JPWO2006098191A1 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
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- JPWO2006098191A1 JPWO2006098191A1 JP2007508081A JP2007508081A JPWO2006098191A1 JP WO2006098191 A1 JPWO2006098191 A1 JP WO2006098191A1 JP 2007508081 A JP2007508081 A JP 2007508081A JP 2007508081 A JP2007508081 A JP 2007508081A JP WO2006098191 A1 JPWO2006098191 A1 JP WO2006098191A1
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Abstract
Description
[3]前記接合材層が、強度(MPa)/ヤング率(GPa)>2.5×10−3の関係を満たす前記[1]に記載のハニカム構造体。
[7]前記接合材層が無機繊維を含有してなり、前記無機繊維の含有率が20〜45質量%、ショット含有率が10〜50質量%、長軸方向に垂直な断面における平均直径値が1〜20μm及び長軸方向の平均長さが10〜400μmである前記[1]〜[6]のいずれかに記載のハニカム構造体。
(ハニカムセグメントの作製)
ハニカムセグメント原料として、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、さら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。この坏土を押出成形し、マイクロ波及び熱風で乾燥して隔壁の厚さが310μm、セル密度が約46.5セル/cm2(300セル/平方インチ)、断面が一辺35mmの正四角形、長さが152mmのハニカムセグメント成形体を得た。このハニカムセグメント成形体を、端面が市松模様状を呈するように、セルの両端面を目封じした。すなわち、隣接するセルが、互いに反対側の端部で封じられるように目封じを行った。目封じ材としては、ハニカムセグメント原料と同様な材料を用いた。セルの両端面を目封じし、乾燥させた後、大気雰囲気中約400℃で脱脂し、その後、Ar不活性雰囲気で約1450℃で焼成して、SiC結晶粒子をSiで結合させた、多孔質構造を有するハニカムセグメントを得た。
無機繊維としてアルミノシリケート繊維、無機バインダーとしてコロイダルシリカ及び粘土、無機粒子としてSiCを混合したものにさらに水を加えて、場合によっては、有機バインダー(CMC、PVA)、発泡樹脂及び分散剤を加えて、ミキサーにて30分間混練を行い、ペースト状の接合材を得た。具体的には、表1に示す条件で、種類及び組成比の異なる接合材(接合材No.1〜16)を得た。
ハニカムセグメントの外壁面に、厚さ約1mmとなるように接合材No.1をコーティングして接合材層を形成し、その上に別のハニカムセグメントを載置する工程を繰り返し、16個のハニカムセグメントからなるハニカムセグメント積層体を作製し、外部より圧力を加え、全体を接合させた後、140℃、2時間乾燥してハニカムセグメント接合体を得た。その後、ハニカムセグメント接合体の外周を円筒状に切断後、コーティング材を塗布し、700℃、2時間乾燥硬化させ、ハニカム構造体を得た。得られたハニカム構造体を切断して所定の気孔率測定用サンプルを切り出し、樹脂埋め、研磨後、気孔率測定用サンプルの断面における気孔の分布状況をSEMにて10〜40倍程度で観察した。得られた写真の画像解析(Media Cybernetics社製、ImagePro(Ver5.0))から気孔率を測定した。気孔の分布状況を観察した結果を図5に示す。気孔率を算出するにあたり、少なくとも試料長さ3mm以上の領域を用いた。結果を表2に示す。接合材中心部分の気孔率は68%で、外側部分の気孔率は37%であった。また所定の強度試験用サンプルを切り出し、JIS R1601に準じた3点曲げ強度の測定を行った。ヤング率は強度測定の時の加重と変位曲線より算出した。結果を表3に示す。接合材の強度/ヤング率比は1.2×10−3であった。また、得られたハニカム構造体の急速加熱試験(バーナースポーリング試験B−sp)、急速冷却試験(電気炉スポーリング試験E−sp)、エンジン試験(E/G試験)を行った。結果を表2、3に示す。
実施例2〜12は、実施例1において、接合材を、接合材No.2〜12に変えたこと以外は実施例1と同様にした。また、比較例1〜3は、接合材を、No.13〜15に変えたこと以外は実施例1と同様にした。各実施例及び比較例における、ハニカム構造体の接合材の各種試験結果を表2、3に示す。
「E−sp」試験:電気炉スポーリング試験(急速冷却試験):温度450℃ハニカム構造体を電気炉にて550℃×2h加熱し、均一な温度にした後、室温に取り出し、ハニカム構造体のクラック発生の有無により耐熱衝撃性を評価する試験
「E/G」試験:エンジン試験1000℃:フィルター再生のために堆積したパーティキュレートを燃焼させ、ハニカム中心止部の温度が1000℃となる条件にて、ハニカム構造体のクラックの有無により耐熱衝撃性を評価する試験
Claims (9)
- 複数のハニカムセグメントが接合材層を介して互いの接合面で一体的に接合されたハニカムセグメント接合体を備え、流体の流路となる複数のセルが中心軸方向に互いに並行するように配設された構造を有するハニカム構造体であって、
前記接合材層の外側部分(ハニカムセグメントの接合面との界面からそれぞれ全体の層厚の20%に相当する長さだけ離れた箇所までの部分)における気孔率が、外側部分より内方に位置する中心部分の気孔率よりも小であることを特徴とするハニカム構造体。 - 前記接合材層が、強度(MPa)/ヤング率(GPa)>1.0×10−3の関係を満たす請求項1に記載のハニカム構造体。
- 前記接合材層が、強度(MPa)/ヤング率(GPa)>2.5×10−3の関係を満たす請求項1に記載のハニカム構造体。
- 前記接合材層が、強度(MPa)/ヤング率(GPa)>3.5×10−3の関係を満たす請求項1に記載のハニカム構造体。
- 前記接合材層の前記外側部分の気孔率が5〜40%であり、かつ前記中心部分の気孔率が25〜90%である請求項1〜4のいずれかに記載のハニカム構造体。
- 前記接合材層の前記外側部分の気孔率が10〜30%であり、かつ前記中心部分の気孔率が30〜70%である請求項1〜4のいずれかに記載のハニカム構造体。
- 前記接合材層が無機繊維を含有してなり、前記無機繊維の含有率が20〜45質量%、ショット含有率が10〜50質量%、長軸方向に垂直な断面における平均直径値が1〜20μm及び長軸方向の平均長さが10〜600μmである請求項1〜6のいずれかに記載のハニカム構造体。
- 前記接合材層の厚さが、0.5〜3mmである請求項1〜7のいずれかに記載のハニカム構造体。
- 前記ハニカムセグメントが、炭化珪素(SiC)から構成されてなるか、又は前記炭化珪素(SiC)を骨材として、かつ珪素(Si)を結合材として形成された珪素−炭化珪素系複合材料から構成されてなる請求項1〜8のいずれかに記載のハニカム構造体。
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