WO2018123653A1 - Procédé de production de filtre en nid d'abeilles poreux - Google Patents

Procédé de production de filtre en nid d'abeilles poreux Download PDF

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Publication number
WO2018123653A1
WO2018123653A1 PCT/JP2017/045098 JP2017045098W WO2018123653A1 WO 2018123653 A1 WO2018123653 A1 WO 2018123653A1 JP 2017045098 W JP2017045098 W JP 2017045098W WO 2018123653 A1 WO2018123653 A1 WO 2018123653A1
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Prior art keywords
parallel
wall
axial direction
filter
cell
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PCT/JP2017/045098
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English (en)
Japanese (ja)
Inventor
泰史 ▲高▼山
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株式会社デンソー
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    • 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
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
    • B28B3/26—Extrusion dies
    • 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
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
    • C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
    • C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
    • 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
    • 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

Definitions

  • the present disclosure relates to a method for manufacturing a porous honeycomb filter having inclined walls and parallel walls.
  • the exhaust pipe of the internal combustion engine is provided with an exhaust gas purification device that collects particulate matter (PM) contained in the exhaust gas.
  • This exhaust gas purification device includes a porous honeycomb filter for collecting PM contained in exhaust gas.
  • the porous honeycomb filter has a large number of cells forming a gas flow path extending in the axial direction surrounded by a porous cell wall.
  • Such a cell structure is formed by extruding unfired clay in the axial direction.
  • the porous honeycomb filter having such a configuration, the exhaust gas flows in from the cell with the inflow end face opened, passes through the cell wall, and is discharged from the cell with the outflow end face opened. PM in the exhaust gas is collected when passing through the cell wall.
  • Patent Document 1 proposes an exhaust gas purifying apparatus having a plurality of passages that are in a lattice shape and have two triangular sides that are narrower toward the back side, and two inner side surfaces that follow each end surface and extend to the vicinity of the opposite end surfaces. Has been.
  • a porous honeycomb filter having a passage extending in a triangular shape for example, has an inclined wall inclined with respect to the axial direction as a cell wall, and the passage converges when the inclined walls approach each other.
  • the cell shape of the cross section orthogonal to the axial direction changes continuously or intermittently with respect to the axial direction.
  • the cell shape of the cross section orthogonal to the axial direction is continuously the same plane with respect to the axial direction except for a plug portion formed separately, and is continuous with respect to the axial direction.
  • the porous honeycomb filter having an inclined wall inclined with respect to the axial direction which is desired in the present application, cannot be continuously formed in the axial direction by the extrusion molding conventionally used.
  • the passage extending in a triangular shape and the inclined wall forming the triangular passage are formed, for example, by pushing a wedge-shaped member into a material mass before firing and then pulling it out as disclosed in Patent Document 1.
  • the pushing and pulling of the wedge-shaped member is performed on one mass of material. Since the shape is formed by the shape change of the material block, it is necessary to simultaneously form the cell walls constituting one honeycomb filter.
  • the meshing area of the wedge-shaped member is too large, so that the releasability from the mold at the time of drawing is not possible. It is bad and it is difficult to cope with continuous production in a short time.
  • the porous honeycomb filter having an inclined wall has a problem in that it is greatly disadvantageous in productivity as compared with a continuous cell wall forming method by extrusion molding.
  • the cell wall formed by pushing and pulling out the wedge-shaped member may change the orientation of crystal grains and the pore state of the cell wall as compared with the cell wall formed by general extrusion molding. . For this reason, manufacturing conditions accumulated by extrusion cannot be adopted, and it is necessary to separately examine raw material conditions, kneading conditions, pore control conditions, and the like.
  • the present disclosure aims to provide a manufacturing method capable of manufacturing a porous honeycomb filter having an inclined wall with high productivity.
  • One aspect of the present disclosure includes a cylindrical outer skin, an inclined wall inclined with respect to the axial direction of the cylindrical outer skin, a parallel wall parallel to the axial direction, and the inclined wall inside the cylindrical outer skin. And a cell forming a gas flow path extending in the axial direction surrounded by the parallel walls, and a method for manufacturing a porous honeycomb filter, By extruding the clay in a direction orthogonal to the axial direction, a plurality of inclined portions whose inclination directions with respect to the axial direction are alternately reversed, and a plurality of connecting portions that connect the inclined portions to each other and extend in the extrusion direction.
  • An extrusion process for obtaining an inclined structure having: A parallel part forming step of obtaining a honeycomb formed body having the inclined part and the parallel part by additionally forming a plurality of parallel parts that become the parallel walls by firing with respect to the inclined part; And a firing step of firing the honeycomb formed body.
  • the above manufacturing method has an extruding step of extruding the clay in the direction orthogonal to the axial direction instead of the axial direction of the cylindrical outer shell. Therefore, the inclined structure can be continuously produced by extrusion. This is because the inclined structure has a plurality of inclined portions and a plurality of connecting portions that connect the inclined portions. Such an inclined structure can be extruded in the direction orthogonal to the axial direction as described above. That is, it is possible to push out a planar body having a cross section perpendicular to the axial direction of the inclined structure body in the extending direction of the connecting portion. As a result, it becomes possible to continuously manufacture the inclined structure by extrusion as described above, and the productivity of the porous honeycomb filter obtained using the inclined structure is improved.
  • the porous honeycomb filter is appropriately referred to as “filter”.
  • the inclined portion is formed by extrusion molding. Therefore, the inclined structure can be produced without separately considering the raw material conditions, kneading conditions, pore control conditions, molding conditions, and the like of the clay. That is, it is possible to apply the same manufacturing conditions as those for manufacturing filters by general extrusion molding.
  • the parallel part forming step a plurality of parallel parts that become parallel walls are formed by firing. Thereby, a honeycomb formed body having a parallel part and an inclined part can be obtained.
  • the parallel part can be formed of substantially the same material as that of the inclined structure, or can be formed of a different material. Therefore, in the manufacturing method described above, it is possible to manufacture not only filters in which the inclined wall and the parallel wall are made of the same material but also filters made of different materials. It is also possible to form inclined walls and parallel walls having different pore conditions such as porosity.
  • the method which can manufacture the filter which has an inclined wall with sufficient productivity can be provided.
  • FIG. 1 is a perspective view of a porous honeycomb filter of Embodiment 1.
  • FIG. 2 is a partially enlarged view of the YZ cross section of the porous honeycomb filter of Embodiment 1.
  • FIG. 3 is a partially enlarged view of the XZ cross section of the porous honeycomb filter of Embodiment 1.
  • FIG. 4 is a partially enlarged view of the inflow end surface of the porous honeycomb filter of Embodiment 1.
  • FIG. 5 is a partially enlarged view of the XY cross section at a position near the inflow end face of the porous honeycomb filter of Embodiment 1.
  • FIG. 1 is a perspective view of a porous honeycomb filter of Embodiment 1.
  • FIG. 2 is a partially enlarged view of the YZ cross section of the porous honeycomb filter of Embodiment 1.
  • FIG. 3 is a partially enlarged view of the XZ cross section of the porous honeycomb filter of Embodiment 1.
  • FIG. 4 is
  • FIG. 6 is a partially enlarged view of the XY cross section at the axial center position of the porous honeycomb filter of the first embodiment.
  • FIG. 7 is a partially enlarged view of the XY cross section at a position near the outflow end face of the porous honeycomb filter of the first embodiment.
  • FIG. 8 is a partially enlarged view of the outflow end surface of the porous honeycomb filter of Embodiment 1.
  • FIG. 9 is a partial cross-sectional enlarged view of the connecting portion of the inclined wall according to the first embodiment.
  • FIG. 10 is an enlarged cross-sectional view of the inclined wall according to the first embodiment.
  • FIG. 11 is an enlarged cross-sectional view of a parallel wall in the first embodiment, FIG.
  • FIG. 12 is an explanatory diagram of an extrusion process for obtaining an inclined structure from the clay in Embodiment 1.
  • FIG. 13 is an explanatory diagram of an extrusion process for extruding an inclined structure from a mold in Embodiment 1.
  • FIG. 14 is a partially enlarged view of the YZ cross section of the inclined structure according to the first embodiment.
  • FIG. 15 is a partially enlarged view of the inclined structure in the XY plane according to the first embodiment.
  • 16 (a) is a partially enlarged sectional view of the clay in the first embodiment
  • FIG. 16 (b) is a partially enlarged sectional view of the inclined portion in the first embodiment, FIG.
  • FIG. 17A is a partial perspective view of the inclined structure in which the parallel wall forming material is filled in the space between the inclined portions in the first embodiment
  • FIG. 17B is the inclined wall in the first embodiment.
  • It is a partial perspective view of an inclined structure in which a parallel wall is formed by partially curing the parallel wall forming material filled in the space between
  • FIG. 18 is a partial perspective view of an inclined structure in which a plurality of parallel portions formed by curing a parallel wall forming material in Embodiment 1 are formed
  • Fig. 19 (a) is an XY plan view of the honeycomb formed body in the first embodiment
  • Fig. 19 (b) is an XY plan view of a columnar honeycomb formed body having a tubular portion in the first embodiment.
  • FIG. 20A is a perspective view of the inclined structure body according to the second embodiment
  • FIG. 20B is a perspective view of the inclined structure body piece according to the second embodiment
  • FIG. 21A is an explanatory diagram of a lamination process of alternately laminating inclined structure pieces and molded sheets according to the second embodiment
  • FIG. 21B is parallel to the inclined structure pieces according to the second embodiment. It is a partially enlarged view of the XY plane of a honeycomb formed body made of a laminate with a portion
  • FIG. 22 is a YZ plane cross-sectional view of the porous honeycomb filter of Modification Example 1
  • FIG. 23 is a partial cross-sectional enlarged view of a connecting portion of an inclined wall inclined in a curved shape in Modification Example 1
  • FIG. 21A is an explanatory diagram of a lamination process of alternately laminating inclined structure pieces and molded sheets according to the second embodiment
  • FIG. 21B is parallel to the inclined structure pieces according to the second embodiment.
  • It is a partially
  • FIG. 24 is a YZ plane cross-sectional view of the porous honeycomb filter of Modification Example 2
  • FIG. 25 is a YZ plane cross-sectional view of a porous honeycomb filter of Modification 3
  • FIG. 26 is a partial cross-sectional enlarged view of the connecting portion of the inclined wall in Modification 3.
  • FIG. 27 is an enlarged view of an end face of the porous honeycomb filter of Modification Example 4
  • 28 (a) is a YZ plane cross-sectional view of the porous honeycomb filter of Modification Example 4
  • FIG. 28 (b) is an XZ plane cross-sectional view of the porous honeycomb filter of Modification Example 4
  • FIG. 29 is a front view of the end face of the porous honeycomb filter of Modification Example 5, FIG.
  • FIG. 30 is a perspective view of the porous honeycomb filter of Comparative Example 1
  • FIG. 31 is a cross-sectional view in a plane parallel to the axial direction of the porous honeycomb filter of Comparative Example 1
  • FIG. 32 is an explanatory view showing a cross section of an inclined wall in the porous honeycomb filter of the sample E2 in the experimental example
  • FIG. 33 is a diagram showing the relationship between the distance in the axial direction from the inflow end face of each porous honeycomb filter and the wall permeation flow velocity in the experimental example.
  • the filter 1 includes a cylindrical outer skin 10, an inclined wall 21, a parallel wall 22, and a cell 3.
  • a wall surrounding the cell 3 serving as a gas flow path, such as the inclined wall 21 and the parallel wall 22, is appropriately referred to as a cell wall 2.
  • the cylindrical outer skin 10 is a cylindrical body having openings at both ends covering the outer periphery of the filter 1.
  • the axial direction of the cylindrical outer skin 10 is referred to as the axial direction Z in this specification.
  • the axial direction Z is the extension direction of the cell 3 forming the gas flow path, the flow direction of the exhaust gas G flowing into the filter 1, the flow direction of the exhaust gas G flowing out from the filter 1, and the exhaust gas G flowing through the cell 3. It is possible to match the flow direction and the like.
  • the inclined wall 21 and the parallel wall 22 define the inside of the cylindrical outer skin 10. Thus, a large number of cells 3 surrounded by the inclined wall 21 and the parallel wall 22 are formed inside the cylindrical outer skin 10.
  • the inclined wall 21 extends while being inclined with respect to the axial direction Z.
  • the inclined wall 21 is porous, for example.
  • the exhaust gas G flowing in the cell 3 can pass through the porous inclined wall 21.
  • FIG. 1 is a perspective view of the filter 1, and the cell wall inside the filter 1 is not originally shown, but the formation pattern of a part of the inclined walls 21 is indicated by dotted lines for convenience of explanation.
  • the parallel wall 22 extends parallel to the axial direction Z.
  • the parallel walls 22 are also parallel to the flow direction of the exhaust gas G, for example. For this reason, the exhaust gas G hardly enters the inside from the wall surface of the parallel wall 22. Even if the parallel wall 22 permeates the exhaust gas G, the parallel wall 22 may not substantially permeate the exhaust gas.
  • the parallel wall 22 preferably has a lower porosity than the inclined wall 21.
  • the strength of the parallel wall can be made higher than that of the inclined wall. Therefore, PM can be collected by the inclined wall 21, and the strength of the filter 1 can be increased by the parallel wall 22.
  • the parallel wall 22 may be porous, but need not be porous, and may be a non-porous body, that is, a dense body.
  • the porosity of the inclined wall 21 and the parallel wall 22 can be changed by adjusting the raw material composition, the particle size of each raw material powder, and the like.
  • the porosity can be compared and measured using a mercury porosimeter by a mercury intrusion method.
  • a mercury porosimeter for example, Autopore IV9500 manufactured by Shimadzu Corporation can be used.
  • the filter 1 is, for example, a columnar shape, but may be another columnar body such as an elliptical column shape, a triangular column shape, or a quadrangular column shape.
  • the filter 1 includes, for example, a cylindrical outer shell 10 that is open at both ends, such as a cylindrical shape, and a cell wall 2 that defines the inner side of the cylindrical outer shell 10.
  • the axial direction Z of the cylindrical outer skin 10 is also the axial direction Z of the filter 1.
  • the outer edge shape of the cell 3 on both end faces 11 and 12 in the axial direction Z of the filter 1 can be a polygon such as a triangle, a square, a rectangle, a hexagon, and an octagon.
  • the outer edge shape of the cell 3 may be circular or elliptical.
  • the outer edge shape of the cell 3 in the cross section orthogonal to the axial direction Z is the same.
  • the outer edge shape of the cell 3 is a polygon
  • at least one cell wall 2 out of the plurality of cell walls 2 surrounding each cell 3 can be inclined to form the inclined wall 21.
  • the outer edge shape of the cell 3 is preferably a polygonal shape having two opposite sides.
  • a pair of inclined walls 21 is preferably formed by inclining two opposing cell walls 2 surrounding the cell 3.
  • the pressure loss can be reduced by reducing the variation in the flow velocity of the exhaust gas G passing through the inclined wall 21.
  • the outer edge shape of the cell 3 is more preferably a quadrangle as illustrated in FIG. 1, and the pair of opposing inclined walls 21 have a wall distance between them facing either one of the end faces 11 and 12. It is more preferable to incline so that it may approach.
  • the pressure loss is hereinafter referred to as “pressure loss” as appropriate.
  • the direction orthogonal to the Z-axis direction and parallel to the wall surface of the parallel wall 22 is defined as the Y-axis direction
  • the direction orthogonal to both the Z-axis direction and the Y-axis direction is defined as the X-axis direction.
  • the filter cross section in the plane having the X axis and the Y axis is the XY cross section
  • the filter cross section in the plane having the Y axis and the Z axis is the YZ cross section
  • the filter cross section in the plane having the X axis and the Z axis is The cross section is XZ.
  • FIG. 2 shows a cross section of the filter 1 in the YZ plane parallel to the flow direction of the exhaust gas G.
  • FIG. 2 shows a cross section of the filter 1 in a plane including the axial direction Z of the filter 1 and the Y-axis direction parallel to the wall surface of the parallel wall 22.
  • the inclined directions Ds1 and Ds2 of the inclined wall 21 intersect with the axial direction Z.
  • the inclined directions Ds1 and Ds2 are the inclined directions of the inclined wall 21.
  • the Y coordinate position of each inclined wall 21 changes continuously with respect to the axial direction Z, for example.
  • the pair of opposed inclined walls 21 are continuously inclined, for example, so that the Y coordinate positions of both approach toward either one of the both end faces 11 and 12, respectively.
  • the inclined wall 21 may be formed in the entire extending direction of the cell wall 2 as illustrated in FIG. 2, but may be partially formed as shown in Modification 2 described later.
  • the inclined wall 21 only needs to be externally inclined with respect to the axial direction Z, and the inclination angle ⁇ 1 of the inclined wall 21 with respect to the axial direction Z is not particularly limited, but is preferably 0.9 ° or more, for example. (See FIG. 9).
  • the upper limit of the inclination angle ⁇ 1 is, for example, less than 30 °.
  • the inclination angle ⁇ 1 can be appropriately adjusted according to the size of the filter 1, desired pressure loss, collection rate, and the like.
  • the inclination angle of each inclined wall 21 may be constant as in the present embodiment or may be changed.
  • each cell 3 is preferably sandwiched between a pair of opposed inclined walls 21.
  • the inclination directions Ds1 and Ds2 of the pair of inclined walls 21 are preferably symmetric with respect to the axial direction Z.
  • the variation in the flow velocity of the exhaust gas G passing through the pair of inclined walls 21 at the predetermined position in the axial direction Z can be reduced. Therefore, the pressure loss can be further reduced.
  • the variation in the amount of PM collected by the pair of inclined walls 21 is reduced. Therefore, the temperature variation during heating of the filter 1 can be reduced.
  • the tilt directions Ds1 and Ds2 can be asymmetric with respect to the axial direction Z.
  • FIG. 3 shows a cross section of the filter 1 in the XZ plane parallel to the flow direction of the exhaust gas G.
  • FIG. 3 shows a cross section of the filter 1 in a plane orthogonal to the wall surface of the parallel wall 22, and shows a cross section of the parallel wall 22.
  • the X coordinate position of each parallel wall 22 does not change with respect to the axial direction Z, and is constant, for example.
  • the parallel walls 22 can also be formed in a pair of opposed cell walls 2 in the same manner as the inclined wall 21 described above.
  • the parallel wall 22 only needs to be parallel to the axial direction Z in terms of appearance, and may include a minute inclination, or a wavy portion that can be formed during molding or sintering.
  • the parallel wall 22 and the inclined wall 21 are preferably orthogonal to each other in the end faces 11 and 12 and the XY cross section of the filter 1.
  • the strength of the filter 1 can be further improved.
  • 5 is a view showing an XY cross section of the filter 1 at the intermediate position between the center in the axial direction Z and the inflow end surface 11 from the inflow end surface 11 side.
  • the position and orientation in the axial direction Z of the XY cross section in FIG. 5 are indicated by the VV line and the arrow in FIG.
  • FIG. 6 is a view showing the XY cross section of the filter 1 at the center position in the axial direction Z from the inflow end face 11 side.
  • FIG. 7 is a view showing an XY cross section of the filter 1 at the intermediate position between the center in the axial direction Z and the outflow end surface 12 from the inflow end surface 11 side.
  • the position and orientation in the axial direction Z of the XY cross section of FIG. 7 are indicated by the VII-VII line and the arrow in FIG. 2, respectively.
  • the filter 1 has an inflow end surface 11 and an outflow end surface 12 for the exhaust gas G at both ends in the axial direction Z.
  • the cell 3 includes a reduced cell 32 in which the gas flow path cross-sectional area S in the cell 3 decreases from the inflow end surface 11 toward the outflow end surface 12, and a gas flow in the cell 3 from the inflow end surface 11 toward the outflow end surface 12. It has the expansion cell 33 with which the road cross-sectional area S becomes large.
  • the reduced cell 32 and the enlarged cell 33 preferably share one inclined wall 21 and are adjacent to each other.
  • the exhaust gas G flows into the reduced cell 32, passes through the shared inclined wall 21 and is easily discharged from the adjacent enlarged cell 33, improves the PM collection rate, and reduces the variation in the collection rate.
  • the gas channel cross-sectional area of the reduced cell 32 is S 1
  • the gas channel cross-sectional area of the enlarged cell 33 is S 2 .
  • the gas flow path cross-sectional area S 1 is the area of the reduced cell 32 in the cross section orthogonal to the axial direction Z
  • the gas flow path cross-sectional area S 2 is the area of the enlarged cell 33 in the cross section orthogonal to the axial direction Z.
  • the reduced cell 32 includes a region where the gas channel cross-sectional area S 1 is constant and a region where the gas channel cross-sectional area S 1 is small, even if the gas channel cross-sectional area S 1 is gradually reduced. Good.
  • the gas flow path cross-sectional area S 2 may be made stepwise increased.
  • the reduced cells 32 and the enlarged cells 33 are alternately formed in the Y-axis direction on the XY plane, and are adjacent to each other in the Y-axis direction.
  • the reduced cells 32 or the enlarged cells 33 are adjacent to each other.
  • the gas flow cross-sectional area S 1 of the reduced cell 32 is maximized at the inflow end surface 11, and the reduced cell 32 is preferably open at the inflow end surface 11. .
  • the gas flow path cross-sectional area S 2 of the expansion cell 33 is minimized at the inflow end surface 11, and the pair of inclined walls 21 forming the expansion cell 33 are directly connected to each other at the inflow end surface 11.
  • the enlarged cell 33 is closed by the inflow end face 11, and the gas flow path cross-sectional area S 2 of the enlarged cell 33 becomes 0 at the inflow end face 11. Therefore, the opening area in the inflow end surface 11 is increased, and the pressure loss can be further reduced.
  • the gas flow path cross-sectional area S 1 of the contraction cell 32 is minimized, and the two opposing inclined walls 21 forming the contraction cell 32 have an outflow.
  • the outflow side connection portion 213 is formed by direct connection at the end face 12.
  • the reduced cell 32 is closed by the outflow side connection portion 213, and the gas flow path cross-sectional area S 1 can be zero at the outflow side connection portion 213 of the outflow end surface 12.
  • the gas flow path cross-sectional area S 2 of the enlarged cell 33 becomes maximum at the outflow end face 12, and the enlarged cell 33 can be opened at the outflow end face 12.
  • the inclination direction can intersect at either the outflow end face 12 or the inflow end face 11 as described above.
  • the pair of inclined walls 21 can be directly connected at the outflow end surface 12 or the inflow end surface 11 where the inclination directions intersect.
  • each cell 3 is surrounded by a pair of inclined walls 21 and parallel walls. Therefore, the shape of the cell 3 is a triangular prism whose X-axis direction is the height direction.
  • the reduced cells 32 and the enlarged cells 33 are adjacent to each other in the Y-axis direction, that is, in the direction parallel to the wall surface of the parallel wall 22 and in the direction orthogonal to the axial direction Z.
  • the adjacent reduced cell 32 and enlarged cell 33 share one inclined wall 21.
  • the filter 1 is made of a ceramic material such as cordierite, SiC, aluminum titanate, ceria-zirconia solid solution, alumina, mullite. Cordierite is preferable from the viewpoint of a small thermal expansion coefficient and excellent thermal shock resistance.
  • the inclined wall 21 and the parallel wall 22 may be formed of the same material, but can also be formed of different materials.
  • the inclined wall 21 can be formed of ceramics such as cordierite
  • the parallel wall 22 can be formed of metal. It is preferable that both the inclined wall 21 and the parallel wall 22 are made of ceramics whose main component is a cordierite crystal phase. In this case, since the difference in thermal expansion between the inclined wall 21 and the parallel wall 22 can be reduced, the occurrence of defects such as cracks can be prevented.
  • the parallel wall 22 is preferably formed of a material having a higher strength per unit thickness than the inclined wall 21. In this case, the strength improvement effect by the parallel walls 22 is further increased.
  • the strength per unit thickness can be measured and compared by, for example, three-point bending strength evaluation of two fulcrums and one load point according to JIS R1601: 2008 “Fine ceramic bending strength test method”. .
  • the exhaust gas purification catalyst 4 can be supported on the inclined wall 21 and the parallel wall 22.
  • the catalyst 4 include a three-way catalyst containing a noble metal.
  • the noble metal is preferably at least one of Pt, Rh, and Pd.
  • the catalyst 4 when the porosity of the inclined wall 21 is increased, the catalyst 4 is supported not only on the surface of the inclined wall 21 but also on the inside. Specifically, since the inclined wall 21 having a high porosity has a large number of large pores 219, the catalyst 4 can be supported on the wall surface facing the pores 219 in the inclined wall 21.
  • the pores 219 serve as exhaust gas passages that pass through the inclined wall 21. From the viewpoint of improving the PM collection rate and reducing the pressure loss, the porosity of the inclined wall 21 can be set in the range of 40 to 70%, for example.
  • the porosity of the parallel wall 22 when the porosity of the parallel wall 22 is lowered, the catalyst 4 is not supported inside the parallel wall 22 but is supported on the surface 228 facing the gas flow path.
  • the parallel wall 22 may not be able to transmit the exhaust gas. Therefore, it is not necessary to carry the catalyst 4 even inside the parallel wall 22.
  • the porosity of the inclined wall 21 can be increased to the extent that the catalyst is supported inside, and the porosity of the parallel wall 22 can be decreased to the extent that the catalyst is supported on the surface 228.
  • the porosity of the parallel wall 22 is preferably 45% or less, and more preferably 30% or less.
  • the parallel wall 22 may be a dense body. That is, the porosity of the parallel wall 22 may be zero.
  • the catalyst can be supported by a known method. For example, there is a method of immersing the filter in a liquid containing the catalyst or a precursor thereof and then baking the catalyst on the filter.
  • the filter 1 as described above is manufactured by performing an extrusion process, a parallel part forming process, and a firing process, as illustrated in FIGS.
  • the clay 20 is extruded in the direction X perpendicular to the axial direction Z.
  • an inclined structure 210 having a large number of inclined portions 211 and connecting portions 213 and 214 that connect the pair of inclined portions 211 to each other is obtained.
  • the inclined portion 211 forms the above-described inclined wall 21 after firing described later. Since the connecting portions 213 and 214 of the inclined wall 21 and the connecting portions 213 and 214 of the inclined portion 211 show substantially the same components, they are indicated by the same reference numerals in this specification.
  • the clay 20 can contain, for example, an inclined wall forming material.
  • the inclined wall forming material is a material for forming the inclined wall 21 after firing described later, and includes, for example, a cordierite raw material described later.
  • the clay 20 is manufactured as follows, for example.
  • a cordierite raw material is prepared by blending raw material powders such as silica, aluminum hydroxide, and talc so as to have a cordierite composition.
  • kaolin, alumina and the like can also be used as the cordierite raw material.
  • the cordierite raw material has a final composition after firing such as SiO 2 : 47 to 53% by mass, Al 2 O 3 : 32 to 38% by mass, and MgO: 12 to 16% by mass. The composition can be adjusted.
  • a clay-like clay 20 water and methylcellulose are added to the powdered cordierite raw material and kneaded to obtain a clay-like clay 20.
  • a thickener, a dispersant, an organic binder, a pore former, a surfactant, and the like can be added to the clay 20.
  • the clay 20 preferably contains a cordierite raw material as described above.
  • the inclined wall 21 containing cordierite having excellent thermal shock resistance can be formed. Therefore, the thermal shock resistance of the filter 1 can be improved.
  • a cordierite raw material is a raw material which produces
  • the cordierite raw material can contain, for example, Mg source, Si source, Al source and the like.
  • the clay 20 preferably contains plate-like particles 201 such as talc and kaolin.
  • the in-plane direction of the plate-like particles 201 in the inclined portion 211 can be oriented in the extrusion direction X as illustrated in FIG.
  • the in-plane direction is a direction orthogonal to the thickness direction of the plate-like particles 201. Therefore, the inclined wall 21 in which the cordierite crystal grains are oriented in the C-axis direction can be formed. As a result, thermal expansion of the inclined wall 21 in the C-axis direction is reduced, so that thermal stress can be reduced. Therefore, the thermal shock resistance of the filter 1 can be improved.
  • the plate-like particle 201 means a plate-like appearance, and is a concept including particles such as scales and flakes.
  • the extrusion direction X of the clay 12 in the extrusion molding is a direction orthogonal to the axial direction Z.
  • the extrusion direction X is the extension direction of the connecting portions 213 and 214.
  • the extension direction of the connecting portions 213 and 214 may be represented by the same reference numeral as the extrusion direction and may be denoted as the extension direction X.
  • the inclined structure 210 has a large number of inclined portions 211 and a large number of connecting portions 213 and 214, as illustrated in FIGS.
  • the inclined portion 211 extends in the axial direction Z while being inclined with respect to the axial direction Z.
  • Each inclined portion 211 has, for example, a plate shape, but may have a curved surface as in Modification 1 described later.
  • a pair of inclined portions 211 adjacent in the Y-axis direction have opposing surfaces facing each other, and the opposing surfaces are arranged in parallel in the Y-axis direction.
  • the inclination directions Ds1 and Ds2 with respect to the axial direction Z of the inclined portion 211 are alternately reversed.
  • the directions in which the inclination directions Ds1 and Ds2 are alternately reversed are such that the intersection points P 1 and P 2 of the inclination directions Ds1 and Ds2 of the pair of inclined portions 211 facing each other are alternately opposite in the Z-axis direction as illustrated in FIG.
  • the inclination directions Ds1 and Ds2 of the pair of opposing inclined portions 211 may be symmetric about the axial direction Z or may be asymmetric. Preferably, it is symmetrical. In this case, an inclined wall symmetrical with respect to the axial direction can be formed. As a result, the pressure loss can be further reduced as described above.
  • the inclination angle of the inclined portion 211 with respect to the axial direction can be appropriately adjusted according to the inclination angle of the inclined wall 21 described above.
  • the angle ⁇ 2 formed by the pair of opposing inclined portions 211 can be adjusted within a range of 0.5 to 30 °, for example. If the angle ⁇ 2 becomes too large, the axial length of the filter 1 becomes too small, so that the fluctuation of pressure loss accompanying soot deposition becomes large and drivability may be deteriorated. On the other hand, if the angle ⁇ 2 is too small, the effect of reducing pressure loss may be reduced, or the axial length of the filter 1 may be too large. From the viewpoint of reducing the size of the filter and reducing the pressure loss, the angle ⁇ 2 is preferably 0.9 to 1.5 °.
  • connection portions 213 and 214 can be formed at the end portion in the axial direction Z of the inclined structure 210. That is, the connection portions 213 and 214 can be formed by connecting the pair of inclined portions 211 at one end or the other end in the axial direction Z of the inclined structure 210.
  • the length in the axial direction Z of the other-end inclined structure 210 is equal to the length in the axial direction Z of the filter 1 unless the shrinkage after firing is taken into consideration.
  • one end and the other end of the inclined structure 210 described above correspond to the inflow end surface 11 and the outflow end surface 12 of the filter 1, respectively.
  • the inclined structure 210 illustrated in FIGS. 12 to 15 has the mountain portions M and the valley portions V alternately.
  • FIG. 14 when the cross-sectional view is rotated by 90 ° counterclockwise, for example, in the drawing, the peak M and valley V become clearer.
  • connection portions 213 and 214 are formed by the peak portions M and the valley portions V.
  • the inclined structure 210 has, for example, a bellows shape, and the cross section of the inclined structure 210 has a zigzag shape, a wave shape, or the like as illustrated in FIG.
  • the cross section of the mountain part M and the valley part V may have a corner part formed by two straight lines and their intersections, and the cross section of the mountain part and the valley part as in Modification Example 1 described later, It may be arcuate.
  • the connecting portions 213 and 214 connect a pair of opposing inclined portions 211.
  • the extending direction of the connecting portions 213 and 214 is the extrusion direction.
  • the extrusion direction is the X-axis direction in FIGS.
  • a plane body indicated by a YZ cross section of the inclined structure 210 illustrated in FIG. 14 can be extruded in the X-axis direction.
  • the X-axis direction is a direction orthogonal to the paper surface in FIG. 14 and is an extension direction of the connecting portions 213 and 214.
  • a plane body indicated by a YZ cross section of the inclined structure 210 is appropriately referred to as a YZ plane body.
  • the YZ plane body can also be called a bellows cross-section plane body, a wavy plane body, a zigzag plane body, a connected V-shaped plane body, or the like.
  • the inclined structure 210 can be obtained.
  • the inclined structure 210 can be obtained by extrusion molding by extruding the YZ plane in the X-axis direction.
  • the mass productivity of the inclined structure 210 is improved and the productivity of the filter 1 is increased.
  • extrusion molding can be performed using, for example, an extrusion molding machine 5 including a main body 51 and a mold 52.
  • the mold 52 has an extrusion hole 521 having the same shape as the YZ section of the inclined structure 210.
  • the extrusion hole 521 is also referred to as an extrusion groove, a molding groove, or a slit.
  • the extrusion hole 521 has a structure in which, for example, crest-shaped holes and valley-shaped holes are alternately connected.
  • the shape of the extrusion holes 521 is, for example, a zigzag shape or a wave shape. It is. That is, the shape of the extrusion hole 521 is the same shape as the YZ plane body (see FIG. 14) of the inclined structure 210 described above.
  • a conventional mold having a general shape that is extruded in the axial direction has a structure in which slits intersect and there is no portion in which the metal portion of the mold is connected in the radial direction.
  • the extrusion mold 52 used in this embodiment has a structure in which slits intersect and a portion where the meat portion of the mold is connected in the radial direction.
  • There is no complicated structure such as no structure. Therefore, as a structure of the mold 52, for example, it is not necessary to combine different shapes in the axial direction, and the mold 52 having a relatively simple structure configured with one cross-sectional shape can be used.
  • the clay 12 kneaded in the main body 51 is extruded from the extrusion hole 521 of the mold.
  • the above-described inclined structure 210 can be obtained. Since the inclined structure 210 is a continuous structure in which the YZ plane body extends in the X-axis direction, the inclined structure 210 can be molded by the extruder 5 by setting the X-axis direction to the extrusion direction as described above.
  • the inclined structure 210 is dried and contracted by microwave drying. Then, it can cut
  • a parallel portion forming step is performed.
  • the several parallel part 221 used as the above-mentioned parallel wall 22 is formed by baking. Thereby, the honeycomb formed body 100 having the inclined portion 211 and the parallel portion 221 as illustrated in FIG. 19A can be obtained.
  • the parallel part forming step a plurality of parallel parts 221 having a surface orthogonal to the extending direction X of the connection parts 213 and 214 can be formed.
  • the parallel part 221 can contain a parallel wall forming material described later.
  • the parallel part forming step includes a curing step and a discharging step.
  • the curing step as illustrated in FIG. 17A, in the curing step, the inclined structure 210 can be arranged so that the extending direction of the connecting portions 213 and 214 is vertical. In this case, filling of the parallel wall forming material 220 described later becomes easy. Further, during the light irradiation described later, the shape of the parallel wall forming material 220 can be maintained by its own weight, so that curing can be easily performed. Vertical is the direction of gravity.
  • the parallel wall forming material 220 is filled into the space Sp between the inclined portions 211 of the inclined structure 210.
  • the parallel wall forming material 220 is filled up to a predetermined height in the extending direction of the connecting portions 213 and 214.
  • the formation pitch of the parallel walls 22 can be adjusted by appropriately adjusting the height.
  • the parallel wall forming material 220 is a material for forming the parallel wall 22 after firing described later.
  • the parallel wall forming material 220 can contain a metal material, a ceramic material, or the like. Thereby, the parallel wall 22 which consists of a metal, ceramics, etc. can be formed.
  • the parallel wall forming material 220 contains a cordierite raw material.
  • the parallel wall 22 containing a cordierite crystal can be formed.
  • the thermal expansion difference between the inclined wall 21 and the parallel wall 22 can be reduced and the thermal shock resistance can be improved.
  • a cordierite raw material the same thing as the above-mentioned inclination part 211 can be illustrated.
  • the parallel wall forming material 220 filled between the inclined portions 211 is irradiated with light LS.
  • the light LS is, for example, laser light.
  • strength of a laser beam can be hardened.
  • the parallel portion 221 having a desired thickness can be formed.
  • the parallel part 221 can be formed as illustrated in FIG.
  • the parallel part 221 is made of a cured product of the parallel wall forming material 220.
  • the irradiation direction of the laser light LS is preferably the vertical direction. In this case, adjustment of the thickness of the parallel part 221 formed after hardening becomes easy. As a result, the parallel portion 221 having a uniform thickness can be easily formed. Irradiation with the laser beam LS can be performed, for example, from the top to the bottom in the vertical direction.
  • the thickness of the parallel part 221 can be appropriately adjusted according to the desired thickness of the parallel wall 22.
  • the thickness of the parallel portion 221 can be controlled by, for example, the composition of the parallel wall forming material, the intensity of the laser light LS, the irradiation time, and the like.
  • the parallel wall forming material 220 preferably contains a photocurable organic component.
  • the parallel wall forming material 220 can be easily cured by irradiation with the laser beam LS.
  • the photocurable organic component is, for example, a photocurable resin.
  • the content of the photocurable organic component resin in the parallel wall forming material 220 is preferably as small as possible if the parallel wall forming material 220 can be cured by laser irradiation. In this case, the strength of the filter 1 can be increased by increasing the density of the parallel walls 22.
  • the parallel part 221 is plate-shaped, for example, and has a surface parallel to the horizontal direction.
  • the parallel wall forming material 220 is further filled on the parallel portions 221 formed between the inclined portions 211.
  • the parallel wall forming material 220 is irradiated with a laser beam LS. Thereby, the parallel wall forming material 220 is cured by a predetermined thickness. In this way, the parallel part 221 is further formed between the inclined parts 211.
  • the filling of the parallel wall forming material 220 and the irradiation with the light LS are repeatedly performed. Thereby, a large number of parallel portions 221 can be formed between the inclined portions 211.
  • a removal process can be performed.
  • the uncured parallel wall forming material 220 is discharged from between the inclined portions 211 of the inclined structure 210.
  • the removal of the uncured parallel wall forming material 220 may be performed after all the parallel portions 221 are formed or after each parallel portion 221 is formed. Thereby, a large number of cells 3 surrounded by the inclined portion 211 and the parallel portion 221 are formed. In this way, the honeycomb formed body 100 can be obtained as illustrated in FIG.
  • the removal of the uncured parallel wall forming material 220 can be easily performed by tilting the honeycomb formed body 100.
  • the parallel wall forming material 220 can be easily removed from the openings of the cells 3 on the end faces 11 and 12. Further, the parallel wall forming material 220 can be removed by using air blow or the like together.
  • the properties of the parallel wall forming material 220 at the time of filling are not particularly limited, and examples thereof include powder, slurry, sol solution, and gas.
  • the parallel wall forming material 220 at the time of filling is preferably in a powder form. In this case, the parallel wall forming material 220 can be easily filled. Further, the parallel wall forming material 220 is easily cured by the laser beam. Furthermore, in this case, it becomes easy to remove the uncured parallel wall forming material 220 in the above-described removing step.
  • the average particle diameter of the parallel wall forming material 220 can be appropriately adjusted from the viewpoints of ease of filling at the time of filling, curability by light irradiation, ease of removal at the removing step, and the like. From the viewpoint of enhancing ease of filling, curability, and ease of removal, the average particle size of the parallel wall forming material 220 is preferably 1 ⁇ m to 30 ⁇ m, and more preferably 15 ⁇ m to 25 ⁇ m.
  • the average particle diameter is the median diameter d50. That is, the average particle diameter means a particle diameter at a volume integrated value of 50% in a particle size distribution obtained by a laser diffraction / scattering method.
  • FIG. 19 (a) is an XY plan view of the honeycomb formed body 100.
  • FIG. 19A is a plan view of the honeycomb formed body 100 as viewed from one connection portion 213 or 214 side.
  • straight lines extending in parallel with the X-axis direction indicate the connecting portions 213 and 214 of the inclined portion 211.
  • the thick line indicates the connection portion 213 located on the near side of the paper surface
  • the thin line indicates the connection portion 214 located on the far side of the paper surface.
  • a straight line extending in parallel with the Y axis indicates the parallel portion 221.
  • the parallel part forming step it is preferable to form the parallel part 221 so as to be orthogonal to the inclined part 211 as illustrated in FIG.
  • a filter in which the inclined wall 21 and the parallel wall 22 are orthogonal can be obtained.
  • Such a filter 1 is further improved in strength.
  • a 3D printer can be used to form the parallel portion 221.
  • the parallel wall forming material 220 containing the photocurable organic component may be used as in the present embodiment, but the parallel wall forming material 220 not containing the photocurable organic component can also be used.
  • a light source that can be absorbed by cordierite can be selected as the light source of the laser light LS.
  • Such a light source has a short wavelength and high energy.
  • the cordierite raw material generates heat by irradiation with the laser beam LS, and can be cured by at least partially sintering the cordierite raw material.
  • a femtosecond laser can be used for the irradiation with the short-wavelength laser light.
  • the honeycomb formed body 100 can be cut into a desired shape.
  • a hollow shape is indicated by a broken line.
  • the honeycomb formed body 100 can be cut out in a columnar shape.
  • the cylindrical portion 110 can be formed as illustrated in FIG. 19B by performing a cylindrical portion forming step.
  • the tubular portion 110 is a tubular portion that covers the outer periphery of the honeycomb formed body 100.
  • the cylindrical portion 110 can be formed by, for example, cementing.
  • the cylindrical portion 110 containing the outer skin forming material can be formed by applying the outer skin forming material to the outer periphery of the honeycomb formed body 100.
  • the outer skin forming material preferably contains, for example, a cordierite raw material.
  • the thermal shock resistance of the filter 1 can be further improved.
  • the honeycomb formed body 100 is fired. Thereby, the filter 1 illustrated in FIGS. 1 to 9 can be obtained.
  • the firing step it is preferable to fire the inclined portion 211 and the parallel portion 221. That is, it is preferable to perform firing by temperature control that allows the inclined portion 211 and the parallel portion 221 to be sintered.
  • firing can be performed in one step. Therefore, for example, compared with the case where the inclined portion 211 and the parallel portion 221 are sintered by different firing operations, the operation during manufacturing can be reduced.
  • the connecting portion between the inclined portion 211 and the parallel portion 221 can be fired. That is, in this case, the inclined portion 211, the parallel portion 221 and these connecting portions can be integrally fired. Therefore, the bonding strength between the inclined wall 21 and the parallel wall 22 after firing can be increased.
  • the inclined part 211 and the parallel part 221 are made of the same material, for example, cordierite having the same composition, the inclined part 211 and the parallel part 221 are simultaneously fired by firing in the above-described one step. It becomes possible.
  • the inclined portion 211 and the parallel portion 221 can be fired by different firing operations. Specifically, an inclined portion firing step of firing the inclined structure 210 after the above-described extrusion step and before the parallel portion forming step can be performed. Therefore, the inclined structure 210 used in the parallel part forming step is a concept including not only an unfired body but also a fired body. Similarly, the honeycomb formed body is a concept including not only a form having an unfired inclined part but also a form having an inclined wall after firing.
  • the joining strength of the cylindrical outer skin 10 in the filter 1 obtained after firing can be increased.
  • the filter shape, cell shape, etc. can be changed as appropriate.
  • dimensions such as the cell pitch, the thickness of the cell wall, the inclination angle of the inclined wall, and the length and width of the filter 1 can be appropriately changed.
  • the clay 20 is extruded in the direction X perpendicular to the axial direction Z as illustrated in FIG. Therefore, it is possible to continuously produce the inclined structure 210 by extrusion molding.
  • the inclined structure 210 includes a plurality of inclined portions 211 and a plurality of connecting portions 213 and 214 that connect the inclined portions 211 to each other, as illustrated in FIGS.
  • Such an inclined structure 210 can be extruded in the axial direction Z and the orthogonal direction X as described above.
  • the YZ plane body of the inclined structure 210 illustrated in FIG. 14 can be pushed out in the extending direction X of the connecting portions 213 and 214.
  • the inclined structure 210 can be continuously manufactured by extrusion as described above. Therefore, the productivity of the filter 1 obtained using the inclined structure 210 is improved.
  • the inclined portion 211 is formed by extrusion molding. Therefore, the inclined structure can be manufactured without separately considering the raw material composition, kneading conditions, pore control conditions, molding conditions, and the like of the clay 20. That is, the same manufacturing conditions as those for manufacturing filters by general extrusion molding can be applied. Therefore, it is advantageous in actual mass production.
  • the parallel wall forming material 220 and the clay 20 may be substantially the same material or different materials. That is, it is possible to manufacture not only the filter 1 made of the same material for the inclined wall 21 and the parallel wall 22 but also the filter 1 made of a different material.
  • the inclined wall 21 and the parallel wall 22 having different pore conditions such as porosity can be formed. it can.
  • the filter 1 of the present embodiment includes an inclined wall 21 and a parallel wall 22 as illustrated in FIGS. 1 to 9.
  • the inclined wall 21 is inclined with respect to the axial direction Z. Therefore, in the reduced cell 32 opened to the inflow end surface 11, the gas flow path cross-sectional area S 1 gradually decreases from the inflow end surface 11 toward the outflow end surface 12.
  • the enlarged cell 33 that opens to the outflow end surface 12 has a gas passage cross-sectional area S 2 that gradually increases, contrary to the reduced cell 32.
  • the internal pressure difference between the reduced cell 32 and the enlarged cell 33 becomes a driving force, and the exhaust gas G passes through the inclined wall 21.
  • the dense dot hatching area and the low density dot hatching area are adjacent to each other via the inclined wall 21, and the areas S 1 , S 1 , S 2 is different.
  • Such a configuration generates the above-described internal pressure difference.
  • the adjacent reduced cell 32 and enlarged cell 33 across the inclined wall 21 open to the inflow end surface 11 and the outflow end surface 12, respectively, and are adjacent cells that cause an internal pressure difference between the reduced cell 32 and the enlarged cell 33.
  • the exhaust gas G passes through the inclined wall 21, and PM in the exhaust gas G is collected on the inclined wall 21.
  • the porosity of the inclined wall 21 it is possible to increase the collection rate or prevent an increase in pressure loss.
  • the cells 3 adjacent to each other with the parallel wall 22 in between are either the reduced cells 32 or the expanded cells 33. Therefore, an internal pressure difference does not occur between the cells 3 adjacent to each other across the parallel wall 22. Therefore, the parallel wall 22 is less likely to transmit the exhaust gas than the inclined wall 21. 5 to 7, dot hatching areas having high density correspond to the relationship of the gas flow path cross-sectional areas of the reduced cells 32 adjacent to each other via the parallel wall 22. The areas of dot hatching with low density correspond to the relationship of the gas flow path cross-sectional areas of the enlarged cells 33 adjacent to each other via the parallel wall 22.
  • the parallel wall 22 since the gas permeation due to the internal pressure difference hardly occurs in the parallel wall 22, the porosity of the parallel wall 22 can be made smaller than that of the inclined wall 21. Thereby, the strength of the filter 1 can be increased. That is, the parallel wall 22 may be porous, but need not be porous, and may be a non-porous body, that is, a dense body. As described above, there is no internal pressure difference between the cells 3 sandwiching the parallel wall 22, so even if the parallel wall 22 is porous, the parallel wall 22 becomes a cell wall that is less permeable to gas than the inclined wall 21. Alternatively, the cell wall does not substantially transmit gas.
  • the strength of the filter 1 can be increased as described above. In this case, it is only necessary to ensure the strength in the Y-axis direction orthogonal to the axial direction Z, and the volume of the structure is as small as possible so that the structure formed by the parallel walls 22 does not become a gas flow resistance. Is desirable. Therefore, it is preferable that the parallel wall 22 is parallel to the axial direction Z and is orthogonal to the inclined wall 21.
  • the inclined wall 21 and the parallel wall 22 can have different functions.
  • PM can be collected in the inclined wall 21 while suppressing an increase in pressure loss, and the parallel wall 22 can have a practically sufficient strength.
  • the inclined structure 210 exemplified in FIGS. 20A and 20B is cut in the axial direction Z.
  • the inclined structure 210 is produced in the same manner as in the first embodiment.
  • the inclined structure 210 can be cut in a cross section orthogonal to the X-axis direction, that is, a YZ cross section.
  • Cutting in the axial direction Z means cutting in parallel with the axial direction Z.
  • the cutting direction of the inclined structure 210 is also a direction orthogonal to the extending direction X of the connecting portions 213 and 214.
  • the inclined structure 210 can be cut with the same width as the formation pitch of the desired parallel walls 22, for example.
  • the shape of the inclined structure piece 209 is substantially the same as that of the inclined structure 210 except that the width in the X-axis direction is small. Therefore, the inclined structure piece 209 includes the inclined portion 211 and the connecting portions 213 and 214 as in the inclined structure 210.
  • a lamination process is performed.
  • a large number of inclined structure pieces 209 and a large number of molded sheets 225 are alternately stacked.
  • the molded sheet 225 contains a parallel wall forming material. As such a molded sheet 225, a so-called green sheet can be used.
  • the molded sheet 225 is manufactured as follows, for example. First, a cordierite raw material, an organic solvent, and a butyral binder are mixed. Thereby, a slurry-like parallel wall forming material is produced. This parallel wall forming material is formed into a sheet having a predetermined thickness by, for example, a doctor blade method. In this way, a molded sheet 225 can be obtained. The thickness of the molded sheet can be adjusted as appropriate so that the parallel wall 22 having a desired thickness is formed after firing.
  • the cut surface 203 of the inclined structure piece 209 and the sheet surface 226 of the formed sheet 225 are brought into contact with each other.
  • the cut surface 203 of the inclined structure piece 209 is, for example, a zigzag or wavy YZ surface in FIG.
  • the stacking direction in the stacking process is a direction in which the extending direction of the connecting portions 213 and 214 of the inclined structure piece 209 and the thickness direction of the molded sheet 225 are parallel to each other.
  • the parallel part 221 includes a molded sheet 225.
  • the honeycomb formed body 100 is formed of a stacked body in which a large number of inclined structure body pieces 209 and a large number of formed sheets 225 are alternately stacked.
  • the stacking step it is preferable to apply an organic solvent to the contact surface between the inclined structure piece 209 and the molded sheet 225.
  • the adhesiveness between the inclined structure piece 209 and the molded sheet 225 can be improved. For this reason, it is possible to prevent the inclined wall 21 and the parallel wall 22 from being cracked or deformed.
  • the same or similar organic solvent as that used when the molded sheet 225 is produced.
  • “similar” means, for example, organic solvents that are compatible with each other.
  • the organic solvent can be applied by spraying, for example.
  • the organic solvent can be applied to the cut surface 203 of the inclined structure piece 209.
  • the filter 1 similar to the first embodiment can be obtained by performing the same operations as in the first embodiment.
  • the parallel portion 221 can be formed using the molded sheet 225 as described above.
  • This molded sheet 225 can be manufactured continuously. Therefore, not only the inclined structure 210 but also the molded sheet 225 can be manufactured continuously. Therefore, the productivity of the filter 1 can be further increased.
  • the inclined wall structure partitioned by the parallel wall 22 can be crossed in steps.
  • the inflow side connection portion 214 and the outflow side connection portion 213 of the inclined wall 21 on the inflow end surface 11 and the outflow end surface 12 are also formed in a different manner.
  • the number of contacts between the parallel wall 22 and the inflow side connection portion 214 of the inclined wall 21 increases, and thermal stress can be dispersed.
  • Other configurations and operational effects are the same as those of the first embodiment.
  • the present disclosure is not limited to the above embodiments, and can be applied to various embodiments without departing from the scope of the disclosure.
  • the manufacturing method of this indication is not limited to manufacture of these filters.
  • the connecting portions 213 and 214 that connect the inclined wall 21 extend in the X-axis direction that is orthogonal to the axial direction Z, the manufacturing method of the present disclosure can be applied.
  • the filter 1 of the present example includes the cells 3 whose outer edge shape in the XY cross section is a square as in the first embodiment.
  • a pair of opposing cell walls 2 is formed by an inclined wall 21, and the remaining pair of opposing cell walls 2 is formed by a parallel wall 22 (see FIG. 1).
  • the two inclined walls 21 facing each other as illustrated in FIG. 22 are linearly inclined in the central portion in the axial direction Z, but as illustrated in FIGS. Inclined in a curved manner toward the outflow end face 12 side.
  • the inclined wall 21 extending in the axial direction Z includes an inflow-side curved inclined area Acf that curves in a direction toward the inflow end surface 11 and an outflow side that inclines in a curve toward the outflow end surface 12. And a curved slope region Acr.
  • the pair of inclined walls 21 are connected in the outflow side curved inclined area Acr to form the outflow side connection portion 213.
  • the pair of inclined walls 21 are connected in the inflow side curved inclined area Acf to form the inflow side connection portion 214.
  • the inflow side connection portion 214 and the outflow side connection portion 213 have a curved structure.
  • the inclined wall 21 between the inflow side curved inclined area Acf and the outflow side curved inclined area Acr is linearly inclined.
  • the angle ⁇ formed between the tangential plane TP of the inclined wall 21 and the axial direction Z increases toward the both end surfaces 11 and 12 in the axial direction.
  • the angle ⁇ 1 formed between the tangential plane TP 1 and the axial direction Z satisfies the relationship ⁇ 1 ⁇ 2 .
  • the inclined wall 21 may have a curved surface, and when the inclined wall 21 is curved and curved in the YZ cross section as illustrated in FIGS. 22 and 23.
  • the variation in the flow rate of the exhaust gas passing through the inclined wall 21 can be further reduced. As shown in an experimental example described later, the variation is the smallest as compared with the filter 1 of the first embodiment and the modified example 2 described later. Therefore, it is possible to show an excellent collection rate while sufficiently reducing the pressure loss.
  • the pair of inclined walls 21 that are inclined in a curved shape are symmetrical with respect to the axial direction Z, and are connected at the inflow end surface 11.
  • the gas flow path cross-sectional area of the cell 3 increases toward the inflow end surface 11 side, and the increase amount also increases toward the inflow end surface 11 side.
  • the outflow side curved slope region Acr side it is considered that the opening area of the cell 3 at the inflow end surface 11 and the outflow end surface 12 becomes larger, and as a result, the pressure loss can be further reduced.
  • the inclination direction of the inclined wall 21 inclined in a curve means a tangential direction.
  • the fact that the inclination direction is symmetric with respect to the axial direction Z means that each tangent on the curved inclined wall 21 is symmetric, but even if not all tangents are strictly symmetric, they are substantially in appearance. As long as it is symmetrical.
  • FIG. 22 shows an example of an inclined wall that linearly slopes between the inflow side curved slope area Acf and the outflow side curved slope area Acr.
  • the linearly sloped area is not necessarily required. Absent.
  • an inflection point can be provided in the center in the axial direction of the inclined wall in the YZ section of the filter. Accordingly, it is possible to form an inclined wall in which the inflow-side curved inclined region Acf and the outflow-side curved inclined region Acr whose inclination directions are symmetric with respect to the axial direction are connected at the inflection point.
  • the filter 1 of this example is manufactured using an inclined structure having a cross-sectional structure similar to that of the inclined wall 21 illustrated in FIG. Specifically, the inclined structure can be obtained by extruding the YZ plane body of the inclined wall in FIG. 22 in the X-axis direction. Using the inclined structure obtained in this manner, the filter 1 can be manufactured in the same manner as in the first or second embodiment. Other configurations and operational effects are the same as those in the first and second embodiments.
  • the filter 1 of this example includes cells 3 whose outer edges are square.
  • a pair of opposed cell walls 2 has an inclined wall 21 inclined with respect to the axial direction Z, and the remaining pair of opposed cell walls 2 are formed by parallel walls 22 extending parallel to the axial direction Z. (See FIG. 1).
  • the pair of inclined walls 21 extending in the axial direction Z are connected to the inner side in the axial direction Z from the inflow end surface 11 or the outflow end surface 12 to form connection portions 213 and 214.
  • the filter 1 of this example illustrated in FIG. 24 will be described by paying attention to a continuous cell wall 2 including the inclined wall 21 and extending to both end faces 11 and 12 in the axial direction Z.
  • the cell wall 2 has an inclined wall 21 formed between the inflow side connection portion 214 and the outflow side connection portion 214 at the center in the axial direction Z.
  • the continuous cell wall 2 is connected to the inflow side of the inclined wall 21 and extends in parallel to the axial direction Z, and is connected to the outflow side of the inclined wall 21 and extends in the axial direction Z. It has an outflow side parallel wall 216 extending in parallel with respect to it.
  • the inclined wall 21, the inflow side parallel wall 215, and the outflow side parallel wall 216 can be formed by components having different compositions and porosity.
  • the inclined wall 21, the inflow side parallel wall 215, and the outflow side parallel wall 216 are made of the same constituent members. It is preferable to become.
  • the filter 1 of this example will be described from the viewpoint of the cell wall surrounding the reduced cell 32 and the enlarged cell 33.
  • the reduced cell 32 into which the exhaust gas G flows from the inflow end face 11 includes a pair of opposed inclined walls 21, a pair of inflow side parallel walls 215 that are connected to the inflow side of each inclined wall 21 and extend parallel to the axial direction Z.
  • Have The pair of inclined walls 21 in the reduced cell 32 are inclined so as to approach each other toward the outflow end surface 12, and are connected inside the outflow end surface 12 in the axial direction Z.
  • the pair of inclined walls 21 are directly connected, for example, to form the outflow side connection portion 213.
  • the reduced cell 32 is blocked at the outflow side connection portion 213.
  • the outflow side connection portion 213 can be formed near the outflow end surface 12 in the axial direction Z, for example.
  • An outflow side parallel wall 216 extending in parallel with the axial direction Z is formed on the outflow end surface 12 side of the outflow side connection portion 213, and the connected inclined wall 21 is formed as one cell wall.
  • the enlarged cell 33 from which the exhaust gas G is discharged from the outflow end face 12 includes a pair of opposed inclined walls 21, a pair of outflow side parallel walls 216 that are connected to the outflow side of each inclined wall 21 and extend parallel to the axial direction Z.
  • the pair of inclined walls 21 in the expansion cell 33 are inclined so as to approach each other toward the inflow end surface 11, and are connected inside the axial direction Z from the inflow end surface 11.
  • the inflow side connection portion 214 is formed by directly connecting the pair of inclined walls 21, for example.
  • the enlarged cell 33 is closed at the inflow side connection portion 214.
  • the inflow side connection portion 214 can be formed near the inflow end surface 11 in the axial direction Z, for example.
  • An inflow side parallel wall 215 extending in parallel with the axial direction Z is formed on the inflow end face 11 side of the inflow side connection portion 214, and the connected inclined wall 21 is formed as one cell wall.
  • the inclination directions of the pair of opposing inclined walls 21 can be made symmetrical with respect to the axial direction Z, for example.
  • the reduced cell 32 and the enlarged cell 33 are adjacent to each other with the common inclined wall 21 therebetween, and are formed alternately in the Y-axis direction, for example.
  • the filter 1 includes a communication region Ac in which the reduced cell 32 and the enlarged cell 33 are adjacent to each other in the Y-axis direction, for example, and a non-adjacent non-communication region Anc through the inclined wall 21.
  • the communication region Ac is a region through which the exhaust gas G passes through the inclined wall 21, and the exhaust gas G that has flowed into the reduced cell 32 passes through the inclined wall 21 in the communication region Ac and is discharged from the enlarged cell 33.
  • the reduced cells 32 are adjacent to each other via the inflow side parallel wall 215, and the enlarged cells 33 are adjacent to each other via the outflow side parallel wall 216.
  • the non-communication region Anc is a region where the exhaust gas G does not substantially pass through the cell wall.
  • the communication area Ac is formed at the center in the axial direction Z, and the non-communication area Anc is formed in each of the predetermined areas from both end faces 11 and 12 in the axial direction Z.
  • the inflow side parallel wall 215 and the outflow side parallel wall 216 have the same length, for example, and the non-communication areas Anc on the inflow end surface 11 side and the outflow end surface 12 side can also have the same length, for example.
  • the length of the inflow side parallel wall 215 and the length of the outflow side parallel wall 216 can be changed as appropriate, and the lengths of both may be the same or different.
  • the connecting portions 213 and 214 of the inclined wall 21 are formed on the outflow end surface 12 and the inflow end surface 11 as in the first embodiment. 2 (see FIG. 2), when the connecting portions 213 and 214 are formed inside the outflow end surface 12 and the inflow end surface 11 in the axial direction Z (see FIG. 24), respectively, as in this example (see FIG. 24).
  • a run-up section where gas permeation to the cell wall 2 at the outflow end face 12 does not occur can be provided. Due to the presence of this running section, inflow loss and gas concentration into the cell 3 caused by the influence of gas turbulence due to the collision with the cell wall 2 at the inflow end face 11 are suppressed. Thereby, pressure loss can be reduced.
  • the filter 1 of the present example uses an inclined structure having a cross-sectional structure similar to that of the cross-sectional body including the inclined wall 21, the inflow side parallel wall 215, and the outflow side parallel wall 216.
  • an inclined structure can be obtained by extruding a YZ plane including the inclined wall 21, the inflow side parallel wall 215, and the outflow side parallel wall 216 in the X-axis direction.
  • the filter 1 can be manufactured in the same manner as in the first or second embodiment.
  • Other configurations and operational effects are the same as those in the first and second embodiments.
  • the filter 1 of the present example includes the cells 3 whose outer edge shape in the XY cross section is a square as in the first embodiment.
  • a pair of opposing cell walls 2 are formed by inclined walls 21 inclined with respect to the axial direction Z, and the remaining pair of opposing cell walls 2 are formed by parallel walls 22 extending parallel to the axial direction Z. (See FIG. 1).
  • the pair of inclined walls 21 extending in the axial direction Z are not directly crossed but connected via a connecting member 23.
  • the reduced cell 32 is closed by an outflow side connecting member 231 provided on the outflow end surface 12, and an outflow side connecting portion 213 is formed by the outflow side connecting member 231.
  • the enlarged cell 33 is closed by an inflow side connecting member 232 provided on the inflow end surface 11, and an inflow side connecting portion 214 is formed by the inflow side connecting member 232.
  • Each inclined wall 21 is continuously and linearly inclined from the inflow end surface 11 toward the outflow end surface 12.
  • the inclined walls 21 are formed at the same cell pitch in the filters 1 having the same shape and size, compared to the case where the inclined walls 21 cross and connect at the end faces 11 and 12 as in the first embodiment (see FIG. 2).
  • the inclined wall 21 is connected to the end surfaces 11 and 12 via the connecting member 23 as in this example, the inclination angle of the inclined wall 21 is reduced.
  • the connecting member 23 has a surface orthogonal to the axial direction Z, for example. As described above, the connecting member 23 can be provided in parallel with the inflow end surfaces 11 and 12, but may be inclined if the pair of inclined walls 21 can be connected.
  • the material of the connecting member 23 can be selected as appropriate. Although not particularly limited, for example, it can be formed of cordierite similarly to the inclined wall 21 and the parallel wall 22.
  • the inclined wall 21 and the connecting member 23 are preferably made of the same constituent members in order to manufacture the inclined structure with high productivity by extrusion as in the first embodiment.
  • the inclined wall 21 extending linearly with respect to the axial direction Z can be connected by the connecting member 23 at both end faces 11 and 12.
  • the connecting member 23 since the inclination angle can be reduced, the passage distance of the exhaust gas G in the inclined wall 21 is increased. Therefore, the PM collection rate can be improved.
  • the PM in the exhaust gas G can be collected also in the connecting member 23 of the end surfaces 11 and 12. Since the inclined wall 21 is provided, the formation area of the connecting member 23 on the end faces 11 and 12 of each cell 3 does not have the inclined wall 21 and extends parallel to the axial direction Z as in Comparative Example 1 described later, for example. This is smaller than the formation area of the connecting member 23 in the filter having cell walls. Therefore, pressure loss can be reduced.
  • the formation area of the connecting member 23 is an area of the connecting member 23 on the end faces 11 and 12 of the filter 1.
  • the filter 1 of this example is manufactured using an inclined structure having a cross-sectional structure similar to that of the cross-sectional body including the inclined wall 21 and the connecting member 23 in the cross-sectional view illustrated in FIG.
  • an inclined structure can be obtained by extruding a YZ plane body composed of the inclined wall 21 and the connecting member 23 in FIG. 25 in the X-axis direction.
  • the filter 1 can be manufactured in the same manner as in the first or second embodiment.
  • Other configurations and operational effects are the same as those in the first and second embodiments.
  • the parallel wall 22 is formed up to both end faces 11 and 12 in the axial direction Z.
  • the parallel wall 22 does not reach both end faces 11, 12 in the axial direction Z, and the parallel wall 22
  • the end portion 222 is inside the axial direction Z with respect to the end surfaces 11 and 12.
  • the filter 1 of the present example includes the cells 3 whose outer edge shape in the XY cross section is a square as in the first embodiment.
  • a pair of opposing cell walls 2 are formed by inclined walls 21 extending in an inclined manner with respect to the axial direction Z.
  • the pair of inclined walls 21 are formed up to the inflow end surface 11 or the outflow end surface 12.
  • the remaining two cell walls 2 facing each other are formed by parallel walls 22 extending parallel to the axial direction Z.
  • the pair of parallel walls 22 does not reach the inflow end surface 11 or the outflow end surface 12, and the end 222 of the parallel wall 22 is , They are inside the axial direction Z from the end faces 11 and 12 respectively.
  • the parallel wall 22 is formed in a predetermined range At in the axial direction Z of the filter 1.
  • the formation region At of the parallel wall 22 is inside the both end surfaces 11 and 12.
  • a non-formation area Ant of the parallel wall 22 is formed in a predetermined area inside the both end faces 11 and 12 of the filter 1.
  • a parallel wall is not formed in the non-forming region Ant.
  • each cell 3 is surrounded by the pair of inclined walls 21 and the pair of parallel walls 22 in the above-described formation region At, but is not sandwiched between the pair of parallel walls 22 in the above-mentioned non-formation region Ant. It is sandwiched and partitioned by a pair of inclined walls 21. Further, on both end faces 11 and 12 of the filter 1, enlarged cell openings 35 that are sandwiched between the pair of inclined walls 21 and do not have the parallel walls 22 are formed.
  • the pressure loss can be further reduced.
  • the enlarged cell opening 35 is formed in the inflow end surface 11, the opening area in the inflow end surface 11 into which exhaust gas flows becomes larger, and thus the effect of reducing the pressure loss becomes more remarkable.
  • the length in the axial direction Z of the formation region At and the non-formation region Ant of the parallel wall 22 can be changed as appropriate.
  • the parallel wall 22 composed of the parallel walls 22 can improve the filter strength as described above, and in order to sufficiently obtain this strength improvement effect, the length of the formation region At of the parallel wall 22 is the axis of the filter.
  • the total length in the direction Z is preferably 80% or more, more preferably 90% or more, and still more preferably 95% or more.
  • the length of the non-forming region Ant in the axial direction Z is preferably 1% or more of the total length in the axial direction Z of the filter. It is more preferably 3% or more, and further preferably 5% or more. In the case where the non-forming regions Ant are formed at both ends in the axial direction Z, the lengths of the non-forming regions Ant in the axial direction Z are the respective lengths.
  • the non-formation region Ant of the parallel wall 22 and the enlarged cell opening 35 formed thereby may be formed on both end surfaces 11 and 12 in the axial direction Z, but may be formed on one end surface. . From the viewpoint that the pressure loss of the inflow end surface 11 can be further reduced as described above, it is preferable that the non-formation region Ant of the parallel wall 22 and the enlarged cell opening 35 are formed at least on the inflow end surface 11.
  • the filter 1 of the present example can be manufactured in the same manner as in the first embodiment in the above-described curing process, for example, by limiting the laser light irradiation range to the formation region At of the parallel wall 22. Further, in the above-described laminating step, the length in the Z-axis direction of the molded sheet is shorter than that in the first embodiment, and the same as in the second embodiment except that the molded sheet is stacked in the formation region At of the parallel wall 22. Can be manufactured. In this case, the area
  • the cross section of the inclined wall 21 is a region extending in parallel with the X-axis direction, and is a region indicated by fine hatching. This region is the cross-sectional area S a of the inclined wall 21. That is, in any cross section in the axial direction and orthogonal direction of the filter 1, the sum of the cross-sectional area of the inclined wall 21 is S a.
  • the cross section of the parallel wall 22 is a region extending in parallel with the Y-axis direction, and is a region indicated by rough hatching. This region is the cross-sectional area S 2 of the parallel wall 22. That is, in any cross section in the axial direction and orthogonal direction of the filter 1, the sum of the cross-sectional area of the parallel walls 22 is S b.
  • the relationship of S a > S b is satisfied in the cross section of the filter 1 in the direction orthogonal to the axial direction at an arbitrary position in the axial direction.
  • the occupied volume of the parallel wall 22 in the filter 1 can be reduced. Therefore, the obstruction of the gas flow by the parallel wall 22 that is difficult to permeate the gas can be alleviated. Thereby, the pressure loss can be further reduced.
  • PM in the exhaust gas G is collected by the inclined wall 21, even if the occupation area of the parallel wall 22 is relatively reduced as described above, it is possible to prevent the collection rate from being lowered. That is, the pressure loss can be reduced while preventing the collection rate from decreasing.
  • FIG. 29 is a front view of the end faces 11 and 12 of the filter 1.
  • the thick lines indicate the connection portions 214 and 213 in the front direction in the direction orthogonal to the paper surface
  • the thin lines indicate the connection portions 213 and 214 in the back direction in the direction orthogonal to the paper surface.
  • the positions of the thick line and the thin line extending in parallel to the X-axis direction are shifted by a half pitch, but the figures are substantially equivalent.
  • the filter 1 illustrated in FIG. 29 has the cells 3 whose outer edge shape of the XY cross section is a square as in the first embodiment.
  • a pair of opposing cell walls 2 are formed by inclined walls 21 extending in an inclined manner with respect to the axial direction Z.
  • the remaining two cell walls 2 facing each other are formed by parallel walls 22 extending parallel to the axial direction Z.
  • the inclined wall 21 and the parallel wall 22 are orthogonal to each other, for example.
  • the cell 3 surrounded by the inclined wall 21 and the parallel wall 22 has a rectangular outer edge shape on the end surfaces 11 and 12.
  • the number of parallel walls 22 that linearly divide the inside of the cylindrical outer skin 10 on the end faces 11 and 12 is smaller than the number of inclined walls 21.
  • the shape of the opening of the cell 3 in the inflow end surface 11 and the outflow end surface 12 is rectangular as illustrated in FIG.
  • the relationship of S a > S b can be satisfied. Therefore, the occupied volume of the parallel wall 22 in the filter 1 can be reduced, and the obstruction of the gas flow by the parallel wall 22 can be reduced. Therefore, the pressure loss can be reduced. In this case, for example, the opening area of the cell 3 on the inflow end face 11 can be increased. From this viewpoint, the pressure loss can be further reduced. Moreover, the number of the parallel walls 22 can be adjusted within a range in which a desired strength can be maintained.
  • the thickness T 2 of the parallel wall 22 is made larger than the thickness T 1 of the inclined wall 21.
  • the relationship of T 1 ⁇ T 2 may be satisfied.
  • the volume occupied by the parallel walls 22 in the filter 1 can be reduced. As a result, the pressure loss can be further reduced.
  • the parallel wall 22 is formed of a material having a higher strength per unit thickness than the inclined wall 21. In this case, since the strength of the parallel wall 22 itself is improved, even if the number of the parallel walls 22 is reduced, the strength reduction is further prevented. Therefore, the pressure loss can be improved while further preventing the strength from being lowered.
  • the filling height of the parallel wall forming material into the space between the inclined portions is made larger than that in the first embodiment, for example, in the above-described curing process, and the others are the same as in the first embodiment.
  • the filter 1 can be manufactured in the same manner as in the second embodiment except that the inclined structure piece 209 has a larger width than that in the first embodiment in the above-described cutting step.
  • the thickness of the parallel wall can be adjusted, for example, by changing the laser beam transmission intensity in the curing step or changing the thickness of the molded sheet.
  • other configurations and operational effects are the same as those in the first and second embodiments.
  • the filter 9 of this example does not have an inclined wall that extends while being inclined in the axial direction Z.
  • the filter 9 includes a cylindrical outer skin 90, a cell wall 91 that partitions the inner skin, and a cell 92 that is surrounded by the cell wall 91 and forms a gas flow path extending in the axial direction Z of the cylindrical outer skin.
  • Each cell 92 is surrounded by four cell walls 91, has two sets of opposing cell walls 91, and each cell wall 91 is orthogonal.
  • the shape of the cell 92 in the cross section orthogonal to the axial direction Z is a quadrangle, more specifically, a square.
  • any one of both end faces 93 and 94 in the axial direction Z of each cell 92 is blocked by a blocking member 95 that does not transmit gas.
  • the cell 92 in which the closing member 95 is provided on the outflow end surface 94 is open to the inflow end surface 93 and becomes an inflow cell 921 into which exhaust gas flows.
  • the cell 92 in which the closing member 95 is provided on the inflow end surface 93 is open to the outflow end surface 94 and becomes an outflow cell 922 from which exhaust gas flows out.
  • the inflow cell 921 and the outflow cell 922 are alternately close to each other. Two adjacent inflow cells 921 and outflow cells 922 share one cell wall 91.
  • the exhaust gas flowing into the inflow cell 921 passes through the cell wall 91 shared with the inflow cell 921 and reaches the outflow cell 922.
  • the exhaust gas G is discharged from the outflow end surface 94 through the outflow cell 922.
  • the cell walls 91 extend parallel to the axial direction Z, and the cells 92 surrounded by the cell walls 91 are alternately closed at the end faces 93 and 94 as described above. Therefore, in the inflow end face 93, half of all the cells 92 are opened, but the other half is closed by the closing member 95. Therefore, the pressure loss at the inflow end face 93 is larger than that of the filter of the first embodiment and the first to fifth modifications. Also on the outflow end surface 94, half of the cells 92 are open and the other half are closed.
  • the magnitude of the flow velocity of the exhaust gas G passing through the cell wall 91 is represented by the length of the arrow that crosses the cell wall 91.
  • the flow rate of the exhaust gas G passing through the cell wall 91 is referred to as a wall permeation flow rate.
  • the wall permeation speed increases as it approaches the inflow end face 93 and the outflow end face 94 provided with the closing member 95, and the wall permeation flow speed is small at the center in the axial direction Z of the filter 9. Become.
  • the variation in the wall permeation flow rate increases and the pressure loss increases.
  • the wall permeation flow rates of three types of filters having inclined walls formed in the same pattern as in the first embodiment, the first modification, and the second modification are measured by simulation and compared with the first comparative example.
  • the sample E1 corresponds to the filter of the first embodiment, the inclined wall 21 is linearly and continuously inclined from the inflow end surface 11 to the outflow end surface 12, and the opposing inclined walls 21 are in one of the both end surfaces 11 and 12.
  • the filter 1 is directly connected (see FIGS. 1 to 9).
  • the actual shape and size of the sample E1 used for measuring the wall permeation flow velocity are as follows.
  • the filter 1 of the sample E1 has a cylindrical shape, the diameter ⁇ is 118.4 mm, and the length in the axial direction Z is 118.4 mm.
  • the thickness of the cell walls 2, i.e., the thickness T 2 of the thickness T 1 and parallel walls 22 of the inclined wall 21 are both 0.203 mm (see FIG. 9, FIG. 3).
  • the thickness T 3 in the Y-axis direction of the connecting portions 213 and 214 of the inclined wall 21 is 0.444 mm, and the width W 1 in the axial direction Z of the connecting portions 213 and 214 is 0.200 mm (see FIG. 9).
  • the inclination angle ⁇ of the inclined wall 21, that is, the angle ⁇ formed between the inclined wall 21 and the axial direction Z is 0.97 ° (see FIG. 9).
  • the outer edge shape of the cell 3 on the end faces 11 and 12 is a square, and the length L 1 of one side of the outer edge is 1.576 mm (see FIG. 4).
  • Sample E2 corresponds to the filter of the first modification, and is the filter 1 in which the inclined wall 21 is curvedly inclined to both end faces 11 and 12 in the axial direction Z and has connection portions 213 and 214 having a curved structure.
  • FIG. 32 shows an actual formation pattern of the inclined wall 21 in the sample E2 used for measuring the wall permeation flow velocity.
  • the horizontal axis indicates the length in the axial direction Z of the filter from the inflow end surface 11 to the outflow end surface 12.
  • the vertical axis is the width in the radial direction, and more specifically indicates the distance in the Y-axis direction from, for example, an arbitrary inflow side connecting portion 214 located at the center.
  • the thickness of the connection parts 213 and 214 is small, the thickness of the connection parts 213 and 214 can be changed arbitrarily. Other shapes and dimensions are the same as those of the sample E1.
  • Sample E3 corresponds to the filter of the second modification, and is the filter 1 in which the inclined wall 21 is connected and closed inside the end surfaces 11 and 12 in the axial direction (see FIG. 24).
  • Each dimension in the sample E3 used for the measurement of the wall permeation flow velocity is as follows.
  • the distance in the axial direction Z between the inflow side connection portion 214 and the outflow side connection portion 213, that is, the length in the axial direction of the region where the inclined wall 21 is formed is 108.4 mm.
  • the length and the length of the outflow side parallel wall 216 are both 5.0 mm.
  • the angle between the inclined wall 21 and the axial direction Z, that is, the inclination angle is 1.06 °.
  • Other shapes and dimensions are the same as those of the sample E1.
  • Sample C1 corresponds to the filter of Comparative Example 1, and is a filter 9 in which all cell walls extend in the axial direction and each cell is alternately closed by a closing member at both ends (see FIGS. 30 and 31). .
  • Each dimension in the sample C1 used for the measurement of the wall permeation flow velocity is the same as that of the sample E1 except that there is no inclined wall.
  • the dimensions of the samples E1 to E3 are representative examples, and the dimensions of the filter 1 are not limited to these and can be changed as appropriate.
  • the relationship between the axial distance from the inflow end face in the filter of each sample and the wall permeation flow velocity was obtained by simulation.
  • the measurement conditions for the simulation are as follows. Gas flow rate: 32 m 3 / min, temperature: 900 ° C., upstream pressure: 60 kPa. The result is shown in FIG.
  • the filter 9 closed by this increases the variation in the wall permeation flow velocity (see FIGS. 30 and 31). Specifically, the wall permeation flow velocity increases as it approaches the inflow end surface 93 and the outflow end surface 94, and is maximized at each end surface 93, 94. On the other hand, it becomes minimum at the center in the axial direction Z. In the sample C1, the minimum value and the maximum value of the wall permeation flow rate are large, and the variation in the wall permeation flow rate is large. Therefore, the pressure loss increases.
  • the variation in the wall permeation flow velocity is small and the pressure loss is small as compared with the sample C1 described above.
  • the variation in the wall permeation flow velocity decreases in the order of the sample E3, the sample E1, and the sample E2.
  • the filter 1 of the sample E3 in which the inclined wall 21 is connected and closed inside the end surfaces 11 and 12 in the axial direction Z is the sample E1 in which the inclined wall 21 is closed at the end surfaces 11 and 12.
  • the opening area of the inflow end face 11 is increased as described above. Therefore, as shown in FIG. 33, the sample E3 has a smaller wall permeation flow rate on the inflow end face 11 side.
  • the wall permeation flow velocity at the center in the axial direction Z is larger in the sample E3.
  • the variation in the wall permeation flow velocity is smaller in the sample E1 than in the sample E3.
  • the wall permeation flow rate is constant, and there is substantially no variation.
  • the pressure loss can be reduced most among the samples E1 to E3.
  • the configurations of the inclined wall, the connecting portion, and the parallel wall in the filters of Embodiment 1 and Modifications 1 to 5 described above can be combined as appropriate.
  • the first and second modifications may be combined to form the inclined wall connecting portions 214 and 213 inclined in a curved shape on the inner side in the axial direction.
  • the modification 1 and the modification 3 are combined, and a pair of inclined walls inclined in a curved shape can be connected via a connecting member at the connection portion.

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Abstract

La présente invention produit un filtre en nid d'abeilles poreux par réalisation d'une étape d'extrusion, d'une étape de formation de section parallèle et d'une étape de cuisson. Dans l'étape d'extrusion, de l'argile (20) est moulée par extrusion dans une direction (X) orthogonale à la direction axiale (Z). Par conséquent, une structure inclinée (210) est obtenue qui a : une pluralité de sections inclinées (211) qui ont des directions d'inclinaison alternativement inversées par rapport à la direction axiale (Z); et une pluralité de sections reliées (213, 214) qui relient des sections inclinées l'une à l'autre et s'étendent dans la direction d'extrusion. Dans l'étape de formation de section parallèle, une pluralité de sections parallèles qui deviennent des parois parallèles en résultat de cuisson sont en outre formées sur les sections inclinées (211). Par conséquent, un corps moulé en nid d'abeilles est obtenu qui a des sections inclinées (211) et des sections parallèles. Le corps moulé en nid d'abeilles est cuit dans l'étape de cuisson.
PCT/JP2017/045098 2016-12-27 2017-12-15 Procédé de production de filtre en nid d'abeilles poreux WO2018123653A1 (fr)

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CN113453842A (zh) * 2019-02-15 2021-09-28 康宁股份有限公司 挤出模头及其制造方法
CN114835511A (zh) * 2022-06-02 2022-08-02 西安交通大学 一种堇青石前驱体光固化膏料及复杂结构多孔堇青石陶瓷的制备方法
DE102022203604A1 (de) 2022-04-11 2023-10-12 Siemens Energy Global GmbH & Co. KG Pulver, keramische Wand, Reaktionskammer sowie Verfahren

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JP7154931B2 (ja) * 2018-10-12 2022-10-18 イビデン株式会社 ハニカム構造体
CN112192739B (zh) * 2020-10-10 2022-04-12 广东萨米特陶瓷有限公司 一种仿水磨石瓷质板材制造工艺及运用该工艺所得的制品

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