JP2015166573A - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- JP2015166573A JP2015166573A JP2014041373A JP2014041373A JP2015166573A JP 2015166573 A JP2015166573 A JP 2015166573A JP 2014041373 A JP2014041373 A JP 2014041373A JP 2014041373 A JP2014041373 A JP 2014041373A JP 2015166573 A JP2015166573 A JP 2015166573A
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- JP
- Japan
- Prior art keywords
- honeycomb
- thermal expansion
- expansion coefficient
- bonding layer
- segment
- 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
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- 238000005192 partition Methods 0.000 claims abstract description 18
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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 25
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- 229910052878 cordierite Inorganic materials 0.000 claims description 7
- 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 description 7
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Abstract
【解決手段】流体の流路となる一方の端面である流入端面11から他方の端面である流出端面12まで延びる複数のセル2を区画形成する多孔質の隔壁1を有する複数個の柱状のハニカムセグメント22と、複数個のハニカムセグメント22の側面同士を接合する接合層24と、を有する柱状のハニカム接合体10を備え、ハニカム接合体10は、25〜800℃における、接合層24の熱膨張率が、ハニカムセグメント22の熱膨張率に比して大きいハニカム構造体100。
【選択図】図1
Description
本発明のハニカム構造体の一の実施形態は、図1、図2に示すような柱状のハニカム構造体100である。つまり、ハニカム構造体100は、複数個の柱状のハニカムセグメント22と、複数個のハニカムセグメント22の側面同士を接合する接合層24と、を有する柱状のハニカム接合体10を備えている。ハニカムセグメント22は、流体の流路となる一方の端面である流入端面11から他方の端面である流出端面12まで延びる複数のセル2を区画形成する多孔質の隔壁1を有している。ハニカム接合体10は、25〜800℃における、接合層24の熱膨張率が、ハニカムセグメント22の熱膨張率に比して大きいものである。
ハニカム接合体10は、複数個の柱状のハニカムセグメント22と、複数個のハニカムセグメント22の側面同士を接合する接合層24と、を備えている。そして、ハニカムセグメント22は、複数のセル2のうちの所定のセルの流入端面11側の端部に配設されるとともに、残余のセルの流出端面12側の端部に配設された目封止部25を備えている。そして、この目封止部25は、流入端面11及び流出端面12のそれぞれにおいて、所定のセルと残余のセルとが交互に、いわゆる市松模様を形成するように配置されている。
接合層は、マイカを含むか、或いは、アルミナファイバー、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含むことが好ましい。
ハニカムセグメントは、炭化珪素、アルミナチタネート、窒化珪素、及び、コージェライトよりなる群から選択される少なくとも一種を含むことが好ましい。耐熱性に優れ、耐化学性に優れている鉱物であり、接合層が耐熱性及び耐化学性に優れるものになるためである。
本発明のハニカム構造体は、ハニカム接合体が、その外周に外周コート層を更に備えることが好ましい。そして、ハニカム接合体が外周コート層を備える場合、以下の条件を満たすことが好ましい。つまり、25〜800℃において、外周コート層の熱膨張率が、ハニカムセグメントの熱膨張率に比して大きく、25〜800℃における、ハニカム接合体の接合層の熱膨張率と外周コート層の熱膨張率とが、以下の式を満たすことが好ましい。
式:0.7<(外周コート層の熱膨張率/接合層の熱膨張率)
式:0.7<(外周コート層の熱膨張率/接合層の熱膨張率)<1.5
次に、本発明のハニカム構造体の製造方法について以下に説明する。
まず、以下の方法で、ハニカム成形体を作製する。ハニカム成形原料、バインダ、界面活性剤、造孔材、水等を混合してハニカム成形原料を作製する。このハニカム成形原料には、炭化珪素、アルミナチタネート、窒化珪素、及び、コージェライトよりなる群から選択される少なくとも一種を含むことが好ましい。なお、このハニカム成形原料は、焼成後にコージェライトとなるコージェライト化原料を含むことも好ましい。
次に、ハニカム接合体を作製する。まず、ハニカムセグメントを接合する接合層を形成するための接合材を作製する。
次に、ハニカム接合体の外周に外周コート層を形成する。まず、外周コート層を形成する外周コート材を調製する。外周コート材は、無機粒子、バインダ、界面活性剤、造孔材、水等を混合して、混練することで作製することができる。外周コート材は、マイカを含むか、或いは、アルミナファイバー、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含むことが好ましい。
SiC粉末及び金属Si粉末を80:20の質量割合で混合し、これに造孔剤として澱粉、発泡樹脂を加え、更にメチルセルロース及びヒドロキシプロポキシルメチルセルロース、界面活性剤及び水を添加して可塑性の坏土を作製した。
接合層の熱膨張率は、以下のよう測定した。まず、接合層を、縦1.5mm×横15mm×厚さ0.5mmとなるように切り出して試料を作製し、マックサイエンス社製の熱膨張率測定装置(TD5000S)を用いて測定を行う。具体的には、上記試料を25〜800℃まで加熱し、試料と標準試料との熱膨張率の差(Δl)を算出する。但し、25℃及び800℃における温度上昇の速度は10℃/分以下とする。その後、熱膨張率(CTE)を以下の式(1)から求める。なお、「標準試料」は石英を用いる。このようにして、接合層の熱膨張率を測定する。
JASO規格M−505−87に規定された方法にて「耐熱衝撃性」の試験を実施した際の外周コート層におけるクラック発生の有無を確認して行った。電気炉スポーリング試験において温度差350℃以上であっても外周コート層にクラックが発生しなかった場合を「無」とする。耐熱衝撃性の試験において温度差350℃以上で外周コート層にクラックが発生した場合を「有」とする。なお、「有」は、触媒の漏れ出しの対策をする限りにおいては使用可能であることを示す。なお、各評価において、クラック発生の有無の確認は、目視にて行った。
「最大スス堆積温度」の測定については、以下のように行った。2.2Lディーゼルエンジンを搭載するエンジンベンチにて運転し、所定量のPM(パティキュレートマター)を、作製したハニカムフィルタ(ハニカム構造体)に堆積させた。その後、再生処理(ポストインジェクションによりPMを燃焼させる処理)を行い、ハニカムフィルタに流入するガス(入口ガス)の温度を上昇させた。その後、ハニカムフィルタ前後の圧力損失(ガスの入口側と出口側における圧力損失)が低下し始めたところで、ポストインジェクションを止め、エンジンをアイドル状態に切り替えた。その後、再生処理前のPM堆積量を徐々に増加させ、ハニカムフィルタにクラックが生じるまで同じ試験を繰り返し行った。このとき、DPFの排ガスの出口側の端面付近における中央セグメントの温度を熱電対で測定した。中央セグメントは、ハニカムフィルタの外周面を構成するハニカムセグメントである外周セグメント以外のハニカムセグメントのことである。そして、ハニカムフィルタにクラックが生じない場合におけるハニカムフィルタ内の最高の温度を「最大スス堆積温度」とした。
「最大スス堆積温度改善率」の算出を行った。なお、「最大スス堆積温度改善率」とは、ハニカム基材が同じで「接合層CTE/ハニカム基材CTE」が1.0以下であり且つその値が最も小さい比較例のハニカム構造体を100%(基準)とした時の改善率を意味する。接合層の熱膨張率は、従来、ハニカムセグメントの熱膨張率と同じにするか、或いは、ハニカムセグメントの熱膨張率に比して小さくするように設定されていたためである。「最大スス堆積温度改善率」の算出については、比較例2、3、実施例1〜7については、比較例1を基準に計算した。実施例8、9については、比較例4を基準に計算した。実施例10については、比較例5を基準に計算した。実施例11については、比較例6を基準に計算した。そして、「最大スス堆積温度改善率」が0%以下である場合には、ハニカム接合体を構成するハニカムセグメントにクラックが発生する。「最大スス堆積温度改善率」が0%超で1%未満のある場合には、ハニカム接合体を構成するハニカムセグメントにクラックが発生することを抑制する効果が、顕著ではないがわずかに確認できる。「最大スス堆積温度改善率」が1%以上で5%未満の場合には、「ハニカム接合体を構成するハニカムセグメントにクラックが発生することを良好に抑制することができる」と判断することができる。更に5%以上の場合には、「ハニカム接合体を構成するハニカムセグメントにクラックが発生することを更に良好に抑制することができる」と判断することができる。
各条件を、表1に示すように変更した以外は、実施例1と同様にしてハニカム構造体を作製した。実施例1の場合と同様にして、「熱膨張率」の測定を行った。結果を表1、2に示す。また、作製したハニカム構造体について、「耐熱衝撃性」、「最大スス堆積温度(℃)」、及び「最大スス堆積温度改善率(%)」の各評価を行った。結果を表2に示す。
Claims (5)
- 流体の流路となる一方の端面である流入端面から他方の端面である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複数個のハニカムセグメントと、
前記複数個のハニカムセグメントの側面同士を接合する接合層と、を有する柱状のハニカム接合体を備え、
前記ハニカム接合体は、25〜800℃における、前記接合層の熱膨張率が、前記ハニカムセグメントの熱膨張率に比して大きいハニカム構造体。 - 25〜800℃における、前記ハニカム接合体の前記接合層の熱膨張率と前記ハニカムセグメントの熱膨張率とが、式:1.1<(接合層の熱膨張率/ハニカムセグメントの熱膨張率)<40の関係を満たす請求項1に記載のハニカム構造体。
- 前記接合層が、マイカを含むか、或いは、アルミナファイバー、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含む請求項1または2に記載のハニカム構造体。
- 前記ハニカムセグメントが、炭化珪素、アルミナチタネート、窒化珪素、及び、コージェライトよりなる群から選択される少なくとも一種を含む請求項1〜3のいずれか一項に記載のハニカム構造体。
- 前記ハニカム接合体の外周に外周コート層を更に備え、
25〜800℃における、前記外周コート層の熱膨張率が、前記ハニカム接合体の前記ハニカムセグメントの熱膨張率に比して大きく、
25〜800℃における、前記ハニカム接合体の前記接合層の熱膨張率と前記外周コート層の熱膨張率とが、式:0.7<(外周コート層の熱膨張率/接合層の熱膨張率)の関係を満たす請求項1〜4のいずれか一項に記載のハニカム構造体。
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JP6169227B1 (ja) * | 2016-06-13 | 2017-07-26 | 日本碍子株式会社 | ハニカムフィルタ |
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