Classifications

• • 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
  • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
  • B01D46/2448—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the adhesive layers, i.e. joints between segments
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D39/00—Filtering material for liquid or gaseous fluids
  • B01D39/14—Other self-supporting filtering material ; Other filtering material
  • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
  • B01D39/2068—Other inorganic materials, e.g. ceramics
• • 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
  • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
  • B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
• • 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
  • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
  • B01D46/24494—Thermal expansion coefficient, heat capacity or thermal conductivity
• • 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
  • B01D46/2455—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
• • 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
  • B01D46/2478—Structures comprising honeycomb segments
• • 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
  • B01D46/2484—Cell density, area or aspect ratio
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/34—Chemical or biological purification of waste gases
  • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
  • B01D53/86—Catalytic processes
  • B01D53/88—Handling or mounting catalysts
  • B01D53/885—Devices in general for catalytic purification of waste gases
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
  • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
  • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
  • C04B35/62605—Treating the starting powders individually or as mixtures
  • C04B35/62625—Wet mixtures
  • C04B35/6263—Wet mixtures characterised by their solids loadings, i.e. the percentage of solids
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
  • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
  • C04B35/6303—Inorganic additives
  • C04B35/6316—Binders based on silicon compounds
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/71—Ceramic products containing macroscopic reinforcing agents
  • C04B35/74—Ceramic products containing macroscopic reinforcing agents containing shaped metallic materials
  • C04B35/76—Fibres, filaments, whiskers, platelets, or the like
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/71—Ceramic products containing macroscopic reinforcing agents
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  • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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  • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
  • C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
  • C04B37/005—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts consisting of glass or ceramic material
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  • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
  • C04B38/0006—Honeycomb structures
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
  • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
  • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
  • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
  • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
  • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
  • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
  • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
  • B01D46/2418—Honeycomb filters
  • B01D46/2498—The honeycomb filter being defined by mathematical relationships
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
  • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
  • B32B2315/02—Ceramics
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  • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
  • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
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  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
  • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
  • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
  • C04B2237/04—Ceramic interlayers
  • C04B2237/06—Oxidic interlayers
  • C04B2237/062—Oxidic interlayers based on silica or silicates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
  • C04B2237/04—Ceramic interlayers
  • C04B2237/08—Non-oxidic interlayers
  • C04B2237/083—Carbide interlayers, e.g. silicon carbide interlayers
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
  • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
  • C04B2237/32—Ceramic
  • C04B2237/36—Non-oxidic
  • C04B2237/365—Silicon carbide
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/10—Internal combustion engine [ICE] based vehicles
  • Y02T10/12—Improving ICE efficiencies
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S55/00—Gas separation
  • Y10S55/10—Residue burned
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S55/00—Gas separation
  • Y10S55/30—Exhaust treatment

Definitions

• the present invention relates to a honeycomb filter used for, for example, a filter for collecting particulates in exhaust gas from an internal combustion engine, a boiler, and the like, and more particularly to a honeycomb filter that can suppress an excessive rise in temperature, has a small variation in temperature distribution, and has excellent durability.
• a honeycomb filter used for, for example, a filter for collecting particulates in exhaust gas from an internal combustion engine, a boiler, and the like, and more particularly to a honeycomb filter that can suppress an excessive rise in temperature, has a small variation in temperature distribution, and has excellent durability.
• Honeycomb filters are used as filters for collecting particulates in exhaust gas from internal combustion engines, boilers, etc., particularly diesel particulates.
• a honeycomb filter used for such a purpose generally has a large number of flow holes 3 penetrating in the X-axis direction, which are partitioned by a partition wall 2 as shown in FIGS. 6 (a) and 6 (b). Adjacent flow holes 3 are sealed at one end opposite to each other so that the end faces have a checkered pattern.
• the fluid to be treated flows into the flow hole 3 in which the inlet-side end surface 42 is not sealed, that is, the flow hole 3 in which the outlet-side end surface 44 is sealed,
• the adjacent flow holes 3, that is, the inflow-side end faces 42 are sealed through the porous partition walls 2, and the outflow-side end faces 44 are discharged from the unsealed flow holes 3.
• the partition wall 2 serves as a filter.
• soot discharged from the diesel engine is captured by the partition wall and deposited on the partition wall.
• the honeycomb filter used in this manner has a problem that the temperature distribution in the honeycomb structure becomes non-uniform due to rapid temperature change of the exhaust gas and local heat generation, and cracks are generated in the honeycomb filter. .
• DPF filter
• Japanese Patent Application Laid-Open Publication No. 2001-162119 discloses that the thickness of a sealing material (bonding material) layer is 0.3 to 5 mm and the thermal conductivity of the sealing material is 0.1 to 1 mm.
• a finalizer is disclosed in which the overall temperature is made uniform and partial unburned residue is less likely to occur.
• the present invention has been made in view of such circumstances, and an object of the present invention is to provide a honeycomb filter having an excellent durability that can suppress an excessive rise in temperature without particularly changing the thickness of a bonding material. Is to provide.
• the present invention is a honeycomb filter in which a plurality of honeycomb segments having a large number of flow holes penetrating in the axial direction and separated by partition walls are joined and integrated via a joining material.
• the ratio of the thermal conductivity / cs of the honeycomb segment to the conductivity / a, ⁇ SZK a is in the range of 5 to 300, and the density Pa of the bonding material is 0.1 to 4 g Z cc
• the present invention provides a honeycomb filter characterized by being in the range of:
• specific heat C heat capacity H a represented by unit volume equivalents have enough in pax density pa is in the range of 0. 1 X 1 0 6 ⁇ 3 X 1 0 6 J Zm 3 'K It is preferred.
• the joining material preferably has pores, and the joining material preferably contains a metal.
• the honeycomb filter of the present invention preferably includes two or more bonding materials having one or both of a thermal conductivity / ca and a heat capacity per unit volume different from each other, and the thermal expansion coefficient of the bonding material is as follows: It is preferably in the range of 1 X 10 16 to 8 X 1 hy 6 /.
• the honeycomb segment contains silicon carbide or a silicon-silicon carbide composite material as a main component.
• the opening of the predetermined flow hole in the honeycomb segment of the present invention is sealed at one end face, and the opening of the remaining flow hole is sealed at the other end face. or% by volume, it is preferred that the cross-sectional area is configured 9 0 O mm 2 ⁇ 1 0 0 0 0 honeycomb segment or al a mm 2.
• FIG. 1A is a schematic perspective view showing one embodiment of a honeycomb segment according to the present invention
• FIG. 1B is a schematic perspective view showing one embodiment of a filter of the present invention
• FIG. 1 (c) is a schematic plan view showing one embodiment of the honeycomb filter of the present invention
• FIG. 2 is a schematic plan view showing another embodiment of the honeycomb filter of the present invention.
• FIG. 3 is a schematic perspective view showing another embodiment of the honeycomb segment according to the present invention.
• FIG. 4 is a schematic plan view showing the honeycomb filter of the present invention created in Examples 1 to 5.
• FIG. 5 is a schematic plan view showing the honeycomb fill of the present invention prepared in Examples 6 and 7.
• FIG. 6 (a) is a schematic perspective view showing a conventional honeycomb filter
• FIG. 6 (b) is a partially enlarged plan view thereof.
• a cross section means a cross section perpendicular to the direction of the flow hole (X-axis direction) unless otherwise specified.
• the honeycomb filter 1 of the present invention has a large number of flow holes 3 penetrating in the X-axis direction, which are partitioned by a partition wall 2 as shown in, for example, FIGS. 1 (a), 1 (b) and 1 (c).
• a plurality of honeycomb segments 12 are joined and integrated via a joining material 8 to form a honeycomb filter.
• the ratio of the thermal conductivity as of the honeycomb segments 12 to the thermal conductivity / ca of the bonding material 8, that is, / csZia is 5 to 300, preferably 8 to 280, and Preferably, it is in the range of 10 to 250, and the density pa of the bonding material 8 is 0.1 to 4 gZc c, preferably 0.3 to 3.5 g / cc, more preferably 0.5 to 0.5 g / cc. 3.0 g / cc.
• soot is deposited in the filter.
• the amount of deposited soot increases, the amount of heat generated during regeneration increases, and the maximum temperature occurs.
• the temperature gradient increases and the thermal stress increases.
• the bonding material 8 does not contribute as a heat insulating layer, so that the heat is transmitted to the adjacent honeycomb segment via the bonding material 8, and the temperature gradient in the honeycomb segment tends to increase. .
• the ⁇ s Z / ca value is too large, the thermal conductivity of the bonding material 8 is too small with respect to the honeycomb segments 12, so that the temperature gradient generated in the bonding material 8 becomes too large and cracks occur in the bonding material 8. This can lead to breakage of the honeycomb filter in some cases.
• the bonding material 8 if the density 0a of the bonding material 8 is too small, the bonding material 8 hardly contributes as a heat insulating layer regardless of the value of the thermal conductivity of the bonding material 8; The effect of heat transfer to the segment increases the temperature gradient generated in the segment. On the other hand, if the density pa of the bonding material 8 is too large, the temperature gradient generated inside the bonding material 8 becomes too large, and cracks are easily generated in the bonding material 8. Therefore, by controlling the values of KsZ / ca and the value of ⁇ a within the range of the present invention, it is possible to obtain a honeycomb filter having excellent durability.
• the thermal conductivity ⁇ s of the honeycomb segment 12 means the average thermal conductivity of the partition wall 2 and the outer peripheral wall 7 of the honeycomb segment 12, and does not include the flow holes 3.
• the ratio of the thermal conductivity KS of the honeycomb segment 1 2 to the thermal conductivity ⁇ a of KS a, that is, / cs ZK a is the average of the thermal conductivity / cs of each honeycomb segment 1 2 in the honeycomb filter 1 and the heat of the bonding material 8. It means the ratio of the conductivity to the average.
• the heat capacity Ha per unit volume of the bonding material 8 is too small.
• the bonding material 8 and the bonding material 8 hardly contribute as a heat insulating layer, heat is easily transmitted to the adjacent honeycomb segment 12 via the bonding material 8, and a temperature gradient in the honeycomb segment 12 is easily generated.
• the bonding material 8 the heat capacity Ha per unit volume represented by the specific heat C pa X density pa is preferably in the range of 0. 1 X 1 0 6 ⁇ 3 X 1 0 6 JZm 3 ⁇ K, 0. 3 X 1 0 6 ⁇ 2. 5 X more preferably in the range of 1 0 6 J / m 3 ⁇ K, 0. 6 X 1 0 6 ⁇ 2. 0 X 1 0 6 J / m 3 ⁇ Most preferably, it is in the range of K.
• the values of ⁇ s / a and ⁇ a can be controlled within the range of the present invention.
• Specific preferred control means for the value of ⁇ s / ⁇ a and a) a is that the bonding material has a certain set of pores and the density of the bonding material is reduced to the target value. Is mentioned. According to this means, it is possible to simultaneously adjust the heat capacity Ha per unit volume, the density pa and the thermal conductivity / ca in a direction of decreasing.
• a method of adding a pore former having a predetermined volume of pores to the raw material of the bonding material when forming the bonding material may be mentioned.
• suitable pore formers include hollow particles of various inorganic and organic materials such as balloon-shaped foamed resin and shirasu balloon. If it is possible to provide a heat treatment step after joining, a method of adding starch, cell mouth, various inorganic or organic particles that form pores by burning or melting at a predetermined temperature as a pore-forming material. There is also.
• Another preferable control means of the values of ⁇ s / ⁇ a and the value of Pa includes a configuration in which the bonding material contains a metal such as a metal fiber or a particle. According to this means, the heat conductivity, the heat capacity, and the density can be adjusted in the direction of increasing simultaneously. Preferred metals include copper and stainless steel, and particularly preferred are fibrous materials thereof.
• the joining material may be configured to include a high specific gravity material, for example, zirconium silicate, zirconia, or the like. According to this means, adjustment can be made in such a direction that only the heat capacity is increased and the thermal conductivity is decreased.
• the value of ⁇ s / ⁇ a can be adjusted to an appropriate range. For example, by using a pore-forming agent as a raw material for the honeycomb segment, the porosity can be increased and the thermal conductivity can be reduced. When silicon and silicon carbide are used as the constituent materials of the honeycomb segment, The thermal conductivity can be increased by increasing the ratio of silicon.
• the honeycomb segment of the present invention can be suitably manufactured.
• the honeycomb filter of the present invention includes two or more bonding materials different in one or both of the thermal conductivity / ca and the heat capacity Ha per unit volume.
• the honeycomb filter of the present invention when used as a DPF, heat is generated particularly in the central portion of the honeycomb filter. Therefore, for example, as shown in FIG. 2, a bonding material 8 A having a small thermal conductivity and a small heat capacity per unit volume at the center portion, and a bonding material 8 B having a high heat conductivity / ca and a large heat capacity Ha at the outer peripheral portion.
• the durability of the honeycomb filter can be further improved by joining the honeycomb segments using different joining materials according to the required characteristics in the filter and controlling the temperature gradient in the filter.
• the joining materials having different a / a and / or Ha can be made by means using the above-mentioned pore-forming agent, metal, and high specific gravity material.
• a material having a relatively low coefficient of thermal expansion is preferable because a large thermal expansion easily causes cracks due to thermal shock or the like.
• 2 0 t of junction member Coefficient of thermal expansion in the range of 1-8 0 0, 1 X 1 0- 6 ⁇ 8 X 1 0 - preferably in the range of at zone, 1 5 X 1 0- 6 ⁇ 7 X more preferably in the range of 1 0 6 / in, 2 X 1 0- 6 ⁇ 6 X 1 O- ⁇ : is most preferred range of.
• Difference in thermal expansion coefficient from 2 0 between the bonding material and the hard second cam segment to 8 0 0 is preferably not more than 1 X 1 0- 6 / ⁇ .
• Joining a material mainly composed of ceramics is usually suitably used.
• a raw material for forming the bonding material for example, a mixture of particles or fibers of aluminum silicate, aluminum phosphate, etc. and colloidal sol, such as colloidal silica, colloidal alumina, etc., according to the necessary characteristics as described above, Metals such as metal fibers, pore-forming materials, and particles of various ceramics are used.
• the main components of the honeycomb segment are cordierite, mullite, alumina, spinel, silicon carbide, silicon carbide-corelite composite material, silicon monocarbide composite material, nitrided silicon nitride from the viewpoints of strength, heat resistance and the like. It is preferable to use at least one material selected from the group consisting of silicon, lithium aluminum silicate, aluminum titanate, Fe—Cr—A1-based metal, and a combination thereof. In this respect, silicon carbide or silicon-silicon carbide composites are particularly suitable.
• the “main component” means that 50% by mass or more, preferably 70% by mass or more, more preferably 80% by mass or more of the honeycomb segment.
• the honeycomb segment when the honeycomb segment is mainly composed of a composite material of metallic silicon (Si) and silicon carbide (SiC), the honeycomb segment is defined by Si / (Si + SiC) of the honeycomb segment. If the Si content is too small, the effect of adding Si becomes difficult to obtain, and if it exceeds 50% by mass, the effects of heat resistance and high thermal conductivity characteristic of SiC become difficult to obtain. Therefore, the Si content is preferably from 5 to 50% by mass, and more preferably from 10 to 40% by mass.
• the partition wall of the honeycomb segment is preferably a porous body that plays a role of a filter.
• the thickness of the partition wall There is no particular limitation on the thickness of the partition wall. If the partition wall is too thick, the pressure loss when the fluid to be treated permeates the porous partition wall becomes too large, and if the partition wall is too thin, the strength as a filter is insufficient. Not preferred.
• the thickness of the septum is preferably in the range from 30 to 200 / m, more preferably from 40 to: 100 m, most preferably from 50 to 500.
• the cell density of the honeycomb segment (the number of flow holes per unit sectional area) is not particularly limited. However, if the cell density is too low, the strength as a filter and the effective GSA (geometric surface area) become insufficient. If the cell density is too high, the pressure loss when the fluid to be processed flows increases.
• the cell density is preferably between 6 and 20 00 serno square inches (0.9 to 311 cells Z cm 2 ), more preferably 50 to: L 000 Serno square inches (7.8 to 15 5 cells cm 2 ), most preferably 1
• the range is from 0.0 to 400 cells square inch (15.5 to 62.0 cells Z cm 2 ).
• the cross-sectional shape (cell shape) of the flow hole is not particularly limited, but is preferably any one of a triangular shape, a square shape, a hexagonal shape, and a corrugated shape from the viewpoint of manufacturing.
• the size of the honeycomb segments is not limited. However, if each segment is too large, a problem of breakage due to thermal stress occurs, and if it is too small, the production and joining of each segment becomes complicated, which is not preferable.
• a preferred honeycomb segment size is a cross-sectional area of 900 mm 2 to 1000 mm 2 , more preferably 90 mm 2 to 500 mm 2 , most preferably 90 mm 2 and 3 6 are 0 0 mm 2, 7 0% or more by volume of the honeycomb filter one is, it is preferably composed of honeycomb segments of this size.
• the shape of the honeycomb segment is not particularly limited, for example, as shown in FIG.
• the cross-sectional shape is a square shape, that is, the honeycomb segment has a square pillar shape, and the basic shape is as shown in FIG. 1 (b), FIG. As shown in c), the shape of the honeycomb segment on the outer peripheral side can be appropriately selected according to the shape of the integrated honeycomb filter.
• the cross-sectional shape of the honeycomb filter of the present invention is not particularly limited.
• polygons such as an elliptical shape, a racetrack shape, an oval shape, a triangular shape, a substantially triangular shape, a square shape, a substantially square shape, and the like. It can be shaped or irregularly shaped.
• thermal conductivity of the entire honeycomb filter There is no particular limitation on the thermal conductivity of the entire honeycomb filter. However, if the thermal conductivity is too high, even if the honeycomb filter of the present invention dissipates too much heat, the temperature does not rise sufficiently during regeneration and the regeneration efficiency is not increased. Is undesirably reduced.
• the thermal conductivity at 40 is preferably from 10 to 60 WZmK: more preferably from 15 to 55 WZmK, and most preferably from 20 to 50 WZmK.
• the honeycomb segment 12 of the present invention particularly when used as a DPF, has an opening of a predetermined flow hole 3a sealed at one end face 46, and the remaining flow hole 3 It is preferable that the opening of b is sealed at the other end face 48. Good.
• the adjacent flow holes 3 are sealed at one end opposite to each other so that the end faces 46 and 48 have a checkered pattern.
• the fluid to be treated flowing from one end face 46 passes through the partition wall 2 and flows out from the other end face 48, and the fluid to be treated passes through the partition wall 2 when the fluid to be treated passes through the partition wall 2.
• the material used for sealing one or two or more materials selected from the above-mentioned ceramics or metals that can be suitably used for the honeycomb segment can be suitably used.
• the honeycomb filter of the present invention When the honeycomb filter of the present invention is to be used as a catalyst carrier for purifying exhaust gas of a heat engine such as an internal combustion engine or a combustion device such as a boiler, or reforming a liquid fuel or a gaseous fuel, the honeycomb filter of the present invention It is preferable to support a catalyst, for example, a metal having catalytic ability.
• a metal having catalytic activity include Pt, Pd, and Rh, and it is preferable that at least one of these metals is supported on a honeycomb filter.
• the raw material powder for the honeycomb filter As the raw material powder for the honeycomb filter, the above-mentioned suitable material, for example, silicon carbide powder is used, and a binder, for example, methylcellulose and hydroxypropoxymethylcellulose is added thereto. A kneaded clay is produced. By extruding the kneaded clay, a honeycomb segment having a predetermined shape is obtained.
• a binder for example, methylcellulose and hydroxypropoxymethylcellulose
• the honeycomb filter 1 After drying with, for example, microwaves and hot air, this is the same as the material used for manufacturing the honeycomb filter 1 at one end where the adjacent flow holes 3 are opposite to each other so that the end face has a checkered pattern.
• it After sealing with a material and further drying, it is heated and degreased in, for example, an N 2 atmosphere, and then fired in an inert atmosphere such as Ar to obtain a honeycomb segment having a predetermined thermal conductivity / s.
• the obtained segments are joined using, for example, a joining material such as a pore former, a metal such as a metal fiber, or a ceramic cement containing a high specific gravity material, and then dried and cured at 200: You can get one.
• the method of supporting a catalyst on a honeycomb filter manufactured in this manner is described in the art.
• the catalyst may be carried out by a method usually performed by a user, for example, by washcoating a catalyst slurry, followed by drying and firing. Further, the catalyst may be carried on the honeycomb segments and then joined to form a honeycomb filter, or the catalyst may be carried as a honeycomb filter.
• Raw materials such as SiC powder and metallic Si powder, and polymethyl methacrylate as a pore-forming material were mixed at the mass ratios shown in Table 1, and then mixed with methylcellulose and hydroxypropoxylmethylcellulose, a surfactant and water.
• This clay was extruded and microwave and then dried with hot air having a partition wall thickness of 3 8 0 u rn, the cell density of about 3 1.0 cell Z cm 2 (2 0 0 Cerno square inch), the cross-sectional surface
• a honeycomb segment with a side of 35 mm and a length of 152 mm was obtained.
• the porosity, 4-point bending strength, Young's modulus and thermal conductivity of the honeycomb segments A and B were measured, and the results are also shown in Table 1.
• the porosity was measured by the Archimedes method.
• the thermal conductivity was measured by the laser flash method according to the method described in JISR 1611.
• the four-point bending strength and the Young's modulus were measured by a method according to JISR 1601. ⁇ 3 ⁇ 4 ⁇ £
• aluminosilicate fiber having an average diameter of 100 / m, silicon carbide powder having an average diameter of 100 m, zirconium silicate, colloidal silica as an inorganic binder and a 40% by mass aqueous solution mixed with clay Water was added and the mixture was kneaded for 30 minutes using a mixer to prepare bonding material materials 1 to 5.
• the bonding material materials 2 and 3 are made by adding foamed resin as a pore-forming material, and the bonding material material 4 is obtained by adding Cu fiber having a length of 1 mm as a metal fiber.
• bonding material material 6 a material using zirconium silicate instead of silicon carbide was used as bonding material material 6, and a material prepared using zirconium silicate and colloidal silica instead of aluminosilicate fiber and silicon carbide was used as bonding material material 7.
• the bonding materials 1 to 7 were dried and hardened with 20 O: to obtain bonding materials 1 to 7, and the thermal conductivity, density, and heat capacity were measured. The results are shown in Table 3.
• the thermal conductivity was measured by a laser flash method according to the method described in JISR 1611.
• the heat capacity was measured by the laser-flash method in accordance with JISR 1611, the density was measured by the Archimedes method, and the product of the two was determined as the heat capacity.
• honeycomb segments A and B obtained by the above operation and the bonding material materials 1 to 7 in the combinations shown in Table 4 were joined, dried and hardened at 200, and then cut, as shown in Fig. 4.
• a cylindrical honeycomb filter for DPF having a diameter of 144 mm and a length of 152 mm was obtained.
• the manufactured honeycomb filter was connected to the exhaust pipe of a direct-injection 3 liter diesel engine, and the engine was operated using light oil containing 3 O ppm of Michiichi-Ce Ce fuel additive, and the specified amount of soot ( After the soot was collected in the filter, the temperature of the honeycomb filter was raised to 600 using a propane gas burner, and the soot was regenerated by switching the bypass valve so that the inside of the honeycomb filter had an oxygen concentration of 18%. The amount of soot was increased from 4 gZ litters to 2 gZ litters, and the amount of collected and deposited soot at the time when cracks were observed on one end of the fillet under microscopic observation was taken as the limit soot amount. It was shown to.
• the honeycomb filters obtained in Examples 1 to 5 show the / csZ / ca value and the Ha value of the present invention, and / s / a values and the values outside the range of the present invention. It can be seen that, compared to the honeycomb filters obtained in Comparative Examples 1 to 3, which show the Ha value, the value of the limit street amount is large and the durability is clearly superior. (Table 4)
• the bonding material of bonding material 8A (the cross-shaped bonding material passing through the center) and bonding material 8B (peripheral portion) were the same as those shown in Table 3 except that the bonding material was a combination.
• a honeycomb filter was prepared in the same manner as in Example 1, and the limit soot deposition amount was measured in the same manner as in Example 1.
• Table 5 the results show that by using a bonding material with a small value of thermal conductivity and heat capacity at the periphery, the temperature distribution tends to be less likely to occur, and only one type of bonding material is used as the bonding material. In comparison with Examples 1 and 3, the limit amount of the strip was increased by one rank, and the durability was further increased.
• the ratio of the thermal conductivity ⁇ s of the honeycomb segment to the thermal conductivity ⁇ a of the bonding material, / cs / K a is in the range of 5 to 300, And the density i0a of the joining material is in the range of 0.1 to 4 g / cc. Therefore, it showed good durability.
• the honeycomb filter of the present invention is particularly preferably used for a DPF, but the effect of the present invention is to suppress an excessive rise in temperature of the filter and to make the temperature distribution in the filter uniform, Applications are not limited to DPFs alone.

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• 2001
  • 2001-10-15 JP JP2001316913A patent/JP4246425B2/ja not_active Expired - Lifetime
• 2002
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