JP2014117663A - 微粒子捕集フィルタ - Google Patents
微粒子捕集フィルタ Download PDFInfo
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- JP2014117663A JP2014117663A JP2012275268A JP2012275268A JP2014117663A JP 2014117663 A JP2014117663 A JP 2014117663A JP 2012275268 A JP2012275268 A JP 2012275268A JP 2012275268 A JP2012275268 A JP 2012275268A JP 2014117663 A JP2014117663 A JP 2014117663A
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Abstract
【解決手段】複数個のハニカムセグメント3が、接合材12により一体的に接合されたハニカム構造体2を備え、入口端面からセル7内に流入した排ガスが、隔壁8を透過した後、出口端面からセル7外に流出する構造の微粒子捕集フィルタであって、隔壁8は骨材であるSiCが結合材であるSiにより結合されたものであり、隔壁8を透過する排ガスの入口側となる隔壁8の表面に開口している細孔の平均開口径及び隔壁8を透過する排ガスの出口側となる隔壁8の表面に開口している細孔の平均開口径の内の少なくとも一方が0.1〜5μmであり、隔壁8全体の平均細孔径が10〜30μmであり、隔壁8の室温における熱伝導率が50〜80W/mKである微粒子捕集フィルタ1。
【選択図】図1
Description
図1は、本発明に係る微粒子捕集フィルタの実施形態の一例を示す斜視概略図であり、図2は、図1の要部拡大図である。また、図3は、本発明に係る微粒子捕集フィルタの実施形態の一例において使用されている、ハニカムセグメントの斜視概略図であり、図4は、図3のA−A線断面図である。
気孔率(%)=100×全細孔容積/{(1/見掛密度)+全細孔容積}
本発明に係る微粒子捕集フィルタの製造方法の一例としては、まず、骨材となる炭化珪素粉末と、焼成により炭化珪素粒子間を結合するSi粉末とを混合し、必要に応じて、バインダ、界面活性剤、造孔材、水等を添加して、成形原料を作製する。
平均粒子径0.1μmの炭化珪素粉末(小粒径粉末)35質量部と、平均粒子径100μmの炭化珪素粉末(大粒径粉末)35質量部と、Si粉末30質量部とを混合して、混合粉末を得た。この混合粉末における炭化珪素粉末(小粒径粉末及び大粒径粉末)の平均粒子径は22.0μmである。この混合粉末100質量部に対し、バインダとしてヒドロキシプロピルメチルセルロースを7質量部、造孔材として平均粒子径20μmのデンプンと吸水性樹脂とを合計12質量部、水を70質量部添加して、成形原料とした。尚、炭化珪素粉末及び造孔材の平均粒子径は、レーザー回折法で測定した値である。
水銀圧入法(JIS R 1655準拠)により測定した。
水銀圧入法(JIS R 1655準拠)により測定した全細孔容積[cm3/g]と、アルキメデス法により測定した見掛密度[g/cm3]とから下式により算出した。
気孔率(%)=100×全細孔容積/{(1/見掛密度)+全細孔容積}
定常法により測定した。
実施例1〜25及び比較例1〜6の微粒子捕集フィルタについて、下記の方法で、スートマスリミット(SML)、圧力損失、及びPM捕集効率の評価を行い、その結果を表2に示した。また、これら各項目の評価結果に基づいて、下記の方法で、総合評価を行い、その結果を同表に示した。
微粒子捕集フィルタを、ディーゼルエンジンの排気系に取り付け、ディーゼルエンジンから排出されたスート(煤)を含む排ガスを、微粒子捕集フィルタの入口端面から流入させ、出口端面から流出させることによって、スートを微粒子捕集フィルタ内に堆積させた。そして、一旦、室温(25℃)まで冷却した後、微粒子捕集フィルタの入口端面から、680℃の燃焼ガスを流入させ、スートが燃焼することにより微粒子捕集フィルタの圧力損失が低下したときに、燃焼ガスの流量を減少させることによって、スートを急燃焼させた。その後、微粒子捕集フィルタにおけるクラックの発生の有無を確認した。このような微粒子捕集フィルタの再生処理を、スートの堆積量を4g/L(微粒子捕集フィルタの容積1リットル当りのスートの堆積量)とした状態から始め、クラックの発生が認められるまで、0.5g/Lずつ堆積量を増加して、繰り返し行った。クラック発生時のスートの堆積量を、スートマスリミット(SML)とした。一般に、スートの堆積量が多い程、それを燃焼させた時の発熱量が大きくなるため、微粒子捕集フィルタに生じる熱応力も大きくなり、クラックが発生しやすくなる。よって、SMLが大きい程、再生時に生じる熱応力の緩和効果が高いと言える。こうして求められたSMLが、8g/L以上のものを「好ましい」とし、8g/L未満のものを「好ましくない」とした。
微粒子捕集フィルタに、室温(25℃)の空気を10Nm3/分の流量で流した際の微粒子捕集フィルタの入口側(上流側)と出口側(下流側)との圧力を測定し、その圧力差を算出することにより、圧力損失を求めた。こうして求められた圧力損失が2.0kPa以下のものを「好ましい」とし、2.0kPaを超えるものを「好ましくない」とした。
微粒子捕集フィルタを、排気量2Lのディーゼルエンジンが搭載された乗用車の排気系に取り付けた。そして、この乗用車をNEDC(New European Driving Cycle)モードで走行させた際の微粒子捕集フィルタの入口側におけるPM個数累計と、微粒子捕集フィルタの出口側におけるPM個数累計との比率から、PM捕集効率を算出した。尚、PM個数の測定は、欧州経済委員会における自動車基準調和世界フォーラムの排出ガスエネルギー専門家会議による粒子測定プログラム(略称「PMP」)によって提案された手法に従って行った。こうして求められたPM捕集効率が90%以上のものを「好ましい」とし、90%未満のものを「好ましくない」とした。
上記の方法で求められたSMLをA(g/L)、圧力損失をB(kPa)、PM捕集効率をC(%)としたときに、A×C/Bという式で算出された値が、400以上のものを「合格」とし、400未満のものを「不合格」とした。
表2に示すとおり、本願発明の実施例である実施例1〜19の微粒子捕集フィルタは、何れの評価項目においても優れた性能を発揮した。また、隔壁の気孔率が34%未満である実施例20の微粒子捕集フィルタは、圧力損失がやや大きめではあったが、SMLが大きく、高いPM捕集効率を示すことから、総合評価としては合格であった。隔壁の気孔率が43%を超える実施例21の微粒子捕集フィルタは、SMLがやや小さめではあったが、圧力損失が低く、高いPM捕集効率を示すことから、総合評価としては合格であった。隔壁の厚さが120μm未満である実施例22の微粒子捕集フィルタも、SMLがやや小さめではあったが、圧力損失が低く、高いPM捕集効率を示すことから、総合評価としては合格であった。ハニカム構造体のセル密度が23セル/cm2未満である実施例23の微粒子捕集フィルタも、SMLがやや小さめではあったが、圧力損失が低く、高いPM捕集効率を示すことから、総合評価としては合格であった。隔壁の厚さが180μmを超える実施例24の微粒子捕集フィルタは、圧力損失がやや大きめではあったが、SMLが大きく、高いPM捕集効率を示すことから、総合評価としては合格であった。ハニカム構造体のセル密度が50セル/cm2を超える実施例25の微粒子捕集フィルタも、圧力損失がやや大きめではあったが、SMLが大きく、高いPM捕集効率を示すことから、総合評価としては合格であった。
Claims (4)
- 排ガスの入口側となる入口端面から排ガスの出口側となる出口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と、所定のセルの前記出口端面側の開口端部及び残余のセルの前記入口端面側の開口端部を目封止する目封止部とを有する複数個のハニカムセグメントが、接合材により一体的に接合されたハニカム構造体を備え、前記入口端面から前記セル内に流入した排ガスが、前記隔壁を透過した後、前記出口端面から前記セル外に流出する構造の微粒子捕集フィルタであって、
前記隔壁は、骨材であるSiCが結合材であるSiにより結合されたものであり、
前記隔壁を透過する排ガスの入口側となる前記隔壁の表面に開口している細孔の平均開口径、及び、前記隔壁を透過する排ガスの出口側となる前記隔壁の表面に開口している細孔の平均開口径の内の少なくとも一方が、0.1〜5μmであり、
前記隔壁全体の平均細孔径が、10〜30μmであり、
前記隔壁の室温における熱伝導率が、50〜80W/mKである微粒子捕集フィルタ。 - 前記隔壁の気孔率が、34〜43%である請求項1に記載の微粒子捕集フィルタ。
- 前記ハニカム構造体のセル密度が、23〜50セル/cm2である請求項1又は2に記載の微粒子捕集フィルタ。
- 前記隔壁の厚さが、120〜180μmである請求項1〜3の何れか一項に記載の微粒子捕集フィルタ。
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