Porous complex and method of producing porous complex

Patent metadata

Field	Value
Publication number	US-2026001018-A1
Application number	US-202519321392-A
Country	US
Kind code	A1
Filing date	Sep 8, 2025
Priority date	Mar 29, 2023
Publication date	Jan 1, 2026
Grant date	—

Abstract

A porous complex includes a base material that is a porous sintered body having air permeability, and a collection layer that is a sintered body provided on the base material and having air permeability, the collection layer exhibiting a dense foam network structure in a longitudinal section. The collection layer is formed by depositing and firing porous particles on the base material. This suppresses the penetration of the collection layer into pores of the base material and allows the porous complex to achieve high collection efficiency and low pressure loss.

First claim

1 . A porous complex comprising:
a base material that is a porous sintered body having air permeability; and a collection layer that is a sintered body provided on said base material and having air permeability, said collection layer exhibiting a dense foam network structure in a longitudinal section, wherein said collection layer has a porosity of higher than or equal to 75% and lower than or equal to 95% and a mean pore diameter of greater than or equal to 0.3 μm and less than or equal to 1.5 μm.

2 . The porous complex according to claim 1 , wherein
said base material has a mean pore diameter of greater than or equal to 10 μm and less than or equal to 30 μm.

3 . The porous complex according to claim 1 , wherein
said collection layer has a mean membrane thickness of greater than or equal to 20 μm and less than or equal to 45 μm.

4 . The porous complex according to claim 1 , wherein
said collection layer is formed of alumina.

5 . The porous complex according to claim 1 , wherein
said collection layer contains silicon carbide, and said base material is cordierite.

6 . The porous complex according to claim 1 ,
the porous complex being a particulate filter that collects particulate matter contained in an exhaust gas exhausted from a gasoline engine or a diesel engine.

7 . A method of producing a porous complex, comprising:
a) generating an aggregate of intermediate particles by drying droplets that contain pore-forming materials and material particles smaller than said pore-forming materials, said intermediate particles being particles where said material particles are present between said pore-forming materials that are densely gathered; b) forming a porous intermediate by pre-firing the aggregate of said intermediate particles; c) obtaining porous particles by disintegration of said porous intermediate; d) preparing a base material that is a porous sintered body having air permeability; e) depositing said porous particles on said base material; and f) forming a collection layer on said base material by firing said porous particles.

8 . The method of producing a porous complex according to claim 7 , wherein
said pore-forming materials have a mean particle diameter of greater than or equal to 500 nm and less than or equal to 10 μm, and said material particles have a specific surface area of higher than or equal to 150 m 2 /g and lower than or equal to 400 m 2 /g or a mean particle diameter of greater than or equal to 10 nm and less than or equal to 50 nm.

9 . The method of producing a porous complex according to claim 7 , wherein
said base material has a mean pore diameter of greater than or equal to 10 μm and less than or equal to 30 μm, and said porous particles have a mean particle diameter of greater than or equal to 15 μm and less than or equal to 40 μm.

10 . The method of producing a porous complex according to claim 9 , wherein
in said operation e), said porous particles are deposited to a thickness of greater than or equal to 25 μm and less than or equal to 50 μm on said base material.

11 . The method of producing a porous complex according to claim 7 , wherein
said material particles are alumina particles.

Assignees

• Ngk Insulators Ltd

Inventors

• Izumi Yunie
• Hidaka Kenichi
• Noguchi Mimika
• Miura Akihiro

Classifications

• F01N2330/48

  characterised by the number of flow passages, e.g. cell density · CPC title

• F01N3/0222 Primary

  the structure being monolithic, e.g. honeycombs · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title

• B01D2239/1241

  Particle diameter · CPC title

• B01D2239/1216

  Pore size · CPC title