Honeycomb filter and ceramic filter assembly
Abstract
An elongated honeycomb filter (F100) formed from a sintered porous ceramic body, being characterized by the fact that: an L / S ratio between a length of filter L in a flow direction of a processed fluid and a cross section of the filter S in a direction perpendicular to the flow direction is 0.06 mm / mm2 to 0.75 mm / mm 2.

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16 claims: 4 independent, 12 dependent
- 1ES 2 277 656 T3 REIVINDICACIONES 1. Un filtro de panal alargado (F100) formado a partir de un cuerpo cerámico poroso sinterizado, estando caracterizado por el hecho de que:una relación L/S entre una longitud de filtro L en una dirección de flujo de un fluido procesado y una sección trasversal del filtro S en una dirección perpendicular a la dirección de flujo es de 0,06 mm/mm 2 a 0,75 mm/mm 2 .
- 2El filtro de panal según la Reivindicación 1, en donde el filtro se forma a partir de un cuerpo de carburo de silicio poroso sinterizado.
- 3El filtro de panal según las Reivindicaciones 1 ó 2, en donde el filtro posee una pluralidad de celdas, y cada celda posee una superficie exterior que lleva al menos un catalizador de oxidación seleccionado de un elemento del grupo platino, otros elementos metálicos y sus óxidos.
- 4El filtro de panal según cualquiera de las Reivindicaciones 1 a 3, en donde el filtro tiene un diámetro medio del poro de 1 a 50 jum.
- 5El filtro de panal según cualquiera de las Reivindicaciones 1 a 4, en donde el filtro tiene una porosidad media de 30 a 70%.
- 6El filtro de panal según cualquiera de las Reivindicaciones 1 a 5, en donde el filtro tiene una forma exterior de un poste triangular, o una forma de poste hexagonal.
- 7El filtro de panal según cualquiera de las Reivindicaciones 1 a 6, en donde la longitud del filtro es de 167 mm a 300 mm.
- 8Un conjunto de filtro de panal (49) producido adhiriendo con una capa de sellado cerámico (15) las superficies exteriores de una pluralidad de filtros de panal alargados (F100) según cualquiera de las Reivindicaciones 1 a 7.
- 9El conjunto de filtro de panal según la Reivindicación 8, en donde los filtros están dispuestos en un estado desplazado los unos de los otros en una dirección perpendicular a la dirección axial del filtro.
- 10El conjunto de filtro de panal según la Reivindicación 8 ó 9, en donde el conjunto es un filtro de partículas diésel.
- 11El conjunto de filtro de panal según cualquiera de las Reivindicaciones 8 a 10, en donde el conjunto posee una forma exterior con sección transversal redondeada o bien una sección transversal ovalada.
- 12El conjunto de filtro de panal según cualquiera de las Reivindicaciones 8 a 11, en donde la capa de sellado (15) incluye al menos fibras inorgánicas, un ligante inorgánico, un ligante orgánico y partículas inorgánicas, y se forma a partir de un material elástico obtenido al unir las fibras inorgánicas y las partículas inorgánicas, interseccionándolas tridimensionalmente entre sí, con el ligante inorgánico y el ligante orgánico.
- 13El conjunto de filtro de panal según cualquiera de las Reivindicaciones 8 a 12, en donde la capa de sellado se forma a partir de 10% en peso hasta 70% en peso de fibra cerámica de sílice y alúmina como un sólido, 1% en peso hasta 30% en peso de sílice sol, 0,1% en peso hasta 5,0% en peso de carboximetilcelulosa, y 3% en peso hasta 80% en peso de polvo de carburo de silicio.
- 14El conjunto de filtro de panal según cualquiera de las Reivindicaciones 8 a 13, en donde la capa de sellado (15) tiene un espesor (t1) de 0,3 a 3 mm.
- 15El conjunto de filtro de panal según cualquiera de las Reivindicaciones 8 a 14, en donde la capa de sellado (15) tiene una conductancia térmica de 0,1 a 10 W/mK.
- 16Un aparato de purificación de gases de escape que incluye el conjunto de filtro cerámico de cualquiera de las reivindicaciones 8 a 15 dispuesto en una carcasa (8) situada en la entrada de los gases de escape de un motor de combustión interna (2).
Independent claims16
148 paragraphs in 2 sections, as filed
ES 2 277 656 T3
DESCRIPTION
Honeycomb filter and ceramic filter set.
Field of the invention
The present invention relates to a honeycomb filter and a ceramic filter assembly, and more particularly, to a honeycomb filter formed by a sintered ceramic body assembly and an integral ceramic filter produced by adhering a plurality of honeycomb filters to each other. .
Background of the technique
The number of cars has increased dramatically this century. As a result, the amount of gases discharged by automobile engines has increased proportionally. Various substances suspended in the exhaust gases are emitted, especially from diesel engines, causing pollution and seriously affecting the environment. In addition, recent research results have shown that fine particles suspended in emissions (diesel particulates) can cause allergies or reduce sperm count. Thus, immediate action must be taken to eliminate fine particulate matter suspended in gas emissions for the good of humanity.
Due to this situation, many apparatuses for purifying exhaust gases have been proposed in the prior art. A typical apparatus for purifying exhaust gases includes a housing, located in an exhaust pipe connected to the exhaust manifold of an engine, and a filter, disposed in the housing and having fine pores. In addition to a metal or an alloy, the filter can be made of ceramic material. A cordierite honeycomb filter is a known example of a ceramic filter. Frequent filters are often formed from a sintered porous silicon carbide body which is advantageous from the point of view of heat resistance and mechanical strength, has high storage efficiency, is chemically stable and exhibits low loss. pressure.
Pressure loss refers to the difference between the pressure value taken upstream of the filter and the pressure value taken downstream of the filter. A major cause of power loss is the resistance of exhaust gases as they pass through a filter.
The honeycomb filter includes a plurality of cells that extend along the axial direction of the honeycomb filter. When the exhaust gases pass through the filter, the cell walls trap fine particles. This removes fine particles from the exhaust gases.
However, the honeycomb filter, made from a sintered porous silicon carbide body, is vulnerable to thermal shock. Therefore, larger filters have a tendency to crack. Consequently, a technique has recently been proposed to manufacture a large size ceramic filter assembly by integrating a plurality of small filters to prevent breakage resulting from cracks.
Next, a typical method for manufacturing a ceramic filter assembly will be described. First, a ceramic raw material is continuously extruded from a mold an extruder to form an elongated square honeycomb molded product. After cutting the honeycomb filter into pieces of equal length, the cut pieces are sintered to form a filter. After the sintering process, a plurality of filters are grouped and integrated by adhering the outer surface of the filters to each other with a ceramic sealing layer with a thickness of 4 to 5 mm. This completes the desired ceramic filter assembly.
A felt-like thermal insulating material made of ceramic fiber or other similar material is wrapped around the outer surface of the ceramic filter assembly. In this state, the assembly is arranged in a housing, located in an exhaust pipe.
However, in the prior art, there is a deficiency in that the fine particles trapped in the ceramic filter assembly are not completely burned out and some of the fine particles remain unburned. Consequently, the efficiency of exhaust gas processing is low.
In addition, the prior art honeycomb filter has corners. Therefore, there is a tendency for stress to concentrate on the outer surface corners and to chip the corners. Also, the sealing layer can crack and break the ceramic filter assembly from the corners damaging the entire ceramic filter assembly. Even if the assembly is not broken, there is a drawback in that such leakage of exhaust gases can reduce the processing efficiency.
During use of the filter assembly, a high temperature difference between the honeycomb filters can cause thermal stress that will crack the honeycomb filters and break the entire assembly. Therefore, the strength of each honeycomb filter must be increased to increase the strength of the honeycomb filter assembly.
The prior art ceramic filter assembly has a rectangular cross section. Therefore, the periphery of the assembly is cut so that the assembly has a rounded or oval cross section.
However, the filter has a plurality of cells. Therefore, if the periphery of the assembly is cut, the cell walls are exposed from the peripheral post-cut surface. This forms bumps and depressions on the peripheral surface. Therefore, even if the assembly is housed in the housing with the thermal insulating material attached to the peripheral surface of the assembly, gaps are formed in the longitudinal direction of the filters. Therefore, the exhaust gases tend to leak through the gaps. This reduces the efficiency of the exhaust gas processing.
In relation to diesel particles trapped in the honeycomb filter, it has been confirmed that particles with a small diameter have a high rate of adherence to the lung and increase health risks. Therefore, there is a great need to trap small particles.
However, when the pore diameter and porosity of the honeycomb filter are small, the honeycomb filter becomes too dense and obstructs the passage of exhaust gases, which, in turn, increases the pressure loss. This reduces the driving performance of the vehicle, reduces fuel efficiency, and impairs driving performance.
On the other hand, if the pore diameter and the porosity rate increase, these problems are solved. However, the number of openings of the honeycomb filter
ES 2 277 656 T3 is too big. Therefore, fine particles cannot be trapped. This decreases the entrapment efficiency. In addition, the mechanical strength of the honeycomb filter becomes low.
It is a first object to provide a ceramic filter assembly with improved exhaust gas processing efficiency.
It is a second object of the present invention to provide a ceramic filter assembly with superior strength.
It is a third object of the present invention to provide a ceramic filter assembly that prevents fluid leakage from the peripheral surface.
It is a fourth object of the present invention to provide a honeycomb filter with low pressure loss and superior mechanical strength. Summary of the invention
One perspective of the present invention is an integral ceramic filter assembly produced by bonding with a ceramic sealing layer the outer surfaces of a plurality of elongated honeycomb filters, each of which is formed from a sintered porous ceramic body, the ratio L / S between a filter length L in a flow direction of a processed fluid and a filter cross section S in a direction perpendicular to the flow direction being 0.06 mm / mm<sup>2</sup> at 0.75 mm / mm<sup>2</sup>.
Another perspective of the present invention is an elongated honeycomb filter formed from a sintered porous ceramic body, the ratio L / S being between a filter length L in a flow direction of a processed fluid and a filter cross section S in a direction perpendicular to the flow direction of 0.06 mm / mm<sup>2</sup> at 0.75 mm / mm<sup>2</sup>.
Brief description of the drawings
Fig. 1 is a schematic view showing an apparatus for purifying exhaust gases, according to the first embodiment of the present invention.
Fig. 2 is a perspective view showing a ceramic filter assembly of the exhaust gas purification apparatus of Fig. 1
Fig. 3 is a perspective view showing a honeycomb filter of the ceramic filter assembly of Fig. 2.
Fig. 4 is an enlarged cross-sectional view showing the main portion of the exhaust gas purifying apparatus of Fig. 1.
Fig. 5 is an enlarged cross-sectional view showing the main portion of a ceramic filter assembly of Fig. 2.
Fig. 6 is an enlarged cross-sectional view showing the main portion of a ceramic filter assembly of a first example assembly modified in accordance with a modified example.
Fig. 7 is a perspective view of a ceramic filter assembly according to one embodiment of the present invention.
Fig. 8 is a perspective view showing a ceramic filter assembly 3 of Fig. 7.
Fig. 9 (a) is a schematic cross-sectional view showing the filter of Fig. 8, while Fig. 9 (b) is a schematic side view showing the filter of Fig. 8.
Best mode of carrying out the invention
Next, a diesel engine exhaust gas purification apparatus 1 according to the present invention will be described with reference to Figs. 1 to 5.
Referring to Fig. 1, the exhaust gas purification apparatus 1 is an apparatus for purifying the exhaust gases emitted by a diesel engine 2, serving an internal combustion engine. The diesel engine 2 has a plurality of cylinders (not shown). Each cylinder is connected to a branch 4 of an exhaust manifold 3, which is made of a metallic material. Each branch 4 is connected to a single collector body 5. Consequently, the exhaust gases emitted by each cylinder are concentrated at one point.
A first exhaust pipe 6 and a second exhaust pipe 7, which are made of a metallic material, are arranged downstream of the exhaust manifold 3. The upstream end of the first exhaust pipe 6 is connected to the body of the manifold 5. A tubular casing 8 made of a metallic material is arranged between the first exhaust pipe 6 and the second exhaust pipe 7. The upstream end of the housing 8 connects to the downstream end of the first exhaust pipe 6, and the downstream end of the housing 8 connects to the upstream end of the second exhaust pipe 7. With this structure, it can be considered that the housing 8 is arranged in the exhaust pipes 6, 7. The first exhaust pipe 6, the housing 8, and the second exhaust pipe 7 communicate with each other so that the exhaust gases flow through them.
As shown in Fig. 1, the intermediate portion of the casing has a larger diameter than that of the exhaust pipes 6, 7. Consequently, the interior of the casing 8 is larger than that of the exhaust pipes 6, 7. A ceramic filter assembly 9 is housed in housing 8.
A thermal insulating material 10 is disposed between the outer surface of the assembly 9 and the inner surface of the housing 8. The thermal insulating material 10 is a felt-like material that includes ceramic fibers and that has a thickness of several millimeters to several tens millimeters. It is preferable that the thermal insulating material 10 is thermally expansive. Thermally expansive refers to the release of thermal stress through an elastic structure. This is to minimize energy loss during playback by preventing the release of heat from the outermost portion of the assembly 9. Furthermore, the expansion of ceramic fibers using the heat produced during playback prevents displacement of the ceramic filter assembly 9, which would be The result of the pressure of the exhaust gases or the vibrations produced by the moving vehicle.
The ceramic filter assembly 9 removes diesel particulate and is therefore commonly referred to as a Diesel Particulate Filter (DPF). As shown in Fig. 2 and Fig. 4, the set 9 is formed by grouping and integrating a plurality of filters F. The elongated square filters F1 are arranged in the central portion of the set 9, and the outer dimension of the square filter elongated F1 is 33mm x 33mm x 167mm (see Fig. 3). Filters F1 having different shapes from elongated square filters F1 are arranged around elongated square filters F1. This forms the ceramic filter body 9, which as a whole is cylindrical (the diameter being around 135 mm).
These F1 filters are made of Si3 carbide
ES 2 277 656 T3 sintered porous lice, which is a kind of sintered ceramic material. The reason for using sintered porous silicon carbide is because it is advantageous especially in that it has superior heat resistance and thermal conductance. In addition to sintered porous silicon carbide, the sintered material can be silicon nitride, sialon, alumina, cordierite, or mullite.
As shown in Fig. 3 and the remaining drawings, the filters F1 have a honeycomb structure. The reason for using the honeycomb structure is that the pressure loss is small when the trapped amount of fine particles increases. Each filter F1 has a plurality of through holes 12, which generally have square cross sections and are normally arranged extending in the axial direction. The through holes 12 are separated from each other by thin cell walls 13. The outer surface of the cell wall 13 carries an oxide catalyst formed from a platinum group element (such as Pt) or other metallic elements and there it oxidizes. The opening of each through hole 12 in one of the end surfaces 9a, 9b is sealed with a sealing body 14 (sintered porous silica carbide body). Consequently, the end surfaces 9a, 9b have the appearance of a checkerboard. Thus, the filters F1 have a plurality of cells with square cross sections. The density of the cells is around 200 / inch, the thickness of the cell wall 13 is around 0.3mm, and the distance between cells is around 1.8mm. Among the plurality of cells, about half are open on the surface of the upstream end 9a, and the rest are open on the surface of the downstream end 9b.
The mean pore diameter of the filter F1 is around 1 µm - 50 jum, and more especially, 5 pm - 20 jum. If the mean pore diameter is less than 1 jum, the deposited fine particles tend to clog the filter F1. If the mean pore diameter is greater than 50 jum, the fine particles would not be entrapped and the entrapment efficiency would decrease.
It is preferable that the porosity index is 30% to 70%, and more especially, 40% to 60%. If the porosity index is less than 30%, the filter F1 will be too fine and will make it difficult for the exhaust gases to circulate through it. If the porosity index is greater than 70%, the amount of voids in the F1 filters would be too large. This reduces the force of the filters f1 and reduces the efficiency of trapping the fine particles.
When selecting the sintered porous silicon carbide, it is preferred that the thermal conductance of the filter F1 is 20 W / mK to 80 W / mK, and more especially 30 W / mK to 70 W / mK.
Referring to Figs. 4 and 5, the outer surfaces of a total of 16 F filters are adhered to each other by a ceramic sealing layer 15.
The ceramic sealing layer 15 is described in detail below.
It is preferable that the thermal conductance of the sealing layer 15 is 0.1 W / mK - 10 W / mK, and more especially 0.2 W / mK - 2 W / mK.
If the thermal conductance is less than 0.1 W / mK, the thermal conductance of the sealing layer 15 cannot be improved sufficiently. Thus, the sealing layer 15 continues to be highly resistant and hinders thermal conduction between the filters F1.
On the other hand, if the thermal conductance is greater than 10 W / mK, properties such as adhesion and thermal resistance can degrade and make manufacturing difficult.
It is necessary that the thickness t1 of the sealing layer 15 is 0.3-3 mm. Furthermore, it is preferable that the thickness is 0.5mm - 2mm.
If the thickness t1 exceeds 3 mm, the sealing layer 15 continues to be a large sealing layer 15 even though the thermal conductance is high and the thermal conductance between the filters F1 becomes difficult. Furthermore, the ratio of the set 9 occupied by the filters F1 would decrease relatively and reduce the filtering capacity. On the other hand, if the thickness t1 of the sealing layer 15 is less than 0.3 mm, the sealing layer 15 would not be of great strength. However, the force that adheres the filters F1 to each other can be too low and make the assembly 9 vulnerable to breakage.
The sealing layer 15 is made up of at least an inorganic fiber, an inorganic binder, an organic binder, and inorganic particles. Furthermore, it is preferable that the sealing layer 15 is an elastic material formed by bonding inorganic fibers and inorganic particles, which intersect three-dimensionally with each other, with an inorganic binder and an organic binder.
At least one kind of ceramic fiber selected from silica fiber and alumina, mullite fiber, alumina fiber and silica fiber are selected as the inorganic fiber included in the sealing layer 15. Among said fibers, it is more preferable to select the fiber silica and alumina ceramics. The silica-alumina ceramic fiber has superior elasticity and serves to absorb thermal stress.
In this case, the content of the silica-alumina ceramic fiber in the sealing layer 15 is 10% by weight - 70% by weight, preferably 10% by weight.
- 40% by weight, and more preferably 20% by weight
- 30% by weight. If the content is less than 10% by weight, the thermal conductivity decreases and the elasticity is reduced. If the content exceeds 70%, the thermal conductivity and elasticity decrease.
The firing content of the silica-alumina ceramic fiber is 1% by weight -10% by weight, preferably 1% by weight-5% by weight, and more preferably 1% by weight-3% by weight. If the content of the shot is less than 1% by weight, manufacturing will be difficult, and if the content of the shot is 50% by weight, the outer surface of the filter F1 may be damaged.
The length of the silica alumina ceramic fiber is 1mm - 100mm, preferably 1mm - 50mm, and more preferably 1mm - 20mm. If the length of the fiber is 1 mm or less, there is a disadvantage that an elastic structure cannot be formed. If the length of the fiber is more than 100 mm, there is a disadvantage that the fiber can produce fiber balls and reduce the dispersion of inorganic fine particles. Also, if the fiber length is more than 100mm, it will be difficult to make the sealing layer thinner than 3mm and improve the thermal conductance between the F1 filters.
It is preferable that the inorganic binder included in the sealing layer 15 is a colloidal sol selected from at least one silica sol and alumina sol. It is especially preferable that sol silica is selected. This is because silica sol is optimal for its
ES 2 277 656 T3 use as bonding agent under elevated temperatures since it can be easily obtained and easily sintered into SiO<sub>2</sub>. Furthermore, silica sol has a superior insulating characteristic.
In this case, the content of silica sol in the sealing layer 15 as a solid is 1% by weight - 30% by weight, preferably 1% by weight - 15% by weight, and more preferably 5% by weight - 9%. in weigh. If the content is less than 1% by weight, the adhesion force decreases. On the other hand, if the content is more than 30% by weight, the thermal conductivity will decrease.
It is preferred that the organic binder included in the seal layer 15 is a high hydrophilic organic polymer and it is also preferable that the organic binder is a polysaccharide selected from at least one polyvinyl alcohol, methyl cellulose, ethyl cellulose and carboxymethyl cellulose. It is especially preferred that carboxymethylcellulose is selected. This is because the seal layer 15 has optimum fluidity due to carboxymethyl cellulose and therefore has superior adhesion under normal temperatures.
In this case, the content of carboxymethylcellulose as a solid is 0.1% by weight - 5.0% by weight, preferably 0.2% by weight - 1.0% by weight, and more preferably 0.4% by weight. - 0.6% by weight. If the content is less than 0.1% by weight, sufficient inhibition of migration is hampered. Migration refers to a phenomenon in which the binder of the seal layer 15 moves as the solvent is removed upon drying when the seal layer 15 loaded between the sealed bodies hardens. If the content is more than 5.0% by weight, the elevated temperature burns and removes the organic binder and decreases the strength of the sealing layer 15.
It is preferable that the inorganic particles included in the sealing layer 15 are an inorganic powder or an elastic material employing a whisker selected from at least one silicon carbide, silicon nitride and boron nitride. These carbides and nitrides have extremely high thermal conductivity and, when included on the surface of a ceramic fiber or on the surface of the interior of a colloidal sol, contribute to increased thermal conductivity.
Among the carbides and nitrides mentioned, it is especially preferred that silicon carbide powder is selected. This is because the thermal conductivity of silicon carbide is extremely high and it adapts easily to ceramic fiber. Furthermore, in the first embodiment, the filter F1, which is the sealed body, is made of sintered porous silicon carbide. Thus, it is preferred that the same type of silicon carbide powder is selected.
In this case, it is preferable that the content of silicon carbide powder as a solid is 3% by weight - 80% by weight, preferably 10% by weight.
- 60% by weight, and more particularly, 20% by weight
- 40% by weight. If the content is 3% by weight or less, the thermal conductivity of the sealing layer 15 decreases which results in the sealing layer 15 having a higher thermal resistance. If the content is more than 80% by weight, the adhesion force decreases when the temperature is high.
The grain diameter is 0.01 µm - 100 µm, preferably 0.1 µm - 15 µm, and more preferably 0.1 µm - 10 µm. If the diameter of the grain is greater than 100 μm, the adhesion and thermal conductivity decrease. If the grain diameter is less than 0.01 µm, the cost of the sealing material increases 15.
Next, the process for manufacturing the ceramic filter assembly 9 will be described.
First, a ceramic raw material slurry used during an extrusion process, a sealing paste used during a final surface sealing process, and a sealing layer-forming paste used during a filter adhesion process are prepared. .
Ceramic feedstock slurry is prepared by combining and kneading predetermined amounts of an organic binder and water with silicon carbide particles. The sealing paste is prepared by combining and kneading an organic binder, a lubricating agent, a plastic agent, and water with silicon carbide powder. The seal layer-forming paste is prepared by combining and kneading predetermined amounts of an inorganic fiber; an inorganic binder, an organic binder, inorganic particles and water.
Next, the ceramic raw material slurry is fed into an extruder and extruded from a mold. Subsequently, the extruded honeycomb molded product is cut into equivalent lengths to obtain elongated, square honeycomb molded pieces. In addition, a predetermined amount of sealing paste is loaded into one of the openings of each cell of the cut pieces, so that the surfaces at both ends of each cut piece are sealed.
Next, the main sintering is performed by setting predetermined conditions, such as temperature and time, to completely sinter the honeycomb moldings and sealing bodies 14. All sintered porous silicon carbide F1 filters obtained in this way they still have the shape of a square post.
The sintering temperature is set at 2,100 ° C to 2,300 ° C in the present embodiment to obtain an average pore diameter of 6 µm - 15 µm and a porosity of 35% to 50%. In addition, the sintering time is set from 0.1 hours to 5 hours. Furthermore, the interior of a furnace has an inert atmosphere during sintering and the pressure in that atmosphere is normal pressure.
Then, after forming a layered ceramic layer on the outer surface of the filters F1 as required, the sealing layer-forming paste is applied. The outer surfaces of sixteen of said filters F1 adhere to each other and are thus integrated.
In the next process of cutting the external shape, the assembly 9, which has been obtained through the adhesion process of the filter and having a square cross section, is connected to form the external shape of the assembly 9 eliminating unnecessary sections of the peripheral portion of the assembly 9 and forming the ceramic filter assembly 9, the cross section of which is rounded.
The trapping of the fine particles performed by the ceramic filter assembly 9 will be briefly described below.
Exhaust gases are fed to the ceramic filter assembly 9 housed in the housing 9a. The exhaust gases supplied through the first exhaust pipe 6 first enter the cells that are open at the upstream end surface 9a. The exhaust gases then pass through the cell wall
ES 2 277 656 T3 and enter adjacent cells, or open cells at the downstream end surface 9b. From the openings of said cells, the exhaust gases flow through the downstream end surfaces 9b of the filters F1. However, the fine particles included in the exhaust gases do not pass through the walls of the cells 13 and are trapped in the walls of the cells 13. As a result, the purified gases are discharged from the downstream end surface 9b of the filters F1. The purified exhaust gases then pass through the second exhaust pipe 7 to be finally discharged into the atmosphere. The trapped fine particles are ignited and burned by the catalytic effect that occurs when the internal temperature of the assembly 9 reaches a predetermined temperature.
Example 1-1 (1) 51.5% by weight of α-silicon carbide powder with a mean grain diameter of 10 pm and 22% by weight of a silicon carbide powder with a grain diameter mean 0.5 pm. Then, 6.5% by weight of the organic binder (methylcellulose) and 20% by weight of water were added to the obtained mixture and kneaded. Next, a small amount of the plastic agent and the lubricating agent were added to the kneaded mixture, it was re-kneaded and extruded to obtain the honeycomb molded product. More specifically, α-silicon carbide powder with a mean particle diameter of around 10 pm was produced by Yakus hima Denkou Kabushiki Kaisha, under the product name C1000F, and α-silicon carbide powder with a diameter mean particle size of about 0.5 pm was produced by Yakushima Denkou Kabushiki Kaisha under the product name GC-15.
(2) Then, after drying the molded product with a microwave dryer, the through holes 12 of the molded product were sealed with the sealing paste made of sintered porous silicon carbide. After that, the sealing paste was dried again with the dryer. After the final surface sealing process, the dry body was degreased at 400 ° C and then sintered for about three hours at 2,200 ° C in an argon atmosphere at normal pressure. Thus the porous silicon carbide F1 honeycomb filters were obtained.
(3) 23.3% by weight of a ceramic fiber (alumina silicate ceramic fiber, shot content 3%, fiber length 0.1mm -100mm), 30.2% in weight of silicon carbide with a mean grain diameter of 0.3 pm, 7% by weight of silica sol (the converted amount being SiO<sub>2</sub> 30% sol) that served as inorganic binder, 0.5% by weight of carboxymethylcellulose that served as organic binder, and 39% by weight of water. The kneaded material was adjusted to an appropriate viscosity to prepare the paste used to form the seal layer 15.
(4) Then, the seal layer-forming paste was uniformly applied to the outer surface of the F1 filters. Furthermore, in a state where the outer surfaces of the F1 filters adhered to each other, the F1 filters were dried and cured under the condition of 50 ° C to 100 ° C for 1 hour. As a result, the sealing layer 15 adhered the filters F1 to each other. The thickness t1 of the sealing layer 15 was adjusted to 0.5 mm. The thermal conductivity of the sealing layer 15 was 0.3 W / mK.
(5) Next, the peripheral portion was cut to shape and complete the ceramic filter assembly 9, the cross section of which was rounded.
Next, the thermal insulating material 10 is wound around the assembly 9 obtained in the manner described. In this state, the assembly 9 is housed in the casing 8 and exhaust gases are fed to it. After a predetermined time, the assembly 9 is extracted and cut in a plurality of locations. The cut surfaces were observed with the naked eye.
Consequently, the presence of fine particle residues in the peripheral portion of assembly 9 (especially, the peripheral portion close to the downstream end surface) where the unburned particles tend to remain, was not confirmed. Of course, the fine particles were completely burned in other portions. These results are considered to be obtained because the use of the sealing layer 15 prevents the thermal conductance between the filters F1 from decreasing and the temperature from increasing sufficiently in the peripheral portion of the assembly 9. Consequently, in Example 1- 1, it is apparent that the exhaust gases were processed efficiently. Examples 1-2, 1-3
In Example 1-2, the ceramic filter assembly 9 was prepared by setting the thickness t1 of the sealing layer 15 to 1.0 mm. The remaining conditions were set according to Example 1-1. In Example 3, the ceramic filter assembly 9 was formed by adjusting the thickness t1 of the sealing layer 15 to 2.5 mm. The remaining conditions were set according to Example 1-1.
Next, the two types of assemblies 9 obtained were used for a certain period of time, and the cut surfaces were observed with the naked eye. The same desirable results were obtained as in Example 1-1. Therefore, it is apparent that the exhaust gases were processed efficiently in Examples 1-2 and 1-3.
Example 1-4
In Example 1-4, the sealing layer-forming paste used was prepared by mixing and kneading 25% by weight of a ceramic fiber (mullite fiber, firing content ratio 5% by weight, fiber length 0, 1mm - 100mm), 30% by weight of silicon nitride powder with a mean grain diameter of 1.0 pm, 7% by weight of sol alumina (the amount of conversion of alumina sol being 20%) serving as an inorganic binder, 0.5% by weight of polyvinyl alcohol that served as the organic binder, and 37.5% by weight of alcohol. The remaining portions were formed according to Example 1-1 to complete the ceramic filter assembly 9. The thickness t1 of the sealing layer 15 was set to 1.0 mm. The thermal conductivity of the sealing layer 15 was 0.2 W / mK.
Then, the set 9 obtained was used for a certain period of time, and the cut surfaces were observed with the naked eye. The same desirable results were obtained as in Example 1. Therefore, it is apparent that the exhaust gases were processed efficiently in Example
4.
Example 1-5
In Example 1-5, the sealing layer-forming paste used was prepared by mixing and kneading 23% by weight of a ceramic fiber (alumina fiber, firing content ratio 4% by weight, fiber length 0, 1 mm - 100 mm), 35% by weight of boron nitride powder with a mean grain diameter of 1 pm, 8% by weight of alumina sol (sien6
ES 2 277 656 T3 (20% sol alumina conversion amount) serving as inorganic binder, 0.5% by weight of ethylcellulose serving as organic binder and 35.5% by weight of acetone. The other portions were formed according to Example 1 to complete the ceramic filter assembly 9. The thickness t1 of the sealing layer 15 was set to 1.0 mm. The thermal conductivity of the sealing layer 15 was 2 W / mK.
Then, the set 9 obtained was used for a certain period of time, and the cut surfaces were observed with the naked eye. The same desirable results were obtained as in Example 1. Therefore, it is apparent that the exhaust gases were processed efficiently in Example
5.
The ceramic filter assembly 9 of the first embodiment has the following advantages:
(1) In each example, the thickness t1 of the sealing layer 15 is determined in the preferable range of 0.3mm - 3mm, and the thermal conductivity of the sealing layer 15 is determined in the preferable range of 0, 1 W / mK - 10 W / mK. In this way, the thermal conductivity of the sealing layer is improved and the thermal conductivity between the filters F1 is prevented from decreasing. Consequently, the heat is quickly and uniformly conducted throughout the assembly 9. In this way a temperature difference is prevented from occurring in the assembly 9. Consequently, the thermal uniformity of the assembly 9 is increased and it is prevented from producing particles without burning locally. The exhaust gas purification apparatus 1, using the assembly 9, possesses superior exhaust gas processing efficiency.
Also, if the thickness t1 and the thermal conductivity are within the described range, the basic properties, such as adhesiveness and thermal resistance, remain the same. In this way, the manufacture of the sealing layer 15 is prevented from being difficult. Furthermore, since the sealing layer 15 serves to adhere the filters F1 to each other, breakage of the assembly 9 is prevented. That is, the assembly 9 is relatively easy to manufacture and has superior durability.
(2) The sealing layer 15 of each example contains as a solid 10% by weight - 70% by weight of ceramic fibers. This allows the sealing layer 15 to have high thermal conductivity and elasticity. Therefore, the thermal conductivity between the filters F1 is improved, and the thermal conductivity of the assembly 9 also increases.
(3) The sealing layer 15 of each example contains ceramic fibers, the lengths of which are 100 mm or less. Accordingly, the thickness t1 of the sealing layer 15 can be adjusted by 3mm or less without further difficulties. In this way, the thermal conductivity between the filters F1 is increased, thus contributing to the thermal uniformity of the assembly 9.
(4) The sealing layer 15 of each example contains as a solid 3% by weight - 80% by weight of inorganic particles. Therefore, the sealing layer 15 has a high thermal conductivity. In this way, the thermal conductivity between the filters F1 is increased, contributing to the thermal uniformity of the set 9.
(5) The sealing layer 15 in the above examples is formed by at least one inorganic fiber, an inorganic binder, an organic binder, and inorganic particles. Furthermore, the sealing layer 15 is made of an elastic material formed by bonding the inorganic fibers with the inorganic particles by intersecting three-dimensionally with an inorganic binder and an organic binder.
This material has the advantages described below. Sufficient adhesion force is obtained in low temperature range and high temperature range. Also, the material is elastic. Therefore, when thermal stress is applied to assembly 9, release of thermal stress is ensured.
This embodiment of the present invention can be modified as described below.
(a) The number of the filters F1 is not limited to 16 and could be any number. In this case, F1 filters with different dimensions and shapes can be combined.
(b) Referring to Fig. 6, in a ceramic filter assembly 21 of another embodiment, the filters F1 are offset from each other in a direction perpendicular to the axial direction of the filter, and the filters F1 are adhered by the layer of sealing 15. In this case, the filters F1 resist displacement when housed in the housing 8. This improves the breaking force of the assembly 21. In the ceramic filter assembly 21 of Fig. 6, the sealing layer 15 does not include transverse portions. This is considered to contribute to the improvement of the breaking force. Furthermore, since the thermal conductivity in the radial direction of the assembly 21 is improved, the thermal uniformity of the assembly 21 is further improved.
(c) Instead of honeycomb filters F1, the filters may have a three-dimensional mesh structure, a matted structure, or a fiber-like structure.
(d) Prior to the outer shape cutting process, the shape of the filter F1 is not limited to the elongated square shape and may have a pole-shaped triangular shape or a pole-shaped hexagonal shape. Furthermore, the assembly 9 does not necessarily have to be formed to have a rounded cross section during the cutting process of the outer shape and can be formed to have, for example, an oval cross section.
FIG. 7 is a schematic perspective view of a ceramic filter assembly 49 according to one embodiment of the present invention. The ceramic filter assembly 49 is formed through a plurality of rectangular post shaped honeycomb filters F100.
In each F100 honeycomb filter, the flow direction of the exhaust gases (direction perpendicular to the final filter surface), which is the processed fluid, is defined as the filter length L (mm). Furthermore, the area obtained by cutting each honeycomb filter F100 in a direction perpendicular to the flow direction (i.e., parallel to the final filter surface) is defined as the filter cross-sectional area S (mm<sup>2</sup>).
In this case, the L / S value should be 0.06 mm / mm<sup>2 </sup>at 0.75 mm / mm<sup>2</sup>. It is preferable that the L / S value is 0.10 mm / mm<sup>2</sup> at 0.60 mm / mm<sup>2</sup> , and more preferable that the L / S value is 0.15mm / mm<sup>2</sup> at 0.40 mm / mm<sup>2</sup>.
When the L / S values are greater than 0.75 mm / mm<sup>2</sup> , a temperature difference occurs in the longitudinal direction of the filter. As a result, a high level of thermal stress is applied to the F100 honeycomb filter allowing cracks to occur easily. On the other hand, when the L / S value is 0.06mm / mm<sup>2</sup> or less, a temperature difference occurs in a perpendicular direction.
ES 2 277 656 T3 lar to the longitudinal direction of the filter. This also applies a high level of thermal stress to the F100 honeycomb filter allowing cracks to occur easily.
It is specifically preferred that the length of the filter L is 120mm to 300mm, and it is especially preferred that the length of the filter is 140mm to 200mm. It is specifically preferred that the cross-sectional area of the filter S is 400 mm<sup>2</sup> at 2,500 mm<sup>2</sup>, and it is especially preferred that the cross-sectional area S is 600 mm<sup>2 </sup>at 2,000 mm<sup>2</sup>, and it is especially preferred that the cross-sectional area S is 600 mm<sup>2</sup> at 2,000 mm<sup>2</sup>. When the L and S values are outside the preferred range, a temperature difference occurs in the honeycomb filter F100. As a result, a thermal stress level is easily formed.
Example 4-1
Basically, the same set 49 was made as in Example 1-1. The height W1 of the filter F100 was 33 mm, the width W2 was 33 mm, and the length L was 16.7 mm. Consequently, the cross-sectional area of the filter S was 1,089 mm<sup>2</sup> and the L / S value was 0.15 mm / m<sup>2 </sup>(=167/1089).
Next, the thermal insulating material 10 was wrapped around the assembly 49. In this state, the assembly was kept in the casing 8 and exhaust gases were fed to it.
Referring to Fig. 9 (A) and 9 (B), thermocouples were installed at each location P1 and P6 and the respective temperatures Ti to T6 were measured over a given period. In addition, maximum differences in AT temperature (° C) were obtained in each of the locations P1 to P6. The white arrow in the drawing shows the direction of the exhaust gas flow. The temperature measurement was conducted to the honeycomb filter F100 indicated by the reference character X in Fig. 7.
After a predetermined time, set 49 was removed and the F100 honeycomb filters were observed with the naked eye. As a result, the maximum temperature difference AT (° C) of Example 41 was around 5 ° C, said value being extremely low. Furthermore, the presence of cracks was not confirmed in any of the F100 honeycomb filters. Examples 4-2 to 4-6
In Examples 4-2 through 4-6, Assembly 49 was manufactured in the same way as in Example 4-1. However, in Example 4-2, the height W1 of each honeycomb filter F100 was set to 50mm, the width W2 was set to 50mm, and the length L was set to 150mm. Consequently, the cross-sectional area of the filter S was 2,500 mm<sup>2</sup>, and the L / S value was (150 / 2,500 =) 0.06 mm / mm<sup>2</sup>.
In Example 4-3, the height W1 was set to 20mm, the width W2 was set to 20mm, and the length L was set to 300mm. Consequently, the cross-sectional area of the filter S was 4,000 mm<sup>2</sup>, and the L / S value was (300/400 =) 0.75 mm / mm<sup>2</sup> .
In Example 4-4, the height W1 was set to 33mm, the width W2 was set to 33mm, and the length L was set to 230mm. Consequently, the cross-sectional area of the filter S was 1,089 mm<sup>2</sup>, and the L / S value was (230/1089) 0.21 mm / mm<sup>2</sup>.
In Example 4-5, the height W1 was set to 25mm, the width W2 was set to 25mm, and the length L was set to 300mm. Consequently, the cross-sectional area of the filter S was 625 mm<sup>2</sup>, and the L / S value was (300/625 =) 0.48 mm / mm<sup>2</sup>.
In Example 4-6, the height W1 was set to 22mm, the width W2 was set to 22mm, and the length L was set to 300mm. Consequently, the cross-sectional area of the filter S was 484 mm<sup>2</sup>, and the L / S value was (300/484 =) 0.62 mm / mm<sup>2</sup>.
An experiment was conducted on the five types of sets 59 in the same manner as in Example 4-1. As a result, the maximum temperature difference AT (° C) was around 0 ° C to 10 ° C, these values being extremely low. In addition, the absence of cracks was confirmed in all the F100 honeycomb filters.
Comparative Example 1
In Comparative Example 1, Assembly 49 was manufactured in the same way as in Example 4-1. However, the height W1 of each honeycomb filter F100 was set to 20mm, the width W2 was set to 20mm, and the length L was set to 400mm. Consequently, the cross-sectional area of the filter S was 1,000 mm<sup>2</sup>, and the L / S value was (400/400 =) 1.00 mm / mm<sup>2</sup>.
An experiment was conducted on Set 49 in the same manner as in Example 4-1. As a result, the maximum temperature difference AT (° C) was around 30 ° C and greater than either of the embodiments. The length L of Comparative Example 1 was especially long. Therefore, there was a trend in a temperature difference produced in the longitudinal direction of the filter.
In addition, the presence of cracks in some of the F100 honeycomb filters was confirmed and the F100 honeycomb filters were damaged.
Comparative Example 2
In Comparative Example 2, assembly 49 was manufactured in the same way as in Example 4-1. However, the height W1 was set to 70mm, the width W2 was set to 70mm, and the length L was set to 167mm. Consequently, the cross-sectional area of the filter S was 4,900 mm<sup>2</sup>, and the L / S value was (167 / 4,900 =) 0.03 mm / mm<sup>2</sup>.
An experiment was conducted on Set 49 in the same manner as in Example 4-1. As a result, the maximum temperature difference AT (° C) was around 20 ° C and higher than either of the embodiments. The cross-sectional area S of the filter of Comparative Example 2 was especially large. Therefore, there was a trend in a temperature difference produced in a direction perpendicular to the longitudinal direction of the filter. In addition, the presence of cracks in some of the F100 honeycomb filters was confirmed and the F100 honeycomb filters were damaged.
The advantages of the ceramic filter assembly 49 of the fourth embodiment will be described below.
1. (1) By adjusting the L / S ratio between the length of the filter L and the cross-sectional area of the filter within the preferred range, the production of a large thermal stress is avoided without producing a large temperature difference in each F100 honeycomb filter. This prevents cracking in the F100 honeycomb filters and the F100 honeycomb filters resist damage. Due to the increased strength of each F100 honeycomb filter, the ceramic filter assembly 49 is manufactured with a higher strength. Furthermore, the use of the assembly 49 increases the strength of the exhaust gas purifying apparatus 1 and allows its use for a long period of time.
This prior embodiment can be modified as described below.
(a) As long as the condition is satisfied that the
ES 2 277 656 T3 L / S value is within the range of 0.06 mm / mm<sup>2</sup> at 0.75 mm / mm<sup>2</sup>, the shape of the F100 honeycomb filter can be changed into a cylindrical post shape, a triangular post shape or a hexagonal post shape.
(b) In addition to using the F100 honeycomb filters as a member that forms the ceramic filter 49, the F100 honeycomb filter may be used as a separate filter.
Industrial application
The ceramic filter assembly of the present invention can be applied to a diesel engine exhaust gas purification filter 2, a heat exchange device, a filter for high-temperature fluids or high-temperature steam, and so on.
Contents2
9 sheets
Sheet 1 Sheet 2 Sheet 3 Sheet 4 Sheet 5 Sheet 6 Sheet 7 Sheet 8 Sheet 9
74 members in 7 offices
Priority claims29
| Document | Office | Kind | Date |
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| 19990277122 | Japan | – | |
| 19990277123 | Japan | – | |
| 19990277432 | Japan | – | |
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| 27743299 | Japan | A | |
| 19990278405 | Japan | – | |
| 19990279866 | Japan | – | |
| 27840599 | Japan | A | |
| 27840599 | Japan | A | |
| 27986699 | Japan | A | |
| 27986699 | Japan | A | |
| 0402597127743299 | – | – | – |
| 27711999 | – | – | – |
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| JP19990277119 | – | – | – |
| JP19990277122 | – | – | – |
| JP19990277123 | – | – | – |
| JP19990277432 | – | – | – |
| JP19990278405 | – | – | – |
| JP19990279866 | – | – | – |
Members74
| Document | Office | Kind | |
|---|---|---|---|
| WO0123069A1 | World Intellectual Property Organization (WIPO) | A1 | |
| JP2001096112A | Japan | A | |
| JP2001096113A | Japan | A | |
| JP2001096116A | Japan | A | |
| JP2001096117A | Japan | A | |
| JP2001162119A | Japan | A | |
| JP2001162121A | Japan | A | |
| EP1142619A1 | European Patent Office (EPO) | A1 | |
| KR20010090852A | Republic of Korea | A | |
| EP1142619A4 | European Patent Office (EPO) | A4 | |
| KR20030088047A | Republic of Korea | A | |
| US6669751B1 | United States of America | B1 | |
| US2004055265A1 | United States of America | A1 | |
| KR100446205B1 | Republic of Korea | B1 | |
| EP1508355A1 | European Patent Office (EPO) | A1 | |
| EP1508356A1 | European Patent Office (EPO) | A1 | |
| EP1508357A1 | European Patent Office (EPO) | A1 | |
| EP1508358A1 | European Patent Office (EPO) | A1 | |
| EP1516659A1 | European Patent Office (EPO) | A1 | |
| KR100482271B1 | Republic of Korea | B1 | |
| US2006021310A1 | United States of America | A1 | |
| JP2006061909A | Japan | A | |
| EP1666121A2 | European Patent Office (EPO) | A2 | |
| EP1666121A3 | European Patent Office (EPO) | A3 | |
| JP2006181575A | Japan | A | |
| JP3803009B2 | Japan | B2 | |
| EP1688171A1 | European Patent Office (EPO) | A1 | |
| US7112233B2 | United States of America | B2 | |
| EP1508356B1 | European Patent Office (EPO) | B1 | |
| EP1516659B1 | European Patent Office (EPO) | B1 | |
| EP1508355B1 | European Patent Office (EPO) | B1 | |
| EP1142619B1 | European Patent Office (EPO) | B1 | |
| DE60032391D1 | Germany | D1 | |
| DE60032392D1 | Germany | D1 | |
| DE60032952D1 | Germany | D1 | |
| EP1508357B1 | European Patent Office (EPO) | B1 | |
| DE60033133D1 | Germany | D1 | |
| EP1775009A1 | European Patent Office (EPO) | A1 | |
| DE60033977D1 | Germany | D1 | |
| ES2276695T3 | Spain | T3 | |
| ES2277654T3 | Spain | T3 | |
| ES2277655T3 | Spain | T3 | |
| ES2277656T3This record | Spain | T3 | |
| ES2281733T3 | Spain | T3 | |
| DE60032391T2 | Germany | T2 | |
| DE60032392T2 | Germany | T2 | |
| DE60033133T2 | Germany | T2 | |
| DE60032952T2 | Germany | T2 | |
| DE60033977T2 | Germany | T2 | |
| JP4051163B2 | Japan | B2 | |
| US2008120950A1 | United States of America | A1 | |
| JP4146048B2 | Japan | B2 | |
| US7427309B2 | United States of America | B2 | |
| DE20023986U1 | Germany | U1 | |
| DE20023987U1 | Germany | U1 | |
| DE20023988U1 | Germany | U1 | |
| DE20023989U1 | Germany | U1 | |
| DE20023990U1 | Germany | U1 | |
| EP1666121B1 | European Patent Office (EPO) | B1 | |
| DE60041464D1 | Germany | D1 | |
| EP1508358B1 | European Patent Office (EPO) | B1 | |
| DE60042036D1 | Germany | D1 | |
| ES2321331T3 | Spain | T3 | |
| ES2324035T3 | Spain | T3 | |
| JP4372760B2 | Japan | B2 | |
| EP1688171B1 | European Patent Office (EPO) | B1 | |
| DE60043867D1 | Germany | D1 | |
| ES2341274T3 | Spain | T3 | |
| US2010209310A1 | United States of America | A1 | |
| US2011070129A1 | United States of America | A1 | |
| US2011304084A1 | United States of America | A1 | |
| US8080082B2 | United States of America | B2 | |
| US8083826B2 | United States of America | B2 | |
| EP1688171B2 | European Patent Office (EPO) | B2 |
Numbers
- Publication
- 2277656
- Publication, DOCDB
- 2277656
- Publication, EPODOC
- ES2277656T
- Application
- 4025971
- Application, DOCDB
- 04025971
- Application, EPODOC
- ES20040025971T
Titles2
- Spanish
- FILTRO EN NIDO DE ABEJAS Y CONJUNTO DE FILTROS CERAMICOS.
- English
- BEE NEST FILTER AND CERAMIC FILTER SET.
Classification
- CPC, 50
- B01D39/2086
- B01D39/20
- B01D39/2075
- B01D46/2429
- B01D46/2448
- B01D46/2455
- B01D46/2462
- B01D46/2466
- B01D46/2474
- B01D2279/30
- C04B28/24
- C04B38/008
- C04B2111/00612
- C04B2111/00793
- F01N3/0222
- F01N2260/10
- F01N2330/06
- F01N2330/14
- F01N2330/30
- F01N2450/28
- C04B35/565
- C04B35/6269
- C04B37/005
- C04B2235/383
- C04B2235/5224
- C04B2235/5228
- C04B2235/5264
- C04B2235/5436
- C04B2235/5445
- C04B2235/5472
- C04B2237/08
- C04B2237/083
- C04B2237/09
- C04B2237/365
- Y10S55/05
- Y10S264/48
- Y10S55/30
- B29C48/11
- B29C48/12
- Y10T428/24149
- Y02T10/12
- B01D46/2496
- B01D46/2486
- B01D46/2498
- B01D46/24492
- B01D46/24491
- B01D46/2478
- B01D46/2484
- B01D46/24494
- B01D46/2482
- IPC, 8
- B01D39 20
- B01D46 24
- B29C48 11
- B29C48 12
- C04B28 24
- C04B38 00
- F01N3 022
- F01N3 027