Joining material and silicon carbide based honeycomb structure

Patent metadata

Field	Value
Publication number	US-11767270-B2
Application number	US-202016803092-A
Country	US
Kind code	B2
Filing date	Feb 27, 2020
Priority date	Mar 27, 2019
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A joining material used for joining side surfaces of a plurality of silicon carbide-based honeycomb segments to each other to produce a silicon carbide-based honeycomb structure. The joining material contains from 0.1 to 50% by mass of processed powder generated in the production of the silicon carbide-based honeycomb segments and/or the silicon carbide-based honeycomb structure. The joining material has an average particle diameter D50 of from 0.5 to 60 μm.

First claim

What is claimed is:

1. A joining material used for joining side surfaces of a plurality of silicon carbide-based honeycomb segments to each other to produce a silicon carbide-based honeycomb structure, the joining material containing from 0.1 to 50% by mass of processed powder generated in the production of the silicon carbide-based honeycomb segments and/or the silicon carbide-based honeycomb structure, the joining material having an average particle diameter D50 of from 0.5 to 60 μm;
wherein the processed powder has a particle size D90 of from 4 to 150 μm in a cumulative particle diameter distribution on a volume basis;
wherein the processed powder has a particle size D10 of from 0.1 to 10 μm in the cumulative particle diameter distribution on the volume basis;
wherein the joining material contains from 0.1 to 8% by mass of a pore former;
wherein the processed powder is a composite material of silicon carbide powder and metallic silicon; and
wherein the joining material is a pasty joining material when joining the side surfaces of the plurality of silicon carbide-based honeycomb segments.

2. The joining material according to claim 1 , further comprising at least one selected from inorganic powder, inorganic fibers, a binder, and a dispersant.

3. A silicon carbide-based honeycomb structure, the silicon carbide-based honeycomb structure comprising: a plurality of silicon carbide-based honeycomb segments; and joining layers, the joining layers joining side surfaces of the plurality of silicon carbide-based honeycomb segments to each other, wherein each of the joining layers is a cured layer of the joining material according to claim 1 .

4. The silicon carbide-based honeycomb structure according to claim 3 , wherein the joining layers have a joining strength of from 200 to 2000 kPa.

5. The silicon carbide-based honeycomb structure according to claim 3 , wherein the joining layers have a Young's modulus of from 4 to 100 MPa.

6. The silicon carbide-based honeycomb structure according to claim 3 , wherein the joining layers have a porosity of from 40 to 85%.

7. The silicon carbide-based honeycomb structure according to claim 3 , wherein the joining layers have a thermal expansion coefficient of from 2.0×10 −6 to 8.0×10 −6 /K.

Assignees

• Ngk Insulators Ltd

Inventors

• Kimura Keisuke

Classifications

• C04B38/0019 Primary

  characterised by the material used for joining separate subunits · CPC title

• B01D39/2068

  Other inorganic materials, e.g. ceramics · CPC title

• B01D46/2418

  Honeycomb filters (used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006) · CPC title

• B01D46/2425

  characterized by parameters related to the physical properties of the honeycomb structure material · CPC title

• B01D46/2448

  of the adhesive layers, i.e. joints between segments · CPC title