Honeycomb structure and die

Patent metadata

Field	Value
Publication number	US-11426896-B2
Application number	US-202016942075-A
Country	US
Kind code	B2
Filing date	Jul 29, 2020
Priority date	Jan 30, 2018
Publication date	Aug 30, 2022
Grant date	Aug 30, 2022

Abstract

A honeycomb structure includes a central area and a reinforced outer peripheral area. A reference boundary cell with an inner wall orthogonal to an imaginary straight line, adjacent to the honeycomb center, and thinner than an outer wall adjacent to the honeycomb periphery has a reference wall different in wall thickness from the other three cell walls among the remaining four cell walls excluding the inner wall and the outer wall. The honeycomb structure includes a reference Y-shaped unit having the reference wall, the outer wall, and a cell wall. The honeycomb structure includes a plurality of Y-shaped units extending in the same directions as the reference Y-shaped unit. For every Y-shaped unit in the central area and the reinforced outer peripheral area of the honeycomb structure, the cell walls of each Y-shaped unit has an equal wall thickness.

First claim

What is claimed is:

1. A honeycomb structure comprising:
a plurality of cells adjacent to each other and hexagonal in cross section; a plurality of cell walls forming the plurality of cells; and an outer peripheral wall provided outside the plurality of cell walls and holding the cell walls, wherein as viewed in a cross section perpendicular to a honeycomb central axis, the honeycomb structure satisfies requirements 1 to 5:

Requirement 1: the honeycomb structure includes a central area having cell walls with a wall thickness equal to a wall thickness of a cell wall of a central cell having a cell center with the honeycomb central axis passing therethrough, and a reinforced outer peripheral area having cell walls around the central area, the cell walls having a wall thickness greater than the wall thickness of the cell wall of the central cell;
Requirement 2: a plurality of cells arranged along an imaginary straight line passing through the honeycomb central axis and orthogonal to cell walls include a reference boundary cell having an inner wall adjacent to a honeycomb center and orthogonal to the imaginary straight line and an outer wall adjacent to a honeycomb periphery and orthogonal to the imaginary straight line, with the inner wall having a wall thickness smaller than a wall thickness of the outer wall, and
the reference boundary cell has a reference wall different in wall thickness from the other three cell walls among the remaining four cell walls excluding the inner wall and the outer wall;

Requirement 3: the honeycomb structure includes a reference Y-shaped unit having three cell walls: the reference wall, the outer wall or the inner wall connected with the reference wall, and another cell wall extending from a reference cell vertex corresponding to the connection between the reference wall and the outer wall or the inner wall;
Requirement 4: the honeycomb structure includes a plurality of Y-shaped units each having three cell walls selected from cell wall sets including three cell walls extending radially from each cell vertex of the plurality of cells, the three selected cell walls extending in radial directions identical to directions of the three cell walls extending radially from the reference cell vertex of the reference Y-shaped unit; and
Requirement 5: for every Y-shaped unit in the central area and the reinforced outer peripheral area, the cell walls of each of the Y-shaped units have an equal wall thickness.

2. The honeycomb structure according to claim 1 , wherein
the cell walls of the reinforced outer peripheral area have a wall thickness distribution having 120-degree rotational symmetry about the honeycomb central axis.

3. The honeycomb structure according to claim 1 , wherein
the wall thickness distribution of the cell walls within the reinforced outer peripheral area is symmetric across a first straight line passing through the cell center of the central cell and one pair of cell vertexes of three pairs of cell vertexes facing each other across the cell center, the first straight line serving as an axis of symmetry, and
the wall thickness distribution of the cell walls within the reinforced outer peripheral area is asymmetric across a second straight line orthogonal to the axis of symmetry and passing through the cell center.

4. The honeycomb structure according to claim 1 , wherein
the honeycomb structure has a wall thickness difference ratio of 10% or less, the ratio being calculated in accordance with a formula:
100×(tmax−tmin)/tmax,

where tmax denotes a maximum wall thickness and tmin denotes a minimum wall thickness of the three cell walls forming each Y-shaped unit.

5. The honeycomb structure according to claim 4 , wherein
the wall thickness difference ratio is 5% or less.

6. The honeycomb structure according to claim 1 , wherein
the reinforced outer peripheral area is composed of a region from the outer peripheral wall to any one of the cells located at least in the fourth cell or more in the honeycomb central axis direction.

7. The honeycomb structure according to claim 1 , wherein
the reinforced outer peripheral area extends to a 20th or any previous cell in a direction from the outer peripheral wall to the honeycomb central axis.

8. The honeycomb structure according to claim 1 , wherein
the wall thickness of the cell walls forming the cells in the reinforced outer peripheral area is greatest at the first cell in a direction from the outer peripheral wall to the honeycomb central axis, and gradually decreases from the outer peripheral wall toward the honeycomb central axis.

9. The honeycomb structure according to claim 1 , wherein
the cell walls included in the reinforced outer peripheral area and forming the first cell in a direction from the outer peripheral wall to the honeycomb central axis are 1.4 or more times as thick as the cell walls forming the central cell in the central area.

Assignees

• Denso Corp

Inventors

• Ito Kenichi
• Hayashi Naohiro

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B28B3/269 Primary

  For multi-channeled structures, e.g. honeycomb structures · CPC title

• F01N3/2803

  characterised by structure, by material or by manufacturing of catalyst support · CPC title

• F01N2330/02

  Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal · CPC title

• F01N2330/32

  characterised by the shape, form or number of corrugations of plates, sheets or foils · CPC title