Porous body, honeycomb filter, microstructure analysis method, program for same, and microstructure analyzer

Patent metadata

Field	Value
Publication number	US-10540775-B2
Application number	US-201715467069-A
Country	US
Kind code	B2
Filing date	Mar 23, 2017
Priority date	Mar 31, 2016
Publication date	Jan 21, 2020
Grant date	Jan 21, 2020

Abstract

In a porous body, a surface layer thickness Ts takes a relatively small value satisfying P≥0.54 Ts (formula (1)), the surface layer thickness Ts being derived by a microstructure analysis using the porous-body data that is prepared through three-dimensional scanning of a region including a surface (inflow plane 61 ) of the porous body. Here, P denotes a porosity [%] of the porous body, and 0%<P<100% and 0 μm<Ts are assumed. The surface layer thickness Ts is derived as a distance in a thickness direction (X direction) between a surface-layer region start plane 92 in which a straight-pore opening ratio becomes 98% or less for the first time and a surface-layer region end plane 93 in which the straight-pore opening ratio becomes 1% or less for the first time.

First claim

What is claimed is:

1. A ceramic honeycomb filter comprising a porous body including a porous base material having a major surface and a porous surface layer formed on the major surface of the base material,
wherein the porous body has a porosity P [%] in the range of 25%<P<70% and a thickness T in the range of from 100 μm or more to 600 μm or less and the surface layer has a thickness Ts>0 μm,
wherein the surface layer thickness Ts and the porosity P of the porous body satisfy a following formula (1):
P≥0.54 Ts  (1)

wherein, the surface layer thickness Ts is determined by collecting porous-body data in which positional information providing a position of a voxel is associated with voxel type information including information that allows determination as to whether the voxel is a spatial voxel representing a space or an object voxel representing an object is prepared through three-dimensional scanning of a region including a surface of the porous body, and then performing the following steps using the porous-body data;
(a) a step of defining an imaginary surface that is in contact with at least one object voxel present in the surface of the porous body,
(b) a step of identifying, as surface layer straight-pore voxels, spatial voxels in contact with the imaginary surface and spatial voxels that continuously lie from the imaginary surface toward an inside of the porous body in a thickness direction, which is perpendicular to the imaginary surface and which extends toward the inside of the porous body, and
(c) a step of successively shifting the imaginary surface in the thickness direction to define the imaginary surface after each shift as an imaginary reference surface, identifying, as a surface-layer region start plane, an imaginary reference plane in which a straight-pore opening ratio denoting a proportion of the surface layer straight-pore voxels occupying the imaginary reference surface becomes 98% or below for first time, identifying, as a surface-layer region end plane, an imaginary reference plane in which the straight-pore opening ratio becomes 1% or below for first time, and deriving, as a surface layer thickness Ts, a distance between the surface-layer region start plane and the surface-layer region end plane in the thickness direction.

2. The ceramic honeycomb filter according to claim 1 , wherein a following formula (2) is satisfied:
P≥0.63 Ts  (2).

3. The ceramic honeycomb filter according to claim 1 , further comprising a plurality of partitions, each of which includes the porous body, and which form a plurality of cells serving as paths of a fluid,
wherein the major surface of the porous body constitutes an inflow plane through which the fluid flows into the partition from the cell.

4. The ceramic honeycomb filter according to claim 1 , wherein the difference between the porous body thickness T and the surface layer thickness Ts (T−Ts) is 100 μm or more and 300 μm or less.

5. The ceramic honeycomb filter according to claim 1 , wherein the ratio between the surface layer thickness Ts and the porous body thickness T (Ts/T) is 0.1 or more and 0.5 or less.

Assignees

• Ngk Insulators Ltd

Inventors

• Sakai Ayaka
• Sakashita Satoshi
• SOKAWA Shingo
• Tajima Yuichi

Classifications

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B38/0006 Primary

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title

• F01N3/022

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01D39/2093 Primary

  Ceramic foam · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title