JP5604047B2 - Honeycomb structure - Google Patents

Description

  The present invention relates to a honeycomb structure, and more specifically, it is possible to suppress an increase in pressure loss due to collection of particulate matter while suppressing a temperature increase during regeneration while preventing a decrease in strength of a wall surface of a partition wall. The present invention relates to a honeycomb structure.

  Particulate matter in exhaust gas discharged from internal combustion engines such as automobile engines, construction machinery engines, stationary engines for industrial machinery, and other combustion equipment must be removed from the exhaust gases in consideration of environmental impact. The nature is increasing. Therefore, a honeycomb structure made of ceramic or the like is widely used as a filter (diesel particulate filter: DPF) for removing particulate matter. The DPF includes, for example, a predetermined cell (predetermined cell) that includes a porous partition wall that partitions and forms a plurality of cells serving as fluid flow paths, one end of which is open and the other end is plugged. A cell having a structure in which one end portion is plugged and the remaining cell having the other end portion opened (the remaining cell) is alternately arranged is used. In use, a fluid (exhaust gas) is allowed to flow from one end where a predetermined cell of the DPF opens, and the exhaust gas that has flowed in is allowed to permeate the partition wall and flow out into the remaining cells as permeate fluid. The particulate matter in the exhaust gas is collected and removed by the partition walls by flowing out from the other end where the remaining cells open.

  When a honeycomb structure is used as a DPF, in order to remove an increase in pressure loss due to PM accumulated over time in the filter, it is necessary to burn (regenerate) the PM accumulated in the filter. However, when the temperature in the DPF increases excessively during the regeneration, there is a problem that defects such as cracks may occur due to thermal stress.

  To solve this problem, the honeycomb structure is composed of a plurality of honeycomb-shaped segments, and each segment is joined and integrated with a bonding material made of an elastic material. A method of dispersing and relaxing stress has been proposed (see, for example, Patent Document 1).

  In addition, by impregnating a slurry containing particles smaller than the average pore diameter of the segment in a portion close to the outlet side end face of each segment constituting the honeycomb structure, the portion is densified to heat the portion and heat capacity and thermal conductivity. Has been proposed to suppress the temperature rise during filter regeneration (see, for example, Patent Document 2).

JP 2000-279729 A International Publication No. 2008/078799 Pamphlet

  However, according to the method described in Patent Document 1, the occurrence of cracks in the DPF at the time of regeneration was reduced, but due to the bonding material, the cell aperture ratio at the end face decreased and the pressure loss increased. In addition, according to the method described in Patent Document 2, the pressure loss increases due to the decrease in the porosity of the partition walls due to densification. Therefore, without worsening the pressure loss. It was necessary to reduce the temperature in the DPF.

  The present invention has been made in view of the problems of the prior art as described above, and prevents a decrease in the strength of the wall surface of the partition wall, suppresses a temperature rise during regeneration, and pressure loss due to collection of particulate matter. It is characterized by providing a honeycomb structure capable of suppressing an increase in the thickness of the honeycomb structure.

  The following honeycomb structure is provided by the present invention.

[1] A partition wall having a porous partition wall for partitioning a plurality of cells penetrating from one end surface to the other end surface serving as a fluid flow path, and the partition wall surface is planar. The value of the ratio of the surface area of the partition wall to the surface area is 1.5 to 5.0, the arithmetic average surface roughness of the surface of the partition wall is 1.0 to 20.0 μm, and the local surface of the partition wall A honeycomb structure having an average distance between the peaks of 10 to 140 μm.

[2] The honeycomb structure according to [1], wherein a value of a ratio of an average interval of local peaks to an arithmetic average surface roughness of the surface of the partition wall is 3 to 35.

[3] The honeycomb structure according to [1] or [2], wherein a value of a ratio of a surface area of the partition wall to a surface area of the partition wall when the surface of the partition wall is planar is uniform overall. body.

[4] The honeycomb structure according to any one of [1] to [3], wherein an arithmetic average surface roughness of a surface of the partition wall is uniform overall.

[5] The honeycomb structure according to any one of [1] to [4], wherein an average interval between local peaks on the surface of the partition walls is uniform overall.

[6] The honeycomb structure according to any one of [1] to [5], wherein a plugged portion is provided at one open end of the predetermined cell and the other open end of the remaining cell.

[7] The honeycomb structure according to [6], wherein an opening ratio of the inlet side end face is larger than an opening ratio of the outlet side end face.

[8] The honeycomb structure according to any one of [1] to [7], wherein a catalyst component is supported on the partition walls.

  The honeycomb structure of the present invention has a partition wall surface area ratio value of 1.5 to 5.0 with respect to the partition wall surface area when the partition wall surface is planar. Therefore, the heat dissipation is good and the temperature rise during reproduction can be suppressed. And since the arithmetic mean surface roughness of the surface of a partition is 1.0-20.0 micrometers, the increase in the pressure loss at the time of PM collection can be suppressed, maintaining the intensity | strength of the wall surface of a partition favorably. . And since the average space | interval of the local peak of the surface of a partition is 10-140 micrometers, the increase in a catalyst coat amount can be suppressed, maintaining the intensity | strength of the wall surface of a partition favorable.

1 is a perspective view schematically showing an embodiment of a honeycomb structure of the present invention. Fig. 3 is a schematic diagram showing a part of a cross section parallel to the central axis direction of an embodiment of the honeycomb structure of the present invention. It is the schematic diagram which expanded the area | region A of FIG. 1B. It is a schematic diagram corresponding to the partition shown in FIG. 2, showing the partition when the partition surface is planar.

  DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Modes for carrying out the present invention will be specifically described below. However, the present invention is not limited to the following embodiments, and the ordinary knowledge of those skilled in the art is within the scope of the present invention. Based on the above, it should be understood that design changes, improvements, and the like can be made as appropriate.

  As shown in FIG. 1A and FIG. 1B, an embodiment of the honeycomb structure of the present invention has a porous structure in which a plurality of cells 2 penetrating from one end face 11 to the other end face 12 serving as a fluid flow path are defined. The partition wall surface 3 surface area (actual partition wall surface surface area (partition wall surface 3) surface area (partition wall surface 3) surface area when the partition wall 1 surface (partition wall surface 3) is planar). The surface area of the surface 3) ”is 1.5 to 5.0, the arithmetic average surface roughness Ra of the partition wall surface 3 is 1.0 to 20.0 μm, and A honeycomb structure having an average interval S of 10 to 140 μm. Here, the “surface of the partition wall” is the surface of the partition wall exposed in the cell. The “arithmetic average surface roughness Ra” is a value defined in JIS B0601-1994, which is extracted from the roughness curve by a reference length in the direction of the average line, and measured from the average line of the extracted part. The absolute value of the deviation up to the curve is summed and averaged. Further, the “average distance S between local peaks” is a value defined in JIS B0601-1994, which is extracted from the roughness curve by a reference length in the direction of the average line, and adjacent local peaks in this extracted portion. This is a value obtained by calculating the length of the average line corresponding to the interval (interval between the local peaks) and arithmetically averaging the intervals between the numerous local peaks. Concavities and convexities are formed on the partition wall surface 3, and the convex portions 4 are convex portions formed on the partition wall surface 3. Further, “the surface area of the surface (partition wall surface) 3 of the partition wall 1 when the surface of the partition wall 1 is planar” means that the surface of the partition wall 1a is not uneven as shown in FIG. This means that the surface area of the partition wall surface 3 is assumed to be flat. FIG. 1A is a perspective view schematically showing an embodiment of a honeycomb structure of the present invention. FIG. 1B is a schematic view showing a part of a cross section parallel to the central axis direction of one embodiment of the honeycomb structure of the present invention. FIG. 2 is an enlarged schematic view of region A in FIG. 1B. FIG. 3 is a schematic diagram corresponding to the partition wall 1 shown in FIG. 2, showing the partition wall 1 a when the partition wall surface 3 is planar.

  In the honeycomb structure 100 of the present embodiment, the ratio of the surface area of the partition wall surface 3 (surface area ratio) to the surface area of the partition wall 1 surface (partition wall surface 3) when the partition wall 1 surface is planar. 1.5 to 5.0, and preferably 2.0 to 4.0. If it is smaller than 1.5, the surface area of the partition wall surface 3 is small, so the heat dissipation effect is reduced and the temperature rise during regeneration cannot be suppressed. If it is larger than 5.0, the unevenness of the partition wall surface 3 becomes large, the strength of the partition wall surface (wall surface) 3 decreases, and the amount of catalyst supported increases due to the increase in surface area, resulting in an increase in cost. Here, the “surface area of the partition wall surface” is a value calculated by computer processing after capturing the surface state of the partition wall with micro CT. Specifically, a test piece is prepared so that the site to be observed of the honeycomb structure is in the center, and a measurement sample is obtained and measured by micro CT. As an apparatus for measuring micro CT, for example, trade name: “skyscan 1172” manufactured by Toyo Technica Co., Ltd. can be mentioned.

  The surface area of the partition wall is obtained by reconstructing the CT-captured image into three-dimensional solid data, recognizing the surface of the partition wall, and calculating the surface area of the partition wall from the spatial coordinates of the partition wall surface.

  In the honeycomb structure 100 of the present embodiment, the arithmetic average surface roughness Ra of the partition wall surface 3 is 1.0 to 20.0 μm, and preferably 2.0 to 15.0 μm. If it is smaller than 1.0 μm, it becomes difficult for the particulate matter to be trapped by the concavo-convex portion of the partition wall surface 3 (captured so as to be sandwiched between the adjacent convex portions 4 and 4), and enters the pores formed in the partition wall. As the amount of particulate matter increases, the pressure loss due to particulate matter build-up increases. If it is larger than 20.0 μm, the unevenness of the partition wall surface 3 becomes large, so that the strength of the partition wall surface 3 decreases, and the amount of catalyst supported increases due to the increase in surface area, resulting in an increase in cost. “Arithmetic average surface roughness Ra of the partition wall surface” is a value measured by a method based on JIS B0601-1994.

  In the honeycomb structure 100 of the present embodiment, the average interval S between the local peaks of the partition wall surface 3 is 10 to 140 μm, and preferably 15 to 100 μm. If it is smaller than 10 μm, the amount of catalyst supported increases, resulting in an increase in cost. If it is larger than 140 μm, it is difficult for the particulate matter to be captured by the uneven portions of the partition wall surface 3, and the amount of particulate matter entering into the pores formed in the partition wall increases, so that the pressure loss due to the deposition of the particulate matter increases. Increase. The “average distance S between local peaks on the partition wall surface” is a value measured by a method based on JIS B0601-1994.

  In the honeycomb structure 100 of the present embodiment, the “surface area of the partition wall surface”, the “arithmetic surface roughness Ra of the partition wall surface”, and the “average interval S of the local peaks on the partition wall surface” are defined within predetermined ranges. The temperature in the DPF during regeneration can be reduced without deteriorating the temperature.

  In the honeycomb structure 100 of the present embodiment, the value (S / Ra) of the ratio of the average interval S of the local peaks on the surface of the partition wall 1 to the arithmetic average surface roughness Ra of the surface of the partition wall 1 is 3 to 35. Is preferable, and 5 to 25 is more preferable. If it is less than 3, the particulate matter is less likely to be trapped by the uneven portions of the partition wall surface 3 and the amount of particulate matter entering the pores formed in the partition wall increases, so that the pressure loss due to the particulate matter deposition is reduced. May increase. If it is larger than 35, the unevenness of the partition wall surface 3 becomes large, so that the strength of the partition wall surface 3 decreases, and the amount of catalyst supported increases due to an increase in surface area, which may increase the cost.

  The honeycomb structure 100 of the present embodiment has a honeycomb shape having porous partition walls 1 for partitioning and forming a plurality of cells 2 serving as fluid flow paths, and the average pore diameter of the partition walls 1 is 5 to 40 μm. Is preferable, and it is still more preferable that it is 5-20 micrometers. If it is smaller than 5 μm, the pressure loss may increase even when the amount of particulate matter deposited is small, and if it is larger than 40 μm, the filter function for collecting PM may deteriorate. The average pore diameter of the partition wall 1 is a value measured with a mercury porosimeter.

  The porosity of the partition wall 1 is preferably 30 to 80%, and more preferably 40 to 80%. If it is less than 30%, the pressure loss may increase, and if it is more than 80%, the honeycomb structure 100 may become brittle and easily lost. The porosity of the partition wall 1 is a value measured by a mercury porosimeter.

  The thickness of the partition wall 1 is preferably 7 to 20 mil, and more preferably 8 to 16 mil. If the thickness is less than 7 mil, the strength of the honeycomb structure 100 may be reduced. If the thickness is more than 20 mil, the pressure loss when the exhaust gas passes through the cell may be increased. The thickness of the partition wall 1 is a value measured by observing an axial cross section with a microscope. Note that 1 (mil) is 1/1000 inch.

The cell density of the cross section perpendicular to the central axis of the honeycomb structure 100 is preferably 140 to 350 cpsi (21.7 to 54.3 cells / cm ² ), and 160 to 320 cpsi (24.8 to 49.6 cells). / Cm ² ) is more preferable. If it is less than 21.7 cells / cm ² , the strength of the honeycomb structure 100 may be reduced, and if it is greater than 54.3 cells / cm ² , the pressure loss may be increased. Moreover, it is preferable that the opening ratio of the inlet side end face of the honeycomb structure 100 is larger than the opening ratio of the outlet side end face. Here, the “aperture ratio of the end face” refers to the ratio of the area of the unsealed cell in the cross-sectional area.

  The cell shape of the honeycomb structure 100 is not particularly limited, but is preferably a polygon, such as a triangle, a quadrangle, a pentagon, or a hexagon, a circle, or an ellipse in a cross section perpendicular to the central axis, and other irregular shapes. May be.

  As a material constituting the honeycomb structure 1 (partition wall 3) of the present embodiment, a material mainly composed of ceramics, heat-resistant paper, sintered metal, or the like can be given as a suitable example. In the case of a material composed mainly of ceramics, specific ceramics include silicon carbide, silicon-silicon carbide based composite material formed of silicon carbide as an aggregate and silicon as a binder, cordierite, alumina Preferable examples include titanate, sialon, mullite, silicon nitride, zirconium phosphate, zirconia, titania, alumina, silica, LAS (lithium aluminum silicate), or a combination thereof. In particular, ceramics such as silicon carbide, cordierite, mullite, silicon nitride, alumina, and alumina titanate are suitable in terms of alkali resistance. Among these, oxide-based ceramics are preferable because they are inexpensive.

  Moreover, the honeycomb structure 100 may have an outer peripheral wall located at the outermost periphery thereof. The outer peripheral wall is not only a molded integral wall that is integrally formed with the honeycomb structure at the time of molding, but also a cement coated wall in which the outer periphery of the honeycomb structure is ground to a predetermined shape after molding to form the outer peripheral wall with cement or the like. But you can.

  The honeycomb structure 100 of the present embodiment preferably has plugged portions at one open end of a predetermined cell and the other open end of the remaining cells. Furthermore, a predetermined cell having one end portion opened and having a plugged portion at the other end portion, and a residue having the plugged portion at the one end portion and the other end portion opened. The cells are alternately arranged, and each end surface is preferably a checkered pattern formed by plugged cells and non-plugged cells. The material of the plugging portion for forming the plugging at the opening of the cell is not particularly limited, but silicon carbide, a silicon-silicon carbide based composite material formed using silicon carbide as an aggregate and silicon as a binder, Preferable examples include cordierite, alumina titanate, sialon, mullite, silicon nitride, zirconium phosphate, zirconia, titania, alumina, silica, LAS (lithium aluminum silicate) or a combination thereof. The material of the plugging portion is more preferably the same as the material of the partition wall. The depth of the plugged portion that enters the cell from the end face of the honeycomb structure is not particularly limited, but the viewpoint of reducing the pressure loss, increasing the effective catalyst area when supporting the catalyst, and increasing the strength From 1 to 20 mm is preferable. The honeycomb structure 100 of the present embodiment includes a plugged portion at the other end portion of the predetermined cell and one end portion of the remaining cells, but the position where each cell includes the plugged portion is this. It is not limited to. That is, in the honeycomb structure of the present invention, a predetermined cell having an opening on one end face side and a remaining cell having an opening on the other end side are opened from the opening on one end face side of the predetermined cell. What is necessary is just to provide the plugging part formed so that the fluid which flowed in may permeate | transmit the partition and flow out from the opening part of the other end surface side of the remaining cell. That is, the plugging portion may be formed not only in the end portion of the cell but also in the cell.

  The honeycomb structure 100 of the present embodiment is preferably one in which a catalyst component is supported on the partition walls 1. By supporting the catalyst on the partition wall 1, combustion of PM during filter regeneration can be promoted or harmful substances in the exhaust gas can be purified. As a method for supporting the catalyst component on the partition wall, for example, a solution containing the catalyst component is impregnated with a powder made of a heat-resistant inorganic oxide having a high specific surface area such as alumina powder, and then dried and fired. A method in which a powder containing components is obtained, a catalyst slurry is prepared by adding alumina sol or water to the powder, a honeycomb segment or a honeycomb structure is immersed therein, the slurry is coated, and then dried and fired. Can be used.

  As the catalyst component, it is preferable to use at least one noble metal selected from the group consisting of Pt, Rh and Pd. The amount of these noble metals supported is preferably 0.3 to 3.5 g / L per unit volume of the honeycomb structure.

  Next, the manufacturing method of one embodiment of the honeycomb structure of the present invention will be described. The honeycomb structure of the present embodiment can be manufactured, for example, by the following method, but the method of manufacturing the honeycomb structure of the present embodiment is not limited to the following method.

  First, a honeycomb formed body is manufactured by a known method. In forming the honeycomb formed body, a predetermined ceramic raw material, a dispersant, a pore former, a binder, and the like are used as a forming raw material, and the forming raw material is mixed and kneaded to prepare a clay. As a ceramic raw material, it is preferable to use a ceramic material that becomes a ceramic as a material constituting the honeycomb structure of the present invention by firing. A well-known thing can be used about a dispersing agent etc.

  There is no restriction | limiting in particular as a method of knead | mixing a shaping | molding raw material and preparing a clay, For example, the method of using a kneader, a vacuum clay kneader, etc. can be mentioned.

  Next, the obtained clay is formed into a honeycomb shape to produce a honeycomb formed body. There is no restriction | limiting in particular as a method of producing a honeycomb molded object, Conventionally well-known shaping | molding methods, such as extrusion molding, injection molding, and press molding, can be used. Among them, a preferable example is a method of extruding the clay prepared as described above using a die having a desired cell shape, partition wall thickness, and cell density.

  Next, plugging portions are formed at both ends of the obtained honeycomb formed body. The method for forming the plugged portions is not particularly limited. For example, first, one end face is alternately covered with cell openings, and a mask is applied in a checkered pattern. Then, a plugging slurry containing a cordierite forming raw material, water or alcohol, and an organic binder is stored in a storage container. And the edge part by the side which gave the said mask is immersed in a storage container, a plugging slurry is filled into the opening part of the cell which is not giving the mask, and a plugging part is formed. For the other end, a mask is applied to the cells plugged at one end, and the plugged portion is formed in the same manner as the plugged portion is formed at the one end. As a result, the cells not plugged at the one end are plugged at the other end, and the cells are alternately closed in a checkered pattern at the other end. The plugging may be performed after the honeycomb formed body is fired to form the honeycomb fired body. In this case, a honeycomb structure is obtained by plugging the honeycomb fired body and then firing again.

  Next, it is preferable to prepare a honeycomb dried body by drying the honeycomb formed body on which the plugged portions are formed. The drying method is not particularly limited, and conventionally known drying methods such as hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, freeze drying and the like can be used. Especially, the drying method which combined hot air drying, microwave drying, or dielectric drying is preferable at the point which can dry the whole molded object rapidly and uniformly.

  Next, it is preferable to subject the partition walls of the obtained honeycomb dried body to a surface treatment. Although the method of surface treatment is not limited, for example, the honeycomb dried body is exposed to an air flow mixed with abrasive grains such as alumina and diamond for a certain period of time (the air flow passes through the cells of the honeycomb dried body). Thus, it is preferable to treat the partition wall surfaces in the cells of the honeycomb dried body. Thereby, the partition wall surface can be roughened and a desired state of the partition wall surface can be obtained.

  Moreover, you may perform the surface treatment of a partition, after performing this baking by the following method. In this case, the main body of the dried honeycomb body (or calcined body) (fired body) is pumped through a liquid in which abrasive grains such as alumina and diamond are dispersed, or alumina, diamond and the like. The surface of the partition walls in the cells of the fired body is treated by exposing it to an air stream mixed with abrasive grains for a certain period of time (by allowing the liquid or air stream to pass through the cells of the fired body). It is preferable to obtain.

  Next, the obtained dried honeycomb body is preferably calcined before main firing to produce a calcined body. The “calcination” means an operation for burning and removing organic substances (organic binder, dispersant, pore former, etc.) in the honeycomb formed body. Generally, the combustion temperature of the organic binder is about 100 to 300 ° C., and the combustion temperature of the pore former is about 200 to 800 ° C. Therefore, the calcining temperature may be about 200 to 1000 ° C. Although there is no restriction | limiting in particular as calcination time, Usually, it is about 10 to 100 hours.

  Next, the obtained calcined body is fired (mainly fired) to obtain a honeycomb structure. In the present invention, “main firing” means an operation for sintering and densifying the forming raw material in the calcined body to ensure a predetermined strength. Since the firing conditions (temperature and time) vary depending on the type of molding raw material, appropriate conditions may be selected depending on the type of the raw material. However, when the cordierite raw material is fired, it is fired at 1410 to 1440 ° C. Is preferred. Moreover, it is preferable to bake for about 3 to 10 hours.

  Next, a catalyst is supported on the obtained honeycomb structure. The method for supporting the catalyst is not particularly limited, and the catalyst can be supported by a known method. For example, first, a catalyst slurry containing a predetermined catalyst is prepared. Next, the catalyst slurry is coated on the partition wall surfaces of the honeycomb structure and the inner surfaces of the pores of the partition walls by a method such as a suction method. Then, the honeycomb catalyst body of this embodiment can be manufactured by drying under room temperature or heating conditions.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to these examples.

Example 1
Talc having an average particle diameter of 45 μm, kaolin having an average particle diameter of 10 μm, alumina having an average particle diameter of 5 μm, aluminum hydroxide having an average particle diameter of 3 μm, and fused silica having an average particle diameter of 40 μm are mixed with 40% by mass of talc, 20% by mass of kaolin, A cordierite forming raw material was prepared by mixing 14 mass% of alumina, 16 mass% of aluminum hydroxide and 10 mass% of fused silica. Next, 2 parts by mass of foamed foamed resin composed of an acrylonitrile-methyl methacrylate copolymer, 4 parts by mass of hydroxypropylmethylcellulose, 0.5 parts by mass of potassium laurate, with respect to 100 parts by mass of the cordierite forming raw material, 30 parts by mass of water was mixed and kneaded to make plastic, and this plastic raw material was kneaded with a vacuum kneader to obtain a cylindrical clay. The obtained kneaded material was formed into a honeycomb shape using an extrusion molding machine to obtain a honeycomb formed body. Next, the obtained honeycomb formed body was dielectrically dried and then completely dried by hot air drying, and both end surfaces were cut into predetermined dimensions to obtain a dried honeycomb body.

  A plugged portion was formed on the obtained honeycomb dried body. In the cell opening of one end face of the obtained honeycomb dried body, a mask is alternately applied in a checkered pattern, and the end on the masked side is immersed in a plugging slurry made of a cordierite forming raw material, Plugged portions alternately arranged in a checkered pattern were formed. As the cordierite forming raw material, the one having the same composition as that used for the dried honeycomb body was used. Further, for the other end, a mask is applied to the cells plugged at one end, and the plugged portion is formed in the same manner as the plugged portion is formed at the one end. did.

  Thereafter, the honeycomb fired body was obtained by firing at 1420 ° C. for 4 hours.

  Then, the surface treatment of the partition walls of the honeycomb fired body was performed. A water-resistant fan was placed in the openable / closable tube, the honeycomb fired body was fixed in the blowing direction, and a water flow was passed through the cells of the honeycomb fired body. Then, diamond abrasive grains were dispersed between the fan and the honeycomb fired body (dispersed in the water stream), and the partition wall surface of the honeycomb fired body was etched (surface treatment) with a slurry in which the diamond abrasive grains were dispersed in the water stream. After the etching treatment, it was sufficiently washed with water and dried to obtain a honeycomb structure. The slurry for surface treatment was prepared by mixing 20 parts by mass of diamond abrasive grains having an average particle diameter of 4 μm with water (100 parts by mass).

The obtained honeycomb structure had a cylindrical shape with a bottom diameter of 144 mm and a length of 152 mm, and the cell density was 46.5 cells / cm ² (300 cpsi). The partition wall thickness was 300 μm, the average pore diameter was 20 μm, and the porosity was 50%. The average pore diameter and porosity are values measured with a commercially available mercury porosimeter.

With respect to the obtained honeycomb structure, the partition wall surface area ratio, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, and the average interval S (average interval S) of the local peaks on the partition wall surface were as follows. ), Thermal diffusivity (cm ² / sec), wrinkled pressure loss (pressure loss) and strength. The results are shown in Table 1. In Table 1, the column “S / Ra” indicates the value of the ratio of the average interval S of the local peaks on the partition wall surface to the arithmetic average surface roughness Ra on the partition wall surface.

(Surface area ratio)
The surface of the partition wall is measured with micro CT (trade name: “skyscan 1172” manufactured by Toyo Technica Co., Ltd.), and the CT image is reconstructed into three-dimensional solid data to recognize the surface of the partition wall. The partition surface area is calculated. And the value of the ratio with respect to an area when the surface of the said partition is assumed flat is calculated | required.

(Arithmetic mean surface roughness Ra (μm))
Measurement is performed using a surface roughness measuring device (Taylor Hobson, FTS-S4C type). The calculation method conforms to JIS B0601. A 2 μm conical diamond is used for the tip measurement part.

(Average distance S (μm) between local peaks)
Measurement is performed using a surface roughness measuring device (Taylor Hobson, FTS-S4C type). The calculation method conforms to JIS B0601. A 2 μm conical diamond is used for the tip measurement part.

(Thermal diffusivity (cm ² / s))
The thermal diffusivity is a value obtained by dividing the thermal conductivity by the product of the density of the substance and the specific heat, and is measured by a laser flash method (JIS R1611).

(Pressure loss with flange)
Rings with an inner diameter (diameter) of 130 mm are pressed against both end faces of the honeycomb structure, and soot (soot) generated by the soot generator flows into the honeycomb structure with a diameter of 130 mm through the rings, 4 g / L of soot is collected. Thereafter, with the honeycomb structure collecting soot, air of 2.27 Nm ³ / min is flowed, the pressure difference before and after the filter is measured, and the pressure loss in the state where soot is collected is evaluated.

(Strength)
Five cordierite flat plates having a width of 30 mm, a thickness of 7 mm, and a length of 150 mm are produced by the same method as that for producing the honeycomb structure. The surface treatment of the cordierite flat plate (corresponding to the surface treatment of the partition walls) was performed after firing and cutting. The cordierite flat plate obtained is measured for four-point bending strength according to JIS R1601.

(Example 2)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle size of diamond abrasive grains contained in the slurry used for the surface treatment was 3.1 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. . In the same manner as in Example 1, the partition wall surface area, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of local peaks on the partition wall surface, and the thermal diffusivity The pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

(Example 3)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle size of the diamond abrasive grains contained in the slurry used for the surface treatment was 2.2 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. . In the same manner as in Example 1, the surface area ratio of the partition wall surface, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of the local peaks on the partition wall surface, The thermal diffusivity, pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

Example 4
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle size of diamond abrasive grains contained in the slurry used for the surface treatment was 1.9 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. did. In the same manner as in Example 1, the surface area ratio of the partition wall surface, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of the local peaks on the partition wall surface, The thermal diffusivity, pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

(Example 5)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle size of diamond abrasive grains contained in the slurry used for the surface treatment was 1.4 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. did. In the same manner as in Example 1, the surface area ratio of the partition wall surface, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of the local peaks on the partition wall surface, The thermal diffusivity, pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

(Comparative Example 1)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle size of diamond abrasive grains contained in the slurry used for the surface treatment was set to 5.2 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. did. In the same manner as in Example 1, the surface area ratio of the partition wall surface, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of the local peaks on the partition wall surface, The thermal diffusivity, pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

(Comparative Example 2)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the average particle diameter of diamond abrasive grains contained in the slurry used for the surface treatment was 1 μm as the surface treatment conditions for the partition walls of the honeycomb fired body. In the same manner as in Example 1, the surface area ratio of the partition wall surface, the arithmetic average surface roughness Ra (surface roughness Ra) of the partition wall surface, the average interval S (average interval S) of the local peaks on the partition wall surface, The thermal diffusivity, pressure loss with pressure (pressure loss) and strength were measured. The obtained results are shown in Table 1.

  As shown in Table 1, it can be seen that the honeycomb structures of Examples 1 to 5 are excellent in thermal diffusivity, wrinkled pressure loss and strength. It can be seen that the honeycomb structure of Comparative Example 1 has a low strength because the surface area ratio and the surface roughness Ra are large. It can be seen that the honeycomb structure of Comparative Example 2 has a small surface area ratio and surface roughness Ra, and thus has a low thermal diffusivity and a large wrinkle pressure loss.

  The honeycomb structure of the present invention is suitable for collecting and removing particulate matter contained in exhaust gas discharged from, for example, automobile engines, construction machine engines, industrial stationary engines, and combustion equipment. Used.

1, 1a: partition wall, 2: cell, 3: partition wall surface, 4: convex portion, 11: one end surface, 12: the other end surface, 100: honeycomb structure, A: region.

Claims (8)

A porous partition wall that partitions and forms a plurality of cells penetrating from one end face to the other end face that serves as a fluid flow path;
The value of the ratio of the surface area of the partition wall to the surface area of the partition wall when the surface of the partition wall is planar is 1.5 to 5.0,
The arithmetic average surface roughness of the surface of the partition wall is 1.0 to 20.0 μm,
A honeycomb structure having an average interval between local peaks on the surface of the partition walls of 10 to 140 μm.   The honeycomb structure according to claim 1, wherein a value of a ratio of an average interval of local peaks to an arithmetic average surface roughness of a surface of the partition wall is 3 to 35.   The honeycomb structure according to claim 1 or 2, wherein a value of a ratio of a surface area of the partition wall to a surface area of the partition wall when the surface of the partition wall is planar is uniform as a whole.   The honeycomb structure according to any one of claims 1 to 3, wherein an arithmetic average surface roughness of a surface of the partition wall is uniform overall.   The honeycomb structure according to any one of claims 1 to 4, wherein an average interval between local peaks on the surface of the partition walls is uniform overall.   The honeycomb structure according to any one of claims 1 to 5, further comprising a plugged portion at one open end of the predetermined cell and the other open end of the remaining cell.   The honeycomb structure according to claim 6, wherein an opening ratio of the inlet side end face is larger than an opening ratio of the outlet side end face.   The honeycomb structure according to any one of claims 1 to 7, wherein a catalyst component is supported on the partition walls.

Images