JP2005199179A - セル構造体及びその製造方法 - Google Patents
セル構造体及びその製造方法 Download PDFInfo
- Publication number
- JP2005199179A JP2005199179A JP2004008263A JP2004008263A JP2005199179A JP 2005199179 A JP2005199179 A JP 2005199179A JP 2004008263 A JP2004008263 A JP 2004008263A JP 2004008263 A JP2004008263 A JP 2004008263A JP 2005199179 A JP2005199179 A JP 2005199179A
- Authority
- JP
- Japan
- Prior art keywords
- cell structure
- wall
- molded body
- cell
- outer peripheral
- 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.)
- Granted
Links
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Images
Classifications
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- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
- Y10T428/24165—Hexagonally shaped cavities
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249961—With gradual property change within a component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249975—Void shape specified [e.g., crushed, flat, round, etc.]
Abstract
【解決手段】一の端面から他の端面まで連通する複数のセル3を形成する隔壁2を含むセル構造部4と、セル構造部4の外周面上に配設された外壁部5とを備えるセル構造体1であって、外壁部5が気孔率40%以上の多孔質層又は中空体を含む多孔質層を少なくとも1層有するセル構造体1及びこれにを容易に製造できる製造方法を提供する。
【選択図】図1
Description
コージェライト化原料、即ち微粒子のタルク、カオリン、アルミナ及び他のコージェライト化原料に、成形助剤、造孔剤及び水を加えて調合した後、混合混練し、その混練物(杯土)を用いて押出成形し、ハニカム状の成形体を製造した。次に、成形体の所定のセルの開口部に、目封じ材を導入、乾燥した後、ハニカム状の成形体を焼成し、所定開口部が目封じされたハニカム状の焼成体を得た。その後、焼成体の外周を研削加工により除去し、所定寸法より外径寸法を小さくし、複数のセルを形成し外周面においてセルの通路方向に溝状に延びる凹部を形成する隔壁からなるハニカム状のセル構造部(セル構造:隔壁厚さ0.42mm、セルピッチ2.5mm)を得た。
表1に示す調合割合のコート材を調製し、コート材をセル構造部の外周面に塗布し、乾燥した後、400℃で仮焼して、実施例1〜6及び比較例1のハニカム構造体(直径267mm×長さ178mm、外壁部厚さ1.2mm)を得た。また、内殻層を形成する内コート材及び外殻層を形成する外コート材を表2に示す調合割合で調製し、内コート材を上記と同様のセル構造部の外周面に塗布し乾燥した後、外コート材をその上から塗布し乾燥し、その後400℃で仮焼して実施例7及び8のハニカム構造体(直径267mm×長さ178mm、内殻層の厚さ0.7mm、外殻層の厚さ0.7mm)を得た。
得られたハニカム構造体より外壁部を切り離し、気孔率を測定した。以下に、気孔率の測定方法を示す。なお、気孔率測定時に同時に細孔径分布も求めることもでき、体積基準における平均細孔径を細孔径の代表値として使われる。
(1)測定試料を150℃で2時間乾燥後、容器に入れ装置にセットした。造孔剤として発泡樹脂を添加した場合には550℃で1時間熱処理後にセットした。
(2)容器内に水銀を注入し規定の細孔径に相当する圧力を加え、測定試料に吸収された水銀容積を求めた。
(3)細孔分布は圧力と吸収された水銀容積から計算し求めた。
(4)細孔容積は68.6MPa(700kgf/cm2)の圧力を加え吸収された水銀容積から計算し求めた。
(5)気孔率は、総細孔容積より、以下の式で求めた。
気孔率(%)=総細孔容積(1g当り)×100/(総細孔容積(1g当り)+1/2.52)
得られたハニカム構造体をバーナー試験装置にセットして、セラミックハニカム構造体のセル構造部に、約400℃の燃焼ガスを流した。そのときに、外壁部の温度を測定し、上昇し続ける温度が止まり、外壁部の温度が定常状態になるまでの時間を評価した。また、評価後のセラミックハニカム構造体を取り外し、外周コート部の欠けの有無を評価した。
Claims (19)
- 一の端面から他の端面まで連通する複数のセルを形成する隔壁を含むセル構造部と、前記セル構造部の外周面上に配設された外壁部とを備えるセル構造体であって、前記外壁部が気孔率40%以上の多孔質層を少なくとも1層有するセル構造体。
- 一の端面から他の端面まで連通する複数のセルを形成する隔壁を含むセル構造部と、前記セル構造部の外周面上に配設された外壁部とを備えるセル構造体であって、前記外壁部が中空体を含む多孔質層を少なくとも1層有するセル構造体。
- 前記外壁部が、前記セル構造部側に位置する内殻層と、その外側に位置する外殻層とを有し、前記内殻層の気孔率が前記外殻層の気孔率よりも高い請求項1又は2に記載のセル構造体。
- 前記セル構造部がセラミック材料又は金属材料を主成分とし、前記外壁部がセラミック材料を主成分とする請求項1〜3のいずれか1項に記載のセル構造体。
- 前記セル構造部がハニカム構造あるいはフォーム状構造である請求項1〜4のいずれか1項に記載のセル構造体。
- 前記セル構造部が吸着機能又は触媒機能を有する材料を含有する請求項1〜5のいずれか1項に記載のセル構造体。
- 前記外壁部が吸着機能又は触媒機能を有する材料を含有する請求項1〜6のいずれか1項に記載のセル構造体。
- 前記セル構造部がハニカム構造であり、少なくとも一部のセルが端部において目封じされている請求項1〜7のいずれか1項に記載のセル構造体。
- 前記セル内及び/又は前記隔壁内部に触媒が担持されている請求項1〜8のいずれか1項に記載のセル構造体。
- 前記触媒が、自動車排ガスを浄化する機能を有する請求項9に記載のセル構造体。
- 複数のセルを形成する隔壁を含む成形体を成形により得る工程と、成形体を焼成して焼成体を得る工程と、成形体又は焼成体の外周面にコート材を配設して外壁部を形成する工程とを含むセル構造体の製造方法であって、前記コート材が造孔剤を含有するセル構造体の製造方法。
- 外壁部を形成する工程の前に、成形体又は焼成体の外周の少なくとも一部を加工除去する工程を含む請求項11に記載のセル構造体の製造方法。
- 外周の少なくとも一部を加工除去する工程が、成形体を焼成する工程の前に行われる請求項12に記載のセル構造体の製造方法。
- 外周の少なくとも一部を加工除去する工程が、成形体を焼成する工程の後に行われる請求項12に記載のセル構造体の製造方法。
- 成形体を得る工程において前記隔壁と一体となった外周壁を含む成形体を得て、外周の少なくとも一部を加工除去する工程において前記外周壁を含む外周を加工除去する請求項12〜14のいずれか1項に記載のセル構造体の製造方法。
- 成形体を得る工程において、外周壁を含まない成形体を得て、成形体又は焼成体の外周部を加工除去することなく、成形体又は焼成体の外周面にコート材を配設して外壁部を形成する請求項11に記載のセル構造体の製造方法。
- 少なくとも一部のセルを端部において目封じする工程を含む請求項11〜16のいずれか1項に記載のセル構造体の製造方法。
- 造孔剤がカーボン、バルーン、発泡樹脂、ポリエステル樹脂、アクリル樹脂、デンプンのいずれか一つあるいはその組み合わせである請求項11〜17のいずれか1項に記載のセル構造体の製造方法。
- 造孔剤が中空体である請求項11〜18のいずれか1項に記載のセル構造体の製造方法。
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US10/585,350 US7615273B2 (en) | 2004-01-15 | 2005-01-13 | Cell structure and method of manufacturing the same |
CNB2005800079099A CN100431663C (zh) | 2004-01-15 | 2005-01-13 | 多孔结构体及其制造方法 |
PCT/JP2005/000306 WO2005068048A1 (ja) | 2004-01-15 | 2005-01-13 | セル構造体及びその製造方法 |
EP20050703545 EP1704908B1 (en) | 2004-01-15 | 2005-01-13 | Cell structure and method of manufacturing the same |
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Also Published As
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US7615273B2 (en) | 2009-11-10 |
CN100431663C (zh) | 2008-11-12 |
US20080220203A1 (en) | 2008-09-11 |
EP1704908B1 (en) | 2014-04-02 |
CN1933889A (zh) | 2007-03-21 |
JP4550434B2 (ja) | 2010-09-22 |
WO2005068048A1 (ja) | 2005-07-28 |
EP1704908A4 (en) | 2007-10-10 |
EP1704908A1 (en) | 2006-09-27 |
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