EP1161332A1 - Procede ameliore de fabrication de filtres multicellulaires - Google Patents

Procede ameliore de fabrication de filtres multicellulaires

Info

Publication number
EP1161332A1
EP1161332A1 EP00904577A EP00904577A EP1161332A1 EP 1161332 A1 EP1161332 A1 EP 1161332A1 EP 00904577 A EP00904577 A EP 00904577A EP 00904577 A EP00904577 A EP 00904577A EP 1161332 A1 EP1161332 A1 EP 1161332A1
Authority
EP
European Patent Office
Prior art keywords
honeycomb
sealant
cells
cell openings
openings
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00904577A
Other languages
German (de)
English (en)
Other versions
EP1161332A4 (fr
Inventor
Willard A. Cutler
Jennifer M. Torns
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Corning Inc
Original Assignee
Corning Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Corning Inc filed Critical Corning Inc
Publication of EP1161332A1 publication Critical patent/EP1161332A1/fr
Publication of EP1161332A4 publication Critical patent/EP1161332A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/745—Filling cavities in the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
    • B01D29/111—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
    • B01D29/31—Self-supporting filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2201/00—Details relating to filtering apparatus
    • B01D2201/46—Several filtrate discharge conduits each connected to one filter element or group of filter elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/14—Filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb
    • B29L2031/608—Honeycomb structures

Definitions

  • This invention relates to an improved plugging method for making multicellular filters.
  • Multicellular structures such as honeycombs find use as filters for fluids. By plugging alternate cells or channels of a honeycomb, fluid flow is forced through the cell walls, allowing the wall to perform particulate filtration. This through-the-wall flow pattern takes advantage of the high surface area/volume ratio of the honeycombs.
  • honeycomb filters in particular, ceramic honeycombs, have been used extensively for gas phase filtration, such as in the diesel particulate filtration application, due to their high temperature capability.
  • I honeycombs must 1 exhibit no bypass (fluid leakage around the plug) to maintain particulate, pollutant, and parasite removal properties of the filters.
  • the present invention sets forth a variety of plugging methods for plugging honeycombs for use in fluid filtration.
  • the methods fulfill the requirements of completely • plugging designated cell channels to a controlled depth, to prevent fluid leakage around the plug.
  • a method of plugging honeycomb cells involves providing a honeycomb having an inlet end and an outlet end and a multiplicity of cells extending from inlet end to outlet end, and introducing the sealant material into pre-selected honeycomb cell openings by capillary action to form a plug on said pre-selected cell openings.
  • the sealant can be thermoplastic polymer preform having sections corresponding to the cell openings on a given surface of a honeycomb, the sections corresponding to the openings that are to be plugged have thermoplastic sealing material.
  • the sealing material has dimensions to allow it to fit securably into horieycomb cell openings to be plugged.
  • the preform is positioned on the honeycomb surface having the pre-selected cell openings so that the sealing material is inserted into the pre-selected cell openings.
  • the pre-selected cell openings are heated to allow the thermoplastic sealing material to deform and bond to inside walls of the preselected cell openings, to produce a plugged honeycomb with plugs securably positioned into the selected cell openings.
  • FIGS 1 and la are schematic diagrams showing plugging selected honeycomb cells by capillary action.
  • Figures 2 and 2a are schematic diagrams showing sealant applied as a continuous line in a diagonal across the cross section of the honeycomb.
  • FIG.3, 3a, 3b, 3c are schematic diagrams showing honeycomb cells being plugged by masking the cells that are to be ultimately left open with a fugitive material, which is removed after the cells to be plugged are filled with sealant by capillary action.
  • Figures 4 and 4A are schematic diagrams showing honeycomb cells being plugged by masking the cells, similar to Figures 3 -3c above, but the mask is in the form of a single piece.
  • Figures 5 and 5a are schematic diagrams showing plugging honeycomb cells with a wedge-shaped sealant material .
  • This invention relates to methods of plugging honeycombs to produce a filter having wall flow, for filtration of fluids. More ' specifically, this invention relates to various methods of applying sealant to honeycomb cells to a controlled depth and pore penetration, within the cells, to form plugs. The sealant forms a plug that is integral with the cell wall and wall pores .
  • honeycombs can be made of any material such as ceramic, metal, polymer, carbon or activated carbon, glass, glass-ceramic, or combinations of these.
  • honeycombs can have any cell density, but cell
  • 2 densities usually range from 235 cells/cm (about 1500 cells/in 2 ) to 1.5 cells/cm2 '(about 10 cells/in2 ) . They can have variable wall thicknesses, but wall thicknesses range typically from about 0.1 to about 1.5 mm (about 4 to about 60 mils) .
  • This invention is especially useful for the more dense honeycombs of 31 cells/cm 2 (200 cells/in 2 ) or greater.
  • the sealant is selected depending on the material of the honeycomb. It must be able to form a strong chemical, mechanical, or frictional bond with the cell surface of the honeycomb so that there is no leakage around the plug that is formed.
  • sealing or plugging materials are polymeric materials such as epoxies, silicones, waxes, thermoplastic polymers, and inorganic/organic mixes such as ceramic/polymer mixes, etc. There are several ways in which the plugging can be done.
  • the pre-selected cells are plugged by capillary action with liquid-based sealant.
  • the top of the cell (s) opening(s) to be 1 plugged are placed in contact with the sealant material ' and the sealant is allowed to be pulled into the cell (s) ' to some desired depth by capillary forces (as opposed to forcing the sealant into the cell by injection, applied pressure, or some other traditional method) .
  • This invention does not require precise placement of the sealant in the center of the cell (s) to be plugged. As long as the majority of the sealant ends up on top of the required cell, capillary action pulls the sealant into the cells and overcomes the misalignment.
  • the sealant can be applied to discrete cells, or it can be applied directionally, in a continuous line pattern, such as diagonally. The latter technique is more efficient because it expedites sealing of a large number of cells.
  • the degree of penetration 1 of sealant into the cell is determined by the size of the cell, .viscosity of the sealant, wetting characteristics of the sealant with the cell, etc.
  • the characteristics of the sealant can be adjusted to yield desired plugging depth and pore penetration.
  • plug penetration depth can be controlled by sealant viscosity. The higher the sealant viscosity, the shorter the plug depth. Lower viscosity sealants can also produce shorter plug depths if used in conjunction with an ultraviolet (UV 1 ) curing, agent initiator in the sealant and exposing the part to UV radiation.
  • UV 1 ultraviolet
  • the entire end of the honeycomb is subjected to the sealing material.
  • Each of the cells are filled to a desired depth (vs. completely filling the entire cell channel) as the sealing material wicks into the cells.
  • the sealed honeycomb end is then removed from the sealant and rods of diameter less than the cell size, arranged in a pattern desired for the open cells, are plunged into the honeycomb.
  • the high viscosity sealant attaches itself to these rods and the sealant is removed from the cell as the rods are withdrawn from the honeycomb. The process is repeated to produce the opposite pattern on the other side of the honeycomb.
  • cells that are to be left open are masked with a removable or fugitive masking material .
  • the entire face of the honeycomb is exposed to the sealant which fills the unmasked cells by capillary action.
  • masking material for this technique, although it is ,to be understood that the invention is not limited to such, are silicones that are removable under the processing conditions, low melting waxes, and thermplastic elastomers.
  • the melting point for the waxes used as fugitive masking materials needs to be low enough that the epoxy or other plugging material is not damaged, but that the low melting point compound can be removed.
  • sealant is a two-part epoxy. Each cell density will require a different viscosity - the higher, the cell density the lower the viscosity. The fugitive masking material is then removed by heating.
  • the cells of a honeycomb to be plugged are plugged at once with a pre-formed mask.
  • the plugs of the mask which' will ultimately be the plugs of the honeycomb, are made of previously described plugging material e.g. molded thermoplastic elastomer, wax, or epoxy with only the epoxy skin being cured either by UV or heat.
  • the mask is physically pressed into the honeycomb to plug all of the desired cells at once.
  • a thermoplastic elastomer or wax insertion into a honeycomb that is at least hot enough to partially melt the sealant plug of the mask, results in a strong
  • FIGs 1 and la illustrate honeycomb cells being put in contact with a sealant and allowing capillary forces to pull the sealant into the cell.
  • Figure 1 is a schematic diagram showing the lengths of honeycomb cells (12) . Cell walls are shown as (14) . Sealant 16) is placed at the opening of a cell or cells.
  • Figure la is similar to Figure 1, but shows the sealant (16a) being subjected to capillary forces that pull the sealant into the cell. Besides being applied to multiple discrete cells as shown in Figure 1, the sealant can be applied in a pattern, such as a diagonal, to expedite the process.
  • Figure 2 is a schematic of a cross section of honeycomb cells (20) , with
  • sealant (22) applied as a continuous line in a diagonal across the cross section of the honeycomb.
  • Figure 2A is similar to Figure 2 but shows sealant plugging (22a) in the cells (20) after the sealant is allowed to plug the cells by capillary action.
  • sealant plugging (22a) is a two part epoxy having a viscosity of e.g. about 250,000 cps .
  • a 200 cell/in 2 porous ceramic honeycomb with about 0.028" thick walls with fine porosity ( ⁇ 10 micrometers) was plugged diagonally using a two-part with a viscosity of about 200,000 c .
  • the epoxy bead was continually dispensed in a diagonal line pattern using a pneumatic syringe, guided by hand.
  • the opposing diagonal line pattern was placed on either side of the honeycomb and the plugged part was subjected to about 70°C for about 1 hour.
  • the final, cured plug depth was about 2 mm.
  • a 300 cell/in 2 porous carbon honeycomb with about 0.015" walls with fine porosity ( ⁇ 2 micrometers) was plugged in a diagonal pattern using a two part epoxy with a viscosity of about 1Q0,000 cp .
  • the epoxy bead was continually dispensed in a diagonal line pattern using a pneumatic syringe, guided by hand.
  • the opposing diagonal line pattern was placed on the other side of the honeycomb and the plugged part was subjected to about 70°C for about 1 hour.
  • the final, cured plug depth was about 2 mm.
  • Example 4 A 400 cell/in 2 porous ceramic honeycomb with about
  • Figures 3, 3a, 3b, and 3c illustrate the principle of masking the cells that are to be ultimately left open, with a fugitive or removable masking material, and then subjecting the whole face of the honeycomb to the sealant and allowing the unmasked cells to be filled by capillary action.
  • Figure 3 is a schematic showing the lengths of cells (32) with mask (33) , and cell walls (34) .
  • Figure 3a shows the cells (32) with mask (33) , and cells (32a) being dipped into a container (36) having sealant (38) .
  • Figure 3b shows the resulting honeycomb cells (32) with masks (33) and cells (32a) with sealant plugs (38a) . The mask is then removed such as by heating.
  • Figure 3C is a schematic showing honeycomb cells, having sealant after the masking material is removed.
  • One suited material for masking the cells that are to remain open is wax, while a two part epoxy having a viscosity of e.g. about 150,000 cp is utilized as the sealant. The viscosity is dependent on the cell geometry.
  • Example 6 Use of a pre-formed mask with mechanical attachment All the cells of a honeycomb to be plugged can be plugged at once with use of a pre-formed mask.
  • the preformed mask can be made of a molded thermoplastic elastomer or wax or related material and would be physically pressed into the honeycomb to plug all of the desired cells at once as shown in Figure 4.
  • Figure 4 is a schematic diagram showing the lengths of honeycomb cells
  • FIG. 5 is a schematic diagram of a wedge-shaped plug (52), about to be inserted into a honeycomb cell (54) having porous walls (56) with pores shown as (58) .
  • Figure 5a shows the cell after plugging with the plug (52a) integrally sealed to the cell wall.
  • Example 7 Use of a pre-molded mask with chemical attachment
  • All the cells to be plugged can be plugged at one time with use of a pre-molded mask that would be made of a molded epoxy with both UV and heat-curable components.
  • a thin skin can be induced using UV radiation allowing the material to retain its shape.
  • the pre- form is physically pressed into the honeycomb as described in Example 6. The mechanical action of the pressing breaks the skin of the wedge-shaped plugs allowing some flow of the uncured epoxy into the cells and along the cell walls.
  • the entire pre- molded mask can then be heat cured, allowing the formation of a chemical bond between the epoxy and the cell walls.
  • Example 8 Use of plugging, followed by clearing of plugs A 100 cell/in 2 porous ceramic honeycomb with about 0.028" walls with fine porosity (5 ⁇ m) was dipped (1/4") into two-part epoxy with a viscosity of about ⁇ 100,000 cp for ⁇ 1 min. The honeycomb was removed from the epoxy and a wooden rod was inserted and removed from the cells to be cleared. The honeycomb, was subjected to about 70°C for about 1 hour. The final, cured plug depth was about 3 mm.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Engineering (AREA)
  • Composite Materials (AREA)
  • Robotics (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Filtering Materials (AREA)

Abstract

Cette invention se rapporte à un procédé servant à obturer des alvéoles (12) d'une structure en nid d'abeilles et consistant à cet effet à prendre une structure en nid d'abeilles comportant une extrémité d'entrée et une extrémité de sortie et une multitude d'alvéoles (12) s'étendant entre cette extrémité d'entrée et cette extrémité de sortie, et à introduire le matériau scellant (16) dans les ouvertures des alvéoles présélectionnées de la structure en nid d'abeilles par réaction capillaire, en vue de former un bouchon dans les ouvertures des alvéoles présélectionnées. Le matériau scellant peut également être une préforme en polymère thermoplastique présentant des sections correspondant aux ouvertures des alvéoles sur une surface donnée de la structure en nid d'abeilles. La préforme est placée sur la surface de la structure en nid d'abeilles comportant les ouvertures des alvéoles présélectionnées, pour que la préforme soit introduite dans les ouvertures des alvéoles présélectionnées. Les ouvertures des alvéoles présélectionnées sont chauffées pour permettre à la préforme de se déformer en un matériau scellant thermoplastique et de coller aux parois intérieures des ouvertures des alvéoles présélectionnées, en vue de produire une structure en nid d'abeilles obturée ayant des bouchons disposés en position fixe dans les ouvertures des alvéoles sélectionnées.
EP00904577A 1999-02-17 2000-01-27 Procede ameliore de fabrication de filtres multicellulaires Withdrawn EP1161332A4 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US25079999A 1999-02-17 1999-02-17
US250799 1999-02-17
PCT/US2000/001929 WO2000048807A1 (fr) 1999-02-17 2000-01-27 Procede ameliore de fabrication de filtres multicellulaires

Publications (2)

Publication Number Publication Date
EP1161332A1 true EP1161332A1 (fr) 2001-12-12
EP1161332A4 EP1161332A4 (fr) 2002-08-07

Family

ID=22949202

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00904577A Withdrawn EP1161332A4 (fr) 1999-02-17 2000-01-27 Procede ameliore de fabrication de filtres multicellulaires

Country Status (4)

Country Link
EP (1) EP1161332A4 (fr)
JP (1) JP2002537100A (fr)
KR (1) KR20010101807A (fr)
WO (1) WO2000048807A1 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4019732B2 (ja) * 2001-03-26 2007-12-12 株式会社デンソー セラミックハニカム成形体の栓詰め方法
JP4464831B2 (ja) 2002-12-11 2010-05-19 日本碍子株式会社 目封止ハニカム構造体及びその製造方法
WO2007004594A1 (fr) * 2005-06-30 2007-01-11 Hitachi Metals, Ltd. Procédé de fabrication d’un filtre en nid d’abeilles céramique
JP2011041933A (ja) * 2009-07-21 2011-03-03 Honda Motor Co Ltd 排気浄化フィルタ
EP2539302A1 (fr) * 2010-02-28 2013-01-02 Corning Incorporated Améliorations d'un procédé d'obturation d'un réacteur à corps en nid d'abeille
GB2494120A (en) * 2011-08-28 2013-03-06 Douglas Michael Simmonds Device for easy and neat application of silicone sealant, caulk and similar materials
GB201402732D0 (en) * 2014-02-17 2014-04-02 Rolls Royce Plc A honeycomb structure

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3906616A (en) * 1974-01-17 1975-09-23 Metal Tech Inc Method for fabricating honeycomb rolls
EP0677498A2 (fr) * 1994-04-12 1995-10-18 Corning Incorporated Procédé d'obturation sélective de bouts ouverts d'une structure céramique en nid d'abeilles

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4411856A (en) * 1981-07-15 1983-10-25 Corning Glass Works Method and apparatus for high speed manifolding of honeycomb structures
JPS5954683A (ja) * 1982-09-20 1984-03-29 日本碍子株式会社 セラミツクハニカム構造体の開口端面封止方法
US4793920A (en) * 1985-12-11 1988-12-27 Lee Scientific, Inc. Chromatography columns with cast porous plugs and methods of fabricating same
DE4211787C1 (de) * 1992-04-08 1993-11-04 Schott Glaswerke Verfahren und vorrichtung zur herstellung eines filters in form eines keramischen wabenkoerper-monolithen
DE4238120C1 (de) * 1992-11-12 1994-03-17 Schott Glaswerke Verfahren zum rechnergesteuerten, stirnseitigen, wechselweisen Verschließen von Kanälen eines Wabenkörper-Monolithen für Abgasreinigungsanlagen von Verbrennungsmotoren
JP3536060B2 (ja) * 1995-07-06 2004-06-07 東京窯業株式会社 セラミックハニカム構造体端面の目封じ方法
US5997746A (en) * 1998-05-29 1999-12-07 New Objective Inc. Evaporative packing of capillary columns

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3906616A (en) * 1974-01-17 1975-09-23 Metal Tech Inc Method for fabricating honeycomb rolls
EP0677498A2 (fr) * 1994-04-12 1995-10-18 Corning Incorporated Procédé d'obturation sélective de bouts ouverts d'une structure céramique en nid d'abeilles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO0048807A1 *

Also Published As

Publication number Publication date
EP1161332A4 (fr) 2002-08-07
WO2000048807A1 (fr) 2000-08-24
KR20010101807A (ko) 2001-11-14
JP2002537100A (ja) 2002-11-05

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