Porous honeycomb structure and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-12570581-B2
Application number	US-202117457312-A
Country	US
Kind code	B2
Filing date	Dec 2, 2021
Priority date	Feb 25, 2021
Publication date	Mar 10, 2026
Grant date	Mar 10, 2026

Abstract

A porous honeycomb structure including cordierite, having a plurality of cell channels which pass through an interior of the porous honeycomb structure and are partitioned by porous partition walls, wherein the porous partition walls have a porosity of 45 to 60% as measured by a mercury intrusion method, wherein in a volume-based cumulative pore diameter distribution measured by the mercury intrusion method, the porous partition walls have a cumulative 10% pore diameter (D10) and a cumulative 50% pore diameter (D50) calculated from a small pore side, and satisfy a relationship of 0.45≤(D50−D10)/D50, and 3 μm≤D50≤10 μm.

First claim

The invention claimed is:

1 . A porous honeycomb structure comprising 70% by mass or more of cordierite, having a plurality of cell channels which pass through an interior of the porous honeycomb structure and are partitioned by porous partition walls,
wherein the porous partition walls have a porosity of 45 to 60% as measured by a mercury intrusion method, wherein in a volume-based cumulative pore diameter distribution measured by the mercury intrusion method, the porous partition walls have a cumulative 10% pore diameter (D10), a cumulative 50% pore diameter (D50), and a cumulative 90% pore diameter (D90) calculated from the volume-based cumulative pore diameter distribution, and satisfy relationships 1.7≤(D90−D10)/D50, 0.45≤(D50-D10)/D50, and 3 μm≤D50≤6 μm, and wherein the porous partition walls have a Young's modulus measured by a resonance method of 10 to 14 GPa.

2 . The porous honeycomb structure according to claim 1 , satisfying 0.50≤(D50−D10)/D50.

3 . The porous honeycomb structure according to claim 1 , wherein thickness of the porous partition walls is 40 to 150 μm.

4 . A method for manufacturing the porous honeycomb structure according to claim 1 , comprising:
molding a green body comprising a cordierite-forming raw material, an organic pore-forming material, a binder and a dispersion medium to obtain a honeycomb formed body, the honeycomb formed body having a plurality of cell channels which pass through an interior of the honeycomb formed body and are partitioned by partition walls, and firing the honeycomb formed body to obtain the porous honeycomb structure; wherein the organic pore-forming material is contained in the honeycomb formed body in an amount of 1.5 parts by mass or more with respect to 100 parts by mass of the cordierite-forming raw material, and in a volume-based cumulative particle diameter distribution measured by a laser diffraction/scattering method, the organic pore-forming material has a cumulative 10% diameter (D10) and a cumulative 50% diameter (D50) calculated from the volume-based cumulative particle diameter distribution, and satisfies a relationship of 0.32≤(D50−D10)/D50, and 10 μm≤D50≤30 μm.

5 . The method according to claim 4 , wherein in the volume-based cumulative particle diameter distribution measured by a laser diffraction/scattering method, the organic pore-forming material has the cumulative 10% diameter (D10), the cumulative 50% diameter (D50), and a cumulative 90% diameter (D90) calculated from the volume-based cumulative particle diameter distribution, and satisfies a relationship of 0.80≤(D90−D10)/D50.

Assignees

• Ngk Insulators Ltd

Inventors

• Aoki Tsubasa
• Sendo Koichi

Classifications

• C04B38/0054

  the pores being microsized or nanosized · CPC title

• C04B38/10

  by using foaming agents (C04B38/02 takes precedence){or by using mechanical means, e.g. adding preformed foam} · CPC title

• C04B38/007

  characterised by the pore distribution, e.g. inhomogeneous distribution of pores · CPC title

• F01N3/0222

  the structure being monolithic, e.g. honeycombs · CPC title

• C04B35/195

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