JP7202236B2 - ハニカムフィルタ - Google Patents
ハニカムフィルタ Download PDFInfo
- Publication number
- JP7202236B2 JP7202236B2 JP2019066132A JP2019066132A JP7202236B2 JP 7202236 B2 JP7202236 B2 JP 7202236B2 JP 2019066132 A JP2019066132 A JP 2019066132A JP 2019066132 A JP2019066132 A JP 2019066132A JP 7202236 B2 JP7202236 B2 JP 7202236B2
- Authority
- JP
- Japan
- Prior art keywords
- plugging
- honeycomb filter
- porosity
- central
- honeycomb
- 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 3
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
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- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
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- 240000007594 Oryza sativa Species 0.000 description 1
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- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
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- 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 1
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
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- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
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- 229910052863 mullite Inorganic materials 0.000 description 1
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- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
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- SBEQWOXEGHQIMW-UHFFFAOYSA-N silicon Chemical compound [Si].[Si] SBEQWOXEGHQIMW-UHFFFAOYSA-N 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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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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- B01D46/2425—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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- B01D46/244—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the plugs
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- F01N3/033—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 in combination with other devices
- F01N3/035—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 in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
Description
前記セルの前記流入端面側の端部又は前記流出端面側の端部のいずれか一方に配設された多孔質の目封止部と、を備え、
前記目封止部は、多孔質体によって構成されたものであり、
前記ハニカム構造体は、前記セルの延びる方向に直交する断面における重心を含む中央領域と、前記中央領域よりも外周側の外周領域と、を有し、且つ、前記中央領域の面積S1に対する、前記外周領域の面積S2の比であるS2/S1が、0.1~0.5であり、
前記中央領域に存在する前記目封止部である中央目封止部の気孔率P1が、前記外周領域に存在する前記目封止部である外周目封止部の気孔率P2よりも低く、
前記目封止部は、それぞれの気孔率P1が60~68%の前記中央目封止部か、それぞれの気孔率P2が70~85%の前記外周目封止部かのいずれかである、ハニカムフィルタ。
前記中央目封止部及び前記外周目封止部は、前記断面の径方向におけるより中心側に配設された前記中央目封止部から、順次外周に向かって配設される前記中央目封止部及び前記外周目封止部の各気孔率が段階的に大きくなるように構成されている、前記[1]に記載のハニカムフィルタ。
本発明のハニカムフィルタの一の実施形態は、図1~図4に示すようなハニカムフィルタ100である。ここで、図1は、本発明のハニカムフィルタの一の実施形態を模式的に示す斜視図である。図2は、図1に示すハニカムフィルタの流入端面側を示す平面図である。図3は、図1に示すハニカムフィルタの流出端面側を示す平面図である。図4は、図2のA-A’断面を模式的に示す断面図である。
本発明のハニカムフィルタを製造する方法については、特に制限はなく、例えば、以下のような方法を挙げることができる。まず、ハニカム構造体を作製するための可塑性の坏土を調製する。ハニカム構造体を作製するための坏土は、原料粉末として、前述の隔壁の好適な材料の中から選ばれた材料に、適宜、バインダ等の添加剤、造孔材、及び水を添加することによって調製することができる。
コージェライト化原料100質量部に、造孔材を10質量部、分散媒を20質量部、有機バインダを1質量部、それぞれ添加し、混合、混練して坏土を調製した。コージェライト化原料としては、アルミナ、水酸化アルミニウム、カオリン、タルク、及びシリカを使用した。分散媒としては、水を使用した。有機バインダとしては、メチルセルロース(Methylcellulose)を使用した。分散剤としては、デキストリン(Dextrin)を使用した。造孔材としては、平均粒子径15μmのコークスを使用した。
各実施例のハニカムフィルタの側面に、以下の方法でマットを巻き、マットを巻いたハニカムフィルタを缶体に押し込むことにより、ハニカムフィルタを缶体に把持させた。マットを巻く際には、マットの端がハニカムフィルタを構成するハニカム構造体の端面から内側に5mmに位置するようにし、ハニカムフィルタの側面全域を覆うようにした。この際のマットの圧縮度合い、即ちGBD(Gap Bulk Density;隙間嵩密度)を0.45g/cm3になるように把持させ、目封止部のセルからの剥落発生を確認した。
評価「OK」:評価対象のハニカムフィルタにおいて「目封止部の剥落」が起こらない場合、その評価を「OK」とする。
評価「NG」:評価対象のハニカムフィルタにおいて「目封止部の剥落」が起こる場合、その評価を「NG」とする。
まず、ハニカムフィルタを缶体にキャニング(収納)して、キャニングされたハニカムフィルタをガスバーナ試験機に配置した。次に、ガスバーナ試験機によりSiC製の砥粒をハニカムフィルタの流入端面に衝突させる。砥粒を衝突させる条件としては、以下の通りとした。投入砥粒量を5gとした。ハニカムフィルタに流入させるガスの温度を、700℃とした。ハニカムフィルタに流入させるガスの流量を、120m/秒とした。試験時間は10分とし、その間砥粒を少しずつ投入した。その後、ハニカムフィルタを取り出し、取り出したハニカムフィルタを断層撮影法(CT)で撮影し、砥粒の衝突によって削られたハニカムフィルタの深さ(エロージョン深さ(mm))を算出する。このエロージョン量の測定試験では、平均粒子径が50μmの砥粒を用いた。以下の評価基準に従い、ハニカムフィルタの「耐エロージョン性」の評価を行った。なお、実施例1~8及び比較例1~3において、基準となるハニカムフィルタを、比較例1とする。なお、「目封止貫通」とは、エロージョンにより目封止部が削られ、目封止部の少なくとも一部がガスの流れ方向に貫通した状態のことを意味する。
評価「優」:基準となるハニカムフィルタの「エロージョン深さ」を100%とした場合に、評価対象のハニカムフィルタの「エロージョン深さ」が、20%未満の場合、その評価を「優」とする。
評価「良」:基準となるハニカムフィルタの「エロージョン深さ」を100%とした場合に、評価対象のハニカムフィルタの「エロージョン深さ」が、20%以上、50%未満の場合、その評価を「良」とする。
評価「可」:基準となるハニカムフィルタの「エロージョン深さ」を100%とした場合に、評価対象のハニカムフィルタの「エロージョン深さ」が、50%以上、80%未満の場合、その評価を「可」とする。
評価「不可」:基準となるハニカムフィルタの「エロージョン深さ」を100%とした場合に、評価対象のハニカムフィルタの「エロージョン深さ」が、80%以上の場合、その評価を「不可」とする。
まず、1.4Lガソリンエンジンを搭載するエンジンベンチにて、一定運転条件にて、所定量の煤を発生させ、発生させた煤を、各実施例及び比較例のハニカムフィルタの隔壁の表面に堆積させた。次に、ポストインジェクションによる再生処理を行い、ハニカムフィルタの入口ガス温度を上昇させ、ハニカムフィルタ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。再生処理前の所定量の煤の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、上記操作を繰り返して行った。ハニカムフィルタにクラックが生じる煤の堆積量を、各ハニカムフィルタにおける「煤の堆積限界量」とした。以下の評価基準に従い、ハニカムフィルタの「煤の堆積限界量」の評価を行った。なお、実施例1~8及び比較例1~3において、基準となるハニカムフィルタを、比較例1とする。
評価「優」:基準となるハニカムフィルタの「煤の堆積限界量」を100%とした場合に、評価対象のハニカムフィルタの「煤の堆積限界量」が、130%以上の場合、その評価を「優」とする。
評価「良」:基準となるハニカムフィルタの「煤の堆積限界量」を100%とした場合に、評価対象のハニカムフィルタの「煤の堆積限界量」が、120%以上、130%未満の場合、その評価を「良」とする。
評価「可」:基準となるハニカムフィルタの「煤の堆積限界量」を100%とした場合に、評価対象のハニカムフィルタの「煤の堆積限界量」が、100%以上、120%未満の場合、その評価を「可」とする。
評価「不可」:基準となるハニカムフィルタの「煤の堆積限界量」を100%とした場合に、評価対象のハニカムフィルタの「煤の堆積限界量」が、100%未満の場合、その評価を「不可」とする。
ハニカムフィルタの構成を、表1に示すように変更した以外は、実施例1のハニカムフィルタと同様の方法でハニカムフィルタを作製した。なお、実施例2~8において、中央目封止部の気孔率P1、及び外周目封止部の気孔率P2の変更は、目封止材を調製する際に、発泡樹脂の量を変更することによって行った。
ハニカムフィルタの構成を、表1に示すように変更した以外は、実施例1のハニカムフィルタと同様の方法でハニカムフィルタを作製した。なお、比較例1~5において、中央目封止部の気孔率P1、及び外周目封止部の気孔率P2の変更は、目封止材を調製する際に、発泡樹脂の量を変更することによって行った。
実施例1~8のハニカムフィルタは、キャニング時のセルからの目封止部の剥落を防ぎつつ、耐エロージョン性に優れ、耐熱衝撃性が向上できるということが分かった。一方、比較例1のハニカムフィルタは、実施例1~8のハニカムフィルタと比較して、セルからの目封止部の剥落、耐エロージョン性、耐熱衝撃性のいずれも効果が小さいということが分かった。なお、中央領域の目封止部の気孔率を低く抑えることで、耐エロージョン性及び耐熱衝撃性が向上し、外周領域の目封止部の気孔率を高く設定することでセルからの目封止部の剥落を抑制できるという傾向が見られた。なお、比較例4のハニカムフィルタのように、外周領域の目封止部の気孔率の絶対値が低すぎると、目封止部の剥落を抑制する効果が十分に得られないことが分かった。また、比較例5のハニカムフィルタのように、中央領域の目封止部の気孔率の絶対値が低すぎると、耐熱衝撃性が低下することが分かった。
Claims (4)
- 流入端面から流出端面まで延びる流体の流路となる複数のセルを取り囲むように配置された多孔質の隔壁を有する柱状のハニカム構造体と、
前記セルの前記流入端面側の端部又は前記流出端面側の端部のいずれか一方に配設された多孔質の目封止部と、を備え、
前記目封止部は、多孔質体によって構成されたものであり、
前記ハニカム構造体は、前記セルの延びる方向に直交する断面における重心を含む中央領域と、前記中央領域よりも外周側の外周領域と、を有し、且つ、前記中央領域の面積S1に対する、前記外周領域の面積S2の比であるS2/S1が、0.1~0.5であり、
前記中央領域に存在する前記目封止部である中央目封止部の気孔率P1が、前記外周領域に存在する前記目封止部である外周目封止部の気孔率P2よりも低く、
前記目封止部は、それぞれの気孔率P1が60~68%の前記中央目封止部か、それぞれの気孔率P2が70~85%の前記外周目封止部かのいずれかである、ハニカムフィルタ。 - 前記ハニカム構造体の前記断面の径方向における中心から外周に向かって複数個の前記中央目封止部及び前記外周目封止部を有し、
前記中央目封止部及び前記外周目封止部は、前記断面の径方向におけるより中心側に配設された前記中央目封止部から、順次外周に向かって配設される前記中央目封止部及び前記外周目封止部の各気孔率が段階的に大きくなるように構成されている、請求項1に記載のハニカムフィルタ。 - 前記中央領域と前記外周領域とにおいて、前記ハニカム構造体のセル構造が同じである、請求項1又は2に記載のハニカムフィルタ。
- 前記隔壁の気孔率が、40~70%である、請求項1~3のいずれか一項に記載のハニカムフィルタ。
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