JPWO2007125667A1 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- JPWO2007125667A1 JPWO2007125667A1 JP2008513093A JP2008513093A JPWO2007125667A1 JP WO2007125667 A1 JPWO2007125667 A1 JP WO2007125667A1 JP 2008513093 A JP2008513093 A JP 2008513093A JP 2008513093 A JP2008513093 A JP 2008513093A JP WO2007125667 A1 JPWO2007125667 A1 JP WO2007125667A1
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- JP
- Japan
- Prior art keywords
- honeycomb structure
- outer peripheral
- honeycomb
- coating material
- thermal conductivity
- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
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- B01D46/2418—Honeycomb filters
- 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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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
- B01D46/2444—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
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24491—Porosity
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/24494—Thermal expansion coefficient, heat capacity or thermal conductivity
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- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2462—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure the outer peripheral sealing
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/2418—Honeycomb filters
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- B01D46/2478—Structures comprising honeycomb segments
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- B01D46/2482—Thickness, height, width, length or diameter
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- B01D46/2498—The honeycomb filter being defined by mathematical relationships
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- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/0038—Machines or methods for applying the material to surfaces to form a permanent layer thereon lining the outer wall of hollow objects, e.g. pipes
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Abstract
Description
このような構造とすることにより、開口している端部から排ガスが流通孔に流入すると、排ガスは多孔質の隔壁を通過して他の流通孔から流出し、隔壁を通過する際に排ガス中のパティキュレートが隔壁に捕捉されるため、排ガスの浄化を行うことができる。
[1]多孔質の隔壁によって区画された流体の流路となる複数のセルを有するセル構造体と、前記セル構造体の外周に配設された多孔質の外壁とを備えたハニカムセグメントの複数個が、これらの前記外壁どうしが接合材で接合されることにより一体化されてなる、セラミックスからなるハニカム構造体において、前記ハニカム構造体の外周壁を構成する外周コーティング材の気孔率が10〜60%であるハニカム構造体。
図1に本発明のハニカム構造体の一実施形態を示す。図1(a)はハニカムセグメントの斜視図である。図1(b)はハニカム構造体の斜視図である。図1(c)はハニカム構造体の上面図を示す。本実施形態のハニカム構造体1は、多孔質の隔壁2によって区画された流体の流路となる複数のセル3を有するセル構造体5と、セル構造体5の外周に配設された多孔質の外壁7とを備えたハニカムセグメント12の複数個が、これらの外壁7どうしが接合材8で接合されることにより一体化されてなるものである。
SiC原料粉末と金属Si粉末を、表1に示す質量割合でそれぞれ配合し、これに増孔材として澱粉、発泡樹脂を加え、さらにメチルセルロースおよびヒドロキシプロポキシルメチルセルロース、界面活性剤および水を添加して、可塑性の坏土を作製した。この坏土を押出成形し、マイクロ波およ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の正方形、長さが152mmのハニカムセグメントを得た。このハニカムセグメントに対し、端面が市松模様状を呈するように、隣接するセルが互いに反対側となる一方の端部でハニカムセグメント2の製造に用いた材料と同様の材料を用いて目封じし、乾燥させた後、大気雰囲気中約400℃で脱脂し、その後、Ar不活性雰囲気中で約1450℃焼成して、Si−SiCのハニカムセグメントを得た。それぞれのハニカムセグメントの熱伝導率をレーザーフラッシュ法にて測定し、その結果を表1に示した。
本発明のコーティング材A〜Fは、酸化物粒子としてアルミナ、シリカ、あるいはジルコニアを35質量%、酸化物繊維としてアルミノシリケート繊維を22質量%、無機バインダーとしてシリカゾル40質量%、水溶液を19.5質量%、粘土を1質量%、有機バインダーとしてメチルセルロースを0.1質量%混合し、水を加え、ミキサーを用いて30分混練して得た。その組成は表2に示す。また、比較例として、G〜Jのコーティング材の組成も同様に表2に示す。
表1に示した焼成ハニカムセグメントを16本接合して得られた接合体の外周を研削した後、その外周部に対して、表2に示した本発明のコーティング材A〜Fと比較例のコーティング材G〜Jをそれぞれ個別に塗布し、200℃で2時間乾燥して、ハニカム構造体を得た。
表3、4、および5に示す組み合わせのハニカム構造体をディーゼルエンジン排気管に取り付け、ハニカム構造体内へスートを5g/l堆積し、排気ガス流量2m3/minでスート再生を行った。再生後のハニカム構造体を電気炉にて700℃、10時間熱処理を行い、その前後の重量差をスート残り量とした。
各コーティング材の所定の強度用サンプルを10個ずつ切り出し、JIS R1601に従って3点曲げ強度の測定を行い、さらに各コーティング材の気孔率をアルキメデス法にて求め、また、外周コーティング材表面のクラック発生有無を観察した結果を表4、および6に示す。
表3に示すように、基材熱伝導率が20W/mK以下で、コーティング材の熱伝導率が0.5W/mKを上回った場合、スート残り量が増加し、スート再生効率が悪化した。
表6に示すように、気孔率を増加させることで、コーティング材の熱伝導率を低下させることに効果がある。コーティング材の気孔率が10〜60%、特に、20〜55%ではクラックの発生は全くなかった。一方、気孔率が65%になると、強度も低下し、クラックが発生した。
Claims (8)
- 多孔質の隔壁によって区画された流体の流路となる複数のセルを有するセル構造体と、前記セル構造体の外周に配設された多孔質の外壁とを備えたハニカムセグメントの複数個が、これらの前記外壁どうしが接合材で接合されることにより一体化されてなる、セラミックスからなるハニカム構造体において、
前記ハニカム構造体の外周壁を構成する外周コーティング材の気孔率が10〜60%であるハニカム構造体。 - 前記ハニカム構造体の外周壁を構成する外周コーティング材の熱伝導率が0.01〜0.5W/mKである請求項1記載のハニカム構造体。
- 前記ハニカム構造体の外周壁を構成する外周コーティング材の厚みが0.01〜1mmである請求項1または2に記載のハニカム構造体。
- 前記外周コーティング材が、酸化物粒子、酸化物繊維、コロイド状酸化物、板状粒子、有機バインダー、有機あるいは無機の中空粒状フィラーのいずれかを含む請求項1〜3のいずれかに記載のハニカム構造体。
- 前記酸化物粒子として、シリカ、アルミナ、ジルコニア、アルミニウムチタネート、ムライト、コージェライトのいずれかを含む請求項4に記載のハニカム構造体。
- 前記酸化物粒子の平均粒径が0.1〜30μmである請求項4または5に記載のハニカム構造体。
- 前記外周コーティング材が、有機及び/又は無機の中空粒状フィラーを含む請求項4〜6のいずれかに記載のハニカム構造体。
- 前記ハニカム構造体を構成する基材の熱伝導率が0.1〜20W/mKである請求項1〜7のいずれかに記載のハニカム構造体。
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