Honeycomb structure

Patent metadata

Field	Value
Publication number	US-9764990-B2
Application number	US-201514592286-A
Country	US
Kind code	B2
Filing date	Jan 8, 2015
Priority date	Mar 12, 2014
Publication date	Sep 19, 2017
Grant date	Sep 19, 2017

Abstract

A honeycomb structure includes a honeycomb structure body having a partition wall which is constituted of a porous body. The porous body includes a refractory aggregate and a bonding material. The porous body constituting includes the bonding material at a mass proportion of 20 to 35 mass %. In an observation of a cross section of the partition wall with an electron microscope, when observing any given ten visual fields meeting a following condition (1), the number of refractory aggregates meeting a following condition (2) is five pieces or more in all of the ten visual fields.
Condition (1): a proportion of an area occupied by the bonding material is 30% or more.
Condition (2): the refractory aggregate has a particle diameter of 5 μm or more, and 60% or more of an outer circumference of the refractory aggregate is surrounded by the bonding material.

First claim

What is claimed is:

1. A honeycomb structure, comprising:
a fired columnar honeycomb structure body that has partition walls, the partition walls defining a plurality of cells, the plurality of cells extending from a first end face to a second end face and becoming channels for fluid,
wherein each partition wall is constituted of a porous body, the porous body including a refractory aggregate and a bonding material, the bonding material having a main constituent of a metal oxide material, the bonding material bonding the refractory aggregate,
wherein the porous body constituting each partition wall includes the bonding material at a mass proportion of 20 to 35 mass %, and
in an observation of a cross section of the partition walls perpendicular to the cell extending direction of the columnar honeycomb structure body with an electron microscope, when observing any given ten visual fields meeting a following condition (1), the number of refractory aggregates meeting a following condition (2) is five pieces or more in all of the ten visual fields;
Condition (1): the visual field is 100 μm square, and in the visual field, a proportion of an area occupied by the bonding material to a total area of the refractory aggregate and the bonding material in the visual field is 30% or more,
Condition (2): the refractory aggregate has a particle diameter of 5 μm or more, and 60% or more of an outer circumference of the refractory aggregate is surrounded by the bonding material.

2. The honeycomb structure according to claim 1 ,
wherein the bonding material has a main constituent of: a metal oxide of at least one kind of metal selected from the group consisting of Al, Si, and Mg; or a mixture of the oxides.

3. The honeycomb structure according to claim 2 ,
wherein in an observation of the cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with the electron microscope, when observing any given ten visual fields meeting the condition (1), the number of refractory aggregates meeting the condition (2) is seven or more.

4. The honeycomb structure according to claim 3 ,
wherein in an observation of a cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with an electron microscope, when observing any given ten visual fields meeting a following condition (3), the number of refractory aggregates meeting the condition (2) is five or more;
Condition (3): the visual field is 70 μm square, and in the visual field, a proportion of an area occupied by the bonding material to a total area of the refractory aggregate and the bonding material in the visual field is 30% or more.

5. The honeycomb structure according to claim 4 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

6. The honeycomb structure according to claim 3 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

7. The honeycomb structure according to claim 2 ,
wherein in an observation of a cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with an electron microscope, when observing any given ten visual fields meeting a following condition (3), the number of refractory aggregates meeting the condition (2) is five or more;
Condition (3): the visual field is 70 μm square, and in the visual field, a proportion of an area occupied by the bonding material to a total area of the refractory aggregate and the bonding material in the visual field is 30% or more.

8. The honeycomb structure according to claim 7 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

9. The honeycomb structure according to claim 2 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

10. The honeycomb structure according to claim 1 ,
wherein in an observation of the cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with the electron microscope, when observing any given ten visual fields meeting the condition (1), the number of refractory aggregates meeting the condition (2) is seven or more.

11. The honeycomb structure according to claim 10 ,
wherein in an observation of a cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with an electron microscope, when observing any given ten visual fields meeting a following condition (3), the number of refractory aggregates meeting the condition (2) is five pieces or more;
Condition (3): the visual field is 70 μM square, and in the visual field, a proportion of an area occupied by the bonding material to a total area of the refractory aggregate and the bonding material in the visual field is 30% or more.

12. The honeycomb structure according to claim 11 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

13. The honeycomb structure according to claim 10 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

14. The honeycomb structure according to claim 1 ,
wherein in an observation of a cross section of the partition walls perpendicular to the cell extending direction of the honeycomb structure body with an electron microscope, when observing any given ten visual fields meeting a following condition (3), the number of refractory aggregates meeting the condition (2) is five or more;
Condition (3): the visual field is 70 μm square, and in the visual field, a proportion of an area occupied by the bonding material to a total area of the refractory aggregate and the bonding material in the visual field is 30% or more.

15. The honeycomb structure according to claim 14 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

16. The honeycomb structure according to claim 1 ,
wherein the refractory aggregate includes silicon carbide particles or silicon nitride particles.

Assignees

• Ngk Insulators Ltd

Inventors

• Ichikawa Shuichi
• Mizuno Atsushi
• Miyairi Yukio

Classifications

• C04B2111/0081

  as catalysts or catalyst carriers · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• Y10T428/24149

  Honeycomb-like · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title

• C04B38/0019 Primary

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