CN1674972A - 用于柴油机颗粒过滤器应用的硅酸铝镁结构 - Google Patents

用于柴油机颗粒过滤器应用的硅酸铝镁结构 Download PDF

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CN1674972A
CN1674972A CNA038197065A CN03819706A CN1674972A CN 1674972 A CN1674972 A CN 1674972A CN A038197065 A CNA038197065 A CN A038197065A CN 03819706 A CN03819706 A CN 03819706A CN 1674972 A CN1674972 A CN 1674972A
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filter
pore
ceramic filter
hole
size distribution
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CN100341602C (zh
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D·M·比尔
G·A·莫克尔
M·J·莫塔格
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Corning Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

一种用于捕集和燃烧柴油机排气颗粒的陶瓷过滤器，其由末端堵塞的堇青石蜂窝结构组成，用水银孔率检测法确定其孔径分布，与孔径分布相关的量d50/(d50+d90)小于0.70，由式[d50/(d50+d90)]/[孔隙率％/100]定义的负载烟灰透气性因子Sf小于1.55，热膨胀系数(25－800℃)不超过17×10－7/℃。该陶瓷过滤器还具有至少4微米而且最高40微米的孔径中值d50。提供了制造这种过滤器的方法。

Description

用于柴油机颗粒过滤器应用的硅酸铝镁结构
发明领域
本发明涉及用于高温过滤应用的，具有低热膨胀和最佳透壁负载烟灰透气性的硅酸铝镁(MAS)型结构。具体而言，本发明涉及具有比市售堇青石壁流过滤器更窄孔径分布和更大互连孔隙率的堇青石壁流颗粒过滤器。
发明背景
由于柴油机的高效，耐用和经济原因，对其的兴趣很大。但是在美国和欧洲，柴油机排放因为其对环境和人类的有害影响而受到攻击。降低柴油机排放的一个最大挑战是控制柴油机排气流中存在分子被宣布为毒性空气污染物的柴油机颗粒物质的含量。
柴油机颗粒物质主要是碳烟灰。一种从柴油机排气中除去碳烟灰的方法是通过柴油机微粒滤清器。最为广泛使用的柴油机微粒滤清器是柴油机壁流颗粒过滤器，通过用过滤器体的多孔壁捕获烟灰而过滤柴油机排气。柴油机颗粒过滤器(DPF)的设计能几乎完全过滤烟灰，而不会明显阻碍排气流过。在工业中，堇青石已是DPF的有成本效益的选择材料，因为它在大多数工作条件下，都能同时表现出极佳的耐热冲击性，过滤效率和耐用性。
随着一层柴油机颗粒材料或碳烟灰被捕集在过滤器进气通道表面上，烟灰层的较低透气性会因为过滤器长度上的压力降而使过滤器对发动机的背压逐渐升高。这使发动机的工作变得更困难。一旦过滤器中的碳烟灰累积到一定程度，则必须通过燃烧烟灰，使背压回复至低水平来再生过滤器。过滤器上的压力降越高，则对发动机的背压越高。
对于指定的过滤器尺寸和孔几何形状，压力降随着烟灰负载量增大而增加下的速率取决于烟灰与过滤器壁中孔隙的相互作用。为卡车发动机设计的市售堇青石DPF具有高压力降，使其高压力降下降成为必要。已观察到由具有很多孔径范围狭窄的互连孔隙的陶瓷制得的过滤器在指定烟灰负载量条件下，具有比孔径范围宽(由水银孔率法检测法测定)的过滤器更低的压力降。
本发明人认为，获得其孔径分布和孔隙连通性能保持低于至今市售堇青石DPF的压力降，同时仍然具有低热膨胀的堇青石柴油机颗粒过滤器，是技术的一种进步。本发明提供了这种过滤器及其制造方法。
发明概述
本发明基于，发现硅酸铝镁(堇青石)柴油机颗粒过滤器具有最佳透壁负载烟灰透气性，能产生低于市售堇青石过滤器的压力降。“透壁负载烟灰透气性”是过滤器的多孔陶瓷壁受到充分烟灰累积，使得烟灰开始在壁的进气表面上形成烟灰层或烟灰饼时，通过该壁的透气性。如果在壁的进气表面下方的孔隙内有一定量烟灰沉积，则透壁负载烟灰透气性低于烟灰沉积之前干净壁的透气性。
使微结构具有更窄的孔径分布和更大的互连孔隙率，能获得更低的压力降。发现在本发明的堇青石过滤体中，通过用片状程度较低的氧化镁(MgO)组分和使用非片状的二氧化硅组分代替一些或全部片状滑石，能减轻孔隙形态的各向异性，可获得更好的孔隙连通性。而且，要从原料混合物中除去粘土组分，因为它会与MgO发生不良反应，形成的堇青石晶体会以它们的高膨胀结晶a轴和b轴在过滤器陶瓷壁平面中生长，导致最终陶瓷体具有高热膨胀系数。虽然降低了本发明过滤器的压力降，但是仍然能保持低热膨胀，从而提供高耐热冲击性。
因此，本发明陶瓷体由包括MgO，氧化铝(Al2O3)和二氧化硅(SiO2)的原料反应而形成。还可以添加尖晶石。原料批料中还可包括成孔剂，比如淀粉，纤维素等有机成孔剂，或石墨等无机成孔剂，或聚丙烯酸酯类，聚乙烯类等合成聚合物成孔剂。先对批料进行塑化和成形，然后干燥并烧制成主要为大致符合Mg2Al4Si5O18化学计量式的相的结构。然后将制得的陶瓷蜂窝结构制成柴油机颗粒过滤器。
在优选实例中，该过滤器蜂窝体结构具有进气端和排气端，以及大量从进气端延伸到排气端的孔，孔具有多孔壁，其中位于进气端的部分孔沿其部分长度被堵塞，开口于进气端的剩余部分孔在排气端沿其部分长度被堵塞，所以从进气端通过蜂窝孔到达排气端的发动机排气流会流入开口孔，透过孔壁，通过排气端的开口孔离开该结构。
附图简要说明
图1所示是对比样品和本发明样品的(d50-d90)/d50对d50的图。
图2所示是对比样品和本发明样品的d90/d50对d50的图。
图3所示是对比样品和本发明样品的d50/(d50+d90)对d50的图。
图4所示是市售堇青石DPF微结构的背散射扫描电子显微照片。
图5所示是本发明样品I9微结构的背散射电子显微照片。
图6比较了在26.25标准立方英尺/分气体流速下压力降和碳烟灰负载量的函数关系，在室温(25℃)下测量两个对比DPF样品(2英寸直径，6英寸长度，200个孔/平方英寸的孔密度；0.022英寸的壁厚)，以及按照本发明方法制造的一个DPF样品(2英寸直径，6英寸长度，200个孔/平方英寸的孔密度；0.022英寸的壁厚)。
发明详细说明
本发明涉及主要是硅酸铝镁相的难熔陶瓷结构(或体)，硅酸铝镁相通常也被称为堇青石。本发明的结构特别适用于过滤应用，比如柴油机排气过滤。柴油机颗粒过滤器优选具有通过挤出制得的蜂窝结构体。
本发明的蜂窝体含有开口孔，该孔由交错的多孔薄壁形成。整个开口孔被限定蜂窝体形状的外壁包围。通常，孔沿蜂窝体的长度延伸，并占据整个长度。可以存在任意数量或密度的孔。优选该蜂窝体的孔密度至少是150个孔/平方英寸正面进气面积，孔壁厚度至少是0.012英寸。
进气端或进气表面上的部分孔堵塞有其组成与过滤器相同或相似的糊料，如本文引用的参考文献美国专利4329162中所述。堵塞仅在孔末端，深度通常约是5到20毫米，不过这个值也可以有变化。位于排气端但除了上述进气端被堵塞之外的部分孔也被堵塞。因此，每个孔都只在一端被堵塞。优选布置是在指定表面上使每隔一个孔堵塞形成方格图案。
这种堵塞结构使排气流和基质多孔壁能更均匀地接触。排气流通过进气端的开口孔流入基质，然后通过多孔壁，通过排气端的开口孔离开蜂窝结构。这里所述类型的过滤器被称为“壁流”过滤器，因为由交替通道堵塞造成的流动通道要求处理的排气在离开过滤器之前流过多孔陶瓷孔壁。
本发明过滤器的一个优点是，其压力降低于目前的市售堇青石DPF可获得的压力降。压力降是柴油机颗粒过滤器壁上所累积含碳烟灰量的函数。随着累积烟灰量的增加，排气流过过滤器壁和碳烟灰层的阻力也逐渐增大。这种流动阻力表现为在过滤器长度上可测得的压力降，并导致对发动机的背压增大。在指定烟灰负载量(克/升)情况下，压力降的增加会受到孔隙率，孔径中值，孔径分布宽度，孔隙连通性，和烟灰进入过滤器壁中孔隙程度的影响。
通过控制孔隙率和孔径分布的共同作用，得到最佳透壁负载烟灰透气性，从而在本发明结构中获得低压力降(千帕)。用d10，d50和d90来定量表示由压汞孔率法确定的孔径分布，这三个术语是指在10％，50％和90％压汞下的孔径。因此d10＞d50＞d90。孔径分布中的小孔宽度对透壁负载烟灰透气性有特别的影响。这是因为，指定孔径中值的小孔数量较多，表明孔隙微结构由通过狭窄孔颈互连的较大孔组成。压汞法仅测量连通较大孔的孔颈直径，而没有表示较大孔本身的直径。
孔径分布小孔拖尾宽度与d50和d90的差相关。由(d50-d90)/d50，d90/d50和d50/(d50+d90)值表示。除以d50起到归一数据的作用，这样，如果两种物质用显微镜获得的孔径分布宽度相似，而其中一种物质具有更粗的整体微结构，即一种物质的微结构看上去象是另一种物质的“放大”版，则这两种物质就具有相同的值。
本发明结构体的d50/(d50+d90)小于0.7，优选小于0.65，更优选小于0.60。d90/d50大于0.40，优选大于0.55，更优选大于0.60，(d50-d90)/d50小于0.60，优选小于0.50，更优选小于0.40。孔径的d50值至少是4微米而且最高40微米，优选在6和25微米之间，更优选在7和15微米之间。本发明结构体的孔隙率至少是40体积％而且小于60体积％，优选是约50体积％，更优选是约55体积％。
本发明结构体的孔径分布和孔隙率满足下式，该式定义了负载烟灰透气性因子，Sf：
Sf＝[d50/(d50+d90)]/[孔隙率％/100]。
负载烟灰透气性Sf小于1.55，优选在0.83和1.40之间，更优选在0.83和1.35之间。已发现通过满足上述负载烟灰透气性因子，本发明结构体能够在过滤体内累积碳烟灰时保持特别低的压力降。虽然没有受到理论的限制，但是据信狭窄的孔径分布提供了更好的孔隙连通性，与较低的孔隙率一起使烟灰进入过滤器壁孔隙中的程度最小，并促进烟灰层或烟灰“饼”在进气通道壁表面上形成，甚至在烟灰负载量非常低的情况下也能起到促进作用。与所谓厚层过滤相比，这通常被称为表面过滤，厚层过滤包括烟灰进入过滤器壁的孔隙中。表面过滤是优选的，因为能更容易更迅速地在过滤器壁表面上燃烧烟灰饼或烟灰层。
因为孔隙是充分连通的，所以该结构体与具有相似的孔径中值和总孔隙率，但更宽孔径分布的过滤器相比，具有更高的透气性和更低的压力降。当孔径中值大于约20微米时，或者当总孔隙率大于约50％时，烟灰就可能更深地进入过滤器壁的孔隙中。但是，由于本发明过滤器的孔隙连通性有所提高，相信进入孔隙的烟灰不会不利地降低气体通过壁的透气性，因为有更多其它通道供气流通过壁。
本发明陶瓷体的另一个优点是，低热膨胀导致极佳的耐热冲击性(TSR)。TSR与热膨胀系数(CTE)成反比。即，具有低热膨胀的蜂窝结构具有良好的耐热冲击性，能够承受应用中遭受的大温度波动。因此，用膨胀法所测得室温(RT)到800℃的热膨胀系数不超过大约17×10-7/℃，优选小于10×10-7/℃，更优选小于5×10-7/℃。
本发明结构体适合于低体积热容和高体积热容过滤器。通常要求高体积热容，因为它能降低过滤器再生时温度升高的程度。因此，优选在约500℃时测得的过滤器体积热容至少是0.67焦·厘米-3·开-1。优选500℃时的过滤器体积热容至少是0.76焦·厘米-3·开-1，更优选至少是0.85焦·厘米-3·开-1。或者，有时要求低体积热容，使过滤器更频繁地再生，具有更低的烟灰累积量，而不要求大量热能输入来将过滤器的温度提高至要求促使再生的温度。
本发明还涉及通过原料反应制造过滤器结构的方法，原料选自氧化镁，氧化铝和二氧化硅组分。还任选地包括尖晶石。如果包括尖晶石组分的话，其化学计量式是MgAl2O4。原料批料任选地包括成孔剂，优选是颗粒材料，选自石墨，纤维素，淀粉，聚丙烯酸酯类和聚乙烯类等合成聚合物，及其组合。
成孔剂的重量百分比计算如下：100×[成孔剂重量/生成堇青石的原料重量]。石墨和玉米淀粉是优选的成孔剂。成孔剂的粒径中值至少是3微米且不超过140微米，优选至少是5微米且不超过80微米，最优选至少是10微米且不超过50微米。当二氧化硅原料的粒径中值大于20微米时，成孔剂的粒径中值必须不超过100微米。
氧化镁由能生成MgO的原料提供，通常是氧化镁，氢氧化镁，碳酸镁，硝酸镁或其组合。氧化铝由能生成Al2O3的原料(在不含其他原料情况下充分加热至足够高的温度后能生成基本纯净的氧化铝)提供，可以是氧化铝，氢氧化铝，水合氧化铝，α-氧化铝，过渡态氧化铝比如γ-氧化铝或ρ-氧化铝，勃拇石，硝酸铝，碳酸铝或其组合。二氧化硅由能生成二氧化硅的原料提供，包括石英，方英石，非晶二氧化硅比如熔凝二氧化硅或溶胶凝胶二氧化硅，沸石，胶体二氧化硅，α-石英及其混合物。氧化硅原料的平均粒度至少是约4微米，优选大于约10微米。
将原料混合物与载体和成型助剂均匀混合，使原料形成结构体时具有塑性成形性和坯料强度。由于是挤出成型，所以使用挤出助剂，最一般是作为粘合剂的甲基纤维素和作为润滑剂的硬脂酸钠。根据所用原料的性质和用量等因素，成形助剂的相对量各不相同。成形助剂以原料总重量计另行添加。在一个实例中，挤出助剂及其含量是2重量％到10重量％，优选是3重量％到6重量％的甲基纤维素，以及0.5重量％到1重量％，优选是0.6重量％的硬脂酸钠。
以干燥状态混合原料和挤出助剂，然后与作为载体的水混合。每批料中的水量各不相同，因此通过对特定批挤出能力的预测试确定。
然后使制得塑性混合物中的原料形成坯体。未烧结的陶瓷体被称为坯体。挤出技术是本领域中众所周知的。干燥坯体，然后在足够高的温度下烧制足够长的时间，形成最终产物结构。优选以15到100℃/小时的速率，烧制至约1405℃到1430℃的最高温度，在最高温度保持6到25小时。本发明组合物所形成陶瓷结构主要是大致具有Mg2Al4Si5O18的化学计量式的相。
为了更全面地说明本发明，提供以下非限制性实施例。所有份数，比例和百分比都是重量比，除非另有说明。
实施例
表1所示是制备样品所用的原料。对比例(非发明)样品如表2中所示。本发明样品如表3和4中所示。表5所示是按照本发明方法制备的过滤器与两个对比堇青石DPF之间压力降的比较。
制备样品时，称取无机粉末和固体有机粘合剂和润滑剂至Nalgene广口瓶中，在Turbula混料机上混合20分钟。将干配料转移至研磨机中，逐渐添加液体有机物和水，将混合物研磨成塑性稠度。
将研磨过的批料三次挤出成空心粉条状，然后形成1或2英寸直径，200个孔/平方英寸，0.019-0.022英寸壁厚的蜂窝体。对于某些组合物，还可以挤出成5/16英寸的棒状或0.020英寸的带状。将1英寸直径的蜂窝体包裹在铝箔中，而将棒状挤出物置于玻璃管中，用箔片松散覆盖玻璃管末端。将带状挤出物切割成1.5英寸长度的片段，置于箔片层之间，用重物盖压以确保平整。在高频干燥炉中部分干燥没有包裹的2英寸直径蜂窝体。然后将所有挤出物在烘箱中以95℃干燥1到3天。
将挤出样品置于氧化铝盒内的氧化铝耐火砂上。在电热炉中以50℃/小时的升温速率将本发明样品I1到I6烧制至1400℃或1425℃的最高温度，保持10或25小时，然后切断炉电源使其冷却。将样品I7到I9烧制至1430℃并保持25小时。将对比样品烧制至1405℃。保持时间和温度如表2-4中所示。
用压汞孔率法表征烧制过样品的孔隙率，沿轴向(挤出)方向用膨胀法测量CTE，用定量粉末X射线衍射法测量次生相(富铝红柱石，刚玉和尖晶石)。按照美国专利5258150所述方法测量横向I-比值。在实心棒上用四点负载测量MOR。在挤出带状物上，用Perm Automated PorometerVersion 6.0(PorousMaterials，Inc.，Ithaca，NY)测量透气性。透气性值以平方微米为单位表示。“Darcy”(达西)是另一种透气性单位，等于0.987平方微米。所有百分比都是重量百分比，所有孔径和粒度都是微米(10-6米)。
按照以下方法测量2英寸直径，6英寸长度蜂窝状过滤体上的压力降。将每个过滤器包裹在陶瓷纤维垫片中，并稳固地镶嵌在圆柱形金属支架上。将支架和过滤器固定在金属管的每个末端上，管中通过空气流。通过该过滤器的压力降是进气面和排气面之间的压力差，以气体流速的函数测量。对全部样品都使用1.9到26.25标准立方英尺/分(scfm)的气体流速。这些样品在向过滤器中引入碳颗粒之前的压力降被称为“干净”压力降，这些干净压力降随着气体流速的增加而增加。
测量干净压力降之后，将样品转移至第二实验装置中，再次连接在金属管上，管中以约13标准立方英尺/分的流速通过气流。然后在一段时间内使非常细的“人造”碳吸入气流中，从而在进气通道壁上涂覆一层碳颗粒，使过滤器部分负载碳。试验中使用的“人造”碳是市售复印机色粉。在本发明中，这种“人造”碳被称为碳或碳烟灰。
然后将样品重新接在第一装置中，再次测量压力降与流速的函数关系。以各种增加的碳烟灰负载量重复这个过程。这样，确定压力降与流速和过滤器中所含的碳烟灰量的函数关系。在大多数情况下，碳烟灰负载量约是0.3到0.5克/升过滤器体积。上述测试方法的条件能对过滤器在流动气体和壁上碳烟灰积累的环境中的特性进行相对比较，以此模拟过滤器被置于柴油发动机排气通路中的环境。为了使发动机性能的降低最小，要求负载有单位体积指定质量碳烟灰的过滤器的压力降尽可能低。表5和图6中的压力降数据是在26.25标准立方英尺/分的流速和25℃室温条件下测量的。
按照美国专利5258150中所述内容制造对比样品C1到C3。对比样品C4是堇青石陶瓷，其原料包括生成MgO的原料，生成Al2O3的原料和二氧化硅原料，不符合一项或多项性质要求。
图1到3所示是用粘土和滑石并且不含生成MgO原料所制造的对比样品的孔径分布(空心圆)，与本发明样品(实心圆)的比较。可观察到，含有滑石和粘土而不含生成MgO原料的原料混合物所制造的结构体，与由包括生成MgO原料，生成氧化铝原料和生成二氧化硅原料的原料混合物制造的本发明样品相比，具有宽得多的孔径分布。
图4所示是用粘土和滑石并且不含生成MgO原料的市售堇青石柴油机颗粒过滤器的背散射扫描电子显微照片。“粗糙”的微结构通常代表具有非常粗糙的表面并且表现出宽广孔径范围的各向异性棱角状孔隙。大孔隙通常仅由狭窄的孔颈连通。
图5所示是本发明样品I9的微结构。本发明样品的原料混合物包括生成MgO的原料，生成氧化铝的原料和生成二氧化硅的原料，具有比对比样品窄得多的孔径分布，其原料混合物包括滑石和粘土，不含生成MgO的原料。这个微结构的各向异性较小，具有平滑得多的孔壁表面。
表5中所示是两个对比堇青石DPF和按照本发明方法所制造过滤器(表4中的样品I9)的压力降和选定物理性质的对比，对比样品从CorningIncorporated获得。样品的孔密度是200个孔/平方英寸，壁厚是0.016和0.022英寸。测量压力降时的碳烟灰负载量在26.25标准立方英尺/分气体流速下为0到4克/升。图6所示是压力降与碳烟灰负载量的图。从中可以看出，本发明样品I9在所有碳烟灰负载量条件下，与对比堇青石DPF相比，具有最低的压力降。
应理解，虽然已经根据某些说明性和具体实例对本发明进行了详细说明，但是本发明并不限于这些实例，可以在不离开本发明精神和所附权利要求书范围情况下以其他方式实施。
                            表1
                            原料
原料     d10     d50     d90
生成MgO的原料
氢氧化镁1(DOW T-100)     -     6.5     -
氧化镁1(MagChem 50Y)     1.7     3.5     7.0
氧化镁2(MagChem 10-325S)     4.1     15.0     33.7
氧化镁3(M-1研磨-150目)     1.4     13.8     50.4
氧化镁4(MagChem 20)     -     1.0*     -
滑石
滑石2(FDC)     -     8.0*     -
滑石3(China 1)     -     10.0*     -
滑石4(Quebec)     -     7.0*     -
尖晶石
尖晶石1     -     1.0     -
高岭土
高岭土1(K10)     -     3.2     -
生成Al2O3的原料
氧化铝1(Alcan C701)     3.5     5.6-7.0*     10.4
氧化铝2(A16)     -     0.6     -
氧化铝3(Alcoa A3000FL)     0.4     1.8-3.5*     4.1
氧化铝4(Alcoa A1000SGD)     0.36     0.55     1.2
氢氧化铝1(Aluchem AC714)     3.3     5.0     7.9
氢氧化铝2(Aluchem AC400)     2.8     11.0     22.6
SiO2原料
氧化硅1(Imsil A25)     1.0     4.6     16.3
氧化硅2(Imsil A75)     1.2     15.4     56.9
氧化硅3(Silcosil 75)     3.4     24.3     64.2
氧化硅4(Supersil-200目)     -     20.0     -
氧化硅5(Berkeley S5)     -     100#     -
成孔剂
成孔剂1(Asbury 4434石墨)     -     101     -
成孔剂2(Superior 5026石墨)     -     39     -
成孔剂3(纤维素)     -     -     -
成孔剂4(玉米淀粉)     11     15     20
*沉降图，#筛析
                               表2
                             对比样品
样品号     C1     C2     C3     C4
保持温度(℃)     1400     1400     1400     1425
保持时间(小时)     7     7     7     25
Methocel(甲基纤维素)     3.0     3.0     3.0     5.0
硬脂酸钠     0.5     0.5     0.5     0
Emersol     0     0     0     0.6
Durasyn     0     0     0     6.0
滑石2     0     0     40.7     0
滑石3     39.9     0     0     0
滑石4     0     39.9     0     0
高岭土1     16.6     16.6     16.0     0
氧化铝1     15.0     15.0     0     0
氧化铝2     0     0     14.8     0
氧化铝3     0     0     0     0
氧化铝4     0     0     0     34.86
氢氧化铝1     15.8     15.8     16.0     0
氧化镁1     0     0     0     13.78
氧化镁4     0     0     0     0
氧化硅1     0     0     0     51.36
氧化硅4     12.7     12.7     6.3     0
氧化硅5     0     0     6.3     0
总压汞体积     -     -     -     0.2651
孔隙率％     45.0     43.0     47.0     39.6
d90     3.0     4.0     3.0     1.2
d50     15.4     12.3     14     2.6
d10     40.0     35.0     57.5     4.1
(d10-d90)/d50     2.40     2.52     3.89     1.13
(d10-d50)/d50     1.60     1.85     3.11     0.60
(d50-d90)/d50     0.81     0.67     0.79     0.53
d90/d50     0.19     0.33     0.21     0.47
d50/(d50+d90)     0.84     0.75     0.82     0.68
Sf     1.87     1.74     1.74     1.70
透气性(10-12平方米)     -     -     -     0.025
CTE(25-800)(10-7/℃)     3.4     0.9     1.4     6.7
横向I-比值     0.88     0.90     0.89     0.72
                                    表3
                                 本发明样品
样品号     I1     I2     I3     I4     I5
保持温度(℃)     1425     1425     1425     1425     1425
保持时间(小时)     10     10     10     25     10
Methocel(甲基纤维素)     4.0     4.0     4.0     5.0     4.0
Emersol     1.0     1.0     1.0     0.6     1.0
Durasyn     6.0     6.0     6.0     6.0     10.0
氧化镁2     0     0     0     0     0
氧化镁4     0     0     0     13.8     10.3
氢氧化镁1     16.0     16.0     18.8     0     0
氧化铝1     0     0     32.84     0     28.9
氧化铝4     0     0     0     0     0
氢氧化铝1     0     42.8     0     34.9     0
氢氧化铝2     42.8     0     0     0     0
二氧化硅1     41.2     0     48.4     0     50.7
二氧化硅2     0     0     0     51.4     0
二氧化硅3     0     41.2     0     0     0
总压汞体积     0.3406     0.3546     0.3092     0.2781     0.4340
孔隙率％     42.7     44.9     41.7     41.2     52.9
d90     5.5     7.5     4.5     12.7     4.0
d50     9.0     16.7     7.3     20.0     7.3
d10     10.5     35.0     10.5     36.6     10.5
(d10-d90)/d50     0.55     1.65     0.82     1.20     0.89
(d10-d50)/d50     0.16     1.09     0.43     0.83     0.44
(d50-d90)/d50     0.39     0.55     0.39     0.36     0.45
d90/d50     0.61     0.45     0.61     0.64     0.55
d50/(d50+d90)     0.62     0.69     0.62     0.61     0.65
Sf     1.29     1.53     1.47     1.48     1.23
透气性(10-12平方米)     0.43     1.41     0.37     2.03     0.455
CTE(25-800)(10-7/℃)     17.0     16.6     13.0     15.5     12.7
横向I-比值     0.78     0.84     0.80     0.72     0.83
MOR棒(磅/平方英寸)     2326     3003     2256     -     2044
                                   表4
                                本发明样品
样品号     I6     I7     I8     I9
保持温度(℃)     1430     1430     1430     1430
保持时间(小时)     25     25     25     25
Methocel(甲基纤维素)     4.0     4.0     4.0     4.0
Emersol     0     0     0     0
Durasyn     0     0     0     0
氧化镁4     14.0     14.0     14.0     14.0
氧化铝1     35.0     0     35.0     0
氧化铝3     0     35.0     0     35.0
氧化铝4     0     0     0     0
二氧化硅1     51.0     51.0     51.0     51.0
二氧化硅4     0     0     0     0
成孔剂4     10.0     10.0     10.0     10.0
总压汞体积     -     -     -     -
孔隙率％     46.0     44.0     49.0     48.0
d90     3.6     2.0     5.2     2.4
d50     6.9     4.4     8.6     4.6
d10     10.2     6.1     12.7     6.7
(d10-d90)/d50     0.95     0.93     0.87     0.93
(d10-d50)/d50     0.48     0.39     0.48     0.45
(d50-d90)/d50     0.48     0.54     0.40     0.48
d90/d50     0.52     0.45     0.60     0.52
d50/(d50+d90)     0.66     0.69     0.62     0.66
Sf     1.44     1.52     1.23     1.40
透气性(10-12平方米)     -     -     -     -
CTE(25-800)(10-7/℃)     5.0     4.35     5.75     5.0
5克/升烟灰，26.25标准立方英尺/分条件下测得的压力降(千帕)     7.9     8.75     5.15     7.60
横向I-比值     -     -     -     -
MOR棒(磅/平方英寸)     -     -     -     -
                              表5
                    本发明和市售DPF的压力降对比
       样品种类 本发明堇青石DFP 市售堇青石DPF 市售堇青石DPF
    烟灰负载量(克/升)                   压力降(千帕)
    0.00     2.99     3.15     3.41
    0.50     3.34     5.73     6.06
    0.70     3.43     6.70     7.38
    1.00     3.56     7.44     7.97
    2.50     4.14     9.26     8.87
    4.00     4.80     10.4     10.2
    5.00     5.2     11.0     11.3
    10.00     7.2     15.2     15.3
    孔隙率％     49     49     43
    d10(微米)     12.7     24     24
    d50(微米)     8.6     13     13
    d90(微米)     5.2     2     5
    d50/(d50+d90)     0.64     0.86     0.72
    Sf     1.23     1.75     1.67

Claims (10)

1.一种用于捕集和燃烧柴油机排气颗粒的陶瓷过滤器，其包括末端堵塞的堇青石蜂窝结构，其中：
与孔径分布相关的d50/(d50+d90)值小于0.70；
由式[d50/(d50+d90)]/[孔隙率％/100]定义的负载烟灰透气性因子Sf小于1.55；
热膨胀系数(25-800℃)不超过17×10-7/℃。
2.如权利要求1所述的陶瓷过滤器，其特征在于负载烟灰透气性因子Sf在0.83和1.40之间。
3.如权利要求1所述的陶瓷过滤器，其特征在于孔径中值d50至少是4微米，最高40微米。
4.如权利要求1所述的陶瓷过滤器，其特征在于与孔径分布相关的d90/d50值大于0.40。
5.如权利要求1所述的陶瓷过滤器，其特征在于与孔径分布相关的(d50-d90)/d50小于0.60。
6.如权利要求1所述的陶瓷过滤器，其特征在于孔隙率至少是40体积％，并小于60体积％。
7.如权利要求1所述的陶瓷过滤器，其特征在于500℃时的过滤器体积热容至少是0.67焦·厘米-3·开-1。
8.一种制造壁流过滤器的方法，包括：
(a)形成包含氧化镁，氧化铝和二氧化硅原料以及含有2-10重量％甲基纤维素粘合剂和0.5-1.0重量％硬脂酸钠润滑剂的挤出成形助剂的批料；
(b)使该批料塑化和成形，其中通过挤出模头形成蜂窝坯体进行成形，该蜂窝坯体具有进气端，排气端，和大量从进气端延伸至排气端的孔；
(c)蜂窝坯体干燥并以15-100℃/小时的速率将其烧制至1405-1430℃的最高温度，并保持6-25小时；
(d)堵塞进气端的第一部分孔，并堵塞排气端的第二部分孔，使每个孔都只在一端被堵塞。
9.如权利要求23所述的方法，其特征在于所述批料还包含具有MgAl2O4化学计量式的尖晶石。
10.如权利要求25所述的方法，其特征在于所述批料还包含粒径中值是3-140微米的成孔剂，所述成孔剂选自石墨、纤维素、淀粉、聚丙烯酸酯类和聚乙烯类，及其组合。
CNB038197065A 2002-06-26 2003-06-25 用于柴油机颗粒过滤器应用的硅酸铝镁结构 Expired - Lifetime CN100341602C (zh)

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CN100341602C (zh) 2007-10-10
EP1515787A4 (en) 2006-11-29
US7141089B2 (en) 2006-11-28
AU2003279633A1 (en) 2004-01-19
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