WO2011090015A1 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- WO2011090015A1 WO2011090015A1 PCT/JP2011/050716 JP2011050716W WO2011090015A1 WO 2011090015 A1 WO2011090015 A1 WO 2011090015A1 JP 2011050716 W JP2011050716 W JP 2011050716W WO 2011090015 A1 WO2011090015 A1 WO 2011090015A1
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- WIPO (PCT)
- Prior art keywords
- hole
- honeycomb structure
- cross
- cell partition
- section
- Prior art date
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- 238000002485 combustion reaction Methods 0.000 claims abstract description 11
- 230000001788 irregular Effects 0.000 claims abstract description 10
- 238000005192 partition Methods 0.000 claims description 92
- 230000002159 abnormal effect Effects 0.000 claims description 2
- 238000007789 sealing Methods 0.000 abstract description 23
- 230000035939 shock Effects 0.000 abstract description 6
- 238000000638 solvent extraction Methods 0.000 abstract 5
- 239000004071 soot Substances 0.000 description 17
- 239000000463 material Substances 0.000 description 14
- 239000000919 ceramic Substances 0.000 description 9
- 230000002093 peripheral effect Effects 0.000 description 8
- 239000010419 fine particle Substances 0.000 description 7
- 239000000470 constituent Substances 0.000 description 4
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- 238000009413 insulation Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
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- 239000011148 porous material Substances 0.000 description 3
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 2
- 241000209094 Oryza Species 0.000 description 2
- 235000007164 Oryza sativa Nutrition 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 2
- 238000011069 regeneration method Methods 0.000 description 2
- 235000009566 rice Nutrition 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 description 1
- 230000000386 athletic effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
- F01N3/2825—Ceramics
- F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
-
- 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
-
- 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
-
- 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
- B01D46/247—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the cells
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2484—Cell density, area or aspect ratio
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
- B01D46/2488—Triangular
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
- B01D46/249—Quadrangular e.g. square or diamond
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- 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
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
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- 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 monoliths
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/02—Air cleaners
- F02M35/024—Air cleaners using filters, e.g. moistened
- F02M35/02475—Air cleaners using filters, e.g. moistened characterised by the shape of the filter element
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
- B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2260/00—Exhaust treating devices having provisions not otherwise provided for
- F01N2260/10—Exhaust treating devices having provisions not otherwise provided for for avoiding stress caused by expansions or contractions due to temperature variations
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/30—Honeycomb supports characterised by their structural details
- F01N2330/48—Honeycomb supports characterised by their structural details characterised by the number of flow passages, e.g. cell density
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- 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
Definitions
- the present invention relates to a honeycomb structure. More specifically, the present invention relates to a honeycomb structure used for a filter that purifies exhaust gas by collecting fine particles (soot and the like) in exhaust gas discharged from an internal combustion engine such as a diesel engine or a gasoline engine.
- a ceramic honeycomb structure formed in a tubular shape is generally used as a filter (Diesel Particulate Filter: DPF) that collects soot contained in exhaust gas.
- DPF Diesel Particulate Filter
- a function of collecting soot is imparted to the honeycomb structure by alternately sealing the openings at both axial ends of the honeycomb structure (Patent Document 1).
- the ceramic honeycomb structure 100 is formed so that gas can pass through the wall surface 101 forming the honeycomb, and each through-hole of the honeycomb structure 100 is formed.
- 105 hereinafter referred to as a cell
- the opening of one of the shaft ends is sealed by the sealing material 106, and the other end is opened.
- the other cell 105b adjacent to the cell 105a is formed in an open state.
- the sealed cells 105a are arranged in a staggered arrangement (an arrangement of every other sealed cell) (see FIG. 2 (A)).
- the DPF functions as follows to clean the exhaust gas.
- exhaust gas for cleaning is supplied from one end of the DPF in the axial direction (left end in FIG. 2B).
- the exhaust gas flows into the DPF from the opened cell 105b (inflow side cell 105b). Since the other end of these inflow side cells 105b is sealed, the exhaust gas flows through the wall surface 101 into the adjacent cell 105a (discharge side cell). Since the discharge side cell 105a is open at the other end (discharge side) in the axial direction of the DPF, the exhaust gas flows out from the other end in the axial direction of the discharge side cell 105a (the right end in FIG. 2B). That is, in the DPF, the wall surface 101 that separates adjacent cells functions as a filter, and harmful substances (for example, fine particles) contained in the exhaust gas can be captured by the wall surface 101, so that the exhaust gas can be purified. is there.
- the honeycomb structure made of ceramic is generally formed by extruding ceramics and firing the molded body as it is.
- the cells in the vicinity of the outer peripheral surface are deformed cells having a smaller cross-sectional area than other cells (
- the cross section is a trapezoidal or triangular cell (hereinafter referred to as a small cross section cell).
- the small cross-sectional cells are easily crushed during extrusion molding or firing, and when the small cross-sectional cells are crushed, streak-like dents are formed on the outer peripheral surface of the honeycomb structure.
- the dents are likely to be the starting point of cracks due to heat shock, and the possibility that the honeycomb structure is damaged by heat shock increases.
- an object of the present invention is to provide a honeycomb structure that can prevent the occurrence of cracking due to poor sealing and heat shock caused by small cross-sectional cells.
- a honeycomb structure of the present invention is a honeycomb structure used for a filter for purifying exhaust gas discharged from an internal combustion engine, and the honeycomb structure has a double structure of an outer cylinder and an inner cylinder.
- An inner cell partition that forms an internal through hole is provided inward of the inner cylinder, and an outer cell partition that forms an external through hole is provided between the outer cylinder and the inner cylinder.
- the inner cell partition wall has a modified cross-sectional through hole, and is connected to the one modified cross-section through hole and one external through hole sharing the inner cylinder, and the one modified cross-sectional through hole and the inner cell partition wall are shared.
- connection through hole is formed by performing at least one connection among the connection with another modified cross-section through hole and the connection between one modified cross-section through hole and the internal through hole sharing the internal cell partition wall. It is characterized by that.
- the modified cross-sectional through-hole having a substantially triangular shape when viewed in cross section of the outer cylinder is connected to the external through-hole closest to the sharpest apex thereof, and the external through-hole is connected.
- a new cell partition extending inward continuously from the outer cell partition to be formed and parallel to the inner cell partition so as to make the shape of the connecting through hole in a cross section substantially a pentagon.
- the new cell partition wall forms a new irregular cross-sectional through hole having a substantially trapezoidal cross-sectional shape with the cell partition as an upper base
- the new abnormal cross-section through hole serves as a cell partition serving as a lower base. It is more preferable to connect with the adjacent deformed cross-sectional through hole sharing the same.
- the through hole having the smallest opening area among all the through holes has an opening area of 40% or more of the average opening area of all the through holes.
- all the internal angles of all the through holes are 30 degrees or more.
- the outer cell partition wall includes an outer circumferential cell partition wall formed adjacent to an outer through hole in the circumferential direction of the outer cylinder, and the outer circumferential cell partition wall is formed so as to be substantially orthogonal to the outer cylinder. It is preferable that It is also preferable that at least one end of the external through hole is sealed.
- a connecting through-hole having a relatively large cross-sectional area can be formed in order to connect the external cross-sectional hole adjacent to the modified cross-sectional through-hole, another external cross-sectional through-hole, or the internal through-hole. Therefore, even if the inner cylinder is provided, it is possible to prevent a through hole having a small cross-sectional area from being formed in the vicinity of the inner cylinder. Also, a modified cross-sectional through hole (that is, a shape having a substantially triangular shape or a substantially trapezoidal shape when viewed from the cross section of the outer cylinder) whose cross-sectional area tends to be smaller than other modified cross-sectional through holes is located in the vicinity thereof.
- the cross-sectional area of all the through holes in the present invention is a predetermined size or more, or when all the internal angles of all the through holes are 30 degrees or more, when sealing the through holes, the partition walls are Even in the vicinity of the intersecting portion, the material to be sealed can be reliably filled, and sealing failure can be prevented.
- the outer circumferential cell partition is formed so as to be substantially orthogonal to the outer cylinder, the cross-sectional area of the external through hole having the outer cylinder as a constituent element can be maintained to a certain size, so that the honeycomb structure is formed. In this case, the possibility that the external through hole is crushed can be reduced. Therefore, the outer peripheral surface of the honeycomb structure can be maintained with a predetermined accuracy. In addition, since the possibility of forming streak-like dents on the outer peripheral surface of the honeycomb structure can be reduced, the possibility of the honeycomb structure being damaged due to heat shock or the like can be reduced.
- the outer circumferential cell partition is formed so as to be substantially orthogonal to the outer cylinder, even if a force is applied to the outer peripheral surface of the honeycomb structure, the force can be supported by the outer circumferential cell partition. This can increase the durability of the honeycomb structure against external forces. In the present invention, if at least one end of the external through hole is sealed, a thermal insulation effect can be expected for these through holes. In addition, since the force applied to the outer cylinder can be supported by the material to be sealed, the strength of the outer cylinder of the honeycomb structure can be increased.
- FIG. 1 It is a schematic explanatory drawing of the honeycomb structure 1 of this embodiment, (A) is a front view, (B) is a partial enlarged view. It is a schematic explanatory drawing of the honeycomb structure 100 of a prior art example, (A) is a front view, (B) is sectional drawing.
- honeycomb structure of the present invention is used for manufacturing an exhaust gas filter for purifying exhaust gas discharged from an internal combustion engine, and is characterized in that a sealing defect does not occur when manufacturing an exhaust gas filter. Have.
- sealing refers to sealing the open end of a through-hole (cell) provided in the honeycomb structure with a material such as ceramics.
- the material used for this sealing may or may not have air permeability, but it is preferable to use a material that does not allow fine particles (such as soot) in the exhaust gas to pass through. That is, by sealing with such a material, fine particles such as soot can be prevented from flowing into the through hole from the sealed end.
- a material used for sealing for example, it has air permeability like a material constituting the wall of the honeycomb structure (the outer cylinder 2, the inner cylinder 11, the outer cell partition wall 13 and the inner cell partition wall 12 in FIG. 1). However, a material that does not allow fine particles such as soot to pass therethrough may be used. In this case, the same material as the walls of the honeycomb structure may be used, or a different material may be used.
- the exhaust gas filter manufactured from the honeycomb structure of the present invention is, for example, a filter (for example, DPF) that captures soot contained in exhaust gas of a diesel engine or a gasoline engine, but is not particularly limited. Moreover, if a catalyst such as platinum is supported on the material of the honeycomb structure of the present invention, a catalyst for purifying harmful substances in the exhaust gas can be produced using the honeycomb structure of the present invention.
- a filter for example, DPF
- honeycomb structure 1 of the present invention is not limited to a cylindrical shape, and the cross section is substantially triangular.
- shape a triangular shape with rounded vertices, a so-called triangular rice ball shape
- elliptical shape an elliptical shape, or a shape in which straight lines and semicircles are combined, such as an athletics track.
- the shape of the opening cross section of the through hole in the honeycomb structure of the present invention is not limited to an accurate square, and may be a substantially square, or may be a pentagon, hexagon, octagon, circle, or the like, and is not particularly limited. .
- a description will be given of a honeycomb structure formed so that the cross-sectional areas of the opening cross sections of adjacent through holes are substantially the same, that is, a so-called symmetrical cell honeycomb structure.
- the honeycomb structure of the present invention has the same effects even in a honeycomb structure formed so that the cross-sectional areas of the opening cross-sections of adjacent through holes are different, that is, a honeycomb structure of an asymmetric cell.
- the honeycomb structure 1 of the present invention is a tubular (cylindrical in the illustrated example) structure extending along the axial direction (direction orthogonal to the paper surface in FIG. 1).
- a plurality of through holes (10h, 13h, 20a, 20b, 20c, 25, etc.) penetrating between both axial ends along the axial direction are provided.
- the honeycomb structure 1 of the present invention is formed of ceramics formed by extruding and forming a clay composed of raw material powder, a molding aid, water, and if necessary, a pore former, and a plurality of ceramics.
- Wall surfaces (inner cell partition 12, outer cell partition 13, outer cylinder 2, inner cylinder 11, etc.) that form through holes 10h and 13h are porous having pores with an average pore diameter of 20 ⁇ m or less.
- the ceramic constituting the honeycomb structure of the present invention is not particularly limited, and examples thereof include aluminum titanate ceramics such as aluminum titanate, magnesium titanate, and aluminum magnesium titanate.
- the honeycomb structure 1 has a cylindrical (cylindrical in the illustrated example) outer cylinder (outer shell) 2, in which a plurality of partition walls are provided, and the outer cylinder A plurality of through holes 10h, 13h and the like are formed by 2 and a plurality of partition walls, and a portion including the through holes formed by these partition walls is also referred to as a cell portion. More specifically, the honeycomb structure 1 has a double structure of an outer cylinder 2 and an inner cylinder (inner partition wall) 11 positioned inward of the outer cylinder 2. A first cell partition (outer cell partition) 13 is provided between the cylinders 11, and a second cell partition (internal cell partition) 12 is formed inside the inner cylinder 11. The outer cell partition wall 13 and the outer cylinder 2 or the outer cell partition wall 13 and the inner cylinder 11 form an external through hole 13h, and the inner cell partition walls 12 form an internal through hole 10h.
- the inner cylinder 11 is a cylindrical wall (cylindrical in the illustrated example) provided inward from the inner surface of the outer cylinder 2 as described above.
- the inner cylinder 11 has a central axis that is coaxial with the outer cylinder 2, and has a shape similar to that of the outer cylinder 2 in an orthogonal cross section (hereinafter simply referred to as a transverse section) orthogonal to the axial direction of the outer cylinder 2. Is formed.
- a plurality of internal cell partition walls 12 that divide the space in the inner cylinder 11 are provided inside the inner cylinder 11.
- Each of the plurality of inner cell partition walls 12 is formed so that the surface thereof is parallel to the axial direction of the outer cylinder 2, and the inner cell partition walls 12 intersecting each other are arranged to be orthogonal to each other. That is, a space surrounded by the plurality of internal cell partition walls 12 is a through hole (hereinafter referred to as an internal through hole) 10h, the cross-sectional shape of the internal through hole 10h is square, and the axial direction of the internal through hole 10h is an outer cylinder.
- a plurality of internal cell partition walls 12 are arranged so as to be parallel to the axial direction of the two.
- a plurality of external cell partition walls 13 that form through holes (hereinafter referred to as external through holes) 13 h are provided between the inner cylinder 11 and the outer cylinder 2.
- Each of the plurality of external cell partition walls 13 is formed so that the surface thereof is parallel to the axial direction of the outer cylinder 2.
- the outer cell partition wall 13 includes an outer circumferential cell partition wall (outer peripheral partition wall) 13 a that forms an outer through hole 13 h adjacent to the outer cylinder 2 in the circumferential direction.
- This outer circumferential cell partition wall 13a divides the space between the outer cylinder 2 and the inner cylinder 11 and forms external through holes 13h adjacent to each other in the direction along the inner surface of the outer cylinder 2. is there.
- the outer circumferential cell partition wall 13 a is formed so as to be substantially orthogonal to the inner surface of the outer cylinder 2.
- the tangent line of the circle C1 at that position and the outer cell partition wall 13 are orthogonal to each other.
- the outer circumferential cell partition wall may not be substantially orthogonal to the outer cylinder, and may be formed so that the cross-sectional shape of the outer through hole adjacent to the outer cylinder in the circumferential direction is substantially trapezoidal.
- the honeycomb structure 1 of the present invention if any one of the end portions of all the internal through holes 10h and all the external through holes 13h is sealed, the honeycomb structure 1 can be used as an exhaust gas filter (FIG. 2). reference). If a gas to be purified, such as exhaust gas, is supplied from one end side of the honeycomb structure 1 after sealing, the gas flows out to the other end side of the honeycomb structure 1 unless it passes through any partition wall. Since it cannot, fine particles such as soot can be collected by the partition wall, and the exhaust gas can be purified.
- a gas to be purified such as exhaust gas
- the inner cylinder 11 is provided, and the outer cell partition wall 13 is provided between the inner cylinder 11 and the outer cylinder 2. Then, since the external through-hole 13h formed between the outer cylinder 2 and the inner cylinder 11 can be shaped independently of the inner through-hole 10h in the inner cylinder 11, the outer cylinder 2 is a component. The cross-sectional area of the external through hole 13h can be maintained at a certain size. Therefore, when the honeycomb structure 1 is formed by extrusion molding or the like, it is possible to reduce the possibility that the external through-hole 13h having the outer cylinder 2 as a constituent element will be crushed. The accuracy can be maintained.
- the outer cell partition wall 13 has an outer circumferential cell partition wall 13 a formed so as to be substantially orthogonal to the inner surface of the outer cylinder 2, the outer cylinder 2 is disposed on the outer peripheral surface of the outer cylinder 2. Even if a force that compresses in the direction is applied, the force can be supported by the outer circumferential cell partition wall 13a. Therefore, the durability of the honeycomb structure 1 against external force can be increased, and the possibility that the honeycomb structure 1 is damaged by the external force can be reduced.
- the sealed portion can support the force applied to the honeycomb structure 1 to the sealed material.
- the height can be increased, and damage to the honeycomb structure 1 can be prevented.
- the honeycomb structure 1 of the present invention is used as an exhaust gas filter for purifying exhaust gas discharged from an internal combustion engine
- the honeycomb structure 1 is made of a metal case in a state of being wrapped in a heat insulating material or the like. Is housed in.
- the edge of the outer cylinder 2 of the honeycomb structure 1 may come into contact with the case, and this contact may cause the outer cylinder 2 to be recessed or chipped, thereby damaging the external through hole 13h.
- the external through-hole 13h having the outer cylinder 2 as a constituent element is sealed, damage to the outer cylinder 2, that is, damage to the external through-hole 13h can be prevented even if such contact occurs.
- the external through-hole 13h formed between the outer cylinder 2 and the inner cylinder 11 are sealed, a gas layer can be formed in the external through-hole 13h. Then, the external through-hole 13h can be made to function as a heat insulating layer for keeping the heat of the region inside the inner cylinder 11 inside the inner cylinder 11.
- the honeycomb structure 1 when used as a DPF, the following effects can be obtained by providing a heat insulating layer.
- fine particles such as soot trapped in the partition walls forming the through holes are heated by, for example, exhaust gas and oxidized and burned, and the partition walls are self-regenerated.
- the temperature of the DPF is uniformly maintained in the cross section of the region where soot is captured.
- the heat radiation to the outside air is large, so that when soot is captured in this portion, the soot cannot be sufficiently burned and the self-regeneration of the partition walls cannot be performed.
- the filter area can be surrounded by the external through-hole 13h as a heat retaining layer, so that heat generated by combustion such as soot is prevented from escaping in the filter area. Can do. Therefore, in the filter region, the temperature in the cross section can be made uniform, so that the DPF can be effectively self-regenerated, and the functional degradation of the DPF due to clogging or the like can be prevented.
- the external through-hole 13h formed between the outer cylinder 2 and the inner cylinder 11 is not necessary to seal both ends.
- the external through hole 13h even if only the end portion on the side where the exhaust gas flows is sealed, the external through hole 13h can be used as a heat retaining layer. This is because if the end on the exhaust gas inflow side is sealed, soot does not flow into the external through hole 13h and soot combustion does not occur in the external through hole 13h. This is because it can function as a layer.
- a plurality of external through holes 13 h may be arranged between the outer cylinder 2 and the inner cylinder 11 along the radial direction of the honeycomb structure 1. That is, a plurality of heat insulation layers may be provided in the radial direction of the honeycomb structure 1 between the outer cylinder 2 and the inner cylinder 11, and in this case, the heat insulation effect can be further enhanced.
- an intermediate cylinder also referred to as an outer radial cell partition wall
- the intermediate cylinder (outer radial cell partition wall) 13b preferably has a cross-sectional shape similar to that of the outer cylinder 2.
- outer circumferential cell partition wall 13a is provided between the outer cylinder 2 and the intermediate cylinder 13b and between the intermediate cylinder 13b and the inner cylinder 11, a plurality of heat insulating layers in the radial direction and the circumferential direction are provided. Can be provided.
- a characteristic cell structure in the honeycomb structure 1 of the present invention will be described. That is, a through-hole (also referred to as a boundary portion or a small section cell) 21a having an irregular shape (preferably a substantially triangular shape or a substantially trapezoidal shape) in cross section between the inner cylinder 11 and the inner cell partition wall 12 inside (near) the inner cylinder 11. , 21b, 21c are formed, there is a possibility that sealing defects may occur in the modified cross-sectional through-holes 21a, 21b, 21c because the hole diameter is small.
- a through-hole also referred to as a boundary portion or a small section cell
- an irregular shape preferably a substantially triangular shape or a substantially trapezoidal shape
- these irregular cross-sectional through-holes 21a, 21b, and 21c are connected to other through-holes that share the inner cylinder 11 with the irregular cross-sectional through-holes 21a (that is, the external through-holes 22a) to connect the first coupling through-holes 20a.
- the second or second through-holes 21b and 21c that are formed or connected to other through-holes that share the internal cell partition wall 12 (that is, other through-holes 22b, internal through-holes 22c, etc.) 3 connecting through holes 20b and 20c are formed.
- the modified cross-sectional through-holes (small cross-section cells) 21a, 21b, 21c are connected to the adjacent through-holes (adjacent cells, also referred to as connecting portions) 22a, 22b, 22c
- the through-hole diameter (cross-sectional area) is enlarged.
- the sealing failure of the through holes 20a, 20b, 20c can be prevented.
- these 1st, 2nd, or 3rd connection through-holes 20a, 20b, and 20c form at least any one, a sealing defect can be reduced rather than the past, Preferably 2 or more are preferable. It is recommended to form (particularly all) connecting through holes.
- the first connecting through hole 20a is formed as follows.
- a modified cross-sectional through hole 21a surrounded by the inner cylinder 11 and the inner cell partition wall 12 and having a substantially triangular cross-sectional shape is defined as an outer through hole 22a closest to the sharpest apex of the modified cross-sectional through hole 21a.
- a new internal cell partition wall 27 extending continuously inward from the external cell partition wall 13c forming the external through hole 22a and parallel to the internal cell partition wall 12 is formed.
- a connecting through hole 20a having a substantially pentagonal shape is formed.
- the connecting through hole 25 may be formed by connecting to the adjacent deformed cross-sectional through hole 24 sharing the cell partition wall 28 serving as the bottom.
- connection through holes 20a, 20b, 20c, 25 formed as described above are newly modified cross sections surrounded by the inner cylinder 11 and the inner cell partition wall 12 (which may include a new inner cell partition wall 27). Is a through-hole.
- the connecting through-holes 20a, 20b, having a relatively large cross-sectional area, 20c, 25 can be formed. That is, since a through hole having a relatively large opening area can be formed in a portion where a through hole having a small opening area was to be formed by providing the inner cylinder 11, a sealing failure is caused in the vicinity of the inner cylinder 11. It is possible to prevent the formation of a through-hole that is likely to cause the occurrence of the problem.
- the through holes having the smallest opening area in the cross section are all the through holes 10h, 13h, 20a, 20b, 20c, 25 (hereinafter simply referred to as “through holes”). It is preferable to have an opening area of 40% or more of the average opening area of all through holes). In this case, since all the through holes including the connecting through holes 20a, 20b, 20c, and 25 have an opening area of a predetermined size or more, occurrence of a sealing failure can be prevented.
- a honeycomb structure used for a DPF has through holes of about 200 to 400, preferably about 250 to 350, in a 1 inch ⁇ 1 inch region, but the opening area of all the through holes is an average opening area (1. if so 0 a ⁇ 40% 1.6mm approximately 2) (0.4 - 0.64 mm approximately 2) above, it is possible to manufacture a DPF that defective sealing does not occur.
- all the internal angles formed by the partition walls that form the through holes and intersect each other are 30 degrees or more in all the through holes.
- the through holes 10h, 13h, 20a, 20b, 20c, 25 are sealed, the material to be sealed can be reliably filled even in the vicinity (corner portion) where the partition walls intersect. As a result, it is possible to prevent a sealing failure from occurring when the honeycomb structure 1 is sealed in order to obtain a filter that purifies the exhaust gas discharged from the internal combustion engine.
- the inner cylinder 11 may be provided twice or more. Even in this case, if the connecting through holes 20a, 20b, 20c, and 25 are formed as described above, it is possible to prevent the formation of through holes having a small opening area, and it is possible to prevent the occurrence of poor sealing. .
- the inner cylinder 11 is similar to the outer cylinder 2 has been described. However, the inner cylinder 11 does not necessarily have to be similar to the outer cylinder 2.
- the outer cylinder 2 may be an oval shape, a rice ball shape, or a track shape for track and field, and the inner cylinder 11 may be a circle.
- the honeycomb structure of the present invention is suitable for a filter for purifying exhaust gas discharged from an internal combustion engine such as a diesel engine or a gasoline engine.
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Abstract
Description
まず、清浄化する為の排ガスは、DPFの軸方向の一端(図2(B)では左端)から供給される。すると、排ガスは、開口しているセル105b(流入側セル105b)からDPFに流入する。これらの流入側セル105bの他端は封口されているため、排ガスは壁面101を通って隣接するセル105a(排出側セル)に流入する。この排出側セル105aはDPFの軸方向の他端(排出側)が開口しているので、排ガスは、排出側セル105aの軸方向の他端(図2(B)では右端)から流出する。つまり、DPFでは、隣接するセルを区切る壁面101がフィルタとして機能し、排ガスに含まれている有害物質(例えば、微細粒子等)を壁面101によって捕捉できるので、排ガスを清浄化することができるのである。
本発明のハニカム構造体は、前記外筒の横断面でみた形状が略三角形または略台形である異形断面貫通孔を連結させることが好ましい。
本発明のハニカム構造体は、前記外筒の横断面でみた形状が略三角形である異形断面貫通孔を、これの最鋭角な頂点に最も近い外部貫通孔と連結させるとともに、この外部貫通孔を形成する外部セル隔壁から連続して内方に延出し、かつ内部セル隔壁と平行な新たなセル隔壁を形成して、連結貫通孔の横断面でみた形状を略五角形にすることも好ましい。この場合、前記新たなセル隔壁が、このセル隔壁を上底とする横断面形状略台形の新たな異形断面貫通孔を形成するとき、この新異形断面貫通孔を、その下底となるセル隔壁を共有する隣の異形断面貫通孔と連結させることが更に好ましい。
本発明のハニカム構造体は、前記外筒の横断面において、(i)全貫通孔のうち最小の開口面積を有する貫通孔が、全貫通孔の平均開口面積の40%以上の開口面積を有することや、(ii)全貫通孔の内角が、全て30度以上であることが好ましい。
前記外部セル隔壁は、前記外筒の周方向に外部貫通孔を隣接して形成する外部周方向セル隔壁を備えており、該外部周方向セル隔壁は、前記外筒と略直交するように形成されていることが好ましい。また、外部貫通孔は、その少なくとも一方の端が封口されていることも好ましい。
また、他の異形断面貫通孔に比べて断面積が小さくなりやすい異形断面貫通孔(すなわち、外筒の横断面でみた形状が略三角形又は略台形であるもの)を、その近傍に位置する外部貫通孔、他の異型断面貫通孔、又は内部貫通孔と連結して比較的断面積が大きい貫通孔にする場合には、断面積が小さい貫通孔が形成されることを防ぐことができる。
本発明における全ての貫通孔の断面積を所定の大きさ以上とする場合には、または全貫通孔の内角を全て30度以上とする場合には、貫通孔を封口する際に、隔壁同士が交わる部分の近傍であっても、封口する材料を確実に充填することができ、封口不良を防ぐことができる。
さらに外部周方向セル隔壁を外筒と略直交するように形成する場合には、外筒を構成要素とする外部貫通孔の断面積をある程度の大きさに維持できるので、ハニカム構造体を成形する際に、該外部貫通孔が潰れる可能性を低くすることができる。よって、ハニカム構造体の外周面を所定の精度に維持することができる。そして、ハニカム構造体の外周面にスジ状の凹みが形成される可能性も低くできるので、熱ショック等によるハニカム構造体の損傷が発生する可能性も低くできる。さらに、外部周方向セル隔壁が外筒と略直交するように形成されている場合には、ハニカム構造体の外周面に力が加わっても、その力を外部周方向セル隔壁によって支持させることができ、外力に対するハニカム構造体の耐久性を高くすることができる。
本発明において外部貫通孔の少なくとも一方の端を封口すれば、これらの貫通孔には保温効果を期待することができる。しかも、外筒に加わる力を、封口する材料にも支持させることができるから、ハニカム構造体の外筒の強度を高くすることができる。
本発明のハニカム構造体は、内燃機関から排出される排ガスを浄化する排ガスフィルタの製造に使用されるものであり、排ガスフィルタを製造する際に、封口不良が発生しない構造としたことに特徴を有している。
また、本発明のハニカム構造体の素材中に白金等の触媒を担持させておけば、本発明のハニカム構造体を用いて、排ガス中の有害物質を浄化する触媒も製造することができる。
まず、本発明のハニカム構造体1について、概略を説明する。
以下では、ハニカム構造体1の断面が円形の場合、つまり、ハニカム構造体1が円筒状の場合を説明するが、本発明のハニカム構造体1は円筒状のものに限られず、断面が略三角形状(頂点が丸められた三角形状、いわゆる三角おむすび形)のものや、楕円形状、又は陸上競技のトラックのように、直線と半円とが組み合わされた形状等でもよく、とくに限定されない。
また、以下では、貫通孔の断面(ハニカム構造体の軸方向と直交する断面)の基本形状、つまり、貫通孔の開口断面の基本形状が方形(正方形または長方形)の場合を説明する。しかし、本発明のハニカム構造体における貫通孔の開口断面の形状は正確な方形に限られず、概ね方形であってもよく、また、五角形や六角形、八角形、円形等でもよく、とくに限定されない。
さらに、以下では、隣接する貫通孔の開口断面の断面積がほぼ同じとなるように形成されたハニカム構造体、いわゆる対称セルのハニカム構造体の場合を説明する。しかし、本発明のハニカム構造体は、隣接する貫通孔の開口断面の断面積が異なるように形成されたハニカム構造体、つまり、非対称セルのハニカム構造体でも同様の作用効果を奏する。
本発明のハニカム構造体1は、原料粉末と成形助剤と水、必要に応じて造孔剤からなる坏土を押出し成形して形成された後焼成されたセラミックスで形成されており、複数の貫通孔10h及び13h等を形成する壁面(内部セル隔壁12、外部セル隔壁13、外筒2、内筒11等)は平均細孔径が20μm以下の孔を有する多孔質となっている。本発明のハニカム構造体を構成するセラミックスは特に限定されないが、例えばチタン酸アルミニウム、チタン酸マグネシウム、チタン酸アルミニウムマグネシウムなどのチタン酸アルミニウム系セラミックスが挙げられる。
この外部セル隔壁13は、外筒2の周方向に外部貫通孔13hを隣接して形成させる外部周方向セル隔壁(外周隔壁)13aを備えている。この外部周方向セル隔壁13aは、前記外筒2と内筒11との間の空間を分割して、外筒2の内面に沿った方向に外部貫通孔13h同士を隣接して形成するものである。また、この外部周方向セル隔壁13aは、外筒2の内面と略直交するように形成されている。言い換えれば、横断面において、外筒2と同じ中心を有する円C1と外部セル隔壁13が交差する位置では、その位置における円C1の接線と外部セル隔壁13とが互いに直交している。
外部周方向セル隔壁は、外筒と略直交していなくても良く、外筒の周方向に隣接する外部貫通孔の横断面形状が略台形となるように形成されていても良い。
そして、封口後のハニカム構造体1の一端側から排ガスなどの浄化すべきガスを供給すれば、そのガスは、必ずいずれかの隔壁を通過しなければハニカム構造体1の他端側には流出できないので、すす等の微細粒子を隔壁で捕集し、排ガスを浄化することができるのである。
よって、ハニカム構造体1を押し出し成形などによって形成する際に、外筒2を構成要素とする外部貫通孔13hが潰れる可能性を低くすることができるから、ハニカム構造体1の外周面を所定の精度に維持することができる。
そして、外筒2を構成要素とする外部貫通孔13hが潰れないので、ハニカム構造体1の外周面にスジ状の凹みが形成される可能性も低くできる。その結果、スジ状の凹みに起因する熱ショック等によるハニカム構造体1の損傷が発生する可能性も低くできる。
具体的には、本発明のハニカム構造体1を内燃機関から排出される排ガスを浄化する排ガスフィルタとして使用する場合には、ハニカム構造体1は断熱材などに包まれた状態で金属製のケースに収容される。このとき、ハニカム構造体1の外筒2の端縁がケースと接触する場合があり、この接触により外筒2が凹んだり欠けたりして、外部貫通孔13hが損傷する可能性がある。しかし、外筒2を構成要素とする外部貫通孔13hが封口されていれば、かかる接触があっても、外筒2の損傷、つまり、外部貫通孔13hの損傷を防ぐことができる。
DPFでは、貫通孔を形成する隔壁に捕捉されたすす等の微細粒子が、例えば、排ガスにより加熱されて酸化燃焼し、隔壁の自己再生が行われている。かかる自己再生を有効に行う上では、すす等を捕捉する領域の横断面内においてDPFの温度が均一に維持されていることが好ましい。
しかし、DPFの外筒2近傍では、外気への放熱が大きいため、この部分ですす等を捕捉した場合、すす等を十分に燃焼できず、隔壁の自己再生ができなくなる。すると、DPFに目詰まりなどが発生し、DPFの機能低下が生じる可能性がある。
そこで、上記のごとき両端を封口した外部貫通孔13hを設けることによって、温度低下しやすい外筒2近傍ではすす等を捕捉せず、外筒2の近傍を保温層として機能させ、すす等を捕捉する領域(内部貫通孔10hなどを指し、以下、フィルター領域という)を保温層としての外部貫通孔13hで囲むことができるから、フィルター領域においてすす等の燃焼により発生した熱が逃げることを防ぐことができる。従って、フィルター領域では、横断面内における温度を均一化できるので、DPFを有効に自己再生でき、目詰まりなどによるDPFの機能低下を防ぐことができるのである。
例えば、図1に示すように、外筒2と内筒11との間に、これらと中心軸を同一とする中間筒(外部径方向セル隔壁ともいう)13bを設けても良い。この中間筒(外部径方向セル隔壁)13bは、横断面形状が外筒2と相似形であるのが好ましい。そして、外筒2と中間筒13bとの間、および、中間筒13bと内筒11との間に、それぞれ外部周方向セル隔壁13aを設ければ、径方向及び周方向に複数層の保温層を設けることができる。
すなわち、内筒11の内側(近傍)に、この内筒11と内部セル隔壁12とで、断面が異形(好ましくは略三角形又は略台形)の貫通孔(境界部分、小断面セルともいう)21a、21b、21cが形成されると、この異形断面貫通孔21a、21b、21cはその孔径が小さいために、そこで封口不良が生じる虞がある。そこで、これら異形断面貫通孔21a、21b、21cは、この異形断面貫通孔21aと内筒11を共有する他の貫通孔(すなわち外部貫通孔22a)と連結して第1の連結貫通孔20aを形成したり、異形貫通孔21b、21cと、それぞれ内部セル隔壁12を共有するその他の貫通孔(即ち、他の異形断面貫通孔22bや、内部貫通孔22cなど)と連結して第2又は第3の連結貫通孔20b、20cを形成する。この様にして異形断面貫通孔(小断面セル)21a、21b、21cを隣接貫通孔(隣接セル、連結部分ともいう)22a、22b、22cと連結すると、貫通孔の孔径(断面積)を拡大でき、貫通孔20a、20b、20cの封口不良を防止できる。なお、これら第1、第2、又は第3の連結貫通孔20a、20b、20cは、少なくともいずれか一つを形成すれば、従来よりも封口不良を減らすことができるが、好ましくは2つ以上(特に全て)の連結貫通孔を形成することが推奨される。
この場合、連結貫通孔20a、20b、20c、25を含む全貫通孔が所定の大きさ以上の開口面積を有することになるので、封口不良の発生を防ぐことができる。
例えば、DPFに使用されるハニカム構造体では、1inch×1inchの領域に200~400程度、好ましくは250~350程度の貫通孔を有するが、全貫通孔の開口面積が、平均開口面積(1.0~1.6mm2程度)の40%(0.4~0.64mm2程度)以上となるようにすれば、封口不良が生じないDPFを製造することができる。
この場合には、貫通孔10h、13h、20a、20b、20c、25を封口する際に、隔壁同士が交わる部分の近傍(角部)でも封口する材料を確実に充填することができる。すると、内燃機関から排出される排ガスを浄化するフィルタとするためにハニカム構造体1に対して封口を施したときに、封口不良が発生することを防ぐことができる。
また、上記例では、内筒11が外筒2と相似形である場合を説明したが、内筒11は必ずしも外筒2と相似形である必要はない。例えば、外筒2を楕円形やおむすび形、陸上競技のトラック形とし、内筒11を円形としてもよい。
2 外筒
10h 内部貫通孔
11 内筒
12 内部セル隔壁
13 外部セル隔壁
13a 外部周方向セル隔壁
13h 外部貫通孔
20a、20b、20c 連結貫通孔
21a、21b、21c 異形断面貫通孔
Claims (8)
- 内燃機関から排出される排ガスを浄化するフィルタに使用されるハニカム構造体であって、
前記ハニカム構造体は、外筒と内筒の二重構造を有しており、
前記内筒よりも内方には、内部貫通孔を形成する内部セル隔壁を備え、
前記外筒と内筒との間には、外部貫通孔を形成する外部セル隔壁を備え、
前記内筒と前記内部セル隔壁は異形断面貫通孔を形成しており、
一の異形断面貫通孔と内筒を共有する一の外部貫通孔との連結、一の異形断面貫通孔と内部セル隔壁を共有する他の異形断面貫通孔との連結、及び一の異形断面貫通孔と内部セル隔壁を共有する内部貫通孔との連結のうち、少なくとも一つの連結を行うことによって、連結貫通孔が形成されていることを特徴とするハニカム構造体。 - 前記外筒の横断面でみた形状が略三角形または略台形である異形断面貫通孔を連結させる請求項1に記載のハニカム構造体。
- 前記外筒の横断面でみた形状が略三角形である異形断面貫通孔を、これの最鋭角な頂点に最も近い外部貫通孔と連結させるとともに、この外部貫通孔を形成する外部セル隔壁から連続して内方に延出し、かつ内部セル隔壁と平行な新たなセル隔壁を形成して、連結貫通孔の横断面でみた形状を略五角形にする請求項1に記載のハニカム構造体。
- 前記新たなセル隔壁が、このセル隔壁を上底とする横断面形状略台形の新たな異形断面貫通孔を形成するとき、この新異形断面貫通孔を、その下底となるセル隔壁を共有する隣の異形断面貫通孔と連結させる請求項3に記載のハニカム構造体。
- 前記外筒の横断面において、全貫通孔のうち最小の開口面積を有する貫通孔が、全貫通孔の平均開口面積の40%以上の開口面積を有する請求項1~4のいずれかに記載のハニカム構造体。
- 前記外筒の横断面において、全貫通孔の内角が、全て30度以上である請求項1~5のいずれかに記載のハニカム構造体。
- 前記外部セル隔壁は、前記外筒の周方向に外部貫通孔を隣接して形成する外部周方向セル隔壁を備えており、
該外部周方向セル隔壁は、前記外筒と略直交するように形成されている請求項1~6のいずれかに記載のハニカム構造体。 - 前記外部貫通孔は、その少なくとも一方の端が封口されている請求項1~7のいずれかに記載のハニカム構造体。
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US13/522,195 US8852311B2 (en) | 2010-01-19 | 2011-01-18 | Honeycomb structure |
BR112012017467A BR112012017467A2 (pt) | 2010-01-19 | 2011-01-18 | estrutura alveolar |
EP11734621.3A EP2527024A4 (en) | 2010-01-19 | 2011-01-18 | hONEYCOMB STRUCTURE |
KR1020127018913A KR20120127418A (ko) | 2010-01-19 | 2011-01-18 | 허니콤 구조체 |
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EP (1) | EP2527024A4 (ja) |
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EP2626123A1 (en) * | 2012-02-10 | 2013-08-14 | NGK Insulators, Ltd. | Plugged honeycomb structure and honeycomb catalyst body using the same |
CN103889544A (zh) * | 2011-10-28 | 2014-06-25 | 住友化学株式会社 | 蜂窝构造体 |
WO2017029975A1 (ja) * | 2015-08-20 | 2017-02-23 | 住友化学株式会社 | ハニカム構造体及びハニカムフィルタ |
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JP2011224973A (ja) * | 2010-03-19 | 2011-11-10 | Ibiden Co Ltd | ハニカム構造体 |
JP2013132879A (ja) * | 2011-12-27 | 2013-07-08 | Sumitomo Chemical Co Ltd | 押出成形金型 |
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JP6137151B2 (ja) * | 2014-03-26 | 2017-05-31 | 株式会社デンソー | ハニカム構造体 |
JP6438939B2 (ja) * | 2014-03-31 | 2018-12-19 | 日本碍子株式会社 | ハニカム構造体 |
JP6485162B2 (ja) * | 2014-07-24 | 2019-03-20 | 株式会社デンソー | 排ガス浄化フィルタ |
JP6934702B2 (ja) * | 2015-03-27 | 2021-09-15 | 株式会社デンソー | 排ガス浄化フィルタ |
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EP2527024A4 (en) | 2015-05-27 |
CN102711949A (zh) | 2012-10-03 |
US8852311B2 (en) | 2014-10-07 |
CN102711949B (zh) | 2014-12-10 |
BR112012017467A2 (pt) | 2016-04-19 |
KR20120127418A (ko) | 2012-11-21 |
JP4825309B2 (ja) | 2011-11-30 |
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US20120317942A1 (en) | 2012-12-20 |
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