WO2011051901A1

WO2011051901A1 - Assembled filter body having variable specific thermal resistance

Info

Publication number: WO2011051901A1
Application number: PCT/IB2010/054886
Authority: WO
Inventors: Fabiano Rodrigues; Adrien Vincent
Original assignee: Saint-Gobain Centre De Recherches Et D'etudes Europeen
Priority date: 2009-10-28
Filing date: 2010-10-28
Publication date: 2011-05-05

Abstract

The present invention relates to a ceramic filter body comprising a plurality of filter blocks, each filter block including a set of adjacent channels extending between inlet and discharge surfaces and separated by means of filter walls, said channels being blocked by plugs upstream and downstream, arranged in alternation next to the inlet surface and the discharge surface, first and second filter blocks comprising first and second outer walls, respectively defining first and second inner surfaces, respectively, and first and second outer surfaces, respectively, said first and second outer surfaces, referred to as "first and second joint surfaces" respectively, being adhered to one another by means of a joint, characterised in that said first and second outer walls and said joint are configured such that the relative difference in thermal resistance among blocks between the first and second measurement sites opposite said joint is higher than 25 %, the resistance among blocks being the specific thermal resistance measured according to the thickness of the joint between the first and second inner surfaces.

Description

_TT

Assembled filter body with variable specific thermal resistance Technical field

The invention relates to an assembled ceramic filter body, especially for the filtration of exhaust gas from a motor vehicle, said body comprising an assembly of a plurality of filter blocks secured by means of seals interposed between said filter blocks.

The invention also relates to a method of manufacturing such a filter body. State of the art

Before being vented to the open air, the exhaust gas of a motor vehicle i o can be purified by means of a particle filter such as that shown in Figures 1 and 2, known from the prior art.

A particle filter 1 is shown in FIG. 1 in cross-section along the section plane B-B shown in FIG. 2, and in FIG. 2 in longitudinal section along the sectional plane A-A shown in FIG.

The particulate filter 1 conventionally comprises at least one filter body 3, of length L, inserted in a metal casing 5.

The filter body can be monolithic. In order to improve its thermomechanical resistance, in particular during the regeneration phases, it is nevertheless advantageous that it results from the assembly and machining of a plurality of filter blocks 1 1, referenced 1 1 a-11 i. SI is then called "assembled" filter body.

Biocs 1a-1h whose side surface is partly exposed outside the filter body are called "peripheral" blocks. The other biocs, in this case the block, are called "central" blocks.

To produce a filter block 11, a ceramic material (cordierite, silicon carbide, etc.) is extruded to form a porous honeycomb structure.

The extruded porous structure conventionally has the shape of a rectangular parallelepiped extending between two upstream faces 12 and downstream 13 substantially square on which opens a plurality of channels 14 adjacent, rectilinear, and parallel.

It is also known, for example from WO 05/016491, porous honeycomb structures having channels of variable section depending on the channel considered. These so-called "asymmetrical" structures generally offer a large storage volume and limit the pressure drop across the filter.

After extrusion, the extruded porous structures are alternately plugged on the upstream face 12 or on the front face 13 by upstream 15s and downstream 15e caps, respectively, as is well known, to form "outlet channels" 14s and " input channels' 14th, respectively. At the end of the output channels 14s and input 14e opposite the upstream plugs 15s and 15e, respectively, the output 14s and input 14e channels open outward through 19s output and input openings 19e, respectively, extending on the downstream faces 13 and upstream 12, respectively. The inlet 14e and exit 14s channels thus define interior spaces 20e and 20s delimited by a side wall 22e and 22s, a closure cap 15e and 15s, and an opening 19s or 19e opening outwards, respectively .

After capping, the extruded structures are sintered. Two input channels 14e and 14s adjacent output are in fluid communication by the common portion of their side walls 22e and 22s, constituting after filtering a porous filter wall. The filter blocks 1 1 a-1 1 i thus manufactured rectangular parallelepiped, each have four outer walls each having an inner face participating in defining so-called "peripheral" channels, and an outer face of generally planar shape. The four outer faces 25 of a filter block (see FIG. 4a) extend from the upstream face 12 to the downstream face 13.

To assemble these filter blocks, opposite outer faces, hereinafter referred to as "joint faces", of filter blocks are glued to each other, preferably parallel to one another, by means of joints 27 in a ceramic cement generally consisting of silica and / or silicon carbide and / or aluminum nitride.

To constitute the ceramic cement joints 27 assembly filter blocks, or "joint cement", also called "ceramic seal layer" in English, it is known in particular a hardened cement comprising between 30 and 60% by weight of silicon carbide . Silicon carbide has a high thermal conductivity advantageously to quickly homogenize the temperature within the filter body. Silicon carbide, however, has a relatively high coefficient of expansion. The silicon carbide content of this type of cement cured must therefore be limited to ensure thermomechanical resistance suitable for application to particulate filters.

The assembly thus formed can then be machined to take, for example, a round section. The cured cement must be able to withstand this machining operation. Preferably, a peripheral coating 27 ', also called "coating", is also applied so as to cover substantially the entire lateral surface of the filter body. The cement used for the joints 27 may possibly be used to manufacture the peripheral coating 27 '. It must then have sufficient mechanical strength to resist insertion into the envelope, or "caning".

It results in a cylindrical filter body 3 of longitudinal axis CC, which can be inserted into the casing 5, an exhaust gas-tight peripheral material 28 being disposed between the peripheral filter units 11a-1 1 h, or , where appropriate, between the coating 27 'and the envelope 5.

As indicated by the arrows shown in FIG. 2, the flow F of the exhaust gases enters the filter body 3 through the openings 19e of the inlet channels 14e, passes through the filtering walls of these channels to join the outlet channels. 14s, then escapes to the outside through the openings 19s.

The faces of the filter body through which the gases enter and exit the filter body, respectively, are referred to as the "inlet face" 30 and "exhaust face" 32.

The seals 27 are preferably gas-tight to force them to pass through the filter walls separating the inlet channels and the outlet channels.

After a period of use, the particles, or "soot", accumulated in the channels of the filter body 3 increase the pressure drop due to the filter body 3 and thus impair the performance of the engine. For this reason, the filter body must be regenerated regularly, for example every 500 kilometers.

Regeneration, or "declogging", consists of oxidizing the soot. To do this, it is necessary to heat them to a temperature that allows them to ignite. The inhomogeneity of the temperatures within the filter body 3 and the possible differences in the nature of the materials used for the filter blocks 1a-1 1i and the seals 27 can then generate high thermomechanical stresses. Joints must be able to withstand thermomechanical stresses during regeneration, and in particular maintain the cohesion of the filter body and its filtering properties.

The stresses on the joints are particularly severe with assemblies of filter biocs with asymmetrical structure, that is to say in which the cross sections of the inlet channels are different from those of the outlet channels.

EP 1 142 619 discloses an assembled filter body implementing a cured cement with low thermal conductivity, the use of a cured cement highly thermally conductive being considered detrimental to adhesion and thermal resistance.

EP 1 479 882 discloses an assembled filter body and recommends a parameterization taking into account the coefficients of thermal expansion of the joints and the filtering biocides. The seal's porosity level can be controlled by the addition of a foaming agent or a resin.

EP 1 437 168 deals with the thermal heterogeneity between the periphery and the central part of the filter and recommends a hardened cement and filter blocks having particular thermal conductivities and densities.

EP 1 447 535 proposes to also take into account the thickness of the joints and the thickness of the outer wall of the filter blocks.

FR 2 902 424 discloses a hardened cement comprising silicon carbide (SiC) and hollow spheres, at least 80% by number of said hollow spheres having a size between 5 and 150 microns.

FR 2 902 423 discloses a hardened cement having a silicon carbide (SiC) content of between 30 and 90% and a thermosetting resin.

US 2006/213163 and US 2004/045267 describe the use of seals with different thermal conductivities, but they do not intend to vary this thermal conductivity within the same joint.

In all the documents cited above, the composition of the cured cement used for a joint is homogeneous in the direction of the length, width and thickness of the joint.

Summary of the invention When the hardened cement is less thermally conductive than the filter media, the inventors have found that during regeneration the heat of soot combustion is "confined" in the filter blocks. As a result, the average temperature of the latter increases, which can lead to mechanical deterioration. This increase in temperature can even lead to the appearance of melting points within the filter blocks, in particular in the filter blocks located in the center of the assembled filter body, especially if the filter blocks are made of cordierite or a less refractory material than silicon carbide.

In addition, in the case of filter blocks consisting of a material having an expansion coefficient greater than 2.5 × 10 ^-6 ° C ^-1 between 20 ° and 1000 ° C., such as silicon carbide, the peripheral and central filter blocks have a deformation very different during the regeneration, which generates transverse stresses (in the transverse planes) high, and possibly leads to longitudinal cracks in the joints.

When the cured cement is more thermally conductive than the filter blocks, the inventors have found that during the regeneration, the heat of combustion is removed more rapidly by the lateral surface of the filter blocks, which leads to the elevation of the filter gradient. temperature between the center and the periphery of these filter blocks. The filter body is then likely to crack at the joint joints, particularly near the discharge face. This phenomenon is particularly detrimental for the filter blocks of a material having a mean coefficient of expansion greater than 2.5x10 ^e X ^"1, such as silicon carbide.

There is a permanent need for an assembled ceramic filter body that may be suitable for the application to the filtration of exhaust gases from internal combustion engines, in particular diesel engines, and having excellent thermomechanical resistance.

An object of the present invention is to satisfy this need.

The invention proposes a ceramic filter body, in particular for the filtration of exhaust gas particles of an internal combustion engine, said filter body comprising a plurality of filter blocks,

each filter block comprising a plurality of adjacent channels extending between inlet and outlet faces and separated by filter walls, said channels being closed by upstream and downstream plugs arranged alternately near the intake face and the discharge face,

first and second impingement blocks having first and second outer walls, respectively, defining first and second inner faces, respectively, and first and second outer faces, respectively, said first and second outer faces, so-called first and second faces of seal ", respectively, being adhered to each other through a seal.

According to the invention, said first and second outer walls and said gasket are configured such that the relative difference in inter-block thermal resistance between two measurement locations opposite said gasket is greater than 25%, greater than 50%, or greater than 100%, or even greater than 200%, or even greater than 500%, the inter-block resistance being the specific thermal resistance measured according to the thickness of the seal between the first and second inner faces. Of course, the measurements are made under the same temperature conditions in each of the measurement locations. Such a seal is called "variable inter-block resistance".

The inventors have discovered that the adaptation of this inter-block resistance to the local stresses encountered during its regenerations makes it possible to improve the life of the filtering body. For this purpose, it is possible to act in particular on the following parameters:

- Local thickness of the seal and / or the first and second outer walls, said inter-block resistance increasing with the thickness;

- Local composition of the seal and / or the first and second outer walls, said inter-block resistance decreasing with the thermal conductivity of the seal material and / or the first and second outer walls. In particular, it is possible to choose filter blocks having a variable composition depending on the location;

- porosity of the seal and / or the first and second outer walls, said inter-block resistance increasing with said porosity;

- Local adhesion of the seal on said first and second outer walls, said inter-block resistance decreasing with this adhesiveness. In particular, to increase inter-block resistance, non-adherence zones may be provided on the seal faces. The composition of the joint can also be adapted for this purpose, for example by modifying the amount of inorganic binder. Those skilled in the art can locate the regions of high thermal gradients of a filter body from a thermal map obtained during a regeneration. It can then act on the above parameters to locally increase or decrease cross-block resistance accordingly.

Inter-block resistance can be measured according to the method described for the examples.

The measuring locations are chosen "with respect to the joint", that is to say they are located in areas where the space between the first and second faces of the joint is at least partially filled, preferably completely filled, by said seal.

A filter body is in accordance with the present invention if it is possible to determine two measurement locations such that the relative difference in inter-block thermal resistance between these locations is greater than 25%.

The spacing between the measurement locations may for example be greater than 1 cm and / or less than 30 cm, less than 20 cm, less than 10 cm,

The two measurement locations can be separated by a distance of less than 5 cm, less than 3 cm or even less than 2 cm, which corresponds to a growing inter-block thermal resistance gradient.

The spacing between the measurement locations may be, for example, greater than 5%, greater than 10%, greater than 20%, greater than 30% and / or less than 90%, and less than 80% greater than the largest. lengths of the first and second seal faces. Preferably, the lengths of the first and second seal faces are substantially identical.

The seal may be continuous or discontinuous. In the latter case, the seal is interrupted and consists of several portions of joint, so there are gaps not filled with cement between these portions of seal. These spaces may especially be empty (not filled with solid material) or filled with a different material than a cement, for example by spacers (or "spacers") possibly not fixed on the filter blocks. These spaces are therefore not part of the joint and the measuring locations can not be chosen by the look (or "right") of these spaces.

In one embodiment, the measurement locations are exclusively located with respect to the same portion of joint. In another embodiment, the measurement locations can be located in relation to two different portions of joint. In one embodiment, the measurement locations are exclusively located in areas where the gap between the first and second seal faces is completely filled by said seal, which particularly excludes the areas in which the seal would be split or taken off from the joint faces.

The measurement locations can be aligned in particular along the length or the width of the joint.

In one embodiment, the resistance i nier-blocks varies in the direction of the length and in the direction of the width of the joint, the relative distance of the inter-block thermal resistance can be greater than 25%, greater than 50 %, or greater than 100%, or even greater than 200%, or even greater than 500%, between two locations aligned according to the length of the joint and between two measurement locations aligned according to the width of the joint.

The measurements are made "according to the thickness of the joint", that is to say by measuring the thermal resistance between two points aligned in the direction of the thickness of the joint. Conventionally, the first and second seal faces are parallel to each other and the direction of the thickness is perpendicular to the seal faces.

In one embodiment, the seal adheres to said first and second seal faces at any point where it extends opposite said seal faces. In other words, i! there is no detachment, for example slit, nor intermediate layer of a material other than a cement, between the seal and the seal faces. This embodiment does not exclude an interruption of the seal.

In one embodiment, the seal extends and adheres to all of said first and second seal faces.

In one embodiment, the inter-block resistance of said seal increases, continuously or stepwise, in the direction of the length of the seal, in particular from the intake face to the discharge face.

In one embodiment, the inter-block resistance of said seal increases, continuously or stepwise, in the direction of the width of the seal as it approaches the periphery of the filter body.

In one embodiment, said two measurement locations are located near the longitudinal axis of the seal and near a longitudinal edge of the joint, respectively. Preferably, the inter-block resistance at the measurement location located near said longitudinal axis is greater than that measured at the measurement location located near said longitudinal edge of the joint. Preferably, these measurement locations are aligned along the width of the joint.

One of said two measurement locations can be located near corners of said first and second filter units, and in particular near the corners of these filter blocks near said discharge face. Preferably, the inter-block resistance facing said seal near corners of said first and second filter blocks, and in particular near the corners of these filter blocks in the vicinity of said discharge face, is higher than any other another measurement location opposite said seal.

Composite seals; thickness

The inter-block resistance can be modified in particular using a joint, called "composite seal", comprising several regions of cured cements having different thermal conductivities. The highest thermal conductivity within said seal is preferably at least 25% greater than the lowest thermal conductivity. The regions may extend over the entire width and / or the entire length of said joint faces. In the remainder of the description, it is said that two regions are of the same "type" when they consist of cements having identical thermal conductivities.

The use of composite joints makes it possible to obtain a wide variety of thermal profiles.

The inter-block resistance can be modified in particular by using a seal whose composition is substantially homogeneous over the direction of its thickness (that is to say that at any point of the joint, the same fresh cement has been put into place. work over the entire thickness of the joint) and heterogeneous in the direction of its length and / or the direction of its width. For example, the first and second measured locations may be opposite first and second regions of the joint in first and second cured cements having different thermal conductivities.

Inter-block resistance can also be modified by adjusting the superimposed layer thicknesses into different cured cements. For example, at the first measurement site, a first cement may represent 80% of the thickness of the joint, the remaining 20% being in a second cement, the proportions being reversed at the second measurement location. The thickness of the superposed layers, and in particular the upper and lower layers, may be greater than 0.05 mm, greater than 0.2 mm, greater than 0.3 mm, greater than 0.5 mm, or even greater than 1 mm and / or less than 6 mm, or less than 2 mm. It is also possible to locally combine the seal with a non-cement layer and having a thickness and / or thermal conductivity and / or adhesion capabilities to substantially modify the inter-block resistance.

Porosity; particle size distribution

The inter-block resistance can also be modified by adjusting the porosity of the cement (s) used and / or the first and / or second outer walls of the filtering bioc. Thus, the total porosity of said seal and / or one or both of the outer walls at the first measurement location may be different from the porosity of said seal and / or outer wall (s), respectively, at the second measurement location. .

In particular, it is possible to increase the macroporosity to increase inter-block resistance.

In one embodiment, to obtain high inter-block resistance, the distribution of the equivalent pore diameter of the joint cement, measured in a transverse sectional plane, may include a first mode centered on a diameter of between 200 microns and 20 microns. mm and a second mode centered on a diameter of between 1 micron and 50 microns. This distribution may be such that said first and second modes are the main modes.

In one embodiment, to obtain a high inter-block resistance, a seal cement has, at one of said first and second measurement locations, pores having an equivalent diameter of between 200 μηη and 20 mm in an amount such that, in a transverse sectional plane, the total area occupied by said pores represents more than 15%, preferably more than 20%, and preferably less than 80%, preferably less than 65%, more preferably less than 50%; % of the total area observed. The particle size of the mineral powders used to manufacture the seal and / or its first and / or second outer walls of the filter blocks makes it possible to modify the porosity.

Adhesiveness

Said seal may adhere over the entire surface of said first and second seal faces, or even over the entire surface of said first and second seal faces ("integral" bonding). In one embodiment, the level of adhesion of the gasket on a gasket face is the same, that! that is the point of this face considered.

The seal may also have areas of lower adhesion or non-adhesion, on a seal face or on both sides of the joint, to obtain inter-block resistance locally lower.

Process

The invention also relates to a method of manufacturing an assembled filter body, comprising the following successive steps:

A) manufacture of at least two filter blocks;

B) preparation of one or more fresh cements;

C) application of fresh cement (s) between two faces of joint defined by external walls of said filter blocks;

D) curing the one or more fresh cements so as to form a seal between said joint faces;

E) optionally, heat treatment. According to the invention,

the local thickness of the joint and / or the external walls; and or

the local composition of the joint and / or the external walls; and or

the particle size distribution of the refractory powder used to manufacture the seal and / or the external walls; and or

the local porosity of the seal and / or the external walls; and or

local adhesion of the seal on said joint faces;

so as to obtain, after step D) or step E), an assembled filter body according to the invention. In one embodiment, step B) comprises the following operations:

a) preparing, from a first feedstock, a first fresh cement capable of forming, after curing, a first cured cement having a first thermal conductivity;

b) preparing, from a second feedstock, a second fresh cement capable of forming, after curing, a second hardened cement having a second thermal conductivity, said first thermal conductivity being at least 25% greater than said second thermal conductivity at any temperature between 20 ° C and 60 ° C.

In preferred embodiments, step b) of preparing the second fresh cement comprises:

an addition, in said second starting feedstock, of organic fibers and / or organic particles, preferably in an amount of between 0.1% and 10% by weight percentage on the basis of the dry mineral matter, and / or - adding, in said second feedstock, hollow inorganic particles, preferably in an amount greater than 5%, as a percentage by weight on the basis of the dry mineral matter; and or

an injection of a gas into said second fresh cement, in particular by insufflation of this gas, preferably in a multitude of injection points distributed in said second fresh cement; and or

an addition, in said second initial charge, of a foaming agent, preferably in an amount of between 0.5 and 10%, and of a gelling agent, preferably in an amount of between 0.05 and 5; %, in percentages by mass on the basis of the dry mineral matter; and or

an addition of porogenic agents in said second feedstock.

Preferably, the heat treatment of step E) is adapted to cause an elimination of organic materials, and in particular an elimination of said organic fibers and / or said organic particles and / or porogenic agents.

Optionally and in order to maintain a Sa seal thickness more constant possible, the filter blocks to be assembled are preferably immobilized during step D), or even during step C).

In one embodiment, the first and / or second fresh cements may be applied, in step C), in the form of a suspension or a paste on at least one of the seal faces of the filter blocks to be assembled. _{] 3}

Definitions

The "longitudinal" or "length" direction of a filter body is defined by the general direction of the flow of the fluid to be filtered through this filter body. Conventionally, all the channels of a filter body extend parallel to the longitudinal direction. Generally, the filter blocks are assembled so that the joint faces between which a seal extends is, at least locally, substantially parallel to the longitudinal direction and, preferably, parallel to each other.

A "longitudinal" plane is a plane parallel to the longitudinal direction of the filter body.

A "transverse" plane is a plane perpendicular to the longitudinal direction.

The term "joint" is understood to mean a mass of refractory cement (s) which is continuous, that is to say uninterrupted or discontinuous, extending between two faces of joint opposite two adjacent filter blocks. When a seal is discontinuous, it has several "joint portions". Empty volumes of solid material between two joint portions are not part of the joint.

The limit of a joint can be physical, when the mass of element (s) is interrupted, or virtual, when the mass of cement (s) reaches the limit of one of the two faces of joint.

Conventionally, the term "length" of a joint is the maximum dimension of this joint measured according to the iongitudinal direction of the filter body, "width" of this seal the maximum dimension measured perpendicular to said longitudinal direction in a median plane between the two faces of joint between which this joint extends, and "thickness" of this joint the maximum dimension of the joint measured perpendicularly to the directions of its length and its width.

A "particulate mixture" is a mixture of particles, dry or wet, able to set in mass after activation.

The particulate mixture is said to be "activated" when in a caking process. The activated state typically results from humidification with water or other liquid. An activated particulate mixture is called "fresh cement". Caking (curing) may result from drying or, for example, hardening of a resin. Finally, heating makes it possible to accelerate the evaporation of water or residual liquid during or after curing.

By definition, a fresh cement is able, after hardening, to coilse firmly between two filter blocks made of a ceramic material so that the assembly thus formed can withstand the stresses in an application to the filtration of gas. exhaust of a vehicle, and in particular thermomechanical stresses encountered during a regeneration.

Layers obtained from PTFE or boron nitride, which can not be activated, do not therefore constitute "cements".

In addition, the definition of a cement implies an ability to withstand temperatures above 500 ° C.

The solid mass obtained by caking a fresh cement is called "hardened cement".

By "temporary" is meant "removed from the product by heat treatment". "Sphere" means a particle having a sphericity, that is to say a ratio between its smallest diameter and its largest diameter, greater than or equal to 0.75, whatever the way in which this sphericity was obtained. A sphere is called "hollow" when it has a central cavity, closed or open on the outside, the volume of which represents more than 50% of the overall external volume of the hollow sphere.

The size of a sphere or particle is called its largest dimension.

Conventionally, the term "median size" or "median diameter", or "d50", is a mixture of particles or a set of grains, the size dividing the particles of this mixture or the grains of this set in first and second populations equal in number, these first and second populations having only particles or grains having a size greater than, or less than, the median size.

The "equivalent diameter" of a pore in a hardened cement is the diameter of a disk whose surface is equal to the opening surface of this pore measured on a section of hardened cement, for example in a photograph of this section. taken by an optical microscope. This diameter is measured in a transverse cutting plane. By "thermosetting resin" is meant a polymer convertible into an infusible and insoluble material after heat treatment (heat, radiation) or physicochemical (catalysis, hardener). The thermosetting resins thus take their definitive form at the first cooling of the resin, the reversibility being impossible, in particular under the conditions of use and regeneration of the filter bodies used in motor vehicles.

A "molten" product is a product obtained by a process comprising a melting of the raw materials, in particular by electrofusion, then a cooling solidification of the molten liquid _T

A relative difference in inter-block resistance between two measurement locations is equal to (R ₁ -R ₁ ₂ ) / _{1 1} , R 1 and R 1 ₂ denoting inter-block resistances at said measurement locations.

Unless otherwise indicated, by "comprising a", it is necessary to include "comprising at least one".

Brief description of the figures

Other characteristics and advantages of the invention will become apparent on reading the following detailed description and on examining the appended drawing in which FIGS. 1 and 2 show schematically, in cross-section and in longitudinal section respectively, a filter body;

Figure 3 schematically shows, in perspective, an exploded view of a filter body having four filter blocks assembled by a set of joints;

Figures 4a and 4b show details of the filter body of Figure 3 for visualizing the boundaries of a seal and an outer wall, respectively;

Figures 5a-5b show, in perspective, a composite seal of a filter body according to the invention, the thermal conductivity of cured cements varying in the direction of the length of said seal;

FIGS. 6a-6b show, in perspective, filter body seals according to the invention, the thermal conductivity of the hardened cements varying in the direction of the width;

FIGS. 7a-7b show, in perspective, filter body seals according to the invention, the thermal conductivity of the hardened cements varying according to the direction the length, in the direction of the direction of the width and in the direction of the thickness;

Figures 8a-8b show, in perspective, the filter body seals according to the invention, the thermal conductivity of cured cements varying both in the direction of the length and in the direction of the thickness;

Figures 9a-9c show, in perspective, the filter body seals according to the invention, the thermal conductivity of cured cements varying both in the direction of the length and in the direction of the width;

Figure 10a shows, in perspective, a seal of a filter body according to the invention, the thermal conductivity of cured cements varying both in the direction of the width and in the direction of the thickness;

Figure 11a shows, in perspective, a seal of a filter body according to the invention, the thermal conductivity of the cured cements varying both in its direction of the length and in the direction of the thickness;

- Figure 12a shows, in perspective, a seal of a filter body according to the invention, the thermal conductivity of cured cements varying both in the directions of the length, width and thickness;

Figure 13 illustrates a measurement method for measuring inter-block resistance.

Identical references are used in the various figures to denote identical or similar objects.

DETAILED DESCRIPTION

A filter body according to the invention may comprise one or more of the characteristics of the assembled filter body described in the preamble of the present description.

The filter blocks conventionally comprise nested sets of inlet channels and adjacent output channels, preferably substantially parallel and / or parallel, arranged in a honeycomb. Preferably, the inlet and outlet channels are arranged alternately so as to form, in section, a checkerboard pattern.

The joint faces between which a composite joint extends may be of generally planar shape. Preferably, they are parallel to each other. Preferably, the overall volume of said input channels is greater than that of said output channels.

The intermediate walls separating two horizontal or vertical rows of the channels may in particular have, in cross section, a corrugated shape, for example a sinusoidal shape. Preferably, the width of a channel is substantially equal to half a period of the sinusoid.

More preferably, the upstream and downstream plugs extend along the intake face and the discharge face, respectively.

The filter blocks may be porous ceramic blocks having greater than 30% or even more than 40% and / or less than 65% or even less than 50% open porosity.

All filter blocks may be of the same material. In one embodiment, said filter blocks are made of a material having a thermal conductivity of less than 10 W / m 2 ° C, or even less than 8 W / m 2 ° C, or less than 5 W / m 2 ° C, or even less than 1 W / m.

The filter blocks may be made of a material having a coefficient of expansion greater than 2.5 × 10 ^-6 ° C ^-1 between 20 ° and 1000 ° C., for which the invention is particularly useful.

Preferably, the filter blocks are of a sintered material and comprise more than 50% or more than 80% by weight of SiC silicon carbide, preferably recrystallized and / or of alumina titanate and / or of mullite and / or and cordierite and / or silicon nitride and / or sintered metals.

In one embodiment, the thermal resistance resulting from the crossing of the first and second outer walls is negligible in comparison with that resulting from the crossing of the seal, for example because the filter blocks are made of a very thermally conductive material such as the carbide of silicon. The thermal resistance resulting from the crossing of an outer wall may be locally modified by a treatment on the preform, for example by soaking a portion of this outer wall in a solution leading to an increase in the porosity of this portion after sintering.

All the seals of the filter body can be "variable inter-block resistance". In particular, all the joints of the filter body can be composite, or even be made of the same cements, possibly arranged identically or similar, regardless of the joint considered.

Said seal can fill the volume between said first and second seal faces. The total porosity of a cured cement used for said seal may be greater than 5% and less than 90%, preferably greater than 30% and less than 85%. A cured cement may advantageously comprise more than 0.05% and less than 5% of a thermosetting resin, in percentages relative to the mass of the mineral material.

A hardened cement used for said joint can be obtained from a mineral powder comprising, in percentage by weight relative to the mineral matter, at least 5% of particles whose median size is between 0.1 and 10 microns preferably between 0.3 and 5 microns. Such a particle size distribution is particularly useful for obtaining low inter-block resistance.

Preferably, silicon carbide (SiC), alumina (Al ₂ O ₃ ), zirconia (ZrO ₂ ), titanium oxide (TiO ₂ ), magnesium oxide, silica (SiO ₂ ) and Mixed compounds derived from these oxides, such as, for example, aluminum titanate, muilite or zircon, together account for more than 85% of the mass of the mineral material of a hardened cement used for said joint.

A hardened cement used for said seal may have a CaO lime content of less than 0.5%, in percentage by weight relative to the mineral matter.

The cured cement may comprise more than 50%, more than 60% or even more than 75% of silicon carbide, in percentage by weight relative to the mineral material, in particular to obtain a high thermal conductivity. Preferably, the silicon carbide is present in the form of particles whose median size is less than 200 microns.

A hardened cement used for said seal preferably comprises less than 10%, preferably less than 5%, preferably less than 1%, of mineral fibers, in particular ceramics, as a percentage by weight on the basis of the dry mineral matter. Preferably none of the cured cements used include such fibers.

Preferably, at least a portion, preferably all cured cements comprise an inorganic and / or organic binder. To benefit from a low thermal conductivity, a hardened cement may comprise more than 5% of inorganic hollow spheres, in percentage relative to the mass of the mineral material. The inorganic hollow spheres are preferably distributed in a particle size distribution having two main modes (peaks): a first mode centered on a size between 1 10 μητι and 150pm and a second mode centered on a size between 35 pm and 55 pm. Preferably, the peak of the first mode is higher than the peak of the second mode.

In order to benefit from a low thermal conductivity, a hardened cement may comprise, before debinding, an amount of organic fibers greater than 0.1%, preferably greater than 2%, more preferably greater than 3% and / or less than 10%, preferably less than 5%, preferably less than 4%, in percentages by weight on the basis of the mineral material.

In one embodiment, with respect to one of said measuring locations, or even with respect to both said measuring locations, the seal does not contain boron, and in particular does not include boron nitride.

The inter-block resistance can be modified in particular by using a composite joint comprising several regions of cured cements having different thermal conductivities.

A composite seal may have two, three, four, five, six, seven, or more than seven cured cements having thermal conductivities all different from each other. The number of hardened cements constituting the seal and having different thermal conductivities may be less than 10, less than 7, less than 5, less than 3.

In one embodiment, regions having different thermal conductivities in pairs follow each other in the direction of the length and / or width and / or thickness of the joint. The successive regions may have the same or different length and / or width and / or thickness. In one embodiment, all the regions made of the same hardened cement have the same length and / or width and / or thickness.

Preferably, the relative difference in thermal resistance (R1-R2) / R1 between the region having the highest thermal resistance, R1, and the region having the _2Q

The lowest thermal resistance, R2, is greater than 25%, preferably greater than 50%, even greater than 100% or even greater than 500%.

In one embodiment, the regions extending to the intake face and the discharge face, called "extreme regions", are regions of the same type. In this embodiment, the relative difference between the inter-bioc resistances with respect to these extreme regions is less than 30%.

In particular embodiments, several cement regions having different thermal conductivities may be aligned to form the length of the joint, and / or juxtaposed to form the width of the joint and / or superimposed to form the thickness of the joint. The dimensions of these regions can be constant or variable. With only two cured cements having different thermal conductivities, it thus becomes possible to create a joint having local inter-bioc resistances evolving along the directions of the length and the width of the joint so as to be adapted precisely to the thermal stresses undergone locally. by the filter body.

In one embodiment, the length of the regions gradually decreases from the intake face to the discharge face. In one embodiment, a multilayer structure constitutes the two longitudinal ends of the joint. Preferably, the ends of the joint are multilayer and have the same layering of layers, the lower and upper layers being made in the cured cement having the lowest thermal conductivity.

In the direction of the length of the joint, the joint may have several multilayer structures, identical or different from each other. In one embodiment, the order of the layers is identical regardless of the multilayer region considered.

The transition between two regions of different types can be abrupt, for example with an interface extending in a transverse plane, or progressive, for example with an interface inclined relative to a transverse plane. This interface can be flat, or not. In particular, it can extend in a curved or crenellated surface, or have one or more bulges.

In one embodiment, the composite seal is formed from only first and second cements for constituting one or more first and second regions, respectively, of cements having first and second second thermal conductivities, respectively, iadite first thermal conductivity being greater than at least 25%, at least 50%, at least 100%, at least 200%, or even at least 500% at iadite second thermal conductivity at any temperature between 20 ° C and 600 ° C. Said first (s) and second (s) regions may be adjacent, that is to say touching, or not. First regions may be alternately arranged with second regions in the direction of the length and / or width and / or thickness of the joint.

In one embodiment, the length and / or width and / or thickness of the first regions decreases from the intake face to the discharge face. In one embodiment, the length and / or width and / or thickness of the first (s) and / or second (s) regions is substantially constant regardless of the region considered.

In one embodiment, the first region is preferably closer to the evacuation face than the second region. .

The first region and / or the second region, preferably the first region, may extend over more than 25%, more than 30%, more than 40%, or even for one of said first and second regions, on more than 50% of the length and / or width of the joint.

The first region and / or the second region may extend to less than 3 cm, less than 2 cm, less than 1 cm from the discharge face or the intake face.

Said first and second regions may be aligned in the direction of the length and / or width of the joint.

The cured cement disposed along the longitudinal edges (which extend along the direction of the length) of the seal, particularly near the corners of the assembled filter blocks, preferably near these corners near the evacuation face or even near these last corners, may be of a different type than the one used along the longitudinal axis of the joint.

In one embodiment, the cured cement disposed along or near the longitudinal edges of the seal is of a less thermally conductive material than the cured cement disposed near the longitudinal axis of the seal. In one embodiment, the inter-bioc resistance measured along or near the longitudinal edges of the joint is greater than the inter-block resistance measured along the longitudinal axis of the joint.

Such a configuration advantageously reduces the thermal gradients in the filter blocks.

In a first preferred embodiment, said seal comprises first and second regions in first and second cured cements having first and second thermal conductivities, respectively, iadite first thermal conductivity being preferably greater than at least 25% to said second thermal conductivity at any temperature between 20 ° C and 600 ° C, the first region extending longitudinally, preferably from the intake face, preferably over 30% greater than 40%, preferably greater than 50% of the length of the joint.

Preferably said gasket fills the space between the first and second gasket faces.

Preferably, each of the first and second regions extends, at any position along its length, over the entire width of the joint and / or, more preferably, over the entire thickness of the joint, as shown in Figure 5a.

The inventors have found that this first preferred embodiment makes it possible to rapidly increase the temperature of the peripheral filter blocks. From the first moments of the regeneration, the isothermal profile is therefore substantially transverse (perpendicular to the longitudinal direction of the filter body), in particular as one approaches the discharge face of the filter body. The thermal gradients between the filter blocks, in particular near the evacuation face are advantageously reduced, and the thermomechanical stresses lessened.

Preferably, in this first preferred embodiment, the first region extends from the intake face to less than 75% of the joint length, less than 50% of the joint length, less than 30% of the joint length. length of the joint.

In this embodiment, the inventors have found that the initiation of the combustion of soot in the peripheral filter blocks disposed near the evacuation face, is fast ("low light off time). In a second preferred embodiment, the seal fills the space between the first and second seal faces and comprises, near the corners of the first and second b! Ocs in contact with the seal, regions in a said second cement, the remainder of the space between said joint faces being filled with a said first hardened cement (see for example Figures 6b and 9a).

This embodiment promotes heat transfer with the corners of the filter blocks, which is particularly advantageous during regeneration.

Detailed description of the figures

FIGS. 1 and 2 having been described in detail in the preamble of the description, reference is made to FIG.

FIG. 3 represents, in an exploded view, four filter blocks 24, 33, 34 and 35 assembled together by means of four seals 27, 36, 38 and 40 interposed each time between two filter block joint faces. .

Since the four filter blocks are substantially identical, only the filter block 24 is described below. This filter block has a generally cylindrical shape of square section delimited laterally by four external walls 23 defining the longitudinal edges of the filter block. The outer walls 23 23 ₄ have each an outer face 25 25 _4, respectively, and an ^"inner face 26 26 _4, respectively, as shown in Figure 4a.

When in contact with a joint, the outer faces are called "faces of joint".

As the four seals are substantially identical, only the seal 27 interposed between the seal face 25- of the filter block 24 and the seal face 33 is described below _. filter block 33.

As shown in FIG. 4b, the seal 27, of longitudinal axis X, extends between the joint faces 25 ₁ and 33τ so as to fill the space between these joint faces. It thus has a width "L" identical to that of the filter blocks, preferably between 10 and 30 cm, for example about 20 cm, and a width "£" identical to that of the filter blocks 24 and 33, preferably between 30 and 40 mm, for example about 36 mm. The thickness "e" of the seal is typically about 3 mm. The joint faces 33i and 25i being substantially parallel, the seal has a generally rectangular parallelepiped shape.

According to the invention, the relative deviation of the inter-block thermal resistance between two measurement locations opposite said seal is greater than 25%, the inter-block resistance being the resistance measured according to the thickness of the seal between the first and second second interior faces.

According to one embodiment of the invention, the seal 27 comprises first and second regions, 40 and 42 respectively, in first and second cured cements having different first and second thermal conductivities. In particular, the thermal conductivity of the first cured cement may be greater than that of the second hardened cement.

In the preferred embodiment of Figure 5a, the first region 40 extends to a longitudinal end of the seal, preferably to the longitudinal end extending along the inlet face 30 through which the gases enter the filter body.

The length L ₁ of the first region is less than one third of the length L of the seal.

The second region 42 is adjacent to the first region, with no empty space left between the first and second regions. In the embodiment of Figure 5a, the interface "ί" between the first region and the second region extends in a transverse plane.

The thermal conductivity is then constant according to the width and the thickness of the joint, but varies according to its length,

In the embodiment of Figure 5b, the seal comprises successively a first region 40, a second region 42, a first region 40 ', a second region 42', a first region 40 "and a second region 42". All interfaces between these regions extend in transverse planes. The lengths L), L'-ι and L "- of the first regions 40, 40 'and 40", respectively, are decreasing from the inlet face 30.

The lengths L ₂ , L ₂ and L ₂ of the second regions 42, 42 'and 42 ", respectively, are constant. In the embodiment of Figure 6a, the seal 27 has first and second regions 40 and 42 separated by an interface I extending in a longitudinal plane and perpendicular to the joint planes between which the seal 27 extends. The thermal conductivity is then constant according to the length of the joint, but varies according to its width.

It is the same in the embodiment of FIG. 6b in which a first region 40 is sandwiched laterally between second regions 42 and 42 'forming the longitudinal edges of the joint. The width t ₂ and ₂ ₂ of the second regions 42 and 42 ', respectively, are here identical, but could be different.

As shown in FIGS. 7a and 7b, the thermal conductivity can also vary according to the length, width and thickness of the seal 27. In these embodiments, the cured cements are arranged in the form of superposed layers. The number of layers depends on the part of the joint considered. It is not limiting.

In FIG. 7a, in a first portion 43 of the seal 27, two layers have been superimposed, the lower layer constitutes a first region 40 and the upper layer a second region 42. In the second portion 43 'of the joint 27, four layers of different hardened cements are superimposed.

In FIG. 7b, in a first portion 43 of the gasket 27, three layers have been superposed, the lower layer constitutes a first region 40, the intermediate layer a second region 42, and the upper layer a third region 44 a third cement having a different thermal conductivity of the first and second cements of the first and second regions. In the second part 43 'of the joint 27, four layers of different cements have been superimposed.

The thermal conductivity can also be variable both in length and in thickness, as in FIGS. 8a and 8b.

The seal of FIG. 8a comprises first, second and third regions, referenced 40, 42 and 44 respectively, having, for example, increasing thermal conductivities. The interfaces ₂ and separating the first and second regions and the second and third regions, respectively, are planar and inclined ia third region 44. The first region 40 is for example in contact with the inlet face 30. In Figure 8b, ie joint 27 comprises a first portion 45 extending from the inlet face 30 of a length ^L ₄₅ and comprising successively, in the thickness direction, a lower layer constituting a first region 40, an intermediate layer constituting a second region 42 and an upper layer constituting a first region 40 '.

The second region 42 extends beyond the first portion 45, over the entire thickness of the gasket 27, to the gas evacuation face 32.

FIG. 8c shows a variant in which "sandwich slices" 45, 45 ', 45 "and 45"' each consisting of an intermediate layer made of the second cement sandwiched between upper and lower layers, and on the other (s) cement (s) succeed, interspersed with homogeneous slices 47, 47 'and 47 "in which the second cement extends over the entire thickness of the seal 27.

The upper and lower layers of a sandwich wafer may be made of the same cement or made of different cements. The upper layers 40 ', 44', 46 'and 48' of the sandwich slices may consist of identical or different cements. It is the same for the lower layers 40, 44, 46 and 48.

In the embodiment of FIG. 8c, the lengths of the sandwich wafers are decreasing from the intake face 30 to the discharge face 32 as the length of the homogeneous wafers increases and then decreases.

Figure 8d shows a seal whose thermal conductivity is variable in the direction of the thickness and in the direction of the length, but constant in the direction of the width. Some or all of the regions 40, 42, 46, 48, 50, 52, 54, 56 and 58 are made of cured cements having different thermal conductivities. They are arranged relative to each other to obtain the desired thermal profile.

In the embodiment shown, the thicknesses of regions 42, 46, 50, 54 and 58 are identical. However, they could be different. It is the same for regions 40, 44, 48, 52 and 56.

In the embodiment of FIG. 9a, the thermal conductivity of the seal 27 varies according to the width in a first wafer 57 of length L ₅₇ , starting from the evacuation face 32. The thermal conductivity is then constant. In the first wafer 57 extending from the discharge face 32, a first region 40 is sandwiched, in the direction of the width, between two second regions 42 and 42 '. The width of these second regions 42 and 42 'is firstly constant, then preferably decreases gradually to zero, moving along the seal from the discharge face 32 to the admission face This embodiment is particularly advantageous.

In FIG. 9b, the four corner regions of the gasket 27 are made of the first cement and form second substantially parallelepipedic regions 42, 42 ', 42 "and 42"'. The remainder of the seal consists of a first region 40.

To increase the inter-block resistance near the corners of the filter blocks, a slot or bubbles, for example air, may be provided in the second regions or between the second regions and one or both joint faces. A . layer of a thermally insulative material may also be provided between a second region and one or both joint faces.

Fig. 9c shows an embodiment in which the interface I between the first and second regions has a stepped or "stepped" shape, so that the thermal conductivity of the joint 27 evolves by jumping both along fa length of the joint and according to the width of the joint.

FIG. 10a shows a configuration in which the thickness of the first region 40 changes stepwise in the width direction in a first longitudinal slice 59. In this longitudinal slice, the thermal conductivity of the seal 27 is therefore variable both in the direction of the width and in the direction of the thickness. In the adjacent longitudinal section 61, the thermal conductivity is constant.

FIG. 11a shows an embodiment in which the thickness of the first region 40 changes into a slot along the joint 27, the thermal conductivity of the joint 27 thus evolving in the direction of the length and in the direction of the thickness of the joint.

Of course, the various embodiments shown and described above can be combined. For example, Figure 12a shows an embodiment wherein the thermal conductivity evolves both in the direction of the length, in the direction of the thickness, and in the direction of the width of the joint.

Detailed description of an embodiment

An assembled filter body according to the invention can be manufactured according to a process comprising steps A) to E) above, in particular by producing a composite joint, as described below.

In step A), all conventional manufacturing processes can be implemented.

In step B), the preparation of the fresh cements can be carried out according to conventional methods by activating a particular mixture, the composition of the fresh cements being able to be chosen according to the desired inter-block resistance.

The particular mixture may in particular comprise refractory powders, a thermosetting resin, a dispersant and shaping and sintering additives.

All refractory powders conventionally used to make cured cements for refractory ceramic joints for assembling filter blocks can be used.

The refractory powders may in particular be powders based on silicon carbide and / or alumina and / or zirconia and / or silica or mixed powders.

The particular mixture can in particular comprise

- more than 10%, even more than 30%, or even more than 65%, even

still more than 80% and / or less than 90% of silicon carbide,

between 1% and 50% of alumina and

between 1% and 50% of silica,

in percentages by weight relative to the dry mineral matter and, preferably, for a total of about 100%. These ranges of alumina and silica facilitate the implementation and increase the mechanical strength after sintering. This silicon carbide range provides good chemical resistance, high heat stiffness and high thermal conductivity of the cured cement.

Preferably, refractory or ceramic powders whose median size is greater than 20 microns, preferably greater than 45 microns, are used. more preferably greater than 60 microns and / or less than 200 microns, less than 150 microns, preferably less than 120 microns, more preferably less than 100 microns.

Preferably, however, more than 5% or even more than 10% and / or less than 50% or even less than 20%, in percentages by weight relative to the dry mineral matter, of a ceramic powder is added to the particulate mixture. having a median size of less than 5 microns, preferably less than 1 micron. This improves the cohesion after drying.

The particulate mixture may also comprise more than 0.05%, preferably more than 0.1%, more preferably more than 0.2%, and / or less than 5% of a thermosetting resin, in percentages by mass. relative to the dry mineral matter.

The thermosetting resin is preferably selected from epoxy silicone, polyimide, phenolic and polyester resins.

Preferably, the thermosetting resin is soluble in water at room temperature.

Preferably, at least after activation of the particulate mixture, the thermosetting resin has a sticky character before curing. It thus facilitates the setting up of the fresh cement and its maintenance in shape before the heat treatment. It preferably has a viscosity of less than 50 Pa.s for a shear rate of 12 s ^-1 measured with the Haake VT550 viscometer.

Depending on the application, it may be advantageous for the resin to be chosen for curing at ambient temperature, for example following the addition of a catalyst, at the drying temperature or at the temperature of the heat treatment.

Advantageously, the presence of thermosetting resin improves the mechanical strength of the cured cement, especially cold.

A thermosetting resin also improves the mechanical strength of the assembled filter body, which is useful for handling the filter body, and is particularly advantageous when mounted in a metal casing.

In a preferred embodiment, the optional thermosetting resin is dissolved to reduce its viscosity, for example with water, before adding it. A resin catalyst may also be added to accelerate caking of the resin. The catalysts, for example furfuryl alcohol or urea, are selected depending on the type of resin and are well known to those skilled in the art.

Preferably, the particulate mixture is determined so that the cured cement has a lime content (CaO) of less than 0.5% by weight percent. The mechanical weakening caused by the presence of CaO is thus advantageously limited. Preferably, the cured cement does not contain CaO, otherwise in the form of possible impurities provided by the raw materials. The longevity of the cured cement, in the application to filter bodies is therefore increased.

This improvement in mechanical strength also makes it possible to limit the content of ceramic fibers, or even to dispense with ceramic fibers and / or to increase the silicon carbide content.

Preferably, the refractory powders used are molten products. The use of sintered products is also possible.

Preferably, the refractory powders represent more than 50%, preferably more than 70% of the mass of the dry mineral matter of the particulate mixture.

In one embodiment, silicon carbide, zirconia, alumina, silica and combinations of these compounds, for example mullite or muilite-zirconia, together represent more than 80%, preferably more than 95% of the mass of the dry mineral matter.

The particulate mixture may comprise between 0.1% and 2%, preferably between 0.1% and 0.5%, preferably less than 0.5% by weight of a dispersant, in percentages by weight relative to dry mineral matter.

The dispersant may for example be chosen from alkali metal polyphosphates or methacrylate derivatives. All known dispersants are conceivable, pure ionic, for example HMPNa, pure steric, for example of the sodium polymethacrylate type, or combined. The addition of a dispersant makes it possible to better distribute the fine particles, less than 50 microns in size, and thus promotes the mechanical strength of the hardened cement.

In addition to the constituents mentioned above, the particulate mixture may also comprise one or more shaping or sintering additives conventionally used, in proportions well known to those skilled in the art. 1

As examples of usable additives, mention may be made, without limitation:

organic temporary binders, such as resins, derivatives of cellulose or lignin, such as carboxymethylcellulose, dextrin, polyvinyl alcohols, polyethylene glycols or other chemical setting agents such as phosphoric acid or sodium silicate;

inorganic binders, such as silica geis or silica in colloidal form;

chemical setting agents, such as phosphoric acid or aluminum monophosphate;

sintering promoters such as titanium dioxide or magnesium hydroxide;

formers such as magnesium stearates or calcium stearates.

The particulate mixture may in particular comprise between 5 and 20% of a sol of silica and / or alumina and / or zirconia, in percentages by weight relative to the mineral matter, said sol being loaded in mass of 20 to 60% in colloids.

The shaping or sintering additives are incorporated in variable proportions, but low enough not to substantially modify the mass proportions of the different constituents of the hardened cement.

As described below, to make a cured cement of very low thermal conductivity, a particulate mixture may comprise organic fibers and / or inorganic hollow spheres and / or blowing agents. These constituents contribute to the creation of macropopres reducing the thermal conductivity. The characteristics mentioned below and relating to these constituents are "preferences" only to reduce the thermal conductivity.

In the present description and claims, there are distinguished "refractory powders" and "inorganic hollow spheres". Unless otherwise indicated, the characteristics of the refractory powders are therefore determined without taking into account any inorganic hollow spheres.

The particular mixture, especially when it is intended for the manufacture of a cement of low thermal conductivity, preferably comprises organic fibers which will be eliminated during the asbestos removal. The amount of organic fibers in the particulate mixture is preferably greater than 0.1%, preferably greater than 2%, more preferably greater than 3% and / or less than 10%, preferably less than 5%, preferably less than 4%, in percentages by weight based on the dry mineral matter of the particulate mixture.

The organic fibers may in particular be chosen from the group formed by synthetic organic fibers such as acrylic fibers or polyethylene fibers, and natural fibers, for example wood or cellulose fibers.

In a preferred embodiment, the organic fibers are cellulose fibers. Advantageously, the use of these fibers limits the toxic fumes during their elimination.

The average length of the organic fibers is preferably greater than 0.03 mm, preferably greater than 0.1 mm and / or less than 20 mm, preferably less than 10 mm.

Preferably, the average equivalent diameter of the organic fibers is greater than 5 microns, preferably greater than 10 microns, more preferably greater than 20 microns, and / or less than 200 microns, preferably less than 100 microns, preferably less than 50 microns, preferably always less than 40 microns. The addition of organic fibers is particularly advantageous for reducing the thermal conductivity of the cured cement. Indeed, these fibers can be removed by heat treatment, leaving room for macropores. It is therefore possible to easily control the pore size and their distribution within the hardened cement.

Furthermore, the use of organic fibers contributes to the formation of macropores by retaining and agglomerating the particles during water migration which occurs following the application of the fresh cement on the seal faces of the filter blocks. This agglomeration also leads to the formation of elongated pores. The mechanism of formation of these macropores is however not explained theoretically by the inventors.

By an unexplained mechanism, the presence of inorganic hollow spheres in the particulate mixture also contributes to the creation of macropores. Preferably for making a cured cement of very low thermal conductivity, the particulate mixture comprises more than 3%, preferably at least 5%, and preferably less than 50%, more preferably less than 30%, hollow spheres. inorganic, in percentage by mass on the basis of the dry mineral matter,

Preferably, the inorganic hollow spheres are spheres obtained by a process comprising a step of melting or combustion of raw materials, for example fly ash from metallurgical processes, and then, in general, a condensation step.

The inorganic hollow spheres preferably have the following chemical composition, in percentages by weight and for a total of at least 99%: between 20 and 99% of silica (Si0 ₂ ) and between 1 and 80% of alumina (A! ₂ 0 ₃ ), the remainder being impurities, especially iron oxide (Fe ₂ O ₃ ) or alkali or alkaline earth metal oxides.

Useful inorganic hollow spheres are for example sold by Enviro-spheres under the name "e-spheres". They typically comprise 60% SiO ₂ silica and 40% Al ₂ O ₃ alumina and are conventionally used to improve the rheology of paints or concretes for civil engineering, or to constitute a mineral filler in order to reduce the cost of plastic products. .

Preferably, the inorganic hollow spheres have a sphericity greater than or equal to 0.8, preferably greater than or equal to 0.9. More preferably, for more than 80%, preferably more than 90% by number, the inorganic hollow spheres are closed.

The walls of the inorganic hollow spheres are preferably solid or weakly porous. Preferably, they have a density greater than 90% of the theoretical density.

In one embodiment, the median size of the population of inorganic hollow spheres is greater than 80 microns, preferably greater than 100 microns and / or less than 160 microns, more preferably less than 140 microns. This median size is more preferably about 120 microns.

In a preferred embodiment, the inorganic hollow spheres of the particulate mixture are obtained by a mixture: a hollow spherical powder representing between 60% and 80%, preferably about 70% of the mass of the inorganic hollow spheres and having a median size greater than 110 microns, preferably greater than 120 microns, and / or less than 150 microns, preferably less than 140 microns, preferably about 30 microns, and

a hollow spherical powder representing between 20% and 40%, preferably about 30% by weight of the inorganic hollow spheres and having a median size greater than 35 microns, preferably greater than 40 microns, and / or less than 55 microns preferably less than 50 microns, preferably about 45 microns.

Porogenic agents, for example selected from cellulose derivatives, acrylic particles, graphite particles and mixtures thereof, may also be incorporated into a particulate mixture to create porosity, and thus reduce thermal conductivity.

The porosity created by the addition of porogenic agents conventionally used to date is generally heterogeneously dispersed in the hardened cement. In addition, in a transverse section plane, the equivalent pore diameter due to pore-forming agents is generally less than 200 microns.

The inventors have also found that an increase in the amount of pore-forming agents or the particle diameter of powders of pore-forming agents can lead to an increase in the pore diameter generated, but also leads to a drop in the mechanical properties of the seal, particularly detrimental to the handling of the assembled filter body. The addition of more than 10% of pore-forming agents, in volume relative to the volume of the particulate mixture, is therefore considered harmful.

Foaming the fresh cement also reduces the thermal conductivity of the corresponding hardened cement.

To manufacture a fresh cement in the form of a foam, it is preferable to add to the particulate mixture between 0.5 and 10% of a foaming agent, in weight percentage relative to the dry mineral matter. The foaming agent may be in particular a soap or a derivative of a soap. Preferably the foaming agent is temporary. Preferably, it is chosen from an ammonium derivative, for example an ammonium hydrogencarbonate, preferably an ammonium sulphate or an ammonium carbonate, an amyl acetate, a butyl acetate, or a diazo amino benzene.

Preferably, in order to reduce the thermal conductivity, in addition to the foaming agent, between 0.05 and 5% of a gelling agent is added to the particulate mixture in percent by weight relative to the dry mineral matter. The gelling agent may in particular be a hydrocolioide of animal or vegetable origin capable of gelling in a thermoreversible manner after foaming. Among the gelling agents, there may be mentioned xanthan and carrageenan.

Suitable foaming agents and gelling agents are described, for example, in F 2,873,686 or EP 1,329,439, incorporated by reference. According to these documents, a stabilizing agent can also be added.

Whatever the cement manufactured, the various constituents of the particulate mixture are preferably kneaded, for example in a planetary type mixer, intensive or otherwise, until homogenization.

Preferably, the particulate mixture is dry. Although this form is not preferred, some of the above-mentioned components, particularly the thermosetting resin or dispersant, may however be added in liquid form.

Conventionally, water is added to the particulate mixture to activate it and obtain fresh cement.

Preferably, the fresh cement has a water content of greater than 20% and / or less than 65%, in percentage by weight relative to the dry matter (mineral or not).

More preferably, the organic fibers are added after the other components, including water, have been mixed with each other.

Alternatively or in addition to the addition of organic fibers and / or inorganic hollow spheres and / or blowing agents and / or foaming agents and gelling agents to the starting feedstock, it is possible, for reduce thermal conductivity, lather the fresh cement. Foaming processes with geiification usable for this purpose are for example described in FR 2,873,686 or EP 1,329,439.

Preferably, the powders are added while the kneader is rotating and then, if necessary, the foaming agent.

To foam a fresh cement, and thus reduce the thermal conductivity of the cured cement manufactured, it can implement intensive mixing by creating a vortex promoting the entry of air into the fresh cement and / or by blowing a gas.

The efficiency of the intensive mixing can be modified by acting on the speed of rotation, the size and shape of the mixer pay and the diameter of the blade with respect to the diameter of the mixer. The mixing can be carried out at atmospheric pressure.

Insufflation of a gas makes it possible to control the macroporosity in a particularly precise manner. The insufflation of gas, in particular of air, also makes it possible to create other forms of porosity than macroporosity.

The gas injection can be carried out by means of a suitable mixer. Preferably, the gas blowing is done in a multitude of distributed injection points in order to substantially uniformly distribute the porosity in the fresh cement. Preferably, the gas is blown through orifices having a diameter greater than 0.05 mm and / or less than 5 mm. The diameter of the gas bubbles thus remains, generally, less than 200 microns. More preferably, the gas is blown during the mixing or homogenization phase following the addition of water.

Preferably, to significantly reduce the thermal conductivity, more than 0.5, preferably more than 0.7, preferably more than 1 liter of gas per liter of fresh cement and / or less than 2.5, preferably is injected. less than 2.0, more preferably less than 1.8 liters of gas per liter of fresh cement. The injection pressure, preferably constant, does not appear to be decisive. In case of manufacture of a foam, the choice of granulometry of the particles of the particulate mixture makes it possible to adjust the structural cohesion of the foam before application for grouting.

In step C), the fresh cement (s) are interposed between the filter blocks to be assembled.

The fresh cements can be applied to any surface of the facing faces of the joint. In one embodiment, however, the fresh cement only covers one part, between 10% and 90%, of this surface. The filter blocks are then unified through the fresh cements.

Fresh cements can be applied between the two filter blocks to be assembled continuously. In one embodiment, they are applied discontinuously, thereby forming, between these two filter blocks, a plurality of seal portions. Between the pads of fresh cement, spacers may be arranged to ensure a determined spacing between the two filter blocks.

The fresh cement may be arranged in such a way that the cured cement obtained adheres with the same force on the two seal faces of the filter blocks that it bonds or with a variable adhesion force in the same seal face.

In one embodiment, the fresh cements are applied so that the first seal face comprises at least a first zone of strong adhesion with the seal and a low or zero adhesion zone with this seal, said zones being disposed respectively facing a first weak or zero adhesion zone of the second seal face, and a strong adhesion zone of the second face with said seal. The first seal face may further comprise a second zone of strong adhesion with the seal disposed opposite a second zone of weak or no adhesion of the second seal face. FR 2,853,255 describes a method for making such joints.

Preferably, the amount of fresh cements is determined so that the thickness of the seal is less than 4 mm, preferably less than 3 mm.

As soon as the fresh cements are put into place, any organic fibers are oriented substantially parallel to the joint faces between which they have been arranged.

In step D), after placing between the seal faces of the filter blocks, the fresh cements are dried, preferably at a temperature of between 100 ° C. and 200 ° C., preferably under air or humidity-controlled atmosphere. preferably so that the residual moisture is between 0 and 20%. Preferably, the drying time is between a few seconds and 10 hours, in particular depending on the size of the joint and the ceramic body assembled.

The filtering biocons are preferably held in position in order to prevent expansion of the fresh cements during curing, for example by setting filter blocks with spacers, as described for example in EP 1 435 348, and strapping of the filter blocks thus set.

In step E), heat treatment at a temperature sufficient to remove any particles and / or organic fibers can then be performed to eliminate them and thus create macroporosity, advantageous for reducing the thermal conductivity.

The heat treatment preferably comprises debinding and / or baking, preferably under an oxidizing atmosphere, preferably at atmospheric pressure, at a temperature between 400 ° C and 1200 ° C. Debinding leads to the polymerization of the optional thermosetting resin, to the hardening of the inorganic binder and to the elimination of any organic components. Baking is generally accompanied by an improvement in mechanical strength.

The duration of the baking, preferably between 1 and 20 hours of cold cold, varies depending on the materials but also the size and shape of the joints.

The cooking can also be carried out in situ. In particular, in the case of filter bodies for motor vehicle filters, the filter bodies can be installed in the motor vehicle before removal of the organic components, the regeneration temperature being sufficient to eliminate them. For example, the combustion temperature of the cellulose fibers is about 200 ° C while the regeneration temperature of the filter bodies is typically about 500 ° C or higher.

The assembled body can then be machined and possibly coated with a ceramic peripheral coating, as described, for example, in EP 142,619 or EP 1,632,657. This peripheral coating can be manufactured using fresh cements such as those described above. .

The assembled body can still undergo additional heat treatment consolidation, or sintering. The sintering temperature is preferably greater than 1000 ° C, but should not lead to degradation of the filter blocks. When a cured cement has been manufactured so as to create macropores, as described above, it may have macropores having a relatively regular shape, resembling crushed bubbles between the joint faces, or being very irregular, when they result from a foaming of the fresh cement in particular. The total porosity of such a cured cement, described here as "macroporous", may be greater than 10%, preferably greater than 30% and / or less than 90%, preferably less than 85%.

The pore size distribution in a macroporous hardened cement is preferably of the bimodal or even multimodal type. In particular, the macroporous hardened cement may comprise micropores, of equivalent diameter, in a transverse sectional plane, typically less than 50 microns. Preferably the distribution of the equivalent diameters of the pores comprises a first mode centered on an equivalent diameter of between 200 microns and 40 mm (macropores) and a second mode centered on an equivalent diameter of between 1 micron and 50 microns (micropores). This distribution may be such that said first and second modes are the main modes.

The presence of micropores improves the thermomechanical resistance while increasing the thermal insulation. The presence of micropores also contributes to reducing the density of hardened cement and therefore the mass of the filter body, which is particularly advantageous for applications in which the filter body is loaded onto a motor vehicle. In a cross-sectional plane, however, the area of the micropores preferably represents less than 20% of the total area.

Potential macropores can be interconnected, for example in a foam-like structure.

In one embodiment, the cured cement comprises macropores which, for more than 50%, preferably more than 80% or even more than 90% by number, have an elongated shape, that is to say such that the ratio between their length and their width is greater than 2, the length and the width being measured in a transverse sectional plane.

Preferably, for more than 50%, preferably more than 80%, or more than 90% by number, its macropores extend substantially parallel to the seal faces. More preferably more than 50%, preferably more than _80%> or even more than 90% by number, the macropores extend substantially along the entire the thickness of the joint. They thus delimit between them "bridges" of material which connect the faces of seal of the filtering blocks opposite.

All the seals of the filter body may be composite, or even be made with the same cements, possibly arranged identically or similar, regardless of the joint considered. ■

The following adaptations are also possible to optimize the weakening of the thermomechanical stresses that can be generated:

- At least two seals different in composition and / or structure and / or thickness.

- At least one seal has anisotropic elastic properties.

- At least one seal comprises a silica fabric impregnated with a cement.

The thicknesses of at least two seals differ in a ratio of at least two.

- At least one seal has a slot.

Said slot is substantially adjacent to the intake face or the discharge face.

Said slot opens on one of the inlet and outlet faces of said filter body.

Said slot is formed in a plane substantially parallel to the joint faces of said filter blocks assembled by said seal.

- The length or depth of said slot is between 0, 1 and 0.9 times the length of the filter body.

Said slot is filled, at least in part, with a filling material which does not adhere to the filter blocks or cement (s) of said joint in which it is formed.

- Said filling material is boron nitride or silica. Examples

All the filter blocks of the examples were synthesized according to the following method: In a kneader, silicon carbide powders, a polyethylene-type pore-blowing agent and an organic binder of the methyelose type were mixed. Water is added and kneaded to obtain a homogeneous paste whose plasticity allows extrusion through a die. This paste is then extruded through a die adapted to the production of monolithic honeycomb preforms of square section 36 mm wide, of the "wave" (or "wavy") type, such as those described in connection with FIG. 3 of the application WO 05/016491, according to a section transversely, the corrugation of the walls has an asymmetry rate, as defined in WO 05/016491, equal to 7%.

The preforms are then dried by microwave for a time sufficient to bring the water content not chemically bound to less than 1%. mass.

The channels are then alternately closed on the upstream face and on the downstream face of the preforms according to known techniques, for example as described in the application WO 2004/065088.

The preforms are then fired in a cycle having a rise in temperature of 20 ° C / hour to a temperature of the order of 2200 ° C, followed by holding at this temperature for 2 hours.

A series of substantially identical silicon carbide filter blocks is thus obtained, the characteristics of which are given in the following Table 1;

Table 1

According to the teaching of the patent application EP 816 065, 16 filter blocks are then assembled together by gluing. The cement is applied without pressure.

First and second fresh cements having the following compositions J1 and J2 were prepared:

Table 2

The calcined alumina powder CL370, with a median diameter of approximately 5 microns, is marketed by Almatis.

Silica fume of type 971 U is supplied by Elkem.

The temporary binder and plasticizer is of the cellulose type.

The hollow spheres are marketed by Enviro-spheres under the name "spheres" and have a typical chemical composition comprising 60% SiO ₂ and 40% Al ₂ O ₃ and a median size of the order of 100 μηι.

SiC powders are supplied by Saint-Gobain Materials.

The hardened cements J 1 ¹ and J 2 'obtained from the fresh cements J1 and J2 have close expansion coefficients, of the order of 5.0 × 10 ^-6 ° C ^-1 between 20 and 000 ° C., which avoids the the appearance of damaging thermomechanical stresses when used in a composite joint.

In all the examples, the cements were uniformly applied so as to obtain a joint with an average thickness of about 2 mm filling the entire gap between the joint faces. In the case of the example Compl (comparative), the filter blocks are assembled by applying a single layer of fresh cement J1.

In the case of Example 1, according to the invention, the filter blocks were assembled by applying, over the entire width of the joint faces, a layer of fresh cement J1 extending over the first third of the length of the faces seal (from the intake face), and a cement layer J2 extending over the last two thirds, in a manner similar to the embodiment shown in Figure 5a.

In the case of Example 2 according to the invention, a layer of fresh cement J1 was deposited over the entire length and over the entire width of the joint faces, except along the longitudinal edges of the filter blocks over a length of one third of the length of the seal faces from the discharge face. In this area, masks were placed so as to reserve strips about 10mm wide for the second fresh cement J2. After drying at 100 ° C for one hour, the masks were removed and the free spots were filled by removing the masks with fresh cement J2 in a manner similar to the embodiment shown in Figure 9a.

The assemblies of the filter blocks are then dried under air at 100 ° C. for 1 hour and then fired at 1000 ° C. under air for 1 hour in order to obtain filter bodies. They are then machined in order to obtain filter bodies of circular cross-section. 144 mm in diameter and 203 mm in length.

The specific heat resistance can be determined according to the following method:

1) Before assembly of the filter blocks, their thermal conductivity is calculated from a measurement of the diffusivity according to the recommendation EN821-2, as a function of the temperature, by the laser flash method, of the heat capacity measured by differential calorimetry and apparent density.

2) Samples such as that shown in Figure 13 are cut in the filter bodies. The height of each sample corresponds to the height of two filter blocks and an assembly cement seal.

The length and width of the samples are determined in such a way that the severed portion of the seal (separating the two filter block portions from the sample) is homogeneous, i.e. the composition and structure of the seal is substantially identical at every point of this part of the joint. The line D, perpendicularly intersecting the upper face of the sample, at its center, defines the measurement location P _s in the filter body.

The spacing between two measurement locations P, and P _j through a seal corresponds to the minimum distance between the two straight lines D ₍ and D _j defining these locations in the filter body.

For example 1 according to the invention, the length and the width of the samples were 36 mm, corresponding to the width of a filter block. A first sample was taken near the longitudinal axis of the seal and the intake face (i.e., in the first third of the seal from the intake face). A second sample was taken near the longitudinal axis of the seal and the discharge face. The locations of the samples of these first and second samples, corresponding to measurement locations, have been referenced Pi and P ₂ , respectively, in FIG. 5a.

For example 2 according to the invention, the first sample was taken near the longitudinal axis of the seal and the intake face. This sample thus included two parts of filter blocks of the same height joined by cement J1 '. The length and width of the sample were 16 mm. The second sample was taken near the discharge face and near a longitudinal edge of the seal so as to comprise two parts of filter blocks of the same height joined by cement J2 '. The length and width of the second sample were 10 mm. The locations of the samples of these first and second samples, corresponding to measurement locations, have been referenced Pi and P ₂ , respectively, in FIG. 9a.

In the case of comparative example Compl, three samples were taken. The length and width of the first two samples were 36 mm, those of the third sample were 10 mm. The first sample was taken near the longitudinal axis of the seal and the intake face. The second sample was taken near the longitudinal axis of the seal and the discharge face. Finally, the third sample was taken near a longitudinal edge of the seal and the discharge face at a location similar to that in which the second sample P ₂ 'was taken from example 2 according to the invention. The locations of the samples of these first, second and third samples, corresponding to measurement locations, have been referenced P-, ^' , P ₂ ^" and P ₃ ", respectively, in FIG. 4a. 3) As shown in FIG. 13, to evaluate the inter-block resistance of a sample 100, this sample is placed on a heated plate 102 at a temperature of 400 ° C., the seal being parallel to the heated plate. A cooled plate 104 is then placed on the sample to cool its upper face to 25 ° C. The assembly is isolated on all its free faces, that is to say on all the faces not in contact with the heated plate 102 or the cooled plate 104, so as to avoid as much as possible the lateral heat losses and so that the heat produced by the heated plate propagates in the thickness of the joint. The thermally insulating material used for this purpose is not shown in FIG. 13 to improve clarity.

Thermocoupts 106 and 108 are disposed in contact with each of the inner faces of the outer walls of the filter blocks in contact with the seal. Thermocouples 1 10 and 1 12 are arranged in contact with the inner faces of the outer walls of the filter blocks in contact with the heated plate 102 and the cooled plate 104, respectively.

The temperatures measured by the thermocouples 1 10, 108, 06 and 1 12, respectively, are denoted by ΤΊ-Τ4.

We call "average temperature" of the lower filter block (T ₁ + T ₂ ) / 2. The heat flux per unit area of joint is calculated, according to the conventional laws of thermal conduction, by multiplying this average temperature by the thermal conductivity of this filter block at this average temperature (as determined in step 1)), then dividing the result obtained by the distance between the thermocouples used to measure ΤΊ and T ₂ . The heat flux is expressed in W / m ² .

In the same way, the measurement of T ₃ and T makes it possible to measure the heat flux for the upper filter block.

The relative difference between the heat flow values of the two filter blocks must be less than 7%. If this is not the case, the lateral thermal insulation or the contact between the samples and the plates should be improved or the sample checked for damage during preparation.

4) The inter-block resistance is obtained by dividing the temperature difference T ₂ -T ₃ by the arithmetic average of the two thermal flows measured in step 4). The inter-block resistance is expressed in .nr W. It particularly represents the capacity of the assembly formed by the seal and the two outer walls in contact with the seal to transmit the heat. It takes into account the specific contact resistance at the interface between the seal and the filter blocks. This inter-block resistance is independent of the surface of the joint faces covered by the joint, but increases as the joint thickness increases.

To evaluate the interest of a variation of the inter-block resistance, the filter bodies of examples Compl, 1 and 2 are mounted on an exhaust line of a 2.0 L direct injection diesel engine running at full power ( 4000 rpm) for 30 minutes. They are then disassembled and weighed to determine their initial mass.

The filter bodies are then reassembled on engine bench operating at a speed of 3000 rpm and a torque of 50 Nm for different durations in order to obtain soot loads of 5, 6 and 7 g / liter (in body volume). filter). The filter bodies thus loaded are reassembled on the line to undergo a severe regeneration thus defined after stabilization at an engine speed of 1700 revolutions / minute for a torque of 95 Nm for 2 minutes, a post-injection is performed with 70 ° phasing for a post-injection flow rate of 18 mm ³ / stroke. When the pressure loss decreases for at least 4 seconds, indicating the initiation of combustion, the engine speed is lowered to 1050 rpm for a torque of 40 Nm for 5 minutes to accelerate the combustion of soot . The filter body is then subjected to an engine speed of 4000 rpm for 30 minutes to remove the remaining soot.

Thermocouples were introduced through the inlet channels so as to be positioned in close proximity to the discharge face. Thermocouples were introduced into an inlet channel in the center (extending substantially along the axis of the filter block) of the central filter block of the filter body and in an inlet channel forming a longitudinal edge of this filter block (channel angle). The maximum temperature difference between these two thermocouples was divided by the distance between the thermocouples.

Table 3 below shows, for the various examples, the following properties:

the nature of the grouting cement of the tested sample (J 1 or J 2);

the values of inter-block resistance;

the maximum temperature gradients between a central input channel and an angle input channel of the central filter block.

Table 3

The filter bodies according to the invention have measurement locations aligned along the length (Example 1) or the width (Example 2), the inter-block resistances differ by more than 25% between these measurement locations.

The weakest thermal gradients are obtained with the filter body of Example 1. Example 2 also shows a lower gradient than that of the comparative example. As a result, the invention improves the thermomechanical behavior of a filter body.

The preceding description makes it possible to illustrate a few possible embodiments of the invention. It is understood that this description is however not limiting and that the skilled person is able to achieve other variants of the invention without departing from its scope.

Claims

A ceramic filter body having a plurality of filter blocks (24,33,34,35), each filter block comprising a plurality of adjacent channels (14) extending between intake (30) and discharge faces ( 32) and separated by filtering walls, said channels being closed by upstream and downstream plugs arranged alternately in the vicinity of the intake face and the discharge face,

first and second filter blocks having first and second outer walls, respectively, defining first and second inner faces, respectively, and first and second outer faces, respectively,

said first and second outer faces, called "first and second seal faces"(25; 33 ₁ ), respectively, being glued together to one another via a seal (27),

characterized in that said first and second outer walls and said gasket are configured such that the relative difference in thermal inter-block resistance between first and second measurement locations opposite said gasket is greater than 25%, the inter resistance -blocks being the specific thermal resistance measured according to the thickness of the joint between the first and second inner faces.

2. Filter body according to the preceding claim, said relative distance being greater than 100%.

3. Filter body according to the preceding claim, said relative distance being greater than 200%.

4. A body according to any one of the preceding claims, wherein said seal (27) comprises first (40; 40 '; 40 "; 40"') and second (42; 42 '; 42 "; 42") regions. cements having first and second thermal conductivities, respectively, said first thermal conductivity being at least 25% greater than said second thermal conductivity at any temperature between 20 ° C and 600 ° C.

5. Body according to the preceding claim, wherein the seal fills the space between the first and second seal faces and comprises a first region extending longitudinally from the intake face over a length. 30% greater than the length of the joint, the thermal conductivity being constant over the thickness at any point of the joint.

6. Body according to any one of the preceding claims, wherein the first and second filter blocks having a thermal conductivity of less than 10 W / m.

7. Body according to any one of the preceding claims, wherein the composition of said seal (27) is homogeneous in its thickness and heterogeneous in the direction of its length or the direction of its width.

A body according to any one of the preceding claims, wherein the porosity of said seal (27) at the first measurement location is different from the porosity of said seal at the second measurement location.

9. Filter body according to the preceding claim, wherein, at one of said first and second measurement locations, the seal has pores having an equivalent diameter of between 200 μηι and 20 mm in an amount such that, in a cross sectional plane the total area occupied by said pores represents more than 15% of the total area observed.

10. Body according to any one of the preceding claims, wherein the seal has areas of lower adhesion or non-adhesion, on one of said first and second seal faces or both said first and second seal faces.

11. Body according to any of claims 1 to 9, wherein the seal adheres to all of said first and second seal faces.

Body according to any one of the preceding claims, said first and second measuring locations being aligned in the direction of the width of the joint.

13. Body according to the preceding claim, the inter-block resistance being further variable in the direction of the length of the seal.

The body according to any one of the preceding claims, wherein said first and second measurement locations are located at near the longitudinal axis (X) of the seal and near a longitudinal edge of the joint, respectively.

15. Body according to the preceding claim, the inter-block resistance at the measurement location located in the vicinity of said longitudinal axis being greater than that measured measurement replacement localized near said longitudinal edge of the seal.

The body of any preceding claim, wherein one of said first and second measurement locations is located near corners of said first and second filter blocks.

17. Body according to the preceding claim, wherein said interblock resistor facing said seal is higher near corners desdiis first and second filter blocks near said discharge face (32) and lower at any other measurement location facing said seal. 8. Body according to any one of the preceding claims, wherein the seal fills the space between said first and second seal faces.

The body of any preceding claim, said first thermal conductivity being at least 200% greater than said second thermal conductivity at any temperature between 20 ° C and 600 ° C.

20. Body according to any one of the preceding claims, wherein the seal adheres at any point where it is in contact with said first and second seal faces.

21. A method of manufacturing an assembled filter body, comprising the following successive steps:

A) manufacture of at least two filter blocks;

B) preparation of one or more fresh cements;

C) applying the fresh cement (s) between two faces of joint defined by external walls of said filter blocks;

E) optionally, heat treatment,

according to which one adjusts

the local thickness of the joint and / or the outer walls; and or the local composition of the joint and / or the outer walls; and or

the granulometric distribution of the refractory powder used to make the seal and / or the outer walls; and or

the local porosity of the seal and / or the outer walls; and or

the local adhesiveness of the gasket on the gasket faces;

so as to obtain, after step D) or step E), an assembled body according to any one of the preceding claims. Method according to the preceding claim, wherein step B) comprises the following operations:

b) preparing, from a second feedstock, a second fresh cement capable of forming, after curing, a second cured cement having a second thermal conductivity, said first thermal conductivity being greater by at least 25% said second thermal conductivity at any temperature between 20 ° C and 600 ° C;

process according to which step b) of preparing the second fresh cement comprises:

an addition, in said second starting feedstock, of organic fibers, in an amount of between 0.1% and 10%, as a percentage by weight on the basis of the dry mineral matter and / or

adding, in said second feedstock, organic and / or hollow particles in an amount of greater than 5%, in weight percent based on the dry mineral matter; and or

injecting a gas into said second fresh cement; and or

an addition, in said second feedstock, of a foaming agent in an amount of between 0.5 and 10%, and a gelling agent in an amount of between 0.05 and 5%, in percentages by weight on the base of the dry mineral matter, and / or

adding, in said second feedstock, blowing agents. A method according to any one of the two immediately preceding claims, wherein the filter blocks to be joined are immobilized during step D).