JP2018143956A - ハニカムフィルタ - Google Patents
ハニカムフィルタ Download PDFInfo
- Publication number
- JP2018143956A JP2018143956A JP2017041791A JP2017041791A JP2018143956A JP 2018143956 A JP2018143956 A JP 2018143956A JP 2017041791 A JP2017041791 A JP 2017041791A JP 2017041791 A JP2017041791 A JP 2017041791A JP 2018143956 A JP2018143956 A JP 2018143956A
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb filter
- cell
- honeycomb
- wall portion
- end side
- 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.)
- Pending
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- 239000000463 material Substances 0.000 claims abstract description 40
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000011230 binding agent Substances 0.000 claims abstract description 22
- 239000011148 porous material Substances 0.000 claims description 60
- 239000002131 composite material Substances 0.000 claims description 37
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 36
- 239000003054 catalyst Substances 0.000 claims description 30
- 230000035699 permeability Effects 0.000 claims description 21
- 239000010419 fine particle Substances 0.000 claims description 15
- 229910000510 noble metal Inorganic materials 0.000 claims description 13
- 239000000470 constituent Substances 0.000 claims description 11
- 230000000149 penetrating effect Effects 0.000 claims description 11
- 239000000758 substrate Substances 0.000 claims description 9
- 239000002245 particle Substances 0.000 abstract description 57
- 238000010792 warming Methods 0.000 abstract 1
- 241000264877 Hippospongia communis Species 0.000 description 125
- 239000007789 gas Substances 0.000 description 45
- 238000000034 method Methods 0.000 description 37
- 239000000203 mixture Substances 0.000 description 32
- 239000002585 base Substances 0.000 description 30
- 238000005192 partition Methods 0.000 description 28
- 230000008569 process Effects 0.000 description 28
- 239000000835 fiber Substances 0.000 description 25
- 238000007789 sealing Methods 0.000 description 22
- 238000005238 degreasing Methods 0.000 description 17
- 238000010304 firing Methods 0.000 description 14
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 13
- 239000002994 raw material Substances 0.000 description 13
- 238000000746 purification Methods 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 9
- 229910010271 silicon carbide Inorganic materials 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 8
- 238000005259 measurement Methods 0.000 description 8
- 230000002093 peripheral effect Effects 0.000 description 8
- 239000003795 chemical substances by application Substances 0.000 description 7
- 238000002156 mixing Methods 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 229910052763 palladium Inorganic materials 0.000 description 6
- 229910052703 rhodium Inorganic materials 0.000 description 6
- 239000010948 rhodium Substances 0.000 description 6
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 6
- 230000015572 biosynthetic process Effects 0.000 description 5
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 5
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 5
- 239000002612 dispersion medium Substances 0.000 description 5
- 238000009826 distribution Methods 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- 239000012784 inorganic fiber Substances 0.000 description 4
- 229920000609 methyl cellulose Polymers 0.000 description 4
- 239000001923 methylcellulose Substances 0.000 description 4
- 235000010981 methylcellulose Nutrition 0.000 description 4
- -1 platinum group metals Chemical class 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 229910001593 boehmite Inorganic materials 0.000 description 3
- 235000014113 dietary fatty acids Nutrition 0.000 description 3
- 239000000194 fatty acid Substances 0.000 description 3
- 229930195729 fatty acid Natural products 0.000 description 3
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 230000000737 periodic effect Effects 0.000 description 3
- 229910052761 rare earth metal Inorganic materials 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- FFJCNSLCJOQHKM-CLFAGFIQSA-N (z)-1-[(z)-octadec-9-enoxy]octadec-9-ene Chemical compound CCCCCCCC\C=C/CCCCCCCCOCCCCCCCC\C=C/CCCCCCCC FFJCNSLCJOQHKM-CLFAGFIQSA-N 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910000502 Li-aluminosilicate Inorganic materials 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 239000012298 atmosphere Substances 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- HSJPMRKMPBAUAU-UHFFFAOYSA-N cerium(3+);trinitrate Chemical compound [Ce+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O HSJPMRKMPBAUAU-UHFFFAOYSA-N 0.000 description 2
- 239000003426 co-catalyst Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 150000004665 fatty acids Chemical class 0.000 description 2
- 238000005342 ion exchange Methods 0.000 description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 239000011259 mixed solution Substances 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000003566 sealing material Substances 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 239000006104 solid solution Substances 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 235000019698 starch Nutrition 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 150000000703 Cerium Chemical class 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 1
- 229910052765 Lutetium Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 239000004113 Sepiolite Substances 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 description 1
- 235000011114 ammonium hydroxide Nutrition 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 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 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 229910000174 eucryptite Inorganic materials 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- 239000010954 inorganic particle Substances 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- OHSVLFRHMCKCQY-UHFFFAOYSA-N lutetium atom Chemical compound [Lu] OHSVLFRHMCKCQY-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- UJVRJBAUJYZFIX-UHFFFAOYSA-N nitric acid;oxozirconium Chemical compound [Zr]=O.O[N+]([O-])=O.O[N+]([O-])=O UJVRJBAUJYZFIX-UHFFFAOYSA-N 0.000 description 1
- 238000005121 nitriding Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- GPNDARIEYHPYAY-UHFFFAOYSA-N palladium(ii) nitrate Chemical compound [Pd+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O GPNDARIEYHPYAY-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 1
- VXNYVYJABGOSBX-UHFFFAOYSA-N rhodium(3+);trinitrate Chemical compound [Rh+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O VXNYVYJABGOSBX-UHFFFAOYSA-N 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 1
- 239000011163 secondary particle Substances 0.000 description 1
- 229910052624 sepiolite Inorganic materials 0.000 description 1
- 235000019355 sepiolite Nutrition 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 150000003754 zirconium Chemical class 0.000 description 1
- 229910052644 β-spodumene Inorganic materials 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24492—Pore diameter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2459—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the plugs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/46—Ruthenium, rhodium, osmium or iridium
-
- B01J35/56—
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/486—Fine ceramics
- C04B35/488—Composites
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
- C04B35/486—Fine ceramics
- C04B35/488—Composites
- C04B35/4885—Composites with aluminium oxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/50—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on rare-earth compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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Abstract
Description
図1に示すように、本実施形態のハニカムフィルタ10は、筒状の周壁11と、周壁11の内部を周壁11の軸方向の一端側から他端側に延びる複数のセルSに区画する断面ハニカム形状の区画壁12とを備えている。周壁11と区画壁12とによって壁部13が構成されている。ハニカムフィルタ10のセル構造は特に限定されるものではないが、例えば、区画壁12の壁厚が0.1〜0.7mmであり、セル密度が1cm2あたり15.5〜124セルであるセル構造とすることができる。なお、上記「0.1〜0.7mm」は、「0.1mm以上0.7mm以下」を意味するものとし、「A〜B」は「A以上B以下」を意味するものとする。
上記無機バインダとしては、例えば、アルミナゾル、シリカゾル、チタニアゾル、水ガラス、セピオライト、アタパルジャイロ、ベントナイト、ベーマイトを用いることができる。基材における無機バインダの含有量は特に限定されないが、基材に対して、10〜30質量%含有していることが好ましい。
本実施形態のハニカムフィルタ10は、車両や建設機械等の内燃機関から排出されるガスに含まれる微粒子の捕集に用いられる。そのため、区画壁12は、処理対象のガスを通過させるための気孔を有している。処理対象のガスを通過させるための気孔を有する区画壁12は、以下に記載する特定のガス透過係数を満たす壁部である。
混合工程は、CZ複合酸化物粒子と無機バインダとアルミナ粒子と有機繊維を有する原料組成物を混合して混合物を作製する工程である。CZ複合酸化物粒子としては、セリアとジルコニアの固溶体を用いることが好ましい。セリアとジルコニアの固溶体は、例えば、硝酸セリウムなどのセリウム塩と、オキシ硝酸ジルコニウムなどのジルコニウム塩を溶解させた水溶液に、アンモニア水を加えて共沈殿を生成させ、得られた沈殿物を乾燥させた後に400〜500℃で5時間程度焼成することにより調製することができる。
低熱膨張係数粒子の平均粒子径は特に限定されるものではないが、1〜10μmであることが好ましく、1〜5μmであることがより好ましい。
有機バインダとしては、例えば、メチルセルロース、カルボキシメチルセルロース、ヒドロキシエチルセルロース、ポリエチレングリコール、フェノール樹脂、エポキシ樹脂が挙げられる。
成形助剤としては、エチレングリコール、デキストリン、脂肪酸、脂肪酸石鹸、ポリアルコール、界面活性剤が挙げられる。
上記原料組成物は、公知のミキサーやアトライタなどを用いて混合してもよく、さらにニーダーなどで混練してもよい。
成形工程は、混合工程により得られた混合物を成形してハニカム成形体を作製する工程である。ハニカム成形体は、後の焼成工程における焼成収縮を経てハニカムフィルタ10と同一形状となるよう、例えば、混合物を押出金型を用いて押出成形し、所定の長さに切断することにより作製する。すなわち、ハニカムフィルタ10の周壁11と区画壁12とを構成する壁部13を一度に押出成形することにより作製する。
封止工程は、成形工程により得られたハニカム成形体のセルSの端部に封止材ペーストを充填して、封止部14を形成する工程である。封止材ペーストとしては、上記混合物と同様のものを用いることができるが、有機繊維を含まないことが好ましい。有機繊維を用いないことにより、封止部14の気孔率を小さくすることができる。封止工程によって封止部14を形成したハニカム成形体は、必要に応じて乾燥を行う。なお、封止工程は後の脱脂工程、焼成工程の後でもよい。
脱脂工程は、封止部14を形成したハニカム成形体を脱脂して、脱脂体を作製する工程である。脱脂工程において長尺状の有機繊維が消失することにより、壁部13に線状の気孔を形成することができる。脱脂工程は、公知の単独炉、いわゆるバッチ炉や、連続炉を用いて行うことができる。脱脂温度は特に限定されないが、300〜800℃が好ましく、400〜750℃であることがより好ましい。脱脂時間は特に限定されないが、上記の脱脂温度において1〜10時間保持することが好ましく、2〜5時間保持することがより好ましい。脱脂雰囲気は特に限定されないが、酸素濃度が0.1〜20%であることが好ましい。
焼成工程は、脱脂工程により得られた脱脂体を焼成してハニカムフィルタ10を作製する工程である。焼成によって、CZ複合酸化物等の粒子間が無機バインダで結合されることにより、ハニカムフィルタ10の機械的強度が向上する。焼成工程は、公知の単独炉、いわゆるバッチ炉や、連続炉を用いて行うことができる。焼成温度は特に限定されないが、800〜1300℃が好ましく、900〜1200℃であることがより好ましい。焼成時間は特に限定されないが、上記の焼成温度において1〜20時間保持することが好ましく、1〜15時間保持することがより好ましい。焼成雰囲気は特に限定されないが、酸素濃度が1〜20%であることが好ましい。焼成工程は、脱脂工程とは別の炉を用いて別途行ってもよいし、脱脂工程と同じ炉を用いて連続的に行ってもよい。上記の混合工程、成形工程、封止工程、脱脂工程、焼成工程を経ることにより、CZ複合酸化物からなり上記気孔径分布を示す壁部13を有する本実施形態のハニカムフィルタ10を製造することができる。
担持工程は、焼成工程により得られたハニカムフィルタ10にさらに触媒を担持する工程である。触媒を担持する方法としては、例えば、触媒の粒子や錯体を含む溶液にハニカムフィルタ10を浸漬した後、ハニカムフィルタ10を引き上げて、加熱する方法が挙げられる。触媒を担持することによって、ハニカムフィルタ10の壁部13は、CZ複合酸化物を構成成分とする基材と、この基材に担持された触媒とを備えるものとなる。
第2の製造方法は、原料組成物中に有機繊維を含有させることに代えて、気孔形成工程を有している点において第1の製造方法と相違している。気孔形成工程について以下に説明する。
気孔形成工程は、成形工程後、脱脂工程後、焼成工程後のいずれかにおいて行う工程である。気孔形成工程の具体的な方法は、上記のいずれのタイミングで行った場合にも同様であり、以下では、一例として、成形工程後に行う気孔形成工程について説明する。
また、治具20に備えられるニードル22の位置や本数は適宜変更してもよい。例えば、図3(c)に示すように、個々のニードル22の間隔Lを約1cmにし、セルSの延びる方向とニードル22の並列方向とを揃えると、セルSの延びる方向に沿って約1cm間隔で気孔を形成することができる。
(1)CZ複合酸化物と無機バインダを構成成分とする基材からなる壁部を備えることにより、炭化ケイ素等の基材からなる壁部にCZ複合酸化物が被覆された構成に比べて、同じCZ複合酸化物の含有量であれば、壁部の熱容量を小さくすることができる。これにより、処理対象となるガスの熱によってハニカムフィルタの温度が上がりやすくなるため、処理対象となるガスの浄化性能が向上する。また、壁部のガス透過係数が1.0μm2以上3.0μm2以下であることにより、CZ複合酸化物を構成成分とする基材からなる壁部のガス透過性が向上したものとなるため、微粒子を捕集するフィルタとしての機能を持たせつつ圧力損失を低く抑えることができる。
(5)触媒は、貴金属である。セリア−ジルコニア複合酸化物は、貴金属からなる触媒の触媒作用を促進させる助触媒としての機能を有する。したがって、本発明のハニカムフィルタは、貴金属からなる触媒と組み合わせることにより、高い触媒作用を発揮することができる。
・本実施形態では、壁部は周壁と区画壁とで構成されていたが、区画壁のみで構成されていてもよい。この場合、区画壁の外周に外周コート層が形成されてハニカムフィルタが形成されていてもよい。
・壁部を構成する基材は、アルミナを構成成分に含まないものであってもよい。また、原料組成物は、アルミナ粒子を含まないものであってもよい。
(実施例1)
下記原料組成物を混合して混合物を調製した。
平均粒子径2μmのθ−アルミナ粒子:12.0質量%
平均繊維径3μm、平均繊維長60μmのαアルミナ繊維(無機繊維):5.0質量%
平均繊維径30μm、平均繊維長1mmのアクリル繊維(有機繊維):13.0質量%
ベーマイト(無機バインダ):10.0質量%
メチルセルロース(有機バインダ):7.0質量%
ポリオキシエチレンオレイルエーテル(成形助剤):4.0質量%
イオン交換水(分散媒):25.0質量%
この混合物を用いて、押出成形機によって円柱状の成形体を成形した。次に、この成形体を所定の長さに切断してハニカム成形体を作製した後、図2に示すように所定のセルの端部を封止剤にて封止して封止部を形成した。封止剤の組成は、有機繊維を含まないこと以外は上記混合物と同じ組成である。また、封止部の長さは約3mmとした。次に、ハニカム成形体を乾燥させた後、700℃で3時間脱脂し、1100℃で10時間焼成することにより、ハニカムフィルタを作製した。
下記原料組成物を混合して混合物を調製した。
平均粒子径2μmのCZ複合酸化物粒子:28.0質量%
平均粒子径2μmのθ−アルミナ粒子:14.0質量%
平均繊維径3μm、平均繊維長60μmのαアルミナ繊維(無機繊維):6.0質量%
ベーマイト(無機バインダ):11.0質量%
メチルセルロース(有機バインダ):8.0質量%
ポリオキシエチレンオレイルエーテル(成形助剤):5.0質量%
イオン交換水(分散媒):28.0質量%
この混合物を用いて、押出成形機によって円柱状の成形体を成形した。次に、この成形体を所定の長さに切断してハニカム成形体を作製した後、図2に示すように所定のセルの端部を封止剤にて封止して封止部を形成した。封止剤の組成は、有機繊維を含まないこと以外は上記混合物と同じ組成である。また、封止部の長さは約3mmとした。
原料組成物に有機繊維を用いず、その他の原料組成物の配合比を固定した点を除いて、実施例1と同様にしてハニカムフィルタを作製し、これを比較例1のハニカムフィルタとした。
まず、下記原料組成物を混合して混合物を調整した。
平均粒子径15μmの炭化ケイ素粒子:28質量%
平均粒子径0.95μmの炭化ケイ素粒子:19質量%
平均粒子径34μmのシラスバルーン(造孔剤):9質量%
平均粒子径28μmのデンプン(造孔剤):16質量%
メチルセルロース(有機バインダー):5質量%
ソルビタン脂肪酸エステル(分散剤):3質量%
ポリオキシアルキレン系化合物(可塑剤):2質量%
水(分散媒):18質量%
この混合物を用いて、押出成形機によって角柱状の成形体を成形した。次に、この成形体を切断してハニカム成形体を作製した後、セルを互い違いに上記混合物と同じ組成の目封止剤にて目封止した。次に、ハニカム成形体を切断した際の切れ端を支持材として用い、この支持材の上にハニカム成形体を載置した状態で、ハニカム成形体を450℃で5時間加熱することにより、有機分が除去された脱脂体を得た。さらに、脱脂体が支持材に載置されたままの状態で、アルゴン雰囲気下2000℃で4.5時間保持してハニカム焼成体を得た。次に、ハニカム焼成体を窒素分圧10kPaの窒素雰囲気下800℃で4.5時間保持して窒化工程を行うことにより、縦34.4mm×横34.3mm×長さ80mmで貫通孔が46.5個/cm2(300cpsi)、隔壁の厚さが0.254mmの炭化ケイ素を主成分とするハニカム構造体を作製した。得られたハニカム構造体は、平均気孔径が20μm、気孔率が60%であった。このハニカム構造体を、無機接着材で接着し、外周加工を施すことで、直径が117mm、長さが80mmの円柱状のハニカム構造体を作製した。
実施例及び比較例のハニカムフィルタについて、以下の方法により、ガス透過係数、暖機性能及び圧力損失を測定した。
実施例1、2及び比較例1のハニカムフィルタを使用してガス透過係数を測定した。まず、ハニカムフィルタを金属管の中に気密状態に配置し、金属管を通じてハニカムフィルタに空気を流通させた。そして、ハニカムフィルタの前後における空気の圧力差ΔPを測定した。圧力差ΔPの測定は、ハニカムフィルタに流入させる空気流量Qを公知のマスフロメータを用いて0〜80L/minの範囲で変化させて、20点の空気流量に対して実施した。得られた20点のデータを、Qを横軸、ΔP/Qを縦軸としたグラフ上にプロットし、プロットを結ぶ直線の切片からガス透過係数kを求めた。結果を表1に示す。
V型6気筒3.5Lエンジンの排気管に、各実施例及び比較例のハニカムフィルタが気密状態で配置された金属管を接続し、ストイキエンジン始動からHC濃度((HCの流入量−HCの流出量)/(HCの流入量)×100)が50%以下となる時間を測定し、暖気性能を評価した。
図6に示したような圧力損失測定装置30を用いて圧力損失を測定した。
図6は、圧力損失測定方法を模式的に示す断面図である。まず、ハニカムフィルタ10を金属管31の中に気密状態に配置する。この金属管31に、送風機32に接続された金属管33を接続する。そして、送風機32から流速が10m/sの空気をハニカムフィルタ10に流通させ、ハニカムフィルタ10の前後における差圧(圧力損失)を圧力計34で測定した。暖機性能測定と圧力損失測定の結果を表2に示す。
Claims (6)
- 微粒子の捕集に用いられるハニカムフィルタであって、
セリア−ジルコニア複合酸化物と無機バインダを構成成分とする基材からなる壁部を備え、
前記壁部のガス透過係数が1.0μm2以上3.0μm2以下であることを特徴とするハニカムフィルタ。 - 前記壁部は、当該壁部を貫通する直径1μm以上200μm以下の線状の気孔を有する請求項1に記載のハニカムフィルタ。
- 前記基材は、構成成分としてアルミナを含む請求項1又は2に記載のハニカムフィルタ。
- 前記基材に触媒が担持されている請求項1〜3のいずれか一項に記載のハニカムフィルタ。
- 前記触媒は、貴金属である請求項4に記載のハニカムフィルタ。
- 前記壁部によって区画されるとともに、前記ハニカムフィルタの一端側から他端側に延びる複数のセルを有し、
前記セルは、前記一端側の端部が開放され、前記他端側の端部が封止された第1セルと、
前記第1セルに隣接して、前記一端側の端部が封止され、前記他端側の端部が開放された第2セルと、
前記第1セル及び前記第2セルの少なくとも一方に隣接して、前記一端側の端部及び前記他方側の端部の両方が開放された第3セルとを備える請求項1〜5のいずれか一項に記載のハニカムフィルタ。
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JP2013517934A (ja) * | 2010-02-01 | 2013-05-20 | ジョンソン、マッセイ、パブリック、リミテッド、カンパニー | 押出しソリッド本体を含む三元触媒 |
JP2013518703A (ja) * | 2010-02-01 | 2013-05-23 | ジョンソン、マッセイ、パブリック、リミテッド、カンパニー | 結合された媒煙酸化及びnh3−scr触媒を含むフィルタ |
JP2011183360A (ja) * | 2010-03-11 | 2011-09-22 | Ngk Insulators Ltd | ハニカム触媒体 |
JP2014024058A (ja) * | 2012-06-20 | 2014-02-06 | Toyota Central R&D Labs Inc | 排ガス浄化用触媒担体、それを用いた排ガス浄化用触媒、及び排ガス浄化用触媒担体の製造方法 |
JP2016055233A (ja) * | 2014-09-08 | 2016-04-21 | 株式会社デンソー | ハニカム構造体及びその製造方法 |
JP2016169127A (ja) * | 2015-03-13 | 2016-09-23 | 日野自動車株式会社 | ハニカム構造体の製造方法 |
WO2017110313A1 (ja) * | 2015-12-25 | 2017-06-29 | 株式会社デンソー | 排ガスフィルタ |
WO2018012565A1 (ja) * | 2016-07-14 | 2018-01-18 | イビデン株式会社 | ハニカム構造体及び該ハニカム構造体の製造方法 |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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DE102021213201A1 (de) | 2021-02-12 | 2022-08-18 | Ngk Insulators, Ltd. | Verschlossene Wabenstruktur |
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US20200030730A1 (en) | 2020-01-30 |
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CN110366442A (zh) | 2019-10-22 |
EP3593884A4 (en) | 2021-01-13 |
WO2018164070A1 (ja) | 2018-09-13 |
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