Porous composite

Patent metadata

Field	Value
Publication number	US-11883770-B2
Application number	US-202117445340-A
Country	US
Kind code	B2
Filing date	Aug 18, 2021
Priority date	Mar 28, 2019
Publication date	Jan 30, 2024
Grant date	Jan 30, 2024

Abstract

In a porous composite, a base material has a honeycomb structure whose inside is partitioned into a plurality of cells. In the plurality of cells, a plurality of first cells whose one ends in the longitudinal direction are sealed, and a plurality of second cells whose other ends in the longitudinal direction are sealed are arranged alternately. A collection layer covers inner surfaces of the plurality of first cells. An overall Sa that is an arithmetical mean height Sa indicating a surface roughness of a surface of the collection layer in the plurality of first cells is greater than or equal to 0.1 μm and less than or equal to 12 μm. An overall mean thickness that is a mean thickness of the collection layer in the plurality of first cells is greater than or equal to 10 μm and less than or equal to 40 μm.

First claim

The invention claimed is:

1. A porous composite comprising:
a porous base material; and
a porous collection layer formed on said base material,
wherein said base material has a honeycomb structure whose inside is partitioned by a partition wall into a plurality of cells extending in a longitudinal direction,
said plurality of cells include a plurality of first cells whose one ends in the longitudinal direction are sealed, and a plurality of second cells whose other ends in the longitudinal direction are sealed, said plurality of first cells and said plurality of second cells being arranged alternately,
said collection layer covers inner surfaces of said plurality of first cells,
an overall Sa that is an arithmetical mean height Sa indicating a surface roughness of a surface of said collection layer in said plurality of first cells is greater than or equal to 0.1 μm and less than or equal to 12 μm, and
an overall mean thickness that is a mean thickness of said collection layer in said plurality of first cells is greater than or equal to 10 μm and less than or equal to 40 μm.

2. The porous composite according to claim 1 , wherein
an outlet-side Sa that is an arithmetical mean height Sa of the surface of said collection layer at end portions in said plurality of first cells is greater than or equal to 0.1 μm and less than or equal to 15 μm, said end portions being located on a side of said one ends in the longitudinal direction.

3. The porous composite according to claim 2 , wherein
an outlet-side mean thickness that is a mean thickness of said collection layer at said end portions in said plurality of first cells is greater than or equal to 35 μm and less than or equal to 50 μm.

4. The porous composite according to claim 1 , wherein
said collection layer in said plurality of first cells has a mean pore diameter greater than or equal to 0.1 μm and less than or equal to 20 μm.

5. The porous composite according to claim 1 , wherein
said collection layer in said plurality of first cells has a porosity greater than or equal to 50% and less than or equal to 90%.

6. The porous composite according to claim 1 , wherein
an aggregate of said collection layer in said plurality of first cells has a mean particle diameter greater than or equal to 0.1 μm and less than or equal to 5 μm.

7. The porous composite according to claim 1 , wherein
said collection layer in said plurality of first cells contains at least one of silicon carbide, cordierite, mullite, aluminum oxide, silicon oxide, titanium oxide, zirconium oxide, iron oxide, and cerium oxide.

8. The porous composite according to claim 1 , wherein
said collection layer doesn't exist in said plurality of second cells.

9. The porous composite according to claim 1 , wherein
a chief material of said partition wall is cordierite,
said partition wall has a mean pore diameter greater than or equal to 5 μm and less than or equal to 30 μm, and
said partition wall has a porosity greater than or equal to 30% and less than or equal to 70%.

10. The porous composite according to claim 1 , being a gasoline particulate filter for collecting particulate matter in an exhaust gas emitted from a gasoline engine.

Assignees

• Ngk Insulators Ltd

Inventors

• Nakashima Takuya
• Takeno Shogo
• Izumi Yunie

Classifications

• B01D46/2429 Primary

  of the honeycomb walls or cells · CPC title

• B01D39/2068

  Other inorganic materials, e.g. ceramics · CPC title

• B01D46/247

  of the cells · CPC title

• B01D46/248

  Structures comprising laminated bodies or discs · CPC title

• B01D46/2462

  the outer peripheral sealing · CPC title