Honeycomb structure and die

Patent metadata

Field	Value
Publication number	US-11465137-B2
Application number	US-202016941621-A
Country	US
Kind code	B2
Filing date	Jul 29, 2020
Priority date	Jan 30, 2018
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

A honeycomb structure includes a central area and a reinforced outer peripheral area. For a boundary cell having cell walls with different wall thicknesses on two sides parallel with an imaginary parallel line, a thin wall thickness t1<a thick wall thickness t3, an inner wall thickness t2<an outer wall thickness t4, t1=t2, and t3=t4. The honeycomb structure includes a cross-shaped unit having a thin wall, an inner wall, a cell wall, and a cell wall and a cross-shaped unit having a thick wall, an outer wall, a cell wall, and a cell wall. The honeycomb structure also includes cross-shaped units extending vertically and horizontally from alternate cell vertexes arranged from a cell vertex as a starting point. In the central area and the reinforced outer peripheral area, the cell walls of each cross-shaped unit have a substantially equal wall thickness.

First claim

What is claimed is:

1. A honeycomb structure comprising:
a plurality of cells adjacent to each other and quadrangular 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 four surrounding cells around the honeycomb central axis or 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 of the reinforced outer peripheral area having a wall thickness greater than the wall thickness of the cell wall of the four surrounding cells or the cell wall of the central cell;
Requirement 2: a plurality of cells arranged on an imaginary parallel line passing through the honeycomb central axis and parallel with cell walls or a plurality of cells arranged along over an imaginary perpendicular line passing through the honeycomb central axis and orthogonal to cell walls in a manner to extend through midpoints of the cell walls include a reference boundary cell having cell walls with different wall thicknesses on two sides parallel with the imaginary parallel line or the imaginary perpendicular line, and
with the reference boundary cell including a thin wall being a thin cell wall on one side parallel with the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 1 , a thick wall being a thick cell wall on the other side parallel with the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 3 , an inner wall being a cell wall more adjacent to a honeycomb center than an outer cell wall of the reference boundary cell and orthogonal to the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 2 , and the outer wall being a cell wall more adjacent to a honeycomb periphery than the inner wall of the reference boundary cell and orthogonal to the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 4 ,
t 1 <t 3 , t 2 <t 4 , t 1 =t 2 , and t 3 =t 4 ;
Requirement 3: the honeycomb structure includes
a first reference cross-shaped unit having four cell walls: the thin wall, the inner wall, a cell wall extending in a direction opposite to the thin wall from a first reference cell vertex corresponding to a connection between the thin wall and the inner wall, and a cell wall extending from the first reference cell vertex in a direction opposite to the inner wall, and
a second reference cross-shaped unit having four cell walls: the thick wall, the outer wall, a cell wall extending in a direction opposite to the thick wall from a second reference cell vertex corresponding to a connection between the thick wall and the outer wall, and a cell wall extending from the second reference cell vertex in a direction opposite to the outer wall;
Requirement 4: the honeycomb structure includes a plurality of cross-shaped units each having four cell walls extending vertically and horizontally from and connected to each other at alternate cell vertexes arranged along the cell walls from the first reference cell vertex or the second reference cell vertex as a starting point; and
Requirement 5: for cross-shaped units with their respective cell vertexes within the central area, each cross-shaped unit with their respective cell vertexes within the central area has cell walls with a substantially equal wall thickness; and
for cross-shaped units with their respective cell vertexes within the reinforced outer peripheral area, each cross-shaped unit with their respective cell vertexes within the reinforced outer peripheral area has cell walls with a substantially equal wall thickness.

2. 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 four cell walls forming each cross-shaped unit.

3. The honeycomb structure according to claim 2 , wherein
the wall thickness difference ratio is 5% or less.

4. The honeycomb structure according to claim 1 , wherein
the reinforced outer peripheral area extends to a fourth or any subsequent cell in a direction from the outer peripheral wall to the honeycomb central axis.

5. 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.

6. 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.

7. 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 four surrounding cells or the central cell in the central area.

8. A honeycomb structure comprising:
a plurality of cells adjacent to each other and quadrangular 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 4:
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 four surrounding cells around the honeycomb central axis or 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 of the reinforced outer peripheral area having a wall thickness greater than the wall thickness of the cell wall of the four surrounding cells or the cell wall of the central cell;
Requirement 2: a plurality of cells arranged on an imaginary parallel line passing through the honeycomb central axis and parallel with cell walls or a plurality of cells arranged along over an imaginary perpendicular line passing through the honeycomb central axis and orthogonal to cell walls in a manner to extend through midpoints of the cell walls include a reference boundary cell having cell walls with different wall thicknesses on two sides parallel with the imaginary parallel line or the imaginary perpendicular line, and
with the reference boundary cell including a thin wall being a thin cell wall on one side parallel with the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 1 , a thick wall being a thick cell wall on the other side parallel with the imaginary parallel line or the imaginary perpendicular line and having a wall thickness represented as t 3 , an inner wall being a cell wall more adjacent to a honeycomb center th

Assignees

• Denso Corp

Inventors

• Hayashi Naohiro
• Ito Kenichi

Classifications

• F01N3/022 Primary

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01D46/2484

  Cell density, area or aspect ratio · CPC title

• B28B3/269 Primary

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

• B29C48/11

  comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped · CPC title

• B01D46/2498

  The honeycomb filter being defined by mathematical relationships · CPC title