JP5161460B2 - ハニカム構造体及びその製法 - Google Patents
ハニカム構造体及びその製法 Download PDFInfo
- Publication number
- JP5161460B2 JP5161460B2 JP2006540843A JP2006540843A JP5161460B2 JP 5161460 B2 JP5161460 B2 JP 5161460B2 JP 2006540843 A JP2006540843 A JP 2006540843A JP 2006540843 A JP2006540843 A JP 2006540843A JP 5161460 B2 JP5161460 B2 JP 5161460B2
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- Prior art keywords
- fiber
- inorganic
- honeycomb structure
- honeycomb
- aspect ratio
- 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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- 238000004519 manufacturing process Methods 0.000 title claims description 10
- 239000000835 fiber Substances 0.000 claims abstract description 70
- 239000012784 inorganic fiber Substances 0.000 claims abstract description 40
- 239000000919 ceramic Substances 0.000 claims abstract description 28
- 239000002245 particle Substances 0.000 claims abstract description 28
- 239000003054 catalyst Substances 0.000 claims description 34
- 239000011230 binding agent Substances 0.000 claims description 22
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 18
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 14
- 238000010304 firing Methods 0.000 claims description 11
- 239000000203 mixture Substances 0.000 claims description 8
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 239000003365 glass fiber Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 5
- OJMOMXZKOWKUTA-UHFFFAOYSA-N aluminum;borate Chemical compound [Al+3].[O-]B([O-])[O-] OJMOMXZKOWKUTA-UHFFFAOYSA-N 0.000 claims description 4
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims description 4
- 238000000746 purification Methods 0.000 claims description 4
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- 239000004927 clay Substances 0.000 description 5
- 239000011247 coating layer Substances 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- 238000013001 point bending Methods 0.000 description 4
- 238000007789 sealing Methods 0.000 description 4
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- 229910052751 metal Inorganic materials 0.000 description 3
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- 239000007787 solid Substances 0.000 description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 150000001339 alkali metal compounds Chemical class 0.000 description 2
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
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- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 239000004113 Sepiolite Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
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- 150000001298 alcohols Chemical class 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 229960000892 attapulgite Drugs 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
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- 239000004917 carbon fiber Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
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- 239000008119 colloidal silica Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
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- 238000010438 heat treatment Methods 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000010954 inorganic particle Substances 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052625 palygorskite Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- NWAHZABTSDUXMJ-UHFFFAOYSA-N platinum(2+);dinitrate Chemical compound [Pt+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O NWAHZABTSDUXMJ-UHFFFAOYSA-N 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 239000000843 powder Substances 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
- 239000011435 rock Substances 0.000 description 1
- 238000000790 scattering method Methods 0.000 description 1
- 239000011163 secondary particle Substances 0.000 description 1
- 229910052624 sepiolite Inorganic materials 0.000 description 1
- 235000019355 sepiolite Nutrition 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000005361 soda-lime glass Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
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- 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
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Description
まず、γアルミナ粒子(平均粒径2μm)40重量%、無機繊維(繊維種類、繊維強度、繊維長、繊維径、アスペクト比は表1のとおり)10重量%、シリカゾル(固体濃度30重量%)50重量%を混合し、得られた混合物100重量部に対して有機バインダとしてメチルセルロース6重量部、可塑剤及び潤滑剤を少量加えて更に混合・混練して混合組成物を得た。次に、この混合組成物を押出成形機により押出成形を行い、生の成形体を得た。そして、マイクロ波乾燥機及び熱風乾燥機を用いて生の成形体を十分乾燥させ、400℃で2時間保持して脱脂した。その後、800℃で2時間保持して焼成を行い、直方体形状(34.3mm×34.3mm×150mm)で、セル密度が62個/cm2(400cpsi)、壁厚が0.25mmの基本ハニカムユニットを得た。
実験例1〜22の3点曲げ強度測定を行った。この測定は、測定機としてインストロン社製5582を用いてJIS−R1601に準じて行った。具体的には、クロスヘッド速度を1mm/min、スパン間距離Lを135mmとし、基本ハニカムユニットの軸に対して垂直方向に荷重をかけて破壊荷重Wを測定し、貫通孔の部分のモーメントを差し引いて断面2次モーメントZを計算して、3点曲げ強度σを下記式より算出した。その結果を表1及び図4〜図8に示す。
σ=WL/4Z
Claims (5)
- セラミック粒子と無機繊維と無機バインダとを含む材料を押出成形してなり、触媒担体として用いられ、該触媒担体の通路をなす貫通孔を有するハニカム構造体であって、
前記無機繊維は、ガラス繊維、シリカ・アルミナ繊維、チタン酸カリウム繊維及びホウ酸アルミニウム繊維からなる群より選ばれる1以上であり、
前記セラミック粒子を30〜90重量%、前記無機繊維を5〜30重量%、前記無機バインダを5〜50重量%含み、前記無機繊維は、アスペクト比≧繊維強度(GPa)/0.3を満たす、ハニカム構造体。 - 前記無機繊維のアスペクト比は5以上である、請求項1に記載のハニカム構造体。
- 車両の排ガス浄化装置の一構成要素として利用される、請求項1又は2に記載のハニカム構造体。
- 少なくともセラミック粒子と無機繊維と無機バインダを混合して混合組成物とし、該混合組成物をハニカム形状に押出成形して成形体とし、該成形体を焼成してハニカム構造体を製造する方法であって、
前記ハニカム構造体は、触媒担体として用いられ、該触媒担体の通路をなす貫通孔を有し、
前記無機繊維は、アスペクト比≧繊維強度(GPa)/0.3を満たし、ガラス繊維、シリカ・アルミナ繊維、チタン酸カリウム繊維及びホウ酸アルミニウム繊維からなる群より選ばれる1以上であり、
前記セラミック粒子の含有量は全体の30〜90重量%であり、前記無機繊維の含有量は全体の5〜30重量%であり、前記無機バインダの含有量は全体の5〜50重量%である、
ハニカム構造体の製法。 - 前記無機繊維のアスペクト比は5以上である、請求項4に記載のハニカム構造体の製法。
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US7939157B2 (en) | 2011-05-10 |
JPWO2006040874A1 (ja) | 2008-05-15 |
US20060263574A1 (en) | 2006-11-23 |
KR100813445B1 (ko) | 2008-03-13 |
DE602005027173D1 (de) | 2011-05-12 |
CN1926076A (zh) | 2007-03-07 |
EP1707545A4 (en) | 2008-08-13 |
EP1707545A1 (en) | 2006-10-04 |
ATE503734T1 (de) | 2011-04-15 |
WO2006040874A1 (ja) | 2006-04-20 |
KR20070041424A (ko) | 2007-04-18 |
EP1707545B1 (en) | 2011-03-30 |
CN100480215C (zh) | 2009-04-22 |
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