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WO2009118808A1 - Structure en nid d'abeilles - Google Patents

Structure en nid d'abeilles Download PDF

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Publication number
WO2009118808A1
WO2009118808A1 PCT/JP2008/055455 JP2008055455W WO2009118808A1 WO 2009118808 A1 WO2009118808 A1 WO 2009118808A1 JP 2008055455 W JP2008055455 W JP 2008055455W WO 2009118808 A1 WO2009118808 A1 WO 2009118808A1
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WO
WIPO (PCT)
Prior art keywords
honeycomb fired
fired body
honeycomb
cross
honeycomb structure
Prior art date
Application number
PCT/JP2008/055455
Other languages
English (en)
Japanese (ja)
Inventor
大野一茂
尾久和丈
石川茂治
Original Assignee
イビデン株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by イビデン株式会社 filed Critical イビデン株式会社
Priority to PCT/JP2008/055455 priority Critical patent/WO2009118808A1/fr
Priority to EP10153599A priority patent/EP2196644B1/fr
Priority to EP10153622A priority patent/EP2196645B1/fr
Priority to AT08291234T priority patent/ATE542985T1/de
Priority to EP10153575A priority patent/EP2196643B1/fr
Priority to EP08291234A priority patent/EP2113643B1/fr
Priority to AT10153622T priority patent/ATE523667T1/de
Priority to AT10153575T priority patent/ATE517236T1/de
Priority to AT10153599T priority patent/ATE517237T1/de
Priority to KR1020090009609A priority patent/KR101046904B1/ko
Priority to CN2009100063531A priority patent/CN101543706B/zh
Priority to US12/395,939 priority patent/US20090239028A1/en
Publication of WO2009118808A1 publication Critical patent/WO2009118808A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2478—Structures comprising honeycomb segments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2455—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the whole honeycomb or segments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2484—Cell density, area or aspect ratio
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/249—Quadrangular e.g. square or diamond
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2498—The honeycomb filter being defined by mathematical relationships
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63424—Polyacrylates; Polymethacrylates
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    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/003—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts
    • C04B37/005—Joining burned ceramic articles with other burned ceramic articles or other articles by heating by means of an interlayer consisting of a combination of materials selected from glass, or ceramic material with metals, metal oxides or metal salts consisting of glass or ceramic material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
    • B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
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    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5445—Particle size related information expressed by the size of the particles or aggregates thereof submicron sized, i.e. from 0,1 to 1 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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    • C04B2235/5463—Particle size distributions
    • C04B2235/5472—Bimodal, multi-modal or multi-fraction
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/06—Oxidic interlayers
    • C04B2237/062—Oxidic interlayers based on silica or silicates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/04—Ceramic interlayers
    • C04B2237/06—Oxidic interlayers
    • C04B2237/064—Oxidic interlayers based on alumina or aluminates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/36—Non-oxidic
    • C04B2237/365—Silicon carbide
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2340/00—Dimensional characteristics of the exhaust system, e.g. length, diameter or volume of the apparatus; Spatial arrangements of exhaust apparatuses
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to a honeycomb structure.
  • particulate matter contained in exhaust gas discharged from internal combustion engines such as buses and trucks and construction machinery and the like causes harm to the environment and the human body. It has become.
  • various honeycomb structures made of porous ceramics have been proposed as filters capable of collecting particulates in exhaust gas and purifying the exhaust gas.
  • a honeycomb structure for example, a honeycomb structure manufactured by binding a plurality of square pillar-shaped honeycomb fired bodies through an adhesive layer and then cutting them into a predetermined shape has been proposed.
  • a honeycomb fired body having a quadrangular cross-sectional shape is located at the center, and a honeycomb fired body having a smaller cross-sectional area than the honeycomb fired body at the center is located at the outer periphery.
  • honeycomb fired body having a quadrangular cross-sectional shape is located in the center in a cross section perpendicular to the longitudinal direction, and the honeycomb fired body at the outer periphery is separated from the honeycomb fired body in the center portion.
  • a honeycomb structure in which a honeycomb fired body having a large area is located has been proposed (see, for example, Patent Document 2).
  • the honeycomb structure When the honeycomb structure is used as an exhaust gas purification filter, the high-temperature exhaust gas discharged from the internal combustion engine flows into the cells of the honeycomb structure. At this time, since a large amount of heat is applied to the honeycomb fired body located in the central portion, the temperature of the honeycomb fired body located in the central portion is likely to increase compared to the honeycomb fired body located in the outer peripheral portion.
  • a honeycomb structure in which a plurality of honeycomb fired bodies are bundled via an adhesive layer (hereinafter also referred to as an aggregated honeycomb structure)
  • the heat conduction of the adhesive layer is usually higher than that of the honeycomb fired body. Therefore, heat conduction is inhibited by the adhesive layer.
  • the temperature difference between the central portion and the outer peripheral portion tends to increase.
  • a honeycomb fired body whose cross-sectional area is sufficiently smaller than that of the honeycomb fired body having a central portion is located on the outer periphery thereof. Since the presence of increases the proportion of the adhesive layer, the temperature difference between the central portion and the outer peripheral portion is likely to increase.
  • a part of the honeycomb fired body located in the outer peripheral portion has a cross-sectional shape perpendicular to the longitudinal direction surrounded by two line segments and an arc
  • the honeycomb fired body is a honeycomb fired body having an angle formed by two line segments and having a right angle.
  • Such a honeycomb fired body has a smaller cross-sectional area than the honeycomb fired body at the stop portion.
  • the temperature difference between the central portion and the outer peripheral portion of the honeycomb structure becomes large, when the honeycomb structure is subjected to a regeneration process for burning and removing the particulates, the unburned particulates on the outer peripheral portion of the honeycomb structure. Is likely to occur.
  • the honeycomb structure according to claim 1 Columnar honeycomb fired bodies in which a large number of cells are arranged in parallel in the longitudinal direction across the cell wall are a honeycomb structure in which a plurality of cells are bound via an adhesive layer,
  • the honeycomb fired body is composed of a central part honeycomb fired body located in the center and a peripheral part honeycomb fired body located in the outer peripheral part in a cross section perpendicular to the longitudinal direction of the honeycomb structure.
  • the shape of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body is a quadrangle, The area of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body is 900 to 2500 mm 2 ;
  • the shape of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is different from the shape of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body, and
  • the area of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is 0.9 to 1.3 times the area of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body. It is a honeycomb structure.
  • a cross-sectional area of a cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is a central honeycomb fired body among a plurality of honeycomb fired bodies bound through an adhesive layer.
  • the cross-sectional area of the cross section perpendicular to the longitudinal direction is 0.9 to 1.3 times. Accordingly, there is no honeycomb fired body having an extremely small cross-sectional area on the outer peripheral portion of the honeycomb structure, and an adhesive layer for binding such a small honeycomb fired body is not necessary.
  • the temperature distribution hardly occurs between the central part and the outer peripheral part of the particle, and the unburned particulates hardly occur when the regeneration process is performed.
  • the cross-sectional area of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is less than 0.9 times the cross-sectional area of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body, The temperature distribution is likely to occur between the honeycomb fired bodies and the particulate burnout tends to occur during the regeneration process. Further, if the cross-sectional area of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body exceeds 1.3 times the cross sectional area of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body, the honeycomb fired body is subjected to thermal stress. Cracks may occur.
  • the cross-sectional area of the central honeycomb fired body is 900 to 2500 mm 2 .
  • the reason is as follows.
  • the cross-sectional area of the central honeycomb fired body is less than 900 mm 2 , the adhesive layer constituting the honeycomb structure tends to increase, and as a result, temperature distribution tends to occur in the honeycomb structure, and the honeycomb structure is regenerated. Cracks are likely to occur in the fired body.
  • the cross-sectional area of the central honeycomb fired body is large, the proportion of the adhesive layer is relatively small, so that the temperature distribution is less likely to occur during the regeneration process, but the thermal stress carried by the adhesive layer is reduced.
  • the upper limit of the cross-sectional area of the central honeycomb fired body is preferably 2500 mm 2 . That is, when the cross-sectional area of the central honeycomb fired body is in the above range, the occurrence of cracks in the honeycomb fired body during the regeneration process can be more reliably prevented.
  • the central honeycomb fired body refers to a honeycomb fired body that does not constitute the outer edge of the honeycomb structure in a cross section perpendicular to the longitudinal direction of the honeycomb structure
  • the outer peripheral honeycomb fired body refers to a honeycomb structure.
  • the cross section perpendicular to the longitudinal direction of the body it means a honeycomb fired body that constitutes the outer edge of the honeycomb structure.
  • the above-mentioned outer peripheral honeycomb fired body refers to a honeycomb fired body that forms the outer edge of the ceramic block.
  • the honeycomb structure according to claim 2 in the honeycomb structure according to claim 1,
  • the shape of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is surrounded by three line segments and one arc or elliptical arc, and two angles formed by two of the three line segments Is a shape having a right angle or an obtuse angle.
  • the shape of a cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body has three lines. It is a shape surrounded by a minute and one arc or elliptical arc, and two angles formed by two of the three line segments are right angles or obtuse angles.
  • the outer peripheral honeycomb fired body has such a shape, the size of the cross section perpendicular to the longitudinal direction of the outer peripheral honeycomb fired body is extremely larger than the size of the cross section perpendicular to the longitudinal direction of the central honeycomb fired body. Hard to get smaller. For this reason, temperature distribution is unlikely to occur at the central portion and the outer peripheral portion of the honeycomb structure, and particulate burn-out is unlikely to occur when the regeneration process is performed.
  • a cross section of a honeycomb structure when simply referred to as a cross section of a honeycomb structure, a cross section of a honeycomb fired body, or a cross section of a honeycomb formed body, a cross section perpendicular to the longitudinal direction of the honeycomb structure, respectively, It refers to a cross section perpendicular to the longitudinal direction or a cross section perpendicular to the longitudinal direction of the honeycomb formed body.
  • a cross-sectional area of a honeycomb structure a cross-sectional area of a honeycomb fired body, or a cross-sectional area of a honeycomb formed body
  • a cross section perpendicular to the longitudinal direction of the honeycomb structure is cut. It refers to the area, the cross-sectional area of the cross section perpendicular to the longitudinal direction of the honeycomb fired body, or the cross-sectional area of the cross section perpendicular to the longitudinal direction of the honeycomb formed body.
  • the honeycomb fired body constituting the honeycomb structure of the present invention is classified into a central part honeycomb fired body and an outer peripheral part honeycomb fired body.
  • a honeycomb fired body when it is not necessary to distinguish between both, it is simply referred to as a honeycomb fired body.
  • FIG. 1 is a perspective view schematically showing the honeycomb structure of the first embodiment.
  • FIG. 2A is a perspective view schematically showing the center-portion honeycomb fired body in the honeycomb structure of the first embodiment.
  • FIG. 2B is a cross-sectional view taken along the line AA in FIG.
  • FIG. 3 is a perspective view schematically showing the outer peripheral honeycomb fired body in the honeycomb structure of the first embodiment.
  • the ceramic block 103 is formed by being bundled individually through the adhesive layer 101, and a coat layer 102 is formed on the outer periphery of the ceramic block 103.
  • the shape of the cross section of the central honeycomb fired body 110 is a square.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 120 is surrounded by three line segments 120a, 120b, and 120c and one arc 120d, and two corners (line lines) formed by two of the three line segments.
  • the angle formed by the minute segment 120b and the line segment 120c and the angle formed by the line segment 120a and the line segment 120b) are 90 ° and 135 °, respectively.
  • the honeycomb fired bodies 110 and 120 are made of a porous silicon carbide sintered body.
  • a large number of cells 111 are arranged in parallel in the longitudinal direction (in the direction of arrow a in FIG. 2 (a)) with a cell wall 113 therebetween.
  • One end of the cell 111 is sealed with a sealing material 112. Therefore, the exhaust gas G (see the arrow in FIG. 2B) that flows into the cell 111 with one end face opened must always pass through the cell wall 113 separating the cell 111 and then the other cell with the other end face open. 111 flows out. Therefore, the cell wall 113 functions as a filter for collecting PM and the like.
  • the outer peripheral honeycomb fired body 120 shown in FIG. 3 has a large number of cells 121 arranged in parallel in the longitudinal direction across the cell wall 123. Is sealed with a sealing material 122. Therefore, the exhaust gas that has flowed into the cell 121 having one open end face always passes through the cell wall 123 separating the cells 121 and then flows out from the other cell 121 having the other end face open. That is, the outer peripheral honeycomb fired body 120 has the same function as the central honeycomb fired body 110, although the outer shape is different from the central honeycomb fired body 110.
  • honeycomb structure 100 As shown in FIG. 1, four central honeycomb fired bodies 110 are located in the central part of the cross section of the honeycomb structure 100, and eight outer peripheral honeycomb fired bodies 120 are located around the central fired bodies.
  • the honeycomb structure 100 (ceramic block 103) is bound via an adhesive layer 101 so that the cross section of the honeycomb structure 100 (ceramic block 103) is circular.
  • the shape of the cross section of the outer peripheral honeycomb fired body 120 is different from the shape of the cross section of the central honeycomb fired body 110. 0.9 to 1.3 times the cross-sectional area. Therefore, there is no honeycomb fired body having an extremely small cross-sectional area on the outer peripheral portion of the honeycomb structure 100, and an adhesive layer for binding such small honeycomb fired bodies is naturally not necessary. Therefore, in the honeycomb structure 100, the temperature distribution hardly occurs in the central portion and the outer peripheral portion, and the particulate unburned residue hardly occurs when the regeneration process is performed.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 120 is surrounded by three line segments 120a, 120b, 120c and one arc 120d, and two of these three line segments are included.
  • the outer peripheral portion honeycomb fired body has a shape in which two corners (an angle formed by the line segment 120b and the line segment 120c and an angle formed by the line segment 120a and the line segment 120b) are 90 ° and 135 °, respectively. That the shape of 120 is such a shape is also a factor that the honeycomb fired body having an extremely small cross-sectional area does not exist in the outer peripheral portion of the honeycomb structure 100.
  • the cross-sectional area of the central honeycomb fired body 110 is 900 to 2500 mm 2 .
  • the cross-sectional area of the central honeycomb fired body 110 is 900 to 2500 mm 2 .
  • a forming step for producing a honeycomb formed body by extruding a wet mixture containing a ceramic powder and a binder is performed. Specifically, a wet mixture for manufacturing a honeycomb formed body is first prepared by mixing silicon carbide powder having different average particle sizes as ceramic powder, an organic binder, a liquid plasticizer, a lubricant, and water. Prepare. Subsequently, the wet mixture is charged into an extruder. The wet mixture is put into an extruder and extruded to produce a honeycomb formed body having a predetermined shape.
  • a honeycomb molded body having a square cross section, or a cross section surrounded by three line segments and one arc, two angles formed by two of the three line segments are 90 ° and 135 °, respectively.
  • an extrusion mold corresponding to each shape is used.
  • the honeycomb formed body is cut into a predetermined length and dried using a microwave dryer, hot air dryer, dielectric dryer, vacuum dryer, vacuum dryer, freeze dryer, or the like. Then, a sealing step of filling a predetermined cell with a sealing material paste as a sealing material and sealing the cell is performed.
  • the conditions conventionally used when manufacturing a honeycomb fired body can be applied to the conditions of the cutting process, the drying process, and the sealing process.
  • a degreasing step of heating the organic matter in the honeycomb molded body in a degreasing furnace is performed, and the honeycomb fired body is transported to the firing furnace and the firing step is performed to produce a honeycomb fired body.
  • the conditions conventionally used when manufacturing a honeycomb fired body are applicable.
  • an adhesive paste layer is formed by applying an adhesive paste to the predetermined side surfaces of the center honeycomb fired body and the peripheral honeycomb fired body in which predetermined ends of each cell are sealed. Then, a step of laminating other honeycomb fired bodies sequentially on this adhesive paste layer is repeated to perform a binding step for producing a ceramic block in which a predetermined number of honeycomb fired bodies are bound.
  • the adhesive paste for example, a paste made of an inorganic binder, an organic binder, and inorganic particles is used.
  • the adhesive paste may further contain inorganic fibers and / or whiskers.
  • a coating layer forming step is performed in which a coating material paste is applied to the outer periphery of the cylindrical ceramic block, dried and solidified to form a coating layer.
  • the coating material paste the same paste as the adhesive paste is used.
  • the coat layer is not necessarily provided, and may be provided as necessary.
  • the shape of the cross section of the outer peripheral honeycomb fired body 120 is different from the shape of the cross section of the central honeycomb fired body 110, and the cross sectional area of the outer peripheral honeycomb fired body 120 is
  • the cross-sectional area of the fired body 110 is 0.9 to 1.3 times. Therefore, there is no honeycomb fired body having a very small cross-sectional area on the outer peripheral portion of the honeycomb structure, and an adhesive layer for binding such a small honeycomb fired body is not necessary.
  • the temperature distribution hardly occurs between the central portion and the outer peripheral portion, and the particulate unburned residue hardly occurs when the regeneration process is performed.
  • the shape of the cross section of the outer peripheral honeycomb fired body is surrounded by three line segments and one arc, and is composed of two of these three line segments. The two corners are 90 ° and 135 °, respectively.
  • the cross-sectional area of the outer peripheral honeycomb fired body is less likely to be extremely smaller than the cross-sectional area of the central honeycomb fired body, and an adhesive layer for binding the honeycomb fired body having a small cross-sectional area is unnecessary.
  • the temperature distribution hardly occurs between the central portion and the outer peripheral portion of the honeycomb structure, and the particulate unburned residue hardly occurs when the regeneration process is performed.
  • the cross-sectional area of the central honeycomb fired body is 900 to 2500 mm 2 . Therefore, cracks do not occur in the honeycomb fired body when the regeneration process is performed.
  • honeycomb fired body constituting the honeycomb structure of the present embodiment
  • one end of each cell is sealed with a sealing material. Therefore, the honeycomb structure of the present embodiment can be suitably used as a diesel particulate filter.
  • Example 1 Examples that more specifically disclose the first embodiment of the present invention will be described below. In addition, this invention is not limited only to these Examples.
  • the raw honeycomb molded body is dried using a microwave dryer to obtain a dried honeycomb molded body, and then a predetermined cell is filled with a paste having the same composition as the wet mixture, and again It dried using the dryer.
  • a degreasing step of degreasing the dried honeycomb formed body at 400 ° C. was performed, and further a firing step was performed at 2200 ° C. for 3 hours under an atmospheric pressure of argon atmosphere.
  • the porosity was 45%
  • the average pore diameter was 15 ⁇ m
  • the size was 34.5 mm ⁇ 34.5 mm ⁇ 150 mm
  • the number of cells (cell density) was 300 / inch 2
  • the cell wall thickness was 0.1.
  • a central honeycomb fired body 110 made of 25 mm (10 mil) porous silicon carbide sintered body;
  • the porosity, the average pore diameter, the number of cells (cell density), and the cell wall thickness are the same as those of the central honeycomb fired body 110, and the cross section is surrounded by three line segments and one arc.
  • the cross-sectional area of the central honeycomb fired body 110 is 1190 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 120 is 1292 mm 2 . Therefore, the cross-sectional area of the peripheral honeycomb fired body 120 is 1.09 times the cross-sectional area of the central honeycomb fired body 110.
  • Adhesive paste is applied to predetermined side surfaces of the central honeycomb fired body 110 and the peripheral honeycomb fired body 120, and four central honeycomb fired bodies 110 and the outer peripheral part are interposed through the adhesive paste.
  • Four honeycomb fired bodies 120 are bonded so that the arrangement shown in FIG. 4 is obtained, and further, the adhesive paste is solidified at 180 ° C. for 20 minutes, so that the thickness of the adhesive layer is 1 mm.
  • the ceramic block 103 was produced.
  • the adhesive paste is composed of 30.0% by weight of silicon carbide particles having an average particle diameter of 0.6 ⁇ m, 21.4% by weight of silica sol, 8.0% by weight of carboxymethylcellulose, and 40.6% by weight of water. Adhesive paste was used.
  • a coating material paste layer was formed on the outer periphery of the ceramic block 103 using a coating material paste having the same composition as the adhesive paste used in the step (4). Thereafter, this coating material paste layer was dried at 120 ° C. to produce a cylindrical honeycomb structure having a diameter of 143.8 mm and a length of 150 mm, in which the coating layer 102 was formed on the outer periphery.
  • the cross-sectional shape of the honeycomb structure 100 manufactured in Example 1 is as shown in FIG.
  • Example 2 Except that the sizes of the central honeycomb fired body 110 and the outer peripheral honeycomb fired body 120 manufactured through the steps (1) to (3) of Example 1 were changed to the following sizes, the same procedure as in Example 1 was performed. A honeycomb structure was manufactured. That is, the porosity is 45%, the average pore diameter is 15 ⁇ m, the size is 36.7 mm ⁇ 36.7 mm ⁇ 150 mm, the number of cells (cell density) is 300 / inch 2 , and the cell wall thickness is 0.25 mm.
  • a central honeycomb fired body 110 made of (10 mil) porous silicon carbide sintered body; The porosity, the average pore diameter, the number of cells (cell density), and the cell wall thickness are the same as those of the central honeycomb fired body 110, and the cross section is surrounded by three line segments and one arc.
  • Part honeycomb fired body 120 was manufactured.
  • the cross-sectional area of the central honeycomb fired body 110 is 1347 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 120 is 1215 mm 2 . Therefore, the cross-sectional area of the peripheral honeycomb fired body 120 is 0.90 times the cross-sectional area of the central honeycomb fired body 110.
  • Example 3 Except that the sizes of the central honeycomb fired body 110 and the outer peripheral honeycomb fired body 120 manufactured through the steps (1) to (3) of Example 1 were changed to the following sizes, the same procedure as in Example 1 was performed. A honeycomb structure was manufactured. That is, the porosity is 45%, the average pore diameter is 15 ⁇ m, the size is 32.4 mm ⁇ 32.4 mm ⁇ 150 mm, the number of cells (cell density) is 300 / inch 2 , and the cell wall thickness is 0.25 mm.
  • a central honeycomb fired body 110 made of (10 mil) porous silicon carbide sintered body;
  • the porosity, the average pore diameter, the number of cells (cell density), and the cell wall thickness are the same as those of the central honeycomb fired body 110, and the cross section is surrounded by three line segments and one arc.
  • the cross-sectional area of the central honeycomb fired body 110 is 1050 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 120 is 1363 mm 2 . Therefore, the cross-sectional area of the peripheral honeycomb fired body 120 is 1.30 times the cross-sectional area of the central honeycomb fired body 110.
  • Example 1 By performing the same steps as the steps (1) to (3) of Example 1, the porosity is 45%, the average pore diameter is 15 ⁇ m, the size is 34.5 mm ⁇ 34.5 mm ⁇ 150 mm, A honeycomb fired body made of a porous silicon carbide sintered body having a cell number (cell density) of 300 cells / inch 2 and a cell wall thickness of 0.25 mm (10 mil) was produced.
  • Adhesive paste is applied to the side face of the honeycomb fired body, 16 honeycomb fired bodies are bonded through the adhesive paste, and further, the adhesive paste is solidified at 180 ° C. for 20 minutes to bond.
  • An aggregate of honeycomb fired bodies having a prism shape with a material layer thickness of 1 mm was manufactured.
  • the same adhesive paste as the adhesive paste used in Example 1 was used as the adhesive paste.
  • the outer periphery of the aggregate of the honeycomb fired bodies was ground using a diamond cutter to produce a cylindrical ceramic block.
  • the coating material paste layer was formed in the outer peripheral part of the ceramic block using the coating material paste which consists of the same material as an adhesive material paste. And this coating material paste layer was dried at 120 degreeC, and the cylindrical honeycomb structure of diameter 143.8mm x length 150mm in which the coating layer was formed in the outer periphery was manufactured.
  • FIG. 5 is a cross-sectional view of the honeycomb structure 400 manufactured in Comparative Example 1.
  • 410 is a central honeycomb fired body
  • 420 and 430 are outer peripheral honeycomb fired bodies
  • 401 is an adhesive layer
  • 402 is an adhesive layer.
  • a coating layer 403 indicates a ceramic block.
  • the cross-sectional area of the peripheral honeycomb fired body 420 is 0.92 times the cross-sectional area of the central honeycomb fired body 410
  • the cross-sectional area of the peripheral honeycomb fired body 430 is the cross-sectional area of the central honeycomb fired body 410. 0.30 times.
  • Example 2 Except that the sizes of the central honeycomb fired body 110 and the outer peripheral honeycomb fired body 120 manufactured through the steps (1) to (3) of Example 1 were changed to the following sizes, the same procedure as in Example 1 was performed. A honeycomb structure was manufactured. That is, the porosity is 45%, the average pore diameter is 15 ⁇ m, the size is 31.5 mm ⁇ 31.5 mm ⁇ 150 mm, the number of cells (cell density) is 300 / inch 2 , and the cell wall thickness is 0.25 mm.
  • a central honeycomb fired body 110 made of (10 mil) porous silicon carbide sintered body; The porosity, the average pore diameter, the number of cells (cell density), and the cell wall thickness are the same as those of the central honeycomb fired body 110, and the cross section is surrounded by three line segments and one arc.
  • the cross-sectional area of the central honeycomb fired body 110 is 992 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 120 is 1392 mm 2 . Therefore, the cross-sectional area of the peripheral honeycomb fired body 120 is 1.40 times the cross-sectional area of the central honeycomb fired body 110.
  • the honeycomb structures of the example and the comparative example are respectively disposed in the exhaust passage of a 2 L engine, and further on the gas inflow side of the honeycomb structure, a catalyst support (diameter: 200 mm, Length: 100 mm, cell density: 400 cells / inch 2 , platinum carrying amount: 5 g / L) is set as an exhaust gas purification device, and the engine is collected for 7 hours at a rotational speed of 3000 min ⁇ 1 and a torque of 50 Nm. did. The amount of particulates collected was 8 g / L. After that, the engine is set at a rotational speed of 1250 min ⁇ 1 and a torque of 60 Nm, and the filter temperature is kept constant for 1 minute.
  • the post-injection is performed, and the exhaust gas temperature is raised using the oxidation catalyst in front.
  • the particulates were burned.
  • the post-injection conditions were set so that the temperature of the exhaust gas flowing into the honeycomb structure after 1 minute from the start became substantially constant at 600 ° C.
  • the honeycomb structure of Example 1 had a regeneration rate of 85%.
  • the honeycomb structure of Example 2 had a regeneration rate of 80%.
  • the regeneration rate of the honeycomb structure of Example 3 was 88%.
  • the regeneration rate of the honeycomb structure of Comparative Example 1 was 70%.
  • the honeycomb structure of Comparative Example 2 had a regeneration rate of 90%, cracks occurred in a part of the outer peripheral honeycomb fired body after the regeneration treatment.
  • no cracks occurred in the honeycomb fired body after the regeneration treatment.
  • the reason why the regeneration rate of the honeycomb structure of Comparative Example 1 was low is considered to be that a large amount of unburned particulates occurred during the regeneration process.
  • FIG. 6 is a cross-sectional view of the honeycomb structure of the second embodiment.
  • a plurality of central honeycomb fired bodies 210 and outer peripheral honeycomb fired bodies 220 and 230 are bonded together via an adhesive layer 201 to form a ceramic block. 203, and further, a coat layer 202 is formed on the outer periphery of the ceramic block 203.
  • the cross-sectional shape of the central honeycomb fired body 210 is a square.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 220 is surrounded by three line segments 220a, 220b, and 220c and one arc 220d, and two corners (line lines) formed by two of the three line segments.
  • the angle formed by the segment 220a and the line segment 220b and the angle formed by the line segment 220b and the line segment 220c) are both 90 °.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 230 is surrounded by three line segments 230a, 230b, and 230c and one arc 230d, and two corners (line lines) formed by two of the three line segments.
  • the angle formed by the minute segment 230b and the line segment 230c and the angle formed by the line segment 230a and the line segment 230b) are 90 ° and 135 °, respectively.
  • the center honeycomb fired body 210 is the same as the center honeycomb fired body 110 constituting the honeycomb structure of the first embodiment, and the outer peripheral honeycomb fired bodies 220 and 230 are the honeycomb structure of the first embodiment.
  • the external shape is different from that of the center-portion honeycomb fired body 110 constituting the above, its function is the same.
  • the honeycomb fired bodies 210, 220, and 230 are made of a porous silicon carbide sintered body.
  • honeycomb structure 200 As shown in FIG. 6, nine central honeycomb fired bodies 210 are located at the center of the cross section of the honeycomb structure 100, and eight outer peripheral honeycomb fired bodies 220 around it, Eight outer peripheral honeycomb fired bodies 230 are positioned, and the honeycomb structure 200 is bound via the adhesive layer 201 so that the cross section of the honeycomb structure 200 is circular.
  • the shape of the cross section of the outer peripheral honeycomb fired bodies 220 and 230 is different from the shape of the cross section of the central honeycomb fired body 210.
  • the cross-sectional area of the fired body 210 is 0.9 to 1.3 times. Therefore, there is no honeycomb fired body having an extremely small cross-sectional area on the outer peripheral portion of the honeycomb structure 200, and naturally an adhesive layer for binding such small honeycomb fired bodies is not necessary. Therefore, in the honeycomb structure 200, the temperature distribution hardly occurs in the central portion and the outer peripheral portion, and the particulate unburned residue hardly occurs when the regeneration process is performed.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 220 is surrounded by the three line segments 220a, 220b, 220c and one arc 220d, and two of the three line segments are included.
  • the two corners are both 90 ° in shape, and the cross section of the outer peripheral honeycomb fired body 230
  • the shape of is surrounded by three line segments 220a, 220b, 220c and one circular arc 220d, and two corners (line segments 220b and 220b) made up of two of these three line segments.
  • the angle formed by the line segment 220c and the angle formed by the line segment 220a and the line segment 220b) are 90 ° and 135 °, respectively, and the outer peripheral honeycomb fired bodies 220 and 230 have such a shape. Be , The cross-sectional area in the peripheral portion of the honeycomb structure 200 is a factor that is not present is extremely small honeycomb fired body.
  • the cross-sectional area of the central honeycomb fired body 210 is 900 to 2500 mm 2 . The reason is as described in the first embodiment.
  • the manufacturing method of the honeycomb structure in the present embodiment is the same as the manufacturing method of the honeycomb structure in the first embodiment except for the following points. That is, the shape of the honeycomb formed body produced in the forming step (1) of the manufacturing method of the first embodiment is the center portion shown in FIG. 6 except that either one end of the cell is not sealed.
  • the honeycomb fired body 210 and the outer peripheral honeycomb fired bodies 220 and 230 have substantially the same shape, and when performing the binding step (4) of the manufacturing method of the first embodiment, it is shown in FIG.
  • the method for manufacturing the honeycomb structure in the first embodiment is the same.
  • the honeycomb structure of the present embodiment can be manufactured.
  • honeycomb structure of the present embodiment the same effects as the honeycomb structure of the first embodiment can be enjoyed.
  • Example 4 Examples that more specifically disclose the second embodiment of the present invention will be described below. In addition, this invention is not limited only to these Examples.
  • the raw honeycomb molded body is dried using a microwave dryer to obtain a dried honeycomb molded body, and then a predetermined cell is filled with a paste having the same composition as the wet mixture, and again It dried using the dryer.
  • a degreasing step of degreasing the dried honeycomb formed body at 400 ° C. was performed, and further a firing step was performed at 2200 ° C. for 3 hours under an atmospheric pressure of argon atmosphere. Accordingly, the porosity is 45%, the average pore diameter is 15 ⁇ m, the size is 34.5 mm ⁇ 34.5 mm ⁇ 200 mm, the number of cells (cell density) is 300 / inch 2 , and the cell wall thickness is 0.00.
  • a central honeycomb fired body 210 made of 25 mm (10 mil) porous silicon carbide sintered body;
  • the porosity, average pore diameter, number of cells (cell density), and cell wall thickness are the same as those of the central honeycomb fired body 210, and the cross section is surrounded by three line segments and one arc.
  • the cross-sectional area of the central honeycomb fired body 210 is 1190 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 220 is 1226 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 230 is 1226 mm 2
  • the cross-sectional area of the outer peripheral honeycomb fired body 220 is 1.03 times the cross-sectional area of the central honeycomb fired body 210
  • the cross-sectional area of the outer peripheral honeycomb fired body 230 is the cross-sectional area of the central honeycomb fired body 210. 1.03 times greater than
  • Adhesive paste is applied to predetermined side surfaces of the central honeycomb fired body 210 and the outer peripheral honeycomb fired bodies 220 and 230, and nine central honeycomb fired bodies 210 are disposed through the adhesive paste.
  • the adhesive paste similar to Example (1) was used as an adhesive paste.
  • a coating material paste layer was formed on the outer periphery of the ceramic block 203 using a coating material paste having the same composition as the adhesive paste used in the step (4). Thereafter, this coating material paste layer was dried at 120 ° C. to manufacture a cylindrical honeycomb structure 200 having a diameter of 203.2 mm and a length of 200 mm, on which the coating layer 202 was formed on the outer periphery.
  • the cross-sectional shape of the honeycomb structure manufactured in Example 4 is as shown in FIG.
  • Example 4 The honeycomb structure manufactured in Example 4 was subjected to a regeneration process in the same manner as in Example 1 except that a 4L engine was used instead of the 2L engine, and the regeneration rate was measured based on the weight difference. As a result, the regeneration rate of the honeycomb structure of Example 4 was 82%.
  • honeycomb structure of the first and second embodiments In the method for manufacturing the honeycomb structure of the first and second embodiments, a honeycomb fired body formed in a predetermined shape is manufactured in advance, and the honeycomb structure is manufactured. However, the honeycomb structure of the embodiment of the present invention is manufactured. You may produce a structure using the following methods, for example. Hereinafter, another method for manufacturing the honeycomb structure of the embodiment of the present invention will be described by taking as an example the case of manufacturing the honeycomb structure of the first embodiment.
  • FIGS. 7A and 7B are cross-sectional views for explaining another example of the method for manufacturing a honeycomb structure according to the embodiment of the present invention.
  • a honeycomb fired body in which either one end of each cell is sealed is manufactured.
  • a central honeycomb fired body 310 having a quadrangular cross section and an outer peripheral honeycomb fired body 320 ′ having a trapezoidal cross section are manufactured (see FIG. 7A).
  • an adhesive is used so that the central honeycomb fired body 310 and the outer peripheral honeycomb fired body 320 ′ are positioned as shown in FIG.
  • a bundle 303 'of honeycomb fired bodies is produced by binding the paste layers and solidifying the adhesive paste layer.
  • an outer periphery processing step is performed in which a side surface of the honeycomb fired body aggregate 303 ′ is processed into a cylindrical shape by using a diamond cutter or the like, and the central honeycomb fired body 310, the outer peripheral honeycomb fired body 320, Is manufactured through the adhesive layer 301 (see FIG. 7B). Thereafter, if necessary, a coat layer (not shown) is formed on the outer peripheral side surface of the ceramic block 303 to complete the honeycomb structure.
  • the cross-sectional shape of the honeycomb structure according to the embodiment of the present invention is not limited to a circular shape, and may be, for example, an elliptical shape, an oval shape, a race track shape, or the like.
  • FIG. 8 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • the cross-sectional shape of the honeycomb structure shown in FIG. 8 is an ellipse.
  • a plurality of central honeycomb fired bodies 510 and outer peripheral honeycomb fired bodies 520, 530, and 540 are bundled together via an adhesive layer 501 to form a ceramic block 503. Further, a coat layer 502 is formed on the outer periphery of the ceramic block 503.
  • the shape of the cross section of the central honeycomb fired body 510 is a square.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 520 is surrounded by three line segments 520a, 520b, and 520c and one elliptical arc 520d, and two corners (lines) formed by two of these three line segments (line
  • the angle formed by the segment 520a and the line segment 520b and the angle formed by the line segment 520b and the line segment 520c are both 90 °.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 530 is surrounded by three line segments 530a, 530b, and 530c and one elliptical arc 530d, and two corners (line lines) formed by two of the three line segments (line
  • the angle formed by the segment 530b and the line segment 530c, and the angle formed by the line segment 530a and the line segment 530b) are 90 ° and 135 °, respectively.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 540 is surrounded by three line segments 540a, 540b, and 540c and one elliptical arc 540d, and two corners (line lines) formed by two of the three line segments (line Both the angle formed by the segment 540a and the line segment 540b and the angle formed by the line segment 540b and the line segment 540c are 135 °. That is, the central honeycomb fired body 510 is the same as the central honeycomb fired body 110 constituting the honeycomb structure of the first embodiment, and the outer peripheral honeycomb fired bodies 520, 530, and 540 are the honeycombs of the first embodiment. Although the appearance shape is different from that of the central honeycomb fired body 110 constituting the structure, its function is the same.
  • the honeycomb structure 500 includes three central honeycomb fired bodies 510 that are bundled through an adhesive layer 501, two peripheral honeycomb fired bodies 520 that are located around the central fired body 520, and four peripheral honeycomb fired bodies. 530 and two outer peripheral honeycomb fired bodies 540, and the honeycomb structure 500 (ceramic block 503) is bound via an adhesive layer 501 so that the cross section of the honeycomb structure 500 (ceramic block 503) is elliptical.
  • the cross-sectional areas of the outer peripheral honeycomb fired bodies 520, 530, and 540 are 0.9 to 1.3 times the cross-sectional area of the central honeycomb fired body 510.
  • FIG. 9 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • the cross-sectional shape of the honeycomb structure shown in FIG. 9 is a race track shape.
  • a plurality of central honeycomb fired bodies 610 and outer peripheral honeycomb fired bodies 620, 630, and 640 are bundled together via an adhesive layer 601 to form a ceramic block 603. Further, a coat layer 602 is formed on the outer periphery of the ceramic block 603.
  • the shape of the cross section of the central honeycomb fired body 610 is a square.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 620 is a rectangle.
  • the shape of the cross section of the outer peripheral honeycomb fired body 630 is surrounded by three line segments 630a, 630b, and 630c and a curve 630d that combines one straight line and an arc, and two of these three line segments
  • the two corners are 90 ° and 135 °, respectively.
  • the cross-sectional shape of the outer peripheral honeycomb fired body 640 is surrounded by three line segments 640a, 640b, and 640c and one arc 640d, and two corners (line lines) formed by two of the three line segments (line Both the angle formed by the segment 640a and the line segment 640b and the angle formed by the line segment 640b and the line segment 640c are 135 °. That is, the central honeycomb fired body 610 is the same as the central honeycomb fired body 110 constituting the honeycomb structure of the first embodiment, and the outer peripheral honeycomb fired bodies 620, 630, and 640 are the honeycombs of the first embodiment. Although the appearance shape is different from that of the central honeycomb fired body 110 constituting the structure, its function is the same.
  • honeycomb structure 600 In the honeycomb structure 600, three central honeycomb fired bodies 610 that are bundled through an adhesive layer 601 and two outer peripheral honeycomb fired bodies 620 and four outer peripheral honeycomb fired bodies positioned around the central fired body 610. 630 and two outer peripheral honeycomb fired bodies 640, and the honeycomb structure 600 (ceramic block 603) is bound via an adhesive layer 601 so that the cross section of the honeycomb structure 600 (ceramic block 603) has a racetrack shape.
  • the cross-sectional area of each of outer peripheral honeycomb fired bodies 620, 630, and 640 is 0.9 to 1.3 times the cross-sectional area of central honeycomb fired body 610.
  • the cross-sectional shape of the honeycomb structure according to the embodiment of the present invention may be an ellipse as shown in FIG. 8 or a racetrack shape as shown in FIG.
  • the number of the central honeycomb fired bodies is not limited to a plurality, and may be one.
  • the shape of the cross section of the honeycomb structure may be a shape as shown in FIG.
  • FIG. 10 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • the configuration of the honeycomb structure 700 shown in FIG. 10 is the same as that of the honeycomb structure 100 of the first embodiment except that the number of central honeycomb fired bodies is different. That is, in the honeycomb structure 700 shown in FIG. 10, instead of the four center-portion honeycomb fired bodies 110 bound through the adhesive layer 101 of the honeycomb structure 100 shown in FIG. Partial honeycomb fired body 710 is provided. Although the central honeycomb fired body 710 has a larger cross-sectional area than the central honeycomb fired body 110, its function is the same.
  • the shape of the cross section of the outer peripheral honeycomb fired body 720 is as follows. Surrounded by three line segments 720a, 720b, 720c and one arc 720d, two corners formed by two of the three line segments (an angle formed by the line segment 720b and the line segment 720c, and , The angle formed by the line segment 720a and the line segment 720b) is 90 ° and 135 °, respectively.
  • the sectional area of the outer peripheral honeycomb fired body 720 is 0.9 to 1.3 times the sectional area of the central honeycomb fired body 710. Also in the honeycomb structure 700 of such an embodiment, the same operational effects as in the first embodiment can be enjoyed.
  • reference numeral 701 denotes an adhesive layer
  • 702 denotes a coat layer
  • 703 denotes a ceramic block.
  • the diameter of the honeycomb structure is arbitrary one in the cross-section of the honeycomb structure, and another diameter orthogonal to the one diameter. It is desirable that four honeycomb fired bodies or five honeycomb fired bodies overlap each other. This is because a honeycomb structure having such a configuration is particularly suitable for enjoying the effects of the present invention.
  • the adhesive layer One side of the honeycomb fired body adjacent to is counted as one.
  • the honeycomb structure of the embodiment described so far in the honeycomb structure of the first embodiment, four honeycomb fired bodies overlap each other with one diameter and the other diameter (see FIG. 4). In the honeycomb structure of the second embodiment, five honeycomb fired bodies overlap each other in one diameter and the other diameter (see FIG. 6). In the honeycomb structure of the embodiment shown in FIG. This means that three honeycomb fired bodies overlap each other with the other diameter. Therefore, among these three embodiments, the first and second embodiments are more desirable embodiments.
  • the end of the cell may not be sealed.
  • a honeycomb structure can be used as a catalyst carrier.
  • Examples of the inorganic binder contained in the adhesive paste include silica sol and alumina sol. These may be used alone or in combination of two or more. Among inorganic binders, silica sol is desirable.
  • Examples of the inorganic particles contained in the adhesive paste include inorganic particles made of carbide, nitride, and the like. Specifically, inorganic particles made of silicon carbide, silicon nitride, boron nitride, and the like can be given. . These may be used alone or in combination of two or more. Among the inorganic particles, inorganic particles made of silicon carbide having excellent thermal conductivity are desirable.
  • inorganic fibers and / or whiskers contained in the adhesive paste examples include inorganic fibers and / or whiskers made of silica-alumina, mullite, alumina, silica, and the like. These may be used alone or in combination of two or more. Among inorganic fibers, alumina fibers are desirable.
  • the porosity of the honeycomb fired body is not particularly limited, but is desirably 35 to 60%. If the porosity is less than 35%, the honeycomb structure of the embodiment of the present invention may be clogged immediately. On the other hand, if the porosity exceeds 60%, the strength of the honeycomb fired body decreases. This is because they can be easily destroyed.
  • the average pore size of the honeycomb fired body is desirably 5 to 30 ⁇ m. If the average pore diameter is less than 5 ⁇ m, the particulates may easily clog. On the other hand, if the average pore diameter exceeds 30 ⁇ m, the particulates pass through the pores and collect the particulates. This is because it may not be able to function as a filter.
  • the porosity and pore diameter can be measured by a conventionally known method such as a mercury intrusion method, an Archimedes method, or a measurement using a scanning electron microscope (SEM).
  • a conventionally known method such as a mercury intrusion method, an Archimedes method, or a measurement using a scanning electron microscope (SEM).
  • the cell density in the cross section of the honeycomb structure is not particularly limited, but a desirable lower limit is 31.0 / cm 2 (200 / in 2 ), and a desirable upper limit is 93 / cm 2 (600 / in 2 ).
  • the more desirable lower value is 38.8 / cm 2 (250 / in 2 ), and the more desirable upper limit is 77.5 / cm 2 (500 / in 2 ).
  • the thickness of the cell wall of the honeycomb structure is not particularly limited, but is preferably 0.1 to 0.4 mm.
  • the main component of the constituent material of the honeycomb structure is not limited to silicon carbide, and other ceramic raw materials include, for example, nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, and titanium nitride, zirconium carbide, Examples thereof include carbide ceramics such as titanium carbide, tantalum carbide, and tungsten carbide, and oxide ceramics such as cordierite and aluminum titanate. Of these, non-oxide ceramics are preferred, and silicon carbide is particularly preferred. It is because it is excellent in heat resistance, mechanical strength, thermal conductivity and the like.
  • ceramic raw materials such as silicon-containing ceramics in which metallic silicon is blended with the above-described ceramics, ceramics bonded with silicon or a silicate compound can be cited as constituent materials, and among these, silicon carbide is blended with silicon carbide.
  • silicon carbide is blended with silicon carbide.
  • silicon-containing silicon carbide is desirable.
  • a silicon-containing silicon carbide ceramic containing 60 wt% or more of silicon carbide is desirable.
  • the particle size of the ceramic powder is not particularly limited, but it is preferable that the size of the honeycomb fired body manufactured through the subsequent firing step is small compared to the size of the degreased honeycomb formed body.
  • organic binder mixed with the said wet mixture For example, methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, polyethyleneglycol etc. are mentioned. Of these, methylcellulose is desirable.
  • the amount of the organic binder is usually 1 to 10 parts by weight with respect to 100 parts by weight of the ceramic powder.
  • the plasticizer mixed with the wet mixture is not particularly limited, and examples thereof include glycerin.
  • the lubricant mixed in the wet mixture is not particularly limited, and examples thereof include polyoxyalkylene compounds such as polyoxyethylene alkyl ether and polyoxypropylene alkyl ether. Specific examples include polyoxyethylene monobutyl ether and polyoxypropylene monobutyl ether. In some cases, the plasticizer and the lubricant may not be contained in the wet mixture.
  • a dispersion medium liquid may be used.
  • the dispersion medium liquid include water, an organic solvent such as benzene, and an alcohol such as methanol.
  • a molding aid may be added to the wet mixture.
  • the molding aid is not particularly limited, and examples thereof include ethylene glycol, dextrin, fatty acid, fatty acid soap, polyalcohol and the like.
  • a pore-forming agent such as balloons that are fine hollow spheres containing oxide-based ceramics, spherical acrylic particles, and graphite may be added to the wet mixture as necessary.
  • the balloon is not particularly limited, and examples thereof include an alumina balloon, a glass micro balloon, a shirasu balloon, a fly ash balloon (FA balloon), and a mullite balloon. Of these, alumina balloons are desirable.
  • the encapsulant paste for sealing the cells is not particularly limited, but it is desirable that the encapsulant produced through a subsequent process has a porosity of 30 to 75%.
  • a paste-like material similar to a wet mixture Can be used.
  • the honeycomb structure may support a catalyst for purifying exhaust gas.
  • a catalyst for purifying exhaust gas for example, a noble metal such as platinum, palladium, rhodium or the like is desirable, and among these, platinum is more desirable.
  • other catalysts for example, alkali metals such as potassium and sodium, and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more.
  • the bundling step in the method for manufacturing a honeycomb structure according to the embodiment of the present invention includes, for example, a ceramic block (or an aggregate of honeycomb fired bodies) to be produced in addition to the method of applying the adhesive paste to the side surfaces of each honeycomb fired body.
  • the honeycomb fired bodies may be temporarily fixed in a form having substantially the same shape as the shape, and an adhesive paste may be injected between the honeycomb fired bodies.
  • FIG. 1 is a perspective view schematically showing the honeycomb structure of the first embodiment.
  • FIG. 2 (a) is a perspective view schematically showing a central honeycomb fired body in the honeycomb structure of the first embodiment, and
  • FIG. 2 (b) is a cross-sectional view taken along line AA in FIG. 2 (a).
  • FIG. FIG. 3 is a perspective view schematically showing an outer peripheral honeycomb fired body in the honeycomb structure of the first embodiment.
  • 4 is a cross-sectional view of the honeycomb structure manufactured in Example 1.
  • FIG. FIG. 5 is a cross-sectional view of the honeycomb structure manufactured in Comparative Example 1.
  • FIG. 6 is a cross-sectional view of the honeycomb structure of the second embodiment.
  • FIG. 7A and 7B are cross-sectional views for explaining another example of the method for manufacturing a honeycomb structure according to the embodiment of the present invention.
  • FIG. 8 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • FIG. 9 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • FIG. 10 is a cross-sectional view of a honeycomb structure according to another embodiment of the present invention.
  • Honeycomb structure 101, 201, 501, 601, 701 Adhesive layer 102, 202, 502, 602, 702 Coat layer 103, 203, 503, 603, 703 Ceramic block 110, 210, 510, 610, 710 Central honeycomb fired body 120, 220, 230, 520, 530, 540, 620, 630, 640, 720 Outer peripheral honeycomb fired body 111, 121 Cell 112, 122 Sealant 113, 123 Cell wall

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  • Chemical & Material Sciences (AREA)
  • Geometry (AREA)
  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Filtering Materials (AREA)

Abstract

L'invention concerne une structure en nid d'abeilles qui lors d'un traitement de régénération, etc., empêche l'apparition d'une répartition de la température entre une zone centrale et une zone périphérique, empêchant l'apparition de résidus de combustion particulaires. La structure en nid d'abeilles est composée de multiples corps cuits en nid d'abeilles colonnaires liés ensemble. La structure en nid d'abeilles présente les caractéristiques suivantes. Chacun des corps cuits en nid d'abeilles est constitué d'un corps cuit en nid d'abeilles périphérique situé dans une zone périphérique et d'un corps cuit en nid d'abeilles central situé dans une zone centrale dans la section transversale perpendiculaire à la direction longitudinale de la structure en nid d'abeilles. La configuration sectionnelle du corps cuit en nid d'abeilles central est quadrangulaire, et la surface du corps cuit en nid d'abeilles central est comprise dans la plage de 900 à 2500 mm2. La configuration sectionnelle du corps cuit en nid d'abeilles périphérique est différente de celle du corps cuit en nid d'abeilles central, et la surface du corps cuit en nid d'abeilles périphérique est comprise dans la plage de 0,9 à 1,3 fois celle du corps cuit en nid d'abeilles central.
PCT/JP2008/055455 2008-03-24 2008-03-24 Structure en nid d'abeilles WO2009118808A1 (fr)

Priority Applications (12)

Application Number Priority Date Filing Date Title
PCT/JP2008/055455 WO2009118808A1 (fr) 2008-03-24 2008-03-24 Structure en nid d'abeilles
EP10153599A EP2196644B1 (fr) 2008-03-24 2008-12-23 Corps structuré en nid d'abeille
EP10153622A EP2196645B1 (fr) 2008-03-24 2008-12-23 Corps structuré en nid d'abeille
AT08291234T ATE542985T1 (de) 2008-03-24 2008-12-23 Wabenstrukturkörper
EP10153575A EP2196643B1 (fr) 2008-03-24 2008-12-23 Corps structuré en nid d'abeille
EP08291234A EP2113643B1 (fr) 2008-03-24 2008-12-23 Corps structuré en nid d'abeille
AT10153622T ATE523667T1 (de) 2008-03-24 2008-12-23 Wabenstrukturkörper
AT10153575T ATE517236T1 (de) 2008-03-24 2008-12-23 Wabenstrukturkörper
AT10153599T ATE517237T1 (de) 2008-03-24 2008-12-23 Wabenstrukturkörper
KR1020090009609A KR101046904B1 (ko) 2008-03-24 2009-02-06 허니컴 구조체
CN2009100063531A CN101543706B (zh) 2008-03-24 2009-02-10 蜂窝结构体
US12/395,939 US20090239028A1 (en) 2008-03-24 2009-03-02 Honeycomb structure

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/JP2008/055455 WO2009118808A1 (fr) 2008-03-24 2008-03-24 Structure en nid d'abeilles

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WO2009118808A1 true WO2009118808A1 (fr) 2009-10-01

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011224970A (ja) * 2010-03-23 2011-11-10 Ibiden Co Ltd ハニカム構造体
CN107228588A (zh) * 2017-08-03 2017-10-03 九江萍钢钢铁有限公司 一种高效率的加热炉蓄热室蜂窝体

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP7002388B2 (ja) * 2018-03-27 2022-02-04 日本碍子株式会社 ハニカム構造体
CN113382797B (zh) * 2018-11-30 2023-07-28 康宁股份有限公司 包含预反应过的无机颗粒的批料混合物及由其制造陶瓷体的方法

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JP2003275521A (ja) * 2002-03-19 2003-09-30 Ngk Insulators Ltd ハニカムフィルター
JP2007252993A (ja) * 2006-03-20 2007-10-04 Ngk Insulators Ltd ハニカム構造体

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2003275521A (ja) * 2002-03-19 2003-09-30 Ngk Insulators Ltd ハニカムフィルター
JP2007252993A (ja) * 2006-03-20 2007-10-04 Ngk Insulators Ltd ハニカム構造体

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011224970A (ja) * 2010-03-23 2011-11-10 Ibiden Co Ltd ハニカム構造体
CN107228588A (zh) * 2017-08-03 2017-10-03 九江萍钢钢铁有限公司 一种高效率的加热炉蓄热室蜂窝体
CN107228588B (zh) * 2017-08-03 2023-08-18 九江萍钢钢铁有限公司 一种高效率的加热炉蓄热室蜂窝体

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CN101543706B (zh) 2012-01-04

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