JP2014087743A - ハニカムフィルタ - Google Patents
ハニカムフィルタ Download PDFInfo
- Publication number
- JP2014087743A JP2014087743A JP2012239374A JP2012239374A JP2014087743A JP 2014087743 A JP2014087743 A JP 2014087743A JP 2012239374 A JP2012239374 A JP 2012239374A JP 2012239374 A JP2012239374 A JP 2012239374A JP 2014087743 A JP2014087743 A JP 2014087743A
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb
- partition wall
- honeycomb filter
- binder
- stress
- 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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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
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- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24491—Porosity
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24494—Thermal expansion coefficient, heat capacity or thermal conductivity
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- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24495—Young's modulus
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- B01D46/247—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the cells
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- B01D46/2474—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the walls along the length of the honeycomb
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Abstract
【解決手段】ハニカム構造体4と目封止部5とを備え、ハニカム構造体4の隔壁1が、炭化珪素又は窒化珪素を主成分とする複数の骨材と、骨材同士を結合する結合材とを含む隔壁材料からなり、隔壁材料が、骨材と結合材との合計質量に対して、結合材を15〜35質量%含有し、結合材が、コージェライト中に強化粒子であるムライト粒子が分散された材料又はコージェライトを主成分とする材料からなり、隔壁の40〜800℃における熱膨張係数が4.2×10−61/K以下であり、900℃における、隔壁材料に加わる応力の値を、隔壁材料にかかる応力の最大値で正規化した際に、正規化された応力値0.9において、全変位に占める塑性変形変位の割合が0.3〜10%の範囲であるハニカムフィルタ100。
【選択図】図3
Description
本発明のハニカムフィルタの一の実施形態は、図1〜図3に示すようなハニカムフィルタ100である。図1〜図3に示すように、本実施形態のハニカムフィルタ100は、多孔質の隔壁1を有するハニカム構造体4と、複数の目封止部5とを備えたハニカムフィルタ100である。ここで、図1は、本発明のハニカムフィルタの一の実施形態を模式的に示す斜視図である。図2は、本発明のハニカムフィルタの一の実施形態の、流入端面を模式的に示す平面図である。図3は、図2のA−A’断面を模式的に示す断面図である。
図1〜図3に示すように、ハニカム構造体4は、流入端面11から流出端面12まで延びる複数のセル2を区画形成する隔壁1を有する筒状のものである。図5及び図6に示すように、ハニカム構造体24は、複数個のハニカムセグメント26が接合層27によって接合されたものであってもよい。
気孔率(%)=100×全細孔容積/{(1/見掛密度)+全細孔容積} (1)
図1〜図3に示すように、目封止部5は、ハニカム構造体4に形成されたセル2の流入端面11側又は流出端面12側の端部に配置され、セル2の一方の端部を封止するものである。このような目封止部5が、セル2の一方の端部を封止することにより、多孔質の隔壁1を有するハニカム構造体4が、排ガス等の流体を浄化するためのフィルタとして機能する。
図5及び図6に示すハニカムフィルタ200においては、複数個のハニカムセグメント26の側面同士が接合層27によって接合されたハニカム構造体24を備えたものである。このようなセグメント構造のハニカムフィルタ200における接合層27は、複数個のハニカムセグメント26を接合して一体化するための接合材からなるものである。
次に、本実施形態のハニカムフィルタを製造する方法について説明する。以下、本実施形態のハニカムフィルタを製造する方法について、セグメント構造のハニカムフィルタを製造する方法を例として説明する。
骨材となる炭化珪素(SiC)粉末と、結合材生成用原料粉末とを、7:3(体積比)の比率で混合して「混合粉末」を作製した。結合材生成用粉末としては、タルクを45.1体積%、カオリンを32.8体積%、水酸化アルミニウムを22.1体積%含有する粉末を用いた。そして、上記「混合粉末」に、バインダとしてヒドロキシプロピルメチルセルロース、造孔材としてデンプン、吸水性樹脂を添加すると共に、水を添加して成形原料とした。バインダの含有量は混合粉末を100質量部としたときに、7質量部であった。造孔材の含有量は混合粉末を100質量部としたときに、10質量部であった。水の含有量は混合粉末を100質量部としたときに、70質量部であった。
JIS R 1655に準拠する方法で隔壁の気孔率を測定した。即ち、水銀圧入法による全細孔容積(cm3/g)と、アルキメデス法により測定した見掛密度(g/cm3)から、下記式(2)を用いて気孔率を算出した。
気孔率(%)=100×全細孔容積/{(1/見掛密度)+全細孔容積} (2)
平均細孔径は、JIS R 1655準拠して、水銀圧入法により測定した。
まず、ハニカムフィルタを構成するハニカム構造体から、曲げ強度を測定するための隔壁材料試験片を作製した。この隔壁材料試験片(以下、単に「試験片」ともいう)は、ハニカム構造体のセルの延びる方向を長手方向とした試験片とした。また、この試験片は、縦が0.3mm、横が4mm、長さが40mmとした。このように作製した試験片を用いて、JIS R 1601に準拠した曲げ試験により、荷重と変位を記録し、荷重、試験片サイズ、及び4点曲げのスパン距離から、隔壁材料に発生した応力を計算し、応力−変位線図を作成した。得られた応力−変位線図から、隔壁材料の全変位u1を求めた。また、計算結果より、隔壁材料に加わる応力の値を、隔壁材料にかかる応力の最大値で正規化した。正規化した応力値を用いて、図4に示すようなグラフを作成し、応力値0と、応力値0.5との2点を結ぶ直線を引き、この直線の応力値0.9での変位と、全変位u1との差分の量(変位量)を、塑性変形変位u2とした。このようにして、「隔壁材料の全変位u1」及び「塑性変形変位u2」を求め、「正規化された応力値0.9における、全変位u1に占める塑性変形変位u2の割合」を算出した。
まず、ハニカムフィルタを、ディーゼルエンジンの排気系に設置した。次に、ディーゼルエンジンを始動させ、ディーゼルエンジンから排出される排ガスをハニカムフィルタに通気して、ハニカムフィルタの隔壁により排ガス中のススを捕集した。隔壁上に捕集したススが堆積した状態で、ススを燃焼除去する再生試験を行った。このような再生試験を、隔壁上に堆積したススの量を増加させて繰り返し行い、ハニカムフィルタにクラックが発生しない限界のススの堆積量を求めた。即ち、ススの燃焼熱による熱応力で、ハニカムフィルタにクラック発生するか否かを確認し、クラックが発生しない限界のススの堆積量を求めた。なお、ススの堆積量を増やすほど、ススの燃焼による発熱が大きくなり、より大きな熱応力を生じて、ハニカムフィルタにクラックが発生し易くなる。クラックが発生しない最大のススの堆積量が、最大スス堆積量(g/L)である。最大スス堆積量(g/L)は、ハニカムフィルタの容積1Lあたりに堆積したススの質量(g)によって示す。最大スス堆積量は、「スート マス リミット(Soot Mass Limit(SML))」とも称されることがある。
結合材生成用原料粉末に用いたタルク、カオリン、水酸化アルミニウムの平均粒子径を、表1に示すように変更した以外は、実施例1と同様の方法でハニカムフィルタを作製した。
結合材生成用原料粉末に用いたタルク、カオリン、水酸化アルミニウムの平均粒子径を、表2に示すように変更し、焼成温度(℃)を、表2に示すように変更した以外は、実施例1と同様の方法でハニカムフィルタを作製した。
結合材生成用原料粉末に用いたタルク、カオリン、水酸化アルミニウムの平均粒子径を、表1に示すように変更し、且つ造孔材の添加量、及び造孔材の平均粒子径を表1に示すように変更した以外は、実施例1と同様の方法でハニカムフィルタを作製した。
造孔材の添加量を表2に示すように変更した以外は、比較例1〜3と同様の方法でハニカムフィルタを作製した。
目封止ハニカム乾燥体を焼成した後に、1200℃で4時間、酸化処理を行ってハニカムセグメントを得たこと以外は、比較例1、2と同様の方法でハニカムフィルタを作製した。表1の「酸化雰囲気熱処理(℃)」の欄に、酸化雰囲気熱処理の温度を示す。
隔壁材料の骨材と結合材(結合材生成用原料粉末)との配合率(%)を、表1に示すように変更した以外は、実施例8と同様の方法でハニカムフィルタを作製した。
実施例11においては、結合材生成用原料粉末として、タルクを32.8体積%、シリカを22.2体積%、水酸化アルミニウムを45.1体積%含有する粉末を用いて、混合粉末を作製した。タルクの平均粒子径は3μmであり、シリカの平均粒子径は1μmであり、水酸化アルミニウムの平均粒子径は0.4μmであった。このような混合粉末を用いて、実施例1と同様の方法でハニカムフィルタを作製した。なお、目封止ハニカム乾燥体の焼成温度は、1450℃とした。実施例11のハニカムフィルタは、結合材の主成分結晶が、コージェライトであった。
表1及び表2に示すように、実施例1〜11のハニカムフィルタは、炭化珪素粉末からなる骨材と、この骨材同士を、隔壁の気孔率が35〜70%となるように細孔を形成した状態で結合する結合材とを含む隔壁材料からなるものであった。また、隔壁を構成する隔壁材料には、骨材と結合材との合計質量に対して、結合材が20〜35質量%含有されていた。このような実施例1〜11のハニカムフィルタは、隔壁の気孔率、隔壁の40〜800℃における熱膨張係数が所定の範囲内にある。このため、実施例1〜11のハニカムフィルタは、エンジン、特に、自動車のエンジンから排出される排ガスから、粒子状物質を捕集するハニカムフィルタとして好適に用いることが可能なものであった。更に、実施例1〜11のハニカムフィルタは、「900℃における、正規化された応力値0.9での全変位に占める塑性変形変位の割合」が、0.3〜10%の範囲内であった。このような実施例1〜11のハニカムフィルタは、最大スス堆積量が10g/L以上であり、ハニカムフィルタに大きな熱応力が生じた場合であっても、ハニカムフィルタにクラックが発生し難いものであった。
Claims (5)
- 流入端面から流出端面まで延びる複数のセルを区画形成する多孔質の隔壁を有する筒状のハニカム構造体と、
前記ハニカム構造体に形成された前記セルのうちの第一セルの前記流入端面側の開口部を封止するとともに、前記第一セル以外の第二セルの前記流出端面側の開口部を封止する複数個の目封止部と、を備え、
前記隔壁が、炭化珪素又は窒化珪素を主成分とする複数の骨材と、前記骨材同士を、前記隔壁の気孔率が35〜70%となるように細孔を形成した状態で結合する結合材とを含む隔壁材料からなり、
前記隔壁材料が、前記骨材と前記結合材との合計質量に対して、前記結合材を15〜35質量%含有し、
前記結合材が、コージェライト中に強化粒子であるムライト粒子が分散された材料、又はコージェライトを主成分とする材料からなり、
前記隔壁の40〜800℃における熱膨張係数が4.2×10−61/K以下であり、
900℃における、前記隔壁材料に加わる応力の値を、前記隔壁材料にかかる応力の最大値で正規化した際に、正規化された応力値0.9において、全変位に占める塑性変形変位の割合が0.3〜10%の範囲であるハニカムフィルタ。 - 自動車から排出された排ガス中の微粒子を捕集するフィルタである請求項1に記載のハニカムフィルタ。
- 前記ハニカム構造体のセル密度が、23セル/cm2以上、60セル/cm2以下である請求項1又は2に記載のハニカムフィルタ。
- 前記ハニカム構造体の前記隔壁の厚さが、120μm以上、400μm以下である請求項1〜3のいずれか一項に記載のハニカムフィルタ。
- 曲げ強度が6.5MPa以上であり、曲げ強度の値をヤング率の値で除した値(曲げ強度/ヤング率)が1.4×10−3以上である請求項1〜4のいずれか一項に記載のハニカムフィルタ。
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EP2415510B1 (en) * | 2009-03-31 | 2015-07-22 | NGK Insulators, Ltd. | Honeycomb filter and method of manufacturing same |
JP5916146B2 (ja) * | 2011-03-18 | 2016-05-11 | 日本碍子株式会社 | 炭化珪素質多孔体、ハニカム構造体及び電気加熱式触媒担体 |
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- 2012-10-30 JP JP2012239374A patent/JP6059954B2/ja active Active
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JP2002154876A (ja) * | 2000-11-17 | 2002-05-28 | Ngk Insulators Ltd | ハニカム構造体及びその製造方法 |
WO2002070433A1 (fr) * | 2001-03-02 | 2002-09-12 | Ngk Insulators,Ltd. | Structure en nid d'abeilles |
WO2005009922A1 (ja) * | 2003-07-25 | 2005-02-03 | Ngk Insulators, Ltd. | セラミックス多孔質体及びその透過性能評価方法 |
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WO2013146953A1 (ja) * | 2012-03-28 | 2013-10-03 | 日本碍子株式会社 | 多孔質材料、ハニカム構造体及び多孔質材料の製造方法 |
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JP2016191335A (ja) * | 2015-03-31 | 2016-11-10 | 日本碍子株式会社 | セラミックスフィルタ |
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EP2727895A1 (en) | 2014-05-07 |
US20140116016A1 (en) | 2014-05-01 |
JP6059954B2 (ja) | 2017-01-11 |
US9217344B2 (en) | 2015-12-22 |
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