US20050169819A1 - Honeycomb filter for purifying exhaust gas - Google Patents

Honeycomb filter for purifying exhaust gas Download PDF

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Publication number
US20050169819A1
US20050169819A1 US10/508,415 US50841505A US2005169819A1 US 20050169819 A1 US20050169819 A1 US 20050169819A1 US 50841505 A US50841505 A US 50841505A US 2005169819 A1 US2005169819 A1 US 2005169819A1
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Prior art keywords
sealing material
honeycomb filter
holes
rate
exhaust gases
Prior art date
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Abandoned
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US10/508,415
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English (en)
Inventor
Toshiaki Shibata
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Ibiden Co Ltd
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Ibiden Co Ltd
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=28449114&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20050169819(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Ibiden Co Ltd filed Critical Ibiden Co Ltd
Assigned to IBIDEN CO., LTD. reassignment IBIDEN CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SHIBATA, TOSHIAKI
Publication of US20050169819A1 publication Critical patent/US20050169819A1/en
Priority to US12/033,417 priority Critical patent/US7713325B2/en
Abandoned legal-status Critical Current

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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
    • 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
    • B01D46/2451—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D46/2455—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the whole honeycomb or segments
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    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths

Definitions

  • the present invention relates to a honeycomb filter for purifying exhaust gases that is used as a filter for removing particulates and the like contained in exhaust gases discharged from an internal combustion engine such as a diesel engine or the like.
  • particulates contained in exhaust gases that are discharged from internal combustion engines of vehicles, such as buses, trucks and the like, and construction machines have raised serious problems since those particulates are harmful to the environment and the human body.
  • a honeycomb filter 10 in FIG. 1 there have been proposed those having a structure in that a sealing material layer 14 is formed on a circumference of a columnar body 15 made of cordierite or the like, which has a number of through holes 11 placed in parallel with one another in the length direction with wall portion 13 interposed therebetween.
  • wall portion 13 that separates the through holes 11 from each other functions as a filter (for example, see J UM Kokai Hei 7-183).
  • the columnar body 15 is constituted by a single sintered body, and as shown in FIG. 1 ( b ), each of the through holes 11 formed in the columnar body 15 is sealed with a plug 12 at either of ends of its exhaust gas inlet side and outlet side, so that exhaust gases that have entered one through hole 11 are discharged from another through hole 11 after having always passed through wall portion 13 that separates the through holes 11 from each other.
  • the sealing material layer 14 is formed in order to reinforce the circumference of the columnar body 15 or improve the heat-insulating property of the honeycomb filter 10 .
  • honeycomb filters made of a porous silicon carbide sintered material, have often been used because this material has advantages such as superior heat resistance, mechanical strength, collecting efficiency and the like, as well as chemical stability and a small pressure loss.
  • each porous ceramic member 30 has a structure in that: a number of through holes 31 are placed in parallel with one another in the length direction; and partition wall 33 that separates the through holes 31 from each other functions as a filter.
  • each of the through holes 31 formed in the porous ceramic member 30 is sealed with a plug 32 at either of ends of its exhaust gas inlet side or outlet side, so that exhaust gases that have entered one through hole 31 are discharged from another through hole 31 after having always passed through partition wall 33 that separates the through holes 31 from each other.
  • the sealing material layer 24 is provided so as to prevent exhaust gases from leaking through the circumference of each ceramic block 25 when the honeycomb filter 20 is installed in an exhaust passage of an internal combustion engine.
  • the honeycomb filter 10 or the honeycomb filter 20 having the above-mentioned structure is installed in the exhaust passage in the internal combustion engine, so that particulates in the exhaust gases discharged from the internal combustion engine are captured by the wall portion 13 or the partition wall 33 when passing through the honeycomb filter; thus, the exhaust gases are purified.
  • honeycomb filter 20 shown in FIG. 2 has superior heat resistance and provides easy regenerating processes and the like, it has been applied to various large-size vehicles and vehicles with diesel engines.
  • the sealing material layer of the conventional honeycomb filter contains a comparatively large amount of organic components, in the case of a honeycomb filter in which sealing material layers account for a great ratio, it contains a large amount of organic components.
  • the sealing material layer is not made into a completely dense body, and exhaust gases are slightly allowed to flow into the layer.
  • a honeycomb filter which has sealing material layers containing a large amount of organic components as described above, is installed in an exhaust passage in a vehicle such as a large-size vehicle, a vehicle having a diesel engine and the like, and used therein, the organic components are discharged outside through exhaust gases that is flown into the sealing material layer, resulting in a great increase in the amount of the organic components (HC) of exhaust gases.
  • honeycomb filters which support a catalyst in order to decompose and eliminate organic components in exhaust gases to be discharged outside.
  • conventional honeycomb filters have failed to sufficiently decompose and eliminate the organic components by using the above-mentioned catalyst.
  • the present invention is made to solve the above problems, and its object is to provide a honeycomb filter for purifying exhaust gases having a structure in that, even when comparatively large sealing material layer is included therein, there is hardly any increase in the amount of organic components contained in exhaust gases to be discharged.
  • a honeycomb filter for purifying exhaust gases has a structure in which: a columnar body made of porous ceramic comprises a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with wall portion interposed therebetween; a sealing material layer is formed on a circumference portion of the above mentioned columnar body; and the above mentioned wall portion which separates the above mentioned through holes functions as a filter for collecting particulates wherein a rate S ⁇ of an area occupied by the sealing material layers to the total area of across-section including the through holes in the direction perpendicular to the through holes, in the above mentioned honeycomb filter for purifying exhaust gases, is set to 0.5% or more, and a rate V ⁇ of organic components to the honeycomb filter for purifying exhaust gases is set to 0.5% by weight or less.
  • a honeycomb filter for purifying exhaust gases has a structure in which: a plurality of a columnar porous ceramic member are combined with one another through a sealing material layer to form a ceramic block, each of the above mentioned columnar porous ceramic member comprising a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with partition wall interposed therebetween; a sealing material layer is formed on a circumference portion of the above mentioned ceramic block; and the above mentioned partition wall which separates the above mentioned through holes functions as a filter for collecting particulates, wherein a rate S ⁇ of an area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes, in the above mentioned honeycomb filter for purifying exhaust gases, is set to 2% or more, and a rate V ⁇ of organic components to the above mentioned honeycomb filter for purifying exhaust gases is set to 0.5% by weight or less.
  • the honeycomb filter for purifying exhaust gases according to the first aspect of the present invention is simply referred to as the honeycomb filter according to the first aspect of the present invention
  • the honeycomb filter for purifying exhaust gases according to the second aspect of the present invention is simply referred to as the honeycomb filter according to the second aspect of the present invention.
  • each of these is also simply referred to as the honeycomb filter of the present invention.
  • FIG. 1 ( a ) is a perspective view that schematically shows one example of a honeycomb filter for purifying exhaust gases according to the first aspect of the present invention
  • FIG. 1 ( b ) is a longitudinal cross-sectional view taken along line A-A of FIG. 1 ( a ).
  • FIG. 2 is a perspective view that schematically shows one example of a honeycomb filter for purifying exhaust gases according to the second aspect of the present invention.
  • FIG. 3 ( a ) is a perspective view that schematically shows a porous ceramic member to be used for the honeycomb filter according to the second aspect of the present invention shown in FIG. 2 ; and FIG. 3 ( b ) is a longitudinal cross-sectional view taken along line B-B of FIG. 3 ( a ).
  • FIG. 4 is a side view that schematically shows a manufacturing process of the honeycomb filter according to the second aspect of the present invention.
  • FIG. 5 is a graph that shows the results of an evaluation test 1 and an evaluation test 2 of honeycomb filters according to Examples 1 to 4 and Comparative Example 1.
  • FIG. 6 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 5 to 8 and Comparative Example 2.
  • FIG. 7 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 9 to 12 and Comparative Example 3.
  • FIG. 8 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Comparative Examples 4 to 8.
  • FIG. 9 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 13 to 16 and Comparative Example 9.
  • FIG. 10 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 17 to 20 and Comparative Example 10.
  • FIG. 11 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 21 to 24 and Comparative Example 11.
  • FIG. 12 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Comparative Examples 12 to 16.
  • honeycomb filter according to the first aspect of the present invention.
  • a honeycomb filter according to the first aspect of the present invention has a structure in which: a columnar body made of porous ceramic comprises a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with wall portion interposed therebetween; a sealing material layer is formed on a circumference portion of the above mentioned columnar body; and the above mentioned wall portion which separates the above mentioned through holes functions as a filter for collecting particulates wherein a rate S ⁇ of an area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes, in the above mentioned honeycomb filter for purifying exhaust gases, is set to 0.5% or more, and a rate V ⁇ of organic components to the honeycomb filter for purifying exhaust gases is set to 0.5% by weight or less.
  • a honeycomb filter having almost the same shape as that of the honeycomb filter 10 shown in FIG. 1 is proposed, and a sealing material layer is formed on a circumference of a columnar body comprising a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with wall portion interposed therebetween.
  • wall portion that separates the through holes from each other functions as a filter for collecting particles.
  • each of the through holes formed in the columnar body has either of its ends on the inlet side and outlet side of exhaust gases sealed with a plug; thus, exhaust gases that have entered one of the through holes are allowed to discharge from another through hole after always passing through the wall portion that separates the corresponding through holes from each other.
  • the sealing material layer is provided in order to reinforce the circumference portion of the columnar body or improve the heat-insulating property of the honeycomb filter according to the first aspect of the present invention.
  • the honeycomb filter according to the first aspect of the present invention may have an optional shape such as an elliptical column shape, a rectangular column shape and the like.
  • the sealing material layer is formed on only the circumference of the columnar body, and the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 0.5% or more.
  • the honeycomb filter according to the first aspect of the present invention contains comparatively large sealing material layer.
  • the above-mentioned rate S ⁇ is defined by (S2/S1) ⁇ 100 based upon the area S1 represented by ⁇ r 2 and the area S2 of the sealing material layer 14 on the above-mentioned end face.
  • the sealing material layer existing on the cross section including the through holes in the direction perpendicular to the through holes of the honeycomb filter becomes very thin, making it difficult for exhaust gases to flow into the sealing material layer.
  • the organic components are hardly discharged outside, with the result that the increase in the amount of organic components in the exhaust gases to be discharged outside upon using the honeycomb filter becomes smaller.
  • the rate S ⁇ of less than 0.5% the area of the sealing material layer becomes so small that the isostatic strength of the honeycomb filter (isotropic pressure breaking strength) becomes insufficient.
  • the rate V ⁇ of the organic components is set to 0.5% by weight or less.
  • the V ⁇ is defined as (V2/V1) ⁇ 100.
  • the rate V ⁇ exceeds 0.5% by weight
  • the organic components contained in the honeycomb filter becomes greater, and in the case where the honeycomb filter according to the first aspect of the present invention that contains comparatively large sealing material layer having the rate S ⁇ exceeding 0.5%, is used, there is a great increase in the amount of organic components in exhaust gases to be discharged outside.
  • the rate V ⁇ of the organic components to the honeycomb filter according to the first aspect of the present invention is desirably set to 0.1% by weight or less. This is because: in the case where a honeycomb filter according to the first aspect of the present invention having comparatively large sealing material layer is used, it becomes possible to further reduce the amount of organic components in exhaust gases to be discharged outside; furthermore, in the case where the honeycomb filter according to the first aspect of the present invention is allowed to support a catalyst which is capable of decomposing and eliminating the organic components in the exhaust gases, it is possible to prevent the deterioration of the sealing property of the sealing material layer, which occurs because of the fact that, upon applying the catalyst thereto, the organic components contained in the sealing material layer absorbs a slurry containing the catalyst to cause an abrupt expansion or the like in the sealing material layer during a heating treatment for fixing the catalyst; and also, it is possible to prevent the organic components contained in the sealing material layer from permeating into the catalyst to intervene the catalyst function, thus, it becomes possible to purify more exhaust gases.
  • the method for setting the rate V ⁇ of the organic components to 0.5% by weight or less to the honeycomb filter according to the first aspect of the present invention is not particularly limited, and examples thereof include a method in which the material, the blending ratio and the like for the sealing material layer forming the honeycomb filter according to the first aspect of the present invention, which will be described later, are adjusted, and a method in which, after forming a honeycomb structural body containing a large amount of organic components, the honeycomb structural body is heated so that the above-mentioned organic components are decomposed and eliminated.
  • the material forming the sealing material layer is not particularly limited, and examples thereof include materials such as an inorganic binder, an organic binder, inorganic fibers, inorganic particles and the like.
  • Examples of the inorganic binder may include silica sol, alumina sol and the like. Each of these may be used alone or two or more kinds of these may be used in combination. Among the inorganic binders, silica sol is more desirably used.
  • the lower limit of the content of the inorganic binder is desirably set to 1% by weight, more desirably 5% by weight on a solid component basis.
  • the upper limit of the content of the inorganic binder is desirably set to 30% by weight, more desirably 15% by weight, furthermore desirably 9% by weight on a solid component basis.
  • the content of the inorganic binder of less than 1% by weight tends to cause a reduction in the adhering strength, while the content exceeding 30% by weight tends to cause a reduction in the thermal conductivity.
  • organic binder examples include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl cellulose and the like. Each of these may be used alone or two or more kinds of these may be used in combination. Among the organic binders, carboxymethylcellulose is more desirably used.
  • the lower limit of the content of the organic binder is desirably set to 0.1% by weight, more desirably 0.2% by weight, furthermore desirably 0.4% by weight on a solid component basis.
  • the upper limit of the content of the organic binder is desirably set to 5.0% by weight, more desirably 1.0% by weight, furthermore desirably 0.6% by weight on a solid component basis.
  • the content of the organic binder of less than 0.1% by weight tends to cause a difficulty in suppressing migration of the sealing material layer, while the content exceeding 5.0% by weight tends to cause the rate V ⁇ of the organic components to a honeycomb filter to be manufactured to exceed 0.5% by weight, depending on the thickness of the sealing material layer, with the result that a heating process needs to be carried out as a post-process upon manufacturing the honeycomb filter.
  • the inorganic fibers may include ceramic fibers such as silica-alumina, mullite, alumina, silica and the like. Each of these may be used alone or two or more kinds of these may be used in combination. Among the inorganic fibers, silica-alumina fibers are more desirably used.
  • the lower limit of the content of the inorganic fibers is desirably set to 10% by weight, more desirably 20% by weight on a solid component basis.
  • the upper limit of the content of the inorganic fibers is desirably set to 70% by weight, more desirably 40% by weight, furthermore desirably 30% by weight on a solid component basis.
  • the content of the inorganic fibers of less than 10% by weight tends to cause a reduction in elasticity, while the content exceeding 70% by weight tends to cause a reduction in thermal conductivity and degradation in effects as an elastic member.
  • examples of the inorganic particles may include carbides, nitrides and the like, and specific examples may include inorganic powder or whiskers made of silicon carbide, silicon nitride and boron nitride. Each of these may be used alone, or two or more kinds of these may be used in combination.
  • silicon carbide having superior thermal conductivity is desirably used.
  • the lower limit of the content of the inorganic particles is desirably set to 3% by weight, more desirably 10% by weight, furthermore desirably 20% by weight on a solid component basis.
  • the upper limit of the content of the inorganic particles is desirably set to 80% by weight, more desirably 60% by weight, further more desirably 40% by weight on a solid component basis.
  • the content of the inorganic particles of less than 3% by weight tends to cause a reduction in thermal conductivity, while the content exceeding 80% by weight tends to cause a reduction in adhering strength when the sealing material layer is exposed to high temperatures.
  • the lower limit of the shot content of the inorganic fibers is desirably set to 1% by weight, and the upper limit thereof is desirably set to 10% by weight, more desirably 5% by weight, furthermore desirably 3% by weight.
  • the lower limit of the fiber length is desirably set to 1 mm, and the upper limit thereof is desirably set to 100 mm, more desirably 50 mm, furthermore desirably 20 mm.
  • the shot content of less than 1% by weight is difficult to be achieved in the manufacturing, and the shot content exceeding 10% by weight tends to damage the circumference of the column body.
  • the fiber length of less than 1 mm makes it difficult to form a honeycomb filter having elasticity, and in contrast, the shot content exceeding 100 mm tends to form fibers into a pill shape, resulting in degradation in dispersion of inorganic particles and the subsequent difficulty in making the thickness of the sealing material layer thinner.
  • the lower limit of the particle size of the inorganic particles is desirably set to 0.01 ⁇ m, more desirably 0.1 ⁇ m.
  • the upper limit of the particle size of the inorganic particles is desirably set to 100 ⁇ m, more desirably 15 ⁇ m, furthermore desirably 10 ⁇ m.
  • the diameter of inorganic particles of less than 0.01 ⁇ m tends to cause high costs, and in contrast, the diameter of inorganic particles exceeding 100 ⁇ m tends to cause degradation in adhering strength and thermal conductivity.
  • the organic components contained in the honeycomb filter according to the first aspect of the present invention specifically correspond to the organic binder, and the rate V ⁇ of the organic binder to the honeycomb filter according to the first aspect of the present invention is set to 0.5% by weight or less.
  • the organic components are easily decomposed into CO 2 and H 2 O when heated in an atmosphere containing sufficient oxygen, and hardly cause toxic gases.
  • the honeycomb filter for purifying exhaust gases is installed at a portion exposed to exhaust gases that contain little oxygen and are discharged from an engine, the organic components are not completely decomposed, and tend to be discharged as hydrocarbons such as methane, ethane, ethylene, propylene and the like and toxic gases such as CO, NO x and the like, resulting in serious problems.
  • the honeycomb filter according to the first aspect of the present invention even though the honeycomb filter includes comparatively large sealing material layer, since the amount of organic components contained therein is extremely small so that, upon actually using the honeycomb filter according to the first aspect of the present invention, there is hardly any increase in the amount of hydrocarbons and toxic gases such as CO, NO x and the like contained in exhaust gases to be discharged outside, making it possible to eliminate problems caused by the organic components contained in the honeycomb filter.
  • the material for the columnar body made of porous ceramics is not particularly limited, and examples thereof may include nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, titanium nitride and the like, carbide ceramics such as silicon carbide, zirconium carbide, titanium carbide, tantalum carbide, tungsten carbide and the like, and oxide ceramics such as alumina, zirconia, cordierite, mullite and the like. Normally, oxide carbide such as cordierite and the like is used. This is because: this material allows low manufacturing costs, has a comparatively small thermal expansion coefficient, and is less susceptible to oxidation in use.
  • silicon-containing ceramics in which metallic silicon is blended in the above-mentioned ceramics and ceramics that are combined by silicon and a silicate compound may be used.
  • the average pore diameter of the honeycomb filter according to the first aspect of the present invention is desirably set in a range from 5 to 100 ⁇ m.
  • the average pore diameter of less than 5 ⁇ m tends to cause clogging of particulates easily.
  • the average pore diameter exceeding 100 ⁇ m tends to cause particulates to pass through the pores, with the result that the particulates cannot be collected, making the honeycomb filter unable to function as a filter.
  • the above-mentioned pore diameter of the porous ceramic member can be measured through known methods such as a mercury press-in method, a measuring method using a scanning electronic microscope (SEM), and the like.
  • the porosity of the honeycomb filter according to the first aspect of the present invention is desirably set in a range from 40 to 80%.
  • the porosity is less than 40%, the honeycomb filter is more susceptible to clogging, while the porosity exceeding 80% causes degradation in the strength of the columnar body, with the result that it might be easily broken.
  • the above-mentioned porosity can be measured through known methods such as a mercury press-in method, Archimedes method, a measuring method using a scanning electronic microscope (SEM), and the like.
  • the particle size of ceramic particles to be used upon manufacturing the columnar body although not particularly limited, those which are less susceptible to shrinkage in the succeeding sintering process are desirably used, and for example, those particles, prepared by combining 100 parts by weight of powder having an average particle size from 0.3 to 50 ⁇ m with 5 to 65 parts by weight of powder having an average particle size from 0.1 to 1.0 ⁇ m, are desirably used.
  • those particles, prepared by combining 100 parts by weight of powder having an average particle size from 0.3 to 50 ⁇ m with 5 to 65 parts by weight of powder having an average particle size from 0.1 to 1.0 ⁇ m are desirably used.
  • the honeycomb filter according to the first aspect of the present invention desirably, a catalyst for purifying exhaust gases is supported inside the columnar body.
  • the honeycomb filter according to the first aspect of the present invention can function as a filter capable of collecting particulates in exhaust gases and, also, function as a catalyst converter capable of purifying toxic components such as HC, CO, NO x and the like as well as HC and the like generated by organic components slightly contained in the honeycomb filter according to the first aspect of the present invention.
  • the catalyst to be supported on the honeycomb filter of the present invention is not particularly limited, and examples thereof may include noble metals such as platinum, palladium, rhodium and the like. Each of these noble metals may be used alone, or a plurality of these may be used in combination.
  • the catalyst for purifying exhaust gases made of the above-mentioned noble metal forms a so-called oxidizing catalyst; however, with respect to the catalyst for purifying exhaust gases, not particularly limited to the noble metals, any optional material such as rare-earth metal, alkali metal, alkali earth metal and the like may be used, as long as it can purify toxic components such as CO, HC, NO x and the like in exhaust gases.
  • the toxic components such as CO, HC, NO x and the like contained in exhaust gases are purified into CO 2 , H 2 O, N 2 and the like, and discharged outside.
  • the honeycomb filter according to the first aspect of the present invention has a rate S ⁇ of 0.5% or more of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes, that is, comparatively large sealing material layer included therein; however, the rate V ⁇ of organic components contained therein is set to 0.5% by weight or less that is a very low level so that, even when the honeycomb filter according to the first aspect of the present invention is installed in an exhaust passage of an internal combustion system such as an engine, and used, there is hardly any increase in the organic components in exhaust gases to be discharged.
  • a catalyst for purifying exhaust gases may be supported on a columnar body of the honeycomb filter according to the first aspect of the present invention so that it is allowed to function as a filter for collecting particulates in exhaust gases, and also to function as a catalyst converter; thus, even in the case where organic components, slightly contained in the honeycomb filter according to the first aspect of the present invention, are discharged outside, these organic components are positively decomposed and purified by the catalyst for purifying exhaust gases.
  • a honeycomb filter for purifying exhaust gases according to the second aspect of the present invention has a structure in which:
  • a honeycomb filter having almost the same shape as that of the honeycomb filter 20 shown in FIG. 2 is proposed, and a plurality of porous ceramic members are combined with one another through sealing material layers to form a ceramic block, and a sealing material layer is also formed on a circumference of the ceramic block.
  • each of the porous ceramic members has a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with partition wall interposed therebetween so that the partition wall that separates the through holes from each other functions as filters.
  • each of the through holes formed in the porous ceramic member has either of its ends on the inlet side and outlet side of exhaust gases sealed with a plug; thus, exhaust gases that have entered one of the through holes are allowed to discharge from another through hole after always passing through the partition wall that separates the corresponding through holes.
  • the sealing material layer which is formed on the circumference of the ceramic block, is provided so as to prevent exhaust gases from leaking from the circumference portion of the ceramic block, when the honeycomb filter according to the second aspect of the present invention is installed in an exhaust passage of an internal combustion system.
  • the honeycomb filter according to the second aspect of the present invention may have an optional shape such as an elliptical column shape, a rectangular column shape or the like.
  • the sealing material layer is formed between porous ceramic members as well as on the circumference of the ceramic block, and the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 2% or more.
  • the honeycomb filter according to the second aspect of the present invention contains comparatively large sealing material layer.
  • the above-mentioned rate S ⁇ is defined by (S′2/S′1) ⁇ 100 based upon an area S′1 represented by ⁇ r′ 2 and the area S′2 of the sealing material layer 23 and the sealing material layer 24 on the above-mentioned end face.
  • the sealing material layer existing on the cross-section including the through holes in the direction perpendicular to the through holes of the honeycomb filter becomes very thin, making it difficult for exhaust gases to flow into the sealing material layer. For this reason, even in the case where a large amount of organic components, that is, the rate V ⁇ exceeding 0.5% by weight of the organic components to the honeycomb filter, is contained, the organic components are hardly discharged outside, with the result that the increase in the organic component amount in the exhaust gases to be discharged outside upon using the honeycomb filter becomes smaller.
  • the rate S ⁇ is less than 2%, the area of the sealing material layer becomes so small that the isostatic strength of the honeycomb filter (isotropic pressure breaking strength) becomes insufficient.
  • the rate V ⁇ of organic components to the honeycomb filter according to the second aspect of the present invention is set to 0.5% by weight or less.
  • the above-mentioned rate V ⁇ is defined as (V′2/V′1) ⁇ 100, supposing that the total weight of the honeycomb filter according to the second aspect of the present invention is V′ 1 , and that the total weight of the organic components contained in the honeycomb filter is V′2.
  • the organic components contained in the honeycomb filter becomes greater, and in the case where the honeycomb filter according to the second aspect of the present invention that contains comparatively large sealing material layer with the above-mentioned rate S ⁇ exceeding 2%, is used, there is a great increase in the amount of organic components in exhaust gases to be discharged outside.
  • the rate V ⁇ of the organic components to the honeycomb filter according to the second aspect of the present invention is desirably set to 0.1% by weight or less. This is because: in the case where a honeycomb filter according to the second aspect of the present invention having comparatively large sealing material layer is used, it becomes possible to further reduce the amount of organic components in exhaust gases to be discharged outside; furthermore, in the case where the honeycomb filter according to the first aspect of the present invention is allowed to support a catalyst capable of decomposing and eliminating the organic components in the exhaust gases, it is possible to prevent the deterioration of the sealing property of the sealing material layer, which occurs because of the fact that, upon applying the catalyst thereto, the organic components contained in the sealing material layer absorbs a slurry containing the catalyst to cause an abrupt expansion or the like in the sealing material layer during a heating treatment for fixing the catalyst; it is possible to prevent the organic components contained in the sealing material layer from permeating into the catalyst to intervene the catalyst function, thus, it becomes possible to purify more exhaust gases.
  • the method for setting the rate V ⁇ of the organic components to 0.5% by weight or less to the honeycomb filter of the present invention is not particularly limited, and examples thereof include a method in which the material, the blending ratio and the like for the sealing material layer forming the honeycomb filter according to the second aspect of the present invention, which will be described later, are adjusted, and a method in which, after forming a honeycomb structural body containing a large amount of organic components, the honeycomb structural body is heated so that the above-mentioned organic components are decomposed and eliminated.
  • the material forming the sealing material layer is not particularly limited, and examples thereof may include materials such as an inorganic binder, an organic binder, inorganic fibers, inorganic particles and the like, which are the same materials as those described in the honeycomb filter according to the first aspect of the present invention.
  • the organic components contained in the honeycomb filter according to the second aspect of the present invention specifically correspond to the above-mentioned organic binder, and the rate V ⁇ of the organic binder to the honeycomb filter according to the second aspect of the present invention is set to 0.5% by weight or less.
  • the honeycomb filter according to the second aspect of the present invention even in the case where the honeycomb filter includes comparatively large sealing material layer, since the amount of organic components contained therein is extremely small so that, upon actually using the honeycomb filter according to the first aspect of the present invention, there is hardly any increase in the amount of hydrocarbons and toxic gases such as CO, NO x and the like contained in exhaust gases to be discharged outside, making it possible to eliminate problems caused by the organic components contained in the honeycomb filter.
  • the material for the porous ceramic member is not particularly limited, and examples thereof may include nitride ceramics, carbide ceramics and oxide ceramics that are the same materials as the columnar body described in the honeycomb filter according to the first aspect of the present invention.
  • silicon carbide which has high heat resistance, superior mechanical properties and high thermal conductivity, is desirably used.
  • silicon-containing ceramics in which metallic silicon is blended in the above-mentioned ceramics and ceramics that are combined by silicon and a silicate compound may be used.
  • the average pore diameter and the porosity of the porous ceramic member according to the second aspect of the present invention are not particularly limited, and the same average pore diameter and porosity as the honeycomb filter according to the first aspect of the present invention are desirably used, and with respect to the particle size of ceramics to be used upon manufacturing such a porous ceramic member, not particularly limited, the same particle size as the above-mentioned honeycomb filter according to the first aspect of the present invention is desirably used.
  • a catalyst for purifying exhaust gases is desirably supported on the porous ceramic member of the honeycomb filter according to the second aspect of the present invention in the same manner as the honeycomb filter according to the first aspect of the present invention.
  • the honeycomb filter according to the second aspect of the present invention has a rate S ⁇ of 2% or more of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes, that is, comparatively large sealing material layer included therein; however, the rate V ⁇ of organic components contained therein is set to 0.5% by weight or less that is a very low level so that, even when the honeycomb filter according to the second aspect of the present invention is placed in an exhaust passage of an internal combustion system such as an engine, and used, there is hardly any increase in the organic components in exhaust gases to be discharged.
  • a catalyst for purifying exhaust gases may be supported on a columnar body of the honeycomb filter according to the second aspect of the present invention so that it is allowed to function as a filter for collecting particulates in exhaust gases, and also to function as a catalyst converter; thus, even in the case where organic components, slightly contained in the honeycomb filter according to the second aspect of the present invention, are discharged outside, these organic components are positively decomposed and purified by the catalyst for purifying exhaust gases.
  • a binder and a dispersant solution are added to the above-mentioned ceramics powder to prepare a material paste.
  • the binder is not particularly limited, and examples thereof may include methylcellulose, carboxy methylcellulose, hydroxy ethylcellulose, polyethylene glycol, phenolic resin and epoxy resin.
  • the blended amount of the above-mentioned binder is desirably set to 1 to 10 parts by weight with respect to 100 parts by weight of ceramic powder.
  • the dispersant solution is not particularly limited, and examples thereof may include an organic solvent such as benzene; alcohol such as methanol; and water.
  • These ceramic powder, binder and dispersant solution are mixed by an attritor or the like, and sufficiently kneaded by a kneader or the like, and then formed into a columnar ceramic formed body having almost the same shape as the columnar body 15 shown in FIG. 1 by using an extrusion-molding method or the like.
  • a molding auxiliary may be added to the above-mentioned material paste, if necessary.
  • the molding auxiliary is not particularly limited, and examples thereof may include ethylene glycol, dextrin, fatty acid soap, polyalcohol and the like.
  • a mouth-sealing process which injects a sealant material (plug) to predetermined through holes, is carried out and this is again subjected to a drying process using a microwave drier or the like.
  • the sealant material (plug) is not particularly limited, and examples thereof may include the same material as the above-mentioned material paste.
  • the formed body that has been subjected to the mouth-sealing process is subjected to degreasing and sintering processes under predetermined conditions so that a columnar body 15 made of porous ceramics is produced.
  • the columnar body 15 is rotated around an axis on which it is supported in the length direction.
  • the rotational speed of the columnar body 15 is desirably set to 2 to 10 min ⁇ 1 .
  • sealing material paste is allowed to adhere to the circumference of the rotating columnar body 15 to form a sealing material paste layer.
  • the sealing material paste is not particularly limited, and examples thereof may include the above-mentioned paste containing materials such as an inorganic binder, an organic binder, inorganic fibers, inorganic particles and the like.
  • the above-mentioned sealing material paste may contain a slight amount of moisture, a solvent and the like; however, most of these moisture, solvent and the like are normally scattered during a heating process and the like that follow the applying process of the sealing material paste.
  • the sealing material paste may contain about 35 to 65% by weight of moisture and other solvents such as acetone, alcohol and the like with respect to the total weight in addition to the above-mentioned inorganic fibers, inorganic binder, organic binder and inorganic particles, in order to soften the sealing material paste and allow it to have proper fluidity so as to be easily applied, and the viscosity of the sealing material paste is desirably set to 15 to 25 Pa ⁇ s (10,000 to 20,000 cps (cP)).
  • the honeycomb filter according to the first aspect of the present invention has a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 0.5% or more.
  • the thickness of the sealing material paste layer needs to be adjusted in this sealing material layer forming process so that the rate S ⁇ is set to 0.5% or more after the honeycomb filter has been manufactured.
  • the organic components contained in the honeycomb filter according to the first aspect of the present invention specifically correspond to the organic binder contained in the sealing material paste.
  • the materials constituting the sealing material paste, blended ratio thereof and the like are desirably adjusted so that the rate V ⁇ of organic components contained in the finished honeycomb filter is set to 0.5% by weight or less.
  • the organic components contained in the sealing material layer are decomposed and removed so that a honeycomb filter in which the rate V ⁇ of organic components contained therein is set to 0.5% by weight or less may be formed.
  • the sealing material paste layer, thus formed is dried at a temperature of about 120° C. so that the moisture is evaporated to form a sealing material layer 14 ; thus, as shown in FIG. 1 , the manufacturing process of the honeycomb filter 10 according to the first aspect of the present invention in which the sealing material layer 14 is formed on the circumference of the columnar body 15 is completed.
  • a ceramic laminated body to become a ceramic block 25 is produced.
  • the ceramic laminated body has a columnar structure in that a plurality of rectangular columnar porous ceramic members 30 having a number of through holes 31 placed in parallel with one another in the length direction with partition wall 33 interposed therebetween are combined with one another through sealing material layers 23 .
  • a mixed composition is prepared by adding a binder and a dispersant solution to the aforementioned ceramic powder.
  • the method for preparing the above-mentioned mixed composition is not particularly limited, and the same method as that of the material paste as described in the manufacturing method for the honeycomb filter according to the first aspect of the present invention may be used.
  • the above-mentioned mixed composition is mixed by an attritor or the like, and sufficiently kneaded by a kneader or the like and then formed into a columnar ceramic raw formed body having almost the same shape as the porous ceramic member 30 shown in FIG. 3 by using an extrusion-molding method or the like.
  • a mouth-sealing process which injects a sealant material (plug) to predetermined through holes, is carried out, and this is again subjected to a drying process using a microwave drier or the like.
  • the above-mentioned sealant material (plug) is not particularly limited and, for example, the same material as the above-mentioned mixed composition may be used.
  • the raw formed body that has been subjected to the mouth-sealing process is subjected to a degreasing process by heating it to a temperature of 400 to 650° C. in an oxygen-containing atmosphere; thus, the binder and the like are vaporized, decomposed and eliminated so that almost only the ceramic powder is allowed to remain.
  • the formed body that has been degreased is sintered by heating it at about 1400 to 2200° C. in an inert gas atmosphere such as nitrogen, argon and the like so that the ceramics powder is sintered to produce a porous ceramic member 30 .
  • porous ceramic members 30 are placed on a base 40 the upper portion of which is designed to have a V-shape in its cross-section so as to allow the porous ceramic members 30 to be stacked thereon in a tilted manner, and sealing material paste to form a sealing material layer 23 is then applied onto two side faces 30 a and 30 b facing upward with an even thickness to form a paste layer 41 ; thereafter, a laminating process for forming another porous ceramic member 30 on this paste layer is successively repeated so that a columnar ceramic laminated body having a predetermined size is manufactured.
  • a triangular columnar porous ceramic member 30 c which is formed by cutting a quadrangular columnar porous ceramic member into two, is bonded to a resin member 42 having the same shape as the triangular columnar porous ceramic member 30 c by using a both-sides tape with easy peelability to prepare a corner member, and these corner members are used for the four corners of the ceramic laminated body, and after the lamination processes of the porous ceramic members 30 , all the resin members 42 forming the four corners of the ceramic laminated body are removed; thus, a ceramic laminated body having a polygonal column-shape in its cross section may be formed. With this arrangement, it is possible to reduce the quantity of a waste corresponding to porous ceramic members to be disposed of, after the formation of the ceramic block by cutting the circumference portion of the ceramic laminated body.
  • a method for manufacturing the ceramic laminated body having a polygonal column-shape in its cross section except for the method shown in FIG. 4 for example, a method in which the porous ceramic members to be located on four corners are omitted and a method in which porous ceramic members having a triangular column shape are combined with one another may be used in accordance with the shape of a honeycomb filter to be manufactured.
  • a quadrangular columnar ceramic member may of course be manufactured.
  • this ceramic laminated body is heated in a temperature range from 50 to 100° C. for about 1 hour so that the paste layer is dried and solidified to form a sealing material layer 23 ; thereafter, by cutting the circumference portion thereof by using a diamond cutter or the like into a shape as shown in FIG. 2 so that a ceramic block 25 is formed.
  • the material for preparing the sealing material paste to form the sealing material layer 23 not particularly limited, for example, the same material as the sealing material paste described in the manufacturing method of the honeycomb filter according to the first aspect of the present invention may be used.
  • a sealing material layer forming process for forming a sealing material layer 24 on the circumference of the columnar body 25 thus manufactured is carried out so that the manufacturing method for a honeycomb filter 20 according to the second aspect of the present invention with the sealing material layer 24 formed on the circumference of the ceramic block 25 is completed.
  • sealing material layer forming process not particularly limited, for example, the same sealing material layer forming process as described in the manufacturing method of the honeycomb filter according to the first aspect of the present invention may be used.
  • the honeycomb filter according to the second aspect of the present invention has a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 2% or more.
  • the thickness of the sealing material paste layer needs to be adjusted so that the above-mentioned rate S ⁇ is set to 2% or more after the honeycomb filter has been manufactured.
  • the organic components contained in the honeycomb filter according to the second aspect of the present invention specifically corresponds to the organic binder contained in the sealing material paste.
  • the materials constituting the sealing material paste, blended ratio thereof and the like are desirably adjusted so that the rate V ⁇ of organic components contained in the finished honeycomb filter is set to 0.5% by weight or less.
  • the organic components contained in the sealing material layer are decomposed and removed so that a honeycomb filter in which the rate V ⁇ of organic components is set to 0.5% by weight or less may be formed.
  • a catalyst for purifying exhaust gases may be supported on the honeycomb filter of the present invention thus manufactured.
  • the honeycomb filter of the present invention on which such a catalyst for purifying exhaust gases has been supported is allowed to function as a filter capable of collecting particulates in exhaust gases, and also to function as a catalyst converter capable of purifying toxic components such as HC, CO, NO x and the like as well as gases generated by organic components slightly contained in the honeycomb filter according to the first aspect of the present invention.
  • Talc having an average particle size of 10 ⁇ m (40 parts by weight), kaolin having an average particle size of 9 ⁇ m (10 parts by weight), alumina having an average particle size of 9.5 ⁇ m (17 parts by weight), aluminum hydroxide having an average particle size of 5 ⁇ m (16 parts by weight), silica having an average particle size of 10 ⁇ m (15 parts by weight) and a molding auxiliary (ethylene glycol) (6 parts by weight) were added to 16 parts by weight of water, and mixed and kneaded to prepare a material paste.
  • the above-mentioned material paste was loaded into an extruder, and extruded at an extrusion rate of 10 cm/min so that a ceramic formed body having almost the same shape as the honeycomb filter 10 shown in FIG. 1 was formed, and the ceramic formed body was dried by a microwave drier, and predetermined through holes were then filled with a paste having the same composition as the material paste, and after this had been again dried by using a drier, this was degreased at 400° C., and sintered at 1400° C. in a normal-pressure argon atmosphere for 3 hours so that a columnar body comprising a cylinder shape, made of cordierite, was manufactured, as shown in FIG. 1 .
  • a heat resistant sealing material paste which was composed of 30% by weight of alumina fibers having a fiber length of 0.2 mm, 21% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 15% by weight of silica sol, 5.6% by weight of carboxymethyl cellulose and 28.4% by weight of water, was used to form a sealing material paste layer on the circumference of the columnar body.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • a sealing material paste layer was formed on the circumference of the columnar body by using the same sealing material paste as the sealing material paste used in (2) of Example 1.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.4%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • honeycomb filters manufactured in Examples 1 to 4 and Comparative Example 1 were installed in an exhaust passage of an engine, and the engine was driven at the highest number of revolutions (3700 rpm, 0 Nm) in an unloaded condition.
  • An alumina layer was applied to each of the honeycomb filters manufactured in Examples 1 to 4 and Comparative Example 1 at a rate of 10 g/L so as to form a backing on which a catalyst was supported, and platinum was supported thereon at a rate of 2 g/L as a catalyst for purifying exhaust gases; thereafter, this was installed in an exhaust passage of an engine, and the engine was driven at the highest number of revolutions (3700 rpm, 0 Nm) in an unloaded condition.
  • FIG. 5 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 1 to 4 and Comparative Example 1.
  • TABLE 1 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2
  • Example 1 1.4 0.05 8 1
  • Example 2 1.4 0.10 10
  • Example 3 1.4 0.20 12
  • Example 4 1.4 0.50 15 10 Comparative 1.4 0.60 40 35
  • Example 2 The same processes as (2) of Example 1 were carried out except that a heat resistant sealing material paste, which was composed of 27% by weight of alumina fibers having a fiber length of 0.2 mm, 19% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 14% by weight of silica sol, 13.2% by weight of carboxymethyl cellulose and 26.8% by weight of water, was used so that a sealing material layer having a thickness of 0.2 mm was formed on the circumference of the columnar body; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 27% by weight of alumina fibers having a fiber length of 0.2 mm, 19% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 14% by weight of silica sol, 13.2% by weight of carboxymethyl cellulose and 26.8% by weight of water, was used so that a sealing material layer having a thickness of 0.2 mm was formed on the circumference of the columnar body; thus
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%, with the rate V ⁇ of organic components being set to 0.05% by weight was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%, with the rate V ⁇ of organic components being set to 0.10% by weight was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%, with the rate V ⁇ of organic components being set to 0.20% by weight was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%, with the rate V ⁇ of organic components being set to 0.50% by weight was manufactured.
  • a sealing material paste layer was formed on the circumference of the columnar body by using the same sealing material paste as the sealing material paste used in (2) of Example 5.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.6%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 6 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 5 to 8 and Comparative Example 2. TABLE 2 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2
  • Example 5 0.6 0.05 6 1
  • Example 6 0.6 0.10 8 1.5
  • Example 7 0.6 0.20 10 6
  • Example 8 0.6 0.50 13 8 Comparative 0.6 0.60 30 25
  • Example 2 The same processes as (2) of Example 1 were carried out except that a heat resistant sealing material paste, which was composed of 26% by weight of alumina fibers having a fiber length of 0.2 mm, 19% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 14% by weight of silica sol, 15.8% by weight of carboxymethyl cellulose and 25.2% by weight of water, was used so that a sealing material layer having a thickness of 0.17 mm was formed on the circumference of the columnar body; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 26% by weight of alumina fibers having a fiber length of 0.2 mm, 19% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 14% by weight of silica sol, 15.8% by weight of carboxymethyl cellulose and 25.2% by weight of water, was used so that a sealing material layer having a thickness of 0.17 mm was formed on the circumference of the columnar body; thus
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • a sealing material paste layer was formed on the circumference of the columnar body by using the same sealing material paste as the sealing material paste used in (2) of Example 9.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.5%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 7 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 9 to 12 and Comparative Example 3. TABLE 3 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2
  • Example 9 0.5 0.05 4 0.5
  • Example 10 0.5 0.10 6 1
  • Example 11 0.5 0.20 8 6
  • Example 12 0.5 0.50 10 8 Comparative 0.5 0.60 25 20
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate sa of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • a sealing material paste layer was formed on the circumference of the columnar body by using the same sealing material paste as the sealing material paste used in (2) of Comparative Example 4.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.3%, and the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 8 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Comparative Examples 4 to 8. TABLE 4 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2 Comparative 0.3 0.05 0.8 0 Example 4 Comparative 0.3 0.10 1 0 Example 5 Comparative 0.3 0.20 3 1 Example 6 Comparative 0.3 0.50 5 3 Example 7 Comparative 0.3 0.60 8 5 Example 8
  • the increasing rate of HC of the honeycomb filters according to Comparative Examples 4 to 8 was in a range of 0.8 to 8% that was a very low level, and based upon the results of the evaluation test 2, the increasing rate of HC of the honeycomb filter according to Comparative Examples 4 to 8 with a catalyst supported thereon was in a range of 0 to 5% that was also a very low level.
  • each of the honeycomb filters according to Examples 1 to 12 and Comparative Examples 1 to 8 has a structure in that a sealing material layer is formed only on the circumference of a columnar body, and in each of the honeycomb filters according to Examples 1 to 12 and Comparative Examples 1 to 3, the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is 0.5% or more.
  • the results of the evaluation test 1 indicate that, in the honeycomb filters according to Examples 1 to 12 in which the rate V ⁇ of organic components is 0.50% by weight or less, the amount of organic components to be discharged from the sealing material layer becomes smaller to cause hardly any increase in HC in discharged exhaust gases, and the results of the evaluation test 2 indicate that, when a catalyst is supported on the honeycomb filter of this type, it becomes possible to significantly decrease the increasing rate of HC to be discharged outside.
  • the results of the evaluation test 1 of the honeycomb filters according to Comparative Examples 4 to 8 indicate that, in the case where the rate S ⁇ of the area occupied by the sealing material layers to the total area of across-section including the through holes in the direction perpendicular to the through holes in the honeycomb filter is less than 0.5%, the amount of organic components to be discharged from the sealing material layer becomes smaller, even in the case of the rate V ⁇ of organic components exceeding 0.50% by weight, resulting in hardly any increase in HC in the discharged exhaust gases.
  • the honeycomb filter in which the rate S ⁇ is less than 0.5%, even when the rate of organic components contained in the sealing material layer becomes greater, the honeycomb filter is less likely to generate a problem, such as an increase in the amount of HC in exhaust gases to be discharged, as shown in Comparative Examples 1 to 3.
  • the results of the evaluation test 2 indicate that by allowing the honeycomb filter of this type to support a catalyst, it becomes possible to significantly decrease the increasing rate of HC to be discharged outside.
  • the above-mentioned raw formed body was dried by using a microwave drier, and predetermined through holes were then filled with a paste having the same composition as the raw formed body, and after this had been again dried by using a drier, this was degreased at 400° C., and sintered at 2200° C. in a normal-pressure argon atmosphere for 3 hours to manufacture a porous ceramic member as shown in FIG. 3 , which was made of a silicon carbide sintered body, and had a size of 34 mm ⁇ 34 mm ⁇ 300 mm, the number of through holes of 31 pcs/cm 2 and a thickness of the partition wall of 0.3 mm.
  • a heat resistant sealing material paste which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 1% by weight of carboxymethyl cellulose and 30% by weight of water, was used so that, by carrying out the processes as described by reference to FIG. 4 , a number of the porous ceramic members were combined with one another, and then cut by using a diamond cutter; thus, a cylinder-shaped ceramic block as shown in FIG. 2 was manufactured.
  • a sealing material paste layer was formed on the circumference of the ceramic block by using the above-mentioned sealing material paste. Further, this sealing material paste layer was dried at 120° C. so that a cylinder-shaped honeycomb structural body having a diameter of 145.8 mm, with sealing material layers, each having a thickness of 1.0 mm, formed between the porous ceramic members as well as on the circumference of the ceramic block, as indicated by a honeycomb filter 20 of FIG. 2 , was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.50% by weight was manufactured.
  • Example 13 The same processes as (1) of Example 13 were carried out to produce a porous ceramic member.
  • a sealing material paste layer was formed on the circumference of the ceramic block by using the above-mentioned sealing material paste. Then, by drying this sealing material paste layer at 120° C., a cylinder-shaped honeycomb filter having a diameter of 145.8 mm with a thickness of sealing material layers formed between porous ceramic members as well as on the circumference of the ceramic block being set to 1.0 mm, was manufactured, as indicated by the honeycomb filter 20 in FIG. 2 .
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 9 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 13 to 16 and Comparative Example 9. TABLE 5 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2 Example 13 7.4 0.05 8 1 Example 14 7.4 0.10 10 2 Example 15 7.4 0.20 12 8 Example 16 7.4 0.50 15 10 Comparative 7.4 0.60 40 35 Example 9
  • the increasing rate of HC in the honeycomb filters according to Examples 13 to 16 was in a range of 8 to 15% that was a very low level; however, the increasing rate of HC in the honeycomb filter according to Comparative Example 9 was 40% that was excessively greater than the increasing rate of HC in the honeycomb filters according to Examples 13 to 16.
  • the increasing rate of HC in the honeycomb filters according to Examples 13 to 16 was in a range of 1 to 10% that was a very low level; however, the increasing rate of HC in the honeycomb filter, with a catalyst supported thereon, according to Comparative Example 9 was 35% that was excessively greater than the increasing rate of HC in the honeycomb filters according to Examples 13 to 16.
  • Example 13 The same processes as (1) of Example 13 were carried out to produce a porous ceramic member.
  • Example 13 The same processes as (2) of Example 13 were carried out except that a heat resistant sealing material paste, which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 2% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.5 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 2% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.5 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes' was 3.8%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 17 The same processes as (1) of Example 17 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 4.0%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 10 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 17 to 20 and Comparative Example 10. TABLE 6 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2 Example 17 3.8 0.05 6 1 Example 18 3.8 0.10 8 1.5 Example 19 3.8 0.20 10 6 Example 20 3.8 0.50 13 8 Comparative 3.8 0.60 30 25 Example 10
  • the results of the evaluation test 1 show that the increasing rate of HC in the honeycomb filters according to Examples 17 to 20 was in a range of 6 to 13%, which was a very low level; however, the increasing rate of HC in the honeycomb filter according to Comparative Example 10 was 30%, which was much greater than the increasing rate of HC of the honeycomb filters according to Examples 17 to 20.
  • the results of the evaluation test 2 show that the increasing rate of HC in the honeycomb filters with a catalyst supported thereon according to Examples 17 to 20 was in a range of 1 to 8%, which was a very low level; however, the increasing rate of HC in the honeycomb filter with a catalyst supported thereon according to Comparative Example 10 was 25%, which was much greater than the increasing rate of HC of the honeycomb filters according to Examples 17 to 20.
  • Example 13 The same processes as (1) of Example 13 were carried out to produce a porous ceramic member.
  • Example 13 The same processes as (2) of Example 13 were carried out except that a heat resistant sealing material paste, which was composed of 30% by weight of alumina fibers having a fiber length of 0.2 mm, 21% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 4% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.25 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 30% by weight of alumina fibers having a fiber length of 0.2 mm, 21% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 4% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.25 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 2.0%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 21 The same processes as (1) of Example 21 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 2.0%, and the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 11 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Examples 21 to 24 and Comparative Example 11. TABLE 7 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2
  • Example 21 1.9 0.05 4 0.5
  • Example 22 1.9 0.10 6 1
  • Example 23 1.9 0.20 8 6
  • Example 24 1.9 0.50 10 8 Comparative 1.9 0.60 25 20
  • the results of the evaluation test 1 show that the increasing rate of HC in the honeycomb filters according to Examples 21 to 24 was in a range of 4 to 10%, which was a very low level; however, the increasing rate of HC in the honeycomb filter according to Comparative Example 11 was 25%, which was much greater than the increasing rate of HC of the honeycomb filters according to Examples 21 to 24.
  • the results of the evaluation test 2 show that the increasing rate of HC in the honeycomb filters with a catalyst supported thereon according to Examples 21 to 24 was in a range of 0.5 to 8%, which was a very low level; however, the increasing rate of HC in the honeycomb filter with a catalyst supported thereon according to Comparative Example 11 was 20%, which was much greater than the increasing rate of HC of the honeycomb filters according to Examples 21 to 24.
  • Example 13 The same processes as (1) of Example 13 were carried out to produce a porous ceramic member.
  • Example 13 The same processes as (2) of Example 13 were carried out except that a heat resistant sealing material paste, which was composed of 28% by weight of alumina fibers having a fiber length of 0.2 mm, 20% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 15% by weight of silica sol, 10% by weight of carboxymethyl cellulose and 27% by weight of water, was used so that a sealing material layer having a thickness of 0.1 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 28% by weight of alumina fibers having a fiber length of 0.2 mm, 20% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 15% by weight of silica sol, 10% by weight of carboxymethyl cellulose and 27% by weight of water, was used so that a sealing material layer having a thickness of 0.1 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 13 The same processes as (1) of Example 13 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • FIG. 12 is a graph that shows the results of the evaluation test 1 and the evaluation test 2 of honeycomb filters according to Comparative Examples 12 to 16. TABLE 8 Increasing rate of HC (%) S ⁇ V ⁇ Evaluation Evaluation (%) (% by weight) test 1 test 2 Comparative 0.8 0.05 0.8 0 Example 12 Comparative 0.8 0.10 1 0 Example 13 Comparative 0.8 0.20 3 1 Example 14 Comparative 0.8 0.50 5 3 Example 15 Comparative 0.8 0.60 8 5 Example 16
  • the results of the evaluation test 1 show that the increasing rate of HC in the honeycomb filters according to Comparative Examples 12 to 16 was in a range of 0.8 to 8%, which was a very low level
  • the results of the evaluation test 2 show that the increasing rate of HC in the honeycomb filters with a catalyst supported thereon according to Comparative Examples 12 to 16 was in a range of 0 to 5%, which was also a very low level.
  • the honeycomb filters according to Examples 13 to 24 and Comparative Examples 9 to 16 have a structure in that sealing material layers are formed between the porous ceramic members as well as on the circumference of the ceramic block, and in each of the honeycomb filters according to Examples 13 to 24 and Comparative Examples 9 to 11, the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 2% or more.
  • the results of the evaluation test 1 show that in the case of honeycomb filters according to Examples 13 to 24 that have the rate V ⁇ of organic components being 0.50% by weight or less, the amount of organic components to be discharged from the sealing material layer becomes smaller to cause hardly any increase in HC in the discharged exhaust gases, and the results of the evaluation test 2 show that, when a catalyst is supported on such a honeycomb filter, it becomes possible to effectively reduce the increasing rate of HC to be discharged outside.
  • the results of the evaluation test 1 of the honeycomb filters according to Comparative Examples 12 to 16 indicate that, in the case where the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes in the honeycomb filter is less than 2%, the amount of organic components to be discharged from the sealing material layer becomes smaller, even in the case of the rate V ⁇ of organic components exceeding 0.5% by weight, resulting in hardly any increase in HC in the discharged exhaust gases.
  • the honeycomb filter in which the rate S ⁇ is less than 2%, even when the rate of organic components contained in the sealing material layer becomes greater, the honeycomb filter is less likely to generate a problem, such as an increase in the amount of HC in exhaust gases to be discharged, as shown in Comparative Examples 9 to 12.
  • the results of the evaluation test 2 indicate that by allowing the honeycomb filter of this type to support a catalyst, it becomes possible to significantly decrease the increasing rate of HC to be discharged outside.
  • the above-mentioned raw formed body was dried by using a microwave drier, and predetermined through holes were then filled with a paste having the same composition as the raw formed body, and after this had been again dried by using a drier, this was degreased at 400° C., and sintered at 1600° C. in a normal-pressure argon atmosphere for 2 hours to manufacture a porous ceramic member as shown in FIG. 3 , which was made of a silicon carbide-silicon sintered body, and had a size of 34 mm ⁇ 34 mm ⁇ 300 mm, the number of through holes of 31 pcs/cm 2 and a thickness of the partition wall of 0.3 mm.
  • a heat resistant sealing material paste which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 1% by weight of carboxymethyl cellulose and 30% by weight of water, was used so that, by carrying out the processes as described by reference to FIG. 4 , a number of the porous ceramic members were combined with one another, and then cut by using a diamond cutter; thus, a cylinder-shaped ceramic block as shown in FIG. 2 was manufactured.
  • a sealing material paste layer was formed on the circumference of the ceramic block by using the above-mentioned sealing material paste. Further, this sealing material paste layer was dried at 120° C. so that a cylinder-shaped honeycomb structural body having a diameter of 145.8 mm, with sealing material layers, each having a thickness of 1.0 mm, formed between the porous ceramic members as well as on the circumference of the ceramic block, as indicated by a honeycomb filter 20 of FIG. 2 , was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure in that the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 25 The same processes as (1) of Example 25 were carried out to produce a porous ceramic member.
  • Example 25 The same processes as (2) of Example 25 were carried out except that a heat resistant sealing material paste, which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 2% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.5 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 31% by weight of alumina fibers having a fiber length of 0.2 mm, 22% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 2% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.5 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 3.8%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 25 The same processes as (1) of Example 25 were carried out to produce a porous ceramic member.
  • Example 25 The same processes as (2) of Example 25 were carried out except that a heat resistant sealing material paste, which was composed of 30% by weight of alumina fibers having a fiber length of 0.2 mm, 21% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 4% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.25 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 30% by weight of alumina fibers having a fiber length of 0.2 mm, 21% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 16% by weight of silica sol, 4% by weight of carboxymethyl cellulose and 29% by weight of water, was used so that a sealing material layer having a thickness of 0.25 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 2.0%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 1.9%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 25 The same processes as (1) of Example 25 were carried out to produce a porous ceramic member.
  • a sealing material paste layer was formed on the circumference of the ceramic block by using the above-mentioned sealing material paste. Then, by drying this sealing material paste layer at 120° C., a cylinder-shaped honeycomb filter having a diameter of 145.8 mm with a thickness of sealing material layers formed between porous ceramic members as well as on the circumference of the ceramic block being set to 1.0 mm, was manufactured, as indicated by the honeycomb filter 20 in FIG. 2 .
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 7.4%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • Example 29 The same processes as (1) of Example 29 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 4.0%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • Example 33 The same processes as (1) of Example 33 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 2.0%, and the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • Example 25 The same processes as (1) of Example 25 were carried out to produce a porous ceramic member.
  • Example 25 The same processes as (2) of Example 25 were carried out except that a heat resistant sealing material paste, which was composed of 28% by weight of alumina fibers having a fiber length of 0.2 mm, 20% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 15% by weight of silica sol, 10% by weight of carboxymethyl cellulose and 27% by weight of water, was used so that a sealing material layer having a thickness of 0.1 mm was formed; thus, a honeycomb structural body was manufactured.
  • a heat resistant sealing material paste which was composed of 28% by weight of alumina fibers having a fiber length of 0.2 mm, 20% by weight of silicon carbide particles having an average particle size of 0.6 ⁇ m, 15% by weight of silica sol, 10% by weight of carboxymethyl cellulose and 27% by weight of water, was used so that a sealing material layer having a thickness of 0.1 mm was formed; thus, a honeycomb structural body was manufactured.
  • the rate of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, and the rate of organic components to the honeycomb structural body was 0.60% by weight.
  • honeycomb structural body was heated at 700° C. in an oxygen atmosphere for 90 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.05% by weight, was manufactured.
  • honeycomb structural body was heated at 600° C. in an oxygen atmosphere for 60 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.10% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 30 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.20% by weight, was manufactured.
  • honeycomb structural body was heated at 500° C. in an oxygen atmosphere for 10 minutes so that a honeycomb filter having a structure, in which the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%, with the rate V ⁇ of organic components being set to 0.50% by weight, was manufactured.
  • Example 25 The same processes as (1) of Example 25 were carried out to produce a porous ceramic member.
  • the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes was 0.8%
  • the rate V ⁇ of organic components to the honeycomb filter was 0.60% by weight.
  • the honeycomb filters according to Examples 25 to 36 and Comparative Examples 17 to 24 have a structure in that sealing material layers are formed between the porous ceramic members as well as on the circumference of the ceramic block, and in each of the honeycomb filters according to Examples 25 to 36 and Comparative Examples 17 to 19, the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes is set to 2% or more.
  • the results of the evaluation test 1 show that in the case of honeycomb filters according to Examples 25 to 36 that have the rate V ⁇ of organic components is 0.50% by weight or less, the amount of organic components to be discharged from the sealing material layer becomes smaller to cause hardly any increase in HC in the discharged exhaust gases, and the results of the evaluation test 2 show that, when a catalyst is supported on such a honeycomb filter, it becomes possible to effectively reduce the increasing rate of HC to be discharged outside.
  • the results of the evaluation test 1 of the honeycomb filters according to Comparative Examples 20 to 24 indicate that, in the case where the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes in the honeycomb filter is less than 2%, the amount of organic components to be discharged from the sealing material layer becomes smaller, even in the case of the rate V ⁇ of organic components exceeding 0.5% by weight, resulting in hardly any increase in HC in the discharged exhaust gases.
  • the honeycomb filter in which the rate S ⁇ is less than 2%, even when the rate of organic components contained in the sealing material layer becomes greater, the honeycomb filter is less likely to generate a problem, such as an increase in the amount of HC in exhaust gases to be discharged, as shown in Comparative Examples 17 to 19.
  • the results of the evaluation test 2 indicate that by allowing the honeycomb filter of this type to support a catalyst, it becomes possible to significantly decrease the increasing rate of HC to be discharged outside.
  • Example 2 The same processes as those of Example 1 were carried out except that the thickness of the sealing material layer formed on the circumference of the columnar body was changed as shown in Table 10, thus a honeycomb filter was manufactured.
  • Example 13 The same processes as those of Example 13 were carried out except that the thickness of the sealing material layer formed between the porous ceramic members as well as on the circumference of the ceramic block was changed as shown in Table 11, thus a honeycomb filter was manufactured.
  • Example 25 The same processes as those of Example 25 were carried out except that the thickness of the sealing material layer formed between the porous ceramic members as well as on the circumference of the ceramic block was changed as shown in Table 11, thus a honeycomb filter was manufactured.
  • Example 11 Thickness of sealing material layer (mm) On the Isostatic Between porous circumference S ⁇ strength ceramic members of ceramic block (%) (kg/cm 2 )
  • Example 13 1 1 7.41 35
  • Example 40 0.5 0.5 3.77 33
  • Example 41 0.25 0.25 1.90 30
  • Reference 0.2 0.2 1.52 25
  • Example 1 Comparative 0.1 0.1 0.76 20
  • Example 27 Example 25 1 1 7.41 34
  • Example 42 0.5 0.5 3.77 33
  • Example 43 0.25 0.25 1.90 29 Reference 0.2 0.2 1.52 24
  • Example 2 Comparative 0.1 0.1 0.76 18
  • Example 28 Comparative 0.1 0.1 0.76
  • a columnar body made of porous ceramic comprises a number of through holes, the above mentioned through holes being placed in parallel with one another in the length direction with wall portion interposed therebetween, with a sealing material layer being formed on the circumference thereof, as the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes becomes smaller, the isostatic strength reduces.
  • the rate S ⁇ is 0.5(0.47)% or more, the necessary isostatic strength is maintained; however, when the rate S ⁇ is less than 0.5 (0.47)%, the reduction in the isostatic strength becomes particularly greater, failing to provide sufficient isostatic strength.
  • the above mentioned through holes being placed in parallel with one another in the length direction with partition wall interposed therebetween, are combined with one another through sealing material layers to form a ceramic block, with a sealing material layer being also formed on the circumference of the ceramic block, as the rate S ⁇ of the area occupied by the sealing material layers to the total area of a cross-section including the through holes in the direction perpendicular to the through holes becomes smaller, the isostatic strength reduces.
  • the rate S ⁇ is 2 (1.90)% or more, the necessary isostatic strength is maintained; however, when the rate S ⁇ is less than 2(1.90)%, the reduction in the isostatic strength becomes particularly greater, failing to provide sufficient isostatic strength.
  • honeycomb filter for purifying exhaust gases of the present invention is structured as described above, even when comparatively large sealing material layer is included therein, there is hardly any increase in the amount of organic components contained in exhaust gases to be discharged.

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  • Filtering Materials (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
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DE60317174T3 (de) 2013-01-17
ATE376880T1 (de) 2007-11-15
DE60317174D1 (de) 2007-12-13
US20080213485A1 (en) 2008-09-04
EP1489277A1 (fr) 2004-12-22
EP1489277A4 (fr) 2006-05-03
US7713325B2 (en) 2010-05-11
JP4229843B2 (ja) 2009-02-25
EP1489277B2 (fr) 2012-08-22
CN1656307A (zh) 2005-08-17
JPWO2003081001A1 (ja) 2005-07-28
CN100410505C (zh) 2008-08-13
EP1489277B1 (fr) 2007-10-31
WO2003081001A1 (fr) 2003-10-02
DE60317174T2 (de) 2008-08-07

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