JPWO2007148764A1 - ハニカム構造体及びその製造方法 - Google Patents
ハニカム構造体及びその製造方法 Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 77
- 230000002093 peripheral effect Effects 0.000 claims abstract description 114
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
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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
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 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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- 229910010271 silicon carbide Inorganic materials 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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- 229910000166 zirconium phosphate Inorganic materials 0.000 description 1
- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 1
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Abstract
Description
まず、本発明のハニカム構造体の一の実施形態について説明する。図1は、本発明のハニカム構造体の一の実施形態を模式的に示す斜視図であり、図2は、図1に示すハニカム構造体の端面を示す平面図である。また、図3は、図1におけるA−A線断面図である。また、図4は、図2示す端面の一部拡大図である。
本実施形態のハニカム構造体1に用いられるセル構造体2は、多孔質の隔壁4を有し、隔壁4によって流体の流路となる複数のセル5が区画形成された筒状のものである。このようなセル構造体は、例えば、複数のセルを区画形成する多孔質の隔壁と、この隔壁と一体的に形成された外壁と、を有する外壁付きセル構造体を成形し、得られた外壁付きセル構造体の外壁を研削砥石等を用いて研削して除去することによって得ることができる。
本実施形態のハニカム構造体1に用いられる外周コート層3は、セル構造体2の外周を覆うように配設された外周コート部6と、セル構造体2の端面8よりも外方に突出し、且つそのセル構造体2の端面8における外側部分を覆うように配設された突出部7と、を有するものである。なお、本実施形態のハニカム構造体1の外周コート層3においては、セル構造体2の少なくとも一方の端面8側に突出部7が形成されていればよいが、図1〜図4に示すように、セル構造体2の両方の端面8側において突出部7を有するものであることが好ましい。
次に、本発明のハニカム構造体の製造方法(第一の製造方法)の一の実施形態について説明する。本実施形態の製造方法により、上記本発明のハニカム構造体の一の実施形態を製造することができる。
次に、本発明のハニカム構造体の製造方法(第二の製造方法)の一の実施形態について説明する。本実施形態の製造方法により、上記本発明のハニカム構造体の一の実施形態を製造することができる。
成形原料としてコージェライト化原料を使用し、これらをニーダーにて混練して成形用坏土を調製した。得られた成形用坏土を、セル構造が四角形セル12mil/300cpsi(0.3048mm/46.5(セル/cm2))、セルピッチ1.47mmとなるような口金を用いて押出成形して成形体を得、得られた成形体の両端面を交互に目封止し、乾燥・焼成して外壁付きセル構造体を得た。
実施例1の場合と同様にして、セル構造が四角形セル17mil/100cpsi(0.4318mm/15.5(セル/cm2))、セルピッチ2.54mmであり、最外周の径が404mmφのセル構造体を得た。その後、外周にコート材を塗布して、外周コート層を構成する外周コート部を形成し、更に、セル構造体の端面における外側部分を覆うように外周コート材を更に塗工することにより、外周コート層を構成する突出部を形成して、図1に示すようなハニカム構造体を製造した。なお、ハニカム構造体の全体の外形は406mmφであり、中心軸方向の長さは432mmである。また、外周コート層の突出部は、セル構造体の端面から1mm外方に突出し、セル構造体の端面における外周側部分から5mmの範囲を覆うように配設されたものである。
実施例2の場合と同様にして、図11に示すような、実施例2と同じサイズ、セル構造のセル構造の外周部分のみに外周コート層を形成してハニカム構造体を製造し比較例1のハニカム構造体とした。
試験装置:ガスバーナースポーリング装置
加熱条件(1サイクル分):100℃(最低温度)から750℃(最高温度)までを10分かけて昇温し、750℃で10分保持し、750℃から100℃までを30分かけて冷却し、100℃で10分保持する。
加熱サイクル数:200サイクル
バーナースポーリング試験の結果、実施例1及び2のハニカム構造体は、外周コート層の欠けは発生しなかった。比較例1のハニカム構造体は、外周コート層の端部に欠けが発生していた。これらの結果より、本発明のハニカム構造体は、セル構造体の外周を覆うように配設された外周コート層の破損や剥離が有効に防止されたものであることがわかる。
Claims (4)
- 多孔質の隔壁を有し、前記隔壁によって流体の流路となる複数のセルが区画形成された筒状のセル構造体と、前記セル構造体の外周を覆うように配設された外周コート層と、を備えたハニカム構造体であって、
前記外周コート層は、前記セル構造体の外周を覆うように配設された外周コート部と、前記セル構造体の端面よりも外方に突出し、且つ前記セル構造体の前記端面における外側部分を覆うように配設された突出部と、を有するものであるハニカム構造体。 - 前記セル構造体の一方の端部側の所定のセルの開口部を封止するとともに、前記セル構造体の他方の端部側の残余のセルの開口部を封止する目封止部を更に備えた請求項1に記載のハニカム構造体。
- 成形用坏土を成形して、流体の流路となる複数のセルを区画形成する多孔質の隔壁を有する筒状のセル構造体を得る工程と、前記セル構造体の外周を覆うように外周コート材を塗工して外周コート層を形成する工程とを備えたハニカム構造体の製造方法であって、
前記セル構造体を、少なくとも一方の前記端面の外側部分が開放されるように二つの挟持部材によって両端面を挟持した状態で、前記セル構造体の外周及び前記端面における開放された前記外側部分を覆うように前記外周コート材を塗工することにより、
前記セル構造体の外周を覆うように配設された外周コート部と、前記セル構造体の端面よりも外方に突出し、且つ前記セル構造体の前記端面における外側部分を覆うように配設された突出部と、を有する前記外周コート層を形成するハニカム構造体の製造方法。 - 成形用坏土を成形して、流体の流路となる複数のセルを区画形成する多孔質の隔壁を有する筒状のセル構造体を得る工程と、前記セル構造体の外周を覆うように外周コート材を塗工して外周コート層を形成する工程とを備えたハニカム構造体の製造方法であって、
前記セル構造体の外周を覆うように前記外周コート材を塗工した後に、前記セル構造体の少なくとも一方の前記端面における外側部分を覆うように前記外周コート材を更に塗工することにより、
前記セル構造体の外周を覆うように配設された外周コート部と、前記セル構造体の端面よりも外方に突出し、且つ前記セル構造体の前記端面における外側部分を覆うように配設された突出部と、を有する前記外周コート層を形成するハニカム構造体の製造方法。
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JP4998346B2 (ja) * | 2008-03-25 | 2012-08-15 | 株式会社デンソー | セラミックハニカム構造体の製造方法 |
JP5608639B2 (ja) * | 2009-04-03 | 2014-10-15 | 株式会社キャタラー | 排ガス浄化用触媒の製造方法及び装置並びにそれに使用するノズル |
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WO2015114949A1 (ja) | 2014-01-30 | 2015-08-06 | カルソニックカンセイ株式会社 | 排気熱回収器 |
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JP2016153622A (ja) * | 2015-02-20 | 2016-08-25 | 日本碍子株式会社 | ハニカム型加熱装置及びその使用方法 |
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