JP2003269131A - Ceramic honeycomb structure - Google Patents
Ceramic honeycomb structureInfo
- Publication number
- JP2003269131A JP2003269131A JP2002068189A JP2002068189A JP2003269131A JP 2003269131 A JP2003269131 A JP 2003269131A JP 2002068189 A JP2002068189 A JP 2002068189A JP 2002068189 A JP2002068189 A JP 2002068189A JP 2003269131 A JP2003269131 A JP 2003269131A
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb structure
- ceramic honeycomb
- curvature
- radius
- ceramic
- 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.)
- Granted
Links
- 239000000919 ceramic Substances 0.000 title claims abstract description 30
- 238000005192 partition Methods 0.000 claims description 29
- 230000002093 peripheral effect Effects 0.000 claims description 14
- 230000035939 shock Effects 0.000 abstract description 16
- 230000004888 barrier function Effects 0.000 abstract 2
- 230000035882 stress Effects 0.000 description 9
- 238000001125 extrusion Methods 0.000 description 7
- 230000006378 damage Effects 0.000 description 6
- 238000005336 cracking Methods 0.000 description 5
- 239000010419 fine particle Substances 0.000 description 5
- 238000003672 processing method Methods 0.000 description 5
- 230000003197 catalytic effect Effects 0.000 description 4
- 210000002421 cell wall Anatomy 0.000 description 4
- 239000004927 clay Substances 0.000 description 4
- 229910052878 cordierite Inorganic materials 0.000 description 4
- 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 description 4
- 239000003054 catalyst Substances 0.000 description 3
- 210000004027 cell Anatomy 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000005995 Aluminium silicate Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 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
- 235000012211 aluminium silicate Nutrition 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 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 2
- 238000000746 purification Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 101100325793 Arabidopsis thaliana BCA2 gene Proteins 0.000 description 1
- BQSLGJHIAGOZCD-CIUDSAMLSA-N Leu-Ala-Ser Chemical compound CC(C)C[C@H](N)C(=O)N[C@@H](C)C(=O)N[C@@H](CO)C(O)=O BQSLGJHIAGOZCD-CIUDSAMLSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 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
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010586 diagram Methods 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
- 230000000694 effects Effects 0.000 description 1
- 238000000866 electrolytic etching Methods 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002994 raw material 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
- 239000000377 silicon dioxide Substances 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
- 239000000126 substance Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
Landscapes
- Filtering Of Dispersed Particles In Gases (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
- Catalysts (AREA)
- Processes For Solid Components From Exhaust (AREA)
- Filtering Materials (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、自動車エンジンの
排気ガス浄化用触媒の担体として或いはディーゼルエン
ジンの排気ガス中の微粒子を除去するためのフィルタと
して使用するに適したセラミックハニカム構造体に関す
るものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a ceramic honeycomb structure suitable for use as a carrier for an exhaust gas purifying catalyst for an automobile engine or as a filter for removing fine particles in exhaust gas of a diesel engine. is there.
【０００２】[0002]
【従来の技術】地域環境や地球環境の保全面から、自動
車などのエンジンから排出される排気ガスに含まれる有
害物質の削減が求められ、これに応えるためセラミック
ハニカム構造体を使用した触媒コンバータ用担体や微粒
子捕集用フィルタが使用されている。このセラミックハ
ニカム構造体のセル構造は、圧力損失を低減させるに適
していること、製造が容易なこと等の理由により図４
（１）に示すように流路の形状を四角形、特に正方形と
するのが一般的である。従って、隔壁交差部に隅角部を
有するため、ハニカム構造体を乾燥工程、焼成工程で加
熱冷却する際に、ハニカム構造体の中心部と周辺部とに
おける熱伝導の差に起因する不均一な膨張収縮により隅
角部に応力集中が起こり、クラックが発生して破損する
ことがあった。また使用中にも、排気ガスによる熱衝撃
や機械的振動が発生した際には、隅角部における応力集
中が発生し、破損のおそれがあった。このような欠点を
解消するため、図４（２）に示すように、特公昭５１−
２０４３５号公報には、セル壁の交差部に円弧状或いは
直線状などの膨大部を形成させる製造法が開示され、従
来技術の欠点である、セル壁交差部の隅角部への応力集
中によるクラック発生や、隅角部付近の排気ガス流動が
悪いことに起因する触媒反応効率の低下の問題を解消で
きるとされ、広く使用されるようになってきた。2. Description of the Related Art In order to meet the demand for reduction of harmful substances contained in exhaust gas emitted from engines such as automobiles from the viewpoint of conservation of local environment and global environment, a catalytic converter using a ceramic honeycomb structure is required. A carrier or a filter for collecting fine particles is used. The cell structure of this ceramic honeycomb structure is suitable for reducing the pressure loss, is easy to manufacture, and so on.
As shown in (1), the shape of the flow path is generally a quadrangle, particularly a square. Therefore, since there is a corner portion at the partition wall intersection, when the honeycomb structure is heated and cooled in the drying step and the firing step, unevenness due to the difference in heat conduction between the central portion and the peripheral portion of the honeycomb structure is caused. Due to the expansion and contraction, stress concentration occurs in the corners, and cracks sometimes occur and damage occurs. Further, during use, when thermal shock or mechanical vibration due to exhaust gas occurs, stress concentration occurs in the corner portion, which may cause damage. In order to eliminate such a defect, as shown in FIG.
Japanese Patent No. 20435 discloses a manufacturing method for forming an enlarged portion such as an arc shape or a straight shape at the intersection of cell walls, which is a drawback of the prior art and is caused by stress concentration on the corners of the cell wall intersection. It is said to be able to solve the problems of cracking and deterioration of catalytic reaction efficiency due to poor exhaust gas flow near the corners, and it has been widely used.
【０００３】[0003]
【発明が解決しようとする課題】しかしながら、上記従
来のハニカム構造体においては、以下のような問題があ
る。すなわち、触媒コンバータや微粒子捕集用フィルタ
は、触媒が担持されたセラミックハニカム構造体、或い
は流路の両端を市松模様に交互に目封止したセラミック
ハニカム構造体と、これらを収納する金属製容器が両者
間に配置された支持部材により強固に把持されている
が、実使用時に、高温排気ガスによる熱衝撃と共に、エ
ンジン振動や路面振動等の機械的衝撃を同時に受ける。
このため、特公昭５１−２０４３５号公報に記載されて
いるようなセル壁の交差部に円弧状或いは直線上などの
膨大部が形成されていても、過大な熱応力や機械的応力
が発生した際には、隔壁の交差部に応力集中による亀裂
が発生し、更には亀裂が進展し、ついにはセラミックハ
ニカム構造体が脱落し、浄化不能になるケースも出ると
いう欠点を有している。換言すれば、隔壁交差部の強度
が、同一ハニカム構造体内の各所で同レベルであること
から、亀裂が発生、進展し易く、ハニカム構造体が脱落
することが起こりうるのである。However, the above-mentioned conventional honeycomb structure has the following problems. That is, the catalytic converter and the filter for collecting fine particles are a ceramic honeycomb structure supporting a catalyst, or a ceramic honeycomb structure in which both ends of a flow path are alternately plugged in a checkered pattern, and a metal container for storing these. Is firmly gripped by a support member arranged between the two, but in actual use, it is simultaneously subjected to mechanical shock such as engine vibration and road surface vibration as well as thermal shock due to high temperature exhaust gas.
For this reason, even if an arcuate portion or a straight portion is formed at the intersection of the cell walls as described in Japanese Patent Publication No. 51-20435, excessive thermal stress and mechanical stress are generated. In this case, there is a defect that cracks are generated at the intersections of the partition walls due to stress concentration, the cracks further propagate, and eventually the ceramic honeycomb structure falls off and purification becomes impossible in some cases. In other words, since the strengths of the partition wall intersecting portions are at the same level in each place in the same honeycomb structure, cracks are likely to occur and propagate, and the honeycomb structure may fall off.
【０００４】本発明は、このような課題に鑑みてなされ
たもので、過大な熱衝撃や機械的衝撃が発生しても応力
集中の発生する隔壁交差部に亀裂が発生、進展し、ハニ
カム構造体が破壊するという現象を防止することができ
るセラミックハニカム構造体を提供しようとするもので
ある。The present invention has been made in view of the above problems, and even if an excessive thermal shock or mechanical shock is generated, cracks are generated and propagate at the intersections of partition walls where stress concentration occurs, and a honeycomb structure is formed. An object of the present invention is to provide a ceramic honeycomb structure capable of preventing the phenomenon of body destruction.
【０００５】[0005]
【課題を解決するための手段】本発明の第一の発明に係
るセラミックハニカム構造体は、外周壁と、この外周壁
の内側で隔壁により仕切られた多数の流路を有するセラ
ミックハニカムフィルタであって、少なくとも一部の前
記流路の軸方向に直交する断面形状が、一方の対向する
隅角部に略円弧状のＲ部を有することを特徴とする。ま
た、本発明の第二の発明に係るセラミックハニカム構造
体は、外周壁と、この外周壁の内側で隔壁により仕切ら
れた多数の流路を有するセラミックハニカム構造体であ
って、少なくとも一部の前記流路の軸方向に直交する断
面形状が、隅角部に略円弧状のＲ部を有し、且つ一方の
対向する隅角部のＲ部曲率半径が他方の対向する隅角部
のＲ部曲率半径より大きくしたことを特徴とする。前記
流路の軸方向に直交する断面形状とは、ハニカム構造体
における排気ガスが流れる方向に直交する方向に切断し
た流路の断面形状をいい、一方の対向する隅角部とは、
前記流路断面形状において、ある流路に着目したときに
その流路の断面形状の対角線上に向かい合う隅角部のこ
とを言う。図１を用いて更に詳しく説明すると、一方の
対向する隅角部とは、隅角部１６に相当し、他方の対向
する隅角部とは、隅角部１７に相当する。A ceramic honeycomb structure according to a first aspect of the present invention is a ceramic honeycomb filter having an outer peripheral wall and a plurality of flow channels partitioned by partition walls inside the outer peripheral wall. The cross-sectional shape of at least a part of the flow path orthogonal to the axial direction has a substantially arcuate R portion at one of the facing corner portions. Further, the ceramic honeycomb structure according to the second invention of the present invention is a ceramic honeycomb structure having an outer peripheral wall and a number of channels partitioned by partition walls inside the outer peripheral wall, and at least a part of The cross-sectional shape orthogonal to the axial direction of the flow path has a substantially arcuate R portion at the corner portion, and the R portion of one opposing corner portion has a radius of curvature of the other opposing corner portion. It is characterized in that it is made larger than the radius of curvature of the part. The cross-sectional shape orthogonal to the axial direction of the flow channel, refers to the cross-sectional shape of the flow channel cut in a direction orthogonal to the flow direction of the exhaust gas in the honeycomb structure, one of the opposite corners,
In the cross-sectional shape of the flow channel, it refers to corner portions facing each other on a diagonal line of the cross-sectional shape of the flow channel when attention is paid to a certain flow channel. To describe in more detail with reference to FIG. 1, one opposing corner portion corresponds to the corner portion 16, and the other opposing corner portion corresponds to the corner portion 17.
【０００６】本発明のセラミックハニカム構造体は、上
記の如き構成とすることにより、ハニカム構造体に過大
な熱衝撃や機械的衝撃が発生しても、応力が集中する流
路隅角部に形成されたＲ部の曲率半径が隣接する隅角部
で異なることから、隔壁交差部の強度が隣接する交差部
で異なり、同程度の強度を有する隔壁交差部が連続しな
いことから亀裂の発生に対する抵抗が大きくなり、ハニ
カム構造体トータルとしての強度が高くなり、亀裂が発
生、進展し、ハニカム構造体が破壊するという現象を防
止することができる。ここで、隣接する隔壁交差部の強
度が同程度にならないようにするためには、（一方の対
向する隅角部のＲ部曲率半径）／（他方の対向する隅角
部のＲ部曲率半径）は１．５以上とすると、亀裂発生に
対する抵抗が更に大きくなり、その効果は大きい。（一
方の対向する隅角部のＲ部曲率半径）／（他方の対向す
る隅角部のＲ部曲率半径）が１．５未満であると、隣接
する隔壁交差部間での強度の違いが小さくなるので、亀
裂発生に対する抵抗が小さくなる。The ceramic honeycomb structure of the present invention having the above-mentioned structure is formed in the corner portion of the flow channel where stress is concentrated even if an excessive thermal shock or mechanical shock is generated in the honeycomb structure. Since the radius of curvature of the curved R portion differs between the adjacent corner portions, the strength of the partition wall crossing portion differs between the adjacent crossing portions, and since the partition wall crossing portions having the same strength do not continue, resistance to crack generation It is possible to prevent a phenomenon in which the honeycomb structure is increased in total strength, the crack is generated and propagates, and the honeycomb structure is destroyed. Here, in order to prevent the strengths of the adjacent partition wall intersections from becoming equal, (R radius of curvature of one opposing corner) / (R radius of curvature of the other opposing corner) When the value of () is 1.5 or more, the resistance to cracking is further increased and the effect is large. If (R radius of curvature of one opposing corner portion) / (R radius of curvature of the other opposing corner portion) is less than 1.5, the difference in strength between adjacent partition wall intersections may be large. Since it becomes smaller, the resistance to crack initiation becomes smaller.
【０００７】また、本発明のセラミックハニカム構造体
は、隔壁の厚さが０．０５〜０．５ｍｍであると好適で
ある。隔壁の厚さが０．０５ｍｍ未満では、如何に隔壁
交差部の形状を調整したところで、隔壁自体の強度が低
下し、破損を防止したハニカム構造体が得られないから
であり、隔壁厚さが０．５ｍｍを越えると、ハニカム構
造体の圧力損失が大きくなってしまい、触媒コンバータ
或いは微粒子捕集用フィルタとして使用した際に、エン
ジンの出力低下を招くからである。また、更には、本発
明のセラミックハニカム構造体を構成するセラミック材
料としては、本発明が主に、自動車エンジンの排気ガス
浄化用触媒の担体として或いはディーゼルエンジンの排
気ガス中の微粒子を除去するためのフィルタとして使用
されるため、耐熱性に優れた材料を使用することが好ま
しく、コージェライト、アルミナ、ムライト、窒化珪
素、炭化珪素及びＬＡＳからなる群から選ばれた少なく
とも１種を主結晶とするセラミック材料を用いることが
好ましい。中でも、コージェライトを主結晶とするセラ
ミックハニカム構造体は、安価で耐熱性、耐食性に優
れ、また低熱膨張であることから最も好ましい。Further, in the ceramic honeycomb structure of the present invention, the partition walls preferably have a thickness of 0.05 to 0.5 mm. This is because when the partition wall thickness is less than 0.05 mm, the strength of the partition wall itself decreases and the honeycomb structure in which breakage is prevented cannot be obtained when the shape of the partition wall intersection is adjusted. This is because if it exceeds 0.5 mm, the pressure loss of the honeycomb structure becomes large and the output of the engine is reduced when it is used as a catalytic converter or a filter for collecting particulates. Furthermore, as the ceramic material constituting the ceramic honeycomb structure of the present invention, the present invention is mainly used as a carrier of an exhaust gas purifying catalyst for an automobile engine or for removing fine particles in an exhaust gas of a diesel engine. It is preferable to use a material having excellent heat resistance because it is used as a filter of, and at least one selected from the group consisting of cordierite, alumina, mullite, silicon nitride, silicon carbide and LAS is the main crystal. It is preferable to use a ceramic material. Among them, the ceramic honeycomb structure having cordierite as a main crystal is most preferable because it is inexpensive, has excellent heat resistance and corrosion resistance, and has low thermal expansion.
【０００８】[0008]
【発明の実施の形態】以下、本発明の実施の形態を、図
１に基づき説明するが、本発明はこれらの実施の形態に
限定されるものではない。図１は、実施の形態のハニカ
ム構造体１０であり、（ａ）は正面図、（ｂ）は（ａ）
でのＡ−Ａ断面図、（ｃ）は（ａ）でのＢ部拡大図を示
す。図１で、ハニカム構造体１０は、外周壁１１と、こ
の外周壁１１の内側で隔壁１３により仕切られて、両端
面１２を軸方向に貫通する多数の正方形の流路１５を有
している。そして、各流路１５は、軸方向に直交する断
面形状が、一方の対向する隅角部１６に略円弧状のＲ部
（曲率半径Ｒａ、Ｒｂ）を有し、他方の対向する隅部１
７にＲ部（曲率半径ｒｃ、ｒｄ）を有し、曲率半径Ｒ
ａ、Ｒｂを曲率半径ｒｃ、ｒｄより大きくしている。そ
して、例えば流路１５−１は隣接する隔壁１３ａ及び１
３ｂを基準としてそれぞれ流路１５ａ、１５ｂへと対称
に配設され、さらに、流路１５ａと１５ｂはそれぞれに
隣接する隔壁１３ｃ及び１３ｄ、１３ｅ及び１３ｆを基
準としてそれぞれ流路１５ｃ及び１５ｄ、１５ｅ及び１
５ｆへと対称に配設されている。ここで、各流路を仕切
る隔壁の交叉部を１３ｘ、１３ｙとすると、従来は１３
ｘと１３ｙの形状が同一となり、交差部の応力集中係数
がほぼ同一となるため、亀裂が発生することがあった。
更には、１３ｘ近傍で発生した亀裂が容易に１３ｙに伝
播する危険があった。しかし、本発明によれば、意図的
に１３ｘと１３ｙの形状を変化させているので亀裂の発
生及び伝播を防止することができる。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to FIG. 1, but the present invention is not limited to these embodiments. FIG. 1 shows a honeycomb structure 10 of an embodiment, (a) is a front view, and (b) is (a).
11A is a sectional view taken along line AA, and FIG. 13C is an enlarged view of a portion B in FIG. In FIG. 1, the honeycomb structure 10 has an outer peripheral wall 11 and a large number of square channels 15 that are partitioned by partition walls 13 inside the outer peripheral wall 11 and axially penetrate through both end faces 12. . Each flow path 15 has a substantially circular arc-shaped R portion (radius of curvature Ra, Rb) in one of the facing corner portions 16 having a sectional shape orthogonal to the axial direction, and the other facing corner portion 1
7 has an R part (radius of curvature rc, rd)
a and Rb are made larger than the radii of curvature rc and rd. Then, for example, the flow path 15-1 has the adjacent partition walls 13a and 1a.
3b are arranged symmetrically with respect to the flow paths 15a and 15b, respectively, and the flow paths 15a and 15b are respectively connected to the partition walls 13c and 13d, 13e and 13f adjacent to the flow paths 15c and 15d, 15e and 15e, respectively. 1
5f are arranged symmetrically. Here, assuming that the crossing portions of the partition walls that partition the respective flow paths are 13x and 13y, conventionally,
Since the shapes of x and 13y are the same and the stress concentration factors at the intersections are almost the same, cracks may occur.
Furthermore, there was a risk that cracks generated near 13x could easily propagate to 13y. However, according to the present invention, since the shapes of 13x and 13y are intentionally changed, the generation and propagation of cracks can be prevented.
【０００９】次に、図１のハニカム構造体１０の製造方
法について、図２及び図３に基づいて説明する。図２
は、ハニカム構造体１０を押出成形する状態を示す要部
断面図であり、図３は、押出成形に使用する口金の出口
側から見た一部の例を示す図である。押出成形用口金５
０は、多数の供給通路５１ａとこの供給通路５１ａか
ら、坏土を集合すると共に格子状に形成する排出通路５
１ｂを有する。そして、排出通路５１ｂを形成するため
の口金の排出ピン部５２の四つの角部には、曲面部が形
成され、一方の対向する曲面部のＲを他方の対向する曲
面部のＲよりも大きくしている。ここで、排出ピン部５
２の角部の曲面は、公知の加工方法である回転工具によ
る研磨加工法、放電加工法、電解加工法、電解エッチン
グ加工法、等々の方法により、所定の曲面が得られるよ
うに加工条件を調節する。一方の対抗する隅角部に曲面
を形成する場合には、口金の排出ピン部５２の四つの角
部の対向する二個所の角部に曲面を形成すれば良い。押
出成形を行う際には、セラミックス杯土を調節し、この
杯土を供給通路５１ａから排出通路５１ｂに押し出すこ
とで、排出通路５１ｂを通った坏土が圧着されて成形さ
れる。そして、外周壁１１と、この外周壁１１の内側で
隔壁１３により仕切られて、両端面間を軸方向に貫通す
る多数の方形の流路１５を有し、この流路１５の軸方向
に直交する断面形状が、一方の対向する隅角部に略円弧
状のＲ部１６（曲率半径Ｒａ、Ｒｂ）を有し、他方の対
向する隅角部１７にＲ部（曲率半径ｒｃ、ｒｄ）を有す
る流路が形成されるようになる。そして、曲率半径Ｒ
ａ、Ｒｂは、曲率半径ｒｃ、ｒｄより大きく形成され
る。更には、隣接する隔壁１３を基準として互いに対称
に連続して配設されたハニカム構造の成形体１０ａとな
る。そして、成形されたハニカム構造体１０ａに、乾
燥、焼成などの工程を加えることでハニカム構造体１０
となる。Next, a method of manufacturing the honeycomb structure 10 shown in FIG. 1 will be described with reference to FIGS. Figure 2
[Fig. 3] is a cross-sectional view of an essential part showing a state in which the honeycomb structure 10 is extrusion-molded, and Fig. 3 is a diagram showing a part of an example of the die used for extrusion molding as seen from the outlet side. Extrusion Molding Base 5
Reference numeral 0 denotes a large number of supply passages 51a and discharge passages 5 that form kneaded clay from the supply passages 51a and form a lattice.
With 1b. Curved surface portions are formed at the four corners of the discharge pin portion 52 of the die for forming the discharge passage 51b, and R of one opposing curved surface portion is larger than R of the other opposing curved surface portion. is doing. Here, the discharge pin portion 5
The curved surface of the corner of 2 is processed by a known processing method such as a polishing processing method using a rotary tool, an electric discharge processing method, an electrolytic processing method, an electrolytic etching processing method, etc. so that a predetermined curved surface can be obtained. Adjust. When a curved surface is formed on one of the opposing corners, it is sufficient to form a curved surface on two opposite corners of the four corners of the discharge pin portion 52 of the die. When performing extrusion molding, the ceramic clay is adjusted, and this clay is pushed out from the supply passage 51a to the discharge passage 51b, whereby the kneaded clay that has passed through the discharge passage 51b is pressed and formed. Further, it has an outer peripheral wall 11 and a large number of rectangular flow paths 15 that are partitioned by partition walls 13 inside the outer peripheral wall 11 and penetrate between the both end surfaces in the axial direction, and are orthogonal to the axial direction of the flow path 15. The cross-sectional shape has a substantially arc-shaped R portion 16 (curvature radius Ra, Rb) at one of the opposing corner portions, and an R portion (curvature radius rc, rd) at the other opposing corner portion 17. The flow path having the same is formed. And the radius of curvature R
a and Rb are formed to be larger than the radii of curvature rc and rd. Furthermore, the honeycomb structure molded body 10a is arranged symmetrically and continuously with respect to the adjacent partition walls 13. Then, the formed honeycomb structure 10a is subjected to processes such as drying and firing to obtain the honeycomb structure 10a.
Becomes
【００１０】図１に示す実施の形態のハニカム構造体１
０は、流路１５の軸方向に直交する断面形状が、一方の
対向する隅角部に略円弧状のＲ部１６（曲率半径Ｒａ、
Ｒｂ）を有し、他方の対向する隅角部１７にＲ部（曲率
半径ｒｃ、ｒｄ）を有する。そして、曲率半径Ｒａ、Ｒ
ｂは、曲率半径ｒｃ、ｒｄより大きく形成される。更に
は、流路１５が隣接する隔壁１３を基準として互いに対
称に連続して配設されていることで、同程度の強度を有
する隔壁交差部が隣接しないことから、ハニカム構造体
１０の亀裂発生に対する抵抗が大きくなり、耐熱衝撃強
度やアイソスタティック強度が向上する。このため、実
使用時の高温排気ガスによる、熱衝撃や、エンジン振
動、路面振動等の機械的衝撃を同時に受けたとしても、
亀裂が発生、進展し、セラミックハニカム構造体が脱落
し、浄化不能となることがない。The honeycomb structure 1 of the embodiment shown in FIG.
0 indicates that the cross-sectional shape orthogonal to the axial direction of the flow path 15 has a substantially arc-shaped R portion 16 (curvature radius Ra,
Rb) and an R portion (radius of curvature rc, rd) at the other opposing corner portion 17. And the radii of curvature Ra, R
b is formed larger than the radii of curvature rc and rd. Furthermore, since the flow paths 15 are arranged symmetrically with respect to each other with respect to the adjacent partition walls 13, the partition wall intersecting portions having the same strength are not adjacent to each other, so that the cracking of the honeycomb structure 10 occurs. Resistance to heat is increased, and thermal shock resistance and isostatic strength are improved. For this reason, even if a mechanical shock such as engine shock, road vibration, etc. is simultaneously received by the high temperature exhaust gas during actual use,
A crack does not occur and propagates, the ceramic honeycomb structure does not fall off, and purification becomes impossible.
【００１１】[0011]
【実施例】図１に示すハニカム構造体１０を以下のよう
にして製造した。カオリン、仮焼カオリン、アルミナ、
水酸化アルミニウム、シリカ、タルク等のコージェライ
ト化原料粉末を、質量％でＳｉＯ２が４２〜５６％、Ａ
ｌ２Ｏ３が３０〜４５％、ＭｇＯが１２〜１６％となる
よう調合する。これに、バインダー、潤滑剤等の成形助
剤、造孔剤を所定量添加混合した後、水を添加して混練
し、可塑化可能なバッチを作製し、押出成形によってハ
ニカム成形体を得た。この際流路の４隅に形成される、
一方の対向する曲面部のＲ及び他方の対向する曲面部の
Ｒの大きさが表１に示す各種のものが得られるように、
押出成形用口金の排出ピン部の角部の曲面の大きさを調
整した口金を各種準備した。その後、得られた成形体に
対して１４００℃の焼成を行い、図１に示すコージェラ
イト質セラミックハニカム構造体１０を得た。ハニカム
構造体の寸法は外径２５７ｍｍ、長さ３０４ｍｍ、セル
壁平均厚さ０．３ｍｍ、セル数４６．５セル／ｃｍ２で
あり、コージェライト質セラミックスの気孔率は６０％
であった。ハニカム構造体の流路の隅角部に形成された
Ｒ部の曲率半径の測定は、アイソスタティック試験終了
後のハニカム構造体から、流路に直角方向の断面形状が
認識できるように試験片を切り出し、１００倍の光学顕
微鏡で流路の隅角部に形成されたＲ部の曲率半径を測定
した。１個のハニカム構造体に対して、５個の流路の測
定を行い、平均値を表１に記載した。EXAMPLE A honeycomb structure 10 shown in FIG. 1 was manufactured as follows. Kaolin, calcined kaolin, alumina,
A cordierite-forming raw material powder such as aluminum hydroxide, silica, or talc has a SiO 2 content of 42 to 56% by mass%, A
I 2 O 3 is mixed at 30 to 45% and MgO is mixed at 12 to 16%. A binder, a molding aid such as a lubricant, and a pore-forming agent were added and mixed in a predetermined amount, and then water was added and kneaded to prepare a plasticizable batch, and a honeycomb molded body was obtained by extrusion molding. . At this time, it is formed at the four corners of the flow path,
The sizes of R of one curved surface portion facing each other and R of the other curved surface portion facing each other can be obtained as shown in Table 1,
Various types of die in which the size of the curved surface of the corner portion of the discharge pin portion of the extrusion die was adjusted were prepared. Then, the obtained compact was fired at 1400 ° C. to obtain a cordierite ceramic honeycomb structure 10 shown in FIG. The honeycomb structure has an outer diameter of 257 mm, a length of 304 mm, an average cell wall thickness of 0.3 mm, and a cell number of 46.5 cells / cm 2 , and the porosity of the cordierite ceramics is 60%.
Met. The radius of curvature of the R portion formed at the corner of the flow channel of the honeycomb structure was measured by using a test piece so that the cross-sectional shape in the direction perpendicular to the flow channel could be recognized from the honeycomb structure after completion of the isostatic test. It was cut out and the radius of curvature of the R portion formed in the corner portion of the channel was measured with a 100 × optical microscope. Five channels were measured for one honeycomb structure, and the average values are shown in Table 1.
【００１２】得られたハニカム構造体１０に、熱衝撃や
機械的衝撃が加わった際の耐破損性、即ち亀裂に対する
抵抗を評価する目的でアイソスタティック強度の測定を
行った。アイソスタティック強度は、社団法人自動車技
術会発行の自動車規格（ＪＡＳＯ）Ｍ５０５−８７に基
づき、ハニカムフィルタの上下面に厚さ１０ｍｍのアル
ミ板を当てて両端を密閉すると共に外周壁の側面を厚さ
２ｍｍゴムで密着して試料とし、この試料を圧力容器内
に入れ、圧力容器内に水を導入し、圧力容器内の圧力を
増加して試料を破壊させ、破壊時の圧力（ＭＰａ）を測
定した。測定は各条件に対して５個行い、これらの平均
値を表１に示した。Isostatic strength was measured for the purpose of evaluating the resistance to damage, that is, the resistance to cracking when a thermal shock or a mechanical shock is applied to the obtained honeycomb structure 10. Isostatic strength is based on the Automotive Standards (JASO) M505-87 issued by Japan Society of Automotive Engineers of Japan, and applies aluminum plates with a thickness of 10 mm to the upper and lower surfaces of the honeycomb filter to seal both ends and the side surface of the outer peripheral wall. Adhere with 2 mm rubber to make a sample, put this sample in a pressure vessel, introduce water into the pressure vessel, increase the pressure in the pressure vessel to destroy the sample, and measure the pressure (MPa) at the time of destruction did. Five measurements were performed for each condition, and the average value of these is shown in Table 1.
【００１３】[0013]
【表１】 [Table 1]
【００１４】表１から、本発明例の試験ＮＯ．１〜４の
セラミックハニカムフィルタは、一方の対向する曲面部
のＲの大きさと他方の対向する曲面部のＲの大きさが異
なることから、アイソスタティック強度は実用上問題な
いレベルである２ＭＰａ以上が得られている。一方、本
発明の比較例である試験ＮＯ．５〜７のセラミックハニ
カムフィルタは、一方の対向する曲面部のＲの大きさと
他方の対向する曲面部のＲの大きさが同程度であること
から、アイソスタティック強度は、２ＭＰａ未満で、実
用化するためには、信頼性が低い。From Table 1, the test No. of the example of the present invention is shown. In the ceramic honeycomb filters 1 to 4, the R size of the curved surface portions facing each other is different from the R size of the curved surface portions facing the other, so that the isostatic strength is 2 MPa or more, which is a practically no problem level. Has been obtained. On the other hand, test No. 1 which is a comparative example of the present invention. The ceramic honeycomb filters of Nos. 5 to 7 have practically no isostatic strength of less than 2 MPa because the size of R of one curved surface facing each other and the size of R of the other curved curved surface facing each other are about the same. In order to do so, the reliability is low.
【００１５】[0015]
【発明の効果】以上、詳細に説明のとおり、本発明のハ
ニカム構造体は、少なくとも一部の流路の軸方向に直交
する断面形状が、一方の対向する隅角部に略円弧状のＲ
部を有する、或いは、一方の対向する隅角部のＲ部曲率
半径が他方の対向する隅角部のＲ部曲率半径より大きく
したので、隔壁交差部への応力集中が緩和されるため、
アイソスタティック強度を向上することができ、触媒コ
ンバーターや微粒子除去用のフィルタとして使用される
際に発生する熱衝撃や機械的衝撃が発生しても、亀裂の
発生や伝播に対する抵抗が大きく、破損を防ぐことがで
きる。As described above in detail, in the honeycomb structure of the present invention, at least a part of the flow passages has a cross-sectional shape orthogonal to the axial direction of a substantially circular arc shape at one of the opposite corners.
Or the radius of curvature of the R portion of one of the opposing corner portions is larger than the radius of curvature of the R portion of the other opposing corner portion, so that stress concentration at the partition crossing portion is relaxed.
The isostatic strength can be improved, and even if a thermal shock or a mechanical shock occurs when it is used as a catalytic converter or a filter for removing fine particles, the resistance to cracking and propagation is large and damage is prevented. Can be prevented.
【図１】実施の形態のハニカム構造体１０であり、
（ａ）は正面図、（ｂ）は（ａ）でのＡ−Ａ断面図、
（ｃ）は（ａ）でのＢ部拡大図を示す。FIG. 1 is a honeycomb structure 10 of an embodiment,
(A) is a front view, (b) is a sectional view taken along the line AA in (a),
(C) shows the B section enlarged view in (a).
【図２】ハニカム構造体１０を押出成形する状態を示す
要部断面図である。[Fig. 2] Fig. 2 is a cross-sectional view of an essential part showing a state where the honeycomb structure 10 is extrusion-molded.
【図３】押出成形用口金を成形体の出口側から見た図で
ある。FIG. 3 is a view of the extrusion-molding die as viewed from the outlet side of the molded body.
【図４】従来のハニカム構造体の隔壁交差部を示す図で
ある。FIG. 4 is a view showing a partition wall intersecting portion of a conventional honeycomb structure.
１０：セラミックハニカム構造体 １０ａ：セラミックハニカム構造体（成形体） １１：外周壁 １２：端面 １３：隔壁 １３ａ：隔壁厚 １３ｐ：ピッチ １５：流路 １６：一方の対向する隅部 １７：他方の対向する隅部 ５０：押出成形用金型 ５１ａ：供給通路 ５１ｂ：排出通路 ５２：排出ピン部 Ｄ１０：外径 Ｌ１０：長さ Ｒ、Ｒａ、Ｒｂ：大きな曲面 ｒ、ｒｃ、ｒｄ：小さな曲面 10: Ceramic honeycomb structure 10a: Ceramic honeycomb structure (molded body) 11: Outer wall 12: End face 13: Partition wall 13a: Partition thickness 13p: pitch 15: flow path 16: One opposite corner 17: the other opposite corner 50: Mold for extrusion molding 51a: Supply passage 51b: discharge passage 52: Discharge pin section D10: Outer diameter L10: Length R, Ra, Rb: Large curved surface r, rc, rd: small curved surface
フロントページの続き Ｆターム(参考） 3G090 AA02 4D019 AA01 BA05 BB06 BD03 BD10 CA01 CB06 4D048 AA06 AA13 AA14 AA18 BA10X BB02 BB12 4D058 JA32 JB06 JB22 KA30 SA08 4G069 AA01 BA13A BA13B CA02 CA03 CA18 EA18 EA19 EA25 EB10 EB12Y EB14Y EB15Y ED03 ED06 Continued front page F-term (reference) 3G090 AA02 4D019 AA01 BA05 BB06 BD03 BD10 CA01 CB06 4D048 AA06 AA13 AA14 AA18 BA10X BB02 BB12 4D058 JA32 JB06 JB22 KA30 SA08 4G069 AA01 BA13A BA13B CA02 CA03 CA18 EA18 EA19 EA25 EB10 EB12Y EB14Y EB15Y ED03 ED06
Claims (2)
り仕切られた多数の流路を有するセラミックハニカム構
造体であって、少なくとも一部の前記流路の軸方向に直
交する断面形状が、一方の対向する隅角部に略円弧状の
Ｒ部を有することを特徴とするセラミックハニカム構造
体。1. A ceramic honeycomb structure having an outer peripheral wall and a large number of flow channels partitioned by partition walls inside the outer peripheral wall, wherein at least a part of the flow channels has a cross-sectional shape orthogonal to the axial direction. A ceramic honeycomb structure having a substantially arcuate R portion at one of the opposite corner portions.
り仕切られた多数の流路を有するセラミックハニカム構
造体であって、少なくとも一部の前記流路の軸方向に直
交する断面形状が、隅角部に略円弧状のＲ部を有し、且
つ一方の対向する隅角部のＲ部曲率半径が他方の対向す
る隅角部のＲ部曲率半径より大きくしたことを特徴とす
るセラミックハニカム構造体。2. A ceramic honeycomb structure having an outer peripheral wall and a plurality of flow channels partitioned by partition walls inside the outer peripheral wall, wherein at least a part of the flow channels has a cross-sectional shape orthogonal to the axial direction. A ceramic having a substantially arcuate R-shaped corner portion, and the radius of curvature of the R portion of one of the facing corner portions is larger than that of the R portion of the other facing corner portion. Honeycomb structure.
Priority Applications (12)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002068189A JP4161292B2 (en) | 2002-03-13 | 2002-03-13 | Ceramic honeycomb structure |
| EP20040021704 EP1491734B1 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| DE2002618538 DE60218538T2 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| EP20060015683 EP1719882B1 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| DE60233448T DE60233448D1 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| EP20020026789 EP1316686B1 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| AT02026789T ATE372449T1 (en) | 2001-12-03 | 2002-12-02 | CERAMIC HONEYCOMB FILTER |
| DE2002622225 DE60222225T2 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter |
| US10/307,360 US6890616B2 (en) | 2001-12-03 | 2002-12-02 | Ceramic honeycomb filter and its structure |
| CN2007101928879A CN101240728B (en) | 2001-12-03 | 2002-12-03 | Ceramic honeycomb structural components |
| CNB021524734A CN100385096C (en) | 2001-12-03 | 2002-12-03 | Honeycomb ceramic filter and structural element thereof |
| CN2007101961133A CN101307704B (en) | 2001-12-03 | 2002-12-03 | Ceramic honeycomb structural components |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002068189A JP4161292B2 (en) | 2002-03-13 | 2002-03-13 | Ceramic honeycomb structure |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003269131A true JP2003269131A (en) | 2003-09-25 |
| JP4161292B2 JP4161292B2 (en) | 2008-10-08 |
Family
ID=29199344
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2002068189A Expired - Fee Related JP4161292B2 (en) | 2001-12-03 | 2002-03-13 | Ceramic honeycomb structure |
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| Country | Link |
|---|---|
| JP (1) | JP4161292B2 (en) |
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005144250A (en) * | 2003-11-12 | 2005-06-09 | Ngk Insulators Ltd | Honeycomb structure body |
| JP2005270969A (en) * | 2004-02-26 | 2005-10-06 | Ngk Insulators Ltd | Honeycomb filter and exhaust gas treatment device |
| JP2007175571A (en) * | 2005-12-27 | 2007-07-12 | Denso Corp | Hexagonal cell honeycomb structure |
| EP2505254A1 (en) | 2011-03-31 | 2012-10-03 | NGK Insulators, Ltd. | Plugged honeycomb structure |
| WO2012133846A1 (en) | 2011-03-31 | 2012-10-04 | 日本碍子株式会社 | Sealed honeycomb structure |
| WO2012133848A1 (en) | 2011-03-31 | 2012-10-04 | 日本碍子株式会社 | Sealed honeycomb structure |
| WO2012133847A1 (en) | 2011-03-31 | 2012-10-04 | 日本碍子株式会社 | Sealed honeycomb structure, and exhaust gas purification device |
| EP2508242A1 (en) | 2011-03-31 | 2012-10-10 | NGK Insulators, Ltd. | Plugged honeycomb structure |
| EP2514503A1 (en) | 2011-03-31 | 2012-10-24 | NGK Insulators, Ltd. | Plugged honeycomb structure |
| EP2705891A1 (en) | 2012-09-06 | 2014-03-12 | NGK Insulators, Ltd. | Plugged honeycomb structure |
| DE102016013084A1 (en) | 2015-11-11 | 2017-05-11 | Ngk Insulators, Ltd. | Locked honeycomb structure |
| DE102017003047A1 (en) | 2016-03-30 | 2017-10-05 | Ngk Insulators, Ltd. | Locked honeycomb structure |
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