Honeycomb structure and manufacturing method of the same

Patent metadata

Field	Value
Publication number	US-9273582-B2
Application number	US-201414187752-A
Country	US
Kind code	B2
Filing date	Feb 24, 2014
Priority date	Mar 29, 2013
Publication date	Mar 1, 2016
Grant date	Mar 1, 2016

Abstract

A honeycomb structure includes a tubular honeycomb structure body having porous partition walls to define and form a plurality of cells, and an outer peripheral wall; and a pair of electrode sections disposed on a side surface of the honeycomb structure body, an electrical resistivity of the honeycomb structure body is from 1 to 200 Ωcm, each of the pair of electrode sections is formed into a band shape extending in an extending direction of the cells, the electrode section contains silicon and an aggregate, and a ratio (the silicon/the aggregate) of a volume of the silicon to be contained in the electrode section to a volume of the aggregate to be contained in the electrode section is from 60/40 to 80/20.

First claim

What is claimed is:

1. A honeycomb structure comprising:
a tubular honeycomb structure body having porous partition walls to define and form a plurality of cells as through channels of a fluid which extend from a first end surface as one end surface to a second end surface as the other end surface, and an outer peripheral wall positioned on the outermost periphery; and
a pair of electrode sections disposed on a side surface of the tubular honeycomb structure body,
wherein an electrical resistivity of the tubular honeycomb structure body is from 1 to 200 Ωcm,
each of the pair of electrode sections is formed into a band shape extending in an extending direction of the plurality of cells of the tubular honeycomb structure body,
in a cross section perpendicular to the extending direction of the plurality of cells, one electrode section in the pair of electrode sections is disposed on a side opposite to the other electrode section in the pair of electrode sections via the center of the tubular honeycomb structure body,
each of the electrode sections contains silicon and an aggregate, and a ratio of a volume of the silicon to be contained in the electrode section to a volume of the aggregate to be contained in the electrode section is from 60/40 to 80/20.

2. The honeycomb structure according to claim 1 ,
wherein an average particle diameter of the aggregate is from 0.1 to 5 μm.

3. The honeycomb structure according to claim 1 ,
wherein the aggregate includes particles made of a material including at least one selected from the group consisting of silicon carbide, silicon nitride, mullite, and alumina.

4. The honeycomb structure according to claim 3 ,
wherein the aggregate includes particles made of silicon carbide and particles made of mullite, and a ratio of a volume of the particles made of the silicon carbide to a volume of the particles made of the mullite is from 20/80 to 80/20.

5. The honeycomb structure according to claim 1 ,
wherein each of the electrode sections further contains an alkaline earth metal oxide, Al 2 O 3 , and SiO 2 .

6. The honeycomb structure according to claim 5 ,
wherein the alkaline earth metal oxide is MgO.

7. The honeycomb structure according to claim 5 ,
wherein each of the electrode sections contains the alkaline earth metal oxide, Al 2 O 3 , and SiO 2 as much as 2 to 10 parts by volume in total, when a total volume of the silicon and the aggregate is 100 parts by volume.

8. The honeycomb structure according to claim 1 ,
wherein each of the electrode sections contains at least one selected from the group consisting of Ni, Co, Fe, Ca, Al, B, and P as a component in the silicon to be contained in the electrode section.

9. The honeycomb structure according to claim 8 ,
wherein each of the electrode sections contains the at least one selected from the group as the component in the silicon at an atomic number ratio of 0.1 to 10 at % to an atomic number of the silicon.

10. The honeycomb structure according to claim 1 ,
wherein each of in the electrode sections, the silicon is an n-type semiconductor.

11. The honeycomb structure according to claim 1 ,
wherein a porosity of each of the electrode sections is from 5 to 40%.

12. The honeycomb structure according to claim 1 ,
wherein a thickness of each of the electrode sections is from 50 to 300 μm.

13. The honeycomb structure according to claim 1 , further comprising:
a surface coating layer disposed to cover at least part of a surface of each of the electrode sections.

14. The honeycomb structure according to claim 13 ,
wherein the surface coating layer is made of a material including at least one selected from the group consisting of silicon carbide, silicon nitride, mullite, and alumina.

15. The honeycomb structure according to claim 14 ,
wherein the surface coating layer further contains an alkaline earth metal oxide, Al 2 O 3 , and SiO 2 .

16. The honeycomb structure according to claim 13 ,
wherein a thickness of the surface coating layer is from 0.5 to 50 μm.

17. A manufacturing method of a honeycomb structure comprising:
an electrode section forming step of applying an electrode section forming raw material to each of a first region and a second region of a side surface of a tubular honeycomb structure body having partition walls to define and form a plurality of cells as through channels of a fluid which extend from a first end surface as one end surface to a second end surface as the other end surface, and an outer peripheral wall positioned on the outermost periphery, or a fired tubular honeycomb structure body obtained by firing the tubular honeycomb structure body, and drying and firing the applied electrode section forming raw material, to form a pair of electrode sections,
wherein in the electrode section forming step, the electrode section forming raw material is applied in a band shape so that in a cross section perpendicular to an extending direction of the plurality of cells of the tubular honeycomb structure body or the fired tubular honeycomb structure body, the first region is positioned on a side opposite to the second region via the center of the tubular honeycomb structure body or the fired tubular honeycomb structure body,
the electrode section forming raw material includes silicon and an aggregate, and a ratio of a volume of the silicon to be included in the electrode section forming raw material to a volume of the aggregate to be included in the electrode section forming raw material is from 60/40 to 80/20, and
wherein the fired tubular honeycomb structure body has an electrical resistivity of from 1 to 200 Ωcm.

18. The manufacturing method of the honeycomb structure according to claim 17 ,
wherein as the silicon to be included in the electrode section forming raw material, silicon powder having an average particle diameter of 5 to 15 μm is used.

19. The manufacturing method of the honeycomb structure according to claim 17 ,
wherein a content of silicon in the silicon powder is from 90.0 to 99.9 at %.

20. The manufacturing method of the honeycomb structure according to claim 17 ,
wherein the electrode section forming raw material applied to the first region and the second region is dried, and then a surface coating layer forming raw material is applied to at least part of the surface of the electrode section forming raw material.

Assignees

• Ngk Insulators Ltd

Inventors

• Kikuchi Yoshio
• Suzuki Takashi

Classifications

• 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

• F01N3/2803 Primary

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

• Y10T29/49204

  Contact or terminal manufacturing · CPC title

• F01N3/2026

  directly electrifying the catalyst substrate, i.e. heating the electrically conductive catalyst substrate by joule effect · CPC title

• C04B2111/00793

  as filters or diaphragms · CPC title