JPWO2007000847A1 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- JPWO2007000847A1 JPWO2007000847A1 JP2007523349A JP2007523349A JPWO2007000847A1 JP WO2007000847 A1 JPWO2007000847 A1 JP WO2007000847A1 JP 2007523349 A JP2007523349 A JP 2007523349A JP 2007523349 A JP2007523349 A JP 2007523349A JP WO2007000847 A1 JPWO2007000847 A1 JP WO2007000847A1
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb
- honeycomb structure
- sealing material
- material layer
- unit
- 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.)
- Granted
Links
- 239000003566 sealing material Substances 0.000 claims abstract description 75
- 239000003054 catalyst Substances 0.000 claims description 50
- 239000010954 inorganic particle Substances 0.000 claims description 20
- 239000012784 inorganic fiber Substances 0.000 claims description 17
- 238000000746 purification Methods 0.000 abstract description 25
- 241000264877 Hippospongia communis Species 0.000 description 182
- 239000007789 gas Substances 0.000 description 42
- 239000011230 binding agent Substances 0.000 description 30
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 22
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 17
- 238000005259 measurement Methods 0.000 description 17
- 239000002245 particle Substances 0.000 description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 12
- 239000000463 material Substances 0.000 description 12
- 229910052697 platinum Inorganic materials 0.000 description 11
- 239000000835 fiber Substances 0.000 description 10
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 10
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 8
- 238000000576 coating method Methods 0.000 description 8
- 238000002156 mixing Methods 0.000 description 8
- 239000004215 Carbon black (E152) Substances 0.000 description 7
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 7
- 229910002091 carbon monoxide Inorganic materials 0.000 description 7
- 229930195733 hydrocarbon Natural products 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 239000002994 raw material Substances 0.000 description 7
- 238000010304 firing Methods 0.000 description 6
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 6
- 229910010271 silicon carbide Inorganic materials 0.000 description 6
- 239000000377 silicon dioxide Substances 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- OJMOMXZKOWKUTA-UHFFFAOYSA-N aluminum;borate Chemical compound [Al+3].[O-]B([O-])[O-] OJMOMXZKOWKUTA-UHFFFAOYSA-N 0.000 description 5
- 230000007423 decrease Effects 0.000 description 5
- 150000002430 hydrocarbons Chemical class 0.000 description 5
- 229920000609 methyl cellulose Polymers 0.000 description 5
- 239000001923 methylcellulose Substances 0.000 description 5
- 235000010981 methylcellulose Nutrition 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 4
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- 230000004913 activation Effects 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- NWAHZABTSDUXMJ-UHFFFAOYSA-N platinum(2+);dinitrate Chemical compound [Pt+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O NWAHZABTSDUXMJ-UHFFFAOYSA-N 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000001768 carboxy methyl cellulose Substances 0.000 description 3
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 3
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 229910000510 noble metal Inorganic materials 0.000 description 3
- 229910052580 B4C Inorganic materials 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- 229910021536 Zeolite Inorganic materials 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 2
- 150000001342 alkaline earth metals Chemical class 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000002585 base Substances 0.000 description 2
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 2
- 238000006555 catalytic reaction Methods 0.000 description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 2
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 229910052878 cordierite Inorganic materials 0.000 description 2
- 238000001739 density measurement Methods 0.000 description 2
- 235000014113 dietary fatty acids Nutrition 0.000 description 2
- 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
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-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
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 239000002612 dispersion medium Substances 0.000 description 2
- 239000000194 fatty acid Substances 0.000 description 2
- 229930195729 fatty acid Natural products 0.000 description 2
- 150000004665 fatty acids Chemical class 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000010457 zeolite Substances 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910018921 CoO 3 Inorganic materials 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 239000001856 Ethyl cellulose Substances 0.000 description 1
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 229920001249 ethyl cellulose Polymers 0.000 description 1
- 235000019325 ethyl cellulose Nutrition 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- -1 hydrocarbon HC Chemical class 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000000691 measurement method Methods 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
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000003981 vehicle Substances 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
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- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
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- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
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- C—CHEMISTRY; METALLURGY
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
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- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
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- C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
- C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
- C04B37/005—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts consisting of glass or ceramic material
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
- F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
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Abstract
Description
複数の貫通孔を有するハニカムユニットと、2以上の該ハニカムユニットを該貫通孔が開口していない外面で接合するシール材層とを備えたハニカム構造体であって、
前記ハニカムユニットの見掛け密度と前記ハニカム構造体の全体に占める前記ハニカムユニットの体積割合との積をA(g/cm3)、前記シール材層の見掛け密度と前記ハニカム構造体の全体に占める前記シール材層の体積割合との積をB(g/cm3)、前記ハニカム構造体の単位体積あたりの比表面積をC(m2/L)としたとき2≦A/B≦0.0002×C+5(28000≦C)を満たすものである。
まず、γアルミナ粒子(住友化学社製KC−501,平均粒径1μm)2250質量部、ホウ酸アルミニウムウィスカ(平均繊維長20μm、平均繊維径0.5μm)680質量部、無機バインダとしてのシリカゾル(固体濃度30重量%)2600質量部、有機バインダとしてのメチルセルロース(MC)320質量部、水、可塑剤(グリセリン)及び潤滑剤(商品名ユニルーブ;日本油脂(株))を適量加えて混合・混練して混合組成物を得た。次に、この混合組成物を長手方向に沿って並列する複数の貫通孔が形成された角柱状に押出成形機により押出成形を行い、生の成形体を得た。そして、マイクロ波乾燥機及び熱風乾燥機を用いて生の成形体を十分乾燥させ、400℃で2h保持して脱脂した。その後、800℃で2h保持して焼成を行い、角柱状(34.3mm×34.3mm×75mm)、セル密度が93個/cm2(600cpsi)、壁厚が0.2mm、セル形状が正方形のハニカムユニット10(以下このサンプルをハニカム1とする)を得た。このハニカム1の構成材料(基材)、シリカゾル及びメチルセルロースなどの配合量、焼成温度などの数値をまとめたものを表1に示す。この表1には、サンプルの測定結果としての見掛け密度、気孔率及び単位体積あたりの比表面積などの数値も示し、後述するハニカム2〜5に関する内容もまとめて示す。得られたハニカム1の見掛け密度は0.45g/cm3であり、気孔率は60%であり、単位体積あたりの比表面積は40000m2/Lであった。なお、見掛け密度、気孔率及び単位体積あたりの比表面積の算出方法は後述する。
表1に示す配合量になるようにハニカムユニット10の原料を混合し、表2に示す配合量になるようにシール材ペーストを調製し、表3に示すハニカムユニット10とシール材との組み合わせ、ユニット面積割合、シール材面積割合及びシール材層厚さに設計したほかは実験例1と同様にして実験例2〜23のハニカム構造体20を作製した。
貫通孔内部に触媒担持層であるアルミナが形成してある市販のコージェライト担体を用意した。このコージェライト担体は、直径135mm、長さ75mm、貫通孔の形状が6角形であり、壁部の厚さ0.18mm、セル密度60個/cm2(400cpsi)であった。次に、0.25mol/Lの硝酸白金溶液を調製した。白金の担持量がハニカム構造体の単位体積当たりの白金の重量で5.0g/Lとなるようにこの硝酸白金水溶液をハニカム担体に吸水させ、600℃で1h焼成した。こうして白金触媒を担持した実験例24のハニカム構造体を得た。得られたハニカム構造体の単位体積あたりの比表面積は25000m2/Lであった。
ハニカムユニット10としてのハニカム1〜5及びシール材層26としてのシール材1〜4の見掛け密度測定を行った。ハニカムユニット10のAは、ハニカムユニット10の乾燥重量Ga(g)及びハニカムユニット10の外形の体積Va(cm3)を測定し、ハニカム構造体20の体積のうちハニカムユニット10の占める体積割合Y(%)を求めて次式(2)から求めた。また、シール材層26のBは、シール材ペーストを立方体状に固化させたのち、1cm角に切り出し、該切り出したシール材層26の乾燥重量Gb(g)、シール材層26の外形の体積Vb(cm3)を測定し、ハニカム構造体20の体積のうちシール材層26の占める体積割合Z(%)を求めて次式(3)から求めた。なお、ハニカムユニット10とシール材層26とのハニカム構造体20の軸方向の長さが同じであるため、上記割合Yとユニット面積割合とが同じ値になり、上記割合Zとシール材層面積割合とが同じ値になる。したがって、Aは、(ハニカムユニット10の見掛け密度)×((ユニット面積割合)/100)により求めることができる。また、Bは、(シール材層の見掛け密度)×((シール材層面積割合)/100)により求めることができる。
A(g/cm3)=(Ga/Va)×(Y/100)…式(2)
B(g/cm3)=(Gb/Vb)×(Z/100)…式(3)
実験例1〜24の気孔率測定を行った。この測定は、測定器として(株)島津製作所社製自動ポロシメータ オートポアIII 9405を用いてJIS−R1655に基づいて水銀圧入法により行った。具体的には、ハニカムユニット10を0.8cm程度の立方体に切断し、イオン交換水で超音波洗浄し乾燥したのち上記測定器を用いて、0.1〜360μmの測定範囲で測定した。100〜360μmの範囲では、0.1psiaの圧力ごとに測定し、0.1〜100μmの範囲では、0.25psiaの圧力ごとに測定した。
実験例1〜24のハニカム構造体の単位体積あたりの比表面積測定を行った。まずハニカムユニット10の単位重量あたりのBET比表面積M(m2/g)を測定した。BET比表面積は、BET測定装置(島津製作所製MicromeriticsフローソーブII−2300)を用いて、日本工業規格で定められるJIS−R−1626(1996)に準じて1点法により測定した。測定には、円柱形状の小片(直径15mm×高さ15mm)に切り出したサンプルを用いた。次に、ハニカムユニット10の見掛け密度N(g/L)をハニカムユニット10の重量と外形の体積とから計算した。なお、このハニカムユニット10の見掛け密度N(g/L)は上述したGa/Va×1000と同じ値である。そして、ユニット面積割合をL(%)とし、実験例1〜24の単位体積当たりの比表面積C(m2/L)を、次式(4)から求めた。ここでのハニカム構造体の比表面積は、ハニカム構造体の見掛け体積あたりの比表面積のことをいう。このユニット面積割合L(%)は、上述したようにハニカムユニット10の占める体積割合Y(%)と同じであることから、式(4)は、式(5)と同じである。また、ハニカムユニット10の単位体積あたりの比表面積は、M×Nにより算出した。なお、この測定や見掛け密度測定や気孔率測定では、触媒(白金)を担持する前のハニカムユニット10を用いて測定を行った。
比表面積C(m2/L)=(L/100)×M×N;式(4)
比表面積C(m2/L)=(Y/100)×M×(Ga/Va×1000)N;式(5)
実験例1〜24の排ガスの浄化率測定を行った。この測定は、図4に示した排ガス浄化測定装置60を用いて行った。排ガス浄化測定装置60は、エンジン30と、ハニカム構造体20を内部に固定したケーシング38と、ハニカム構造体20を流通する前の排ガスをサンプリングするガスサンプラー61と、ハニカム構造体20を流通した後の排ガスをサンプリングするガスサンプラー62と、排ガスに含まれる有害物質の濃度を分析するガス分析計63と、熱電対によりハニカム構造体20の温度を測定する温度測定器64とにより構成されている。エンジン30に接続されたマニホールド32にケーシング38を接続した。次に、測定手順を説明する。まず、上述した実験例1〜24にエンジン30からの排ガスを流通させた。この測定では、ディーゼル自動車の10・15モード排出ガス測定方法に準じたサイクルを3回行うようにエンジン30を運転した。そして、ガスサンプラー61,62によってサンプリングされた排ガスに含まれる炭化水素(HC)及び一酸化炭素(CO)の濃度をガス分析計63によって測定した。浄化率は、ハニカム構造体20を流通する前の排ガスに含まれる濃度C0と、ハニカム構造体20を流通した後の排ガスに含まれる濃度をCiとを用いて次式(5)より計算した。
浄化率(%)=(C0−Ci)/C0×100;式(5)
表4は、実験例1〜24のユニット種類、シール材層種類、A、B、A/B、ハニカム構造体20の単位体積あたりの比表面積C、排ガスのうちHC及びCOの浄化率などをまとめたものであり、図5は、実験例1〜24について、横軸をハニカム構造体20の単位体積あたりの比表面積Cとし、縦軸をA/Bとしてプロットした単位体積あたりの比表面積CとA/Bとの関係を表す説明図である。なお、図5では、上述した式(1)の範囲にあるものを○、式(1)の範囲外のものを△としてプロットし、各実験例のサンプル番号を各点に付した。表4及び図5から明らかなように、実験例1〜3,6〜7,9〜12,15〜18,21のサンプル、つまり、図3の好適範囲(式(1)を満たす範囲)に入るサンプルでは、HC及びCOの浄化率が80%以上であり、排ガスの浄化率が高かった。また、比表面積Cが35000m2/L以上ではより浄化率が高くなる傾向を示した。この理由としては比表面積Cが大きくなると触媒の分散性が向上するため、排ガスの浄化率が向上したものと考えられる。ここで、好適範囲である2≦A/B≦0.0002×C+5(28000≦C)を満たすときには、ハニカムユニット10の外面13を覆っているシール材層26が保温材の役割を果たし、ハニカム構造体20の降温が抑制されるため、排ガスの浄化率が向上するものと推測された。
Claims (7)
- 複数の貫通孔を有するハニカムユニットと、2以上の該ハニカムユニットを該貫通孔が開口していない外面で接合するシール材層とを備えたハニカム構造体であって、
前記ハニカムユニットの見掛け密度と前記ハニカム構造体の全体に占める前記ハニカムユニットの体積割合との積をA(g/cm3)、前記シール材層の見掛け密度と前記ハニカム構造体の全体に占める前記シール材層の体積割合との積をB(g/cm3)、前記ハニカム構造体の単位体積あたりの比表面積をC(m2/L)としたとき2≦A/B≦0.0002×C+5(28000≦C)を満たす、
ハニカム構造体。 - 前記比表面積Cが35000以上を満たす、
請求項1に記載のハニカム構造体。 - 前記比表面積Cが70000以下を満たす、
請求項1又は2に記載のハニカム構造体。 - 前記積Aが0.2以上0.5以下を満たす、
請求項1〜3のいずれかに記載のハニカム構造体。 - 前記シール材層の厚さが0.1〜2.0mmである、
請求項1〜4のいずれかに記載のハニカム構造体。 - 前記ハニカムユニットは、無機粒子及び無機繊維を含み、
前記シール材層は、前記ハニカムユニットに含まれる無機粒子と同じか又は異なる無機粒子及び前記ハニカムユニットに含まれる無機繊維と同じか又は異なる無機繊維を含む、
請求項1〜5のいずれかに記載のハニカム構造体。 - 排ガスを浄化可能な触媒が担持されてなる、
請求項1〜6のいずれかに記載のハニカム構造体。
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WO2008059607A1 (fr) | 2006-11-16 | 2008-05-22 | Ibiden Co., Ltd. | Procédé permettant de produire une structure en nid d'abeilles et structure en nid d'abeilles ainsi formée |
EP1923373B1 (en) | 2006-11-16 | 2010-01-20 | Ibiden Co., Ltd. | Method for manufacturing honeycomb structured body |
WO2008096413A1 (ja) | 2007-02-06 | 2008-08-14 | Ibiden Co., Ltd. | ハニカム構造体 |
JPWO2008126307A1 (ja) | 2007-03-30 | 2010-07-22 | イビデン株式会社 | 触媒担持体および触媒担持体の製造方法 |
WO2008126305A1 (ja) | 2007-03-30 | 2008-10-23 | Ibiden Co., Ltd. | 触媒担持体および排気ガス処理装置 |
WO2008126306A1 (ja) | 2007-03-30 | 2008-10-23 | Ibiden Co., Ltd. | 触媒担持体 |
WO2008129670A1 (ja) | 2007-04-17 | 2008-10-30 | Ibiden Co., Ltd. | 触媒担持ハニカムおよびその製造方法 |
-
2006
- 2006-04-14 WO PCT/JP2006/307955 patent/WO2007000847A1/ja active Application Filing
- 2006-04-14 KR KR1020077025381A patent/KR100891892B1/ko not_active IP Right Cessation
- 2006-04-14 CN CN200680015512A patent/CN100574882C/zh not_active Expired - Fee Related
- 2006-04-14 JP JP2007523349A patent/JP5042827B2/ja not_active Expired - Fee Related
- 2006-06-27 EP EP06013270.1A patent/EP1752203B1/en not_active Not-in-force
- 2006-06-28 US US11/475,967 patent/US7794815B2/en not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
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US7794815B2 (en) | 2010-09-14 |
KR20080002918A (ko) | 2008-01-04 |
WO2007000847A1 (ja) | 2007-01-04 |
JP5042827B2 (ja) | 2012-10-03 |
EP1752203A1 (en) | 2007-02-14 |
CN100574882C (zh) | 2009-12-30 |
US20070004593A1 (en) | 2007-01-04 |
CN101171083A (zh) | 2008-04-30 |
KR100891892B1 (ko) | 2009-04-03 |
EP1752203B1 (en) | 2014-06-25 |
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