Honeycomb filter

Patent metadata

Field	Value
Publication number	US-9700842-B2
Application number	US-201514840466-A
Country	US
Kind code	B2
Filing date	Aug 31, 2015
Priority date	Sep 4, 2014
Publication date	Jul 11, 2017
Grant date	Jul 11, 2017

Abstract

In a cross section perpendicular to a central axis direction of the honeycomb substrate, cells are arranged so that a periphery of an inlet plugged cell is surrounded with four rectangular outlet plugged cells and four square outlet plugged cells, and in the cross section, a partition wall center distance a, a partition wall center distance b and a partition wall thickness t satisfy the following equation (1). Additionally, an amount of a catalyst per unit volume of partition walls which is loaded onto the partition walls defining the rectangular outlet plugged cells and the inlet plugged cells is larger than an amount of a catalyst per unit volume of the partition walls which is loaded onto the partition walls defining the rectangular outlet plugged cells and the square outlet plugged cells

0.95< b/at <1.90  (1).

First claim

What is claimed is:

1. A honeycomb filter comprising:
a honeycomb substrate having porous partition walls defining a plurality of cells which extend from an inflow end face as an end face on an exhaust gas inflow side to an outflow end face as an end face on an exhaust gas outflow side and which become through channels for a fluid; and
plugging portions disposed in end portions of the plurality of cells on one of an inflow end face side and an outflow end face side,
wherein the cells of part of the plurality of cells are inlet plugged cells whose end portions are closed by the plugging portions on the inflow end face side of the honeycomb substrate, and the residual cells among the plurality of cells are outlet plugged cells whose end portions are closed by the plugging portions on the outflow end face side of the honeycomb substrate,
the honeycomb filter further comprising:
a catalyst which is loaded onto at least one of the surface of each of the partition walls defining the outlet plugged cells and an inner portion of each of pores of the partition walls, to purify the exhaust gas,
wherein the plurality of cells are arranged so that a periphery of one of the inlet plugged cells is surrounded with eight of the outlet plugged cells in a cross section perpendicular to a central axis direction of the honeycomb substrate,
a shape of an open end of each of the inlet plugged cells in the cross section is a square in which a length of one side is L 1 ,
the outlet plugged cells include square outlet plugged cells and rectangular outlet plugged cells,
a shape of an open end of each of the square outlet plugged cells in the cross section is a square in which a length of one side is L 2 , and L 2 is smaller than L 1 ,
a shape of an open end of each of the rectangular outlet plugged cells in the cross section is a rectangle in which a length of a long side is L 1 and a length of a short side is L 2 ,
in each diagonal direction of the square in which the length of the one side is L 1 in the cross section, four of the square outlet plugged cells are arranged adjacent to the inlet plugged cell,
in a linear direction perpendicular to each side of the square in which the length of the one side is L 1 in the cross section, four of the rectangular outlet plugged cells are arranged so that the cells are adjacent to the inlet plugged cell and so that the long side of the rectangle in the cross section is parallel to one side of the square in which the length of the one side is L 1 in the cross section,
a partition wall thickness of the partition walls of the honeycomb substrate is defined as t,
a distance from an intermediate point of the thickness of the partition wall defining one side of the open end of the square in which the length of the one side is L 1 in the cross section of the honeycomb substrate to an intermediate point of the thickness of the partition wall defining a side facing the one side is defined as a partition wall center distance a,
a distance from an intermediate point of the thickness of the partition wall defining a long side of the open end of the rectangle in the cross section of the honeycomb substrate to an intermediate point of the thickness of the partition wall defining a side facing the long side is defined as a partition wall center distance b,
the partition wall center distance a, the partition wall center distance b and the partition wall thickness t satisfy the following equation (1), and
an amount of the catalyst per unit volume of the partition walls which is loaded onto the partition walls defining the rectangular outlet plugged cells and the inlet plugged cells is larger than an amount of the catalyst per unit volume of the partition walls which is loaded onto the partition walls defining the rectangular outlet plugged cells and the square outlet plugged cells,
0.95< b/at< 1.90  (1).

2. The honeycomb filter according to claim 1 ,
wherein the partition wall defining the rectangular outlet plugged cell and the inlet plugged cell has a high noble metal loading region where a large amount of a noble metal as the catalyst is loaded, and the partition wall defining the rectangular outlet plugged cell and the square outlet plugged cell has a low noble metal loading region where a smaller amount of the noble metal is loaded than in the high noble metal loading region.

3. The honeycomb filter according to claim 2 ,
wherein the partition wall center distance a is 1.4 mm or more and 2.4 mm or less.

4. The honeycomb filter according to claim 3 ,
wherein the partition wall center distance b is 0.22 mm or more and 1.08 mm or less.

5. The honeycomb filter according to claim 2 ,
wherein the partition wall center distance b is 0.22 mm or more and 1.08 mm or less.

6. The honeycomb filter according to claim 1 ,
wherein the partition wall center distance a is 1.4 mm or more and 2.4 mm or less.

7. The honeycomb filter according to claim 6 ,
wherein the partition wall center distance b is 0.22 mm or more and 1.08 mm or less.

8. The honeycomb filter according to claim 1 ,
wherein the partition wall center distance b is 0.22 mm or more and 1.08 mm or less.

9. The honeycomb filter according to claim 1 ,
wherein the partition wall thickness t is 0.16 mm or more and 0.34 mm or less.

10. The honeycomb filter according to claim 1 ,
wherein a cell density of the honeycomb substrate is from 100 to 650 cells/cm 2 .

11. The honeycomb filter according to claim 1 ,
wherein an open frontal area of the outlet plugged cells on the inflow end face side is from 13 to 50%.

12. The honeycomb filter according to claim 1 ,
wherein a porosity of the partition walls is from 28 to 70%.

13. The honeycomb filter according to claim 1 ,
wherein a catalyst amount on an inflow end portion side of the partition wall defining the outlet plugged cell is larger than a catalyst amount of an outflow end portion side of the partition wall defining the outlet plugged cell.

14. The honeycomb filter according to claim 1 ,
wherein the catalyst is a catalyst including at least one selected from the group consisting of platinum, palladium, rhodium and ruthenium.

Assignees

• Ngk Insulators Ltd

Inventors

• Miyairi Yukio
• Kumazawa Kazuhiko
• Hirakawa Toshihiro
• Yamada Toshio

Classifications

• B01D2255/1023

  Palladium · CPC title

• B01J37/0228

  in several steps · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title

• B01D2255/1025

  Rhodium · CPC title

• B01D2255/9155

  Wall flow filters · CPC title