WO2009157504A1

WO2009157504A1 - Honeycomb structure

Info

Publication number: WO2009157504A1
Application number: PCT/JP2009/061568
Authority: WO
Inventors: 泰之古田
Original assignee: 日本碍子株式会社
Priority date: 2008-06-25
Filing date: 2009-06-25
Publication date: 2009-12-30
Also published as: WO2009157503A1; JP5649964B2; JPWO2009157503A1

Abstract

A honeycomb structure having honeycomb segments integrally joined together at the outer walls thereof by a jointing material containing inorganic particles. The honeycomb segments each have an entrance-side end face on the fluid entrance side, an exit-side end face on the fluid exit side, outer walls for interconnecting the outer peripheral sections of the two end faces, and cells partitioned and formed, on the inner side of the outer walls and between the two end faces, by partition walls which consist of a porous body and functioning as fluid flow paths. In the honeycomb structure, if the average distance between local crests on the surfaces of the outer walls is S, the arithmetic average surface roughness of the surfaces of the outer walls is Ra, the porosity of the outer walls is a, the average diameter of pores in the outer walls is b, and the average diameter of the inorganic particles is c, X represented by the expression (1) below and Y represented by the expression (2) below satisfy the relationship represented by the expression (3) below. X = log_e(a × 10^-2 × b² × c^-2) (1) Y = 1/log_e(S/Ra) (2) 0.023X + 0.22 ≤ Y ≤ 0.027X + 0.54 (3)

Description

Honeycomb structure

The present invention relates to a honeycomb structure suitably used as a dust collection filter such as a diesel particulate filter.

As a collection filter for exhaust gas, for example, a diesel particulate filter (DPF) for capturing and removing particulate matter (particulate matter (PM)) such as soot contained in exhaust gas from diesel engines, etc. Honeycomb structures are widely used.

In order to continuously use such a honeycomb structure (filter) for a long period of time, it is necessary to periodically regenerate the filter. That is, in order to reduce the pressure loss increased by the PM accumulated with time in the filter and return the filter performance to the initial state, it is necessary to burn and remove the PM accumulated in the filter. When this filter is regenerated, the PM accumulated inside the filter burns in order from the fluid (exhaust gas) inlet side, so the temperature rises due to the heat generated in the front and the heat burned on the spot closer to the outlet side. Becomes intense. Therefore, the temperature rise of each part of the filter is likely to be non-uniform, and there is a problem that defects such as cracks are generated due to thermal stress.

In response to these problems, the honeycomb structure is composed of a plurality of honeycomb-shaped segments (honeycomb segments), and each segment is joined and integrated with a bonding material made of an elastic material, thereby acting on the honeycomb structure. A method for dispersing and relaxing the thermal stress is proposed (see, for example, Patent Document 1).

By the way, when a honeycomb structure is configured by bonding a plurality of honeycomb segments in this way, the bonding material for bonding the honeycomb segments is an outer wall of the honeycomb segment that is a bonded surface in a paste state containing moisture. It is hardened when it is dried and joined between the honeycomb segments, but depending on how moisture is scattered during this drying, the joining material tends to break inside, There is a problem that the ring-off crack limit becomes low.

For example, if the porosity of the outer wall of the honeycomb segment is too low, or if the particle size of the inorganic particles contained in the bonding material is too large, when the bonding material dries, moisture in the bonding material is difficult to scatter, Many large voids (so-called fool holes) are formed in the bonding material, and the physical strength of the bonding material is weakened. As a result, not the interface between the honeycomb segment and the bonding material, but breakage within the bonding material is likely to occur, and the shear strength of the honeycomb structure decreases.

On the other hand, when the porosity of the outer wall of the honeycomb segment is too high, the average pore diameter of the outer wall of the honeycomb segment is too large, or the average particle diameter of the inorganic particles contained in the bonding material is too small, the bonding material is dried. In addition, moisture in the bonding material is likely to be scattered, the porosity of the bonding material is lowered, and the Young's modulus is increased. As a result, the ring-off crack limit of the honeycomb structure is lowered.

In addition, since the surface roughness of the outer wall of the honeycomb segment and the interval between the local peaks also affect the shear strength of the honeycomb structure through the bonding material, it is included in the porosity, average pore diameter, and bonding material of the outer wall of the honeycomb segment. Using only the particle size of the inorganic particles as an adjustment factor for the shear strength results in one hand dropping. However, the surface roughness of the outer wall of the honeycomb segment and the interval between the local peaks can be arbitrarily and arbitrarily set independently depending on the average particle diameter of each raw material component including the pore former used in the manufacture of the honeycomb segment and the mixing ratio thereof. However, since there are an excessive number of adjustment factors, it is difficult to set their preferred ranges individually, it is difficult to break inside the bonding material, and the ring-off crack limit However, when trying to produce a well-balanced honeycomb structure, craftsmanship know-how was required. Furthermore, the problem is further complicated by the fact that the surface roughness of the outer wall of the honeycomb segment and the interval between the local peaks can be arbitrarily adjusted to desired values by applying a base material to the outer wall of the honeycomb segment.

JP 2000-279729 A

The present invention has been made in view of such conventional circumstances, and the object of the present invention is to determine the average particle diameter of individual raw material components including the pore former used in the manufacture of honeycomb segments and the mixing ratio thereof. The individual specific independent adjustment factors such as the presence / absence of application of various base materials are arranged, and the surface roughness (arithmetic average surface roughness: Ra) of the honeycomb segment outer wall that can be adjusted according to the factors or the local peak By optimizing the relationship between the interval (average interval between local peaks: S) and the porosity of the honeycomb segment outer wall, the average pore size, and the average particle size of the inorganic particles contained in the bonding material An object of the present invention is to provide a honeycomb structure excellent in thermal shock resistance, which is less likely to break inside the bonding material and has a high ring-off crack limit.

In order to achieve the above object, according to the present invention, the following honeycomb structure is provided.

[1] An inlet side end surface serving as a fluid inlet side, an outlet side end surface serving as a fluid outlet side, an outer wall connecting the outer peripheral portions of the two end surfaces, and porous between the two end surfaces inside the outer wall A plurality of honeycomb segments defined by partition walls of the body and having a plurality of cells serving as fluid flow paths are integrated by bonding the outer walls with a bonding material containing inorganic particles. A honeycomb structure, wherein an average interval between local peaks of the outer wall surface is S, an arithmetic average surface roughness of the outer wall surface is Ra, a porosity of the outer wall is a, an average pore diameter of the outer wall is b, and the inorganic A honeycomb structure in which X represented by the following formula (1) and Y represented by the following formula (2) satisfy the relationship of the following formula (3), where c is the average particle diameter of the particles.
X = log _e (a × 10 ⁻² × b ² × c ⁻² ) (1)
Y = 1 / log _e (S / Ra) (2)
0.023X + 0.22 ≦ Y ≦ 0.027X + 0.54 (3)

[2] The honeycomb structure according to [1], wherein an average interval S between local peaks on the outer wall surface is 10 to 140 μm.

[3] The honeycomb structure according to [1] or [2], wherein the inorganic particles have an average particle diameter of 0.5 to 30 μm.

[4] The honeycomb structure according to any one of [1] to [3], wherein an arithmetic average surface roughness Ra of the outer wall surface is 0.4 to 23.5 μm.

[5] Any one of [1] to [4], wherein a ratio (S / Ra) of an average interval S between the local peaks on the outer wall surface to an arithmetic average surface roughness Ra is 1.8 to 37.5. Honeycomb structure.

[6] The honeycomb structure according to any one of [1] to [5], wherein a base material containing particles is applied to an outer wall surface of the honeycomb segment.

[7] The honeycomb structure according to any one of [1] to [6], wherein the honeycomb segment has a porosity of 30 to 80% and an average pore diameter of 5 to 50 μm.

[8] A plugging portion that plugs a predetermined opening of the cell with the end surface on the inlet side and plugs the remaining opening of the cell with the end surface on the outlet side is provided [1] to [7] The honeycomb structure according to any one of [7].

[9] The honeycomb structure according to [8], wherein an opening ratio of the inlet side end face is larger than an opening ratio of the outlet side end face.

[10] The honeycomb structure according to any one of [1] to [9], wherein a catalyst component is supported on the partition walls.

Since the honeycomb structure of the present invention is less likely to break inside the bonding material and has a high ring-off crack limit, when used in applications such as DPF where the temperature of each part tends to be non-uniform, it has high heat resistance. Demonstrate impact.

It is a schematic perspective view which shows an example of the basic structure of the honeycomb structure which concerns on this invention. 1 is a schematic perspective view showing an example of a honeycomb segment constituting a honeycomb structure according to the present invention. FIG. 6 is a schematic perspective view showing another example of a honeycomb segment constituting the honeycomb structure according to the present invention. It is the elements on larger scale of the entrance side end surface which shows an example of embodiment of the honeycomb structure from which an aperture ratio differs in an entrance side end surface and an exit side end surface. It is the elements on larger scale of the exit side end surface which shows an example of embodiment of the honeycomb structure from which an aperture ratio differs in an entrance side end surface and an exit side end surface. FIG. 5 is an explanatory diagram schematically showing the influence of the surface roughness of the outer wall surface of the honeycomb segment and the interval between the local peaks on the bonding state between the outer wall of the honeycomb segment and the inorganic particles contained in the bonding material. FIG. 5 is an explanatory diagram schematically showing the influence of the surface roughness of the outer wall surface of the honeycomb segment and the interval between the local peaks on the bonding state between the outer wall of the honeycomb segment and the inorganic particles contained in the bonding material. FIG. 5 is an explanatory diagram schematically showing the influence of the surface roughness of the outer wall surface of the honeycomb segment and the interval between the local peaks on the bonding state between the outer wall of the honeycomb segment and the inorganic particles contained in the bonding material. FIG. 5 is an explanatory diagram schematically showing the influence of the surface roughness of the outer wall surface of the honeycomb segment and the interval between the local peaks on the bonding state between the outer wall of the honeycomb segment and the inorganic particles contained in the bonding material.

Hereinafter, the present invention will be described based on specific embodiments, but the present invention should not be construed as being limited thereto, and based on the knowledge of those skilled in the art without departing from the scope of the present invention. Various changes, modifications, and improvements can be added.

The honeycomb structure of the present invention is formed by integrating a plurality of honeycomb segments by bonding with a bonding material. FIG. 1 is a schematic perspective view showing an example of a basic structure of a honeycomb structure according to the present invention, and FIG. 2 is a schematic perspective view showing an example of a honeycomb segment constituting the honeycomb structure according to the present invention.

As shown in Fig. 2, the honeycomb segment 2 has an inlet side end face 10 which is a fluid inlet side and an outlet side end face 11 which is a fluid outlet side. The outer peripheral portions of the two end faces are connected by an outer wall 8, and a plurality of cells (through holes) 5 serving as a fluid flow path are defined by a porous partition wall 3 inside the outer wall 8. In addition, when used as a filter such as a DPF, a plugging portion that plugs the opening of a predetermined cell at the inlet side end face and plugs the remaining cell opening at the outlet side end face is provided. Usually, as shown in FIG. 3, one end face is plugged by a plugging portion 9 so as to exhibit a checkered pattern, and the other end face is plugged by a plugging portion. And plugged so as to show a complementary checkerboard pattern. That is, the plugged portions are formed so that the openings of adjacent cells are plugged at the end surfaces opposite to each other.

When a fluid containing PM such as soot is vented from one end face (inlet side end face) of the honeycomb structure constituted of the honeycomb segments thus plugged, the fluid is opened at the one end face side. Flows into the inside of the honeycomb structure from the cells that are not plugged, passes through the porous partition wall having filtration ability, and enters the other flow hole in which the other end surface (end surface side surface) is not plugged. . And when passing through this partition, PM in the fluid is captured by the partition, and the purified fluid from which PM has been removed is discharged from the other end surface.

As shown in FIG. 1, the honeycomb structure 1 of the present invention is formed by integrating a plurality of honeycomb segments 2 by joining their outer walls together. A bonding material is used for bonding the honeycomb segments 2. This bonding material contains inorganic particles, and preferably contains inorganic fibers and colloidal oxides as other components. When joining the honeycomb segments, in addition to these components, if necessary, an organic binder such as methylcellulose and carboxymethylcellulose, a dispersant, water, etc. are added and mixed and kneaded using a kneader such as a mixer. What was made into the paste-form can use it conveniently.

As the constituent material of the inorganic particles contained in the bonding material, for example, ceramics selected from the group consisting of silicon carbide, silicon nitride, cordierite, alumina, mullite, zirconia, zirconium phosphate, aluminum titanate, titania and combinations thereof, Fe A —Cr—Al-based metal, nickel-based metal, silicon-silicon carbide based composite material, or the like can be preferably used.

As the inorganic fiber, ceramic fibers such as aluminosilicate and silicon carbide, metal fibers such as copper and iron, and the like can be suitably used. As the colloidal oxide, silica sol, alumina sol and the like are preferable. The colloidal oxide is suitable for imparting an appropriate adhesive force to the bonding material, and is bonded to inorganic fibers and inorganic particles by drying and dehydrating, so that the bonding material after drying has heat resistance and the like. It can be excellent and strong.

By applying such a bonding material to the outer wall surface to be bonded surfaces of the honeycomb segments at a predetermined thickness and combining the plurality of honeycomb segments, the bonding material is dried and cured, whereby the plurality of honeycomb segments are formed. An integrated honeycomb structure is obtained. Thereafter, if necessary, the outer peripheral portion may be ground into a desired shape such as a columnar shape. In this case, since the outer wall is removed by processing and the inner partition walls and cells are exposed, it is preferable to re-form the outer wall by covering the exposed surface with a coating material.

The present invention is a honeycomb structure having the basic structure as described above, wherein the average interval between the local peaks of the outer wall surface of the honeycomb segment is S, the arithmetic average surface roughness of the outer wall surface of the honeycomb segment is Ra, When the porosity of the outer wall is a, the average pore diameter of the outer wall of the honeycomb segment is b, and the average particle diameter of the inorganic particles contained in the bonding material is c, X represented by the following formula (1) and the following formula (2 The main feature is that Y represented by) satisfies the relationship of the following expression (3).
X = log _e (a × 10 ⁻² × b ² × c ⁻² ) (1)
Y = 1 / log _e (S / Ra) (2)
0.023X + 0.22 ≦ Y ≦ 0.027X + 0.54 (3)

According to the knowledge obtained by the present inventors through repeated trials, the porosity of the outer wall of the honeycomb segment, the average pore diameter of the outer wall of the honeycomb segment, and the average particle diameter of the inorganic particles contained in the bonding material are When X represented by the formula (1) satisfies the relationship of the above formula (3) with Y represented by the above formula (2), the balance of moisture scattering when the bonding material dries. As a result, the balance of the porosity and pore shape in the bonding material is improved, and a good Young's modulus can be obtained. As a result, the strength of the bonding material is increased and the ring-off crack limit is also increased.

The relationship between X and Y is such that Y> 0.0 due to factors such as a decrease in the porosity of the outer wall of the honeycomb segment, a decrease in the average pore size of the outer wall of the honeycomb segment, and an increase in the average particle size of the inorganic particles contained in the bonding material. In the case of 027X + 0.54, when the bonding material dries, moisture in the bonding material becomes difficult to scatter, and a large number of large voids (so-called fool holes) are formed in the bonding material. The physical strength of the material is weakened. As a result, not the interface between the honeycomb segment and the bonding material, but breakage within the bonding material is likely to occur, and the shear strength of the honeycomb structure decreases.

On the other hand, the relationship between X and Y is 0.1 due to factors such as an increase in the porosity of the outer wall of the honeycomb segment, an increase in the average pore size of the outer wall of the honeycomb segment, and a decrease in the average particle size of the inorganic particles contained in the bonding material. In the case of 023X + 0.22> Y, when the bonding material dries, moisture in the bonding material is easily scattered, the porosity of the bonding material decreases, and the Young's modulus increases. As a result, the ring-off crack limit is lowered.

In the present invention, the average interval S between the local peaks on the outer wall surface of the honeycomb segment is preferably 10 to 140 μm, and more preferably 15 to 100 μm. In the present invention, the “average distance S between local peaks” is a value defined in JIS B0601-1994, and is extracted from the roughness curve by a reference length in the direction of the average line. The average line length (interval between local summits) corresponding to the interval between adjacent local summits is obtained, and the arithmetic average value of the intervals between the many local summits is shown.

FIGS. 6 to 9 show the influence of the surface roughness of the outer wall surface of the honeycomb segment and the interval between the local peaks on the bonding state between the outer wall of the honeycomb segment and the inorganic particles contained in the bonding material. 6 and 8, when the surface roughness of the surface of the outer wall 8 of the honeycomb segment and the particle diameter of the inorganic particles 15 contained in the bonding material are approximately the same, the wider the distance between the local peaks, the inorganic particles 15 easily enters a valley (concave portion) on the surface of the honeycomb segment outer wall 8, and a phenomenon (so-called bridge) in which a void surrounded by the surface of the outer wall 8 and the inorganic particles 15 is less likely to occur, so that the contact area between the honeycomb segment and the bonding material is reduced. Will increase. On the other hand, as the distance between the local peaks increases, the number of irregularities at the same length on the outer wall surface decreases, so that the inorganic particles contained in the bonding material bite into the irregularities on the honeycomb segment outer wall surface. The effect (anchor effect) of increasing the joining strength is reduced.

Thus, as a result of studying the influence of the spacing between the local peaks, which is a lateral parameter of the unevenness on the surface of the honeycomb segment outer wall, on the contact area between the honeycomb segment and the bonding material and the anchor effect, By setting the average interval S of the local peaks on the outer wall surface in the above range and the average particle diameter of the inorganic particles contained in the bonding material within a predetermined range, a sufficient anchor effect can be secured, and the honeycomb segment can be bonded. Good bonding strength between the material and the surface of the honeycomb segment outer wall and the inorganic particles can be kept large, and heat transfer between the honeycomb segment and the bonding material can be smooth. all right.

If the average distance S between the local peaks is less than 10 μm, the contact area between the honeycomb segment and the bonding material may be reduced, and heat transfer between the two may not be performed smoothly. On the other hand, if the average distance S exceeds 140 μm, a sufficient anchor effect may not be obtained, and the necessary bonding strength may not be ensured.

In the present invention, from the viewpoint of improving the balance between the bonding strength between the honeycomb segment and the bonding material and the transfer of heat, in addition to the optimization of the average interval S between the local peaks as described above, The arithmetic average surface roughness Ra of the outer wall surface is preferably 0.4 to 23.5 μm, and more preferably 1 to 17.5 μm. In the present invention, the “average surface roughness Ra” is a value defined in JIS B0601-1994, and is extracted from the roughness curve by a reference length in the direction of the average line. The absolute values of deviations from the average line to the measurement curve are summed and the average value is shown.

From the comparison between FIG. 6 and FIG. 7, the surface roughness of the surface of the outer wall 8 is large (coarse) when the distance between the local peaks on the surface of the outer wall 8 and the particle diameter of the inorganic particles 15 included in the bonding material are approximately the same. It is considered that the inorganic particles 15 are less likely to enter the valleys (recesses) on the surface of the outer wall 8 of the honeycomb segment, so that so-called bridges are likely to occur, and the contact area between the honeycomb segment and the bonding material is reduced. On the other hand, the anchor effect decreases as the surface roughness of the outer wall 8 surface decreases.

As a result of investigating the influence of the surface roughness, which is a parameter in the height direction of the unevenness of the honeycomb segment outer wall surface, on the contact area and anchor effect between the honeycomb segment and the bonding material, It was found that when the arithmetic average surface roughness Ra of the outer wall surface is in the above range, the balance between the bonding strength between the honeycomb segment and the bonding material and the transfer of heat is improved.

If this arithmetic average surface roughness Ra is less than 0.4 μm, the anchor effect may be reduced and it may be difficult to ensure the required bonding strength. If it exceeds 23.5 μm, the contact area between the honeycomb segment and the bonding material decreases. As a result, heat cannot be transferred smoothly between the two, or the inorganic particles do not enter the valleys (recesses) on the surface of the outer wall of the honeycomb segment, and cracks occur at the interface between the honeycomb segment and the bonding material when the bonding material is dried. There is a case. Setting the arithmetic mean surface roughness Ra of the honeycomb segment outer wall surface within the preferred range is particularly effective in that it is easy to ensure the necessary bonding strength.

In the present invention, similarly, from the viewpoint of improving the balance between the bonding strength between the honeycomb segment and the bonding material and the transfer of heat, the average interval S between the local peaks on the outer wall surface of the honeycomb segment and the arithmetic average surface The ratio to the roughness Ra (S / Ra) is preferably 1.8 to 37.5, and more preferably 4 to 27.5.

If S / Ra is less than 1.8, heat transfer between the honeycomb segment and the bonding material may not be performed smoothly, and if it exceeds 37.5, sufficient bonding strength may not be obtained. Setting S / Ra within the preferred range is particularly effective in terms of smooth heat transfer between the honeycomb segment and the bonding material.

Further, as can be seen from the comparison between FIG. 8 and FIG. 9, even if the distance between the local peaks on the surface of the outer wall 8 of the honeycomb segment is large, so-called bridging is likely to occur when the surface roughness increases to some extent. Therefore, as described above, defining the average distance S between the local peaks on the outer wall surface in relation to the arithmetic average surface roughness Ra is effective for obtaining a better bonding state.

The average distance S between the local peaks on the outer surface of the honeycomb segment outer wall surface and the arithmetic average surface roughness Ra are adjusted to be within a predetermined range by controlling the particle size distribution and firing conditions of the raw material particles used for manufacturing the honeycomb segment. It is possible. In addition, the average interval S and the arithmetic average surface roughness Ra of the local peaks on the outer wall surface of the honeycomb segment are changed by once forming the honeycomb segment and then applying a base material containing particles such as ceramic particles to the outer wall. By adjusting the particle size distribution of the particles in the base material, it is possible to adjust the average distance S between the local peaks and the arithmetic average surface roughness Ra to be within a predetermined range.

Furthermore, in the present invention, similarly, from the viewpoint of improving the balance between the bonding strength between the honeycomb segment and the bonding material and the transfer of heat, the average particle size of the inorganic particles contained in the bonding material is set to 0.5. The thickness is preferably from 30 to 30 μm, and more preferably from 1.0 to 15 μm. In the present invention, the “average particle size” is a value of 50% particle size measured using LA-920 (trade name) manufactured by HORIBA, Ltd. as a measuring device in accordance with JIS R1629. Shall mean.

If the average particle size of the inorganic particles contained in the bonding material is less than 0.5 μm, the inorganic particles may penetrate into the inside of the honeycomb segment, thereby changing the material ratio of the bonding material and reducing the bonding strength. If it exceeds 30 μm, inorganic particles cannot easily enter the recesses on the outer wall surface of the honeycomb segment and a sufficient anchor effect cannot be obtained, or the contact area between the outer surface of the honeycomb segment wall and the inorganic particles is reduced, May interfere with the exchange of heat between the two. Setting the average particle diameter of the inorganic particles contained in the bonding material within the above range makes it easy to ensure the necessary bonding strength between the honeycomb segment and the bonding material, and the transfer of heat between them. It is effective both in terms of smoothness. When the average particle diameter of the inorganic particles is within the above range, the behavior of the inorganic particles with respect to the outer wall surface of the honeycomb segment when the honeycomb segments are bonded with the bonding material is substantially the same.

In the present invention, the porosity of the honeycomb segment is preferably 30 to 80%, more preferably 45 to 80%. When the porosity of the honeycomb segment is less than 30%, when the honeycomb structure of the present invention is used for a filter such as DPF, the pressure loss is too large, and when it exceeds 80%, the maximum temperature at the time of filter regeneration rises too much. Problems may arise. Further, the average pore diameter of the honeycomb segment is preferably 5 to 40 μm, and more preferably 5 to 20 μm. If the average pore diameter of the honeycomb segment is less than 5 μm, the pressure loss is too large when the honeycomb structure of the present invention is used for a filter such as DPF, and if it exceeds 40 μm, the filter function for collecting PM is too low. There may be problems above.

The “porosity” in the present invention is measured by Archimedes method by cutting a flat plate having a partition wall thickness from a honeycomb segment as a test piece, and the “average pore diameter” is a predetermined shape (□ 5 × 15 mm from the honeycomb segment). ) Was cut out and measured with a mercury porosimeter.

As the constituent material of the honeycomb segment, from the viewpoint of strength, heat resistance, etc., silicon carbide, a silicon-silicon carbide composite material formed using silicon carbide as an aggregate and silicon as a binder, silicon nitride, cordierite, mullite, Preferable examples include at least one material selected from the group consisting of alumina, spinel, silicon carbide-cordierite composite material, lithium aluminum silicate, aluminum titanate, and Fe—Cr—Al metal. Further, as shown in FIG. 3, when the plugging portion is formed in the opening of the cell, the constituent material of the plugging portion is made of the same material as that of the honeycomb segment in order to reduce the difference in thermal expansion from the honeycomb segment. It is preferable to use it.

A conventionally well-known method can be used for the manufacturing method of a honeycomb segment. As an example of a specific method, a binder such as methyl cellulose, hydroxypropoxyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and polyvinyl alcohol, a pore former, a surfactant, and water as a solvent are added to the above-described materials. Then, a plastic clay is formed, and the clay is extruded so as to have a predetermined honeycomb shape, and then dried by microwaves, hot air or the like, and then fired. When the plugged portion is formed in the cell, the firing may be performed before the plugged portion is formed in the cell, or the plugged portion is fired after the plugged portion is formed in the cell. May be performed together with.

A conventionally known method can also be used as a method for plugging the cells. As an example of a specific method, after a sheet is attached to the end face of the honeycomb segment, a hole is made at a position corresponding to the cell to be plugged of the sheet, and the sheet is left attached. In the plugging slurry obtained by slurrying the constituent material of the plugging portion, the end face of the honeycomb segment is immersed in the opening end portion of the cell to be plugged through the hole formed in the sheet. Fill the slurry and dry and / or bake it to cure.

The porosity and average pore diameter of the honeycomb segment can be adjusted by the particle diameter of the material, the particle diameter and addition amount of the pore former, the firing conditions, and the like.

The honeycomb structure used in the DPF has all the cells in the same shape (usually a quadrangle) and the same opening area, and the ends of the cells are alternately shown in a checkered pattern at the inlet side end face and the outlet side end face. It is generally plugged and the opening ratio at the inlet side end face and the outlet side end face is generally the same, but recently, the opening at the inlet side end face is aimed at suppressing the increase in pressure loss after PM collection. A honeycomb structure having a higher rate than the opening ratio of the outlet side end face has been proposed, and such a structure can also be applied to the honeycomb structure of the present invention.

4 and 5 show an example of an embodiment of a plugged honeycomb structure in which the opening ratio is different between the inlet side end face and the outlet side end face, FIG. 4 is a partially enlarged view of the inlet side end face, and FIG. It is the elements on larger scale of an exit side end surface. As shown in these drawings, in this embodiment, quadrangular cells 5a and octagonal cells 5b having a larger opening area are alternately arranged in two orthogonal directions on each end face. 5a is plugged by the plugging portion 9 at the inlet end surface, and the octagonal cell 5b is plugged by the plugging portion 9 at the outlet side end surface. . Thus, by opening the octagonal cell 5b having a large opening area on the inlet side end face and opening the quadrangular cell 5a having a small opening area on the outlet side end face, the opening ratio of the inlet side end face is more than the opening ratio of the outlet side end face. Can also be increased.

In the honeycomb structured body of the present invention, the partition wall thickness of the honeycomb segment is preferably 7 to 20 mil (178 to 508 μm), more preferably 8 to 16 mil (203 to 406 μm), and 10 to 12 mil ( More preferably, it is 254 to 305 μm. If the partition wall thickness is less than 7 mil, the strength may be insufficient and the thermal shock resistance may be reduced. On the other hand, if the partition wall thickness exceeds 20 mil, the pressure loss may be too large.

The cell density is preferably 140 to 350 cells / in ² (cpsi), more preferably 160 to 320 cpsi, and still more preferably 200 to 300 cpsi. If the cell density is less than 140 cpsi, the contact efficiency with the fluid may be insufficient. On the other hand, if the cell density exceeds 350 cpsi, the pressure loss may increase excessively. “Cpsi” is an abbreviation for “cells per square inch”, and is a unit representing the number of cells per square inch. For example, 10 cpsi is about 1.55 cells / cm ² .

The cell shape (cell cross-sectional shape) is not particularly limited, and may be, for example, a polygon such as a quadrangle, a triangle, a hexagon, an octagon, or a round shape, as described above. Different shapes of cells may be combined and arranged.

Moreover, in the honeycomb structure of the present invention, a catalyst component may be supported on the partition wall for the purpose of promoting PM combustion during filter regeneration or purifying harmful substances in the exhaust gas. As a method for supporting the catalyst component on the partition wall, for example, a solution containing the catalyst component is impregnated with a powder made of a heat-resistant inorganic oxide having a high specific surface area such as alumina powder, and then dried and fired. A method in which a powder containing components is obtained, a catalyst slurry is prepared by adding alumina sol or water to the powder, a honeycomb segment or a honeycomb structure is immersed therein, the slurry is coated, and then dried and fired. Can be used.

As the catalyst component, it is preferable to use one or more precious metals selected from the group consisting of Pt, Rh, and Pd. The amount of these noble metals supported is preferably 0.3 to 3.5 g / L per unit volume of the honeycomb structure.

Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.

(Examples 1 to 18 and Comparative Examples 1 to 6)
SiC powder and metal Si powder were mixed at a predetermined mass ratio, and a pore former, an organic binder, a surfactant and water were added thereto to obtain a plastic clay. This kneaded material was extruded and dried to obtain a honeycomb-shaped formed body. A plugged portion was formed at one end of each cell so that both end faces of the honeycomb formed body had a complementary checkerboard pattern. That is, the plugged portion was formed so that adjacent cells were sealed at the opposite ends. The same material as that for the honeycomb formed body was used as the material for the plugging portion. After the plugging portions are formed and dried in this way, the honeycomb-shaped formed body is degreased at about 400 ° C. in an air atmosphere, and further fired at about 1450 ° C. in an Ar atmosphere to obtain SiC particles in the formed body. Are bonded with Si, the porosity, the average pore diameter, the average distance S between the local peaks of the outer wall surface, the arithmetic average surface roughness Ra, and S / Ra as shown in Table 1, and the partition wall thickness is A square pillar-shaped honeycomb having a 12 mil (305 μm) cell shape, a square cell shape, a cell density of about 46.5 cells / cm ² (300 cells / in ² ), a cross-sectional shape of a square with a side of 35 mm, and an axial length of 152 mm Got a segment. It should be noted that the porosity, average pore diameter, average distance S between the local peaks of the outer wall surface, arithmetic average surface roughness Ra, and adjustment of the values of S / Ra were mainly adjusted with SiC powder and metal Si powder used as the raw material for clay. And adjusting the particle size distribution and amount of the pore former. For example, in Example 1, 65% by mass of SiC powder having an average particle size of 5 μm, 16% by mass of metal Si powder having an average particle size of 3 μm, and 19% by mass of a pore former having an average particle size of 10 μm, 1.4 μm Ra and 46 μm S were obtained. In Example 8, 65% by mass of SiC powder having an average particle size of 60 μm, 16% of metal Si powder having an average particle size of 6 μm, and 19% by mass of a pore former having an average particle size of 50 μm were mixed. 0.5 μm Ra and 71 μm S were obtained.

Next, using SiC powder having an average particle size shown in Table 1 as inorganic particles, to this mixed aluminosilicate fiber, silica sol aqueous solution and clay, water was further added, and kneaded for 30 minutes using a mixer, A paste-like bonding material was obtained. This bonding material is applied to the outer wall surface of the honeycomb segment so as to have a thickness of about 1 mm to form a bonding material layer, and a process of placing another honeycomb segment thereon is repeated. A honeycomb segment laminate including a total of 16 honeycomb segments combined in a piece was produced. Then, the whole was joined as appropriate by applying pressure from the outside, and then dried at 120 ° C. for 2 hours to obtain a joined honeycomb segment. After grinding the outer periphery so that the outer shape of the joined honeycomb segment assembly is a cylindrical shape, a coating material having the same composition as the joining material is applied to the processed surface to re-form the outer wall, and at 700 ° C. for 2 hours. Drying and curing were performed to obtain honeycomb structures of Examples 1 to 18 and Comparative Examples 1 to 6. With respect to the honeycomb structures of Examples 1 to 18 and Comparative Examples 1 to 6 thus manufactured, the shear strength, fracture location and crack limit of the joint were examined by the following method. The results are shown in Table 1. Moreover, X and Y were calculated from the above-mentioned formulas (1) and (2), and those values are also shown in the same table. In each of the examples and comparative examples, the honeycomb structure used for measuring the shear strength of the joint and the honeycomb structure used for investigating the crack limit are different individuals produced by the same method. That is, for each of the examples and comparative examples, two honeycomb structures were prepared, one of which was used for the measurement of the shear strength of the joint and the investigation of the breakage point, and the other was used for the investigation of the crack limit. .

[Shear strength]
Two honeycomb segments adjacent to each other were cut out from the honeycomb structure in a joined state, one honeycomb segment was fixed, and a load F was applied to the other honeycomb segment from the major axis direction.

[Break point]
The fracture location when the shear strength was measured was examined.

[Crack limit]
After the honeycomb structure was heated to 1200 ° C., the presence or absence of cracks in the honeycomb structure was confirmed by X-ray CT.

(Discussion)
As shown in Table 1, Examples 1 to 18 included in the scope of the present invention had high shear strength, the joined body itself did not break inside, and the ring-off crack limit was also high. . On the other hand, X and Y calculated from the above formulas (1) and (2) do not satisfy formula (3), and the relationship between X and Y is Y> 0.027X + 0.54. In Nos. 2 to 5, since the physical strength of the bonding material is insufficient, the fracture occurs not in the interface between the honeycomb segment and the bonding material but in the bonding material, and the relationship between X and Y is 0.023X + 0. In Comparative Examples 1 and 6 where 22> Y, the ring-off crack limit was low.

(Examples 19 to 22 and Comparative Examples 7 to 12)
SiC powder and metal Si powder were mixed at a predetermined mass ratio, and a pore former, an organic binder, a surfactant and water were added thereto to obtain a plastic clay. This kneaded material was extruded and dried to obtain a honeycomb-shaped formed body. A plugged portion was formed at one end of each cell so that both end faces of the honeycomb formed body had a complementary checkerboard pattern. That is, the plugged portion was formed so that adjacent cells were sealed at the opposite ends. The same material as that for the honeycomb formed body was used as the material for the plugging portion. After the plugging portions are formed and dried in this way, the honeycomb-shaped formed body is degreased at about 400 ° C. in an air atmosphere, and further fired at about 1450 ° C. in an Ar atmosphere to obtain SiC particles in the formed body. Were bonded with Si to obtain a honeycomb fired body.

Next, a base material is applied to the outer wall of the honeycomb-shaped fired body, and is naturally dried. The partition wall thickness is 12 mil (305 μm), the cell shape is square, and the cell density is about 46.5 cells / cm ² (300 cells). / Square inch), a square column-shaped honeycomb segment having a cross-sectional shape of a square with a side of 35 mm and an axial length of 152 mm was obtained. The base material is a mixture of SiC powder, silica sol aqueous solution and water, and after applying and naturally drying, the porosity, the average pore diameter, the average interval S of the local peaks on the outer wall surface, the arithmetic average surface roughness. The particle size distribution and the like of the SiC powder in the base material were adjusted so that the thickness Ra and S / Ra were values shown in Table 2. For example, in Example 19, 37% by mass of SiC powder having an average particle size of 1.9 μm, 37% by mass of an aqueous silica sol solution having an average particle size of SiO ₂ of 40 nm, and 26% by mass of water were mixed to form a base material. None, 5.9 μm Ra and 72 μm S were obtained. In Example 22, the base material was prepared by mixing 32% by mass of SiC powder having an average particle diameter of 0.6 μm, 27% by mass of silica sol aqueous solution having an average particle diameter of SiO ₂ of 33 nm, and 41% by mass of water. As a result, 0.6 μm Ra and 62 μm S were obtained.

Subsequently, SiC powder having the average particle size shown in Table 2 was used as inorganic particles, and water was added to the mixture of aluminosilicate fiber, silica sol aqueous solution and clay, and kneaded for 30 minutes using a mixer. A paste-like bonding material was obtained. This bonding material is applied to the outer wall surface of the honeycomb segment so as to have a thickness of about 1 mm to form a bonding material layer, and a process of placing another honeycomb segment thereon is repeated. A honeycomb segment laminate including a total of 16 honeycomb segments combined in a piece was produced. Then, the whole was joined as appropriate by applying pressure from the outside, and then dried at 120 ° C. for 2 hours to obtain a joined honeycomb segment. After grinding the outer periphery so that the outer shape of the joined honeycomb segment assembly is a cylindrical shape, a coating material having the same composition as the joining material is applied to the processed surface to re-form the outer wall, and at 700 ° C. for 2 hours. Dry and cured to obtain honeycomb structures of Examples 19 to 22 and Comparative Examples 7 to 12. With respect to the honeycomb structures of Examples 19 to 22 and Comparative Examples 7 to 12 manufactured in this way, the shear strength, fracture location, and crack limit of the joint were examined by the above-described method. The results are shown in Table 2. Moreover, X and Y were calculated from the above-mentioned formulas (1) and (2), and those values are also shown in the same table.

(Discussion)
As shown in Table 2, Examples 19 to 22 included in the scope of the present invention had high shear strength, the joined body itself did not break inside, and the ring-off crack limit was also high. . On the other hand, X and Y calculated from the above formulas (1) and (2) do not satisfy formula (3), and the relationship between X and Y is Y> 0.027X + 0.54. 7, 8 and 10 to 12, the physical strength of the bonding material is insufficient, so that the fracture occurs not in the interface between the honeycomb segment and the bonding material but in the bonding material, and the relationship between X and Y is In Comparative Example 9 where 0.023X + 0.22> Y, the ring-off crack limit was low.

The present invention can be suitably used as a dust collection filter such as DPF.

1: honeycomb structure, 2: honeycomb segment, 3: partition, 5: cell, 5a: square cell, 5b: octagonal cell, 8: outer wall, 9: plugging portion, 10: end surface on the inlet side, 11: outlet Side end face, 15: inorganic particles.

Claims

An inlet-side end face that becomes the fluid inlet side, an outlet-side end face that becomes the fluid outlet side, an outer wall that connects the outer peripheral portions of the two end faces, and a partition wall of the porous body between the two end faces inside the outer wall A honeycomb structure in which a plurality of honeycomb segments having a plurality of cells that serve as fluid flow paths and formed by partitioning are integrated by joining the outer walls with a joining material containing inorganic particles. Because
The average interval between the local peaks of the outer wall surface is S, the arithmetic average surface roughness of the outer wall surface is Ra, the porosity of the outer wall is a, the average pore diameter of the outer wall is b, and the average particle size of the inorganic particles is c. A honeycomb structure in which X represented by the following formula (1) and Y represented by the following formula (2) satisfy the relationship of the following formula (3).
X = log e (a × 10 −2 × b 2 × c −2 ) (1)
Y = 1 / log e (S / Ra) (2)
0.023X + 0.22 ≦ Y ≦ 0.027X + 0.54 (3)
The honeycomb structure according to claim 1, wherein an average interval S between local peaks on the outer wall surface is 10 to 140 µm.
The honeycomb structure according to claim 1 or 2, wherein the inorganic particles have an average particle diameter of 0.5 to 30 µm.
The honeycomb structure according to any one of claims 1 to 3, wherein an arithmetic average surface roughness Ra of the outer wall surface is 0.4 to 23.5 µm.
The honeycomb structure according to any one of claims 1 to 4, wherein a ratio (S / Ra) of an average interval S between the local peaks of the outer wall surface to an arithmetic average surface roughness Ra is 1.8 to 37.5. body.
The honeycomb structure according to any one of claims 1 to 5, wherein a base material containing particles is applied to an outer wall surface of the honeycomb segment.
The honeycomb structure according to any one of claims 1 to 6, wherein the honeycomb segment has a porosity of 30 to 80% and an average pore diameter of 5 to 50 µm.
8. The method according to claim 1, further comprising: a plugging portion that plugs a predetermined opening of the cell at the inlet side end face and plugs a remaining opening of the cell at the outlet side end face. A honeycomb structure according to claim 1.
The honeycomb structure according to claim 8, wherein an opening ratio of the inlet side end face is larger than an opening ratio of the outlet side end face.
The honeycomb structure according to any one of claims 1 to 9, wherein a catalyst component is supported on the partition walls.