JP2007290951A - ハニカム構造体およびその製造方法 - Google Patents
ハニカム構造体およびその製造方法 Download PDFInfo
- Publication number
- JP2007290951A JP2007290951A JP2007047945A JP2007047945A JP2007290951A JP 2007290951 A JP2007290951 A JP 2007290951A JP 2007047945 A JP2007047945 A JP 2007047945A JP 2007047945 A JP2007047945 A JP 2007047945A JP 2007290951 A JP2007290951 A JP 2007290951A
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- JP
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- Prior art keywords
- silicon carbide
- average particle
- honeycomb structure
- pore
- honeycomb
- 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.)
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- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 78
- 239000002994 raw material Substances 0.000 claims abstract description 39
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- 238000000034 method Methods 0.000 claims abstract description 32
- 238000002156 mixing Methods 0.000 claims abstract description 9
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- 210000004027 cell Anatomy 0.000 claims description 31
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Abstract
【解決手段】本発明では、平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料から、平均気孔径Z(μm)が10μm以上、20μm以下のハニカム構造体を製造する方法が提供される。本方法は、前記2種類の炭化珪素粒子と、造孔材とを含む原料を混合して、成形体原料を得るステップであって、平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・Xおよび0.8・Z≦Y≦1.8・Zであるステップと、前記成形体原料を成形して、成形体を形成するステップと、前記成形体を脱脂して、前記造孔材を焼失させるステップと、前記成形体を焼成して、多孔質炭化珪素を形成するステップと、を有する。
【選択図】図2
Description
2種類以上の平均粒径を有する炭化珪素と、造孔材とを含む原料を成形することにより、ハニカム成形体を得るステップと、
前記ハニカム成形体を焼成して、多孔質ハニカム焼結体を得るステップと、
を有し、
前記多孔質ハニカム焼結体は、平均気孔径Z(μm)が10μm以上、20μm以下であり、
前記2種類以上の平均粒径を有する炭化珪素のうち、重量換算での配合量が最も高い炭化珪素の平均粒径をX(μm)とし、造孔材の平均粒径をY(μm)としたとき、
15≦X、0.5・X≦Z≦0.9・X、0.8・Z≦Y≦1.8・Zの関係を満たすことを特徴とする、ハニカム焼結体を製造する方法が提供される。
平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・X、0.8・Z≦Y≦1.8・Zの関係を満たすことを特徴とするハニカム構造体が提供される。このような関係を満たすようにしてハニカム構造体を製造することにより、高気孔率(45〜60%)でかつシャープな気孔径分布を有するハニカム構造体を得ることができる。
平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料を混合して、成形体原料を得るステップであって、平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・Xおよび0.8・Z≦Y≦1.8・Zであるステップと、
前記成形体原料を成形して、成形体を形成するステップと、
前記成形体を脱脂して、前記造孔材を焼失させるステップと、
前記成形体を焼成して、多孔質炭化珪素焼結体を形成するステップと、
を有することを特徴とするハニカム構造体を製造する方法が提供される。このような方法によって、高気孔率(45〜60%)でかつシャープな気孔径分布を有するハニカム構造体を、従来に比べて短時間または低温で、効率的に製造することができる。
平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料を混合して、成形体原料を得るステップであって、平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・Xおよび0.8・Z≦Y≦1.8・Zであるステップと、
前記成形体原料を成形して、成形体を形成するステップと、
前記成形体を脱脂して、前記造孔材を焼失させるステップと、
前記成形体を焼成して、多孔質炭化珪素焼結体を形成するステップと、
を有することを特徴とする方法が提案される。なお、本願において、平均粒径の大きな炭化珪素粒子(以下、「粗粒炭化珪素粒子」という)、造孔材等の平均粒径は、全てレーザー回折・散乱法によって測定される値である。
平均粒径20μmの粗粒炭化珪素粉末6000重量部と、平均粒径0.5μmの微粒炭化珪素粉末2570重量部と、造孔材としての平均粒径17.5μmの中空アクリル粒子300重量部と、有機バインダ(メチルセルロース)550重量部とを乾式混合して、混合組成物を得た。
粗粒炭化珪素粉末の平均粒径と添加量、微粒炭化珪素粉末の添加量、造孔材としての中空アクリル粒子の平均粒径と添加量、およびメチルセルロースの添加量を変化させた各種混合組成物を調製し、実施例1の場合と同様の方法で、実施例2〜16に係るハニカム構造体を製作した。ただし、これらのハニカム構造体のうち実施例12および実施例13では、焼成温度と焼成時間(2200℃、5時間)が実施例1とは異なっている。実施例1〜16のハニカム構造体の使用原料仕様および焼成条件を表1にまとめて示す。
同様に、成形体を製作する際に、表1に示す各成分を混合して、混合組成物を形成し、押出成形により成形体を製作した他は、実施例1と同様の方法で、比較例1〜9のハニカム構造体を製造した。なお、これらのハニカム構造体のうち比較例3では、焼成温度と焼成時間が実施例1とは異なっている(2250℃、7時間)。
(1)平均気孔径および気孔率の測定
実施例1〜16および比較例1〜9に係るハニカム構造体をポロシメータ(島津製作所社製、オートポアIII9420)を用い、水銀圧入法により細孔直径0.1〜360μmの範囲で細孔分布を測定した。この測定によって、各試験体の平均気孔径および気孔率が得られた。得られた結果を表2に示す。全てのハニカム構造体において、気孔率は、目標通り45〜60%程度であった。また、気孔径は、10〜20μmの範囲を目標としたが、比較例4では目標値を下回り(気孔径は、9.8μm)、比較例7および8では、目標値を超えていることがわかる(気孔径は、それぞれ20.3、21.5μm)。
Vld(1)=0、
Vld(n)={V(n)−V(n−1)}/{log[D(n−1)]−log[D(n)]}、(n≧2)
で表される。
実施例1〜16および比較例1〜9に係るハニカム構造体をエンジンの排気通路に配設し、ハニカム構造体の捕集効率を測定した。捕集効率は、以下のようにして測定した。排気量2リットルのディーゼルエンジンを回転数2000rpm、トルク47N・mの条件で運転する。このような運転によってエンジンから排出される排ガスをハニカム構造体に流通させる。ハニカム構造体に流入される前の排ガス中のPM量(P0)とハニカム構造体を通過した排ガス中のPM量(P1)とを、PMカウンタによって測定する。得られた結果から、捕集効率(%)=(P0−P1)/P0×100として、捕集効率を算定する。なお、ここでは、初期捕集効率の値(新品あるいは新品同様の状態にあるハニカム構造体に排ガスを流通させて、捕集を開始した直後の捕集効率の値)を用いて評価を行っている。
11 接着材層
12 シール材層
15 炭化珪素ブロック
20 多孔質炭化珪素部材
21 セル
22 封止材
23 セル壁
70 排ガス浄化装置。
Claims (5)
- ハニカム焼結体を製造する方法であって、
2種類以上の平均粒径を有する炭化珪素と、造孔材とを含む原料を成形することにより、ハニカム成形体を得るステップと、
前記ハニカム成形体を焼成して、多孔質ハニカム焼結体を得るステップと、
を有し、
前記多孔質ハニカム焼結体は、平均気孔径Z(μm)が10μm以上、20μm以下であり、
前記2種類以上の平均粒径を有する炭化珪素のうち、重量換算での配合量が最も高い炭化珪素の平均粒径をX(μm)とし、造孔材の平均粒径をY(μm)としたとき、
15≦X、0.5・X≦Z≦0.9・X、0.8・Z≦Y≦1.8・Zの関係を満たすことを特徴とする、ハニカム焼結体を製造する方法。 - 平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料を用いて製造された、複数のセルがセル壁を隔てて長手方向に並設された、平均気孔径Z(μm)が10μm以上、20μm以下のハニカム構造体であって、
平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・X、0.8・Z≦Y≦1.8・Zの関係を満たすことを特徴とするハニカム構造体。 - 前記セルのセル壁に触媒が担持されていることを特徴とする請求項2に記載のハニカム構造体。
- 平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料から、複数のセルがセル壁を隔てて長手方向に並設され、平均気孔径Z(μm)が10μm以上、20μm以下のハニカム構造体を製造する方法であって、
平均粒径の異なる少なくとも2種類の炭化珪素粒子と、造孔材とを含む原料を混合して、成形体原料を得るステップであって、平均粒径の大きな炭化珪素粒子の平均粒径をX(μm)、造孔材の平均粒径をY(μm)としたとき、15≦X、0.5・X≦Z≦0.9・Xおよび0.8・Z≦Y≦1.8・Zであるステップと、
前記成形体原料をハニカム形状に成形して、成形体を形成するステップと、
前記成形体を脱脂して、前記造孔材を焼失させるステップと、
前記成形体を焼成して、多孔質炭化珪素焼結体を形成するステップと、
を有することを特徴とするハニカム構造体を製造する方法。 - さらに、前記セルのセル壁に触媒を担持させるステップを有することを特徴とする請求項4に記載のハニカム構造体を製造する方法。
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Also Published As
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EP1839720A1 (en) | 2007-10-03 |
EP1839720B1 (en) | 2012-12-05 |
KR100882767B1 (ko) | 2009-02-09 |
US7851396B2 (en) | 2010-12-14 |
KR20070098699A (ko) | 2007-10-05 |
US20070293392A1 (en) | 2007-12-20 |
JP4863904B2 (ja) | 2012-01-25 |
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