JP2014505646A - 多孔質セラミックハニカム物品およびその作製方法 - Google Patents
多孔質セラミックハニカム物品およびその作製方法 Download PDFInfo
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- JP2014505646A JP2014505646A JP2013542055A JP2013542055A JP2014505646A JP 2014505646 A JP2014505646 A JP 2014505646A JP 2013542055 A JP2013542055 A JP 2013542055A JP 2013542055 A JP2013542055 A JP 2013542055A JP 2014505646 A JP2014505646 A JP 2014505646A
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- porous ceramic
- ceramic honeycomb
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- honeycomb article
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- 238000004519 manufacturing process Methods 0.000 title description 3
- 239000011148 porous material Substances 0.000 claims abstract description 155
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- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims abstract description 49
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 30
- 238000010304 firing Methods 0.000 claims description 28
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 22
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 11
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Images
Classifications
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Abstract
Description
VP=(1−OFA)*(%P)
本明細書に記載される多孔質セラミックハニカム物品は、一般に、比較的低い比細孔容積VPを有する。本明細書に記載される実施形態において、多孔質セラミックハニカム物品は、0.22未満の比細孔容積を有する。いくつかの実施形態において、比細孔容積は、0.2未満あるいは0.185未満であり得る。さらに別の実施形態において、比細孔容積は、0.18未満であり得る。いくつかの他の実施形態において、比細孔容積は、0.21≦VP≦0.14の範囲であり得る。
df=(d50−d10)/d50
式中、d50およびd10が、上に定義されるとおりである。本明細書に記載される実施形態において、多孔質セラミックハニカム物品の多孔質の壁の開放相互連結気孔率の細孔径分布は、df≦0.35、df≦0.3、df≦0.25、df≦0.22、あるいはdf≦0.2であるように比較的狭い。いくつかの実施形態において、多孔質セラミックハニカム物品のd因子は、約0.15〜約0.35の範囲である。
dAbsb=(d75−d25)
式中、本明細書において使用される際の量d25は、細孔容積の25%が、d25の値より小さい直径を有する細孔から構成される細孔径であり、本明細書において使用される際の量d75は、細孔容積の75%が、d75の値より小さい直径を有する細孔から構成される細孔径である。本明細書に記載される多孔質セラミックハニカム物品は、10マイクロメートル以下のdAbsbを示す細孔径分布を有し得る。いくつかの実施形態において、多孔質セラミックハニカム物品は、8マイクロメートル以下のdAbsbあるいは6マイクロメートル以下のdAbsbを示す。中央細孔径値の周辺の幅が狭いと、細孔および孔隙/細孔容積の大部分が所望の範囲内に入り、多孔質セラミックハニカム物品の容積のほとんどが小さ過ぎるかまたは多き過ぎる細孔となって失われない。この狭い絶対幅が、触媒ウォッシュコートによる塗布に伴う改良された触媒ウォッシュコート被覆性ならびに高い透過性(すなわち、流れのための細孔利用の高い効率)を与えることが予測されると考えられる。
TSL=TSP+500℃
式中、TSPが、以下のようになる熱衝撃パラメータであり:
TSP=MOR/{[Emod][CTEH]}
Emodが、25℃(すなわち、室温(RT))における物品の弾性率であり、MORが、室温における破壊強度係数であり、psiの単位で測定され、CTEHが、500℃〜900℃で測定される高温熱膨張係数である。TSPが増加するにつれて、物品が温度勾配に耐える能力も増大する。MOR、Emod、およびCTEHは全て、本明細書において軸方向と呼ばれるチャネルの長さに平行なセル試験片において測定される。4×1×0.5インチ(10.16×2.54×1.27cm)の寸法を有する矩形セルバーの軸方向における四点曲げ方法を用いてMORを測定した。
Claims (5)
- コージエライトセラミックから形成され、かつ多孔質チャネル壁によって形成される複数のセルチャネルを含むハニカム体を含む多孔質セラミックハニカム物品であって:
前記ハニカム体が、55%以上の気孔率P%を有し;
前記ハニカム体が、150cpsi(23セル/cm2)以上のセルチャネル密度CDを有し;
前記ハニカム体の前記多孔質チャネル壁が、壁厚T(ここで、(11+(300−CD)*0.03)≧T≧(8+(300−CD)*0.02)であり、前記壁厚Tがミルの単位で表される)を有し;
前記ハニカム体の前記多孔質チャネル壁が、20マイクロメートル以下の中央細孔径を有し;
前記ハニカム体の前記多孔質チャネル壁が、0.35以下のd因子(ここで、前記d因子=(d50−d10)/d50である)を有する細孔径分布を有し;
前記ハニカム体の容積当たりの比細孔容積VPが、0.22以下であり、ここで、VP=(1−OFA)*P%であり、OFAが、前記ハニカム体の開口面積率であり;
前記多孔質セラミックハニカム物品が、100g/Lのウォッシュコート触媒で被覆され、5g/Lの煤が負荷された場合、26.5立方フィート(0.75m3)/分の流量で8kPa以下の被覆圧力降下の増加を有することを特徴とする多孔質セラミックハニカム物品。 - 非被覆初期ろ過効率および被覆初期ろ過効率が50%以上であることを特徴とする、請求項1に記載の多孔質セラミックハニカム物品。
- 前記ハニカム体が、35%を超える非被覆表面気孔率を有することを特徴とする、請求項1に記載の多孔質セラミックハニカム物品。
- 前記細孔径分布の絶対幅dAbsb(ここで、dAbsb=d75−d25である)が、10マイクロメートル以下であることを特徴とする、請求項1に記載の多孔質セラミックハニカム物品。
- 無機成分のバッチを、有機細孔形成剤および少なくとも1種の加工助剤と混合して、可塑化されたバッチを形成する工程であって:
無機成分の前記バッチが、15マイクロメートル以下の中央無機粒径d50IPを有し、10μm以下のdpt50を有するタルク、20μm以下のdps50を有するシリカ形成源、および10.0μm以下の中央粒径dpa50を有するアルミナ形成源を含み、ここで、dps50が、前記シリカ形成源の中央粒径であり、dpa50が、前記アルミナ形成源の中央粒径であり、dpt50が、前記タルクの中央粒径であり;
前記有機細孔形成剤が、前記無機成分の少なくとも30重量%を超える量で前記可塑化されたバッチ中に存在し、前記有機細孔形成剤が、25μm以下のdpp50を有し、ここで、dpp50が、前記有機細孔形成剤の中央粒径である
工程と;
前記可塑化されたバッチを未焼成ハニカム物品へと成形する工程と;
前記有機細孔形成剤を、前記未焼成ハニカム物品から燃焼し尽くす工程と;
以下のもの:
約0.04〜約0.25の微小亀裂パラメータ(Nb3)を有するコージエライト結晶相;
55%以上の気孔率P%;
20マイクロメートル以下の中央細孔径;
壁厚T(ここで、(11+(300−CD)*0.03)≧T≧(8+(300−CD)*0.02)であり、前記壁厚Tが、ミルの単位で表される);および
0.35以下のd因子(ここで、前記d因子=(d50−d10)/d50である)を有する細孔径分布
を含む多孔質セラミックハニカム物品を形成するのに有効な条件下で、前記未焼成ハニカム物品を焼成する工程と;
焼成工程の後、前記多孔質セラミックハニカム物品を微小亀裂条件に曝す工程であって、前記微小亀裂条件に曝した後、前記多孔質セラミックハニカム物品が、前記微小亀裂条件に曝される前の微小亀裂パラメータより少なくとも20%高い微小亀裂パラメータ(Nb3)を有する工程と
を含むことを特徴とする、多孔質セラミックハニカム物品を作製する方法。
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WO2012074833A1 (en) | 2012-06-07 |
CN103282327B (zh) | 2016-06-08 |
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CN103282327A (zh) | 2013-09-04 |
US8673207B1 (en) | 2014-03-18 |
JP6324472B2 (ja) | 2018-05-16 |
US20120134891A1 (en) | 2012-05-31 |
US8609032B2 (en) | 2013-12-17 |
PL2646393T3 (pl) | 2017-10-31 |
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