JP2007522919A - 疎水性コーティングを有するセラミック構造体 - Google Patents
疎水性コーティングを有するセラミック構造体 Download PDFInfo
- Publication number
- JP2007522919A JP2007522919A JP2006547138A JP2006547138A JP2007522919A JP 2007522919 A JP2007522919 A JP 2007522919A JP 2006547138 A JP2006547138 A JP 2006547138A JP 2006547138 A JP2006547138 A JP 2006547138A JP 2007522919 A JP2007522919 A JP 2007522919A
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- JP
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- Prior art keywords
- ceramic body
- coating
- ceramic
- catalyst support
- support structure
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000000919 ceramic Substances 0.000 title claims abstract description 109
- 238000000576 coating method Methods 0.000 title claims abstract description 100
- 239000011248 coating agent Substances 0.000 title claims abstract description 88
- 230000002209 hydrophobic effect Effects 0.000 title claims abstract description 45
- 239000003054 catalyst Substances 0.000 claims abstract description 64
- 229910052878 cordierite Inorganic materials 0.000 claims abstract description 49
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims abstract description 49
- 238000000034 method Methods 0.000 claims abstract description 23
- 239000007788 liquid Substances 0.000 claims abstract description 16
- 230000008569 process Effects 0.000 claims abstract description 10
- 238000010521 absorption reaction Methods 0.000 claims abstract description 9
- 239000000463 material Substances 0.000 claims description 59
- 239000000203 mixture Substances 0.000 claims description 29
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 19
- 239000004568 cement Substances 0.000 claims description 14
- 238000001035 drying Methods 0.000 claims description 13
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 10
- 229910052799 carbon Inorganic materials 0.000 claims description 10
- 239000004071 soot Substances 0.000 claims description 8
- 229920002050 silicone resin Polymers 0.000 claims description 7
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 5
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 5
- 239000012736 aqueous medium Substances 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 5
- 239000008119 colloidal silica Substances 0.000 claims description 5
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 5
- 239000000835 fiber Substances 0.000 claims description 5
- 229920000609 methyl cellulose Polymers 0.000 claims description 5
- 239000001923 methylcellulose Substances 0.000 claims description 5
- 239000006254 rheological additive Substances 0.000 claims description 5
- 239000008367 deionised water Substances 0.000 claims description 4
- 229910021641 deionized water Inorganic materials 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 3
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 3
- 238000007598 dipping method Methods 0.000 claims description 3
- 229910000077 silane Inorganic materials 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 238000002161 passivation Methods 0.000 claims description 2
- 238000005096 rolling process Methods 0.000 claims description 2
- 229910000505 Al2TiO5 Inorganic materials 0.000 abstract description 10
- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 abstract description 10
- 230000001747 exhibiting effect Effects 0.000 abstract description 2
- 210000003491 skin Anatomy 0.000 description 44
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 37
- 241000264877 Hippospongia communis Species 0.000 description 22
- 239000000758 substrate Substances 0.000 description 15
- 239000000243 solution Substances 0.000 description 13
- HSJPMRKMPBAUAU-UHFFFAOYSA-N cerium(3+);trinitrate Chemical compound [Ce+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O HSJPMRKMPBAUAU-UHFFFAOYSA-N 0.000 description 10
- 230000003197 catalytic effect Effects 0.000 description 8
- 238000009736 wetting Methods 0.000 description 7
- 210000002615 epidermis Anatomy 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 239000010410 layer Substances 0.000 description 6
- 229910010293 ceramic material Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000011777 magnesium Substances 0.000 description 4
- 238000001179 sorption measurement Methods 0.000 description 4
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- 125000004429 atom Chemical group 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 230000005661 hydrophobic surface Effects 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 3
- 239000002609 medium Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 230000035939 shock Effects 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000006467 substitution reaction Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 2
- 150000001342 alkaline earth metals Chemical class 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000008199 coating composition Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VIZORQUEIQEFRT-UHFFFAOYSA-N Diethyl adipate Chemical compound CCOC(=O)CCCCC(=O)OCC VIZORQUEIQEFRT-UHFFFAOYSA-N 0.000 description 1
- 229910002060 Fe-Cr-Al alloy Inorganic materials 0.000 description 1
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 239000000809 air pollutant Substances 0.000 description 1
- 231100001243 air pollutant Toxicity 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- 239000006105 batch ingredient Substances 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000005524 ceramic coating Methods 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 239000011222 crystalline ceramic Substances 0.000 description 1
- 229910002106 crystalline ceramic Inorganic materials 0.000 description 1
- QYMFNZIUDRQRSA-UHFFFAOYSA-N dimethyl butanedioate;dimethyl hexanedioate;dimethyl pentanedioate Chemical compound COC(=O)CCC(=O)OC.COC(=O)CCCC(=O)OC.COC(=O)CCCCC(=O)OC QYMFNZIUDRQRSA-UHFFFAOYSA-N 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 229920006242 ethylene acrylic acid copolymer Polymers 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 229910052732 germanium Inorganic materials 0.000 description 1
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000009931 harmful effect Effects 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- LAQFLZHBVPULPL-UHFFFAOYSA-N methyl(phenyl)silicon Chemical compound C[Si]C1=CC=CC=C1 LAQFLZHBVPULPL-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 1
- 150000004756 silanes Chemical class 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 125000001424 substituent group Chemical group 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 150000003673 urethanes Chemical class 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/10—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of rare earths
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- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
- B01J37/0217—Pretreatment of the substrate before coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J37/02—Impregnation, coating or precipitation
- B01J37/024—Multiple impregnation or coating
- B01J37/0242—Coating followed by impregnation
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- 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
- C04B35/185—Mullite 3Al2O3-2SiO2
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- C04B35/6263—Wet mixtures characterised by their solids loadings, i.e. the percentage of solids
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- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
- F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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Abstract
Description
(a) セラミック外皮コーティングを有する焼成されたマルチセルラ・セラミック体を提供し、
(b) 外皮コーティングまたはセラミック体全体のいずれかに、不動態化材料を含むコーティングを施し、
(c) 得られた被覆れさたセラミック体を乾燥させ、
(d) 必要に応じて、セラミック体の表面に疎水性コーティングを製造するのに十分な温度で十分な時間に亘り、乾燥した被覆されたマルチセルラ・セラミック体を熱処理する。
(a) 焼成されたマルチセルラ・セラミック体を提供し、
(b) セラミック体の外面に、不動態化材料を中に有するセラミック・セメントを含むコーティングを施し、
(c) 得られた被覆されたマルチセルラ・セラミック体を乾燥させ、
(d) 必要に応じて、セラミック体の表面に疎水性コーティングを製造するのに十分な温度で十分な時間に亘り、乾燥した被覆されたマルチセルラ・セラミック体を熱処理する。
ある実施の形態において、上述したように、不動態化材料が標準的な常温硬化コージエライト・セメント中に直接含まれる。このセメント自体は、その後、基体材料に施すことができる。表Iには、標準的な表皮組成物(質量%)およびコージエライト表皮またはコーティングを疎水性にするメチルフェニルシリコーン樹脂不動態化材料を中に有する同じ標準的な表皮組成物(これも質量%)が報告されている。
表Iに詳述された標準的なコージエライト表皮組成物から構成された4つのコージエライト・セラミック・サンプルを製造した。具体的には、2mm厚(100mm×200mm)のシートを形成した。比較のために、第1のシートは不動態化材料により被覆せず、一方で、他の3つのシートは本発明の疎水性コーティングにより被覆した。表IIに報告した本発明のサンプルA,BおよびCに用いた不動態化材料は、それぞれ、シリコーン樹脂(2:1の質量比で、アジピン酸ジエチルの二塩基エステル中に溶解したダウ・コーニング社のDC233シリコーン樹脂)、キリ油、およびMichem4983Rエチレンアクリル酸コポリマーからなるコポリマーを含有していた。本発明のサンプルの各々について、不動態化材料は、基体を飽和させるのに十分な時間に亘り(約1分間)、シートを浸漬することによって、標準的な表皮組成物シート(上述したのと同じ質量%)に施した。
62個のセラミック・ハニカム・サンプルを製造した(31個はコージエライトからなり、31個はチタン酸アルミニウムからなる)。各サンプルは、対応する組成のセラミック・ハニカムから切断した8mm×8mm×50mmの棒材からなるものであった。表IIIに詳述されるように、31個の異なる不動態化材料の各々をコージエライト・ハニカムおよびチタン酸アルミニウム・ハニカムの棒材に施した。これらのコーティング材料を施すために、各基体を2分間に亘り室温で希釈コーティング材料溶液中に浸漬した。使用したコーティング材料/不動態化コーティング濃度が表IIIに詳述されている。IPA中10%は、10%のイソプロピルアルコール希釈溶液を表し、H2O中10%は10%の脱イオン水希釈溶液を表し、100%は全強度の材料溶液を表す。次いで、過剰のコーティングを、圧縮窒素を用いてサンプルから吹き飛ばした。次いで、被覆サンプルを、最低で2時間に亘り、60℃で循環炉内で乾燥させた。
2,2a 水
Claims (16)
- 疎水性コーティングを含むマルチセルラ・セラミック体を含む触媒支持構造体であって、前記疎水性コーティングにより、液体の触媒コーティング混合物および該コーティング混合物を施すプロセスに用いられる水性媒質の吸収が少ない被覆セラミック体が得られることを特徴とする触媒支持構造体。
- 前記疎水性コーティングが前記セラミック体の外皮部分の内部またはその上に形成されることを特徴とする請求項1記載の触媒支持構造体。
- 前記被覆セラミック体が、2μLの脱イオン水の水滴が、前記セラミック体の表面と接触したときに、50°より大きい接触角を示すように低い吸収を示すことを特徴とする請求項1記載の触媒支持構造体。
- 前記疎水性コーティングが、不動態化材料を含有するコージエライト・セメントから構成されることを特徴とする請求項2記載の触媒支持構造体。
- 前記マルチセルラ・セラミック体がモノリス・セラミック・ハニカムであって、該セラミック・ハニカムが、入口端、出口端、および該入口端から該出口端まで前記セラミック・ハニカムの長手方向に沿って延在する相互に隣接した多数のセルを有し、該セルが多孔質壁により互いから隔てられていることを特徴とする請求項1記載の触媒支持構造体。
- 前記入口端のセルの一部および前記出口端のセルの一部が塞がれており、前記入口端のセルの塞がれた部分が、前記出口端のセルの塞がれた部分とは異なり、したがって、排気ガスが、前記入口端で開いたセルを通って、前記セラミック・ハニカムに進入し、前記多孔質壁を通って流動し、前記出口端で開いたセルを通って流出することを特徴とする請求項5記載の触媒支持構造体。
- 外部疎水性コーティングを有する被覆触媒支持構造体を製造する方法であって、
a. 焼成されたマルチセルラ・セラミック体を提供し、
b. 前記マルチセルラ・セラミック体に、セラミック・セメントから構成された外皮コーティングを施し、
c. 得られた被覆されたマルチセルラ・セラミック体を乾燥させて、その上にセラミック・セメント表皮コーティングを形成し、
d. 前記セラミック・セメント表皮コーティングおよび/または前記マルチセルラ・セラミック体全体に、不動態化材料を含む液体コーティングを施し、
e. 被覆されたマルチセルラ・セラミック体を再度乾燥させる、
各工程を有してなる方法。 - 前記マルチセルラ・セラミック体上に疎水性コーティングを製造するのに少なくとも十分な時間に亘り、少なくとも60℃の温度で前記乾燥した被覆されたマルチセルラ・セラミック体を熱処理する工程をさらに含むことを特徴とする請求項7記載の方法。
- 前記熱処理工程を、3時間に亘り、約60〜500℃の温度で行うことを特徴とする請求項8記載の方法。
- 前記不動態化材料を含む液体コーティングを施す工程が、浸漬、シャワーリング、吹付け、ローリング、ブロッティングおよび噴射のいずれかを含むことを特徴とする請求項7記載の方法。
- 前記不動態化材料が、シリコーン樹脂、ウレタン、油、シラン、ワックス、炭素、炭素煤およびそれらの混合物からなる群より選択されることを特徴とする請求項7記載の方法。
- 外部疎水性コーティングを有する被覆触媒支持構造体を製造する方法であって、
a. 焼成されたマルチセルラ・セラミック体を提供し、
b. 前記マルチセルラ・セラミック体の外面に、中に不動態化材料を有するセラミック・セメントを含む疎水性コーティングを施し、
c. 得られた被覆されたマルチセルラ・セラミック体を乾燥させる、
各工程を有してなる方法。 - 質量パーセントで表して、50〜65%の粉砕コージエライト、0.1〜1%のメチルセルロース結合剤、1〜6%のコロイドシリカ、0〜20%のアルミノケイ酸塩繊維、10〜20%の水、0.1〜1%のレオロジー改質剤および1〜6%の、シリコーン樹脂、ウレタン、油、シラン、ワックス、炭素、炭素煤およびそれらの混合物からなる群より選択される不動態化材料を含む、触媒支持構造体を被覆するためのコージエライト組成物。
- 質量パーセントで表して、50〜60%の粉砕コージエライト、0.1〜1%のメチルセルロース結合剤、3〜5%のコロイドシリカ、13〜20%のアルミノケイ酸塩繊維、18〜20%の水、0.4〜0.6%のレオロジー改質剤および4〜6%の不動態化材料を含むことを特徴とする請求項13記載のコージエライト組成物。
- 質量パーセントで表して、55.5%の粉砕コージエライト、0.5%のメチルセルロース結合剤、3.5%のコロイドシリカ、15%のアルミノケイ酸塩繊維、19.5%の水、0.5%のレオロジー改質剤および5.5%の不動態化材料を含むことを特徴とする請求項14記載のコージエライト組成物。
- 外部疎水性コーティングを有する被覆触媒支持構造体を製造する方法であって、
a. 焼成されたマルチセルラ・セラミック体を提供し、
b. 前記マルチセルラ・セラミック体の外面に疎水性コーティングを施し、
c. 得られた被覆されたマルチセルラ・セラミック体を乾燥させる、
各工程を有してなる方法。
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Cited By (10)
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JP2007528342A (ja) * | 2004-03-11 | 2007-10-11 | コーニング インコーポレイテッド | シルセスキオキサンポリマーを含むセラミック組成物 |
JP2009541191A (ja) * | 2006-06-19 | 2009-11-26 | サン−ゴベン・セントル・ドゥ・レシェルシェ・エ・デチュード・ユーロペアン | 粒子フィルター用のセメント |
JP2010132538A (ja) * | 2008-11-10 | 2010-06-17 | Ngk Insulators Ltd | セラミックスハニカム構造体の製造方法およびセラミックスハニカム構造体用のコート材 |
WO2013038564A1 (ja) * | 2011-09-16 | 2013-03-21 | イビデン株式会社 | ハニカム構造体の製造方法および排ガス浄化装置の製造方法 |
JP2014124574A (ja) * | 2012-12-26 | 2014-07-07 | Denso Corp | ハニカム構造体及びその製造方法 |
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WO2017061382A1 (ja) * | 2015-10-09 | 2017-04-13 | 住友化学株式会社 | ハニカムフィルタ |
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JP2019177362A (ja) * | 2018-03-30 | 2019-10-17 | 日本碍子株式会社 | 触媒担持用ハニカム構造体 |
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JP2020165418A (ja) * | 2019-03-29 | 2020-10-08 | 日本碍子株式会社 | パティキュレートフィルタ及びキャニング構造体 |
JP7329950B2 (ja) | 2019-03-29 | 2023-08-21 | 日本碍子株式会社 | パティキュレートフィルタ及びキャニング構造体 |
Also Published As
Publication number | Publication date |
---|---|
US8518857B2 (en) | 2013-08-27 |
EP1699554A2 (en) | 2006-09-13 |
EP1699554A4 (en) | 2007-12-26 |
JP4874123B2 (ja) | 2012-02-15 |
US20050159308A1 (en) | 2005-07-21 |
WO2005065199A3 (en) | 2005-10-06 |
CN1901989B (zh) | 2011-04-13 |
WO2005065199A2 (en) | 2005-07-21 |
CN1901989A (zh) | 2007-01-24 |
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