JP6389045B2 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
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- JP6389045B2 JP6389045B2 JP2014041375A JP2014041375A JP6389045B2 JP 6389045 B2 JP6389045 B2 JP 6389045B2 JP 2014041375 A JP2014041375 A JP 2014041375A JP 2014041375 A JP2014041375 A JP 2014041375A JP 6389045 B2 JP6389045 B2 JP 6389045B2
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- honeycomb
- thermal expansion
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- expansion coefficient
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
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- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24494—Thermal expansion coefficient, heat capacity or thermal conductivity
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- B01D46/2418—Honeycomb filters
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- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- 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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- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/2444—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the outer peripheral sealing
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- B01D46/2418—Honeycomb filters
- B01D46/2498—The honeycomb filter being defined by mathematical relationships
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- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
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- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
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Description
本発明のハニカム構造体の一の実施形態は、図1、図2に示すような柱状のハニカム構造体100である。つまり、ハニカム構造体100は、柱状のハニカム基材10と、このハニカム基材10の外周に配設される外周コート層26と、を備えている。ハニカム基材10は、流体の流路となる一方の端面である流入端面11から他方の端面である流出端面12まで延びる複数のセル2を区画形成する多孔質の隔壁1を有している。ハニカム構造体100は、25〜800℃の範囲において、外周コート層26の熱膨張率が、ハニカム基材10の熱膨張率に比して大きいものである。
ハニカム基材10は、複数のセル2のうちの所定のセルの流入端面11側の端部に配設されるとともに、残余のセルの流出端面12側の端部に配設された目封止部25を備えている。そして、この目封止部25は、流入端面11及び流出端面12のそれぞれにおいて、所定のセルと残余のセルとが交互に、いわゆる市松模様を形成するように配置されている。
本発明のハニカム構造体は、以下の条件を満たすことが好ましい。つまり、25〜800℃における、外周コート層の熱膨張率が、ハニカム基材の熱膨張率に比して大きく、25〜800℃における、外周コート層の熱膨張率とハニカム基材の熱膨張率とが、以下の式を満たす。
式:5.9<(外周コート層の熱膨張率/ハニカム基材の熱膨張率)<40
ハニカム基材は、図1に示すように1つの構造体から構成されていてもよいし、複数個のハニカムセグメントからなるもの(ハニカム接合体)であってもよい。ハニカム接合体は、具体的には、複数個の柱状のハニカムセグメントと、複数個のハニカムセグメントの側面同士を接合する接合層と、を備えるものである。
式:0.7<(外周コート層の熱膨張率/接合層の熱膨張率)
式:0.7<(外周コート層の熱膨張率/接合層の熱膨張率)<1.5
次に、本発明のハニカム構造体の製造方法について以下に説明する。
まず、以下の方法で、ハニカム成形体を作製する。ハニカム成形原料、バインダ、界面活性剤、造孔材、水等を混合してハニカム成形原料を作製する。このハニカム成形原料には、炭化珪素、アルミナチタネート、窒化珪素、及び、コージェライトよりなる群から選択される少なくとも一種を含むことが好ましい。なお、このハニカム成形原料は、焼成後にコージェライトとなるコージェライト化原料を含むことも好ましい。
次に、ハニカム成形体の外周に外周コート層を形成する。まず、外周コート層を形成する外周コート材を調製する。外周コート材は、無機粒子、バインダ、界面活性剤、造孔材、水等を混合して、混練することで作製することができる。外周コート材は、マイカを含むか、或いは、アルミナファイバー、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含むことが好ましい。
SiC粉末及び金属Si粉末を80:20の質量割合で混合し、これに造孔剤として澱粉、発泡樹脂を加え、更にメチルセルロース及びヒドロキシプロポキシルメチルセルロース、界面活性剤及び水を添加して可塑性の坏土を作製した。
外周コート層の熱膨張率は、以下のよう測定した。まず、外周コート層を、縦1.5mm×横15mm×厚さ0.5mmとなるように切り出して試料を作製し、マックサイエンス社製の熱膨張率測定装置(TD5000S)を用いて測定を行う。具体的には、上記試料を25〜800℃まで加熱し、試料と標準試料との熱膨張率の差(Δl)を算出する。但し、25℃及び800℃における温度上昇の速度は10℃/分以下とする。その後、熱膨張率(CTE)を以下の式(1)から求める。なお、「標準試料」は、石英を用いる。このようにして、外周コート層の熱膨張率を測定する。
「最大スス堆積温度」の測定については、以下のように行った。2.2Lディーゼルエンジンを搭載するエンジンベンチにて運転し、所定量のPM(パティキュレートマター)を、作製したハニカムフィルタ(ハニカム構造体)に堆積させた。その後、再生処理(ポストインジェクションによりPMを燃焼させる処理)を行い、ハニカムフィルタに流入するガス(入口ガス)の温度を上昇させた。その後、ハニカムフィルタ前後の圧力損失(ガスの入口側と出口側における圧力損失)が低下し始めたところで、ポストインジェクションを止め、エンジンをアイドル状態に切り替えた。その後、再生処理前の所定量のPM堆積量を徐々に増加させ、ハニカムフィルタにクラックが生じるまで同じ試験を繰り返し行った。このとき、DPFの排ガスの出口側の端面付近における中央セグメントの温度を熱電対で測定した。中央セグメントは、ハニカムフィルタの外周面を構成するハニカムセグメントである外周セグメント以外のハニカムセグメントのことである。そして、ハニカムフィルタにクラックが生じない場合におけるハニカムフィルタ内の最高の温度を「最大スス堆積温度」とした。なお、各評価において、クラック発生の有無の確認は、目視にて行った。
「最大スス堆積温度改善率」の算出を行った。なお、「最大スス堆積温度改善率」とは、ハニカム基材が同じで「外周コート層CTE/ハニカム基材CTE」が1.0以下であり且つその値が最も小さい比較例のハニカム構造体を100%(基準)とした時の改善率を意味する。外周コート層の熱膨張率は、従来、ハニカムセグメントの熱膨張率と同じにするか、或いは、ハニカムセグメントの熱膨張率に比して小さくするように設定されていたためである。「最大スス堆積温度改善率」の算出については、比較例2、3、参考例1〜5については、比較例1を基準に計算した。参考例6、実施例7については、比較例4を基準に計算した。実施例8については、比較例5を基準に計算した。実施例9については、比較例6を基準に計算した。「最大スス堆積温度改善率」が0%以下である場合には、ハニカム接合体を構成するハニカムセグメントにクラックが発生する。「最大スス堆積温度改善率」が0%超で1%未満のある場合には、ハニカム接合体を構成するハニカムセグメントにクラックが発生することを抑制する効果が、顕著ではないがわずかに確認できる。「最大スス堆積温度改善率」が1%以上で5%未満の場合には、「ハニカム接合体を構成するハニカムセグメントにクラックが発生することを良好に抑制することができる」と判断することができる。更に5%以上の場合には、「ハニカム接合体を構成するハニカムセグメントにクラックが発生することを更に良好に抑制することができる」と判断することができる。
各条件を、表1に示すように変更した以外は、参考例1と同様にしてハニカム構造体を作製した。参考例1の場合と同様にして、「熱膨張率」の測定を行った。また、作製したハニカム構造体について、「最大スス堆積温度(℃)」、及び「最大スス堆積温度改善率(%)」の各評価を行った。結果を表1に示す。
Claims (2)
- 流体の流路となる一方の端面である流入端面から他方の端面である流出端面まで延び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基材と、
前記ハニカム基材の外周に配設される外周コート層と、を備え、
25〜800℃における、前記外周コート層の熱膨張率が、前記ハニカム基材の熱膨張率に比して大きく、
25〜800℃における、前記外周コート層の熱膨張率と前記ハニカム基材の熱膨張率とが、式:5.9<(外周コート層の熱膨張率/ハニカム基材の熱膨張率)<40の関係を満たし、
前記外周コート層が、マイカを含むか、或いは、アルミナファイバー、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含み、
前記ハニカム基材が、アルミナチタネート、及び、コージェライトよりなる群から選択される少なくとも一種を含むハニカム構造体。 - 前記外周コート層が、マイカを含むか、或いは、仮焼したマイカ、及び、生体溶解性ファイバーからなる群より選択される少なくとも一種とアルミナとを含む請求項1に記載のハニカム構造体。
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