JP2019177313A - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
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- JP2019177313A JP2019177313A JP2018066770A JP2018066770A JP2019177313A JP 2019177313 A JP2019177313 A JP 2019177313A JP 2018066770 A JP2018066770 A JP 2018066770A JP 2018066770 A JP2018066770 A JP 2018066770A JP 2019177313 A JP2019177313 A JP 2019177313A
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- 238000005192 partition Methods 0.000 claims abstract description 60
- 230000002093 peripheral effect Effects 0.000 claims abstract description 14
- 239000012530 fluid Substances 0.000 claims abstract description 6
- 239000007789 gas Substances 0.000 description 29
- 239000003054 catalyst Substances 0.000 description 28
- 239000002994 raw material Substances 0.000 description 24
- 239000000919 ceramic Substances 0.000 description 13
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- 229910052878 cordierite Inorganic materials 0.000 description 8
- 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 7
- 239000000463 material Substances 0.000 description 7
- 238000001035 drying Methods 0.000 description 6
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 230000006866 deterioration Effects 0.000 description 5
- 229910010271 silicon carbide Inorganic materials 0.000 description 5
- 239000011230 binding agent Substances 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000002276 dielectric drying Methods 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000011156 evaluation Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 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 2
- SBEQWOXEGHQIMW-UHFFFAOYSA-N silicon Chemical compound [Si].[Si] SBEQWOXEGHQIMW-UHFFFAOYSA-N 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
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- 239000008119 colloidal silica Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
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- 238000001746 injection moulding Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
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- 239000011347 resin Substances 0.000 description 1
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- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
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- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
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- 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
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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- B01D53/34—Chemical or biological purification of waste gases
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- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
- B01D53/9463—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/08—Heat treatment
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- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2807—Metal other than sintered metal
- F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
- F01N3/2821—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
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- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
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- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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Abstract
Description
一の前記セルを取り囲む前記隔壁のうち、当該セルを挟んで対向する2辺を構成する前記隔壁のそれぞれに、当該セル内に延びるように突出し、且つ、当該セルの延びる方向に連続して設けられた、突起部を有し、
前記ハニカム構造部の前記セルの延びる方向に直交する断面において、前記セル内に突出する2つの前記突起部は、それぞれの先端同士を仮想的に結ぶ仮想線により、当該セル内を2つに分断する位置に配置されており、
前記仮想線によって分断される前記セルの一の領域の面積をS1とし、前記セルの他方の領域の面積をS2とした場合に、下記式(1)を満たすように構成されている、ハニカム構造体。
式(1):70%≦S1/S2×100%
(但し、上記式(1)において、S1≦S2の関係を示す。)
式(2):15%≦H1/H2×100%≦40%
本発明のハニカム構造体の一実施形態は、図1〜図4に示すハニカム構造体100である。ハニカム構造体100は、柱状のハニカム構造部10を備えている。ここで、図1は、本発明のハニカム構造体の一実施形態を模式的に示す斜視図である。図2は、本発明のハニカム構造体の一実施形態の流入端面を模式的に示す平面図である。図3は、図2のA−A’断面を模式的に示す断面図である。図4は、図2に示す流入端面の一部(領域P)を拡大して模式的に示す平面図である。
(但し、上記式(1)において、S1≦S2の関係を示す。)
本発明のハニカム構造体は、ハニカム成形工程と、焼成工程と、を有する方法により製造できる。以下に各工程について説明する。
本工程においては、セラミック原料を含有するセラミック成形原料を成形して、流体の流路となる複数のセルを取り囲むように配設された隔壁を有するハニカム成形体を形成する。
次に、ハニカム成形体を焼成してハニカム焼成体を作製する。ハニカム成形体の焼成は、ハニカム成形体を構成する成形原料を焼結させて緻密化し、所定の強度を確保するために行われる。焼成条件(温度、時間、雰囲気等)は、成形原料の種類により異なるため、その種類に応じて適当な条件を選択すればよい。例えば、コージェライト化原料を使用している場合には、焼成温度は、1410〜1440℃が好ましい。また、焼成時間は、最高温度での保持時間として、4〜8時間が好ましい。焼成を行う装置としては、電気炉、ガス炉等を用いることができる。以上のようにして得られたハニカム焼成体を、本発明のハニカム構造体とすることができる。なお、ハニカム構造体の製造方法においては、以下に示すような外周コート工程を更に有していてもよい。
本工程では、得られたハニカム焼成体の外周に、外周コート材を塗布して外周壁を形成する。なお、外周壁は、ハニカム成形体の作製時に、隔壁と一体となるように形成してもよい。外周コート工程によって更に外周壁を形成することにより、ハニカム構造体に外力が加わった際にハニカム構造体が欠けてしまうことを防止できる。
実施例1においては、まず、ハニカム構造体を作製するための成形原料を調製した。具体的には、セラミック原料に、バインダ、界面活性剤、造孔材、水を添加して成形原料とした。なお、セラミック原料としては、コージェライト化原料である、カオリン、タルク、アルミナを用いた。
作製したハニカム構造体について、大型風洞試験機を用いて圧力損失を測定した。このとき、ガス温度は25℃とし、ガス流量は10Nm3/分とした。評価基準は、2.00kPa以下を「OK」とし、2.00kPa超を「NG」とした。これは、圧力損失が2.00kPa超となると、出力が悪化するためである。
まず、以下の方法で、作製したハニカム構造体について、米国Fedral Test ProcedureのLA−4モードに基づく試験(以下、「LA−4試験」ともいう)を行った。まず、ハニカム構造体の隔壁に、触媒(三元触媒)を190g/L担持させた。なお、触媒を担持させたハニカム構造体は、電気炉を用いて、950℃で12時間エージング処理を行った。次に、触媒を担持させたハニカム構造体を、排気量が2400ccの車両の床下位置に搭載し、LA−4試験を行った。LA−4試験においては、排ガス測定装置(HORIBA社製、型番「MEXA−7400」)を用いて排ガス成分ごとのダイレクトモーダルマス(Direct Modal Mass)を測定した。また、代表的な排ガス成分としてHCの排出量を測定した。LA−4試験による排ガスの空間速度は、約10000(1/時間)(高流量)であった。そして、バッグエミッションで、HCの排出量が、0.020g/mile以下となる場合「OK」とし、0.020g/mile超となる場合を「NG」とした。なお、本評価が「OK」であると、触媒が均一に塗布されていることから排ガスの浄化に有効に利用されるため、浄化性能が上がると考えられる。
圧力損失の判定とバッグエミッションの判定に基づいて、以下の判断基準により総合判定を行った。圧力損失の判定とバッグエミッションの判定が共に「OK」である場合を「OK」とし、それ以外の場合を「NG」とした。
隔壁の厚さ、及び突起部の構成を、表1及び表2に示すように変更した以外は、実施例1と同様の方法でハニカム構造体を作製した。実施例2〜14、比較例1のハニカム構造体についても、実施例1と同様の方法で、圧力損失の測定、及びバッグエミッションの測定を行った。各結果を、表1及び表2に示す。
表1及び表2に示すように、実施例1〜14のハニカム構造体は、比較例1のハニカム構造体に比べて、圧力損失が低く、また、バッグエミッションでのHCの排出量が低いものであった。このため、実施例1〜14のハニカム構造体は、圧力損失の増加を抑制しつつ、エミッションの悪化を抑制することができることが分かった。
Claims (5)
- 第一端面から第二端面まで延びる流体の流路となる複数のセルを取り囲むように配設された多孔質の隔壁、及び前記隔壁を囲繞するように配設された外周壁を有する、柱状のハニカム構造部を備え、
一の前記セルを取り囲む前記隔壁のうち、当該セルを挟んで対向する2辺を構成する前記隔壁のそれぞれに、当該セル内に延びるように突出し、且つ、当該セルの延びる方向に連続して設けられた、突起部を有し、
前記ハニカム構造部の前記セルの延びる方向に直交する断面において、前記セル内に突出する2つの前記突起部は、それぞれの先端同士を仮想的に結ぶ仮想線により、当該セル内を2つに分断する位置に配置されており、
前記仮想線によって分断される前記セルの一の領域の面積をS1とし、前記セルの他方の領域の面積をS2とした場合に、下記式(1)を満たすように構成されている、ハニカム構造体。
式(1):70%≦S1/S2×100%
(但し、上記式(1)において、S1≦S2の関係を示す。) - 前記突起部は、当該突起部の側面が、前記隔壁の表面に対して、50〜90°の角度となるにように配置されている、請求項1に記載のハニカム構造体。
- 前記隔壁の厚さが、0.05〜0.153mmである、請求項1又は2に記載のハニカム構造体。
- 前記突起部の高さH1と、前記ハニカム構造部のセルピッチH2とが、下記式(2)の関係を満たす、請求項1〜3のいずれか一項に記載のハニカム構造体。
式(2):15%≦H1/H2×100%≦40% - 前記突起部の幅W1が、0.0127〜0.203mmである、請求項1〜4のいずれか一項に記載のハニカム構造体。
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