JP2021137685A - ハニカムフィルタ - Google Patents
ハニカムフィルタ Download PDFInfo
- Publication number
- JP2021137685A JP2021137685A JP2020034884A JP2020034884A JP2021137685A JP 2021137685 A JP2021137685 A JP 2021137685A JP 2020034884 A JP2020034884 A JP 2020034884A JP 2020034884 A JP2020034884 A JP 2020034884A JP 2021137685 A JP2021137685 A JP 2021137685A
- Authority
- JP
- Japan
- Prior art keywords
- partition wall
- honeycomb filter
- honeycomb
- raw material
- pores
- 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.)
- Granted
Links
- 239000011148 porous material Substances 0.000 claims abstract description 47
- 239000000463 material Substances 0.000 claims abstract description 44
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 13
- 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 claims abstract description 13
- 238000005192 partition Methods 0.000 claims description 98
- 238000007789 sealing Methods 0.000 claims description 19
- 239000012530 fluid Substances 0.000 claims description 3
- 239000002994 raw material Substances 0.000 description 68
- 239000002245 particle Substances 0.000 description 41
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 33
- 238000011156 evaluation Methods 0.000 description 30
- 239000004927 clay Substances 0.000 description 26
- 238000000034 method Methods 0.000 description 23
- 238000009826 distribution Methods 0.000 description 18
- 238000010304 firing Methods 0.000 description 18
- 238000005259 measurement Methods 0.000 description 16
- 239000000377 silicon dioxide Substances 0.000 description 16
- 230000001186 cumulative effect Effects 0.000 description 14
- 238000000465 moulding Methods 0.000 description 14
- 238000002360 preparation method Methods 0.000 description 13
- 238000002156 mixing Methods 0.000 description 12
- 230000002093 peripheral effect Effects 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 9
- 239000000565 sealant Substances 0.000 description 7
- 238000012545 processing Methods 0.000 description 6
- 238000000746 purification Methods 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 239000000919 ceramic Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000003566 sealing material Substances 0.000 description 5
- 239000004071 soot Substances 0.000 description 5
- 238000012935 Averaging Methods 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 4
- 239000002612 dispersion medium Substances 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000005995 Aluminium silicate Substances 0.000 description 3
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 3
- 235000012211 aluminium silicate Nutrition 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 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 3
- 238000000691 measurement method Methods 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 239000002689 soil Substances 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- 239000000454 talc Substances 0.000 description 3
- 229910052623 talc Inorganic materials 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
- 239000000571 coke Substances 0.000 description 2
- 238000002276 dielectric drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
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- 238000007602 hot air drying Methods 0.000 description 2
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- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
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- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000001291 vacuum drying Methods 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- LNAZSHAWQACDHT-XIYTZBAFSA-N (2r,3r,4s,5r,6s)-4,5-dimethoxy-2-(methoxymethyl)-3-[(2s,3r,4s,5r,6r)-3,4,5-trimethoxy-6-(methoxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6r)-4,5,6-trimethoxy-2-(methoxymethyl)oxan-3-yl]oxyoxane Chemical compound CO[C@@H]1[C@@H](OC)[C@H](OC)[C@@H](COC)O[C@H]1O[C@H]1[C@H](OC)[C@@H](OC)[C@H](O[C@H]2[C@@H]([C@@H](OC)[C@H](OC)O[C@@H]2COC)OC)O[C@@H]1COC LNAZSHAWQACDHT-XIYTZBAFSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000003610 charcoal Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910002026 crystalline silica Inorganic materials 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 229910001649 dickite Inorganic materials 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- -1 for example Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 description 1
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 description 1
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 description 1
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000007561 laser diffraction method Methods 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 238000009777 vacuum freeze-drying Methods 0.000 description 1
Images
Classifications
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- B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
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- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
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- C04B2235/3436—Alkaline earth metal silicates, e.g. barium silicate
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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Abstract
Description
それぞれの前記セルの前記第一端面側又は前記第二端面側の開口部に配設された目封止部と、を備え、
前記隔壁が、コージェライトを主成分として含む材料から構成され、
前記隔壁の表面に存在する円相当径3.0μm超の細孔の単位面積当たりの個数が、600個/mm2以上である、ハニカムフィルタ。
図1〜図3に示すように、本発明のハニカムフィルタの第一実施形態は、ハニカム構造部4と、目封止部5と、を備えた、ハニカムフィルタ100である。ハニカム構造部4は、第一端面11から第二端面12まで延びる流体の流路となる複数のセル2を取り囲むように配置された多孔質の隔壁1を有する柱状のものである。ハニカムフィルタ100において、ハニカム構造部4は、柱状を呈し、その外周側面に、外周壁3を更に有している。即ち、外周壁3は、格子状に配設された隔壁1を囲繞するように配設されている。目封止部5は、それぞれのセル2の第一端面11側又は第二端面12側の開口部に配設されている。
本実施形態のハニカムフィルタの製造方法については、特に制限はなく、例えば、以下のような、坏土調製工程と、成形工程と、焼成工程と、を備えた製造方法を挙げることができる。
坏土調製工程では、まず、坏土の原料となる、コージェライト化原料、有機造孔材及び分散媒を用意する。ここで、「コージェライト化原料」とは、シリカが42〜56質量%、アルミナが30〜45質量%、マグネシアが12〜16質量%の範囲に入る化学組成となるように配合されたセラミック原料であって、焼成されてコージェライトになるものである。
式(2):|log10D(a)50−log10D(b)50|≦0.50
成形工程では、坏土調製工程にて得られた坏土をハニカム形状に成形してハニカム成形体を作製する。坏土をハニカム形状に成形する成形方法については特に制限はないが、押出成形、射出成形、プレス成形等の従来公知の成形方法を挙げることができる。中でも、上述のように調製した坏土を、所望のセル形状、隔壁厚さ、セル密度に対応した口金を用いて押出成形する方法を好適例として挙げることができる。
焼成工程は、成形工程によって得られたハニカム成形体を焼成してハニカムフィルタを得る工程である。ハニカム成形体を焼成する際の焼成雰囲気の温度は、例えば、1300〜1450℃が好ましく、1400〜1450℃が更に好ましい。また、焼成時間は、最高温度でのキープ時間として2〜8時間程度とすることが好ましい。
コージェライト化原料として、タルク、カオリン、アルミナ、水酸化アルミニウム、及び多孔質シリカを用意した。そして、各原料の累積粒度分布を、HORIBA社製のレーザ回折/散乱式粒子径分布測定装置(商品名:LA−960)を用いて測定した。実施例1においては、各原料の配合比率(質量部)が表1に示す値となるように、各原料を配合してコージェライト化原料を調製した。表1において、「粒度D50(μm)」の横方向の行は、各原料の50体積%の粒子径(即ち、メジアン径)を示している。多孔質シリカは、JIS−R1626に準拠して測定されたBET比表面積が、200〜400m2/gのものを用いた。
まず、各実施例及び比較例のハニカムフィルタを排ガス浄化用フィルタとした排ガス浄化装置を作製した。次に、作製した排ガス浄化装置を、1.2L直噴ガソリンエンジン車両のエンジン排気マニホルドの出口側に接続して、排ガス浄化装置の流出口から排出されるガスに含まれる煤の個数を、PN測定方法によって測定した。走行モードに関しては、RDE走行のワーストを模擬した走行モード(RTS95)を実施した。モード走行後に排出された煤の個数の累計を、判定対象となる排ガス浄化装置の煤の個数とし、その煤の個数から捕集効率(%)を算出した。算出した捕集効率(%)の値に基づいて、以下の評価基準にて評価を行った。
[評価基準]
評価「優」:捕集効率が90%以上、100%以下。
評価「良」:捕集効率が85%以上、90%未満。
評価「可」:捕集効率が80%以上、85%未満。
評価「不可」:捕集効率が80%未満。
大型風洞試験機を用いて、ハニカムフィルタの圧力損失(kPa)を測定した。圧力損失の測定条件は、ガス温度を25℃とし、ガス流量を10Nm3/分とした。圧力損失の評価においては、圧力損失が8.2kPa以下の場合を「合格」とし、圧力損失が8.2kPaを超える場合を「不合格」とした。
評価「優」:圧力損失の評価結果が「合格」で、捕集効率の評価結果が「優」。
評価「良」:圧力損失の評価結果が「合格」で、捕集効率の評価結果が「良」。
評価「可」:圧力損失の評価結果が「合格」で、捕集効率の評価結果が「可」。
評価「不可」:圧力損失の評価結果が「不合格」又は捕集効率の評価結果が「不可」。
実施例2〜3においては、コージェライト化原料に用いる各原料の配合比率(質量部)を表1に示すように変更した。また、有機造孔材及びその他原料の配合比率(質量部)についても表2に示すように変更した。このような原料を用いて坏土を調製したこと以外は、実施例1と同様の方法でハニカムフィルタを作製した。
比較例1〜3においては、コージェライト化原料に用いる各原料の配合比率(質量部)を表1に示すように変更した。また、有機造孔材及びその他原料の配合比率(質量部)についても表2に示すように変更した。このような原料を用いて坏土を調製したこと以外は、実施例1と同様の方法でハニカムフィルタを作製した。
実施例1〜3のハニカムフィルタは、捕集効率の評価結果が、「優」又は「良」のいずれかであり、圧力損失の評価結果についても全て「合格」であった。一方で、比較例1〜3のハニカムフィルタは、実施例1〜3のハニカムフィルタに比して、捕集効率の評価結果が劣るものであった。
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置された多孔質の隔壁を有する柱状のハニカム構造部と、
それぞれの前記セルの前記第一端面側又は前記第二端面側の開口部に配設された目封止部と、を備え、
前記隔壁が、コージェライトを主成分として含む材料から構成され、
前記隔壁の表面に存在する円相当径3.0μm超の細孔の単位面積当たりの個数が、600個/mm2以上である、ハニカムフィルタ。 - 前記隔壁の表面に存在する円相当径3.0μm超の細孔の開気孔率が、25%以上である、請求項1に記載のハニカムフィルタ。
- 前記隔壁の気孔率が、60〜70%である、請求項1又は2に記載のハニカムフィルタ。
- 前記隔壁の平均細孔径が、10〜20μmである、請求項1〜3のいずれか一項に記載のハニカムフィルタ。
- 前記隔壁の厚さが、152〜305μmである、請求項1〜4のいずれか一項に記載のハニカムフィルタ。
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JPS61129015A (ja) * | 1984-11-24 | 1986-06-17 | Nippon Denso Co Ltd | 排出ガス浄化用フイルタおよびその製造方法 |
JP2004360654A (ja) * | 2003-06-06 | 2004-12-24 | Hitachi Metals Ltd | セラミックハニカムフィルタ |
WO2011102487A1 (ja) * | 2010-02-22 | 2011-08-25 | 日立金属株式会社 | セラミックハニカム構造体及びその製造方法 |
US20120317947A1 (en) * | 2010-02-22 | 2012-12-20 | Hitachi Metals, Ltd. | Ceramic honeycomb structure and its production method |
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