JP2020158351A - ハニカム構造体、および、ハニカム構造体の製造方法 - Google Patents
ハニカム構造体、および、ハニカム構造体の製造方法 Download PDFInfo
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Abstract
Description
20 軸方向
21 入口端面(一方の端面)
22 出口端面(他方の端面)
23 隔壁
24 セル
32 表層部
33 内部
S11〜S15 ステップ
Claims (11)
- ハニカム構造体であって、
一方の端面と、
他方の端面と、
前記一方の端面から前記他方の端面の向かう軸方向に延びる複数の隔壁と、
前記一方の端面および前記他方の端面に設けられた複数の目封止部と、
を備え、
前記複数の隔壁により、前記軸方向に延びる空間であって前記軸方向から見た場合に2次元に配列された複数のセルが形成され、
前記複数の目封止部は、前記複数のセルの一部の前記一方の端面の開口および前記複数のセルの残りの前記他方の端面の開口を封止し、
前記複数の隔壁がコージェライトを主成分とする多孔質材料で形成され、
隣接するセルの間の隔壁において、両表面のそれぞれから前記隔壁の厚さの25%の深さまで部位である表層部の気孔率、および、他の部位である内部の気孔率が、50%以上であり、
前記表層部が、前記軸方向に平行な断面の2値化画像における前記軸方向の気孔幅である軸方向気孔幅が30μm未満の気孔と、前記軸方向幅が30μm以上の気孔とを含み、
前記内部が、前記軸方向気孔幅が30μm未満の気孔と、前記軸方向気孔幅が30μm以上の気孔とを含み、
前記2値化画像における前記表層部の前記軸方向の平均気孔幅である軸方向平均気孔幅が、前記内部の前記軸方向平均気孔幅よりも小さく、
前記隔壁の中央から表面に向かって前記軸方向平均気孔幅が漸次減少することを特徴とするハニカム構造体。 - 請求項1に記載のハニカム構造体であって、
前記表層部の前記軸方向気孔幅の分布における10μm未満の気孔幅の個数の百分率をNsp10、前記表層部の前記分布における50μm以上の気孔幅の個数の百分率をNsp50、前記内部の前記軸方向気孔幅の分布における10μm未満の気孔幅の個数の百分率をNip10、前記内部の前記分布における50μm以上の気孔幅の個数の百分率をNip50として、
Nsp10>Nip10、かつ、Nsp50<Nip50
を満たすことを特徴とするハニカム構造体。 - 請求項2に記載のハニカム構造体であって、
Nsp10−Nip10≧5、かつ、Nsp50−Nip50≦−4
をさらに満たすことを特徴とするハニカム構造体。 - 請求項2または3に記載のハニカム構造体であって、
−30≦Nsp50−Nip50≦−4
をさらに満たすことを特徴とするハニカム構造体。 - 請求項2ないし4のいずれか1つに記載のハニカム構造体であって、
Nsp10≧45、かつ、Nip50≧5
をさらに満たすことを特徴とするハニカム構造体。 - 請求項1ないし5のいずれか1つに記載のハニカム構造体であって、
前記内部における前記軸方向気孔幅が1μm以上250μm以下の気孔に関する前記軸方向平均気孔幅が、前記表層部における前記軸方向気孔幅が1μm以上250μm以下の気孔に関する前記軸方向平均気孔幅よりも大きいことを特徴とするハニカム構造体。 - 請求項1ないし6のいずれか1つに記載のハニカム構造体であって、
前記内部における前記軸方向平均気孔幅が17μm以上であることを特徴とするハニカム構造体。 - 請求項7に記載のハニカム構造体であって、
前記内部における前記軸方向平均気孔幅が20μm以上であることを特徴とするハニカム構造体。 - 請求項1ないし8のいずれか1つに記載のハニカム構造体であって、
前記表層部の前記軸方向気孔幅が、100μm以下であり、
前記内部の前記軸方向気孔幅が、250μm以下であることを特徴とするハニカム構造体。 - 請求項1ないし9のいずれか1つに記載のハニカム構造体であって、
前記内部の前記軸方向気孔幅が50μm以上の気孔に関する前記軸方向平均気孔幅が、前記内部の前記軸方向に垂直な方向の気孔幅が50μm以上の気孔に関する前記軸方向に垂直な方向における平均気孔幅よりも大きいことを特徴とするハニカム構造体。 - ハニカム構造体の製造方法であって、
前記ハニカム構造体が、
一方の端面と、
他方の端面と、
前記一方の端面から前記他方の端面の向かう軸方向に延びる複数の隔壁と、
前記一方の端面および前記他方の端面に設けられた複数の目封止部と、
を備え、
前記複数の隔壁により、前記軸方向に延びる空間であって前記軸方向から見た場合に2次元に配列された複数のセルが形成され、
前記複数の目封止部は、前記複数のセルの一部の前記一方の端面の開口および前記複数のセルの残りの前記他方の端面の開口を封止し、
前記複数の隔壁が多孔質のコージェライトで形成され、
前記ハニカム構造体の製造方法が、
小造孔材と大造孔材とを含むコージェライト原料を混練し、前記小造孔材が凝集した状態を維持した坏土を生成する工程と、
前記坏土から押出成形によりハニカム成形体を成形する工程と、
前記ハニカム成形体を乾燥する工程と、
前記ハニカム成形体に複数の目封止部を設ける工程と、
前記ハニカム成形体を焼成する工程と、
を備えることを特徴とするハニカム構造体の製造方法。
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