CN101534921A - 陶瓷蜂窝过滤器及其制造方法 - Google Patents
陶瓷蜂窝过滤器及其制造方法 Download PDFInfo
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Abstract
一种陶瓷蜂窝过滤器,是具有有着被多孔质的隔壁分开的多个流路的蜂窝结构体,和交互地被设于所述流路的废气流入侧或废气流出侧的封闭部的陶瓷蜂窝过滤器,所述流出侧封闭部的气孔率为65%以下,且所述流出侧封闭部的上游侧端面的表面粗糙度Ra为13~50μm。
Description
技术领域
本发明涉及净化从柴油发动机等排出的含有粒状物质的废气所使用的陶瓷蜂窝过滤器及其制造方法。
背景技术
在柴油发动机的废气中,含有由碳质构成的煤和高沸点碳氢化合物所成分构成的SOF成分(Soluble Organic Fraction:可溶性有机成分)为主成分PM(Particulate Matter:粒状物质),若其被排放到大气中,则有可能对人体和环境造成不利影响。因此,历来进行的是在柴油发动机的排气管的途中装配用于捕集PM的陶瓷蜂窝过滤器(以下将陶瓷蜂蜜过滤器称称为“蜂窝过滤器”)。捕集并净化废气中的PM的蜂窝过滤器的一例显示在图2(a)及图2(b)中。蜂窝过滤器10由如下构成:陶瓷蜂窝结构体,其由形成多个流出侧封闭流路3和流入侧封闭流路4的多孔质隔壁2和外周壁1构成;上游侧封闭部6a和下游侧封闭部6c,其将流出侧封闭流路3和流入侧封闭流路4的废气流入侧端面8和废气流出侧端面9方格样地交互封闭。蜂窝的所述外周壁1被金属网或陶瓷制的垫子等所形成的夹持构件(未图示)夹持而使之在使用中无法移动,并被配置在金属制收纳容器(未图示)内。
在蜂窝过滤器10中,废气的净化以如下方式进行。如虚线箭头所示,废气从开口于废气流入侧端面8的流出侧封闭流路3流入。然后在通过隔壁2时,详细地说是在通过存在于隔壁2的表面及内部的由相互连通的细孔形成的连通孔时,废气中所含的PM被捕集。得到净化的废气从开口于废气流出侧端面9的流入侧封闭流路4流出,被排放到大气中。
若PM继续被隔壁2捕集,则隔壁的表面和内部的连通孔被PM堵塞,废气通过蜂窝过滤器时的压力损失增加。因此,需要在压力损失达到规定值之前,燃烧除去PM使蜂窝过滤器再生。但是,在被捕集的PM量多时,会发生燃烧热导致蜂窝过滤器熔损的问题。该熔损容易在PM的堆积容易发生的蜂窝过滤器的废气流出侧端面9的附近发生,特别是容易发生在其轴向垂直面的中央部。
在特开2005—2972号中公开了通过在废气流出侧的端部设置热容量比其他部位大的吸热部而可以吸收分散所述燃烧热的蜂窝过滤器。具体地说,通过加厚废气流出侧的隔壁、减小废气流出侧的隔壁的气孔率、或者加长流出侧封闭部,形成热容量大的吸热部,使PM的燃烧惹分散吸收。但是,为了加厚隔壁的一部分或者部分地减小隔壁的气孔率需要新的制造工序,成本负荷增大,并且,防止蜂窝过滤器的熔损的效果不充分。另外,在加长流出侧封闭部时,虽然确实全体的热容量变大,但是PM的燃烧若不能被流出侧封闭部全体有效地吸收,不能得到充分的熔损防止效果。
在特开2000—279729号、特开平10—52618号以及WO2004/113252号中记载有控制隔壁的气孔率、气孔径以及表面粗糙度的技术。在特开2000—279729号中记载了使隔壁气孔率变化时的平均气孔径和隔壁表面粗糙度Rz(10点平均粗糙度)的关系,气孔率或气孔径越大隔壁的表面粗糙度越大。在特开平10—52618号中作为制造隔壁表面的粗糙度(Rz)为30μm以上和/或开气孔径为20μm以上的蜂窝结构体的方法,公开了用导电性材料形成蜂窝成形体,在非氧化性气氛下,在蜂窝贯通孔的轴向通电,通过单元壁的自身发热进行烧结的方法。该方法因为优先使自由能大的表面附近的晶粒烧结,所以通过此时的粒成长能够使单元壁的表面粗糙度变粗。在WO2004/113252号中记载有通过增大用于挤压成形的模具的狭缝表面的表面粗糙度Ra,能够增大隔壁的表面粗糙度Ra。但是,将特开2000—279729号、特开平10—52618号以及WO2004/113252号中记载的控制隔壁的气孔率以及表面粗糙度的技术适用于封闭部是困难的。
发明内容
因此本发明的目的在于,提供一种蜂窝过滤器及其制造方法,其与现有的蜂窝过滤器相比,PM的燃烧热更有效地被流出侧封闭部吸收,能够降低熔损的发生。
鉴于上述目的而锐意研究的结果是,本发明者等发现,通过使流出侧封闭部的气孔率低,且加大流出侧封闭部的上游侧端面的粗糙度,PM的燃烧热会被有效地吸收,能够显著降低熔损的发生,从而达成本发明。
即,本发明的蜂窝过滤器,是具有有着被多孔质的隔壁分开的多个流路的蜂窝结构体,和交互地被设于所述流路的废气流入侧或废气流出侧的封闭部的陶瓷蜂窝过滤器,其中,所述流出侧封闭部的气孔率为65%以下,且所述流出侧封闭部的上游侧端面的表面粗糙度Ra为13~50μm。
所述流出侧封闭部的气孔率优选为45%以下。优选所述流出侧封闭部的流路方向长度是所述流出侧封闭部的宽度的6~30倍。所述流出侧封闭部的流路方向长度优选为流路垂直方向截面的中心部比外周部长。
制造具有有着被多孔质的隔壁分开的多个流路的蜂窝结构体,和交互地被设于所述流路的废气流入侧或废气流出侧的封闭部,所述流出侧封闭部的气孔率为65%以下,且所述流出侧封闭部的上游侧端面的表面粗糙度Ra为13μm以上的陶瓷蜂窝过滤器的本发明的方法,具有如下工序:以具有平均粒径为5μm以下的陶瓷粉的浆体形成流出侧封闭部后,在该封闭部的上游侧端面堆积具有10~200μm的平均粒径的陶瓷粉,之后进行烧成而成为一体。
本发明的蜂窝过滤器与现有的蜂窝过滤器相比,能够降低熔损的发生,因此适合作为用于柴油发动机等的过滤器。根据本发明的制造方法,能够以很少的工序容易地制造蜂窝过滤器,该蜂窝过滤器流出侧封闭部的热容量大,且能够有效地吸收PM的燃烧热。
附图说明
图1是表示本发明的蜂窝过滤器的流出侧封闭部附近的模式剖面图。
图2(a)是垂直于流路的表示蜂窝过滤器的一例的模式剖面图。
图2(b)是平行于流路的表示蜂窝过滤器的一例的模式剖面图。
图3是表示现有的蜂窝过滤器的流出侧封闭部附近的模式剖面图。
图4是平行于流路地表示实施例19的蜂窝过滤器的一例的模式剖面图。
具体实施方式
(1)流出侧封闭部的表面粗糙度及气孔率
如图3所示,现有的蜂窝过滤器的流出侧封闭部6c的内部大量存在气孔63,在流出侧封闭部6c的上游侧端面61具有所述气孔露出到表面而形成的凹凸。该凹凸越大,即流出侧封闭部6c的上游侧端面61的粗糙度越大,则流出侧封闭流路3内部和流出侧封闭部6c的接触面积就越大,从而使PM的燃烧热充分流入到流出侧封闭部6c。本发明的蜂窝过滤器,如图1所示,通过规定所述上游侧端面61的表面粗糙度Ra为13μm以上,从而流出侧封闭部6c的上游侧端面61的表面积变大,使PM的燃烧热充分流入到流出侧封闭部6c。表面粗糙度Ra优选为22μm以上,更优选30μm以上,最优选40μm以上。另一方面,若表面粗糙度Ra过大,则上游侧端面61的一部分有可能缺落。因此表面粗糙度Ra为50μm以下。
若流入流出侧封闭部6c的PM的燃烧热没有迅速流到流出侧封闭部6c的下游侧,则流出侧封闭部6c的上游侧端面61的温度过度上升而发生熔损。因此,优选流出侧封闭部6c的热容量和热传导率尽可能大。为此,有效的是减小流出侧封闭部6c的气孔率,本发明的蜂窝过滤器需要气孔率65%以下。如图1的模式图所示,通过加大流出侧封闭部6c的表面粗糙度Ra,并且使流出侧封闭部6c的气孔率为65%以下,能够使流出侧封闭部6c的热容量和热传导率提高,并能够更有效率地吸收释放PM的燃烧热。流出侧封闭部6c的气孔率优选为45%以下。
在形成流出侧封闭部6c时,使流出侧封闭部形成用陶瓷原料最密填充而使粒度分布最优化,或使成形助剂和水分等的调配比最优化,由此能够减小流出侧封闭部6c的气孔率。流出侧封闭部形成用陶瓷的材料的粒度优选为平均粒径在10μm以下,更优选5μm以下。还有,上述所谓气孔率,是与流路方向平行地切断流出侧封闭部6c的截面中的气孔的面积比例。
如上述,本发明虽然以流出侧封闭部6c的气孔率小,其上游侧端面61的表面粗糙度Ra大为特征,为了形成具有65%以下的气孔率,且上游侧端面61具有13μm以上的表面粗糙度Ra的流出侧封闭部6c,例如可以运用如下方法:(a)在形成流出侧封闭部6c后,将捆扎金属制的细线的金属线由废气流出侧端面8插入流出侧封闭流路3,对流出侧封闭部6c的上游侧端面61时行压印(stamp)的方法;(b)先以粒度小的(例如平均粒径为5μm以下)陶瓷粉等形成流出侧封闭部后,再使粒度大的(例如平均粒径为10μm以上)陶瓷粉等堆积在先形成的流出侧封闭部的上游侧端面,进行烧成而使之一体化。
在上述(b)的方法中,通过使用由粒度小的陶瓷粉构成的浆体形成气孔率小的出侧封闭部,在其上游侧端面使粒度大的陶瓷粉堆积,由此能够形成表示粗糙度大的表层。所述粒度大的陶瓷粉等的平均粒径优选为15μm以上,更优选为20μm以上。若堆积的陶瓷粉等的粒径过大,则表面粗糙度Ra变得过大,上游侧端面61的强度变弱,端面的一部分有可能缺落。因此陶瓷粉等的平均粒径为200μm以下。平均粒径优选为150μm以下。通过在所述粒度大的陶瓷粉等之中混合碳粉等造孔材,能够进一步加大表面粗糙度Ra。为了使表面表面粗糙度Ra为13μm以上,优选所述表层的厚度为25μm以上。为了使PM的燃烧热容量易传导到流出侧封闭部的下游侧,优选所述表层的厚度为2mm以下。
流出侧封闭部6c的材质能够适用现有的蜂窝过滤器所使用的,例如堇青石、氧化铝、莫来石、氮化硅、碳化硅、LAS、钛酸铝、二氧化钛、氧化锆、氮化铝之中的至少1种,优选使用以2种以上为主结晶的陶瓷材料。其中,以堇青石为主结晶的陶瓷蜂窝过滤器由于廉价而耐热性、耐腐蚀性优异,另外为低热膨胀,所以最为优选。
(2)流出侧封闭部的长度
因为流出侧封闭部6c越长热容量越大,所以使PM的燃烧热有效地被流出封闭部6c吸收。为了得到充分的热容量,优选流出侧封闭部6c的流路方向(图1的左右方向)长度是流出侧封闭部6c的宽度(图1的上下方向)的6倍以上。即,例如流出侧封闭部6c的宽度为1.2mm时,优选流出侧封闭部6c的流出封闭部6c的流路方向长度为7.2mm以上,例如流出侧封闭部6c的宽度为1.5mm时,优选流出侧封闭部6c的流路方向长度为9mm以上。流出侧封闭部6c的宽度越大,流出侧封闭流路3的流路垂直方向截面的面积就越大,因此PM的捕集量越多,再生蜂窝过滤器时的PM的燃烧热就越大。因此在本发明中,流出侧封闭部6c的流路方向长度并不是规定为例如7.2mm这样的绝对长度,而是以流出侧封闭部6c的宽度的倍率规定。
优选即使在蜂窝过滤器冷的状态下起动发动机时,蜂窝过滤器的温度仍迅速地上升,在PM的堆积增加之前PM的燃烧就已开始的。因此,如果是熔损没有发生的程度,则流出侧封闭部6c的热容量不需要过大,优选流出侧封闭部6c的流路长度是流出侧封闭部的宽度的30倍以下。通过如此设定流出侧封闭部6c的流路方向长度的上限,能够防止隔壁2的总面积(过滤器在效面积)变得过窄,也能够有助于蜂窝过滤器的压力损失的降低。更优选流出侧封闭部6c的流路方向长度为流出侧封闭部的宽度的25倍以下。
在此,上述所谓流出侧封闭部6c的流路方向长度,是指在流出侧封闭部6c的上游侧端面61之内,从最接近蜂窝过滤器的废气流入侧端面8的部分,到流出侧封闭部6c的下游侧端面62之内,距蜂窝过滤器的废流入侧端面8最远的部分的流路方向的距离。
另外,特别是为了加大熔损不易发生的蜂窝过滤器的流路垂直方向的中心部的流出侧封闭部的热容量,优选在流路方向加长中心部的流出侧封闭部,使之比流路垂直方向截面的外周部长。为了加长中心部的流出侧封闭部而仍使中心部和外周部的过滤器有效面积相同,蜂窝过滤器如图4所示,优选使废气流出侧端面9为凸状。
(3)流出侧封闭部内部的气孔结构
如上述若使流出侧封闭部6c的流路长度为流出侧封闭部6c的宽度的6倍以上,加大流出侧封闭部6c的热容量时,在流出侧封闭部6c的内部仍存在大的气孔,则上游侧的热量将难以传导到该大的气孔的下游侧。特别是若在流出侧封闭部6c的上游侧端面61的附近存在大的气孔,则加长流出侧封闭部6c而增大热容量的效果丧失。因此,在延流路方向切断流出侧封闭部6c的截面中,优选从流出侧封闭部6c的上游侧端面61至少到流出侧封闭部6c的宽度的4倍的距离内,不存在面积为0.3mm2以上的气孔,更优选面积为0.15mm2以上的气孔的面积低于30%。上述这种大的气孔,容易在将作为孔封闭部的浆体插入流路而形成流出侧封闭部6c时,浆体中的水分被隔壁2吸收,浆体的容积急剧减少时作为缩孔而形成。因此,调整浆体的配合必须使水分充足,或者通过预先对隔壁2补充水分等方法,能够防止流出侧封闭部6c内部形成大的气孔。另外,对插入到流路的浆体进行干燥时,若使流出侧封闭部6c的下游侧端面62保持在上游侧端面61上方,则特别是在上游侧端面61附近难以形成大的气孔。
(4)催化剂的负载
也能够使隔壁2负载催化剂。通过负载催化剂,即使在废气比较低温的情况下PM也会燃烧,向隔壁表面堆积的PM的量减少,难以引起熔损的发生。
通过以下的实施例更详细地说明本发明,但本发明不受其限定。
实施例1
(蜂窝过滤器的制作)
图2所示的蜂窝过滤器10通过公知的方法制造。首先,使用高岭土、滑石、硅石、氧化铝和氢氧化铝的粉末,调整成含有50质量%的SiO2、35质量%的Al2O3和15质量%的MgO的堇青石生成原料粉末(其含量可以在SiO2:48~52质量%、Al2O3:33~37质量%和MgO:12~15质量%的范围调节。)。其中作为粘合剂添加甲基纤维素和羟丙基甲基纤维素,作为润滑材、造孔剂添加发泡树脂,进行充分干式混合后,添加水,进行充分的混匀,制造可塑化的陶瓷坯土。将该坯土压出成形并切断,得到具有蜂窝结构的成形体。干燥并烧成该成形体,得到堇青石质陶瓷蜂窝结构体。该陶瓷蜂窝结构体,外径为150mm,长202mm,隔壁的厚度为0.3mm以入隔壁间距为1.5mm。
其次以公知的方法,如图2所示,在蜂窝结构体的两端面的流路方格样地交互插入浆体而设置封闭部6a、6c。浆体采用在平均粒径为8μm的堇青石粉末中添加水并混均。使设有封闭部6a、6c的蜂窝结构的废气流出侧端面8在上,从上方散布平均粒径28μm的堇青石粉末,使之堆积在封闭部6a、6c的上游侧端面61上。干燥浆体后进行烧成,使封闭部6a、6c粘结在隔壁2上。从对于封闭部6a、6c进行了烧成的蜂窝结构体的废气流入侧端面8切下2mm,除去在流入侧封闭部6a堆积的粒径大的堇青石粉末所构成的上游侧端面,得到蜂窝过滤器10。以上述方向制造2个相同的蜂窝过滤器,使用其中1个,按以下的方法测定蜂窝过滤器的流出侧封闭部6c的长度、气孔率及上游侧端面的表面粗糙度Ra。这些结果显示在表1中。
(封闭部长度的测定)
流出侧封闭部6c的长度,是从废气流入侧端面8向流出侧封闭流路3的内部插入直径1mm的棒而掌握流出侧封闭部6c的上游侧端面61的位置,测定从上游侧端面61的位置到流出侧封闭部6c的下游侧端面62的距离而求得。表1中记录的封闭部长度,是以上述方法随机选择的20处的流出侧封闭部6c的长度的平均值。
(上游侧端面表面粗糙度的测定)
在流出侧封闭部6c的上游侧切断蜂窝过滤器,测定流出侧封闭部6c的上游侧端面61的表面粗糙度Ra。上游侧端面61的表面粗糙度Ra是依据JIS B0601,由激光显微镜测定的算术平均粗糙度,作为距上游侧端面61的凹凸的平均线的绝对值偏差的平均值进行计算。
(气孔率的测定)
流出侧封闭部6c的气孔率,是在流路方向切断流出侧封闭部6c,对于随机选择的10处流出侧封闭部6c,以SEM观察其剖面的长度及宽度方向中央部,采用此照片,利用市场销售的图像分析软件(メデイアサイバネテイクス社制Image Pro Plus version 3.0)进行图像分析,作为封闭部的气孔率的面积率进行计算。
(熔损的评价)
使用实施例1剩余的1个蜂窝过滤器,从蜂窝过滤器的废气流入侧端面8侧以15Nm3/min的流量送给空气并计测压力损失(初期压损)。接着从废气流入侧端面8侧以15Nm3/min的空气流量,以13g/h投入由微粒子发生器发生的粒径0.042μm的碳粉1小时,使蜂窝过滤器的流出侧封闭流路3的内部堆积碳粉。再从废气流入侧端面8侧以15Nm3/min流出680℃的空气5分钟,使碳粉燃烧。再使上述碳粉的投入和燃烧同样反复4次后,再度以15Nm3/min的空气流量计测压力损失,该压力损失的计测值低于初期压损的测定值的95%时,切断蜂窝过滤器而确认熔损的发生。另一方面,压力损失的计测值为初期压损的测定值的95%以上时,使碳粉增量至20g/h(与实际的蜂窝过滤器的使用环境相比被认为是充分多的量),除此以外均与前述同样,再将使上述碳粉的投入和燃烧同样反复5次后,切断蜂窝过滤器,以表1-1的标准评价熔损。结果显在表1-2中。
[表1-1]
评价 | 熔损的评价标准 |
× | 以13g/h投入碳粉时熔损发生的 |
○ | 将碳粉的投入量增量至20g/h时,首次有影响实用的熔损发生的 |
◎ | 将碳粉的投入量增量至20g/h时,虽然熔损发生但没有到影响实用的程度 |
◎◎ | 将碳粉的投入量增量至20g/h熔损也没有发生的 |
[表1-2]
例编号 | 封闭部长度(mm) | 封闭部长度/宽度 | 封闭部气孔率(%) | 封闭部表面粗糙度(Ra) | 熔损评价 |
实施例1 | 10 | 8.3 | 40 | 27 | ◎ |
实施例2 | 6 | 5 | 65 | 22 | ○ |
实施例3 | 6 | 5 | 50 | 25 | ○ |
实施例4 | 7.2 | 6 | 45 | 26 | ◎ |
实施例5 | 9 | 7.5 | 40 | 30 | ◎◎ |
实施例6 | 10 | 8.3 | 35 | 35 | ◎◎ |
实施例7 | 24 | 20 | 25 | 40 | ◎◎ |
实施例8 | 36 | 30 | 20 | 45 | ◎◎ |
实施例9 | 6 | 5 | 46 | 45 | ○ |
实施例10 | 6 | 5 | 20 | 21 | ○ |
实施例11 | 6 | 5 | 45 | 45 | ◎ |
实施例12 | 6 | 5 | 20 | 22 | ◎ |
实施例13 | 6 | 5 | 20 | 13 | ○ |
比较例1 | 7.2 | 6 | 68 | 45 | × |
比较例2 | 7.2 | 6 | 68 | 22 | × |
比较例3 | 7.2 | 6 | 65 | 11 | × |
比较例4 | 7.2 | 6 | 20 | 11 | × |
实施例2~10和比较例1~4
变更构成流出侧封闭部6c的堇青石粉末的粒径、在流出侧封闭部6c的上游侧端面61堆积的堇青石粉末的粒径、和流出侧封闭部6c的长度的至少一个,除此以外均与实施例1相同,制作实施例2~10和比较例1~4的蜂窝过滤器。与实施例1同样地进行实施例2~10和比较例1~4的蜂窝过滤器的流出侧封闭部6c的长度、气孔率和上游侧端面61的表面粗糙度Ra的测定,以及熔损的评价。这些结果显示在表1中。关于比较例2的蜂窝过滤器,与上游侧端面61的表面粗糙度Ra一样,测定上游侧端面61的表面粗糙度Rz时是108。
实施例11~13
在预先含有水分的蜂窝结构体的流路中插入封闭材浆体,使废气流出侧端面9保持为上方而使之干燥后,使废气流入侧端面8处于上方而载置蜂窝结构体,散布粒径大的堇青石粉末,除此以外均与实施例9和实施例10一样,分别制作实施例11及实施例12的蜂窝过滤器10。对蜂窝结构体的水分的含浸,通过将形成有流出侧封闭部6c的部分浸渍在水中而进行。此外,还变更在流出侧封闭部6c的上游侧端面61堆积的堇青石粉末的粒径,除此以外均与实施例12相同而制作实施例13的蜂窝过滤器10。
与实施例1同样地进行实施例11~13的蜂窝过滤器的流出侧封闭部6c的长度、气孔率和上游侧端面61的表面粗糙度Ra的测定,以及熔损的评价,这些结果显示在表1中。还有,通过测定气孔率时的剖面观察,确认实施例11~13的蜂窝过滤器10,在从流出侧封闭部6c的上游侧端面61至少到流出侧封闭部6c的宽度的4倍以内,不存在面积0.3mm2以上的气孔,有面积为0.15mm2以上的气孔的面积低于30%。
由表1可知,流出侧封闭部的气孔率为65%以下,且流出侧封闭部的上游侧端面的粗糙度Ra为13μm以上的本发明的蜂窝过滤器(实施例1~13),由PM的燃烧热造成的熔损的发生降低。特别是可知流出侧封闭部的气孔率为45%以下,且流出侧封闭部6c的长度/宽度的值为6以上的实施例1及实施例4~8的蜂窝过滤器,由PM的燃烧热造成的熔损的发生进一步降低。
实施例14
制作与实施例7中制作的相同的蜂窝过滤器,按以下步骤评价PM的燃烧效率。
(PM的燃烧效率的评价)
首先根据以5Nm3/min的流量流通空气时的蜂窝过滤器的上游侧和下游侧的差压测定压力损失(压力损失B)。其次由蜂窝过滤器的废气流入侧端面8侧以15Nm3/min的空气流量,以8g/h投入由微粒子发生器发生的粒径0.042μm的碳粉1小时,使蜂窝过滤器的流出侧封闭流路3的内部堆积碳粉。再从蜂窝过滤器的废气流入侧端面8侧以5Nm3/min流出680℃的空气,边使碳粉燃烧边根据蜂窝过滤器的上游侧和下游侧的差压测定压力损失(压力损失A)。然后计测到达(压力损失A/压力损失B)的值比1.05小的时刻的时间T。时间T越短表示PM越容易燃烧除去。
实施例15
除了加长流出侧封闭部6c的长度至30mm以外,均与实施例14同样地评价PM的燃烧效率。
实施例16
使用实施例8制作的蜂窝过滤器,与实施例14同样地评价PM的燃烧效率。
实施例17
除了进一步加长流出侧封闭部6c的长度至42mm以外,均与实施例16同样地评价PM的燃烧效率。
实施例14~17的结果显示在表2中。可知流出侧封闭部6c的长度/宽度的值为30以下的实施例14~16的蜂窝过滤器,PM容易被燃烧除去。
[表2]
例编号 | 封闭部长度(mm) | 封闭部长度/宽度 | 时间T(1)(min) |
实施例14 | 24 | 20 | 4 |
实施例15 | 30 | 25 | 4.3 |
实施例16 | 36 | 30 | 5 |
实施例17 | 42 | 35 | 7 |
注(1):是表示PM的燃烧效率的指标,时间T越短表示PM越容易燃烧去除。
实施例18
制作与实施例8中制作的相同的蜂窝过滤器,根据以8Nm3/min的流量流通空气时的蜂窝过滤器的上游侧和下游侧的差压测定压力损失。
实施例19
磨削加工实施例18的蜂窝过滤器的废气流出侧端面9,如图4所示使废气流出侧端面9成为圆锥状,由此从外周部的流出侧封闭部进一步加长蜂窝过滤器的的流路垂直方向截面的中心部的流出侧封闭部6c的流路方向长度,并且使外周部的流路的长度比中心部的流路短。与实施例18同样测定该蜂窝过滤器的压力损失。
实施例18和实施例19的蜂窝过滤器的压力损失显示在表3中。还有,压力损失的值由以实施例18作为100的相对值表示。另外在实施例19的蜂窝过滤器中,中心部的流路长度表示蜂窝过滤器的全长(图4所示的L1),外周部的流路长度表示蜂窝过滤器的外壁的流路方向长度(图4所示的L2)。与实施例18的蜂窝过滤器相比较,外周部的流路长度比中心部的流路短的实施例19的蜂窝过滤器,压力损失降低。
[表3]
Claims (5)
1.一种陶瓷蜂窝过滤器,其包括:具有被多孔质的隔壁分开的多个流路的蜂窝结构体;交互地被设于所述流路的废气流入侧或废气流出侧的封闭部,其特征在于,所述流出侧封闭部的气孔率为65%以下,并且所述流出侧封闭部的上游侧端面的表面粗糙度Ra为13~50μm。
2.根据权利要求1所述的陶瓷蜂窝过滤器,其特征在于,所述流出侧封闭部的气孔率为45%以下。
3.根据权利要求1或2所述的陶瓷蜂窝过滤器,其特征在于,所述流出侧封闭部的流路方向长度是所述流出侧封闭部的宽度的6~30倍。
4.根据权利要求1~3中任一项所述的陶瓷蜂窝过滤器,其特征在于,所述流出侧封闭部的流路方向长度为在流路垂直方向截面的中心部比外周部长。
5.一种制造陶瓷蜂窝过滤器的方法,该陶瓷蜂窝过滤器包括:具有被多孔质的隔壁分开的多个流路的蜂窝结构体;交互地被设于所述流路的废气流入侧或废气流出侧的封闭部,所述流出侧封闭部的气孔率为65%以下,并且所述流出侧封闭部的上游侧端面的表面粗糙度Ra为13μm以上,该方法的特征在于,具有如下工序:用具有平均粒径为5μm以下的陶瓷粉的浆体形成流出侧封闭部后,在该封闭部的上游侧端面上堆积具有10~200μm的平均粒径的陶瓷粉,之后进行烧成而形成一体。
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CN111742207B (zh) * | 2018-04-23 | 2023-10-17 | 日本碍子株式会社 | 确定有效或无效流路的方法和装置 |
CN113646511A (zh) * | 2019-07-31 | 2021-11-12 | 株式会社电装 | 废气净化过滤器 |
CN113646511B (zh) * | 2019-07-31 | 2022-06-24 | 株式会社电装 | 废气净化过滤器 |
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CN101534921B (zh) | 2012-05-23 |
US8092568B2 (en) | 2012-01-10 |
EP2098273A4 (en) | 2012-05-30 |
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EP2098273A1 (en) | 2009-09-09 |
KR101436878B1 (ko) | 2014-09-02 |
US20100058725A1 (en) | 2010-03-11 |
JP5272733B2 (ja) | 2013-08-28 |
EP2098273B1 (en) | 2013-07-17 |
KR20090095544A (ko) | 2009-09-09 |
WO2008078716A1 (ja) | 2008-07-03 |
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