JP2020040035A - ハニカム構造体の製造方法 - Google Patents
ハニカム構造体の製造方法 Download PDFInfo
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- JP2020040035A JP2020040035A JP2018170620A JP2018170620A JP2020040035A JP 2020040035 A JP2020040035 A JP 2020040035A JP 2018170620 A JP2018170620 A JP 2018170620A JP 2018170620 A JP2018170620 A JP 2018170620A JP 2020040035 A JP2020040035 A JP 2020040035A
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- honeycomb
- honeycomb structure
- raw material
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- manufacturing
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 33
- 239000002245 particle Substances 0.000 claims abstract description 90
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 49
- 239000002994 raw material Substances 0.000 claims abstract description 43
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- 238000010304 firing Methods 0.000 claims abstract description 19
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims abstract description 17
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- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical group O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 9
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- 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 1
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- OJMOMXZKOWKUTA-UHFFFAOYSA-N aluminum;borate Chemical compound [Al+3].[O-]B([O-])[O-] OJMOMXZKOWKUTA-UHFFFAOYSA-N 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
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- 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
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 1
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- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
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- 229910052624 sepiolite Inorganic materials 0.000 description 1
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- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
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- 235000019698 starch Nutrition 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 238000004506 ultrasonic cleaning Methods 0.000 description 1
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Abstract
Description
これに対して、本発明のハニカム構造体の製造方法では、原料混合工程において、無機バインダと無機繊維とを予混合する。
無機バインダと無機繊維とを予混合することによって、無機繊維の表面に存在する無機バインダの量を増加させることができるため、無機繊維と他の材料との結合強度を増加させることができると考えられる。
なお、無機繊維とは、アスペクト比が5以上のものをいう。
ベーマイトは、AlOOHの組成で示されるアルミナ1水和物であり、水等の媒体に良好に分散するので、本発明のハニカム構造体の製造方法では、ベーマイトを無機バインダとして用いることが望ましい。
無機繊維がアルミナ繊維であると、ハニカム構造体の耐熱性が向上する。
上記重量比(セリア−ジルコニア複合酸化物粒子/アルミナ粒子)が1.0〜3.0であると、セリア−ジルコニア複合酸化物粒子の含有率が高く、このセリア−ジルコニア複合酸化物粒子は、助触媒として使用されるものであるので、排ガスの浄化性能が向上する。
ハニカム焼成体に貴金属を担持させることにより、排ガス浄化用途に使用することが可能となる。
[ハニカム構造体]
まず、本発明のハニカム構造体の製造方法により得られるハニカム構造体について説明する。
図1に示すハニカム構造体10は、複数の貫通孔12が隔壁13を隔てて長手方向(図1中、両矢印Lで示す方向)に並設された単一のハニカム焼成体11を備えている。ハニカム焼成体11は、CZ粒子とアルミナ粒子とを含み、押出成形体の形状を有している。
図1に示すように、ハニカム構造体10が単一のハニカム焼成体11からなる場合、ハニカム構造体10はハニカム焼成体そのものでもある。
後述するように、ハニカム焼成体は、CZ粒子、アルミナ粒子、無機バインダ及び無機繊維を含む原料ペーストを押出成形した後、焼成することにより作製されている。
本発明のハニカム構造体がCZ粒子とアルミナ粒子を有しているか否かについては、X線回折(XRD)にて確認できる。
ハニカム焼成体の気孔率が45〜70体積%であると、高い機械的強度と排ガス浄化性能を両立させることができる。
(1)ハニカム焼成体を10セル×10セル×10mmの大きさに切断して、測定試料とする。この測定試料をイオン交換水及びアセトンを用いて超音波洗浄した後、オーブンを用いて100℃で乾燥する。なお、10セル×10セル×10mmの測定試料とは、貫通孔が縦方向に10個、横方向に10個並んだ状態で、最も外側の貫通孔とその貫通孔を構成する隔壁を含み、長手方向の長さが10mmとなるように切り出した試料を指す。
(2)測定顕微鏡(ニコン製Measuring Microscope MM−40 倍率:100倍)を用いて、測定試料の断面形状の寸法を測定し、幾何学的な計算から体積を求める(なお、幾何学的な計算から体積を求めることができない場合は、飽水重量と水中重量とを実測して体積を測定する)。
(3)計算から求められた体積及びピクノメータで測定した測定試料の真密度から、測定試料が完全な緻密体であると仮定した場合の重量を計算する。なお、ピクノメータでの測定手順は(4)に示す通りとする。
(4)ハニカム焼成体を粉砕し、23.6ccの粉末を準備する。得られた粉末を200℃で8時間乾燥させる。その後、Micromeritics社製 Auto Pycnometer1320を用いて、JIS R 1620(1995)に準拠して真密度を測定する。排気時間は40分とする。
(5)測定試料の実際の重量を電子天秤(A&D製 HR202i)で測定する。
(6)以下の式から、ハニカム焼成体の気孔率を求める。
(ハニカム焼成体の気孔率)=100−(測定試料の実際の重量/測定試料が完全な緻密体であると仮定した場合の重量)×100[%]
なお、本発明のハニカム構造体に貴金属を直接担持させた場合であっても、貴金属担持によるハニカム焼成体の気孔率の変化は無視できるほど小さい。
アルミナ粒子がθ相のアルミナ粒子であると耐熱性が高いため、貴金属を担持させ、長時間使用した後であっても高い排ガス浄化性能を発揮することができる。
上記ハニカム構造体において、上記ハニカム焼成体に触媒として機能する貴金属が担持されていると、排ガス浄化用のハニカム触媒としても使用することができる。
貴金属としては、例えば、白金、パラジウム、ロジウム等が挙げられる。
本明細書において、貴金属の担持量とは、ハニカム構造体の見掛けの体積当たりの貴金属の重量をいう。なお、ハニカム構造体の見掛けの体積とは、空隙の体積を含む体積であり、外周コート層及び/又は接着層の体積を含むこととする。
次に、本発明のハニカム構造体の製造方法について説明する。
本発明のハニカム構造体の製造方法は、複数の貫通孔が隔壁を隔てて長手方向に並設されたハニカム焼成体からなるハニカム構造体の製造方法であって、セリア−ジルコニア複合酸化物粒子、アルミナ粒子、無機バインダ及び無機繊維を含む原料ペーストを作製する原料混合工程と、上記原料ペーストを成形することにより、複数の貫通孔が隔壁を隔てて長手方向に並設されたハニカム成形体を作製する成形工程と、上記成形工程により成形されたハニカム成形体を乾燥する乾燥工程と、上記乾燥工程により乾燥されたハニカム成形体を焼成することにより、ハニカム焼成体を作製する焼成工程と、を含み、上記原料混合工程では、上記無機バインダと上記無機繊維を予混合することを特徴とする。
原料混合工程では、CZ粒子、アルミナ粒子、無機バインダ及び無機繊維を含む原料ペーストを作製するが、このとき、無機バインダと無機繊維を予混合する。
その他、界面活性剤等の助剤を添加してもよい。
また、CZ粒子として、その平均粒子径が1〜10μmのものを使用することが望ましい。
さらに、使用するアルミナ粒子の平均粒子径は、CZ粒子の平均粒子径よりも大きいことが望ましい。
なお、CZ粒子及びアルミナ粒子の平均粒子径は、レーザー回折式粒度分布測定装置(MALVERN社製 MASTERSIZER2000)により求めることができる。
上記重量比(セリア−ジルコニア複合酸化物粒子/アルミナ粒子)が1.0〜3.0であると、セリア−ジルコニア複合酸化物粒子の含有率が高く、このセリア−ジルコニア複合酸化物粒子は、助触媒として使用されるものであるので、排ガスの浄化性能が向上する。
造孔剤の平均粒子径は特に限定されないが、10〜60μmであることが望ましい。
造孔剤の平均粒子径は、アルミナ粒子及びCZ粒子の平均粒子径と同様に、レーザー回折式粒度分布測定装置(MALVERN社製 MASTERSIZER2000)を用いて測定することができる。
成形工程では、原料混合工程によって得られた原料ペーストを成形することにより、複数の貫通孔が隔壁を隔てて長手方向に並設されたハニカム成形体を作製する。
原料ペーストは例えば、押出成形等の方法により成形することができる。
具体的には、所定の形状の金型を通過させることにより、所定の形状の貫通孔を有するハニカム成形体の連続体を形成し、所定の長さにカットすることにより、ハニカム成形体とする。
本発明のハニカム構造体の製造方法では、上記成形工程により成形された成形体を乾燥する。
この際、マイクロ波乾燥機、熱風乾燥機、誘電乾燥機、減圧乾燥機、真空乾燥機、凍結乾燥機等の乾燥機を用いて、ハニカム成形体を乾燥し、ハニカム乾燥体を作製することが望ましい。
焼成工程では、乾燥工程により乾燥された成形体を焼成することにより、ハニカム焼成体を作製する。なお、この工程は、ハニカム成形体の脱脂及び焼成が行われるため、「脱脂・焼成工程」ということもできるが、便宜上「焼成工程」という。
本発明のハニカム構造体の製造方法は、必要に応じて、上記ハニカム焼成体に貴金属を担持させる担持工程をさらに含んでいてもよい。
ハニカム焼成体に貴金属を担持する方法としては、例えば、貴金属粒子もしくは錯体を含む溶液にハニカム焼成体又はハニカム構造体を浸漬した後、引き上げて加熱する方法等が挙げられる。
ハニカム構造体が外周コート層を備える場合、外周コート層を形成する前のハニカム焼成体に貴金属を担持してもよいし、外周コート層を形成した後のハニカム焼成体又はハニカム構造体に貴金属を担持してもよい。
以下、本発明をより具体的に開示した実施例を示す。なお、本発明は、以下の実施例のみに限定されるものではない。
(実施例1)
まずアルミナ繊維(平均繊維径:3μm、平均繊維長:60μm)を10.6重量%、無機バインダとしてベーマイトを2.8重量%とイオン交換水10.0重量%とを10分間予混合した。
続いて、CZ粒子(平均粒子径:2μm)を16.9重量%、γアルミナ粒子(平均粒子径:2μm)を8.5重量%、有機バインダとしてメチルセルロースを3.9重量%、造孔剤として、アクリル樹脂(平均粒子径:32μm)を28.1重量%、成形助剤として界面活性剤であるポリオキシエチレンオレイルエーテルを2.9重量%及びイオン交換水を16.2重量%を添加してさらに混合混練して、原料ペーストを調製した。
原料ペーストを調製する原料をすべて一度に混合したほかは、実施例1と同様の手順で比較例1に係るハニカム構造体を製造した。
まず、3点曲げ強度測定用サンプルとして、実施例1及び比較例1と同じ配合で混合、混練した原料ペーストを直方体に成形して、同条件で脱脂、焼成後に6mm×6mm×40mmに加工した部材を10本準備し、3点曲げ強度測定用サンプル(以下、サンプル)とした。サンプルの主面(サンプルの外周面のうち広い方の面)に対して垂直な方向に荷重を印加し、破壊荷重(サンプルが破壊した荷重)を測定した。10本の3点曲げ強度測定用サンプルについて破壊荷重を測定し、その平均値を曲げ強度とした。3点曲げ強度試験は、JIS R 1601を参考に、インストロン5582を用い、スパン間距離:30mm、スピード1mm/minで行った。3点曲げ強度は、実施例1で6.9MPa、比較例1で5.2MPaであった。
さらに、破壊により露出したサンプルの表面(破壊断面)をSEMで観察した。結果を図2及び図3に示す。図2は、実施例1に係るハニカム構造体の破壊断面のSEM画像であり、図3は、比較例1に係るハニカム構造体の破壊断面のSEM画像である。
11 ハニカム焼成体
12 貫通孔
13 隔壁
Claims (5)
- 複数の貫通孔が隔壁を隔てて長手方向に並設されたハニカム焼成体からなるハニカム構造体の製造方法であって、
セリア−ジルコニア複合酸化物粒子、アルミナ粒子、無機バインダ及び無機繊維を含む原料ペーストを作製する原料混合工程と、
前記原料ペーストを成形することにより、複数の貫通孔が隔壁を隔てて長手方向に並設されたハニカム成形体を作製する成形工程と、
前記成形工程により成形されたハニカム成形体を乾燥する乾燥工程と、
前記乾燥工程により乾燥されたハニカム成形体を焼成することにより、ハニカム焼成体を作製する焼成工程と、を含み、
前記原料混合工程では、前記無機バインダと前記無機繊維を予混合することを特徴とするハニカム構造体の製造方法。 - 前記無機バインダはベーマイトである請求項1に記載のハニカム構造体の製造方法。
- 前記無機繊維はアルミナ繊維である請求項1又は2に記載のハニカム構造体の製造方法。
- 前記原料混合工程における、前記アルミナ粒子に対する前記セリア−ジルコニア複合酸化物粒子の重量比(セリア−ジルコニア複合酸化物粒子/アルミナ粒子)は、1.0〜3.0である請求項1〜3のいずれかに記載のハニカム構造体の製造方法。
- 前記ハニカム焼成体に貴金属を担持させる担持工程をさらに含む請求項1〜4のいずれかに記載のハニカム構造体の製造方法。
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