Honeycomb structure and production method for said honeycomb structure

Patent metadata

Field	Value
Publication number	US-10472290-B2
Application number	US-201916245257-A
Country	US
Kind code	B2
Filing date	Jan 11, 2019
Priority date	Jul 14, 2016
Publication date	Nov 12, 2019
Grant date	Nov 12, 2019

Abstract

The present invention relates to a honeycomb structured body including a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, wherein the honeycomb fired body is an extrudate containing ceria-zirconia composite oxide particles and alumina particles, and when the pore size of the partition wall of the honeycomb fired body is measured by mercury porosimetry, and the measurement results are shown as a pore size distribution curve with pore size (μm) on the horizontal axis and log differential pore volume (ml) on the vertical axis, at least one peak is present in each of the pore size ranges of 0.01 to 0.1 μm and 0.1 to 5 μm.

First claim

The invention claimed is:

1. A honeycomb structured body comprising:
a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween,
wherein the honeycomb fired body is an extrudate containing ceria-zirconia composite oxide particles and alumina particles, and
when the pore size of the partition wall of the honeycomb fired body is measured by mercury porosimetry, and the measurement results are shown as a pore size distribution curve with pore size (μm) on the horizontal axis and log differential pore volume (ml) on the vertical axis,
at least one peak is present in each of the ranges of 0.01 to 0.1 μm and 0.1 to 5 μm.

2. The honeycomb structured body according to claim 1 ,
wherein the volume of pores having a size of 0.1 μm or less is 50% by volume or more relative to the total pore volume.

3. The honeycomb structured body according to claim 2 ,
wherein the volume of pores having a size of 0.1 μm or less is 70% by volume or more relative to the total pore volume.

4. The honeycomb structured body according to claim 3 ,
wherein the honeycomb fired body has a porosity of 55 to 70%.

5. The honeycomb structured body according to claim 3 ,
wherein the alumina particles are θ-phase alumina particles.

6. The honeycomb structured body according to claim 3 ,
wherein a noble metal is supported on the honeycomb fired body.

7. The honeycomb structured body according to claim 2 ,
wherein the honeycomb fired body has a porosity of 55 to 70%.

8. The honeycomb structured body according to claim 2 ,
wherein the alumina particles are θ-phase alumina particles.

9. The honeycomb structured body according to claim 2 ,
wherein a noble metal is supported on the honeycomb fired body.

10. The honeycomb structured body according to claim 1 ,
wherein the honeycomb fired body has a porosity of 55 to 70%.

11. The honeycomb structured body according to claim 10 ,
wherein the alumina particles are θ-phase alumina particles.

12. The honeycomb structured body according to claim 10 ,
wherein a noble metal is supported on the honeycomb fired body.

13. The honeycomb structured body according to claim 1 ,
wherein the alumina particles are θ-phase alumina particles.

14. The honeycomb structured body according to claim 13 ,
wherein a noble metal is supported on the honeycomb fired body.

15. The honeycomb structured body according to claim 1 ,
wherein a noble metal is supported on the honeycomb fired body.

16. A method for producing a honeycomb structured body comprising a honeycomb fired body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween, the method comprising:
a molding step of molding a raw material paste containing ceria-zirconia composite oxide particles and alumina particles into a honeycomb molded body in which multiple through-holes are arranged longitudinally in parallel with one another with a partition wall therebetween;
a drying step of drying the honeycomb molded body obtained in the molding step; and
a firing step of firing the honeycomb molded body dried in the drying step into a honeycomb fired body,
wherein the alumina particles for use in preparation of the raw material paste have an average particle size of 1 to 5 μm, a cumulative particle size distribution D10 of 0.5 to 2 μm, and a cumulative particle size distribution D90 of 2 to 10 μm,
the ceria-zirconia composite oxide particles have an average particle size of 1 to 5 μm, a cumulative particle size distribution D10 of 0.5 to 2 μm, and a cumulative particle size distribution D90 of 2 to 10 μm, and
the alumina particles have an average particle size larger than the average particle size of the ceria-zirconia composite oxide particles.

17. The method for producing a honeycomb structured body according to claim 16 ,
wherein in the drying step, the honeycomb molded body obtained in the molding step is freeze-dried.

18. The method for producing a honeycomb structured body according to claim 17 ,
wherein the weight ratio of the ceria-zirconia composite oxide particles to the alumina particles (ceria-zirconia composite oxide particles/alumina particles) for use in preparation of the raw material paste is 1.0 to 3.0.

19. The method for producing a honeycomb structured body according to claim 16 ,
wherein the weight ratio of the ceria-zirconia composite oxide particles to the alumina particles (ceria-zirconia composite oxide particles/alumina particles) for use in preparation of the raw material paste is 1.0 to 3.0.

20. The method for producing a honeycomb structured body according to claim 16 ,
further comprising a supporting step of allowing a noble metal to be supported on the honeycomb fired body.

Assignees

• Ibiden Co Ltd
• Toyota Motor Co Ltd

Inventors

• Goto Shinnosuke
• Nomura Kenta
• Tojo Takumi
• Yoshida Takeru
• Suzuki Hiromasa

Classifications

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• B01J23/63

  with rare earths or actinides · CPC title

• C04B35/4885

  with aluminium oxide · CPC title

• F01N2510/06

  for exhaust purification, e.g. catalytic reaction · CPC title

• F01N3/2828

  Ceramic multi-channel monoliths, e.g. honeycombs · CPC title