JP5894577B2 - 目封止ハニカム構造体 - Google Patents
目封止ハニカム構造体 Download PDFInfo
- Publication number
- JP5894577B2 JP5894577B2 JP2013507828A JP2013507828A JP5894577B2 JP 5894577 B2 JP5894577 B2 JP 5894577B2 JP 2013507828 A JP2013507828 A JP 2013507828A JP 2013507828 A JP2013507828 A JP 2013507828A JP 5894577 B2 JP5894577 B2 JP 5894577B2
- Authority
- JP
- Japan
- Prior art keywords
- cell
- honeycomb structure
- reinforcing
- outflow
- side end
- 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.)
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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 14
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Images
Classifications
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Description
図1〜図5に示すように、本発明の目封止ハニカム構造体の一実施形態(目封止ハニカム構造体100)は、「流入側端面11から流出側端面12まで延びる流体の流路となる複数のセル2を区画形成する多孔質の隔壁1を有するハニカム構造体4」と、「流出側端面12における所定のセルの開口部に配設されて、流入側端面11が開口し且つ流出側端面12が封止された流入セル2aを形成する流出側目封止部5b」と、「流入側端面11における残余のセルの開口部に配設されて、流出側端面12が開口し且つ流入側端面11が封止された流出セル2bを形成する流入側目封止部5a」と、を備えた目封止ハニカム構造体100である。
本実施形態の目封止ハニカム構造体の製造方法について説明する。まず、ハニカム構造体を作製するための坏土を調整し、この坏土を成形して、ハニカム成形体を作製する(成形工程)。本実施形態の目封止ハニカム構造体を製造する際には、ハニカム成形体を得た後に、ハニカム成形体、ハニカム成形体を乾燥したハニカム乾燥体、又は、ハニカム乾燥体を焼成したハニカム構造体のいずれかに、補強部を形成することとなる。なお、補強部の形成は、ハニカム成形体又はハニカム乾燥体の状態で行うことが好ましい。ハニカム成形体又はハニカム乾燥体の状態で補強部を形成することにより、補強部と隔壁との境界部がよりでき難くなり、隔壁から補強部が剥離し難くなる。また、ハニカム成形体に補強部を形成することは、乾燥工程も兼ねることができるのでコストの観点からもより好ましい。
まず、成形工程においては、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区画形成するハニカム成形体を形成する。
次に、得られたハニカム成形体を焼成してハニカム構造体を得ることが好ましい。なお、ハニカム成形体の焼成は、ハニカム成形体に目封止部を配設した後に行ってもよい。
次に、ハニカム構造体の、流体の流入側端面における流出セルの開口部と、流体の流出側の端面における流入セルの開口部とに、目封止材料を充填して、流入側端面における流出セルの開口部と、流出側端面における流入セルの開口部とに、目封止部を形成する。
次に、目封止部を形成したハニカム構造体の流出セルのうちの少なくとも一のセルの角部、または、流出セル及び流入セルのうちの少なくとも一のセルの角部に、流出側端面又は流入側端面からセルの延びる方向の一部にかけて補強部を形成する。具体的な方法としては、補強部を形成するための材料を選択し、この材料を含む補強部用スラリーを調製する。次に、このスラリーに、ハニカム構造体を、流出側端面側から、または、流出側端面及び流入側端面から浸漬(ディッピング:Dipping)させる。浸漬させる深さは、形成する補強部の長さとすることが好ましい。このようにハニカム構造体を流出側端面側から浸漬させることにより、上記補強部用スラリーが、流出セルの角部に付着する。ハニカム構造体を、補強部用スラリーから引出した後、補強部用スラリーを乾燥し、更に必要に応じて焼成することにより、流出セルの角部に補強部を形成することができる。
セラミック原料として、コージェライト化原料(アルミナ、タルク、カオリン)を用いた。アルミナ、タルク、カオリンの質量比は、焼成後、コージェライトが得られる質量比とした。セラミック原料に、バインダ(メチルセルロース)、水を混合してセラミック成形原料を得た。得られたセラミック成形原料を、ニーダーを用いて混練して、坏土を得た。
目封止ハニカム構造体の幾何学構造をCADモデルより構築し、アンシス・ジャパン社製の有限要素法解析ソフト(商品名:ANSYS Release 11.0)にて、モデル構築した構造体に発生する最大主応力を求める。その際、構造体の幾何学構造パラメータとしては、「隔壁の厚さ」、「セル密度」、「セルピッチ」、「底面の直径」、「セルの延びる方向における長さ」、「流入セル又は流出セルの交点比」、「目封じ長さ」、「外壁の厚さ」をそれぞれ与え、また有限要素法解析においては事前に測定されたハニカム構造体の「ヤング率」、「ポアソン比」、「熱膨張係数」を与えると同時に、事前に実施した煤の燃焼試験にて得られた目封じハニカム構造体内で発生する温度分布を適宜与えることで目的とする最大主応力を得ることができる。
目封止ハニカム構造体をDPFとして用い、順次、煤(スート)の堆積量を増加させて、再生(煤の燃焼)を行い、クラックが発生する限界を確認する。先ず、得られた目封止ハニカム構造体の外周に、保持材としてセラミック製非熱膨張性マットを巻き、ステンレス鋼(SUS409)製のキャニング用缶体に押し込んで、キャニング構造体とする。その後、ディーゼル燃料(軽油)の燃焼により発生させた煤を含む燃焼ガスを、ハニカム構造体の一方の端面(短尺セグメントの片側の端面を含む端面)より流入させ、他方の端面より流出させることによって、煤をハニカム構造体内に堆積させる。そして、一旦、室温(25℃)まで冷却した後、ハニカム構造体の上記一方の端面より、680℃の燃焼ガスを流入させ、煤が燃焼することによりハニカム構造体の圧力損失が低下したときに、燃焼ガスの流量を減少させることによって、煤を急燃焼させ、その後の目封止ハニカム構造体におけるクラックの発生の有無を確認する。この試験は、煤の堆積量がハニカム構造体の容積1リットル当り4g(以下4g/リットル等と表記)から始め、クラックの発生が認められるまで、0.5(g/リットル)ずつ増加して、繰り返し行う。クラック発生時の煤量(g/リットル)を、SMLの値とした。各実施例、参考例、比較例のハニカム構造体を5個ずつ作製し、当該5個の(N=5)測定結果のうち、全5個がSML値として6g/Lを達成できた場合を「合格」、全5個のうち1個でもSML値が6g/Lを達成できなかった場合を「不合格」とした。
目封止ハニカム構造体の断面の面積に対して流入側端部の流入セルが占める面積比率を測定する。この面積比率(%)を、入口開口率(%)とする。
特開2005−172652号公報に記載の「フィルタの圧力損失測定装置」を用いて、目封止ハニカム構造体の圧力損失を測定した。測定条件としては、流体の流量を10Nm3/分とし、実験時の流体温度を25℃とした。
各実施例の目封止ハニカム構造体の質量を測定した。この質量を、フィルタ質量(g)とした。
目封止ハニカム構造体をDPFとして用い、680℃の燃焼ガスを流入させ、DPFの流出側端部が650℃に到達する時間を計測する。具体的には、まず、得られた目封止ハニカム構造体の外周に、保持材としてセラミック製非熱膨張性マットを巻き、ステンレス鋼(SUS409)製のキャニング用缶体に押し込んで、キャニング構造体とする。更にキャニング構造体の流出側端部にKタイプ・シース熱電対を設置する。その後、ディーゼル燃料(軽油)の燃焼により680℃の燃焼ガスを流入させ、事前に設置した熱電対の温度をモニターし、それが650℃に到達する時間(650℃到達時間(秒))を測定する。
目封止部の目封止長さ、補強部を形成するセル(補強部の有無)、補強部の長さ、ハニカム構造体の隔壁厚さ、セルピッチを表1に示すように変更し、且つ、流入セルの交点比(L/T)及び流出セルの交点比(L/T)を表1に示すように変更した以外は、参考例1と同様の方法で目封止ハニカム構造体を製造した。なお、参考例15は、流出セル及び流入セルの一部に補強部が形成された例を示す。得られた目封止ハニカム構造体について、参考例1の場合と同様の評価を行った。結果を表2に示す。なお、「スートマスリミット(SML)」の測定については、実施例2、10、11、14、参考例1、15、比較例1、4、7、8について行った。
セラミック原料として、炭化珪素(SiC)を用いて、ハニカムセグメントを作製し、16個のハニカムセグメントを接合してセグメント構造のハニカム構造体を作製した。具体的には、SiC粉、金属Si粉を80:20の質量割合で混合し、これに、バインダとしてメチルセルロース及びヒドロキシプロポキシメチルセルロース、造孔材として澱粉と吸水性樹脂、界面活性剤及び水を混合してセラミック成形原料を得た。得られたセラミック成形原料を、ニーダーを用いて混練して、坏土を得た。
目封止部の目封止長さ、補強部を形成するセル(補強部の有無)、補強部の長さ、ハニカム構造体の隔壁厚さ、セルピッチを表1に示すように変更し、且つ、流入セルの交点比(L/T)及び流出セルの交点比(L/T)を表1に示すように変更した以外は、実施例10と同様の方法で目封止ハニカム構造体を製造した。得られた目封止ハニカム構造体について、参考例1の場合と同様の評価を行った。結果を表2に示す。なお、表1において、特段の数値の記載がなく、「あり」とのみ記載されている実施例、参考例、比較例においては、全てのコーナーに補強部があり、「なし」とのみ記載されている実施例、参考例、比較例においては、全てのコーナーに補強部がないことを示す。
Claims (7)
- 流入側端面から流出側端面まで延びる流体の流路となる複数のセルを区画形成する多孔質の隔壁を有するハニカム構造体と、
前記流出側端面における所定のセルの開口部に配設されて、前記流入側端面が開口し且つ前記流出側端面が封止された流入セルを形成する流出側目封止部と、
前記流入側端面における残余のセルの開口部に配設されて、前記流出側端面が開口し且つ前記流入側端面が封止された流出セルを形成する流入側目封止部と、を備え、
前記流出セルのうちの少なくとも一のセルは、前記セルの延びる方向に垂直な断面における前記隔壁が交差する少なくとも一の角部に、前記流出セルを補強する補強部が形成された補強セルであり、且つ、
前記流入セルは、前記セルの延びる方向に垂直な断面における前記隔壁が交差する少なくとも一の角部に、前記流入セルを補強する補強部が形成され、且つ、前記流入セルの補強された角部の数が、前記流出セルの補強された角部の数より少なく、
前記流出セルの前記補強部は、前記ハニカム構造体の前記流出側端面から、前記ハニカム構造体の前記セルの延びる方向の一部に形成されたものであり、
前記流入セルの前記補強部は、前記ハニカム構造体の前記流入側端面から、前記ハニカム構造体の前記セルの延びる方向の一部に形成されたものである目封止ハニカム構造体であって、
前記流入セルの前記補強部は、前記ハニカム構造体の前記流出側端面から、前記流出側目封止部の前記セルの延びる方向の長さ以上で、且つ前記ハニカム構造体の前記セルの延びる方向の長さの1/3以下までの範囲に亘って形成されたものである、目封止ハニカム構造体。 - 流入側端面から流出側端面まで延びる流体の流路となる複数のセルを区画形成する多孔質の隔壁を有するハニカム構造体と、
前記流出側端面における所定のセルの開口部に配設されて、前記流入側端面が開口し且つ前記流出側端面が封止された流入セルを形成する流出側目封止部と、
前記流入側端面における残余のセルの開口部に配設されて、前記流出側端面が開口し且つ前記流入側端面が封止された流出セルを形成する流入側目封止部と、を備え、
前記流出セルのうちの少なくとも一のセルは、前記セルの延びる方向に垂直な断面における前記隔壁が交差する少なくとも一の角部に、前記流出セルを補強する補強部が形成された補強セルであり、且つ、
前記流入セルは、前記セルの延びる方向に垂直な断面における前記隔壁が交差する全ての角部に、前記補強部が形成されていない非補強セルであり、
前記補強セルの前記補強部は、前記ハニカム構造体の前記流出側端面から、前記ハニカム構造体の前記セルの延びる方向の一部に形成されたものである目封止ハニカム構造体であって、
前記補強部は、前記ハニカム構造体の前記流出側端面から、前記流出側目封止部の前記セルの延びる方向の長さ以上で、且つ前記ハニカム構造体の前記セルの延びる方向の長さの1/3以下までの範囲に亘って形成されたものである、目封止ハニカム構造体。 - 前記補強セルは、前記補強部が形成された補強角部と、前記補強部が形成されていない非補強角度部とを含むものである請求項1又は2に記載の目封止ハニカム構造体。
- 前記補強セルは、前記ハニカム構造体の前記流出側端面又は前記流入側端面において、前記補強セルを構成する全ての角部に、前記補強部が形成されたものである請求項1〜3のいずれか一項に記載の目封止ハニカム構造体。
- 前記流入セルと前記流出セルとが、前記隔壁を隔てて交互に配置されている請求項1〜4のいずれか一項に記載の目封止ハニカム構造体。
- 前記補強部を除く前記隔壁の平均厚さに対する、前記補強セルの前記補強部の表面から、前記補強セルを区画形成する前記隔壁の交差点を隔てて配置された他のセルの表面までの隔壁交差部分の交差距離の比の値が、1.5〜9.3である請求項1〜5のいずれか一項に記載の目封止ハニカム構造体。
- 各前記補強部は、前記セルの延びる方向に垂直な断面における前記補強部が除かれた開口部分の面積の0.05〜20%に相当する範囲を占める大きさのものである請求項1〜6のいずれか一項に記載の目封止ハニカム構造体。
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