JP2015520718A - 軸方向に区画されたセラミックハニカム集成体 - Google Patents
軸方向に区画されたセラミックハニカム集成体 Download PDFInfo
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- JP2015520718A JP2015520718A JP2015507022A JP2015507022A JP2015520718A JP 2015520718 A JP2015520718 A JP 2015520718A JP 2015507022 A JP2015507022 A JP 2015507022A JP 2015507022 A JP2015507022 A JP 2015507022A JP 2015520718 A JP2015520718 A JP 2015520718A
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Abstract
Description
(a)少なくとも1つの下流セラミックハニカム区画が少なくとも1つの貫通セラミックハニカム区画の下流に配置され、
(b)貫通セラミックハニカム区画と下流セラミックハニカム区画が、多孔質隔壁により画定される複数の軸方向に延びるセルをそれぞれ有し、
(c)貫通セラミックハニカム区画(1つまたは複数)の軸方向に延びるセルと、下流ハニカム区画(1つまたは複数)の軸方向に延びるセルが、セラミックハニカム集成体を上流端から下流端まで通る複数の流体流路を一緒に画定し、
(d)各貫通セラミックハニカム区画が、(i)両端部が開口し、流体がセル壁を貫通することなく貫通セラミックハニカムを流れる流路を形成する、少なくとも15数量%の貫通セルと、(ii)前記貫通セラミックハニカム区画の出口端部が閉鎖されているが入口端部は閉鎖されていないので、入った流体は前記貫通セラミックハニカムを通過するときに少なくとも1つのセル壁を貫通しなければならない、入口セルを含み、
(e)各下流セラミックハニカム区画が、(i)前記下流セラミックハニカム区画の入口端部が閉鎖されているが出口端部は閉鎖されていない出口セル、(ii)前記下流セラミックハニカム区画の出口端部が閉鎖されているが入口端部は閉鎖されていないので、その入口端部に入った流体は前記下流セラミックハニカムの出口端部から出るにはセル壁を貫通しなければならない、入口セル、および(iii)両端部が開口し、流体がセル壁を貫通することなく下流セラミックハニカムを通過する通路を形成する、0〜10数量%の貫通セルを含む。
四角形の断面をもつ同一のハニカムを9つ準備する。それぞれ長さはおよそ20.3cm、断面は8.0cm×8.0cmである。それぞれ断面積の1平方センチあたり約31個のセル(セル約200個/in2)を含む。壁厚は265μmであり、壁気孔率は68.6%であり、孔径は10.7μmである。これらのハニカムは3×3のパターンに配置され互いに接着される。次いで得られた集成体を直径約22.9cm、長さ20.3cmのシリンダに切断する。次いで得られたシリンダを切断して2つの区分されたハニカム区画を作製するが、その長さは一方は3.8cm、他方は16.5cmである。
実施例2を、区分されたハニカムシリンダを長さが等しい2つの区画に切断し、目封止および外殻を施して軸方向に分割されたハニカム集成体を作製することを除き、実施例1と同様に準備する。比較試料Bを比較試料Aと同様に作製する。
ハニカム集成体の実施例3を、個々のハニカムをそれぞれ1個の8.9cm片と1個の11.4cm片に切断することを除いて実施例1と概ね同様に準備する。8.9cm片1個と11.4cm片8個を、出口端部のセルを交互に目封止して市松模様にし、同数の貫通セルと入口セル(出口セルなし)を形成して、貫通区画に形成する。残りの8個の8.9cm片と1個の残りの11.4cm片を、両端部でセルを交互に目封止して市松模様にし、同数の入口セルと出口セル(貫通セルなし)を形成して、下流区画に形成する。次に、図5に示すように、目封止した区画を接着して、図5の区画42B、42A、44Bおよび44Aにそれぞれ対応する8.9cmの貫通区画、11.4cmの貫通区画、11.4cmの下流区画および8.9cmの下流区画を有する3×3のハニカム集成体にする。次に、3〜5mm厚の紙スペーサを各貫通区画の出口端部と、次の下流区画の入口端部の間に配置する。次にセメント外殻が周辺に適用され、得られた集成体はセメントを乾かすために焼成され、周辺セメント壁を生成し、紙スペーサを除去するとハニカム区画の間に3〜5mmの空隙ができている。
MTSF=破壊強さ/(CTE×ヤング率)
MTSFの単位は℃であり、値が高いほど熱衝撃耐性が良好である。実施例3は、破壊強さ24.0mPa、ヤング率21.5GPa、MTSF214℃である。比較試料Bは、破壊強さ24.8mPa、ヤング率21.9GPa、MTSF214℃である。これらの値は機械的特性と熱衝撃耐性にほとんど差がないことを示す。
ハニカム集成体の実施例4を、個別のハニカムのうち8つをそれぞれ1個の3.8cm片と1個の16.5cm片に切断することを除いて実施例1と概ね同様に準備する。9つ目のハニカムは切断しない。未切断のハニカムの両端部を市松模様に目封止し、同数の入口セルと出口セル(貫通セルなし)を形成する。3.8cmのハニカムは、出口端部でセルを交互に目封止して市松模様にし、同数の貫通セルと入口セル(出口セルなし)を形成して、貫通区画に形成する。16.5cmのハニカムは、両端部でセルを交互に目封止して市松模様にし、同数の入口セルと出口セル(貫通セルなし)を形成して、下流区画に形成する。次に、図6に示すように、目封止したハニカムを接着して、図6の区画45、42Aおよび44Aにそれぞれ対応する未切断ハニカム、3.8cmの貫通ハニカムおよび16.5cmの下流ハニカムを有する3×3のハニカム集成体にする。次に、3〜5mm厚の紙スペーサを各貫通区画の出口端部と、隣接する下流区画の入口端部の間に配置する。次にセメント外殻が周辺に適用され、得られた集成体はセメントを乾かすために焼成され、周辺セメント壁を生成し、紙スペーサを除去するとハニカム区画の間に3〜5mmの空隙ができている。
Claims (17)
- 1つまたは複数の貫通セラミックハニカム区画および1つまたは複数の下流セラミックハニカム区画を備えるセラミックハニカム集成体であって、セラミックハニカム区画は、軸方向に連続的に配置され、ハニカム区画の各連続対の間には空隙が設けられ、前記ハニカム区分を互いに固定された空間的関係に保持する構造的手段と、ハニカム区画の各連続対の間の1つまたは複数の空隙の周辺を包囲する包囲手段を備え、
(a)少なくとも1つの下流セラミックハニカム区画が少なくとも1つの貫通セラミックハニカム区画の下流に配置され、
(b)貫通セラミックハニカム区画と下流セラミックハニカム区画が、多孔隔壁により画定される複数の軸方向に延びるセルをそれぞれ有し、
(c)貫通セラミックハニカム区画(1つまたは複数)の軸方向に延びるセルと、下流ハニカム区画(1つまたは複数)の軸方向に延びるセルが、セラミックハニカム集成体を上流端から下流端まで通る複数の流体流路を一緒に画定し、
(d)各貫通セラミックハニカム区画が、(i)両端が開口し、流体がセル壁を貫通することなく貫通セラミックハニカムを流れる流路を形成する、少なくとも15数量%の貫通セルと、(ii)前記貫通セラミックハニカム区画の出口端部が閉鎖されているが入口端部は閉鎖されていないので、入った流体は前記貫通セラミックハニカムを通過するときに少なくとも1つのセル壁を貫通しなければならない、入口セルを含み、
(e)各下流セラミックハニカム区画が、(i)前記下流セラミックハニカム区画の入口端部が閉鎖されているが出口端部は閉鎖されていない出口セル、(ii)前記下流セラミックハニカム区画の出口端部が閉鎖されているが入口端部は閉鎖されていないので、その入口端部に入った流体は前記下流セラミックハニカムの出口端部から出るにはセル壁を貫通しなければならない、入口セル、および(iii)両端部が開口し、流体がセル壁を貫通することなく下流セラミックハニカムを通過する通路を形成する、0〜10数量%の貫通セルを含む、セラミックハニカム集成体。 - 下流区画が集成体の最後の区画である、請求項1に記載のセラミックハニカム集成体。
- 下流区画を1つだけ含む、請求項1または2に記載のセラミックハニカム集成体。
- 下流区画が貫通セルを含まない、請求項1から3のいずれか一項に記載のセラミックハニカム集成体。
- 少なくとも2つの貫通区画と、それに続く1つの下流区画を含む、請求項1から4のいずれか一項に記載のセラミックハニカム集成体。
- 周壁が構造的手段と包囲手段を形成する、請求項1から5のいずれか一項に記載のセラミックハニカム集成体。
- 缶が構造的手段と包囲手段を形成する、請求項1から6のいずれか一項に記載のセラミックハニカム集成体。
- 各空隙の長さが1〜25mmである、請求項1から7のいずれか一項に記載のセラミックハニカム集成体。
- 少なくとも長さの一部分が半径方向に区分されている、請求項1から8のいずれか一項に記載のセラミックハニカム集成体。
- 各半径方向区分が、少なくとも1つの貫通ハニカム区画の下流に配置された少なくとも1つの下流ハニカム区画を含み、ハニカム区画の各連続対の間に空隙を有する、請求項9に記載のセラミックハニカム集成体。
- 少なくとも1つの半径方向区分の少なくとも1つの空隙が、隣接する半径方向区分の空隙からずれている、請求項9に記載のセラミックハニカム集成体。
- 半径方向区分の少なくとも1つがハニカム集成体の全長にわたり延在し、半径方向区分の少なくとも1つが少なくとも1つの貫通ハニカム区画の下流に配置された少なくとも1つの下流ハニカム区画を含み、ハニカム区画の各連続対の間に空隙を有する、請求項9に記載のセラミックハニカム集成体。
- 少なくとも1つのハニカム区画の壁が触媒物質でコーティングされている、請求項1から12のいずれか一項に記載のセラミックハニカム集成体。
- 触媒物質がディーゼル酸化触媒を含む、請求項13に記載のセラミックハニカム集成体。
- 請求項1から14のいずれか一項に記載のセラミックハニカム集成体を形成する方法であって、(1)セラミックハニカムを形成すること、(2)ハニカムうちの少なくとも1つのセルを塞いで入口セルと出口セルを有する貫通ハニカム区画を形成し、少なくとももう1つのハニカムのセルを塞いで入口セルと出口セルと0〜10数量%の貫通セルを有する下流ハニカム区画を形成すること、および(3)貫通ハニカム区画(複数可)と下流ハニカム区画(複数可)を、少なくとも1つの貫通区画の後ろに配置された少なくとも1つの下流ハニカム区画と、連続ハニカム区画の各対の間に空隙を有して該空隙を包囲して固定された空間関係に組み立てることを含む、方法。
- 空隙が、ハニカム区画の各連続対の間に一時的なスペーサを挿入し、集成体を焼成して一時的なスペーサを除去して空隙を形成することにより形成される、請求項15に記載の方法。
- 燃焼排気流から微粒子物質を除去する方法であって、燃焼排気流に請求項1から14のいずれか一項に記載のセラミックハニカム集成体を通過させることを含む、方法。
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