WO2012121331A1 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
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- WO2012121331A1 WO2012121331A1 PCT/JP2012/055965 JP2012055965W WO2012121331A1 WO 2012121331 A1 WO2012121331 A1 WO 2012121331A1 JP 2012055965 W JP2012055965 W JP 2012055965W WO 2012121331 A1 WO2012121331 A1 WO 2012121331A1
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- WIPO (PCT)
- Prior art keywords
- honeycomb structure
- honeycomb
- joint
- thickness
- minor axis
- Prior art date
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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
- B01D46/2482—Thickness, height, width, length or diameter
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2455—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the whole honeycomb or segments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2478—Structures comprising honeycomb segments
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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
- B01D46/2466—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the adhesive layers, i.e. joints between segments
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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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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0006—Honeycomb structures
- C04B38/0016—Honeycomb structures assembled from subunits
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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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
Definitions
- the present invention relates to a honeycomb structure, and more particularly to a honeycomb structure in which an end face has an aspect ratio of 1.2 or more and a crack is hardly generated in a joint portion of a filter when a temperature difference between the inside and outside of the filter occurs.
- a catalyst carrier utilizing catalytic action such as an internal combustion engine, a boiler, a chemical reaction device, and a fuel cell reformer, and a filter for collecting particulate matter in exhaust gas, particularly diesel particulates (diesel particulate filter: Hereinafter, a honeycomb structure made of ceramics is used for “DPF”).
- a honeycomb structure used for such a purpose generally has a plurality of cells serving as fluid flow paths partitioned by porous partition walls.
- a filter for collecting particulate matter When used as a filter for collecting particulate matter, it has a structure in which adjacent cells are plugged at opposite ends so that the end faces have a checkered pattern.
- the fluid to be treated flows into a cell whose end face on the inflow side is not sealed, that is, a cell whose end face on the outflow side is sealed.
- the cells are discharged from the cells whose inflow end face is sealed and whose outflow end face is not sealed.
- the partition wall serves as a filter.
- particulate matter such as soot discharged from a diesel engine (particulate matter: hereinafter sometimes referred to as “PM”) is partition wall. And is deposited on the partition wall.
- a honeycomb structure a structure in which a plurality of honeycomb-shaped honeycomb segments are bonded with a bonding material is known. Specifically, a honeycomb structure portion formed by bonding a plurality of honeycomb-shaped honeycomb segments with a bonding material, and an outer peripheral wall formed so as to cover the outer peripheral surface of the honeycomb structure portion, etc. (For example, refer to Patent Document 1).
- soot mass limit (hereinafter sometimes referred to as “SML”), pressure loss, and cost are important.
- SML soot mass limit
- methods of increasing the filter capacity and densifying the filter base material are conceivable.
- the former increases costs and the latter worsens pressure loss. Therefore, as another method, there is an example in which a base material having high thermal conductivity such as SiC or SiN is used.
- a base material having high thermal conductivity such as SiC or SiN is used.
- these substrates have the disadvantage of a large coefficient of thermal expansion.
- a structure called a segment shaped like a quadrangular prism or a triangular prism is bonded with a bonding material, and the bonding material absorbs the thermal expansion of the segment and has the disadvantage that the base material has a high coefficient of thermal expansion.
- the thermal expansion coefficient is still high, when excessive soot (particulate matter in exhaust gas) is deposited on the filter and burned, the base material and the joint are cracked, The function as a filter will be affected.
- soot partate matter in exhaust gas
- the present invention has been made in view of such problems of the prior art, and the problem is that the longest part on both end faces of the honeycomb structure has a long diameter, and the long diameter on the end face
- An object of the present invention is to provide a honeycomb structure having an aspect ratio (major axis / minor axis) of 1.2 or more when the longest portion in the orthogonal direction has a minor axis, and is less susceptible to cracking.
- the present inventors have found that the above-mentioned problems can be achieved by defining the thickness of the joint at a specific site, and the present invention is completed. It came to.
- the following honeycomb structure is provided.
- a porous partition wall that defines a plurality of cells that penetrate from one end face to the other end face and serve as a fluid flow path, an opening of a predetermined cell on the one end face, and a remaining part on the other end face
- a plurality of honeycomb segments arranged adjacent to each other so that the side surfaces thereof are opposed to each other, and the opposing side surfaces of the plurality of honeycomb segments are joined to each other.
- an outer peripheral wall that covers an outer peripheral surface of the honeycomb structure part composed of the plurality of honeycomb segments and the joint parts, the longest part on both end faces of the honeycomb structure having a long diameter, and on the end face
- the honeycomb structure having an aspect ratio (major axis / minor axis) of 1.2 or more, where the longest portion in the direction orthogonal to the major axis is the minor axis, the intersection between the joined portion and the outer peripheral wall is A corner portion that is a region of a joint within 10 mm along the direction of the minor axis is present within 25 mm from a straight line passing through the central point on the major axis and parallel to the minor axis, and the central point on the major axis
- the thickness of the joint portion including the corner portion existing within 25 mm from the straight line parallel to the minor axis is 0.5 mm or more and 5 mm or less, and the thickness of the joint portion in the other portion is 1.5 mm or less.
- a honeycomb structure is 0.5 mm
- the thickness of the joint portion including the corner portion existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis is 1.0 mm or more and 1.5 mm or less.
- At least one joint portion having a thickness of less than 0.5 mm in a joint portion other than the joint portion including the corner portion existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis A honeycomb structure according to any one of the above [1] to [4].
- the honeycomb structure of the present invention in the honeycomb structure having an aspect ratio of 1.2 or more, a joined portion including a corner portion existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis. Therefore, the generation of cracks at the end face of the honeycomb structure caused by a rapid temperature change is suppressed.
- the corner portion is a region of the joint portion within 10 mm along the minor axis direction from the intersection of the joint portion and the outer peripheral wall.
- FIG. 1 is a schematic perspective view showing a first embodiment of a honeycomb structure of the present invention.
- FIG. 3 is a plan view showing an end face of a honeycomb segment constituting the first embodiment of the honeycomb structure of the present invention. It is a top view which shows the end surface of 2nd Embodiment of the honeycomb structure of this invention. It is a top view which shows the end surface of 3rd Embodiment of the honeycomb structure of this invention. It is a top view which shows the end surface of 4th Embodiment of the honeycomb structure of this invention.
- FIG. 2 is a plan view showing an end face of the first embodiment of the honeycomb structure of the present invention, and is a diagram for explaining a mechanism of crack generation in the honeycomb structure. It is a partial enlarged view of the end face of the first embodiment of the honeycomb structure of the present invention, and is a diagram illustrating a joint portion including a corner portion. It is an enlarged view of the end face of the 4th embodiment of the honeycomb structure of the present invention, and is a figure explaining the joined part containing a corner.
- FIG. 1 is a plan view showing an end face of the first embodiment of the honeycomb structure of the present invention
- FIG. 2 is a schematic perspective view showing the first embodiment of the honeycomb structure of the present invention
- FIG. 3 is a plan view showing an end face of the honeycomb segment constituting the first embodiment of the honeycomb structure of the present invention.
- the honeycomb structure 100 of the present embodiment has a porous partition wall that forms a plurality of cells 4 that penetrate from one end face 2 to the other end face 2 and serve as fluid flow paths.
- honeycomb structure portion 11 including a plurality of honeycomb segments 10 each having an opening portion of a predetermined cell 4 on one end face 2 and a plugging portion 8 for sealing the opening portion of the remaining cell 4 on the other end face 2.
- an outer peripheral wall 20 formed so as to cover the outer peripheral surface of the honeycomb structure portion 11.
- the honeycomb structure 100 of the present embodiment when the longest portion of the end surface and the major axis L L, the longest portion of the direction perpendicular to the major axis L L on the end face and the minor diameter L S
- the aspect ratio (major axis / minor axis) is 1.2 or more. That is, the aspect ratio of the major axis L L to the minor axis L S is 1.2 or more.
- the DPF center part when the DPF center part is at a high temperature and the outer peripheral part is at a low temperature, an expansion force is generated in the central part, but the outer peripheral part is in a low temperature region. No expansion force is generated. For this reason, tensile stress is generated.
- the tensile stress becomes maximum at the central portion in the major axis direction, and if there is a joint 40 there is a crack at the joint because the bond peel strength is weaker than the substrate strength. Will do.
- a material having a certain Young's modulus is used as the bonding material used for the bonding portion 40 in order to prevent the occurrence of such cracks, but when the bonding portion 40 is thin, the bonding material has. With Young's modulus, stress cannot be absorbed and cracks occur.
- the corner portion which is the region of the joint portion 40 within 10 mm along the direction of the short diameter L S from the intersection of the joint portion 40 and the outer peripheral wall 20, is the long diameter L L. exist within 25mm from a straight line parallel C L as minor L S the center point C of the upper, including 50 "corners present within 25mm from a straight line parallel to the minor axis passing through the center point on the major axis"
- the thickness of the joint part 40 was 0.5 mm or more.
- the thickness of the joined portion refers to the distance between the side surfaces of the honeycomb segments joined by the joined portion.
- the junction part containing a corner part refers to the whole junction part which exists in the part which extended the junction part which forms a corner part in the direction perpendicular
- the thickness of the joint portion 40 including the corner portion 50 existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis is preferably 0.5 to 5.0 mm. More preferably, it is 5 mm. If it is thinner than 0.5 mm, cracks are likely to occur at the corners due to a rapid temperature change. If it is thicker than 5.0 mm, the area of the joint 40 becomes large in the cross section perpendicular to the direction in which the exhaust gas passes (cell extending direction), and thus pressure loss may increase when the exhaust gas flows.
- the thickness of the joined portion 40 other than the joined portion including the corner portion 50 existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis is preferably 1.5 mm or less, and 0.1 to More preferably, it is 1.5 mm. If the thickness is less than 0.1 mm, the force for joining the honeycomb segments 10 may be weakened, and the adjacent honeycomb segments 10 may contact each other. If it is thicker than 1.5 mm, the area of the joint 40 becomes larger in the cross section perpendicular to the direction in which the exhaust gas passes (cell extending direction), and therefore the pressure loss may increase when the exhaust gas flows. Note that the thickness of the joint portion 40 is the distance between the adjacent honeycomb segments 10.
- the center point on the major axis passes through the center point on the major axis as compared to the thickness of the joint portion including the corner portion 50 existing within 25 mm from the straight line passing through the central point on the major axis and parallel to the minor axis. It is preferable that the thickness of the joint portion 40 other than the joint portion including the corner portion 50 existing within 25 mm from a straight line parallel to the minor axis is thinner.
- the honeycomb structure used for an exhaust gas purification filter of an internal combustion engine has little pressure loss.
- One method for reducing the pressure loss of the honeycomb structure is to increase the opening ratio of the end face.
- the aperture ratio can be increased by reducing the thickness of the joined portion.
- the center point on the major axis passes through the center point on the major axis as compared to the thickness of the joint portion including the corner portion 50 existing within 25 mm from the straight line passing through the central point on the major axis and parallel to the minor axis.
- the thickness is less than 0.5 mm. It is preferable to include at least one joint 40.
- the honeycomb structure used for an exhaust gas purification filter of an internal combustion engine has little pressure loss.
- One method for reducing the pressure loss of the honeycomb structure is to increase the opening ratio of the end face. In a honeycomb structure including a honeycomb segment and a joined portion, the aperture ratio can be increased by reducing the thickness of the joined portion.
- the thickness of the joint portion 40 other than the joint portion including the corner portion 50 existing within 25 mm from a straight line passing through the center point on the long diameter and parallel to the short diameter is at least at one place. By making it less than 0.5 mm, it is possible to increase the aperture ratio and reduce the pressure loss while suppressing the generation of cracks.
- the thickness of at least one joint portion 40 other than the joint portion including the corner portion 50 existing within 25 mm from a straight line passing through the center point on the major axis and parallel to the minor axis is 0.1 mm or more and less than 0.5 mm. It is preferable.
- the overall shape in a cross section perpendicular to the extending direction of the cells 4 is triangular, quadrangular, hexagonal, octagonal, circular, or a combination of these shapes (for example, the overall shape on one end face). Is a quadrangle, and the entire shape of the other end surface is a circle).
- the overall size of the honeycomb structure 100 is not particularly limited, and can be a desired size.
- the major axis of the honeycomb structure 100 is preferably 80 to 300 mm, and more preferably 100 to 280 mm.
- the length of the honeycomb structure 100 in the cell 4 extending direction is preferably 100 to 350 mm, and more preferably 100 to 300 mm.
- honeycomb segment 10 The material of the honeycomb segment 10 is preferably ceramic, and is excellent in strength and heat resistance. Therefore, silicon carbide (SiC), nitrogen carbide (SiN), silicon-silicon carbide based composite material, cordierite, mullite, alumina, spinel, More preferably, it is at least one selected from the group consisting of silicon carbide-cordierite composite material, lithium aluminum silicate, aluminum titanate, and iron-chromium-aluminum alloy. Among these, silicon carbide is preferable.
- the content of the ceramic raw material is preferably 40 to 90% by mass with respect to the entire forming raw material.
- the honeycomb segment 10 (the partition walls 5 constituting the honeycomb segment 10) is preferably porous.
- the porosity of the honeycomb segment 10 is preferably 30 to 70%, and more preferably 40 to 60%. By setting the porosity in such a range, the pressure loss can be reduced while maintaining the strength. If the porosity is less than 30%, the pressure loss may increase. When the porosity exceeds 70%, the strength may decrease or the thermal conductivity may decrease.
- the porosity is a value measured with a mercury porosimeter.
- the honeycomb segment 10 preferably has an average pore diameter of 5 to 30 ⁇ m, and more preferably 10 to 25 ⁇ m.
- the average pore diameter is a value measured with a mercury porosimeter.
- the silicon carbide particles preferably have an average particle size of 5 to 40 ⁇ m.
- an average particle diameter By setting it as such an average particle diameter, there exists an advantage that it is easy to control to the porosity and pore diameter suitable for a filter.
- the average particle size is smaller than 5 ⁇ m, the pore size is too small, and when it is larger than 40 ⁇ m, the porosity may be too large. If the pore diameter is too small, clogging may easily occur due to particulate matter (PM), and if the porosity is too large, pressure loss may increase.
- the average particle diameter of the raw material is a value measured by a method based on JIS R 1629.
- the shape of the cells 4 of the honeycomb segment 10 is preferably a square, a hexagon, an octagon, or a combination thereof. Further preferred.
- the thickness of the partition wall 5 is preferably 0.20 to 0.50 mm, and more preferably 0.25 to 0.45 mm. If the thickness of the partition wall 5 is thinner than 0.20 mm, the strength of the honeycomb structure 100 may be lowered. When the thickness of the partition wall 5 is greater than 0.50 mm, the area of the partition wall 5 for treating the exhaust gas becomes small, the ability to treat the exhaust gas may be reduced, and the pressure loss when treating the exhaust gas increases. Sometimes.
- the cell density of the honeycomb segment 10 is preferably 20 to 90 cells / cm 2 , and more preferably 30 to 70 cells / cm 2 . If it is less than 20 cells / cm 2 , the partition wall thickness may be too thick, or the cell width may be too large. If it is greater than 90 cells / cm 2 , the partition wall thickness may be too thin, or the cell width may be too small.
- the number of the honeycomb segments 10 is preferably 4 to 60, and more preferably 9 to 40 in a cross section perpendicular to the cell 4 extending direction of the honeycomb structure 100 of the present embodiment.
- the area of the cross section perpendicular to the extending direction of the cells 4 is preferably 9 to 25 cm 2 , and more preferably 12 to 19 cm 2 . If it is smaller than 9 cm 2 , the pressure loss when exhaust gas flows through the honeycomb structure 100 may increase, and if it is larger than 25 cm 2 , the honeycomb segment 10 may be damaged.
- the plurality of honeycomb segments 10 include polygonal columnar honeycomb segments 10.
- Specific examples of the columnar honeycomb segment 10 include a quadrangular column shape, a hexagonal column shape, an octagonal column shape, a triangular column shape, and a columnar shape. Or they may be combined. Among these, from the viewpoint of easy production, a quadrangular prism shape is preferable as shown in FIG.
- the honeycomb structure 100 (honeycomb structure portion 11) includes a plurality of honeycomb segments 10 arranged adjacent to each other so that the side surfaces face each other, and the side surfaces facing each other. Are joined by the joint 40. It is preferable that the joint portion 40 is disposed on the entire side surfaces of the adjacent honeycomb segments 10 that face each other.
- the material of the joint portion 40 was kneaded by adding water to an inorganic raw material such as inorganic fiber, colloidal silica, clay, or SiC (silicon carbide) particles and an additive such as an organic binder, a foamed resin, or a dispersant. The thing etc. are preferable.
- the material (ceramic raw material) of the plugging portion 8 is preferably the same as the material of the partition walls 5 constituting the honeycomb structure 100. Thereby, the plugging portion 8 is firmly bonded to the partition wall 5 during firing.
- the predetermined cells 4 and the remaining cells 4 are alternately arranged so that a checkered pattern is formed on the end face of the honeycomb segment 10.
- the depth of the plugging portion 8 is preferably 1.0 to 15.0 mm, and more preferably 3.0 to 12.0 mm. If it is shallower than 1.0 mm, the strength of the plugged portion 8 may be reduced. On the other hand, if it is deeper than 15.0 mm, the area of the partition wall 5 for collecting PM may be small.
- the depth of the plugged portion 8 means the length of the plugged portion 8 in the cell 4 extending direction.
- Outer peripheral wall As described above, the outer peripheral wall 20 is formed so as to cover the outer peripheral surface of the honeycomb structure portion 11. By providing the outer peripheral wall 20 in this way, the irregularities on the outer periphery of the honeycomb structure 100 can be reduced.
- the outer peripheral wall 20 is preferably a molded integral wall that is integrally formed with the porous base material during molding. However, after molding, the outer periphery of the porous base material is ground to a predetermined shape, and the outer peripheral wall is made of ceramic cement or the like. It is also a preferred embodiment that the wall is a cement-coated wall that forms. In the case of a molded integrated wall, the material of the outer peripheral wall 20 is preferably the same as the material of the partition wall 5.
- the material of the cement coated wall include a material obtained by adding a flux component such as glass to a common substrate.
- the thickness of the outer peripheral wall 20 is preferably 0.1 to 3.0 mm, and more preferably 0.3 to 2.0 mm. If it is thinner than 0.1 mm, cracks are likely to occur when outer periphery coating is performed. If it is thicker than 3.0 mm, pressure loss may increase when exhaust gas flows.
- Catalyst In the honeycomb structure of the present invention, a catalyst may be supported on the partition walls. By supporting the catalyst, CO contained in exhaust gas, it is possible to purify HC and NO X.
- the catalyst examples include a three-way catalyst, an oxidation catalyst, an SCR catalyst for NO X selective reduction, and an NO X storage catalyst.
- the oxidation catalyst contains a noble metal.
- the noble metal is preferably one or more selected from the group consisting of platinum (Pt), rhodium (Rh), and palladium (Pd).
- the total amount of the noble metal is preferably 10 to 100 g per unit volume (1 liter) of the honeycomb structure 100.
- a three-way catalyst refers to a catalyst that mainly purifies hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NO x ).
- a catalyst containing platinum (Pt), palladium (Pd), and rhodium (Rh) can be given.
- This three-way catalyst purifies hydrocarbons by water or carbon dioxide, carbon monoxide by carbon dioxide, and nitrogen oxides by nitrogen by oxidation or reduction.
- Examples of the SCR catalyst for NO X selective reduction include those containing at least one selected from the group consisting of metal-substituted zeolite, vanadium, titania, tungsten oxide, silver, and alumina.
- examples of the NO X storage catalyst include alkali metals and / or alkaline earth metals.
- Examples of the alkali metal include K, Na, and Li.
- Examples of the alkaline earth metal include Ca.
- the total amount of K, Na, Li, and Ca is preferably 30 to 300 g per unit volume (1 liter) of the honeycomb structure 100.
- Ceramic raw materials include silicon carbide, silicon-silicon carbide composite materials, cordierite, mullite, alumina, spinel, silicon carbide- cordierite composite materials, lithium aluminum silicate, aluminum titanate, iron-chromium-aluminum alloys It is preferably at least one selected from the group consisting of Among these, silicon carbide or silicon-silicon carbide based composite material is preferable.
- a ceramic raw material is a mixture of silicon carbide powder and metal silicon powder. The content of the ceramic raw material is preferably 40 to 90% by mass with respect to the entire forming raw material.
- binder examples include methyl cellulose, hydroxypropoxyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and polyvinyl alcohol. Among these, it is preferable to use methyl cellulose and hydroxypropoxyl cellulose in combination.
- the binder content is preferably 2 to 20% by mass with respect to the entire forming raw material.
- the water content is preferably 7 to 45% by mass with respect to the entire forming raw material.
- ethylene glycol, dextrin, fatty acid soap, polyalcohol and the like can be used as the surfactant. These may be used individually by 1 type, and may be used in combination of 2 or more type.
- the content of the surfactant is preferably 5% by mass or less with respect to the entire forming raw material.
- the pore former is not particularly limited as long as it becomes pores after firing, and examples thereof include starch, foamed resin, water absorbent resin, and silica gel.
- the pore former content is preferably 15% by mass or less based on the entire forming raw material.
- the forming raw material is kneaded to form a clay.
- molding raw material and forming a clay For example, the method of using a kneader, a vacuum clay kneader, etc. can be mentioned.
- honeycomb formed bodies are formed by extruding the clay.
- extrusion molding it is preferable to use a die having a desired honeycomb segment shape, cell shape, partition wall thickness, cell density, and the like.
- a cemented carbide which does not easily wear is preferable.
- the honeycomb formed body has porous partition walls that define and form a plurality of cells serving as fluid flow paths, and an outer peripheral wall located at the outermost periphery.
- the partition wall thickness, cell density, outer peripheral thickness and the like of the honeycomb formed body can be appropriately determined in accordance with the structure of the honeycomb structure of the present invention to be manufactured in consideration of shrinkage during drying and firing.
- the drying method is not particularly limited, and examples thereof include an electromagnetic heating method such as microwave heating drying and high-frequency dielectric heating drying, and an external heating method such as hot air drying and superheated steam drying.
- an electromagnetic heating method such as microwave heating drying and high-frequency dielectric heating drying
- an external heating method such as hot air drying and superheated steam drying.
- the entire molded body can be dried quickly and uniformly without cracks, and after drying a certain amount of moisture with an electromagnetic heating method, the remaining moisture is dried with an external heating method. It is preferable to make it.
- As a drying condition it is preferable to remove water of 30 to 90% by mass with respect to the amount of moisture before drying by an electromagnetic heating method, and then to make the moisture to 3% by mass or less by an external heating method.
- the electromagnetic heating method dielectric heating drying is preferable, and as the external heating method, hot air drying is preferable.
- the cutting method is not particularly limited, and examples thereof include a method using a circular saw cutting machine.
- Pre-baking is preferably performed at 400 to 500 ° C. for 0.5 to 20 hours in an air atmosphere.
- pre-baking and baking methods can be performed using an electric furnace, a gas furnace, or the like.
- heating is preferably performed at 1300 to 1500 ° C. for 1 to 20 hours in an inert atmosphere such as nitrogen and argon.
- plugging portions are formed in the openings of predetermined cells on the end face on the fluid inlet side of the obtained honeycomb fired body and the openings of the remaining cells on the end face on the outlet side of the fluid.
- a method for forming the plugged portion is not particularly limited, and examples thereof include the following methods. After the sheet is attached to one end face of the honeycomb fired body, a hole is opened at a position corresponding to a cell where a plugging portion of the sheet is to be formed. Then, in the plugging slurry in which the constituent material of the plugging portion is slurried, the honeycomb fired body is immersed in the end face on which the sheet is pasted, and an attempt is made to form the plugging portion through holes formed in the sheet. The plugging slurry is filled in the opening of the cell.
- plugging portions are formed in the same manner as the method in which the plugging portions are formed on the one end surface with respect to the cells not plugged on one end surface.
- the plugging slurry it is preferable to use a slurry obtained by adding a binder such as methyl cellulose and a pore former to a ceramic raw material of a honeycomb formed body. After forming the plugged portion, it is preferable to perform baking under the same conditions as the above baking conditions.
- the plugging portion may be formed before firing the honeycomb formed body.
- honeycomb structure A predetermined number of honeycomb segments are bonded with a bonding material and dried, and a plurality of honeycomb segments are arranged adjacent to each other such that the side surfaces face each other, and the opposite side surfaces are bonded to each other by the bonding portion.
- a honeycomb structure is formed. It is preferable that the joining portion is disposed on the entire side surfaces facing each other. The joined portion plays a role of buffering (absorbing) a volume change when the honeycomb segments are thermally expanded and contracted, and also serves to join the honeycomb segments.
- the method for applying the bonding material to the side surfaces of the honeycomb segment is not particularly limited, and a method such as brush coating can be used.
- the bonding material examples include a slurry obtained by adding water to an inorganic raw material such as inorganic fiber, colloidal silica, clay, and SiC particles, and adding an additive such as an organic binder, a foamed resin, and a dispersant. it can.
- honeycomb segment assembly A plurality of honeycomb segments are bonded with a bonding material and dried to obtain a bonded honeycomb segment body (honeycomb structure).
- the outer peripheral portion of the joined honeycomb segment assembly is cut along a predetermined cutting line to obtain a cut honeycomb segment assembly.
- An outer peripheral wall is formed by performing an outer peripheral coating process on the outer peripheral surface of the bonded honeycomb segment assembly.
- a method of the outer periphery coating treatment a method of applying an outer periphery coating material to the outer peripheral surface of the joined honeycomb segment assembly and drying it can be mentioned.
- the outer periphery coating material a mixture of inorganic fiber, colloidal silica, clay, SiC particles, organic binder, foamed resin, dispersant, water, or the like can be used.
- the method of applying the outer periphery coating material is not particularly limited, and examples thereof include a method of coating the bonded honeycomb segment assembly with a rubber spatula while rotating on the wheel.
- Example 1 First, as a ceramic raw material, SiC powder and metal Si powder are mixed at a mass ratio of 80:20, to this, methyl cellulose and hydroxypropoxymethyl cellulose as a molding aid, starch and a water-absorbing resin, a surfactant and a pore former Water was added and kneaded, and a square columnar clay was prepared with a vacuum kneader.
- the kneaded material was extruded using a predetermined mold to obtain a honeycomb molded body having a square cell shape and a quadrangular prism shape as a whole. Then, the honeycomb formed body was dried with a microwave dryer and further completely dried with a hot air dryer, and then both end faces of the honeycomb formed body were cut and adjusted to a predetermined size. Next, a mask was attached to both end faces of the honeycomb formed body. Thereafter, a hole was made in a portion of the mask corresponding to the opening portion of the predetermined cell on one end face of the honeycomb formed body and a portion corresponding to the opening portion of the remaining cell on the other end face.
- the plugging slurry was alternately filled in a so-called checkered pattern in predetermined cell openings on one end face and the remaining cell openings on the other end face. Thereafter, it is dried with a hot air dryer, and further baked at 1410 to 1440 ° C. for 15 hours, so that a predetermined cell opening on one end face and a remaining cell opening on the other end face are formed in a so-called checkered pattern.
- a honeycomb fired body (honeycomb segment) in which plugged portions were alternately arranged in a pattern was obtained.
- the obtained honeycomb segment had an end width of 36.0 mm in a cross section perpendicular to the cell extending direction. Further, the area (segment area) of the cross section perpendicular to the cell extending direction of the honeycomb segment was 1296 mm 2 . The length of the honeycomb segment in the cell extending direction was 152.4 mm. The partition wall thickness of the honeycomb segment was 0.3 mm, and the cell density was 46.5 cells / cm 2 .
- a predetermined number of honeycomb segments are bonded with a bonding material and dried, and a plurality of honeycomb segments are arranged adjacent to each other so that the side surfaces thereof face each other.
- a bonded honeycomb segment bonded body was formed.
- the bonded honeycomb segment bonded body is a rectangle having an aspect ratio of 1.0 to 2.0, and includes a corner portion existing within 25 mm from a straight line passing through the central point on the major axis and parallel to the minor axis.
- a plurality of bonded honeycomb segment assemblies were manufactured by adjusting the thickness of the part (hereinafter, sometimes referred to as the center joint) to 0.2 to 1.0 mm after drying.
- the corner is an area of the joint within 10 mm along the minor axis direction from the intersection of the joint and the outer peripheral wall. The thickness of the joined part of the other part was adjusted to 1.0 mm after drying.
- the outer periphery of the plurality of joined honeycomb segment assemblies was roughly processed and ground to obtain a desired elliptical cylindrical shape.
- the holding position of the joined honeycomb segment assembly on the outer peripheral lathe was adjusted so that the aspect ratio was 1.0 to 2.0.
- the outer periphery coating process was performed on the joined honeycomb segment assembly, and the outer peripheral portion was disposed on the outermost periphery of the joined honeycomb segment assembly to obtain a plurality of honeycomb structures as shown in FIG.
- the outer periphery coating material used for the outer periphery coating treatment a mixture of SiC particles and colloidal silica was used as the outer periphery coating treatment.
- the volume is 2.5 L
- the length is 152.4 mm
- the aspect ratio is 1.0 to 2.0
- the thickness of the central joint is 0.2 to 1.0.
- the obtained honeycomb structure was subjected to “electric furnace poling test”.
- the entire product is held in the electric furnace until it reaches 350 ° C., and then the product is taken out from the electric furnace into the atmosphere at a stretch and cooled, and cracks are generated in the product.
- This method is often used as a thermal shock resistance test for a ceramic carrier for exhaust gas purification of an internal combustion engine.
- Table 1 “OK” is indicated when no crack is generated, and “NG” is indicated when a crack is generated. In addition, all the cracks that occurred in the case of NG occurred at the joint.
- Example 2 A test similar to that of Experimental Example 1 was performed except that the temperature of the electric furnace was set to 400 ° C. (Experimental Example 2) and 450 ° C. (Experimental Example 3). The results are shown in Tables 2 and 3. In Table 2, “OK” is indicated when no crack is generated, and “NG” is indicated when a crack is generated. In addition, all the cracks that occurred in the case of NG occurred at the joint.
- FIG. 7 is a plan view showing the shape of the end face of the honeycomb structure used in Experimental Example 7.
- FIG. 7 the thickness of the joined portion of the broken line portion which is a joined portion other than the joined portion including the corner portion existing within 25 mm from the straight line passing through the center point on the major axis and parallel to the minor axis is 0.2 It was the same as Experimental Example 1 except that the thickness of the other joints was 1.0 and the temperature of the electric furnace was 450 ° C. The results are shown in Table 4. In Table 4, “OK” was indicated when no crack occurred, and “NG” was indicated when a crack occurred. In addition, all the cracks that occurred in the case of NG occurred at the joint.
- Example 8 The thickness of the joint including the corner at a position 0 to 40 mm away from the straight line passing through the center point on the major axis and parallel to the minor axis is 0.4 mm, and the thickness of the joint at the other part is 1.0 mm.
- the same test as in Experimental Example 1 was performed with an aspect ratio of 1.8.
- the results are shown in FIG. FIG. 8 is a graph showing the relationship between the crack generation temperature and the position where the thickness of the joint (joint width) is 0.4 mm.
- the horizontal axis indicates the position where the joint thickness is 0.4 mm, that is, the distance (mm) from a straight line passing through the center point of the major axis and parallel to the minor axis. Show.
- the crack generation temperature is remarkably lowered.
- FIG. 9 is a plan view showing one end face of the first embodiment of the honeycomb structure of the present invention, and is a diagram for explaining a mechanism of crack generation in the honeycomb structure.
- the honeycomb structure of the present invention can be used as a filter for collecting fine particles in exhaust gas discharged from an internal combustion engine or the like.
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Abstract
Description
図1は、本発明のハニカム構造体の第1の実施形態の端面を示す平面図であり、図2は、本発明のハニカム構造体の第1の実施形態を示す模式的斜視図であり、図3は、本発明のハニカム構造体の第1の実施形態を構成するハニカムセグメントの端面を示す平面図である。図1~図3に示すように、本実施形態のハニカム構造体100は、一方の端面2から他方の端面2まで貫通し流体の流路となる複数のセル4を区画形成する多孔質の隔壁5と一方の端面2における所定のセル4の開口部及び他方の端面2における残余のセル4の開口部を封止する目封止部8とを有する複数のハニカムセグメント10からなるハニカム構造部11と、このハニカム構造部11の外周面を覆うように形成された外周壁20と、を備えている。
ハニカムセグメント10の材料としては、セラミックが好ましく、強度及び耐熱性に優れることより、炭化珪素(SiC)、炭化窒素(SiN)、珪素-炭化珪素系複合材料、コージェライト、ムライト、アルミナ、スピネル、炭化珪素-コージェライト系複合材料、リチウムアルミニウムシリケート、チタン酸アルミニウム、鉄-クロム-アルミニウム系合金からなる群から選択される少なくとも1種であることが更に好ましい。これらの中でも、炭化珪素が好ましい。セラミック原料の含有量は、成形原料全体に対して40~90質量%であることが好ましい。
外周壁20は、上述したように、ハニカム構造部11の外周面を覆うように形成されたものである。このように外周壁20を備えることによって、ハニカム構造体100の外周の凹凸をより少なくすることができる。
本発明のハニカム構造体は、隔壁に触媒を担持していてもよい。触媒を担持することによって、排ガス中に含まれるCO、HCおよびNOXを浄化することができる。
本発明のハニカム構造体の一実施形態は、例えば、以下のようにして作製することができる。
まず、セラミック原料にバインダ、界面活性剤、造孔材、水などを添加して成形原料とする。セラミック原料としては、炭化珪素、珪素-炭化珪素系複合材料、コージェライト、ムライト、アルミナ、スピネル、炭化珪素-コージェライト系複合材料、リチウムアルミニウムシリケート、チタン酸アルミニウム、鉄-クロム-アルミニウム系合金からなる群から選択される少なくとも1種であることが好ましい。これらの中でも、炭化珪素又は珪素-炭化珪素系複合材料が好ましい。珪素-炭化珪素系複合材料とする場合、炭化珪素粉末及び金属珪素粉末を混合したものをセラミック原料とする。セラミック原料の含有量は、成形原料全体に対して40~90質量%であることが好ましい。
所定数のハニカムセグメントを接合材で接合し、乾燥させて、複数個のハニカムセグメントが、互いの側面同士が対向するように隣接して配置されると共に、対向する側面同士が接合部により接合されたハニカム構造体を形成する。接合部は、対向する側面全体に配設されることが好ましい。接合部は、ハニカムセグメントが熱膨張、熱収縮したときに、体積変化分を緩衝する(吸収する)役割を果たすとともに、各ハニカムセグメントを接合する役割を果たす。
まず、セラミックス原料として、SiC粉、金属Si粉を80:20の質量割合で混合し、これに、成形助材としてメチルセルロースおよびヒドロキシプロポキシメチルセルロース、造孔材として澱粉と吸水性樹脂、界面活性剤および水を添加して混練し、真空土練機により四角柱状の坏土を作製した。
電気炉の温度を400℃(実験例2)および450℃(実験例3)としたことを除いて、実験例1と同様の試験を行った。結果を表2および3に示す。表2において、クラックが発生しなかった場合にOK、クラックが発生した場合にNGと表記した。なお、NGの場合に発生したクラックは、いずれも接合部に発生していた。
ハニカム構造体の形状を、端面が図4、図5および図6の形状となる形状とした以外、上記実験例1と同様にして実験を行った。実験例1と同様な結果が得られた。
図7は、実験例7に使用したハニカム構造体の端面の形状を示す平面図である。実験例7においては、長径上の中心点を通り前記短径に平行な直線から25mm以内に存在する角部を含む接合部以外の接合部である破線部の接合部の厚さを0.2~1.0mmとし、その他の接合部の厚さを1.0とし、電気炉の温度を450℃とした以外、実験例1と同様とした。結果を表4に示す。表4において、クラックが発生しなかった場合にOK、クラックが発生した場合にNGと表記した。なお、NGの場合に発生したクラックは、いずれも接合部に発生していた。
長径上の中心点を通り短径に平行な直線から0~40mm離れた位置における角部を含む接合部の厚さを0.4mmとし、その他の部位の接合部の厚さは1.0mmとし、アスペクト比を1.8として、実験例1と同様の試験を行った。結果を図8に示す。図8は、クラック発生温度と接合部の厚さ(接合幅)が0.4mmである位置の関係を示すグラフである。図8中、横軸は、接合厚さを0.4mmとした位置、すなわち、長径の中心点を通り短径に平行な直線からの距離(mm)を示し、縦軸は、クラック発生温度を示す。図8より明らかなように、長径の中心点を通り短径に平行な直線から25mm以内にあるときにクラック発生温度が著しく低下する。
Claims (5)
- 一方の端面から他方の端面まで貫通し流体の流路となる複数のセルを区画形成する多孔質の隔壁と、前記一方の端面における所定のセルの開口部および前記他方の端面における残余のセルの開口部を封止する目封止部とを有し、互いの側面同士が対向するように隣接して配置された複数のハニカムセグメント、
前記複数のハニカムセグメントの対向する側面同士を接合する接合部、および、
前記複数のハニカムセグメントと接合部とで構成されるハニカム構造部の外周面を覆う外周壁を含み、
前記ハニカム構造体の両端面上における最長部を長径とし、前記端面上において前記長径と直交する向きの最長部を短径としたとき、アスペクト比(長径/短径)が1.2以上であるハニカム構造体において、
前記接合部と前記外周壁との交点から前記短径の方向に沿って10mm以内の接合部の領域である角部が、前記長径上の中心点を通り前記短径に平行な直線から25mm以内に存在し、前記長径上の中心点を通り前記短径に平行な直線から25mm以内に存在する前記角部を含む接合部の厚さが0.5mm以上5mm以下であって、その他の部分における接合部の厚さが1.5mm以下であるハニカム構造体。 - 前記長径上の中心点を通り前記短径に平行な直線から25mm以内に存在する前記角部を含む接合部の厚さが1mm以上1.5mm以下である請求項1に記載のハニカム構造体。
- 短径が150mm以上である請求項1に記載のハニカム構造体。
- 25mm以内に存在する前記角部を含む接合部の厚さより、その他の接合部の厚さ薄い事を特徴とする請求項1~3のいずれか1項に記載のハニカム構造体。
- 前記長径上の中心点を通り前記短径に平行な直線から25mm以内に存在する前記角部を含む接合部以外の接合部において、厚さ0.5mm未満の接合部を少なくとも1箇所含む請求項1~4のいずれか1項に記載のハニカム構造体。
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JP2003291054A (ja) | 2002-03-29 | 2003-10-14 | Ngk Insulators Ltd | ハニカム構造体の製造方法 |
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