Honeycomb structure and manufacturing method of honeycomb structure

Patent metadata

Field	Value
Publication number	US-10195813-B2
Application number	US-201615077033-A
Country	US
Kind code	B2
Filing date	Mar 22, 2016
Priority date	Mar 31, 2015
Publication date	Feb 5, 2019
Grant date	Feb 5, 2019

Abstract

A honeycomb structure includes latticed partition walls defining a plurality of polygonal cells which extends from one end face to the other end face and forms through channels for fluid, the partition walls are porously formed by using aggregates and a bonding material different from a material of the aggregates, and the partition walls have a relation indicating that a surface porosity of a surface region from a partition wall surface of each of the partition walls to a depth of 15% of a partition wall thickness T and an inner porosity of an inner region from the partition wall surface to a depth of 15% to 50% of the partition wall thickness are different from each other, and a difference obtained by subtracting the surface porosity from the inner porosity is in excess of 1.5%.

First claim

What is claimed is:

1. A honeycomb structure comprising porous partition walls defining a plurality of polygonal cells which extends from one end face to an other end face and forms through channels for fluid,
wherein the porous partition walls include an aggregate material and a bonding material different from the aggregate material, and
the porous partition walls have a surface porosity of a surface region from a porous partition wall surface of each of the porous partition walls to a depth of 15% of a porous partition wall thickness that is different from an inner porosity of an inner region that is from a depth of 15% to 50% of the porous partition wall thickness from the porous partition wall surface, and
a difference obtained by subtracting the surface porosity from the inner porosity is in excess of 1.5%.

2. The honeycomb structure according to claim 1 , wherein the surface porosity is in a range of 10% to 50%, and
the inner porosity is in a range of 20% to 75%.

3. The honeycomb structure according to claim 1 ,
wherein the bonding material is at least one selected from the group consisting of metal silicon and cordierite.

4. The honeycomb structure according to claim 1 ,
wherein the aggregates have a melting point higher than the bonding material, and have an average particle diameter in a range of 10 to 60 micrometers.

5. A honeycomb structure comprising porous partition walls defining a plurality of polygonal cells which extends from one end face to an other end face and forms through channels for fluid,
wherein the porous partition walls include an aggregate material and a bonding material different from the aggregate material, and
the porous partition walls have a surface porosity of a surface region from a porous partition wall surface of each of the porous partition walls to a depth of 15% of a porous partition wall thickness that is different from an inner porosity of an inner region that is from a depth of 15% to 50% of the porous partition wall thickness from the porous partition wall surface, and
a difference obtained by subtracting a surface average pore diameter of the surface region from an inner average pore diameter of the inner region is in excess of 0.5 micrometer.

6. The honeycomb structure according to claim 5 ,
wherein the surface average pore diameter is in a range of 5 to 40 micrometers and,
the inner average pore diameter is in a range of 8 to 50 micrometers.

7. The honeycomb structure according to claim 5 , wherein the same aggregate material and the same bonding material different from the aggregate material are used to form the entire thickness of the porous partition walls.

8. A manufacturing method of a honeycomb structure in which the honeycomb structure according to claim 1 is manufactured,
the method comprising:
a forming material providing step of mixing aggregates, a bonding material different from a material of the aggregates, and a bonding aid to form a forming material;
a forming step of extruding the provided forming material to form a honeycomb formed body; and
a firing step of firing the provided honeycomb formed body to form a honeycomb structure,
wherein in the forming material providing step, anisotropic particles are used as the bonding aid in which an average size of major axis of the particles is at least 5micrometers or more, an aspect ratio of the average size of the major axis to an average size of the minor axis is at least 5 or more, and a melting point is lower than that of the bonding material, and the bonding aid is added to and mixed with the aggregates and the bonding material having the melting point lower than the aggregates, and
in the firing step, the firing is performed at a firing temperature higher than the melting point of the bonding material.

Assignees

• Ngk Insulators Ltd

Inventors

• Ouchi Takahiro
• Ichikawa Shuichi

Classifications

• C04B35/565

  based on silicon carbide · CPC title

• C04B2111/00405

  Materials with a gradually increasing or decreasing concentration of ingredients or property from one layer to another · CPC title

• C04B2235/788

  Aspect ratio of the grains · CPC title

• Y10T428/12479

  Porous [e.g., foamed, spongy, cracked, etc.] · CPC title

• C04B35/195

  Alkaline earth aluminosilicates, e.g. cordierite {or anorthite} · CPC title