnesium-containing substance
- an average particle size capacity as a magnesium source for forming cordierite in a molding composition. Since the predetermined second magnesium-containing substance of ⁇ m or less is contained, the moldability is improved even if the content of the organic binder in the clay is small. This makes it possible to satisfactorily form a two-cam molded body and to obtain a high-quality honeycomb structure.
- the method of manufacturing a her cam structure of the present invention is a method of forming a her cam molded body by molding a clay containing a molding compound made of cordierite forming material into a her cam shape.
- the average particle size of the magnesium-containing material other than talc (second magnesium-containing material) is 4 ⁇ m or less.
- the content of the organic binder is 3% by mass or less based on the whole molding composition!
- the molding composition comprising the cordierite-forming material is prepared by blending a predetermined ceramic raw material so as to form cordierite when fired.
- the same composition cordierite composition.
- An example of a suitable composition of cordierite is 2MgO-2AlO-5SiO.
- the talc which is a magnesium-containing material
- the second magnesium-containing material serve as the magnesium source of the cordierite. (When aluminum or silicon is contained together with magnesium, it is a magnesium source and an aluminum source or silicon source. is there).
- the source of magnesium is usually talc (3MgO '4SiO ⁇ ⁇ ⁇ ⁇
- talc has a property that its surface is hydrophobic and does not wet with water.
- the moldability is poor if there are many raw materials that do not wet with water.
- the resulting hard cam structure may be deformed, cracked, or sagging.
- the moldability is improved by using an organic binder in an amount corresponding to the blending ratio of talc.
- the organic binder causes a decrease in the strength of the hard cam structure and environmental pollution. Therefore, the amount used is preferably reduced as much as possible.
- the amount of talc added is reduced. Instead, use a magnesium source (second magnesium-containing substance) with a small average particle size! And it is preferable that the second magnesium-containing substance wets water better than talc.
- the second magnesium-containing material that wets well with water, the plasticity of the clay is improved, so that the moldability can be improved. It also functions as a shape-retaining agent that retains the shape of the material. As a result, a high-quality hard cam structure can be manufactured.
- the contact angle refers to the angle between the liquid surface and the solid surface where the free surface of the stationary liquid is in contact with the solid wall (surface) (the angle inside the liquid is taken). The smaller the contact angle, the easier it is to get wet.
- the “apparent contact angle” shown below was defined as the contact angle of the powder, and it was used as the wettability index. "Apparent contact angle” is uniaxial compression molding of the powder to be tested (10 4 N / cm 2 ) Droplets of distilled water (approximately 0.1 cm 3 ) were placed on the pellets ( ⁇ 20mm x t5mm), and the state of the droplets on the pellets was photographed with a video camera.
- the shape of the droplet immediately after it touched the pellet was analyzed, and the contact angle was measured. This was the “apparent contact angle”.
- the contact angle of each magnesium-containing substance is as follows: talc 40-70 °, magnesium hydroxide 5-35 °, magnesium oxide 7-35 °, magnesium carbonate 8-35 °, magnesium silicate 10-38 °, magnesium aluminum
- the acid salt is 5-37 °.
- the value of the “apparent contact angle” of the second magnesium-containing substance is preferably less than 40 °, more preferably 35 ° or less.
- Powder is used as the second magnesium-containing substance, and the average particle size is 4 m or less, preferably 3.5 m or less, and 3.0 m or less. Is even more preferred. If it is larger than 4 m, it is difficult to obtain a cordierite single phase when it is fired to form cordierite, and the thermal expansion coefficient of the obtained cordierite (a hard cam structure) increases.
- the average particle diameter is a value measured by a laser diffraction scattering method (based on CFIS R 1629).
- the second magnesium-containing substance is preferably magnesium hydroxide (Mg (OH)
- magnesium oxide MgO
- magnesium carbonate MgCO
- Musilicate and magnesium aluminate power group power is at least one selected
- magnesium hydroxide More preferably, it is at least one selected from the group power consisting of magnesium hydroxide, magnesium oxide and magnesium carbonate. All of these have the property of being better wetted with water than talc, so that the moldability can be improved.
- magnesium silicates other than talc include enstatite (MgSiO) and forsterite (Mg SiO).
- the content ratio of the first magnesium-containing substance and the second magnesium-containing substance contained in the molding compound is determined by the second magnesium-containing substance force.
- the first magnesium-containing substance and the second magnesium-containing substance It is preferably 40% by mass or less, more preferably 30% by mass or less, based on the total amount with the magnesium-containing substance. When it is more than 40% by mass, it is difficult to obtain a cordierite single phase when it is fired to form cordierite. The coefficient of thermal expansion of the light (honeycomb structure) increases.
- talc which is the first magnesium-containing substance
- usually powder is used, and the average particle diameter is not particularly limited, but is preferably 0.1 to 50 / ⁇ ⁇ force S, More preferably, it is 5-40 / zm.
- kaolin Al O-2S
- the molding material comprising the cordierite forming material by mixing the raw materials such as the first magnesium-containing substance and the second magnesium-containing substance described above.
- This is a formulation.
- the mixing device a device that is usually used for mixing powders can be used.
- an organic binder is added to a molding composition and kneaded to form a clay.
- a pore former and a surfactant are used. It is preferable to add clay and water, and knead to make a clay.
- the organic noinda functions as a shape-retaining agent that improves the plasticity and moldability of the clay and retains the shape of the Hercam molded body.
- an organic binder has a problem that the space occupied by the organic binder at the time of molding becomes a defect, or a defect such as a crack occurs in the hard cam structure, thereby reducing the strength of the hard cam structure. It is preferable to keep the content in the dredged material to the minimum necessary. Also, from the viewpoint of environmental problems, it is preferable to minimize the content of the organic binder. For this reason, in the present invention, the content of the organic binder is preferably 3% by mass or less with respect to the entire clay, and more preferably 2.5% by mass or less. It is particularly preferably 2% by mass or less. Moreover, 0 mass% may be sufficient.
- Examples of such an organic binder include organic polymers. Concrete Specifically, hydroxypropoxyl methylcellulose, hydroxypropyl methylcellulose, methinoresenorelose, hydroxyethinoresenorelose, force novoxino retinoresenorelose, polyvinyl alcohol and the like can be mentioned.
- the organic noda can be used alone or in combination of two or more.
- a pore forming agent in the clay.
- a pore-forming agent can form pores having a desired shape, size and distribution in the honeycomb structure, increase the porosity, and obtain a high-porosity hearth structure.
- pore-forming agents include graphite, wheat flour, starch, phenol resin, polymethyl methacrylate, polyethylene, polyethylene terephthalate, or foamed resin (acrylonitrile plastic balloon, etc.). it can. Instead of forming pores, they burn themselves. Above all, from the viewpoint of suppressing the generation of CO and harmful gases and cracks,
- the content of the pore-forming agent is not particularly limited, but it is preferably 15% by mass or less, more preferably 13% by mass or less, based on the entire clay. preferable. If it is more than 15% by mass, the strength of the resulting her cam structure may be lowered.
- the hard cam structure of the present embodiment it is preferable to contain a surfactant in the clay.
- the surfactant functions to improve the dispersibility of the raw material particles and to facilitate the orientation of the raw material particles during extrusion molding.
- it also acts on the hydrophobic surface of talc particles to improve water wettability.
- the surfactant may be any of anionic, cationic, nonionic and amphoteric, but the anionic surfactant fatty acid salt, alkyl sulfate ester salt, polyoxyethylene Alkyl ether sulfate, polycarboxylate, polyacrylate, nonionic surfactant polyoxyethylene alkyl ether, polyoxyethylene glycerin fatty acid ester, polyoxyethylene sorbitan (or sorbitol) fatty acid ester, etc. be able to.
- potassium laurate is preferable from the viewpoint of particle orientation.
- the amount can be adjusted so that the clay at the time of molding has an appropriate hardness, but it is preferably 10 to 50% by mass with respect to the entire molding formulation.
- the method for manufacturing a honeycomb structure according to the present embodiment exhibits a particularly excellent effect when a kneaded material is prepared by mixing water in a molding composition or the like.
- an organic substance is used as a molding compound.
- the obtained clay is molded into a two-cam shape and dried to obtain a her cam molded body.
- shape of the honeycomb molded body for example, a honeycomb-shaped partition wall that penetrates between two end faces and has a plurality of cells formed therein.
- DPF a filter
- the end portions of the cells are alternately sealed at the two end face portions.
- the overall shape of the Hercam molded body examples thereof include a cylindrical shape, a quadrangular prism shape, and a triangular prism shape.
- the cell shape of the honeycomb formed body (cell shape in a cross section perpendicular to the cell formation direction), for example, a quadrangle, a hexagon, a triangle, and the like can be given.
- a method for producing the honeycomb formed body conventionally known forming methods such as extrusion forming, injection forming, press forming and the like are not particularly limited. Among them, a preferred example is a method of extruding the clay prepared as described above using a die having a desired cell shape, partition wall thickness, and cell density.
- the drying method is not particularly limited, and conventionally known drying methods such as hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, freeze drying and the like can be used. Of these, a drying method that combines hot air drying with microwave drying or dielectric drying is preferable in that the entire molded body can be quickly and uniformly dried.
- the honeycomb formed body may be calcined before firing (main firing).
- Preliminary firing means an operation of burning and removing organic substances (a binder, a pore forming agent, a surfactant, etc.) in a honeycomb formed body, and is also referred to as degreasing, debinding, and the like.
- the combustion temperature of organic binder is about 100-300 ° C
- the combustion temperature of pore-forming agent is about 200-800 ° C
- the combustion temperature of surfactant is about 100-400 ° C. What is necessary is just about 100-800 degreeC.
- the force is about 1 to 20 hours.
- the amount of the organic noinda used can be reduced, so that the calcination time can be shortened. Specifically 0.5 ⁇ : LO time. Thereby, manufacturing time can be shortened and production efficiency improves.
- the calcined body obtained as described above is fired (main firing) to obtain a honeycomb structure.
- “Main firing” means an operation for sintering and densifying the forming raw material in the calcined body to ensure a predetermined strength.
- the ceramics compact is preferably fired at 1300-1500 ° C, more preferably 1350-1450 ° C. If the temperature is less than 1300 ° C, the target cordierite single phase may be difficult to obtain, and if it exceeds 1500 ° C, it may melt.
- the firing atmosphere include an air atmosphere, an atmosphere in which oxygen and nitrogen are mixed at an arbitrary ratio, and the like. Moreover, it is preferable to bake for about 1 to 12 hours.
- the her-cam structure of the present invention is obtained by the above-described method of manufacturing a her-cam structure, and is a high-quality honeycomb structure (small coefficient of thermal expansion with few defects and cracks). is there.
- Ha of the present invention - cam structure is more preferable that the thermal expansion coefficient of 1. 7 X 10- 6 ⁇ - 1 be less that or less favorable Mashigu 1. 5 X 10- _1 . 1. larger than 7 X 10- 6 ⁇ - 1, Ha second cam structure thermal shock resistance is deteriorated, and it may damage due to thermal stress during use occurs.
- Example 1 The talc, which is the first magnesium-containing substance, and the second magnesium-containing substance (second Mg source) shown in Table 1 are combined between the content ratio talc of the second Mg source and the second Mg source. The total amount was mixed so that each value shown in Table 1 (ratio (mass%) of the second Mg source) was obtained.
- Table 1 shows the average particle size (particle size) m) of the second Mg source used.
- kaolin, alumina, aluminum hydroxide and silica were added to prepare a cordierite-forming material (molding preparation).
- the cordierite-forming material is a raw material (material) having a composition that, when fired, becomes cordierite.
- the average particle diameter is a value measured by a laser diffraction scattering method (based on CFIS R 16 29).
- methyl cellulose as an organic binder was added to the molding composition in the amount shown in Table 1 (organic binder (mass%)) with respect to the entire molding composition, and as a surfactant.
- 0.5 mass% of potassium laurate and 30 mass% of water relative to the whole molding composition were added and kneaded to obtain a clay.
- the obtained clay was made into a cell structure with a cell partition force of 00 ⁇ m and a cell count of 300 cells.
- the obtained honeycomb-shaped formed body was free from abnormal forming pressure, defects and cracks.
- Table 1 shows the molding process.
- the obtained honeycomb-shaped formed body was dielectrically dried and then completely dried by hot air drying to produce a her cam formed body, and the obtained her cam formed body was heated in air at 1420 ° C, 4
- the honeycomb structure was obtained by firing under conditions of time (Examples 1 to 15).
- the crystal phase of the Nono-cam structure was identified by X-ray diffraction. Was the main phase.
- the talc, which is the first magnesium-containing substance, and the second magnesium-containing substance (second Mg source) shown in Table 1 are combined between the content ratio talc of the second Mg source and the second Mg source.
- the total amount was mixed so that each value shown in Table 1 (ratio (mass%) of the second Mg source) was obtained.
- Table 1 shows the average particle diameter m) of the second Mg source used.
- a cordierite-forming material (formulation preparation) was prepared by mixing force-olin, alumina, aluminum hydroxide and silica.
- methyl cellulose as an organic binder is added to the molding formulation in the amount shown in Table 1 (organic binder (mass%)) with respect to the entire molding formulation, and further, as a surfactant.
- organic binder (mass%) 0.5 mass% of potassium laurate and 30 mass% of water relative to the whole molding composition were added and kneaded to obtain a clay.
- the obtained clay is made into a cell structure with a cell partition force of 00 ⁇ m and a cell count of 300 cells.
- the obtained honeycomb-shaped formed bodies had no abnormal molding pressure, no defects or cracks.
- abnormal molding pressures pressure Ascending
- Table 1 shows the molding process.
- the obtained honeycomb-shaped formed body was dielectrically dried and then completely dried by hot air drying to produce a honeycomb formed body, and the obtained honeycomb formed body was subjected to the conditions of 1420 ° C for 4 hours in an air atmosphere. After firing, a Hercam structure was obtained.
- Cordierite-forming material (molding preparation) was prepared by adding kaolin, alumina, hydroxyaluminum hydroxide and silica to talc, which is the first magnesium-containing substance (the second magnesium-containing substance was used) I didn't.) [0051] Next, methyl cellulose as an organic binder is added to the molding composition in the amount shown in Table 1 (organic binder (% by mass)) with respect to the entire molding composition, and as a surfactant. 0.5 mass% of potassium laurate and 30 mass% of water relative to the whole molding composition were added and kneaded to obtain a clay.
- Table 1 organic binder (% by mass)
- the obtained clay was made into a cell structure with a cell partition force of 00 ⁇ m and a cell count of 300 cells.
- the obtained honeycomb-shaped formed body was found to have abnormal forming pressure, or a force that was free from defects and cracks.
- abnormal forming pressure pressure increase
- a molded product could not be obtained.
- Table 1 shows the molding process.
- the resulting honeycomb-shaped molded body was dielectrically dried and then completely dried by hot air drying to produce a honeycomb molded body.
- the resulting honeycomb molded body was heated at 1420 ° C, 4 A honeycomb structure was obtained by firing under conditions of time.
- the present invention is suitably used in various separation and purification apparatuses effective as a measure for preventing environmental pollution and global warming in various fields such as chemical, electric power, steel, and industrial waste treatment. It can be used to manufacture a her cam structure.
Abstract
Description
Claims
Priority Applications (3)
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JP2006543159A JP4847339B2 (ja) | 2004-10-29 | 2005-10-25 | ハニカム構造体の製造方法及びハニカム構造体 |
EP05798998.0A EP1808421B1 (en) | 2004-10-29 | 2005-10-25 | Method for producing honeycomb structure |
US11/684,759 US8017214B2 (en) | 2004-10-29 | 2007-03-12 | Method for producing honeycomb structure and honeycomb structure |
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JP2004-315326 | 2004-10-29 | ||
JP2004315326 | 2004-10-29 |
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US11/684,759 Continuation US8017214B2 (en) | 2004-10-29 | 2007-03-12 | Method for producing honeycomb structure and honeycomb structure |
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WO2006046542A1 true WO2006046542A1 (ja) | 2006-05-04 |
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PCT/JP2005/019567 WO2006046542A1 (ja) | 2004-10-29 | 2005-10-25 | ハニカム構造体の製造方法及びハニカム構造体 |
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US (1) | US8017214B2 (ja) |
EP (1) | EP1808421B1 (ja) |
JP (1) | JP4847339B2 (ja) |
CN (1) | CN101048352A (ja) |
WO (1) | WO2006046542A1 (ja) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2008119663A (ja) * | 2006-11-15 | 2008-05-29 | Denso Corp | 排ガス浄化フィルタの製造方法 |
JP2008119666A (ja) * | 2006-11-15 | 2008-05-29 | Denso Corp | 排ガス浄化フィルタの製造方法 |
US7780755B2 (en) | 2006-05-31 | 2010-08-24 | Corning Incorporated | Crack-resistant ceramic honeycomb articles and methods of manufacturing same |
JP2010201923A (ja) * | 2009-02-03 | 2010-09-16 | Ngk Insulators Ltd | ハニカム構造体の製造方法 |
JP2010222202A (ja) * | 2009-03-25 | 2010-10-07 | Ngk Insulators Ltd | ハニカム構造体の製造方法及びハニカム構造体 |
JP2019019227A (ja) * | 2017-07-18 | 2019-02-07 | 信越化学工業株式会社 | 熱伝導性シリコーン樹脂組成物 |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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JP6726634B2 (ja) * | 2017-03-28 | 2020-07-22 | 日本碍子株式会社 | ハニカム構造体の製造方法 |
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JPH11100259A (ja) | 1997-07-28 | 1999-04-13 | Corning Inc | 焼成時間が実質的に減少したコージエライト体の製造方法 |
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2005
- 2005-10-25 WO PCT/JP2005/019567 patent/WO2006046542A1/ja active Application Filing
- 2005-10-25 EP EP05798998.0A patent/EP1808421B1/en not_active Expired - Fee Related
- 2005-10-25 CN CNA2005800364844A patent/CN101048352A/zh active Pending
- 2005-10-25 JP JP2006543159A patent/JP4847339B2/ja not_active Expired - Fee Related
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2007
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JPS52123408A (en) * | 1976-04-08 | 1977-10-17 | Ngk Insulators Ltd | Cordierite ceramic honeycombs and manufacture |
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JPH1192214A (ja) | 1997-07-28 | 1999-04-06 | Corning Inc | 焼成時間の速いコージエライト体の製造方法 |
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JP2002284582A (ja) * | 2001-03-26 | 2002-10-03 | Ngk Insulators Ltd | セラミックハニカム体の焼成方法 |
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Publication number | Priority date | Publication date | Assignee | Title |
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US7780755B2 (en) | 2006-05-31 | 2010-08-24 | Corning Incorporated | Crack-resistant ceramic honeycomb articles and methods of manufacturing same |
JP2008119663A (ja) * | 2006-11-15 | 2008-05-29 | Denso Corp | 排ガス浄化フィルタの製造方法 |
JP2008119666A (ja) * | 2006-11-15 | 2008-05-29 | Denso Corp | 排ガス浄化フィルタの製造方法 |
JP2010201923A (ja) * | 2009-02-03 | 2010-09-16 | Ngk Insulators Ltd | ハニカム構造体の製造方法 |
JP2010222202A (ja) * | 2009-03-25 | 2010-10-07 | Ngk Insulators Ltd | ハニカム構造体の製造方法及びハニカム構造体 |
US8518322B2 (en) | 2009-03-25 | 2013-08-27 | Ngk Insulators, Ltd. | Method for manufacturing honeycomb structure and honeycomb structure |
JP2019019227A (ja) * | 2017-07-18 | 2019-02-07 | 信越化学工業株式会社 | 熱伝導性シリコーン樹脂組成物 |
Also Published As
Publication number | Publication date |
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US8017214B2 (en) | 2011-09-13 |
US20070148404A1 (en) | 2007-06-28 |
EP1808421A1 (en) | 2007-07-18 |
CN101048352A (zh) | 2007-10-03 |
EP1808421B1 (en) | 2014-03-26 |
JP4847339B2 (ja) | 2011-12-28 |
EP1808421A4 (en) | 2011-03-30 |
JPWO2006046542A1 (ja) | 2008-05-22 |
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