Honeycomb structural body and manufacturing method thereof

• US 20050247038A1
• Filed: 03/30/2005
• Published: 11/10/2005
• Est. Priority Date: 05/06/2004
• Status: Active Grant

• Current Assignee: Ibiden Co., Ltd.
• Original Assignee: Ibiden Co., Ltd.
• Inventors: Takahashi, Tomohisa
• Granted Patent: US 7,846,229 B2
• Time in Patent Office: Days
• US Class Current: 55/523
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 46/2466 of the adhesive layers, i.e. joints between segments
• CPC Class Codes: B01D 46/2482 Thickness, height, width, length or diameter
• CPC Class Codes: B01D 46/2484 Cell density, area or aspect ratio
• CPC Class Codes: B01D 46/2486 characterised by the shapes or configurations
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: B01D 53/9454 characterised by a specific device
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 27/224 Silicon carbide
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B28B 1/002 assembled from preformed elements
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 2235/383 Alpha silicon carbide
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5228 Silica and alumina, including aluminosilicates, e.g. mullite
• CPC Class Codes: C04B 2235/5232 Silica or silicates other than aluminosilicates, e.g. quartz
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/5445 submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/5472 : Bimodal, multi-modal or multi-fraction
• CPC Class Codes: C04B 2237/08 : Non-oxidic interlayers
• CPC Class Codes: C04B 2237/083 : Carbide interlayers, e.g. silicon carbide interlayers
• CPC Class Codes: C04B 2237/09 : wherein the active component for bonding is not the largest fraction of the interlayer
• CPC Class Codes: C04B 2237/34 : Oxidic
• CPC Class Codes: C04B 2237/341 : Silica or silicates
• CPC Class Codes: C04B 2237/343 : Alumina or aluminates
• CPC Class Codes: C04B 2237/346 : Titania or titanates
• CPC Class Codes: C04B 2237/348 : Zirconia, hafnia, zirconates or hafnates
• CPC Class Codes: C04B 2237/36 : Non-oxidic
• CPC Class Codes: C04B 2237/361 : Boron nitride
• CPC Class Codes: C04B 2237/365 : Silicon carbide
• CPC Class Codes: C04B 2237/366 : Aluminium nitride
• CPC Class Codes: C04B 2237/368 : Silicon nitride
• CPC Class Codes: C04B 2237/708 : of one or more of the interlayers
• CPC Class Codes: C04B 2237/76 : Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
• CPC Class Codes: C04B 35/00 : Shaped ceramic products characterised by their composition porous ceramic products C04B38/00; ceramic articles characterised by particular shape, see the relevant classes, e.g. linings for casting ladles, tundishes, cups or the like B22D41/02; ceramic substrates for microelectronic semi-conductors H01L23/15; Ceramics compositions containing free metal bonded to carbides, diamond, oxides, borides, nitrides, silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides or sulfides other than as macroscopic reinforcing agents C22C; shaping of ceramics B28B; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products chemical preparation of powders of inorganic compounds C01; infiltration of sintered ceramic preforms with molten metal C04B41/51
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/6263 : characterised by their solids loadings, i.e. the percentage of solids
• CPC Class Codes: C04B 38/00 : Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: C04B 38/0006 : Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 41/48 : Macromolecular compounds
• CPC Class Codes: C04B 41/50 : with inorganic materials
• CPC Class Codes: F01N 2450/28 : by using adhesive material, e.g. cement
• CPC Class Codes: F01N 3/0222 : the structure being monolithic, e.g. honeycombs
• CPC Class Codes: F01N 3/2828 : Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• CPC Class Codes: Y10T 29/49604 : Filter

Abstract

A honeycomb structural body comprising: a ceramic block having a flat shape in which a plurality of honeycomb units are bonded to each other through a sealing material layer, said honeycomb unit mainly comprises porous ceramic and includes a large number of through holes placed in parallel with one another in a longitudinal direction with a partition wall interposed therebetween; and a sealing material layer formed on a peripheral portion thereof, wherein the sealing material layer among the honeycomb units on a cross section perpendicular to the longitudinal direction has a pattern that is formed in a diagonal direction with respect to a major axis of a shape forming a contour of the cross section.

Claims

1. A honeycomb structural body comprising:

a ceramic block having a flat shape in which a plurality of honeycomb units are bonded to each other through a sealing material layer, said honeycomb unit mainly comprises porous ceramic and includes a large number of through holes placed in parallel with one another in a longitudinal direction with a partition wall interposed therebetween; and

a sealing material layer formed on a peripheral portion thereof,

wherein

the sealing material layer among the honeycomb units on a cross section perpendicular to the longitudinal direction has a pattern that is formed in a diagonal direction with respect to a major axis of a shape forming a contour of the cross section.

2. The honeycomb structural body according to claim 1,

wherein

said honeycomb unit has a cross-sectional area of about 25 cm² or less in a direction perpendicular to the longitudinal direction.

3. The honeycomb structural body according to claim 2,

wherein

said honeycomb unit has a cross-sectional area of about 1 cm² or more in a direction perpendicular to the longitudinal direction.

4. The honeycomb structural body according to claim 1,

wherein

said honeycomb unit has a race-track shape or an elliptical shape on the cross section perpendicular to the longitudinal direction.

5. The honeycomb structural body according to claim 1,

wherein

the angle, formed by the pattern of the sealing material layer among the honeycomb units on the cross section perpendicular to the longitudinal direction and the major axis in the shape forming the contour of the cross section, is at least about 5°

and at most about 85°

.

6. The honeycomb structural body according to claim 5,

wherein

the angle, formed by the pattern of the sealing material layer among the honeycomb units on the cross section perpendicular to the longitudinal direction and the major axis in the shape forming the contour of the cross section, is in the range of about 15°

to 75°

.

7. The honeycomb structural body according to claim 5,

wherein

the angle, formed by the pattern of the sealing material layer among the honeycomb units on the cross section perpendicular to the longitudinal direction and the major axis in the shape forming the contour of the cross section, is in the range of about 30°

to 60°

.

8. The honeycomb structural body according to claim 1,

wherein

said sealing material layer on the peripheral portion has a thickness of at least about 0.1 mm and at most about 10 mm.

9. The honeycomb structural body according to claim 8,

wherein

said sealing material layer on the peripheral portion has a thickness in the range of about 0.1 to 4 mm.

10. The honeycomb structural body according to claim 1,

wherein

said sealing material layer bonding said honeycomb units has a thickness of at least about 0.1 mm and at most about 10 mm.

11. The honeycomb structural body according to claim 10,

wherein

said sealing material layer bonding said honeycomb units has a thickness in the range of about 0.2 to 3 mm.

12. The honeycomb structural body according to claim 1,

wherein

said sealing material layer comprises an in organic binder, an organic binder and an inorganic fiber and/or an inorganic particle.

13. The honeycomb structural body according to claim 1,

wherein

said honeycomb unit comprises at least one member selected from the group consisting of nitride ceramics, carbide ceramics, and oxide ceramics.

14. The honeycomb structural body according to claim 13,

wherein

said honeycomb unit comprises a silicon carbide-natured ceramic.

15. The honeycomb structural body according to claim 1,

further comprising a catalyst supported thereon.

16. The honeycomb structural body according to claim 1,

wherein each of said through holes is sealed on either one of the end sides.

17. A method for manufacturing a honeycomb structural body having a flat shape,

comprising the steps of:

the honeycomb unit bonding process of

bonding a plurality of honeycomb units, each of which mainly comprises porous ceramics and includes a large number of through holes placed in parallel with one another in the longitudinal direction with a partition wall interposed therebetween, to one another through a sealing material layer and drying the honeycomb units; and

the ceramic block manufacturing process of

carrying out a cutting process on a honeycomb unit aggregated body in which a plurality of honeycomb units are bonded to each other through a sealing material layer in a manner that the pattern of the sealing material layer among the honeycomb units on a cross section perpendicular to the longitudinal direction is formed in a diagonal direction with respect to a major axis of a shape forming a contour of the cross section so as to obtain a ceramic block having a flat shape.

18. The method for manufacturing a honeycomb structural body according to claim 17,

wherein

said honeycomb unit comprises at least one member selected from the group consisting of nitride ceramics, carbide ceramics, and oxide ceramics.

19. The method for manufacturing a honeycomb structural body according to claim 18,

wherein

said honeycomb unit comprises a silicon carbide-natured ceramic.

20. The method for manufacturing a honeycomb structural body according to claim 17,

wherein

the plurality of honeycomb units are bonded to each other through the sealing material layer so that the thickness of the sealing material layer after drying is at least about 0.1 mm and at most about 10 mm.

21. The method for manufacturing a honeycomb structural body according to claim 20,

wherein

the plurality of honeycomb units are bonded to each other through the sealing material layer so that the thickness of the sealing material layer after drying is in the range of about 0.2 to 3 mm.

22. The method for manufacturing a honeycomb structural body according to claim 17,

wherein a diamond cutter is used in the cutting process.