JP5171279B2 - Honeycomb structure, filter and exhaust gas treatment device - Google Patents

Description

  The present invention relates to a honeycomb structure, a filter using the honeycomb structure, and an exhaust gas treatment apparatus using the filter. Filters include internal combustion engines (power sources for automobiles, forklifts, generators, ships, hydraulic excavators, bulldozers, wheel loaders, rough terrain cranes, tractors, combiners, tillers, construction vehicles, etc.), incinerators and boilers. For example, a filter that collects fine particles mainly composed of carbon, for example, a filter that decomposes and removes harmful substances such as dioxin, or a filter for filtering liquids such as clean water and sewage Etc. are applicable.

  Conventionally, the purpose is to collect fine particles mainly composed of carbon contained in exhaust gas generated from internal combustion engines, incinerators and boilers (particularly fine particles mainly composed of carbon in exhaust gas from diesel engines). As a filter, a honeycomb structure is used. These fine particles cause environmental pollution and are adsorbed on the filter.

  A honeycomb structure used for a filter includes partition walls having wall surfaces along the axial direction, a plurality of flow holes partitioned by the partition walls, and a sealing material that alternately seals both ends of the plurality of flow holes. Become. This partition is formed by extruding a clay mainly composed of cordierite or aluminum titanate. Since any component has anisotropy in thermal expansion, it is oriented in the direction in which the thermal expansion is lowest along the axial direction by extrusion molding. Since the sealing portion cannot orient each crystal of cordierite and aluminum titanate due to its manufacturing method, even if the sealing portion and the partition are formed of the same material, the thermal expansion coefficient will be different. .

  Therefore, when a thermal shock is applied to the partition wall, the stress concentrates on the boundary between the sealing portion and the partition wall, cracks are generated along this boundary, and in an extreme case, the sealing portion and the partition wall may be separated. there were. In order to suppress such stress concentration, proposals as shown in Patent Documents 1 to 3 have been made. 6 to 8 are cross-sectional views of the filters shown in each patent document cut in parallel to the axial direction.

  In Patent Document 1, as shown in FIG. 6, plugging is performed on one end portion of a predetermined through-hole and the other end portion of the remaining through-hole of a honeycomb structure having a large number of through-holes 22 made of a porous ceramic material. An exhaust gas purifying filter 21 is disclosed in which the partition wall 24 that partitions the through hole 22 is formed as a filtration layer by forming the portion 23. The plugging length of the through hole 22 in the central part A of the exhaust gas purification filter 21 is formed to be gradually shorter than the plugging length of the through hole 22 in the outer peripheral part B of the exhaust gas purification filter. . Further, the plugging length at the central portion A of the plugging portion 23 is formed to be gradually shorter than the plugging length at the outer peripheral portion B of the plugging portion 23.

  Further, in Patent Document 2, as shown in FIG. 7, it has a large number of flow holes 22 penetrating in the axial direction partitioned by the partition wall 24, and the partition wall 24 of the flow hole 22 has a filtering ability, One end of the flow hole 22 is plugged, and the other end of the remaining flow hole 22 is plugged to collect and remove particulate matter contained in the dust-containing fluid. A filter 21 is disclosed. In the cross section perpendicular to the axial direction of the honeycomb filter 21, the heat capacity at the center is higher than the heat capacity at the periphery. Specifically, plugging is performed such that the plugging depth is deep at the center and shallow at the periphery, so that the heat capacity at the center of the honeycomb filter 21 is made higher than that at the periphery.

Patent Document 3 discloses a ceramic honeycomb filter 21 in which a desired flow path of a porous ceramic honeycomb structure is plugged as shown in FIG. At least one plugging portion 23 on the exhaust gas inflow side is arranged away from the exhaust gas inflow side end surface IF of the ceramic honeycomb filter 21, and at both end portions 23 a and 23 b of the exhaust gas inflow side plugging portion 23. A recess is formed.
JP 2003-269132 A JP 2003-254034 A JP 2006-305503 A

  In the filter having the structure disclosed in Patent Document 1, the surface area of the partition wall capable of adsorbing fine particles in the outer peripheral portion is reduced. For this reason, it is conceivable that the collection rate tends to decrease at the outer peripheral portion where the collection rate of fine particles is usually high, and the collection rate of fine particles in the exhaust gas purification filter as a whole tends to decrease.

  Further, in the filter having the structure disclosed in Patent Document 2, since the inner end portion is formed in a flat shape, it is considered that fine particles are likely to be deposited and the collection rate of the fine particles is likely to be reduced.

  Furthermore, in the filter having the structure disclosed in Patent Document 3, since the inner end portion on the outflow side is formed in a flat shape, fine particles are likely to be deposited, and the collection rate of the fine particles is likely to be reduced. Conceivable.

  Thus, a filter that sufficiently suppresses the occurrence of cracks and erosion and has a high particulate collection rate is desired.

  In view of such problems, the present invention provides a honeycomb structure, a filter, and an exhaust gas treatment device that can suppress the occurrence of cracks and erosion, and are less likely to reduce the collection rate of fine particles even when used for a long period of time. Is.

The honeycomb structure of the present invention comprises a partition wall having a wall surface in the axial direction, and a plurality of flow holes partitioned by the partition walls, and a sealing member for sealing alternating ends of said plurality of flow holes Te becomes, in a cross-sectional view taken parallel to to said axis, said a said inner end that put the fluid passing holes of the sealing material is concave, and the outer end portion of the flow hole of the sealing member , the length L _a between the boundary and the outer peripheral side end portion of the inner end partition wall that Majiwa includes: the outer side end portion of the sealing member, the inner peripheral end of the inner end together with different lengths _{L b} and length between the partition wall and is Majiwa that boundary and parts, the length _L a, coefficient of variation of _{L b σ a / x a,} σ b / x b (σ a : _{L a} standard deviation _of, x a: mean value of _{L a, σ b: L b} standard _deviation, x b: with _L average value of _b) is 0.08 or more, and toward the outer peripheral side Accordingly, characterized in that the length of the sealing material is shorter.

Another aspect according to the honeycomb structure of the present invention, alternating with a septum having a wall surface in the axial direction, and a plurality of flow holes partitioned by the partition walls, the inside and the ends of said plurality of distribution holes to be provided with a sealing member for sealing, in a cross-sectional view taken parallel to to said axial direction, the inner end that put the flow hole of the sealing member is concave, the sealing and the outer end portion of the flow hole of the timber, the length L _a between the outer peripheral side end portion and the partition wall and is Majiwa that boundary of the inner end, said outer end portion of the sealing member , with the length L _b and the length between the boundary and the inner peripheral end of the inner end portion and the partition wall that Majiwa differ, the lengths L _a, coefficient of variation of L _b σ _{a /} x _{a, σ b / x b (} σ a: L a standard deviation _of, x a: mean value of _{L a, σ b: L b} standard _deviation, x b: mean value of _{L b)} is 0.0 Wherein the length of the sealing material is shorter in accordance with the above, and toward the outer peripheral side.

  In addition, the honeycomb structure is characterized in that, in particular, each of the sealing materials has a bowl-like inner end portion.

Further, the honeycomb structure is made of a sintered body mainly composed of aluminum titanate. The filter of the present invention is a filter using the honeycomb structure, wherein one end of the flow hole is provided. The exhaust gas is allowed to pass through the inlet and the other end as an outlet, and particulates in the exhaust gas are collected by a partition wall and a sealing material.

  The exhaust gas treatment device of the present invention includes the above filter.

According to the honeycomb structure of the present invention, in the cross-sectional view, the inner end portion of the sealing material is concave, the outer end portion in the flow hole of the sealing material, and the outer peripheral side end of the inner end portion. the length L _a between the partition wall and is Majiwa that boundary is part, border the said outer end portion of the sealing material, the inner circumferential end of the inner end portion and the partition wall that Majiwa with the length _{L b} and the length between the field Metropolitan different, the lengths _L a, _{L b} of the coefficient of variation _{σ a / x a, σ b} / x b (σ a: L a standard deviation of, _{x a} Is the average value of L _a , σ _{b is} the standard deviation of L _b , and x _b is the average value of L _b ) of 0.08 or more, and the length of the sealing material becomes shorter toward the outer peripheral side. For this reason, since the surface area of the partition wall on the outer peripheral side where fine particles can be adsorbed tends to increase as a whole, the collection rate of the fine particles is unlikely to decrease. Further, compared to the case where the length of the sealing material is substantially the same, the stress generated at the boundary between the partition wall and the inner end portion is easily relieved, and the sealing material has a concave inner end portion. Therefore, since the stress concentration at the boundary between the partition wall and the inner end can be further reduced, it is possible to suppress the occurrence of cracks and erosion caused at the boundary.

According to the honeycomb structure of the present invention, the length L _a between the outer end portion of the flow hole of the sealing material, the boundary between the outer peripheral end of the inner end portion and the partition wall that Majiwa , the said outer end portion of the sealing material, with the length L _b and the length between the inner peripheral end of the inner end the partition wall and is Majiwa that boundaries are different, the lengths is _L a, _{L b} of the coefficient of variation _{σ a / x a, σ b} / x b (σ a: L a standard deviation _of, x a: _L average value of _{a, σ b: L b} standard deviation, _{x b} : the L average value of _b) is 0.08 or more, and since the length of the sealing member toward the outer peripheral side is shorter, the same effect as described above is obtained.

In particular, prior Symbol each sealant, when the inner end portion is bowl-shaped, in order to selectively deposit the fine particles on the inner end portion of the concave from the partition wall, even if repeated use reduces the collection rate of the particulate Hateful. Furthermore, when it consists of the sintered compact which has aluminum titanate as a main component, thermal shock resistance can be made high and it can be made reliable over a long period of time.

  According to the filter of the present invention, it is a filter using the above honeycomb structure, and allows the exhaust gas to pass through with one end of the flow hole as an inlet and the other end as an outlet. Since the filter collects fine particles, the fine particles can be efficiently collected over a long period of time.

  According to the exhaust gas treatment device of the present invention, since the filter is provided, it can be used for a long period of time.

  The best mode for carrying out the present invention will be described below in detail with reference to the drawings.

FIG. 1 is a reference diagram schematically showing the honeycomb structure 1 of the present embodiment. FIG. 1A is a cross-sectional view showing a state in which the honeycomb structure 1 is cut in parallel to the axial direction AX through the central portion of the main body of the honeycomb structure 1 (however, the central portion is omitted), and FIG. It is an enlarged view in the inner side edge part of a sealing material.

Honeycomb structure 1, a partition 4 having a wall along the axial direction AX, a plurality of flow holes 2 which are partitioned by partition walls 4, the sealing material 3 for sealing both ends of the plurality of communication holes 2 are alternately , 30. Inner ends 3c and 30c located on the inner side of the respective flow holes 2 of the sealing materials 3 and 30 in a cross-sectional view cut in parallel to the axial direction AX through the center of the main body of the honeycomb structure 1 Is concave. Further, sealing in accordance with encapsulating material 3a present on the outer peripheral side of the main body, the length of 30a, toward the outer circumferential side from the sealing member 3b, shorter than the length of 30b, or One in mind portions existing in the center of the body have I short kuna as a whole while the variation in length of the sealing material 3, 30.

More specifically, the honeycomb structure 1 is positioned in the vicinity of the straight lines L1, L2, L3, and L4 indicated by broken lines at the bottoms of the inner end portions 3c and 30c of the sealing materials 3 and 30, respectively. The length of the materials 3 and 30 is shortened as a whole toward the outer peripheral side.
FIG. 2 is a cross-sectional view showing the sealing material 3 in a cross-sectional view in which the flow hole 2 is cut in parallel to the axial direction AX. As shown in FIG. 2, the sealing material 3 is asymmetric with respect to the center line CL parallel to the axial direction AX in any of the shapes (a), (b), (c), (d), and (e). in length _{L a} between the outer side end portion 3d, the outer end portion of the inner end portion 3c and the partition wall 4a and is Majiwa that boundary in the distribution hole 2 of the sealant 3 and 30, the sealing an outer side end portion 3d of the timber 3, 30 has a length _{L b} and the length between the inner peripheral end of the inner end portion 3c and the partition wall 4b and is Majiwa that boundary varies. Furthermore, the length _L a of the sealing material 3, 30 in the cross section, the variation of _{L b} is the coefficient of variation is an indicator showing a relatively variation _{σ a / x a, σ b} / x b (σ a : _{L a} standard deviation _of, x a: mean value of _{L a, σ b: L b} standard _deviation, x b: mean value of _{L b)} is 0.08 or more.

  By configuring the sealing materials 3 and 30 in this way, the surface area of the partition walls 4 capable of adsorbing fine particles contained in a gas such as exhaust gas tends to increase on the outer peripheral side as a whole. Thereby, the collection rate of fine particles is difficult to decrease.

Here, straight lines L1, L2, L3, and L4 indicated by broken lines in FIG. 1 are straight lines that contact the bottom of the sealing material 3a located at the outermost periphery of the honeycomb structure 1 and the bottom of the sealing material 3b located at the center. If the sealing material 3b is not at the center, the bottom of the sealing material 3b existing at the position closest to the center may be used.

  The main body includes a partition wall 4 having a wall surface along the axial direction AX and a plurality of flow holes 2 partitioned by the partition wall 4. Exhaust gas containing fine particles containing carbon as a main component (hereinafter referred to as diesel fine particles) flows in the direction indicated by the arrow in the axial direction AX in FIG.

  Also, by making the inner end portions 3c, 30c of the sealing materials 3, 30 concave, the surfaces of the inner end portions 3c, 30c are not all orthogonal to the partition walls 4 as in the prior art, On the other hand, it includes a surface that is inclined, and the surface area of the inner end portions 3c and 30c is larger than the area of the surface of the conventional flat inner end portion.

  Moreover, compared with the case where the length of a sealing material is substantially the same, the stress which generate | occur | produces in the boundary of the partition 4 and the inner side edge parts 3c and 30c is easy to be relieved. Furthermore, since the inner end portions 3c and 30c are concave in the sealing materials 3 and 30, the stress concentration at the boundary between the partition wall 4 and the inner end portions 3c and 30c can be reduced. Thereby, the crack and melting loss which have arisen in this boundary can be suppressed. In addition, when the honeycomb structure 1 is used as a filter for collecting fine particles, the fine particles are selectively deposited on the concave inner end portion 30c from the partition wall 4, so that the collection rate of the fine particles is reduced even after repeated use. Can be delayed.

Moreover, the sealing materials 3 and 30 differ in the degree of stress concentration at the boundary between the partition wall 4 and the inner end portions 3c and 30c depending on their shapes. In the honeycomb structure 1 of the present embodiment, the sealing materials 3 and 30 in a cross-sectional view in which the flow hole 2 is cut in parallel to the axial direction AX through the central portion of the main body are parallel to the axial direction AX. In the case of being asymmetric with respect to the center line, the stress concentration at the boundary between the partition wall 4 and the inner end portions 3c and 30c is further reduced. As a result, cracks and erosion generated at the boundary between the partition wall 4 and the inner end portions 3c and 30c are less likely to occur.
Here, the absolute value of the difference between the length L _a and the length L _b is desirably 2 mm or more and 3 mm or less. This is because cracks and erosion generated at the boundary between the partition wall 4 and the inner end 3c are less likely to occur when the thickness is 2 mm or more, and the surface area of the partition wall is hardly reduced when the thickness is 3 mm or less. This is because the efficiency can be maintained.

FIG. 3 is a reference diagram schematically showing a honeycomb structure according to another embodiment of the present invention. 3 (a) is a sectional view showing a state in which cutting the body parallel to the axial direction AX (where omitted center section), and FIG. 3 (b) is an enlarged view of the inner end portion of the sealing member It is. In addition, when showing a common part with FIG. 1, it shows using the same code | symbol.

The honeycomb structure 1 shown in FIG. 3, the partition walls 4 having a wall along the axial direction AX, a plurality of flow holes 2 which are partitioned by partition walls 4, alternates between the internal ends of the plurality of communication holes 2 Each of the sealing materials 3 and 30 in a cross-sectional view cut in parallel to the axial direction AX through the central portion of the main body. The inner end portions 3c and 30c are concave, and the lengths of the sealing materials 3a and 30a existing on the outer peripheral side of the main body are the same as the lengths 3b and 30b of the sealing material existing in the central portion of the main body. The length of each of the sealing materials 3 and 30 is shortened as a whole as the length decreases toward the outer peripheral side.

More specifically, the honeycomb structure 1 shown in FIG. 3 is located in the vicinity of the straight lines L1, L2, L3, L4 indicated by broken lines at the bottoms of the inner end portions 3c, 30c of the sealing materials 3, 30, The length of the sealing materials 3 and 30 tends to become shorter as a whole from the center of the main body toward the outer peripheral side. Note that straight lines L1, L2, L3, and L4 indicated by broken lines are formed at the bottom of the sealing material 3a located at the outermost periphery of the honeycomb structure 1 and the bottom of the sealing material 3b located at the center, as in FIG. When the sealing material 3b is not in the center, the bottom of the sealing material 3b existing at the position closest to the center may be used.
In addition, as shown in FIG. 2, the sealing material 3 has any shape of (a), (b), (c), (d) and (e) with respect to the center line CL parallel to the axial direction AX. in asymmetric length L _a between the outer side end portion 3d, the outer end portion of the inner end portion 3c and the partition wall 4a and is Majiwa that boundary, the outer side end portion 3d of the sealing material 3, 30 When, different length L _b and the length between the inner circumferential side end of the partition wall 4b and is Majiwa that boundary of the inner end portion 3c. Furthermore, variations in the lengths L _a and L _b in the axial direction AX of the sealing materials 3 and 30 are variation coefficients σ _a / x _a and σ _b / x _b (σ _a : _{L a} standard deviation _of, x a: mean value of _{L a, σ b: L b} standard _deviation, x b: mean value of _{L b)} is 0.08 or more.
Further, the main body has a partition wall 4 having a wall surface along the axial direction AX and a plurality of flow holes 2 partitioned by the partition wall 4, and the exhaust gas containing diesel particulates is axial in FIG. It flows in the direction of arrow AX. Also, the honeycomb structure 1 in FIG. 2, catalyst is supported on the inflow side of the partition wall 4c of the inner end and the exhaust gases of the sealing material 3. Here, examples of the catalyst include platinum group metals such as platinum (Pt), palladium (Pd), ruthenium (Ru), rhodium (Rh) and oxides thereof, alkaline earth metal oxides, rare earth oxidations, and the like. Products, vanadium oxide (V ₂ O ₃ ), lanthanum (La), cesium (Cs), and the like.

Also in the honeycomb structure 1 shown in FIG. 3 , the same effects as those obtained with the honeycomb structure 1 shown in FIG. 1 can be obtained.

  During the operation of the internal combustion engine, the incinerator, the boiler, etc., the amount of particulates collected by the honeycomb structure 1 exceeds a certain value, and unburned hydrocarbon gas contained in the exhaust gas is discharged to the honeycomb structure 1. When the gas is injected, the hydrocarbon gas generates reaction heat due to the oxidation reaction by the catalyst, so that the temperature at the outer end of the sealing material 3 on the inflow side where fine particles are likely to accumulate rises.

  Thus, when the temperature of the outer end portion of the inflow side sealing material 3 is increased, the activity of the catalyst is increased, so that the particulates can be easily burned at the outer end portion of the inflow side sealing material 3. The deposition of fine particles can be suppressed.

According to the honeycomb structure 1 shown in FIG. 3 , there is almost no increase in pressure loss caused by the blockage of the flow holes 2 caused by the accumulation of fine particles on the inlet end face (IF) of the flow holes 2, The fine particles are effectively burned by the catalyst, and the honeycomb structure 1 can be reduced in breakage and melting, and can be used without increasing the pressure loss over a long period of time.
Here, the absolute value of the difference between the length a and the length b is preferably 2 mm or more and 3 mm or less. This is because cracks and erosion generated at the boundary between the partition wall 4 and the inner end 3c are less likely to occur when the thickness is 2 mm or more, and the surface area of the partition wall is hardly reduced when the thickness is 3 mm or less. This is because the efficiency can be maintained.

  The inner end portions 3c and 30c of the sealing materials 3 and 30 are concave in that the surface is the outer end portions 3d and 30d in a cross-sectional view when the flow hole 2 is cut parallel to the axial direction AX. For example, a bowl shape, a pyramid shape, a cone shape, a truncated pyramid shape, a truncated cone shape, or a shape obtained by combining these shapes is used.

4A to 4E are cross-sectional reference diagrams illustrating the shape of the inner end 30c of the sealing material 30 in a cross-sectional view in which the flow hole 2 is cut in parallel to the axial direction AX. 4A is a rectangular shape with a cross-sectional shape of which is a cylindrical shape or a rectangular parallelepiped shape, FIG. 4B is a pyramidal or conical shape where the concave portion is formed, and FIG. A truncated cone shape, (d) is a shape in which a recessed portion is connected to either a prismatic shape or a cylindrical shape, and a pyramid shape or a conical shape from the inner end portion 30c toward the outer end portion 30d. (E) shows the shape in which either the truncated pyramid shape or the truncated cone shape is provided on the inner end 30c side in addition to the shape shown in (d). FIG. 4F is a perspective view showing the shape of the inner end portion of the sealing material.

  In particular, the inner end 30c is preferably bowl-shaped as shown in the perspective view of FIG. By making the inner end portion 30c into a bowl shape, most of the surface of the inner end portion 30c is inclined with respect to the partition wall 4, and the surface area of the inner end portion 30c of the sealing material 30 is the conventional flat inner end portion. This is because the surface area becomes larger.

  Since the sealing material 30 has a bowl-shaped inner end portion, the stress concentration at the boundary between the partition wall 4 and the inner end portion 30c is further reduced, and the partition wall 4 and the inner end portion 30c can be used for a long period of use. There is almost no crack or melting at the boundary. In addition, when the inner end portion 30c is bowl-shaped, if the honeycomb structure 1 is used as a filter for collecting fine particles, the fine particles are selectively deposited on the inner end portion 30c having a concave shape from the partition wall 4, so that the use is repeated. However, the collection rate of fine particles is difficult to decrease.

A honeycomb structure 1 shown in FIGS. 1 and 3 is a sintered body mainly containing at least one of cordierite, aluminum titanate, silicon carbide, silicon nitride, alumina, mullite, lithium aluminum silicate, and spodumene. It is formed by. For example, the outer diameter is 100 to 200 mm, the length in the axial direction AX is 100 to 250 mm, and the number of the flow holes 2 in the cross section perpendicular to the axial direction AX is 50 to 1 per square inch. 800, cross-sectional area is 1-10 mm < ² >, and the thickness of the partition 4 is 0.05-1.0 mm.

As shown in FIGS. 1 and 3, in the honeycomb structure 1 in which the inner end portions 3c and 30c of the sealing materials 3 and 30 are concave, the outer end portion 3d in the axial direction AX of the sealing materials 3 and 30 and The length L _a between the outer peripheral side end of the inner end 3c and the boundary where the partition 4a intersects , the outer end 3d, and the boundary where the inner peripheral end of the inner end 3c and the partition 4b intersect Although not particularly limited to L _b between the, it preferred that the length ratio of the length _{L a} of the total length L of the honeycomb structure 1 _(L a / L) is 0.007 to 0.2 It is. This is because if the length ratio (L _a / L) is 0.007 or more, the possibility of the sealing material 3 falling off is reduced, and sufficient reliability can be secured. This is because the collection efficiency of the can be maintained above a certain limit. On the other hand, the length ratio (L _b / L) of the length L _b to the total length L of the honeycomb structure 1 is preferably 0.007 or more and 0.2 or less for the same reason.

  The inner end portions 3c and 30c preferably have a depth d of 0.1 mm to 0.5 mm.

Furthermore, the length L _a between the outer end 3d , the boundary between the outer peripheral end of the inner end 3c and the partition wall 4a , the outer end 3d, and the inner peripheral end of the inner end 3c L variation coefficient variation is an index indicating relatively of _{b σ a} / _{x a} between boundary and the partition wall 4b _{intersect, σ b / x b (σ} a: L a standard deviation _of, x _{a: L} a The average value of σ _b : the standard deviation of L _b and x _b : the average value of L _b ) is preferably 0.08 or more.

  The honeycomb structure 1 is preferably a sintered body mainly composed of aluminum titanate because the thermal shock resistance is affected by the composition of the honeycomb structure 1. This is because the thermal shock resistance of aluminum titanate is particularly high, so that the long-term reliability can be improved.

  In addition, the main component in this invention means the component which occupies 50 mass% or more among the components which comprise the honeycomb structure 1. FIG.

  Next, a method for manufacturing the honeycomb structure of the present embodiment will be described.

Here, the honeycomb structure 1 whose main component is cordierite will be described. First, code composition of cordierite is SiO ₂ is 40 to 56 wt% in the sintered body, _Al 2 _{O 3} is 30 to 46 wt%, such MgO is 12 to 16 wt%, kaolin, calcined kaolin, alumina Then, a raw material to be converted into cordierite such as aluminum hydroxide, silica, talc or baked talc is prepared to obtain a mixed raw material. After adding a predetermined amount of pore-forming agent such as graphite, starch or resin powder, add a plasticizer, thickener, slip agent, water, etc., and use a universal stirrer, rotary mill or V-type stirrer To make a mixture. And this mixture is knead | mixed using a 3 roll, a kneader, etc., and the kneaded body plasticized is obtained.

  Next, the inner diameter that determines the outer diameter of the molded body is, for example, 100 to 250 mm, and the kneaded body is put into an extruder using a mold having slits for forming the partition walls of the honeycomb structure. Then, after forming a honeycomb shape by applying pressure, it is dried and cut into a predetermined length. Then, after inserting the blended raw material dissolved in water from the outlet end face (OF) masked in a checkered pattern by a dipping method, the tip is formed in a convex shape from the inlet end face (IF), The sealing material 30 is formed by drying at room temperature with a pin coated with a water-repellent resin inserted.

  The length of the sealing material 30 is adjusted by the depth at which the pins are inserted. As the shape of the sealing material 30, since the tip shape of the pin is transferred to the sealing material 30, the tip shape of the pin may be appropriately selected. After drying, in order to obtain the honeycomb structure 1 in which the pins are removed and both ends of the flow hole 2 are alternately sealed with the sealing materials 3 and 30, the same operation as that described above is performed on the inflow side, and the sealing material 3 Form. In order to obtain the honeycomb structure 1 in which the one end and the inside of the flow hole 2 are alternately sealed with the sealing materials 3 and 30, the formation of the sealing material 30 on the outlet end face (OF) can be performed by using the above-described forming method. Good.

  About the formation method of the sealing material 3 in the inside of the circulation hole 2, it is as follows. First, the blended raw material dissolved in water and made into a slurry from the inlet end face (IF) masked in a checkered pattern is inserted by a dipping method. Then, in a state where the slurry is attached to the partition wall 4 and shape retention is obtained and becomes a precursor of the sealing material 3, a pin coated with a water-repellent resin is inserted from the inlet end surface (IF). The precursor is moved into the flow hole 2. Then, the pin inserted from the inlet end face (IF) is left as it is, and the pin coated with the water-repellent resin is inserted from the outlet end face (OF) and dried at room temperature to form the sealing material 3. . Thereafter, the inlet side of the honeycomb structure 1 is immersed in a slurry containing a platinum group metal such as platinum (Pt), palladium (Pd), ruthenium (Ru) or rhodium (Rh) and a catalyst such as an oxide thereof. Then, after drying and firing, the catalyst can be attached to the wall surfaces of the partition walls 4 and the pores inside the partition walls 4.

  After forming the sealing materials 3, 30, the formed body is fired at a temperature of 1350 ° C. to 1450 ° C. using a firing furnace such as an electric furnace or a gas furnace to obtain the honeycomb structure of the present invention.

In order to obtain a honeycomb structure whose main component is aluminum titanate, 100 parts by mass of a component having a molar ratio of TiO ₂ to Al ₂ O ₃ of 40 to 60:60 to 40, and a composition formula of (Na _y K _1-y ) AlSi ₃ O ₈ (0 ≦ y ≦ 1) represented by alkali feldspar, Mg-containing spinel structure oxide, MgO, and Mg-containing compound that is converted to MgO by firing 1 to 10 parts by mass of a component consisting of Thereafter, the process until the sealing material is formed is the same as the case where the main component is cordierite. When the main component of the honeycomb structure is aluminum titanate, a fired furnace such as an electric furnace or a gas furnace is used, and the formed body is fired at a temperature of 1250 ° C. to 1700 ° C. to obtain the honeycomb structure of the present invention. .

  The honeycomb structure manufactured in this way is suitable as a filter that allows exhaust gas to pass through with one end of the flow hole 2 as an inlet and the other end as an outlet, and collects diesel particulates by the partition walls 4 and the sealing materials 3 and 30. Can be used.

FIG. 5 is a reference diagram schematically showing an exhaust gas treatment device 10 (an exhaust gas treatment device using the honeycomb structure 1 shown in FIG. 1 as a filter for collecting diesel particulates) (however, the central portion is shown). (Omitted).

  The case where the honeycomb structure 1 of the present embodiment is used as a filter for collecting diesel particulates in exhaust gas (EG) of a diesel engine will be described as an example. The honeycomb structure 1 is formed on the inner surface of a case 7 made of a cone-shaped metal (for example, stainless steel such as SUS304) having an exhaust gas inlet 5 and an exhaust gas outlet 6 at both ends in the axial direction. It is fixed in the exhaust gas treatment device 10 through a mat-like heat insulating material layer 8 containing ceramic fibers whose main component is silicon oxide. An exhaust pipe 9 communicates with the case 7, and exhaust gas (EG) flows into the case 7 from the exhaust pipe 9. When a diesel engine (not shown) is activated and exhaust gas (EG) flows into the case 7 from the exhaust pipe 9, the honeycomb structure 1 has an inlet end face (IF) through the flow hole 2 without a sealing material. Although exhaust gas (EG) is introduced, the outflow of exhaust gas (EG) is blocked by the sealing material 30 formed on the outlet end face (OF). Exhaust gas (EG) whose outflow is blocked passes through the porous partition wall 4 and is discharged from the adjacent circulation hole 2. In the partition 4, diesel particulates in the exhaust gas (EG) are collected in the pores, and the sealing material 3 is formed at the inlet of the adjacent circulation hole 2, so the exhaust gas does not contain diesel particulates. It is purified to a state and can be discharged to the outside from the outlet end face (OF).

  In such an exhaust gas treatment device 10, the honeycomb structure 1 of the present embodiment can be suitably used as a filter, and diesel particulates can be efficiently collected over a long period of time.

FIG. 3 is a reference diagram of a honeycomb structure according to the present invention (excluding the central portion), (a) is a cross-sectional view of the main body cut in parallel to the axial direction AX, and (b) is an enlarged view of a sealing material. FIG. It is sectional drawing which shows the sealing material in the cross sectional view which cut | disconnected the flow hole in parallel with respect to the axial direction AX. FIG. 3 is a reference diagram of a honeycomb structure according to the present invention (excluding the central portion), (a) is a cross-sectional view of the main body cut in parallel to the axial direction AX, and (b) is an enlarged view of a sealing material. FIG. (A)-(e) is a reference drawing which shows the shape of the inner side edge part of the sealing material in the cross sectional view which cut | disconnected the flow hole in parallel with respect to the axial direction AX, respectively, (f) is an inner side of a sealing material. It is a perspective view which shows the shape of an edge part. 1 is a reference diagram showing an exhaust gas treatment apparatus using a honeycomb structure according to the present invention. It is sectional drawing which cut | disconnected the conventional filter parallel to the axial direction. It is sectional drawing which cut | disconnected the conventional filter parallel to the axial direction. It is sectional drawing which cut | disconnected the conventional filter parallel to the axial direction.

Explanation of symbols

1: honeycomb structure 2: flow hole 3, 30: sealing material 4: partition wall 5: exhaust gas inlet 6: exhaust gas outlet 7: case 8: heat insulating material layer 9: exhaust pipe

Claims (6)

A partition wall having a wall surface along the axial direction, a plurality of flow holes partitioned by the partition wall, and a sealing material that alternately seals both ends of the plurality of flow holes. in a cross-sectional view taken parallel to Te, the a the inner side end portion that put the fluid passing holes of the sealing material is concave, and the outer end portion of the flow hole of the sealing member, the outer peripheral side of the inner end the length L _a between the end portion and the partition wall and is Majiwa that boundary includes the outer side end portion of the sealing member, and the inner end portion and the partition wall of the inner end portion that Majiwa with the length _{L b} and the length between the boundary it is different, the lengths _L a, _{L b} of the coefficient of variation _{σ a / x a, σ b} / x b (σ a: L standard deviation _a, x _a: average value of _{L a, σ b: L b} standard _deviation, x b: with _L average value of _b) is 0.08 or more and the length of the sealing member toward the outer peripheral side Honeycomb structure characterized by being Kuna'. A partition wall having a wall surface along the axial direction, a plurality of flow holes partitioned by the partition wall, and a sealing material that alternately seals the ends and the inside of the plurality of flow holes, in a cross-sectional view taken parallel to the axial direction, said a said inner end that put the fluid passing holes of the sealing material is concave, and the outer end portion of the flow hole of the sealing member, the inner end the length L _a between the outer peripheral side end portion and the partition wall and is Majiwa that boundary parts, the said outer end portion of the sealing member, the inner circumferential end of the inner end bulkhead DOO together with different length _{L b} and the length between the a boundary that Majiwa, the length _L a, coefficient of variation of _{L b σ a / x a,} σ b / x b (σ a: a _{L a} standard _deviation, x a: mean value of _{L a, σ b: L b} standard _deviation, x b: the sealing according to an average value of _{L b)} is 0.08 or more, and toward the outer peripheral side Honeycomb structure, characterized in that the length of is shortened.   The honeycomb structure according to claim 1 or 2, wherein each of the sealing materials has a bowl-like inner end portion.   The honeycomb structure according to any one of claims 1 to 3, wherein the honeycomb structure is made of a sintered body mainly composed of aluminum titanate.   A filter using the honeycomb structure according to any one of claims 1 to 4, wherein an exhaust gas is allowed to pass through one end of the flow hole as an inlet and the other end as an outlet. A filter that collects particulates in the exhaust gas.   An exhaust gas processing apparatus comprising the filter according to claim 5.

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