JP6802075B2 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- JP6802075B2 JP6802075B2 JP2017008903A JP2017008903A JP6802075B2 JP 6802075 B2 JP6802075 B2 JP 6802075B2 JP 2017008903 A JP2017008903 A JP 2017008903A JP 2017008903 A JP2017008903 A JP 2017008903A JP 6802075 B2 JP6802075 B2 JP 6802075B2
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- Prior art keywords
- honeycomb
- segment
- honeycomb structure
- segments
- bonding layer
- 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 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
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Images
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- C04B2237/78—Side-way connecting, e.g. connecting two plates through their sides
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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
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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
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Description
複数個の前記ハニカムセグメントの側面同士を互いに接合する接合層と、を備え、
複数個の前記ハニカムセグメントは、前記セルの延びる方向に直交する断面の形状が同一の完全セグメント、及び前記断面の形状が前記完全セグメントの一部の形状である不完全セグメントを、それぞれ複数個含み、
前記完全セグメントの全体形状が、前記流入端面と前記流出端面の形状及び大きさが同一の四角柱状であり、
前記接合層は、前記セルの延びる方向に直交する断面において、対向配置された2つの前記ハニカムセグメントの相互間に配置された部分接合層の複数個が、前記ハニカムセグメントの接合体の周縁の一の点から他の点まで延びるように配列した複数の列を有し、
それぞれの前記列の前記接合層は、一の方向に配列した複数個の前記部分接合層のうち、前記断面における最外周に配置された最外周部分接合層と、当該一の方向に配列した他の前記部分接合層のうちの少なく1つとが、当該一の方向の延長線上において相互に重ならないように配置されており、
複数個の前記ハニカムセグメントのそれぞれは、隣り合う前記ハニカムセグメント同士の互いに対向する側面のずれ量が、前記完全セグメントの側面の1辺の長さに対して、1.4%以上、10%以下である、ハニカム構造体。
本発明のハニカム構造体の第一実施形態は、図1〜図5に示すように、複数個の角柱状のハニカムセグメント4と、接合層6と、を備えた、ハニカム構造体100である。本実施形態のハニカム構造体100は、所謂、セグメント構造のハニカム構造体である。ハニカム構造体100の外周には、複数個のハニカムセグメント4を囲繞するように配設された外壁8を更に備えている。本実施形態のハニカム構造体100は、排ガス中に含まれる粒子状物質を除去するための捕集フィルタとして好適に利用することができる。
次に、本発明のハニカム構造体を製造する方法について説明する。なお、本発明のハニカム構造体を製造する方法については、以下に説明する製造方法に限定されることはない。
まず、炭化珪素粉末を80質量部と、Si粉末を20質量部とを混合して、混合粉末を得た。この混合粉末に、バインダ、造孔材、及び水を添加して、混合、混練して坏土を調製した。
接合層の列の配置を、表2に示すように変更して、実施例2及び3のハニカム構造体を作製した。実施例2のハニカム構造体は、接合層の列の配置が、a、及びbのうちのいずれかの配置であった。実施例3のハニカム構造体は、接合層の列の配置が、b、及びcのうちのいずれかの配置であった。隣り合うハニカムセグメント同士の互いに対向する側面の最大ずれ量YMAXは、実施例2のハニカム構造体が、2.5mmで、実施例3のハニカム構造体が、1mmであった。
実施例4〜12においては、表1のセル構造の欄に示されるようなハニカムセグメントを複数個作製し、作製したハニカムセグメントを用いてハニカム構造体を作製した。各実施例において、表1の「セグメント数」の欄に示すような個数のハニカムセグメントを用いた。得られたハニカム構造体の「接合層の列の配置」、及び「隣り合うセグメントの最大ずれ量YMAX」、及び「最大ずれ比率」を表2に示す。
表3に示すようなセル構造のハニカムセグメントを作製し、接合層の列の配置を、表4に示すように変更して、比較例1〜12のハニカム構造体を作製した。接合層の列の配置において、パターンd、又はパターンeが含まれている場合は、最外周部分接合層と、他の部分接合層とが、一の方向の延長線上において相互に重なっている接合層を含むこととなる。また、「最大ずれ比率」が10%を超えている場合は、隣り合うハニカムセグメント同士の互いに対向する側面の最大ずれ量YMAXが、完全セグメントの側面の1辺の長さZに対して、10%を超えることとなる。
耐熱衝撃性(1)の評価として、ハニカム構造体に以下に記載する試験を行い、試験後のハニカム構造体におけるクラックの発生の有無により、ハニカム構造体のロバスト(robust)性を評価するものとした。具体的には、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、エンジン回転数2000rpm、エンジントルク60Nmの運転条件にて、2〜12g/Lの煤を、各実施例及び比較例のハニカム構造体の内部に堆積させた。その後、ポストインジェクションによる再生処理を行い、ハニカム構造体の入口ガス温度を上昇させ、ハニカム構造体の前後の圧損が低下し始めたところでポストインジェクションを切り、エンジンをアイドル状態に切り替えた。このときの煤堆積量は、実施例の各水準において、流出側端面の中央部における最高温度が1000℃となるようにし、実施例と比較例の同じ番号は同一煤量となる条件で試験を実施した。そして、ハニカム構造体の流出端面側及び流入端面側におけるクラックの有無を、それぞれ目視にて観察した。クラックが確認されない場合を合格とし、クラックが確認された場合を不合格として、流出端面側及び流入端面側のそれぞれの結果に基づいて、以下の評価基準により、耐熱衝撃性(1)の評価を行った。耐熱衝撃性(1)の評価において、流入端面側及び流出端面側が共に「合格」の場合を、評価Aとした。耐熱衝撃性(1)の評価において、流入端面側及び流出端面側の少なくとも一方が「不合格」の場合を、評価Cとした。評価結果を表2及び表4に示す。
図14に示すせん断強度試験機110を用い、実施例1〜12及び比較例1〜12のハニカム構造体に対してせん断強度の評価を行った。具体的には、まず、各ハニカム構造体100の外壁8の周りに緩衝用のマット22を巻き付けた。次に、緩衝用のマット22を巻き付けた状態のハニカム構造体100を、金属製の缶体21内に挿入し、せん断強度測定用の測定試料とした。マット22としては、三菱樹脂製のセラミックマット(商品名:マフテック OBM−P)を用いた。使用したマット22は、単位面積当たりの質量が1000〜1200g/m2であり、その厚さが、4.0〜5.0mmであった。このようにして作製した測定試料に対して、第一荷重方向L1、第二荷重方向L2、及び第三荷重方向L3のそれぞれから荷重を負荷し、ハニカム構造体100にせん断が発生する強度を測定した。各荷重の負荷は、ダイヤルゲージ(Dial gauge)を取り付けた荷重供給部24を、測定試料とした缶体21の一方の端面近傍の端部に押し付けることによって行った。測定試料に負荷する荷重は、せん断強度試験の負荷荷重を読み取ることによって確認した。測定試料に負荷する荷重を徐々に大きくしていき、ハニカム構造体100にせん断が発生した際の荷重を、ハニカム構造体100のせん断強度とした。
実施例1〜12のハニカム構造体は、耐熱衝撃性(1)及びせん断強度の評価において、共に良好な結果を得ることができた。一方、比較例1、3〜8、10及び12のハニカム構造体は、せん断強度の評価において、大きなせん断強度の低下が認められた。比較例1、3〜8、10及び12のハニカム構造体は、接合層の列の配置において、パターンd、又はパターンeが含まれているものであった。また、比較例2、5、7、9、11及び12のハニカム構造体は、耐熱衝撃性(1)の評価において、流入端面側及び流出端面側の少なくとも一方が「不合格」であった。比較例2、5、7、9、11及び12のハニカム構造体は、「最大ずれ比率」が10%を超えているものであった。
実施例13〜24においては、表5のセル構造の欄に示されるようなハニカムセグメントを複数個作製し、作製したハニカムセグメントを用いてハニカム構造体を作製した。なお、実施例13〜24においては、作製したハニカムセグメントの各セルに目封止部を配設しない状態で、ハニカム構造体を作製した。なお、実施例13のハニカム構造体は、目封止部を有していないこと以外は、実施例1のハニカム構造体と同様に構成されたものである。同様に、実施例14〜24のハニカム構造体も、その順番に、実施例2〜12のハニカム構造体と同様に構成されたものである。
比較例13〜24においては、表7のセル構造の欄に示されるようなハニカムセグメントを複数個作製し、作製したハニカムセグメントを用いてハニカム構造体を作製した。なお、比較例13〜24においては、作製したハニカムセグメントの各セルに目封止部を配設しない状態で、ハニカム構造体を作製した。なお、比較例13のハニカム構造体は、目封止部を有していないこと以外は、比較例1のハニカム構造体と同様に構成されたものである。同様に、比較例14〜24のハニカム構造体も、その順番に、比較例2〜12のハニカム構造体と同様に構成されたものである。
ハニカム構造体を収納する缶体内に加熱ガスを供給することができる「プロパンガスバーナー装置」を用いて、ハニカム構造体の耐熱衝撃性(2)の評価を行った。具体的には、各実施例のハニカム構造体を缶体内に収納(キャニング)し、その缶体を、上記プロパンガスバーナー装置に設置した。次に、ハニカム構造体に燃焼ガスを流した。燃焼ガスは、まず、流量60NL/minで10分間流した。ハニカム構造体の前方10mm位置での中央部のガス温度は、10分後に1100℃であった。その後、燃焼ガスの通気を停止し、燃焼ガスの代わりに冷却エアーを、流量250NL/minで10分間流した。冷却エアーを流すことにより、10分後、ハニカム構造体の前方10mm位置での中央部のガス温度は、100℃であった。このような、燃焼ガスと冷却エアーの通気を1サイクル(cycle)とし、これを20サイクル実施した。その後、ハニカム構造体の流出端面側及び流入端面側におけるクラックの有無を、それぞれ目視にて観察した。クラックが確認されない場合を合格とし、クラックが確認された場合を不合格として、流出端面側及び流入端面側のそれぞれの結果に基づいて、以下の評価基準により、耐熱衝撃性(2)の評価を行った。耐熱衝撃性(2)の評価において、流入端面側及び流出端面側が共に「合格」の場合を、評価Aとした。耐熱衝撃性(2)の評価において、流入端面側及び流出端面側の少なくとも一方が「不合格」の場合を、評価Cとした。
実施例13〜24のハニカム構造体は、耐熱衝撃性(2)及びせん断強度の評価において、共に良好な結果を得ることができた。一方、比較例13、15〜20、22及び24のハニカム構造体は、せん断強度の評価において、大きなせん断強度の低下が認められた。比較例13、15〜20、22及び24のハニカム構造体は、接合層の列の配置において、パターンd、又はパターンeが含まれているものであった。また、比較例14、17、19、21、23及び24のハニカム構造体は、耐熱衝撃性(2)の評価において、流入端面側及び流出端面側の少なくとも一方が「不合格」であった。比較例14、17、19、21、23及び24のハニカム構造体は、「最大ずれ比率」が10%を超えているものであった。
Claims (3)
- 流体が流入する流入端面から流体が流出す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、及び最外周に配設されたセグメント外周壁を有する、複数個の角柱状のハニカムセグメントと、
複数個の前記ハニカムセグメントの側面同士を互いに接合する接合層と、を備え、
複数個の前記ハニカムセグメントは、前記セルの延びる方向に直交する断面の形状が同一の完全セグメント、及び前記断面の形状が前記完全セグメントの一部の形状である不完全セグメントを、それぞれ複数個含み、
前記完全セグメントの全体形状が、前記流入端面と前記流出端面の形状及び大きさが同一の四角柱状であり、
前記接合層は、前記セルの延びる方向に直交する断面において、対向配置された2つの前記ハニカムセグメントの相互間に配置された部分接合層の複数個が、前記ハニカムセグメントの接合体の周縁の一の点から他の点まで延びるように配列した複数の列を有し、
それぞれの前記列の前記接合層は、一の方向に配列した複数個の前記部分接合層のうち、前記断面における最外周に配置された最外周部分接合層と、当該一の方向に配列した他の前記部分接合層のうちの少なく1つとが、当該一の方向の延長線上において相互に重ならないように配置されており、
複数個の前記ハニカムセグメントのそれぞれは、隣り合う前記ハニカムセグメント同士の互いに対向する側面のずれ量が、前記完全セグメントの側面の1辺の長さに対して、1.4%以上、10%以下である、ハニカム構造体。 - 前記部分接合層の幅が、0.5〜3.0mmである、請求項1に記載のハニカム構造体。
- 前記ハニカムセグメントに形成された前記セルのいずれか一方の開口部を目封止するように配設された目封止部を更に備えた、請求項1又は2に記載のハニカム構造体。
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JP6320798B2 (ja) * | 2014-03-04 | 2018-05-09 | 日本碍子株式会社 | ハニカム構造体 |
JP2017008903A (ja) | 2015-06-26 | 2017-01-12 | カルソニックカンセイ株式会社 | エンジンの吸気装置 |
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US20180207571A1 (en) | 2018-07-26 |
DE102018200762B4 (de) | 2019-06-19 |
CN108331642A (zh) | 2018-07-27 |
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US10543446B2 (en) | 2020-01-28 |
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