CN109311767A - 蜂窝结构体 - Google Patents
蜂窝结构体 Download PDFInfo
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Abstract
蜂窝结构体具备筒状的周壁(11)、以及将周壁(11)的内部划分成沿周壁(11)的轴向延伸的多个孔道(S)的截面为蜂窝形状的划分壁(12)。划分壁(12)由骨架部分和填充部分构成,该骨架部分是将多个陶瓷粒子配置成与划分壁(12)的形状相当的形状而成的,该填充部分由填充在骨架部分中的陶瓷粒子间的间隙中的金属硅形成,骨架部分通过填充部分被保持为与划分壁(12)相当的形状。
Description
技术领域
本发明涉及在周壁的内部具备截面为蜂窝形状的划分壁的蜂窝结构体。
背景技术
专利文献1中公开了一种高温用热交换器,其具备在贯通地流过内侧的流体与存在于外侧的流体之间进行热量交换的多孔质碳化硅烧结体制造的元件。该热交换器的元件为具有在长度方向上延伸的多个孔道的蜂窝结构体。另外,该蜂窝结构体在多孔质碳化硅烧结体的表面浸渗有硅。
现有技术文献
专利文献
专利文献1:日本特开平06-345555号公报
发明内容
发明所要解决的课题
在蜂窝结构体中,截面为蜂窝形状的划分壁会由于在孔道中通过的流体的温度而产生变形。特别是根据使用形态的不同,该蜂窝结构体内的温度差会增大,从而使变形也随之增大。因此,作为蜂窝结构体,要求有针对变形的耐性。
解决课题的手段
用于解决上述课题的蜂窝结构体是具备筒状的周壁、以及将上述周壁的内部划分成在上述周壁的轴向延伸的多个孔道的截面为蜂窝形状的划分壁的蜂窝结构体,其要点在于,上述划分壁由骨架部分和填充部分构成,该骨架部分是将多个陶瓷粒子配置成相当于上述划分壁的形状而成的,该填充部分由填充在上述骨架部分中的陶瓷粒子间的间隙中的金属硅形成;上述骨架部分通过上述填充部分被保持为与上述划分壁相当的形状。
关于上述蜂窝结构体,优选上述陶瓷粒子是未烧结的。
例如,在上述专利文献1所公开的蜂窝结构体的情况下,为陶瓷粒子相互通过烧结而结合的构成。与之相对,在上述构成中,骨架部分中的陶瓷粒子利用所填充的填充部件保持形状,陶瓷粒子相互间的结合受到抑制。由于在骨架部分采用这样的结构,因而能够提高针对变形的耐性。即能够提高杨氏模量。
在上述蜂窝结构体中,上述陶瓷粒子与上述金属硅的体积比优选为60:40~40:60。陶瓷粒子的比例为60体积%以下的情况下,金属硅容易进入到陶瓷粒子间的间隙,因而针对变形的耐性容易提高;上述比例为40体积%以上的情况下,即使在未烧结时也容易充分确保划分壁的强度。
在上述蜂窝结构体中,上述陶瓷粒子优选为碳化硅粒子。这种情况下,由于碳化硅的热传导率高,因此能够抑制在蜂窝结构体中产生温度差。并且作为热交换器是有用的。
发明的效果
根据本发明的蜂窝结构体,能够提高针对变形的耐性。
附图说明
图1是蜂窝结构体的立体图。
图2是图1的2-2线端面图。
图3是图1的3-3线端面图。
图4是非烧结的蜂窝结构体的显微镜照片。
图5是非烧结的蜂窝结构体的显微镜照片。
图6是烧结蜂窝结构体的显微镜照片。
图7的(a)、(b)是骨架部分的放大示意图。
图8是成型工序的说明图。
图9是加工工序(第1加工)的说明图。
图10是加工工序(第2加工)的说明图。
图11是加工工序(第3加工)的说明图。
图12是脱脂工序的说明图。
图13是浸渗工序的说明图。
具体实施方式
对蜂窝结构体的一个实施方式进行说明。
如图1所示,蜂窝结构体10具备筒状的周壁11、以及将周壁11的内部划分成在周壁11的轴向延伸的多个孔道的截面为蜂窝形状的划分壁12。在周壁11的两端部分别设有朝径向外方向突出的环状的肋13。
如图1~3所示,通过划分壁12划分出的孔道S由下述两种孔道构成:两端部均开放的第1孔道S1;以及两端部均封闭的第2孔道S2。如图1所示,在第1方向(图1的上下方向)上排列的各孔道S全部为相同种类的孔道。另外,在与第1方向正交的第2方向(图1的纸面前后方向)上相邻的各孔道S为相互不同种类的孔道。
如图1和图3所示,在蜂窝结构体10中,在由沿第1方向排列的第2孔道S2构成的部分(由第2孔道S2构成的孔道列)分别设有第1连通部14a和第2连通部14b,它们按照在第1方向延伸的方式形成,将在第1方向上相邻的第2孔道S2彼此连通。
第1连通部14a设于蜂窝结构体10的第1端部侧。第1连通部14a中的第1方向的一侧(图3的上侧)的端部(即基端)开口于周壁11,并且其另一侧(图3的下侧)的端部(即末端)到达至位于第1方向上的最靠另一侧的第2孔道S2。
第2连通部14b设于蜂窝结构体10的第2端部侧。第2连通部14b中的第1方向的另一侧(图3的下侧)的端部(即基端)开口于周壁11,并且其一侧(图3的上侧)的端部(即末端)到达至位于第1方向上的最靠一侧的第2孔道S2。
因此,在蜂窝结构体10的内部形成有第1流路和第2流路,该第1流路由第1孔道S1构成,并以蜂窝结构体10的轴向两端部作为流入口或流出口,该第2流路由第2孔道S2构成,并以形成于蜂窝结构体10的周壁11上的第1连通部14a和第2连通部14b的各开口作为流入口或流出口。
图4中示出了蜂窝结构体10的横截面的显微镜照片。蜂窝结构体10由骨架部分和填充部分构成,该骨架部分是将多个陶瓷粒子配置成划分壁的形状而成的,该填充部分由填充在陶瓷粒子间的间隙中的金属硅形成。
对构成蜂窝结构体10的骨架部分的材料没有特别限定,可以使用用于公知的蜂窝结构体10的材料,例如可以举出碳化硅、碳化钽、碳化钨等碳化物、氮化铝、氮化硅、氮化硼等氮化物。这些之中,优选使用碳化硅。
对陶瓷粒子的平均粒径没有特别限定,优选为10~50μm的范围。陶瓷粒子的平均粒径可以通过利用电子显微镜对蜂窝结构体10的横截面进行观察来测定。
需要说明的是,图6所示的显微镜照片示出了作为比较的蜂窝结构体(下文中也称为“烧结蜂窝结构体”)的横截面的显微镜照片,该作为比较的蜂窝结构体是通过在脱脂工序后进行烧制并对所得到的烧制体进行浸渗工序而得到的蜂窝结构体(下文中也称为“烧结蜂窝结构体”)。在烧结蜂窝结构体中,通过烧结形成陶瓷粒子相互结合而成的结合部(颈部,ネック)。陶瓷粒子以相互藉由颈部结合起来的状态构成骨架部分,成为在该骨架部分的间隙填充有填充部件的构成。
图7(a)和图7(b)为将陶瓷粒子配置成与划分壁12相当的形状而成的骨架部分的一部分的放大示意图。在表示蜂窝结构体10、即未烧结的蜂窝结构体中的骨架部分的图7(a)中,尽管陶瓷粒子相互接触配置来构成骨架部分,但这些陶瓷粒子相互间不具有因烧制所致的颈部。另一方面,在示出烧结蜂窝结构体中的骨架部分的图7(b)中,陶瓷粒子相互藉由颈部结合而构成骨架部分。该颈部是通过烧制蜂窝结构体、陶瓷粒子被烧结而形成的部位。
图7(a)的骨架部分通过填充部分保持为划分壁12的形状。换言之,构成骨架部分的陶瓷粒子大部分不具有通过烧结而结合成的颈部,以各粒子接触的状态进行配置,该接触配置的状态是由填充部分保持的。因此通过在陶瓷粒子间的间隙填充有金属硅而保持了划分壁12的形状。
构成骨架部分的多个陶瓷粒子相互间是否具有颈部例如可以通过在对蜂窝结构体进行氢氟酸处理使金属硅溶解时骨架部分的形状是否得到了保持来进行确认。如图7(a)所示,在构成骨架部分的陶瓷粒子相互间不具有颈部的情况下,由于各陶瓷粒子以接触的状态进行配置,因而在氢氟酸处理后未能保持骨架部分的形状。与之相对,如图7(b)所示,在构成骨架部分的陶瓷粒子相互间具有通过烧结而结合成的颈部的情况下,在氢氟酸处理后可保持骨架部分的形状。
在构成骨架部分的陶瓷粒子中,氢氟酸处理后的陶瓷粒子相互间的结合部(颈部)的个数相对于氢氟酸处理前的陶瓷粒子相互间的接点的个数的比例(下文中也称为“结合部比率”)优选为20%以下。通过使结合部比率为20%以下,适于提高针对变形的耐性。陶瓷粒子相互的接点与结合部的个数可以通过利用电子显微镜对骨架部分进行观察来测定。
接下来对本实施方式的作用效果进行叙述。
例如,在蜂窝结构体内具有较大的温度差时,在截面为蜂窝形状的划分壁产生变形。据信,此时在陶瓷粒子中的任一者发生龟裂,该龟裂伸展。在烧结蜂窝结构体的情况下,有时陶瓷粒子相互间藉由颈部结合而形成为相应的尺寸,因此可以认为,龟裂容易伸展、变形增大。与之相对,在本实施方式的蜂窝结构体的情况下,陶瓷粒子的相互结合受到抑制。因此认为,即使任一陶瓷粒子发生龟裂时,由于陶瓷粒子构成得较小,因而该龟裂不容易伸展、可抑制变形增大。因此,与烧结蜂窝结构体相比,本实施方式的蜂窝结构体具有杨氏模量高、不容易变形的性质,能够提高针对变形的耐性。另外,通过在陶瓷粒子间的间隙填充金属硅,能够确保与烧结蜂窝结构体同等程度的强度。
接下来,基于图8~13对本实施方式的蜂窝结构体10的一个制造方法进行说明。蜂窝结构体10通过依次经历以下记载的成型工序、加工工序、脱脂工序、浸渗工序来制造。
(成型工序)
作为蜂窝结构体10的成型中使用的原料,制备含有公知的蜂窝结构体10中使用的陶瓷粒子、有机粘结剂和分散介质的粘土状的混合物。如图8所示,在成型工序,使用与公知的蜂窝结构体10中使用的混合物同样的混合物成型出成型体10A,该成型体10A具备筒状的周壁11、以及将周壁11的内部划分成在周壁11的轴向延伸的多个孔道S的截面为蜂窝形状的划分壁12。该成型体10A为省略了环状的肋13的形状,并且全部的孔道S呈其两端开放的状态。成型体10A可以通过例如挤出成型进行成型。对于所得到的成型体10A进行使成型体10A干燥的干燥处理。
(加工工序)
加工工序是得到加工成型体10B的工序,该加工成型体10B是将成型体10A的外形形状加工成与蜂窝结构体10的外形形状大致相同形状而成的。在加工工序中,进行在成型体10A上形成肋13的第1加工、在成型体10A中形成第1连通部14a和第2连通部14b的第2加工、以及封闭成型体10A中的一部分孔道S的两端部的第3加工。
如图9所示,在第1加工中,通过使成型工序中使用的粘土状的混合物以规定形状附着于成型体10A的周壁11的外表面而形成环状的肋13。之后对成型体10A进行使所形成的肋13干燥的干燥处理。
如图10所示,在第2加工中,例如使用使经加热的加工具与成型体10A接触的方法来除去成型体10A中的周壁11和划分壁12的一部分,形成第1连通部14a和第2连通部14b。
如图11所示,在第3加工中,在成型体10A中所形成的多个孔道S中,对于构成第2孔道S2的孔道S的两端部填充在成型工序中使用的粘土状的混合物,形成封闭该孔道S的两端部的封闭部15。之后对成型体10A进行使封闭部15干燥的干燥处理。
通过经历由上述第1加工、第2加工、第3加工构成的加工工序,得到加工成型体10B。
(脱脂工序)
脱脂工序为下述的工序:通过对加工成型体10B进行加热使加工成型体10B中含有的有机粘结剂燃烧而被烧失,由此得到从加工成型体10B中除去了有机粘结剂的脱脂体10C。如图12所示,通过经历脱脂工序,从加工成型体10B中除去有机粘结剂,得到在陶瓷粒子间具有间隙的脱脂体10C。
(浸渗工序)
浸渗工序是使金属硅浸渗到脱脂体10C的各壁的内部的工序。在浸渗工序中,以金属硅块与脱脂体10C接触的状态加热至金属硅的熔点以上(例如1450℃以上)。由此,如图13所示,熔融的金属硅通过毛细管现象而进入到脱脂体10C的构成各壁的陶瓷粒子间的间隙中,使金属硅浸渗到该间隙中。
通过经历上述浸渗工序,得到蜂窝结构体10。
此处,在本实施方式中,在脱脂工序以后的工序中进行特殊的温度管理。即,在脱脂工序以后的工序中,在小于成型工序中使用的混合物所含有的陶瓷粒子的烧结温度的温度下实施,以使得加工成型体10B、脱脂体10C不会暴露在上述烧结温度以上的温度下。因此,在脱脂工序中,以有机粘结剂能够烧失的温度以上、且小于上述烧结温度的温度进行加热。同样地,在浸渗工序中,以金属硅的熔点以上、且小于上述烧结温度的温度进行加热。
本实施方式还能够如下进行变更来实施。另外,还能够将上述实施方式的构成或以下的变更例中示出的构成适宜地组合来实施。
·蜂窝结构体的外形形状不限于圆柱,也可以为椭圆筒状或方筒状的外形形状。另外,在本实施方式中,周壁和划分壁是由相同的材料构成的,但周壁和划分壁也可以由不同的材料构成。例如,可以通过在划分壁的外周形成被覆层而将被覆层作为周壁。
·第1孔道S1和第2孔道S2不一定必须在图1所示的第2方向上相邻,例如,也可以以第2孔道S2、第1孔道S1、第1孔道S1(以下重复)的顺序配置。
·蜂窝结构体可以为将通过划分壁划分出的多个孔道在长度方向并设的柱状的蜂窝部件藉由接合层进行多个捆束而成的。
接着,在下面追述能够从上述各实施方式和其他例中掌握的技术思想。
一种蜂窝结构体,其陶瓷粒子的结合部比率为5%以下。
实施例
下面对进一步具体化上述实施方式的实施例进行说明。
(实施例)
首先制备下述组成的混合物。
平均粒径15μm的碳化硅的粒子(大粒子):52.5质量份
平均粒径0.5μm的碳化硅的粒子(小粒子):23.6质量份
甲基纤维素(有机粘结剂):5.4质量份
甘油(润滑剂):1.1质量份
聚氧化烯系化合物(增塑剂):3.2质量份
水(分散介质):11.5质量份
使用该混合物,成型出具有直径35mm、长度100mm、周壁的厚度0.3mm、划分壁的厚度0.1mm、孔道宽度0.94mm的蜂窝结构的圆柱状的成型体。接着,通过将成型体在450℃加热5小时而得到除去了有机粘结剂的脱脂体。之后通过以在脱脂体上载置金属硅的板材20g的状态在真空下在1550℃加热7小时而使金属硅浸渗,得到实施例1的蜂窝结构体。另外,通过变成在氩气氛下在1700℃加热7小时的条件来实施上述金属硅的浸渗而得到实施例2的蜂窝结构体。需要说明的是,图4、5所示的显微镜照片是对实施例1、2的蜂窝结构体进行拍摄得到的照片。
(比较例1)
与实施例同样地得到成型体和脱脂体。通过将脱脂体在氩气氛下在2200℃加热3小时而得到烧制体。之后,通过以在烧制体上载置金属硅的板材20g的状态在真空下在1550℃加热7小时使金属硅浸渗,得到比较例1的蜂窝结构体。需要说明的是,图6所示的显微镜照片为对比较例1的蜂窝结构体进行拍摄得到的照片。
(评价试验)
对实施例1~3和比较例1的蜂窝结构体的弯曲强度和杨氏模量进行测定。将它们的结果示于表1。
蜂窝结构体的弯曲强度利用以下的方法测定。
作为3点弯曲强度测定用样品,从实施例和比较例的蜂窝结构体切出10条除周壁和封闭部以外的2孔道×4孔道×40mm尺寸的样品。之后相对于测定用样品的主表面(较宽的表面)沿垂直方向施加负荷,测定破坏负荷(样品发生破坏的负荷)。对10条3点弯曲强度测定用样品测定破坏负荷,将其平均值作为弯曲强度。3点弯曲强度试验参考JIS R 1601,使用INSTRON 5582以30mm的跨矩、1mm/min的速度进行。
蜂窝结构体的杨氏模量利用下述方法测定。作为杨氏模量测定用样品,从实施例和比较例的蜂窝结构体切出除周壁和封闭部以外的宽10mm×长50mm×厚0.4mm尺寸的测定样品。之后将其设于杨氏模量测定装置,通过共振法对测定用样品的杨氏模量进行测定。测定装置使用JE-RT型弹性模量测定装置(日本Technoplas(株式会社)制造)。设测定气氛为大气、测定温度为室温。
从蜂窝结构体切出具有规定形状的试验片,通过氢氟酸处理来测试是否保持了骨架部分的形状。对氢氟酸处理后的外观进行观察,在维持了蜂窝结构体的形状的情况下,记为“维持”,在蜂窝结构体崩塌、未能维持形状的情况下,记为“未维持”。另外,利用电子显微镜测定氢氟酸处理前的单位面积的碳化硅粒子相互间的接点的个数、以及氢氟酸处理后的单位面积的碳化硅粒子相互间的接点(结合部)的个数,计算出氢氟酸处理后的碳化硅粒子相互间的结合部的个数相对于氢氟酸处理前的碳化硅粒子相互间的接点的个数的比例、即结合部比率(%)。在实施例1、2、比较例1中,结合部比率分别为5%、20%、95%。
关于结合部比率,利用SEM以1000倍拍摄100处的碳化硅粒子,通过目视判断该粒子与相邻粒子间是否具有结合部。
[表1]
实施例1 | 实施例2 | 比较例1 | |
烧制温度(℃) | - | - | 2100℃ |
浸渗温度(℃) | 1550℃ | 1700℃ | 1550℃ |
弯曲强度(MPa) | 64.3 | 64.5 | 64.7 |
杨氏模量(MPa) | 540 | 535 | 494 |
氢氟酸处理后的形状 | 未维持 | 未维持 | 维持 |
由表1所示的结果可知,实施例1、2的蜂窝结构体与比较例1的蜂窝结构体具有同等程度的弯曲强度。另外,与比较例1的蜂窝结构体相比,实施例1、2的蜂窝结构体具有杨氏模量高、不容易变形的性质。因此可知,针对变形的耐性提高。
符号说明
10…蜂窝结构体、10A…成型体、10B…加工成型体、10C…脱脂体、11…周壁、12…划分壁、13…肋、14a…第1连通部、14b…第2连通部、15…封闭部。
Claims (4)
1.一种蜂窝结构体,其具备筒状的周壁、以及将所述周壁的内部划分成在所述周壁的轴向延伸的多个孔道的划分壁,该划分壁的截面为蜂窝形状,该蜂窝结构体的特征在于,
所述划分壁由骨架部分和填充部分构成,该骨架部分是将多个陶瓷粒子配置成与所述划分壁相当的形状而成的,该填充部分由填充在所述骨架部分中的陶瓷粒子间的间隙中的金属硅形成,
所述骨架部分通过所述填充部分被保持为与所述划分壁相当的形状。
2.如权利要求1所述的蜂窝结构体,其特征在于,所述陶瓷粒子是未烧结的。
3.如权利要求1或2所述的蜂窝结构体,其特征在于,所述陶瓷粒子与所述金属硅的体积比为60:40~40:60。
4.如权利要求1~3中任一项所述的蜂窝结构体,其特征在于,所述陶瓷粒子为碳化硅粒子。
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JP6746386B2 (ja) | 2020-08-26 |
US20200165502A1 (en) | 2020-05-28 |
WO2017213088A1 (ja) | 2017-12-14 |
EP3466906A1 (en) | 2019-04-10 |
EP3466906A4 (en) | 2019-11-06 |
JP2017218341A (ja) | 2017-12-14 |
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