Exhaust gas purifying filter

Patent metadata

Field	Value
Publication number	US-9273574-B2
Application number	US-201013499002-A
Country	US
Kind code	B2
Filing date	Sep 30, 2010
Priority date	Sep 30, 2009
Publication date	Mar 1, 2016
Grant date	Mar 1, 2016

Abstract

According to the present invention, there is provided an exhaust gas purifying filter capable of effectively removing collected particulate matter. An exhaust gas purifying filter of the present invention includes an inflow surface into which exhaust gas including particulate matter flows, an exhaust surface which exhausts purified gas, and a filter substrate which is constructed of a porous body, wherein the filter substrate includes porous partitions and gas passages which are enclosed by the partitions, and a porous film, which includes silicon carbide and pores having a smaller pore diameter than the pores of the partitions, is provided on the surface of the partitions, and a silicon dioxide layer is formed on at least an outer surface portion of the porous film.

First claim

We claim:

1. An exhaust gas purifying filter comprising
an inflow section into which exhaust gas including particulate matter flows,
an exhaust section in which purified gas exits the exhaust gas purifying filter, and
a filter substrate which is constructed of a porous body,
wherein the filter substrate includes porous partitions and gas passages which are enclosed by the partitions,
a porous film, which includes silicon carbide particles and pores having a smaller pore diameter than the pores of the partitions, is provided on the surface of the partitions, the pores existing in an outer surface portion and an inner portion of the porous film,
a silicon dioxide layer is formed on a surface of silicon carbide particles which configure the outer surface portion of the porous film,
the gas passage is constructed of a structure in which an upstream side end and a downstream side end are alternately occluded when viewed from a flow direction of the exhaust gas, a cell in which the upstream side end is opened is an inflow cell, and the porous film is formed on an inner wall surface of the porous partition constructing the inflow cell,
a thickness of the silicon dioxide layer is 0.5 nm or more and 30 nm or less, and wherein the porous film is obtained by oxidizing a sintered body of the silicon carbide particles.

2. The exhaust gas purifying filter according to claim 1 ,
wherein the silicon dioxide layer is formed on a surface of silicon carbide particles which configure the outer surface portion of the porous film and on a surface of silicon carbide particles of the inner portions of the porous film which contacts the exhaust gas when the exhaust gas flows in the porous film.

3. The exhaust gas purifying filter according to claim 1 ,
wherein the silicon dioxide layer is a layer which is formed by oxidizing a surface of the silicon carbide particles configuring the porous film.

4. The exhaust gas purifying filter according to claim 1 ,
wherein the silicon dioxide layer is a layer which is formed of a silane compound which is coated, impregnated, or adsorbed on the porous film.

5. The exhaust gas purifying filter according to claim 1 ,
wherein the porous film is obtained by sintering silicon carbide particles which include the silicon dioxide layer on the surface.

6. The exhaust gas purifying filter according to claim 2 ,
wherein the silicon dioxide layer is a layer which is formed by oxidizing a surface of the silicon carbide particles configuring the porous film.

7. The exhaust gas purifying filter according to claim 2 ,
wherein the silicon dioxide layer is a layer which is formed of a silane compound which is coated, impregnated, or adsorbed on the porous film.

8. The exhaust gas purifying filter according to claim 2 ,
wherein the porous film is obtained by sintering silicon carbide particles which include the silicon dioxide layer on the surface.

9. The exhaust gas purifying filter according to claim 1 ,
wherein an average pore diameter of the porous film is more than 0.05 μm and 3 μm or less.

10. The exhaust gas purifying filter according to claim 2 ,
wherein an average pore diameter of the porous film is more than 0.05 μm and 3 μm or less.

11. The exhaust gas purifying filter according to claim 1 ,
wherein the filter substrate is a honeycomb structure which is configured of heat-resistant porous ceramic selected from the group consisting of silicon carbide, cordierite, aluminum titanate, and silicon nitride.

12. The exhaust gas purifying filter according to claim 1 ,
wherein the particles which form the porous film is any one of (1) the particles which are configured of only the silicon carbide, (2) the particles of the silicon carbide complexed with the components other than the silicon carbide, an element of at least one kind selected from group 3 to group 14 or an oxide, a carbide, and a nitride thereof, (3) a composite of the particles which are configured of only the silicon carbide and the particles which are configured of the components other than the silicon carbide, an element of at least one kind selected from group 3 to group 14 or an oxide, a carbide, and a nitride thereof, and (4) a composite of the particles of the silicon carbide complexed with the components other than the silicon carbide, an element of at least one kind selected from group 3 to group 14 or an oxide, a carbide, and a nitride thereof and the particles which is configured of the components other than the silicon carbide, an element of at least one kind selected from group 3 to group 14 or an oxide, a carbide, and a nitride thereof.

13. The exhaust gas purifying filter according to claim 1 ,
wherein the silicon dioxide layer is present within a range of from 2 volume % to 50 volume % in terms of a volume ratio of the silicon dioxide layer in the porous film.

14. The exhaust gas purifying filter according to claim 1 ,
wherein the thickness of the porous film is 60 μm or less in a portion which is planarly overlapped with a hole portion which is included in the partition in the inner wall surface, and ranges from 5 μm to 60 μm in a place which is planarly overlapped with a solid portion of the partition in the inner wall surface.

Assignees

• Tanaka Masamichi
• Kishimoto Atsushi
• Neya Tadashi
• Ishizaki Keita
• Sumitomo Osaka Cement Co Ltd
• Honda Motor Co Ltd

Inventors

• Tanaka Masamichi
• Kishimoto Atsushi
• Neya Tadashi
• Ishizaki Keita

Classifications

• F01N3/0222 Primary

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

• B01D2275/30

  Porosity of filtering material · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title

• Y02T10/20

  Cross-Sectional Technologies · mapped topic

• B01D2046/2437

  Operations & Transport · mapped topic