JP6350142B2 - ハニカム構造体及びその製造方法 - Google Patents
ハニカム構造体及びその製造方法 Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 239000002245 particle Substances 0.000 claims description 116
- 239000011230 binding agent Substances 0.000 claims description 50
- VXLGWCOZCKOULK-UHFFFAOYSA-K aluminum;cerium(3+);trihydroxide Chemical compound [OH-].[OH-].[OH-].[Al].[Ce+3] VXLGWCOZCKOULK-UHFFFAOYSA-K 0.000 claims description 30
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 15
- 239000006104 solid solution Substances 0.000 claims description 15
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 14
- 239000001301 oxygen Substances 0.000 claims description 14
- 229910052760 oxygen Inorganic materials 0.000 claims description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 13
- 238000010304 firing Methods 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 8
- 239000004927 clay Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 5
- 239000013078 crystal Substances 0.000 claims description 4
- 239000007789 gas Substances 0.000 description 12
- 210000004027 cell Anatomy 0.000 description 10
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 10
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 10
- 238000002441 X-ray diffraction Methods 0.000 description 8
- 239000003054 catalyst Substances 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 8
- 238000000746 purification Methods 0.000 description 8
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 4
- 210000002421 cell wall Anatomy 0.000 description 4
- 229910000510 noble metal Inorganic materials 0.000 description 4
- 229910052726 zirconium Inorganic materials 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000000634 powder X-ray diffraction Methods 0.000 description 3
- 150000004645 aluminates Chemical class 0.000 description 2
- 239000012752 auxiliary agent Substances 0.000 description 2
- 239000003426 co-catalyst Substances 0.000 description 2
- 229910052746 lanthanum Inorganic materials 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Substances N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 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
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000007561 laser diffraction method Methods 0.000 description 1
- 235000013372 meat Nutrition 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 239000002923 metal particle 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
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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Description
該助触媒粒子の間に介在し、アルミナからなる無機バインダ粒子と、
上記助触媒粒子と上記無機バインダ粒子との界面に存在するセリウムアルミネート相とを有し、
上記セリウムアルミネート相の結晶格子が歪んでいることを特徴とするハニカム構造体にある。
上記助触媒粒子と、上記無機バインダ粒子を含むゾルとの混合物を含有する坏土をハニカム形状に成形することにより成形体を得る第1工程と、
上記成形体を酸素濃度0.5体積%以下の雰囲気条件で焼成することにより上記ハニカム構造体を得る第2工程とを有することを特徴とするハニカム構造体の製造方法にある。
ハニカム構造体には、例えばPt、Rh、Pdから選ばれる少なくとも1種の貴金属を含有する三元触媒が担持される。このような三元触媒が担持されることにより、助触媒粒子を含有するハニカム構造体自体が三元触媒の触媒性能をより高めることができる。助触媒粒子は、セリアにジルコニウムが固溶したセリア−ジルコニア固溶体からなる。本明細書において、セリア−ジルコニア固溶体は、ジルコニウムの他にも、La、Y等の希土類元素がセリアに固溶した固溶体を含む概念である。
次に、実施例にかかるハニカム構造体について説明する。
本例のハニカム構造体1は、図1に示すごとく、全体としては四角柱状(35mm×35mm×130mm)であり、四角筒状の外皮11と、この外皮11内において四角形格子状に配設されたセル壁12と、セル壁12に区画された多数のセル13とを有する多孔体である。ハニカム構造体1は、気孔率が50%であり、セル密度が78個/cm2(500cpsi)であり、セル壁の厚みが125μmである。本例のような四角柱状のハニカム構造体1は、例えば次のようにして用いられる。
本例は、セリウムアルミネート相を有さないハニカム構造体を製造する例である。
具体的には、まず、実施例1と同様にして坏土を成形して成形体を得た。次いで、酸素濃度20体積%の雰囲気中で、成形体を温度1000℃で30時間焼成した。これにより、ハニカム構造体を得た。なお、雰囲気中の酸素以外のガスは窒素である。
次に、上述の実施例1及び比較例1において作製した各ハニカム構造体の強度を比較した。具体的には、まず、各ハニカム構造体から3セル×3セル×10mm(長さ)の試験片を作製した。次いで、オートグラフ((株)島津製作所製の「AG−X Plus」)を用いてセルの伸長方向(試験片の長手方向)に圧縮荷重を加え、破壊荷重(L)を測定した。そして、この測定値(L)と、試験片の実肉部分の断面積(S)とから、下記の式(1)に基づいて強度(I)を算出した。なお、実肉部分の断面積とは、サンプルの長手方向と直交方向の断面積からセルの開口部の面積を引いた面積のことである。各試料について、試験片を10個ずつ作製し、これらの強度の算術平均を求めた。そして、比較例に対する実施例のハニカム構造体の強度比を調べた。その結果を図6に示す。
I(MPa)=L/S ・・・(1)
2 助触媒粒子
3 無機バインダ粒子
4 セリウムアルミネート相
Claims (4)
- セリア−ジルコニア固溶体からなる複数の助触媒粒子(2)と、
該助触媒粒子(2)の間に介在し、アルミナからなる無機バインダ粒子(3)と、
上記助触媒粒子(2)と上記無機バインダ粒子(3)との界面に存在するセリウムアルミネート相(4)とを有し、
上記セリウムアルミネート相(4)の結晶格子が歪んでいることを特徴とするハニカム構造体(1)。 - 上記助触媒粒子(2)100質量部に対する上記無機バインダ粒子(3)の配合割合が15質量部以下であることを特徴とする、請求項1に記載のハニカム構造体(1)。
- 上記ハニカム構造体(1)の気孔率が40〜60体積%であることを特徴とする、請求項1又は2に記載のハニカム構造体(1)。
- 請求項1〜3のいずれか1項に記載のハニカム構造体(1)の製造方法であって、
上記助触媒粒子(2)と、上記無機バインダ粒子(3)を含むゾルとの混合物を含有する坏土をハニカム形状に成形することにより成形体を得る第1工程と、
上記成形体を酸素濃度0.5体積%以下の雰囲気条件で焼成することにより上記ハニカム構造体を得る第2工程とを有することを特徴とするハニカム構造体(1)の製造方法。
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