JP5833015B2 - 熱衝撃抵抗性セラミックハニカム構造体を得るための改良されたセメントおよびそれらの作製方法 - Google Patents
熱衝撃抵抗性セラミックハニカム構造体を得るための改良されたセメントおよびそれらの作製方法 Download PDFInfo
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- JP5833015B2 JP5833015B2 JP2012538838A JP2012538838A JP5833015B2 JP 5833015 B2 JP5833015 B2 JP 5833015B2 JP 2012538838 A JP2012538838 A JP 2012538838A JP 2012538838 A JP2012538838 A JP 2012538838A JP 5833015 B2 JP5833015 B2 JP 5833015B2
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- cement
- ceramic
- porosity
- honeycomb structure
- ceramic honeycomb
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/2448—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the adhesive layers, i.e. joints between segments
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- B01D39/14—Other self-supporting filtering material ; Other filtering material
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- F01N2450/28—Methods or apparatus for fitting, inserting or repairing different elements by using adhesive material, e.g. cement
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Physics & Mathematics (AREA)
- Geometry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Thermal Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Filtering Materials (AREA)
- Civil Engineering (AREA)
- Dispersion Chemistry (AREA)
- Nanotechnology (AREA)
- Laminated Bodies (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Ceramic Products (AREA)
Description
本出願は、全ての目的のため参照により本明細書に組み込まれている、2009年11月11日に出願された米国特許出願第61/2760,043号の出願日の利益を主張するものである。
a)第1のハニカムセグメントの外側表面の少なくとも1つを、(i)無機繊維、加熱すると無機繊維を生成する前駆体またはこれらの組合せから構成される凝集体(agglomerate)から構成される第1の繊維組成物と、(ii)無機繊維、加熱すると無機繊維を生成する微粒子前駆体またはこれらの組合せ、およびポロジェン(porogen)から構成される第2の繊維組成物と、(iii)担体流体とから構成されるセメントと接触させるステップ、
b)第2のハニカムセグメントを第1のハニカムセグメントと接触させるステップであって、前記ハニカムセグメント間にセメントを介在させることにより前記ハニカムセグメントが接着するようにするステップ、ならびに
c)接着したセグメントを十分に加熱して、担体流体を除去し、前記第1および第2の繊維組成物の反応、結合もしくはその組合せを行うステップであって、前記セグメントが、互いに化学結合している繊維から構成されるセメント層によって互いに接着し、セメント層が、気孔率の異なる少なくとも2つの領域を有するようにするステップ
を含む方法である。
(a)無機繊維、加熱すると無機繊維を生成する前駆体またはこれらの組合せから構成される凝集体から構成される第1の繊維組成物を形成するステップ、ならびに
(b)この第1の繊維組成物と、(ii)無機繊維または、加熱すると無機繊維を生成する微粒子前駆体およびポロジェンから構成される第2の繊維組成物と(iii)担体流体とを混合するステップ
を含む方法であり、前記凝集体が、混合する間に実質的にばらばらに壊されない(fail to break-up)方法である。
本発明のセメントは、第1の繊維組成物および第2の繊維組成物を内部に有する担体液体を含む。担体液体は、例えば、水、任意の有機液体例えばアルコール、脂肪族化合物、グリコール、ケトン、エーテル、アルデヒド、エステル、芳香族化合物、アルケン、アルキン、カルボン酸、カルボン酸クロリド、アミド、アミン、ニトリル、ニトロ、硫化物、スルホキシド、スルホン、有機金属化合物など、またはこれらの混合物とすることができる。担体流体は、水、脂肪族化合物、アルケンまたはアルコールであることが好ましい。この液体は、アルコール、水またはこれらの組合せであることがより好ましい。アルコールが使用される場合、それはメタノール、プロパノール、エタノールまたはこれらの組合せであることが好ましい。担体流体は水であることが最も好ましい。
より小さなセラミックハニカムF1(すなわち、ハニカムセグメント)は、任意の適切な多孔性セラミック、例えば、ディーゼルすすを濾過捕集する技術において知られているものなどとすることができる。例示的セラミックには、アルミナ、ジルコニア、炭化ケイ素、窒化ケイ素および窒化アルミニウム、酸窒化ケイ素および炭窒化ケイ素、ムライト、コージライト、ベータスポジュメン、チタン酸アルミニウム、ケイ酸ストロンチウムアルミニウムならびにケイ酸リチウムアルミニウムが含まれる。好ましい多孔性セラミック体には、炭化ケイ素、コージライト、チタン酸アルミニウムおよびムライトまたはこれらの組合せが含まれる。炭化ケイ素は、米国特許第6,669,751B1号および国際公開、EP1142619A1およびWO2002/070106A1中に記載されるものが好ましい。他の適切な多孔体は、米国特許第4,652,286号、米国特許第5,322,537号、WO2004/011386A1、WO2004/011124A1、US2004/0020359A1およびWO2003/051488A1により記述されている。
本発明のハニカム構造体を作製する場合、使用される担体流体の合計量は、以下に記述されるものなどの他の有機添加剤、および繊維である固形分配合量、ならびにセグメントを互いに接触させるのに使用される技術に応じて、広い範囲にわたって変動できる。流体(例えば、水)の合計量は、一般にセメントの無機部分の少なくとも約40体積%から約90体積%以下である。
30.0重量%のムライト前駆体の300マイクロメートル凝集体(成分A)、14.74重量%の平均粒径約30マイクロメートルを有する黒鉛、商標名A625のもとにCumming Moore Carbon Inc.、Detroit、MIから入手可能なもの(成分B)、7.89重量%の摩砕したアルミナおよび粘土(成分C)、1.05重量%のセルロースエーテルバインダーMETHOCEL A4M(The Dow Chemical Company、Midland MIから入手可能)(成分D)、および46.32%の水を混合することによって、セメントを調製した。
比較の目的のため、いくつかの他のセメント接合セラミックセグメントを作製し、試験した。全ての比較例セメントは、セメント全体にわたって本質的に同一の気孔率のみを有していた。
2つの針状ムライトセグメント式DPFは、1.5×1.5×7インチの針状ムライトハニカム16個を、実施例1に記述したセメントを使用して個々に接着することによって作製し(本明細書において、実施例1E)、また比較例Aに記述したセメントを使用して個々に接着することによって作製した(本明細書において、比較例AE)。これらの接着した組立体は、バインダーを除去しまたセメント接合を強化するため、1065Cで1時間か焼した。か焼後、組立体を研磨して、直径5.6インチおよび6インチのセグメント式微粒子フィルターとした。両方のセグメント式微粒子フィルターに、セメント膜を塗布した。膜セメントは、62重量部(pbw)の平均粒径325メッシュを有するMULCOAムライト粉末(CE Minerals、Andersonville、GA)と、4.8pbwのWF−7工業用Nut Powder(Agrashell、Los Angeles、CA)と、1.4pbwの、やはりThe Dow Chemical Companyから入手可能なMETHOCELL A15Lセルロースエーテルバインダーと、31.9pbwの水とを混合して、ペーストを形成し、それぞれのセグメント式微粒子フィルター上に、約2mmの厚さで、こて塗りした。膜のあるセグメント式フィルターを、80℃で24時間乾燥した。
F1 ハニカムセグメント
15 セメント
100 SDCB試験片
110 V形ノッチ
120 セメント
130 亀裂チップ
SDCB サンドイッチ型二重片持ちはり
DPF ディーゼル用微粒子フィルター
pbw 重量部
Claims (8)
- 少なくとも2つの別々のより小さなセラミックハニカムから構成されるセラミックハニカム構造体であって、前記セラミックハニカムは、繊維から構成されるセメント層によって互いに接着しており、前記セメント層が、より高い気孔率の第2の連続マトリックス内に分散された、より低い気孔率のドメインを有し、前記より低い気孔率のドメインが65%以下の気孔率を有し、前記連続マトリックスが少なくとも70%の気孔率を有し、前記より低い気孔率のドメインが250から1000マイクロメートルの数値の平均サイズを有する、セラミックハニカム構造体。
- 前記セメントが、少なくとも0.1のKIC/靭性(MPa・m1/2)/ヤング率(GPa)の比率を有する、請求項1に記載のセラミックハニカム構造体。
- 前記連続マトリックスが微小亀裂を有する、請求項1に記載のセラミックハニカム構造体。
- 前記微小亀裂が、前記連続マトリックス内に埋め込まれた微粒子の周囲に存在し、前記微粒子が、前記微粒子が埋め込まれている前記連続マトリックスと異なる熱膨張率を有する、請求項3に記載のセラミックハニカム構造体。
- 前記微粒子が、炭化ケイ素微粒子である、請求項4に記載のセラミックハニカム構造体。
- 前記より小さなハニカムが、針状ムライトである、請求項5に記載のセラミックハニカム構造体。
- 前記連続マトリックス及びより低い気孔率のドメインが、針状ムライトである、請求項6に記載のセラミックハニカム構造体。
- 前記セメントが、前記セラミックハニカム構造体の周囲にも塗布されて、その上に膜を形成する、請求項1に記載のセラミックハニカム構造体。
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US26004309P | 2009-11-11 | 2009-11-11 | |
US61/260,043 | 2009-11-11 | ||
PCT/US2010/054184 WO2011059699A1 (en) | 2009-11-11 | 2010-10-27 | Improved cement to make thermal shock resistant ceramic honeycomb structures and method to make them |
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JP2013510791A JP2013510791A (ja) | 2013-03-28 |
JP2013510791A5 JP2013510791A5 (ja) | 2013-12-19 |
JP5833015B2 true JP5833015B2 (ja) | 2015-12-16 |
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US (1) | US9174158B2 (ja) |
EP (1) | EP2498894A1 (ja) |
JP (1) | JP5833015B2 (ja) |
KR (1) | KR20120095960A (ja) |
CN (1) | CN102665854B (ja) |
BR (1) | BR112012010615A2 (ja) |
CA (1) | CA2780250A1 (ja) |
MX (1) | MX2012005382A (ja) |
WO (1) | WO2011059699A1 (ja) |
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JP7002377B2 (ja) * | 2018-03-19 | 2022-01-20 | 日本碍子株式会社 | ハニカム構造体 |
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-
2010
- 2010-10-27 US US13/501,853 patent/US9174158B2/en not_active Expired - Fee Related
- 2010-10-27 EP EP10773502A patent/EP2498894A1/en not_active Withdrawn
- 2010-10-27 MX MX2012005382A patent/MX2012005382A/es not_active Application Discontinuation
- 2010-10-27 CN CN201080051378.4A patent/CN102665854B/zh not_active Expired - Fee Related
- 2010-10-27 CA CA 2780250 patent/CA2780250A1/en not_active Abandoned
- 2010-10-27 WO PCT/US2010/054184 patent/WO2011059699A1/en active Application Filing
- 2010-10-27 BR BR112012010615A patent/BR112012010615A2/pt not_active Application Discontinuation
- 2010-10-27 JP JP2012538838A patent/JP5833015B2/ja not_active Expired - Fee Related
- 2010-10-27 KR KR20127014892A patent/KR20120095960A/ko not_active Application Discontinuation
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EP2498894A1 (en) | 2012-09-19 |
KR20120095960A (ko) | 2012-08-29 |
JP2013510791A (ja) | 2013-03-28 |
CN102665854A (zh) | 2012-09-12 |
BR112012010615A2 (pt) | 2016-03-29 |
US20120207967A1 (en) | 2012-08-16 |
CN102665854B (zh) | 2015-11-25 |
CA2780250A1 (en) | 2011-05-19 |
MX2012005382A (es) | 2012-05-29 |
WO2011059699A1 (en) | 2011-05-19 |
US9174158B2 (en) | 2015-11-03 |
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