JP2017149593A - Ceramic component and method for three-dimensionally producing ceramic component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable treatment of high-temperature fluid such as exhaust gas from an automobile under the reduced influence of a temperature distribution in the direction of flow of the fluid.SOLUTION: A ceramic component 1 is a ceramic component including: a substrate 2 including a ceramic material; plural first flow passages 6 which is disposed on the substrate, and through which fluid passes from a first side 3 to a second side 4 of the substrate; and reaction contribution members disposed on the inner surfaces of the first flow passages. In the ceramic component, the flow passage resistances of the first flow passages increase from an upstream side to a downstream side in the passing direction of the fluid.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a ceramic part having a flow path through which a high-temperature fluid such as exhaust gas passes, and a reaction participating member such as an exhaust gas purification catalyst provided in the flow path, and to a three-dimensional manufacturing method of the ceramic part.

  Patent Document 1 describes a honeycomb filter (ceramic part) for exhaust gas purification. This honeycomb filter has a structure in which a partition wall that defines a flow path through which exhaust gas passes is made porous. A manufacturing method for manufacturing a honeycomb filter having this structure using a three-dimensional modeling method is disclosed (0048).

JP-A-2015-189666

When the high-temperature fluid passes through the flow path of the ceramic component, heat flows from the upstream side to the downstream side of the flow channel while transferring heat to the ceramic component side by contact with the inner surface of the flow channel. For this reason, the temperature of the fluid decreases from the upstream side to the downstream side of the flow path, and there is a problem that the temperature distribution is generated and the purification ability of the exhaust gas is difficult to stabilize. Moreover, since the upstream side of the flow path of the ceramic component is exposed to a fluid having a higher temperature than the downstream side, there is a problem that high temperature deterioration is likely to occur on the upstream side.
Patent Document 1 neither describes nor suggests the problem of the temperature distribution.

  An object of the present invention is to reduce the influence of the temperature distribution in the direction in which the fluid flows when processing a high-temperature fluid such as automobile exhaust gas.

  In order to solve the above-described problems, a ceramic component according to a first aspect of the present invention includes a base made of a ceramic material, and a plurality of fluids that are provided on the base and pass from one side of the base to the other side. A ceramic component having a first flow path and a reaction participating member provided on an inner surface of the first flow path, wherein the first flow path is from an upstream side to a downstream side in a direction in which the fluid passes. The channel resistance is increased.

Here, the “reaction participation member” has a function related to the progress of a desired chemical reaction in contact with the fluid passing through the flow path. For example, a catalyst used for exhaust gas purification treatment.
The “flow path resistance” is a resistance when a fluid passes through the first flow path. A flow path with a large flow path resistance is difficult to pass through a fluid, and a flow path with a low flow resistance is passed through a fluid. Cheap. For example, when the channel cross-sectional area is small or the channel inner diameter is small, the channel resistance increases. When the channel cross-sectional area is large or the channel inner diameter is large, the channel resistance decreases.

According to this aspect, the first channel has a channel resistance that increases from the upstream side to the downstream side in the direction in which the fluid passes. Since the flow path resistance is small on the inlet side, that is, the upstream side in the flow direction, it passes at a high speed. On the other hand, the outlet side, that is, the downstream side of the flow path passes at a low speed because the flow path resistance is larger than that of the upstream side.
Therefore, the amount of heat transferred from the high-temperature fluid to the ceramic component is reduced in the upstream portion of the flow path, and the fluid moves to the downstream side of the flow path in a state where the temperature drop of the fluid is suppressed. On the other hand, in the downstream portion of the flow path, the amount of heat transfer increases due to a decrease in the passage speed of the fluid. Thereby, the influence of the temperature distribution in the direction in which the fluid flows can be reduced, and stabilization of processing such as exhaust gas purification by the reaction participating member can be promoted. Moreover, the high temperature deterioration of the upstream part of a flow path can be suppressed.
The ceramic component having such a structure can be easily manufactured by a three-dimensional manufacturing method described later.

  According to a second aspect of the ceramic component of the present invention, in the first aspect, the first flow path includes a plurality of second flow paths through which fluid passes in a direction crossing a direction from the one side toward the other side. And the second channel has a channel resistance that increases from the upstream side toward the downstream side in the direction in which the fluid passes.

According to this aspect, since the flow resistance of the second flow path also increases from the upstream side to the downstream side in the direction in which the fluid passes, the influence of the temperature distribution is also reduced in the second flow path. Stabilization of processing such as exhaust gas purification by the participating member can be promoted. Moreover, the high temperature deterioration of the upstream part of a flow path can be suppressed.
This aspect is particularly effective in the case where the diameter of the fluid inlet portion of the ceramic component is smaller than the diameter of the main body portion (portion where a plurality of flow paths exist) of the ceramic component.
A ceramic component having a structure including such a second flow path can also be easily manufactured by a three-dimensional manufacturing method described later.

According to a third aspect of the ceramic component of the present invention, in the first aspect or the second aspect, at least one of the first flow path and the second flow path is formed by a series of pores. Due to the difference, the flow path resistance increases from the upstream side to the downstream side in the direction in which the fluid passes.
Here, “a series of pores” means that when a ceramic part is produced by sintering and solidifying raw material particles, a gap (pore) formed between the raw material particles communicates with an adjacent gap (pore). This means that a channel such as the first channel is formed by the communication.

  According to this aspect, a fluid flow path such as the first flow path can be formed by utilizing the gap between the raw material particles.

  According to a fourth aspect of the present invention, there is provided a ceramic component comprising: a base composed of a ceramic material; a plurality of first flow paths provided on the base and allowing fluid to pass from one side to the other side of the base; A ceramic component having a reaction participating member provided on the inner surface of one flow path, wherein the reaction changing member changes its property from high temperature activity to low temperature activity from the upstream side to the downstream side in the direction in which the fluid passes. It is characterized by that.

According to this aspect, since the characteristic of the reaction participating member changes from the high temperature activity to the low temperature activity from the upstream side to the downstream side in the direction in which the fluid passes, the reaction participating member depends on the characteristics of the reaction participating member even if the temperature distribution occurs. It is less affected by the temperature distribution. That is, the upstream portion is in contact with the hottest fluid, but the reaction-related member in this portion has a high-temperature active characteristic, so that an effective treatment is performed. As the fluid proceeds downstream, the temperature decreases due to heat transfer. However, since the downstream portion is provided with a low-temperature active reaction participating member, effective processing is performed at the decreased temperature. Thereby, the influence of the temperature distribution in the direction in which the fluid flows can be reduced, and stabilization of processing such as exhaust gas purification by the reaction participating member can be promoted.
The ceramic component having such a structure can be easily manufactured by a three-dimensional manufacturing method described later.

  According to a fifth aspect of the ceramic component of the present invention, in the fourth aspect, the first flow path includes a plurality of second flow paths through which fluid passes in a direction intersecting with the direction from the one side toward the other side. And the second flow path is characterized in that the characteristic of the reaction participating member changes from high temperature activity to low temperature activity from the upstream side to the downstream side in the direction in which the fluid passes.

According to this aspect, since the characteristic of the reaction participating member changes from the high temperature activity to the low temperature activity from the upstream side to the downstream side in the direction in which the fluid passes, the temperature distribution also in the second channel. Thus, stabilization of treatment such as exhaust gas purification by the reaction participating member can be promoted.
This aspect is particularly effective in the case where the diameter of the fluid inlet portion of the ceramic component is smaller than the diameter of the main body portion (portion where a plurality of flow paths exist) of the ceramic component.
A ceramic component having a structure including such a second flow path can also be easily manufactured by a three-dimensional manufacturing method described later.

  The ceramic component according to a sixth aspect of the present invention is the ceramic component according to any one of the first to fifth aspects, wherein the base body has a plurality of blocks stacked from the one side to the other side. The block has a stacked structure, and the plurality of blocks have different characteristics of the flow path resistance or the reaction participating member for each block.

  According to this aspect, since it is a block overlapping structure in which a plurality of blocks are overlapped, the structure of each aspect can be easily manufactured by changing the characteristics of the flow path resistance or the reaction participating member for each of the plurality of blocks. Can be realized.

  The ceramic component according to a seventh aspect of the present invention is the ceramic component according to any one of the first to sixth aspects, wherein the reaction participating member is a catalyst for exhaust gas treatment.

  According to this aspect, since the reaction participating member is a catalyst for exhaust gas treatment, it is effective when applied to ceramic parts for exhaust gas treatment of automobiles (gasoline vehicles and diesel vehicles).

  According to an eighth aspect of the present invention, in the ceramic component according to any one of the first to seventh aspects, a plurality of the bases are provided in a direction from the one side to the other side, and the reaction participation is performed. The member is of a different type for each of the substrates.

  For example, when the particulate matter (PM) is contained in the exhaust gas in addition to the gas to be removed such as HC, CO and NOX, such as a diesel engine car, the purification of the gas to be removed in the fluid flow direction. The structure in which the part for the catalyst (oxidation catalyst supporting part) is arranged in the previous stage and the PM removal part (PM removal filter) is arranged in the subsequent stage is adopted. It is effective to apply this aspect to the ceramic parts having such a structure. It is.

  A ceramic component according to a ninth aspect of the present invention is the ceramic component according to any one of the first to sixth aspects, wherein the base of the ceramic component is divided into a plurality from the one side to the other side. The heat capacity of the ceramic component corresponding to the substrate on the one side is smaller than the heat capacity of the ceramic component corresponding to the other substrate.

  According to this aspect, the base of the ceramic part is divided into a plurality from the one side to the other side, and the heat capacity of the ceramic part corresponding to the base on the one side is greater than the heat capacity of the ceramic part corresponding to the other base. When the fluid flows into the ceramic part at room temperature at the beginning of fluid treatment, the portion that comes into contact first has a small heat capacity, so it rises to an appropriate temperature in a short time, shortening the effective treatment state. Can be realized in time.

  According to a tenth aspect of the present invention, there is provided a three-dimensional manufacturing method for a ceramic component, comprising: a base composed of a ceramic material; and a plurality of first flows provided on the base and allowing fluid to pass from one side to the other side of the base. A three-dimensional manufacturing method of a ceramic component having a path and a reaction-related member provided on the inner surface of the first flow path, wherein the first fluid composition containing ceramic material particles for the substrate is first A second flowable composition containing a material that is discharged from the discharge portion to the portion corresponding to the substrate and that is a material for the first flow path and that can be heat-dissipated corresponds to the first flow path from the second discharge section. The first flow path formed by the loss of heating is discharged so that the flow resistance increases from the upstream side to the downstream side in the direction in which the fluid passes. Contains particles of material A layer forming step of forming a single layer by discharging a three-fluid composition from a third discharge portion to a site corresponding to the reaction-participating member, a laminating step of repeating the layer forming step in the laminating direction, And a solidification step of forming the first flow path by applying energy and causing the heat-dissipable material to disappear by heating, and solidifying the particles to form the ceramic part.

  According to this aspect, the ceramic component of the first aspect can be easily manufactured.

  According to an eleventh aspect of the present invention, there is provided a three-dimensional manufacturing method of a ceramic component comprising: a base composed of a ceramic material; and a plurality of first flows provided on the base and allowing fluid to pass from one side to the other side of the base. A three-dimensional manufacturing method of a ceramic component having a path and a reaction-related member provided on the inner surface of the first flow path, wherein the first fluid composition containing ceramic material particles for the substrate is first A second flowable composition containing a material that is discharged from the discharge portion to the portion corresponding to the substrate and that is a material for the first flow path and that can be heat-dissipated corresponds to the first flow path from the second discharge section. Reaction at a high temperature when discharging a plurality of third fluid compositions containing particles of different materials for the reaction-participating member from a plurality of third discharge portions to a part corresponding to the reaction-participating member. Participating member on the upstream side of the first flow path And a layer forming step for forming a single layer by discharging so that a low temperature active reaction-related member is located on the downstream side, a laminating step for repeating the layer forming step in the laminating direction, and applying energy to the layer And a solidification step of forming the first flow path by causing the heat-dissipable material to disappear by heating and solidifying the particles to form the ceramic part.

  According to this aspect, the ceramic component of the fourth aspect can be easily manufactured.

The principal part sectional side view showing the ceramic component which concerns on Embodiment 1 of this invention. The principal part expanded side sectional view seen from the flow direction of the fluid of the ceramic component which concerns on Embodiment 1 of this invention. 1 is an overall schematic side sectional view of a ceramic component according to Embodiment 1 of the present invention. The whole schematic sectional side view showing the ceramic component which concerns on Embodiment 2 of this invention. The whole schematic sectional side view showing the ceramic component which concerns on Embodiment 3 of this invention. The whole schematic sectional side view showing the ceramic component which concerns on Embodiment 4 of this invention. Explanatory drawing showing the layer formation process of the three-dimensional manufacturing method of the ceramic components which concerns on Embodiment 1 of this invention.

Hereinafter, a ceramic component and a three-dimensional manufacturing method of the ceramic component according to the embodiment of the present invention will be described in detail with reference to the accompanying drawings.
In the following description, the configuration and operation of the ceramic component according to Embodiment 1 of the present invention will be specifically described with reference to Embodiment 1 shown in FIGS. 1 and 2 as an example. Next, regarding the three embodiments according to the second to fourth embodiments shown individually in FIGS. 3 to 5, the configuration of ceramic parts and the operation thereof will be described focusing on the differences from the first embodiment.
Next, the content of the three-dimensional manufacturing method for ceramic parts according to Embodiment 5 of the present invention will be described together with the schematic configuration of the three-dimensional manufacturing apparatus used in the three-dimensional manufacturing method based on FIG. Finally, other embodiments of the ceramic component and the three-dimensional manufacturing method of the ceramic component according to the present invention, which are partially different from the above embodiments, will be described.

◆◆◆ Embodiment 1 (see FIGS. 1 to 3) ◆◆◆
The ceramic component 1A (1) according to the first embodiment is a ceramic component used in an exhaust gas treatment apparatus for a gasoline engine vehicle. The ceramic component 1A of the present embodiment includes a base body 2 made of a ceramic material and a plurality of first parts that are provided on the base body 2 and through which a fluid 5 that is high-temperature exhaust gas passes from one side 3 to the other side 4 of the base body 2. It has the flow path 6 and the reaction participating member 8 (FIG. 2) provided in the inner surface 7 (FIG. 2) of the first flow path 6.
And the 1st flow path 6 is comprised so that flow path resistance may become large toward the downstream (the other side 4) from the upstream (one side 3) in the direction through which the fluid 5 passes.

Here, cordierite is used as the ceramic material forming the substrate 2, but the present invention is not limited to this, and other ceramic materials such as alumina and silicon carbide can also be used.
The reaction participating member 8 has a function related to the progress of a desired chemical reaction in contact with the fluid 5 passing through the first flow path 6. In this embodiment, the gasoline vehicle used for the exhaust gas purification process. Three-way catalyst (Pt—Rh—Pd, Pt—Rh—CeO _2, etc.). The three-way catalyst (8) is provided on the inner surface 7 of the substrate 2 so as to be included in the alumina coat layer 9. Of course, the reaction participating member 8 is not limited to the three-way catalyst.
The “flow path resistance” means the ease or difficulty of passage of the fluid 5 through the first flow path 6, and the flow path having a large flow resistance is difficult for the fluid 5 to pass. The fluid 5 tends to pass through the flow path having a small resistance. Here, the flow path cross-sectional area is large on the upstream side in the flow direction of the fluid 5, and in other words, the flow path inner diameter is formed large, and on the downstream side in the fluid flow direction, the flow path cross-sectional area is smaller than that on the upstream side. In other words, the inner diameter of the flow path is smaller than that of the upstream side.

According to the first embodiment, the flow resistance of the first flow path 6 increases from the upstream side (one side 3) to the downstream side (the other side 4) in the direction in which the fluid 5 passes. As a result, the fluid 5 such as exhaust gas flowing into the flow path at a high temperature passes at a high speed because the flow path resistance is small on the inlet side (one side 3) of the flow path 6, that is, the upstream side in the flow direction. On the other hand, the outlet side (the other side 4) of the flow path, that is, the downstream side passes through at a low speed because the flow path resistance is larger than the upstream side.
Therefore, the amount of heat transferred from the high-temperature fluid to the ceramic component 1A is reduced in the upstream portion of the flow path 6 and moves to the downstream side of the flow path 6 with the temperature drop of the fluid 5 suppressed. On the other hand, in the downstream side portion of the flow path 6, the amount of heat transfer increases as the passage speed of the fluid 5 decreases. Thereby, the influence of the temperature distribution in the direction in which the fluid 5 flows can be reduced, and stabilization of processing such as exhaust gas purification by the reaction participating member 8 can be promoted. Moreover, the high temperature deterioration of the upstream part (one side 3) of the flow path 6 can be suppressed.

Furthermore, in the first embodiment, the first flow path 6 has a plurality of second flows through which the fluid 5 passes in the direction (Y direction and Z direction) intersecting the direction (X direction) from the one side 3 toward the other side 4. A path 6 is also provided. In the following description, when the first flow path 6 and the second flow path 6 are distinguished, they are referred to as “first flow path 6A” and “second flow path 6B”. Similarly, the fluid 5 flowing along the first flow path 6A is referred to as “fluid 5A”, and the fluid flowing along the second flow path 6B is referred to as “fluid 5B”.
And the 2nd flow path 6B is comprised so that flow path resistance may become large toward the downstream from the upstream in the direction through which the fluid 5B passes. In FIG. 1, the size of the lattice indicating each flow path surrounded by the substrate 2 represents the size of the flow path resistance easily. Actually, the flow path is connected in the direction in which the fluid 5 flows (reference numerals 5A and 5B in FIG. 1).
1 and 3, reference numeral 10 denotes a ceramic component housing.

According to the first embodiment having the second flow path 6B, the flow resistance of the second flow path 6B also increases from the upstream side to the downstream side in the direction in which the fluid 5 passes. In addition, it is possible to reduce the influence of the temperature distribution and to promote stabilization of processing such as exhaust gas purification by the reaction participating member 8. Moreover, the high temperature deterioration of the upstream part of a flow path can be suppressed.
In the structure having the second flow path 6B, the diameter R1 (FIG. 3) of the inlet portion of the fluid 5 of the ceramic component 1A is the same as that of the main body portion (portion where a plurality of flow paths exist) of the ceramic component 1A. This is particularly effective when the structure is smaller than the diameter R2 (FIG. 3).

Further, in the first embodiment, the base body 2 is configured in a block overlapping structure B in which a plurality (four) of blocks B1, B2, B3, and B4 are stacked from one side 3 to the other side 4. The four blocks B1, B2, B3, and B4 are configured so that the flow path resistance is different for each block.
Specifically, the next-stage block B2 has a larger flow resistance in the direction from the one side 3 to the other side 4 (X direction) than the most upstream block B1. The relationship between the other blocks B3 and B4 is the same, and the subsequent block is configured to have a larger flow path resistance than the preceding block.
Furthermore, in each block, it is comprised so that flow-path resistance may differ in the direction (Y direction and Z direction) which cross | intersects the said direction X. FIG. Specifically, as shown in FIG. 3, each block has a central portion (in FIG. 3, the “middle” portion when divided into three parts, upper, middle, and lower). (The “upper” and “lower” portions in FIG. 3 divided into upper, middle, and lower) are configured to have a smaller flow resistance than the central portion.

According to the first embodiment having the block overlap structure B, since the block overlap structure is a state in which a plurality of blocks B1, B2, B3, and B4 are overlapped, the block B1, B2, B3, and B4 are described for each of the blocks B1, B2, B3, and B4. By changing the channel resistance, the ceramic component 1A having the above structure can be easily manufactured.
In addition, the detailed manufacturing method of 1 A of ceramic components of the structure of Embodiment 1 is mentioned later.

◆◆◆ Embodiment 2 (see FIG. 4) ◆◆◆
The ceramic component 1B (1) according to the second embodiment is partially different from the ceramic component 1A according to the first embodiment in the configuration for reducing the influence of the temperature distribution in the fluid flow direction and the type of the reaction participating member. The other basic configuration is the same as that of the first embodiment.
Therefore, the description of the same configuration as that of the first embodiment is omitted here, and the configuration and operation unique to the second embodiment that are different from the first embodiment will be described.

In the ceramic component 1B according to the second embodiment, the reaction participating member 8 is configured such that the characteristics change from high temperature activity to low temperature activity from the upstream side to the downstream side in the direction in which the fluid 5 passes. That is, the high temperature active reaction participating member 8 is positioned upstream of the first flow path 6 and the low temperature active reaction participating member 8 is positioned downstream.
Specifically, four reaction participating members 8A, 8B, 8C, and 8D having different high-temperature characteristics are provided from the upstream side to the downstream side of the first flow path 6. The reaction participation member 8A has the highest high temperature activity, and the reaction participation member 8D has the lowest high temperature activity and the lowest low temperature activity. The flow path resistance of the first flow path 6 is not different as in the first embodiment, and is configured uniformly in the direction in which the fluid 5 flows. A material having high high-temperature activity as a reaction-participating member exhibits high activity without denaturation of the member even at high temperatures. In addition, a material having a high low temperature activity exhibits a high activity in a low temperature region than the high temperature.

  According to the second embodiment, the reaction participating member 8 changes its characteristic from the high temperature activity to the low temperature activity from the upstream side to the downstream side in the direction in which the fluid 5 passes. Therefore, even if the temperature distribution occurs, the reaction participating member 8A. , 8B, 8C, and 8D are hardly affected by the temperature distribution. That is, the upstream portion is in contact with the fluid 5 having the highest temperature, but the reaction participating member 8A in this portion has a high temperature active characteristic, so that an effective process is performed. The temperature of the fluid 5 is lowered by heat transfer as it goes downstream, but the downstream portion is provided with a low-temperature active reaction member 8D, so that effective treatment is performed at the lowered temperature. . Thereby, the influence of the temperature distribution in the direction in which the fluid 5 flows can be reduced, and stabilization of processing such as exhaust gas purification by the reaction participating member 8 can be promoted.

Further, in the second embodiment, as in the first embodiment, the first flow path 6 has the fluid 5 in the direction (Y direction and Z direction) intersecting the direction (X direction) from the one side 3 toward the other side 4. A plurality of second flow paths 6 that pass therethrough are also provided. The structure of the first flow path 6A and the second flow path 6B is different from that of the first embodiment in that the flow path resistance is uniform, but the other structures are the same.
The second flow path 6B is also configured such that the characteristic of the reaction participating member 8 changes from the low temperature activity to the high temperature activity from the upstream side to the downstream side in the direction in which the fluid 5 passes. Specifically, as shown in FIG. 4, the central portion of the substrate 2 (the “medium” portion in FIG. 4 when divided into three parts, upper, middle, and lower) is a high-temperature active reaction participating member 8. Yes, the peripheral part ("upper" and "lower" parts when divided into three parts, upper, middle, and lower in FIG. 4) is provided with a low-temperature active reaction participation member 8 having lower high-temperature activity than the central part. ing.

  According to the second embodiment having the second flow path 6B, the characteristics of the reaction participating member 8 change from the high temperature activity to the low temperature activity from the upstream side to the downstream side in the direction in which the fluid 5B also passes through the second flow path 6B. Therefore, also in the 2nd flow path 6B, the influence of temperature distribution can be reduced and stabilization of processing, such as exhaust gas purification by the reaction participating member 8, can be accelerated | stimulated.

Further, in the second embodiment, as in the first embodiment, the base 2 has a block overlapping structure B in which a plurality of (four) blocks B1, B2, B3, B4 are stacked from one side 3 to the other side 4. It is configured. The four blocks B1, B2, B3, and B4 are configured so that the characteristics of the reaction participating member are different for each block.
Specifically, the next-stage block B2 is provided with a reaction participation member that is active at a lower temperature in the direction from the one side 3 to the other side 4 (X direction) than the most upstream block B1. . The relationship with the other blocks B3 and B4 is the same, and the reaction block is configured to be activated at a lower temperature in the latter block than in the previous block.
Furthermore, the characteristics of the reaction-participating member are different in each block in the direction (Y direction and Z direction) intersecting the direction X. Specifically, as shown in FIG. 4, each block has a central portion (in FIG. 3, “middle” portion when divided into three parts, upper, middle, and lower), which is active at high temperature, and surroundings. (The “upper” and “lower” parts when divided into three parts, upper, middle, and lower in FIG. 3) are configured such that the high-temperature activity is lower than the central part and the low-temperature activity is achieved.

According to the second embodiment having the block overlapping structure B, since the block overlapping structure is a state in which a plurality of blocks B1, B2, B3, and B4 are overlapped, the block B1, B2, B3, and B4 are described for each of the blocks B1, B2, B3, and B4. By changing the characteristics of the reaction participating member 8, the ceramic component 1B having the above structure can be easily manufactured.
In addition, the detailed manufacturing method of the ceramic component 1B of the structure of Embodiment 2 is mentioned later.

◆◆◆ Embodiment 3 (see FIG. 5) ◆◆◆
The ceramic component 1C (1) according to the third embodiment has a configuration in which a plurality of bases 2 having different types of reaction-participating members are arranged apart from each other in the direction of fluid flow, according to the first or second embodiment. 1B, and other basic configurations are the same as those in the first or second embodiment.
Therefore, the description of the same configuration as that of the first embodiment or the second embodiment is omitted here, and the configuration and operation unique to the third embodiment which are different from those will be described.

  When the particulate matter (PM) is contained in the exhaust gas in addition to the gas to be removed such as HC, CO and NOX as in a diesel engine vehicle, the purification of the gas to be removed in the flow direction of the fluid 5 A structure is employed in which the part for use (oxidation catalyst support part) is arranged in the previous stage and the PM removal part (PM removal filter) is arranged in the subsequent stage.

In Embodiment 3, the base body 2 is provided with a plurality of base bodies 2A and 2B separately in the direction from the one side to the other side. The basic structure of the substrates 2A and 2B is the same as that of the first embodiment. That is, the first flow paths 6 of the base bodies 2A and 2B are configured so that the flow path resistance increases from the upstream side to the downstream side in the direction in which the fluid 5 passes.
And the reaction participation member 8 is a different kind for every base | substrate 2A, 2B. Specifically, the reaction participating member 8E of the base 2A is a catalyst (oxidation catalyst) that has a purification capability for the gas to be removed such as HC, CO, and NOX. The reaction participating member 8F of the substrate 2B is a catalyst (particulate filter) having a purification capacity for particulate matter (PM).

  According to the third embodiment, when the particulate matter (PM) is contained in the exhaust gas in addition to the gas to be removed such as HC, CO and NOX as in a diesel engine vehicle, the flow direction of the fluid 2A, the reaction participation member 2A (oxidation catalyst) as a portion for purifying the gas to be removed is disposed in the previous stage, and the reaction participation member 2B (PM removal filter) as the PM removal portion is disposed in the rear stage. Thus, exhaust gas purification can be performed effectively.

◆◆◆ Embodiment 4 (see FIG. 6) ◆◆◆
The ceramic part 1D (1) according to the fourth embodiment is different from the ceramic parts 1A and 1B according to the first or second embodiment in that the base 2 is divided into a plurality of parts. The same as in the first embodiment or the second embodiment.
Therefore, the description of the same configuration as that of the first embodiment or the second embodiment is omitted here, and the configuration and operation unique to the fourth embodiment, which are different from those, will be described.

  In the fourth embodiment, the base 2 is divided into a plurality of bases 21 and 22 in the direction from the one side to the other side. The heat capacity of the ceramic component 1D1 corresponding to the base 21 on the one side 3 is configured to be smaller than the heat capacity of the ceramic component 1D2 corresponding to the other base 22. Specifically, the base 21 is formed smaller than the base 22, and the difference in heat capacity is created by the difference in size.

  According to the fourth embodiment, the base 2 of the ceramic part 1D is divided into a plurality of bases 21 and 22 from the one side 3 toward the other side 4, and the heat capacity of the ceramic part 1D1 corresponding to the base 21 on the one side 3 Is smaller than the heat capacity of the ceramic part 1D2 corresponding to the other base 22, so that when the fluid 5 flows into the ceramic part 1D at the room temperature at the beginning of the fluid treatment, the part (21) that contacts first has a heat capacity. Since it is small, it rises to an appropriate temperature in a short time (corresponding to cold start), and an effective processing state can be realized in a short time.

◆◆◆ Embodiment 5 (see FIG. 7) ◆◆◆
Next, according to the fifth embodiment, a schematic configuration of a three-dimensional manufacturing apparatus 41 that can be used for manufacturing the ceramic component 1 according to the embodiment, and a book that is executed by using the three-dimensional manufacturing apparatus 41. The content of an example of the three-dimensional manufacturing method of the ceramic component of the invention will be described.

(1) Schematic configuration of 3D manufacturing equipment (see Fig. 7)
As an example of the three-dimensional manufacturing apparatus 41 for manufacturing the ceramic component 1, an articulated industrial robot including a plurality of robot arms 43, 45, and 47 can be employed.
Specifically, the first discharge head 51 that discharges the first fluid composition 31 including the ceramic material particles for the substrate 2 and the first material that is a material for the first flow path 6 and that can be heat-dissipated. A second discharge head 53 for discharging the two-fluid composition 33 and a third discharge head 55 for discharging a third fluid composition containing particles of the material for the reaction-participating member are provided. Further, a fourth discharge head (not shown) for discharging a fourth fluid support material including a material for a support material to be used as necessary is provided. These ejection heads 51, 53, and 55 are a first ejection unit 51, a second ejection unit 53, and a third ejection unit 55, respectively.

  Here, the heat-dissipative material in the material for the first flow path 6 that can be dissipated by heating is thermally decomposed in the heat treatment for sintering the ceramic particles and disappears to become voids after disappearance. It is a material that can form the first flow path 6, and examples thereof include organic substances such as a binder and a pore former.

  Further, the three-dimensional manufacturing apparatus 41 is irradiated with laser light E, which is an example of energy, on the layer 11 formed by the fluid compositions 31, 33, and 37 discharged from the discharge heads 51, 53, and 55. A plurality of irradiation heads 61, 63, 65 to be sintered and solidified, and a stage including a flat base plate 71 as an example of a layer formation region on the upper surface of each of the flowable compositions 31, 33, 37. 73, a drive unit (not shown) that performs driving of the robot arms 43, 45, and 47 and a raising / lowering operation of the stage 73 in the stacking direction Z, and driving of these drive units and the ejection heads 51, 53, and 55 A control unit (not shown) that performs discharge control of the flowable compositions 31, 33, and 37 and irradiation control of the laser light E emitted from the irradiation heads 61, 63, and 65.The three-dimensional manufacturing apparatus 41 is used for manufacturing the ceramic component 1 by including these members as an example.

(2) Details of the three-dimensional manufacturing method for ceramic parts (see Fig. 7)
The three-dimensional manufacturing method of a ceramic part according to the fifth embodiment includes a base 2 made of a ceramic material, and a plurality of first parts provided on the base 2 and through which the fluid 5 passes from one side 3 to the other side 4 of the base 2. A three-dimensional manufacturing method of a ceramic component having one flow path 6 and a reaction participating member 8 provided on the inner surface of the first flow path 6, and is basically provided with a layer formation step, a lamination step, and a solidification step It is structured.
Hereinafter, each step will be described in order.

(A) Layer formation step (see FIG. 7)
In this layer forming step, the first fluid composition 31 containing the ceramic material particles for the substrate 2 is discharged from the first discharge portion 51 to a portion corresponding to the substrate 2, and is a material for the first flow path 6. When the second flowable composition 33 containing a material that can be lost by heating is discharged from the second discharge portion 53 to a portion corresponding to the first flow path 6, the first flow path 6 formed by the loss of heating is the fluid 5. A third fluid composition containing particles of a material for the reaction-participating member 8 that is discharged so that the flow path resistance increases (the cross-sectional area of the flow path decreases) from the upstream side 3 to the downstream side 4 in the passing direction. In this step, the material 37 is discharged from the third discharge portion 55 to the site corresponding to the reaction participating member 8 to form one layer 11.
Here, the discharge to the site corresponding to the reaction participating member 8 is the position between the second fluid composition (including a material that can be lost by heating) 33 and the first fluid composition 31, that is, the first flow. This is the position corresponding to the inner surface 7 of the path 6.
Further, in the fifth embodiment, although not shown, a fourth fluid support material containing a material for a support material is supplied from a fourth discharge head to a predetermined portion as necessary to form one layer D. .

In the fifth embodiment, all of the three types of discharge units 51, 53, and 55 are configured by the discharge heads 51, 53, and 55, respectively, and all of the three types of flowable compositions 31, 33, and 37 are used. It is comprised so that it may discharge in a droplet state.
In addition, the three types of ejection units 51, 53, and 55 do not necessarily have to be constituted by ejection heads, and some or all of these may be constituted by other means (for example, a coating roller) having a different structure. Is also possible.

The ceramic material is not limited to that described in the first embodiment, and various kinds of particles such as various metals and metal compounds shown below can be applied depending on the use conditions and applications.
For example, various metals such as aluminum, titanium, iron, copper, magnesium, stainless steel, maraging steel, etc., various metal oxides such as silica, alumina, titanium oxide, zinc oxide, zircon oxide, tin oxide, magnesium oxide, potassium titanate, etc. Metal nitrides such as silicon nitride, titanium nitride and aluminum nitride; various metal carbides such as silicon carbide and titanium carbide; various metal sulfides such as zinc sulfide; carbonates of various metals such as calcium carbonate and magnesium carbonate; Sulfates of various metals such as calcium sulfate and magnesium sulfate, silicates of various metals such as calcium silicate and magnesium silicate, phosphates of various metals such as calcium phosphate, various metals such as aluminum borate and magnesium borate Borate and their composites, gypsum (calcium sulfate hydrates, sulfuric acid Anhydrides of calcium) and the like.

In addition, each fluid composition 31, 33, 37 generally contains a solvent or dispersion medium and a binder in addition to the particles of the three kinds of materials 21, 23, 35 described above.
Examples of the solvent or dispersion medium include various waters such as distilled water, pure water, and RO water, as well as methanol, ethanol, 2-propanol, 1-butanol, 2-butanol, octanol, ethylene glycol, diethylene glycol, glycerin, and the like. Alcohols, ethers such as ethylene glycol monomethyl ether (methyl cellosolve) (cellosolves), esters such as methyl acetate, ethyl acetate, butyl acetate, ethyl formate, acetone, methyl ethyl ketone, diethyl ketone, methyl isobutyl ketone, methyl isopropyl ketone , Ketones such as cyclohexanone, aliphatic hydrocarbons such as pentane, hexane and octane, cyclic hydrocarbons such as cyclohexane and methylcyclohexane, benzene, toluene, xylene, hexylbenzene and hebutylbenzene Aromatic hydrocarbons with long-chain alkyl groups and benzene rings such as zen, octylbenzene, nonylbenzene, decylbenzene, undecylbenzene, dodecylbenzene, tridecylbenzene, tetradecylbenzene, methylene chloride, chloroform, carbon tetrachloride , Halogenated hydrocarbons such as 1,2-dichloroethane, aromatic heterocycles containing any one of pyridine, pyrazine, furan, pyrrole, thiophene, and methylpyrrolidone, nitriles such as acetononitrile, propionitrile, acrylonitrile, etc. , N, N-dimethylamide, amides such as N, N-dimethylacetamide, carboxylates or other various oils.

The binder is not limited as long as it is soluble in the aforementioned solvent or dispersion medium. For example, an acrylic resin, an epoxy resin, a silicone resin, a cellulose resin, a synthetic resin, or the like can be used. Further, for example, thermoplastic resins such as PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide) can be used.
Moreover, you may make it disperse | distribute in the solvent or dispersion medium mentioned above not in a soluble state but in the state of the fine particle | grains of resin, such as an acrylic resin mentioned above.
Examples of the material that can be heat-dissipated include the above-described solvents or dispersion media, and binders.

(B) Lamination process and solidification process Subsequent to the layer formation process, the layer formation process is repeated in the lamination direction Z. The layer forming process is repeated a predetermined number of times in the stacking direction Z to form a desired three-dimensional ceramic component precursor in which a plurality of layers 11 are stacked. After that, energy is applied to the ceramic component precursor in a state where the layer 11 is laminated, and the material that can be heat-dissipated is heat-dissipated to form the first flow path 6 and the particles are solidified to solidify the ceramic component 1. Is shaped. The unnecessary support material 25 is removed, and the ceramic component 1 as a product is obtained.
And according to the three-dimensional manufacturing method of the ceramic component which concerns on this embodiment comprised in this way, the ceramic component 1 of Embodiment 1, Embodiment 3, and Embodiment 4 can be manufactured easily.

◆◆◆ Embodiment 6 ◆◆◆
Next, the sixth embodiment is an example of a three-dimensional manufacturing method of a ceramic component that can be used to manufacture the ceramic component 1B according to the second embodiment.
Basically, since most of the parts are the same as those in the fifth embodiment, description of those parts is omitted, and only the parts unique to the sixth embodiment will be described.
In the sixth embodiment, the reaction participating member 8 is performed as follows in order to change the characteristics from the high temperature activity to the low temperature activity from the upstream side to the downstream side in the direction in which the fluid 5 passes.

A first fluid composition 31 containing ceramic material particles for the substrate 2 is discharged from the first discharge portion 51 to a portion corresponding to the substrate 2, and a material that is a material for the first flow path 6 and can be lost by heating. The second fluid composition 33 containing the second fluid composition 33 is ejected from the second ejection part 53 to the site corresponding to the first flow path 6, and a plurality of third fluid compositions containing particles of different materials for the reaction participating member 8 are provided. When discharging from the third discharge portions 55, 55,... To the site corresponding to the reaction participating member 8, the high temperature active reaction participating member 8A is positioned upstream of the first flow path, and the low temperature active reaction participating member 8D is provided. One layer 11 is formed by discharging so as to be located on the downstream side.
And according to the three-dimensional manufacturing method of the ceramic component which concerns on this embodiment comprised in this way, the ceramic component 1 of Embodiment 2 can be manufactured easily.

[Other Embodiments]
The ceramic component 1 and the three-dimensional manufacturing method of the ceramic component according to the present invention are basically based on the configuration as described above, but have a partial configuration within the scope of the present invention. Of course, changes and omissions can be made.
(1) For example, the application target of the present invention is not limited to a gasoline engine vehicle or a diesel engine vehicle, but can be applied to other exhaust gas generating vehicles.
(2) In the above embodiment, the manufacturing method of discharging the second fluid composition 33 containing the material for the first flow path 6 and including the material that can be lost by heating from the second discharge unit 53 has been described. This heat-dissipable material may be added to the first fluid composition 31 containing ceramic material particles for the substrate 2. In this case, the layer forming process is as follows.
Discharging the first fluid composition 31 containing the ceramic material particles for the substrate 2 and the material for the first flow path 6 and capable of being heat-dissipated from the first discharge portion 51 to the portion corresponding to the substrate 2; In addition, the first flow path 6 formed by the disappearance of heat is discharged from the upstream side to the downstream side in the direction in which the fluid 5 passes so that the flow path resistance increases (so that the cross-sectional area of the flow path decreases). One layer 11 is formed. Then, after the laminating step, energy is applied to the layer 11 to cause the heat-dissipable material to be heat-dissipated to form the first flow path, and the particles are sintered and solidified to form a ceramic part.
This manufacturing method utilizes the fact that the size of the gaps (pores) formed between the particles varies depending on the particle size of the material particles of the substrate 2. This can be achieved by adjusting the particle diameter of the material particles of the substrate 2 and adjusting the mixing ratio of the heat-extinguishable material so that the pores are connected to form a flow path.
(3) The material for the reaction participating member 8 is made to adhere to the inner surface of the first flow path by forming a ceramic component precursor without the reaction participating member 8 and then impregnating and drying and solidifying it. You can also.
(4) The heating source for the solidification step is not limited to laser light, and may be heated in a sintering furnace or the like.
(5) The flow resistance can be adjusted by filling the flow path with a uniform inner diameter with a mesh material and adjusting the flow resistance by the difference in the filling rate.

DESCRIPTION OF SYMBOLS 1 ... Ceramics part, 2 ... Base | substrate, 3 ... One side, 4 ... The other side, 5 ... Fluid,
6 ... 1st flow path, 2nd flow path, 7 ... Inner surface, 8 ... Reaction participation member, 9 ... Ceramic coating layer,
DESCRIPTION OF SYMBOLS 10 ... Housing, 11 ... Layer, 31 ... 1st fluid composition, 33 ... 2nd fluid composition,
35 ... 5th material, 37 ... 3rd fluid composition, 41 ... 3D manufacturing apparatus,
43 ... Robot arm, 45 ... Robot arm, 47 ... Robot arm,
51 ... 1st discharge head (1st discharge part) 53 ... 2nd discharge head (2nd discharge part),
55 ... 3rd discharge head (3rd discharge part), 61 ... 1st irradiation head, 63 ... 2nd irradiation head,
65 ... third irradiation head, 71 ... base plate (layer formation region), 73 ... stage,
P1 ... layer formation process, E ... laser beam (energy)

Claims (11)

A substrate composed of a ceramic material;
A plurality of first flow paths provided in the base and through which fluid passes from one side of the base to the other;
A ceramic component having a reaction participation member provided on an inner surface of the first flow path,
The ceramic part according to claim 1, wherein the first channel has a channel resistance that increases from an upstream side toward a downstream side in a direction in which the fluid passes. The ceramic component according to claim 1,
The first flow path has a plurality of second flow paths through which fluid passes in a direction intersecting the direction from the one side to the other side,
The ceramic part according to claim 2, wherein the second channel has a channel resistance that increases from the upstream side toward the downstream side in the direction in which the fluid passes. In the ceramic part according to claim 1 or 2,
At least one of the first channel and the second channel is
Formed by a series of pores,
A ceramic part characterized in that flow path resistance increases from an upstream side to a downstream side in a direction in which the fluid passes due to a difference in porosity. A substrate composed of a ceramic material;
A plurality of first flow paths provided in the base and through which fluid passes from one side of the base to the other;
A ceramic component having a reaction participation member provided on an inner surface of the first flow path,
The ceramic part characterized in that the characteristics of the reaction participating member change from high temperature activity to low temperature activity from the upstream side to the downstream side in the direction in which the fluid passes. In the ceramic part according to claim 4,
The first flow path has a plurality of second flow paths through which fluid passes in a direction intersecting the direction from the one side to the other side,
The ceramic component according to claim 2, wherein the characteristic of the reaction participating member changes from a low temperature activity to a high temperature activity from the upstream side to the downstream side in the fluid passage direction. In the ceramic component according to any one of claims 1 to 5,
The base has a block overlapping structure in which a plurality of blocks are stacked from the one side to the other side,
The ceramic part, wherein the plurality of blocks have different flow path resistances or characteristics for each block. In the ceramic component according to any one of claims 1 to 6,
The ceramic component, wherein the reaction participating member is a catalyst for exhaust gas treatment. In the ceramic component according to any one of claims 1 to 7,
A plurality of the bases are provided in the direction from the one side to the other side,
The ceramic component characterized in that the reaction participating member is of a different type for each of the substrates. In the ceramic component according to any one of claims 1 to 7,
The base of the ceramic component is divided into a plurality from the one side to the other side,
A ceramic part having a heat capacity of a ceramic part corresponding to the base on one side is smaller than a heat capacity of a ceramic part corresponding to the other base. A substrate composed of a ceramic material;
A plurality of first flow paths provided in the base and through which fluid passes from one side of the base to the other;
A reaction participating member provided on the inner surface of the first flow path;
A first fluid composition containing ceramic material particles for the substrate is discharged from a first discharge portion to a portion corresponding to the substrate, and a first flow path material that is a material that can be heat-dissipated. When the two-fluid composition is discharged from the second discharge portion to the portion corresponding to the first flow path, the first flow path formed by the heat dissipation disappears from the upstream side to the downstream side in the direction in which the fluid passes. And discharging the third fluid composition containing particles of the material for the reaction-participating member from the third discharge part to a part corresponding to the reaction-participating member to form one layer. Forming a layer; and
A laminating step for repeating the layer forming step in the laminating direction;
A solidification step of forming the ceramic part by solidifying the particles while forming the first flow path by applying energy to the layer to dissipate the heat-dissipable material by heating;
A three-dimensional manufacturing method of ceramic parts, comprising: A substrate composed of a ceramic material;
A plurality of first flow paths provided in the base and through which fluid passes from one side of the base to the other;
A reaction participating member provided on the inner surface of the first flow path;
A first fluid composition containing ceramic material particles for the substrate is discharged from a first discharge portion to a portion corresponding to the substrate, and a first flow path material that is a material that can be heat-dissipated. A two-fluid composition is ejected from a second ejection part to a portion corresponding to the first flow path, and a plurality of third fluid compositions containing particles of different materials for the reaction participating member are ejected to a plurality of third fluids. When discharging from a section to a site corresponding to the reaction-related member, the high-temperature active reaction-related member is positioned upstream of the first flow path, and the low-temperature active reaction-related member is positioned downstream. A layer forming step of forming two layers;
A laminating step for repeating the layer forming step in the laminating direction;
A solidification step of forming the ceramic part by solidifying the particles while forming the first flow path by applying energy to the layer to dissipate the heat-dissipable material by heating;
A three-dimensional manufacturing method of ceramic parts, comprising:

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