CN115103716B - 蜂窝结构体 - Google Patents

蜂窝结构体 Download PDF

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Publication number
CN115103716B
CN115103716B CN202080004154.1A CN202080004154A CN115103716B CN 115103716 B CN115103716 B CN 115103716B CN 202080004154 A CN202080004154 A CN 202080004154A CN 115103716 B CN115103716 B CN 115103716B
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Prior art keywords
honeycomb structure
partition wall
honeycomb
bonding layer
columnar
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CN202080004154.1A
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CN115103716A (zh
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昆野由规
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NGK Insulators Ltd
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NGK Insulators Ltd
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Priority claimed from PCT/JP2020/034764 external-priority patent/WO2021166297A1/ja
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Abstract

蜂窝结构体100具备：多个柱状蜂窝单元10、以及配置成将柱状蜂窝单元10的侧面彼此接合的接合层20，该柱状蜂窝单元10具有：隔壁13，该隔壁13区划形成多个隔室12，该多个隔室12从第一端面11a延伸至第二端面11b而形成流体的流路；以及封孔部14，该封孔部14将规定隔室12的第一端面11a侧的开口端部及剩余隔室12的第二端面11b侧的开口端部封孔。隔壁13含有硅及碳化硅，且平均厚度为0.152～0.254mm。蜂窝结构体100满足以下的式(1)～(3)。(1)y≤1000，(2)y≤717.92x‑0.095，(3)y≥462.4x‑0.153，式中，y为蜂窝结构体100的使用所容许的最高温度(℃)，x为利用以下的式子表示的热传导因子。热传导因子＝(隔壁13的热传导率×接合层20的热传导率)/(接合层20的平均厚度×隔壁13的气孔率)。

Description

蜂窝结构体
技术领域
本发明涉及蜂窝结构体。
背景技术
从柴油发动机、汽油发动机等内燃机、各种燃烧装置等中排出的废气中包含有大量的烟灰等粒子状物质(也称为“PM”)。如果该PM直接释放到大气中，则会引起环境污染，因此，在废气的排气系统搭载有用于捕集PM的集尘用过滤器(也称为“颗粒过滤器”)。作为集尘用过滤器，例如可以举出：从柴油发动机、汽油发动机中排出的废气的净化用的柴油颗粒过滤器(DPF)、汽油颗粒过滤器(GPF)等。上述DPF及GPF中使用蜂窝结构体，该蜂窝结构体具备区划形成多个隔室的隔壁，该多个隔室从第一端面延伸至第二端面而形成流体的流路。
集尘用过滤器中使用的蜂窝结构体随着其使用，粒子状物质堆积到内部。结果，蜂窝结构体的压力损失增大，无法充分得到作为集尘用过滤器的功能。因此，出于使作为集尘用过滤器的捕集能力再生的目的，进行使蜂窝结构体的内部所堆积的粒子状物质定期地燃烧而除去的再生处理。再生处理中，因粒子状物质的燃烧热而在蜂窝结构体产生热应力，因此，蜂窝结构体有时发生破损。
因此，作为用于抑制蜂窝结构体破损的对策，专利文献1中提出了：具有将多个柱状蜂窝单元的侧面彼此进行了接合的接合层的蜂窝结构体。
另外，近年来，为了抑制压力损失上升，多数情况下将隔壁的厚度较小的蜂窝结构体用于集尘用过滤器。专利文献2中提出一种蜂窝结构体，其为了抑制压力损失上升、并且提高废气中的粒子状物质的捕集效率，使隔壁的厚度减小，并且，对隔壁的平均细孔径进行了控制。
现有技术文献
专利文献
专利文献1：日本特开2002－253916号公报
专利文献2：日本特开2013－000680号公报
发明内容
针对具有将多个柱状蜂窝单元的侧面彼此进行了接合的接合层的蜂窝结构体，也研究了使柱状蜂窝单元的隔壁的厚度减小。
然而，如果使柱状蜂窝单元的隔壁的厚度减小，则在再生处理时容易产生裂纹。特别是，蜂窝结构体的内部所堆积的粒子状物质有时急剧燃烧，柱状蜂窝单元的隔壁的厚度越小，越容易因急剧的温度变化而在蜂窝结构体产生裂纹。例如，对该粒子状物质的异常燃烧进行评价的DTI(Drop To Idle)试验中，蜂窝结构体的内部所堆积的粒子状物质在空转状态下急剧燃烧而使蜂窝结构体的温度显著上升，因此，容易因其温度变化而在蜂窝结构体产生裂纹。
本发明是为了解决如上所述的课题而实施的，其目的在于，提供一种即便使柱状蜂窝单元的隔壁的厚度减小、也能够在再生处理时抑制裂纹产生的蜂窝结构体。
本发明的发明人对具有将隔壁厚度较小的多个柱状蜂窝单元的侧面彼此进行了接合的接合层的蜂窝结构体进行了潜心研究，结果发现，通过对蜂窝结构体的使用所容许的最高温度与热传导因子之间的关系进行控制，能够解决上述的课题，以至完成本发明，该热传导因子利用构成柱状蜂窝单元的隔壁的热传导率及气孔率、以及将柱状蜂窝单元的侧面彼此接合的接合层的热传导率及平均厚度表示。
即，本发明是一种蜂窝结构体，其具备：多个柱状蜂窝单元、以及配置成将所述柱状蜂窝单元的侧面彼此接合的接合层，
所述柱状蜂窝单元具有：隔壁，该隔壁区划形成多个隔室，该多个隔室从第一端面延伸至第二端面而形成流体的流路；以及封孔部，该封孔部将规定的隔室的所述第一端面侧的开口端部及剩余的隔室的所述第二端面侧的开口端部封孔，
所述蜂窝结构体的特征在于，
所述隔壁含有硅及碳化硅，且平均厚度为0.152～0.254mm，
所述蜂窝结构体满足以下的式(1)～(3)。
(1)y≤1000
(2)y≤717.92x-0.095
(3)y≥462.4x-0.153
式中，y为蜂窝结构体的使用所容许的最高温度(℃)，x为利用以下的式子表示的热传导因子。
热传导因子＝(隔壁的热传导率×接合层的热传导率)/(接合层的平均厚度×隔壁的气孔率)
发明效果
根据本发明，能够提供即便使柱状蜂窝单元的隔壁的厚度减小、也能够在再生处理时抑制裂纹产生的蜂窝结构体。
附图说明
图1是本发明的实施方式所涉及的蜂窝结构体的端面图。
图2是构成图1的蜂窝结构体的柱状蜂窝单元的与隔室延伸的方向平行的截面图。
图3是表示热传导因子与蜂窝结构体的最高温度之间的关系的曲线图。
图4是样品No.B－5的蜂窝结构体的空转状态下的温度分布图。
图5是样品No.B－2的蜂窝结构体的空转状态下的温度分布图。
具体实施方式
以下，参照附图，对本发明的实施方式具体地进行说明。本发明并不限定于以下的实施方式，应当理解：在不脱离本发明的主旨的范围内，基于本领域技术人员的通常知识，对以下的实施方式适当加以变更、改良等得到的实施方式也落在本发明的范围内。
图1是本发明的实施方式所涉及的蜂窝结构体的端面图。另外，图2是构成图1的蜂窝结构体的柱状蜂窝单元的与隔室延伸的方向平行的截面图。
如图1所示，蜂窝结构体100具备：多个柱状蜂窝单元10、以及配置成将柱状蜂窝单元10的侧面彼此接合的接合层20。另外，对于蜂窝结构体100，可以根据需要对外周部进行磨削加工等而加工成圆柱状等规定形状。这种情况下，通过加工而成为柱状蜂窝单元10的内部的隔壁13及隔室12露出的状态，因此，可以将露出面利用涂层材料进行被覆等而设置外周涂层30。
蜂窝结构体100的形状没有特别限定，除了圆柱状以外，可以采用端面为椭圆形的柱状、端面为正方形、长方形、三角形、五边形、六边形等多边形的柱状等。
如图2所示，柱状蜂窝单元10具有：隔壁13，该隔壁13区划形成多个隔室12，该多个隔室12从第一端面11a延伸至第二端面11b而形成流体的流路；以及封孔部14，该封孔部14将规定隔室12的第一端面11a侧的开口端部及剩余隔室12的第二端面11b侧的开口端部封孔。
隔壁13含有硅及碳化硅。通过采用含有像这样的成分的隔壁13，能够提高耐热性及热传导性，因此，能够抑制因热应力而产生裂纹。
隔壁13除了含有上述的成分以外，还可以含有堇青石、多铝红柱石、氧化铝、二氧化钛、尖晶石、碳化硅－堇青石系复合材料、硅酸锂铝、钛酸铝、铁－铬－铝系合金等公知的成分。
隔壁13的平均厚度为0.152～0.254mm。通过使平均厚度为0.152mm以上，能够确保作为集尘用过滤器的强度。另外，通过使平均厚度为0.254mm以下，能够抑制压力损失上升。
蜂窝结构体100满足以下的式(1)～(3)。
(1)y≤1000
(2)y≤717.92x-0.095
(3)y≥462.4x-0.153
式中，y为蜂窝结构体100的使用所容许的最高温度(℃)，x为利用以下的式子表示的热传导因子。
热传导因子＝(隔壁13的热传导率×接合层20的热传导率)/(接合层20的平均厚度×隔壁13的气孔率)
上述的式(1)～(3)是如下得到的关系式，即，制作蜂窝结构体100的各种样品，对再生处理时有无产生裂纹(具体而言、产生环状裂纹或端面裂纹)及即将进入空转状态之前的烟灰的燃烧率进行调查，根据该调查结果，通过实验导出关系式。应予说明，环状裂纹是：在蜂窝结构体100的外周沿着外周方向而形成的环状的裂纹。另外，端面裂纹是：在蜂窝结构体100的端面的隔壁13所形成的裂纹。
此处，对上述的调查结果进行说明。
首先，如下制作蜂窝结构体100的各种样品。
(柱状蜂窝单元10的制作)
作为原料，将碳化硅粉末及金属硅粉末按20：35的质量比例混合，在其中加入造孔材料(相对于碳化硅粉末及金属硅粉末的合计质量而言为10质量％以下)、粘合剂(相对于碳化硅粉末及金属硅粉末的合计质量而言为2～10质量％)、表面活性剂及水，进行混合及混炼，制成坯土。接下来，将得到的坯土挤出成型并切断，利用微波及热风进行干燥，由此得到柱状蜂窝成型体。接下来，针对该柱状蜂窝成型体，按一个端面(第一端面11a)和另一个端面(第二端面11b)呈互补的棋盘格状的方式，将1个隔室12的2个端面中的任一个端面的开口端部封孔。封孔用浆料使用与柱状蜂窝成型体的原料同样的材料。将封孔用浆料向开口端部填充并使其干燥后，将已封孔的柱状蜂窝成型体在大气气氛中于200～600℃进行脱脂，然后，在Ar惰性气氛中于1420～1480℃进行烧成，由此得到柱状蜂窝单元10。通过在挤出成型时调整口模的狭缝宽度来控制柱状蜂窝单元10的隔壁13的平均厚度。另外，通过调整造孔材料的量来控制隔壁13的气孔率。采用压汞仪(Micromeritics公司制、商品名：Autopore 9500)来测定隔壁13的气孔率。通过调整气孔率或对烧成后的柱状蜂窝单元10进行氧化处理来控制隔壁13的热传导率。可以利用现有公知的方法来进行氧化处理。具体而言，可以通过将烧成后的柱状蜂窝单元10在氧气氛下(例如氧浓度15～20质量％)加热到900～1400℃来进行氧化处理。
(接合材料的制备)
接合材料为用于形成接合层20的材料，通过使其固化而成为接合层20。配合与柱状蜂窝单元10相同的原料，进行混合，由此制备糊料状的接合材料。通过调整气孔率来控制接合层20的热传导率。与上述柱状蜂窝单元10同样地，通过调整造孔材料的量来控制气孔率。
(蜂窝结构体100的制作)
按规定平均厚度在柱状蜂窝单元10的侧面涂布接合材料，与另一柱状蜂窝单元10的侧面接合。反复进行该工序，制作将纵3个×横3个柱状蜂窝单元10接合得到的共9个柱状蜂窝单元10的层叠体。然后，通过从外部施加压力而使柱状蜂窝单元10彼此压接，于120℃使其干燥2小时，由此得到柱状蜂窝单元10的接合体。接下来，对接合体的外周进行切削加工，以使得到的接合体的与中心轴垂直的方向上的截面为圆形。接下来，在其加工面涂布与接合材料相同组成的外周涂层材料，然后，于600℃加热0.5小时以上，由此使其干燥并固化而形成外周涂层30，得到样品No.A－1～A－9、B－1～B－9及C－1～C－9的蜂窝结构体100。
接下来，如下调查有无产生裂纹。
在上述制作的蜂窝结构体100的外周部卷上陶瓷制的非膨胀垫，装罐于不锈钢(SUS409)制的罐体，制成装罐结构体。然后，使包含通过柴油燃料(轻油)燃烧而产生的烟灰(粒子状物质)的燃烧气体从蜂窝结构体100的一个端面流入，并从另一个端面流出。由此，使烟灰堆积在蜂窝结构体100内。接下来，将装罐结构体与排气系统连接，进行DTI(Drop ToIdle)试验。具体而言，在全油门状态(2300rpm)下利用废气的热使蜂窝结构体100升温后，在温度达到650℃时，迅速切换到空转状态(600rpm)，使烟灰燃烧，由此对蜂窝结构体100进行再生处理。全油门状态下的废气的氧浓度为6％，空转状态下的氧浓度为15％。
上述的DTI试验中，对空转状态下的蜂窝结构体100的温度进行测定，将该测定得到的温度的最大值设为最高温度。这是因为：蜂窝结构体100内所堆积的烟灰在空转状态下急剧燃烧而使蜂窝结构体100的温度明显上升。
另外，DTI试验后，利用X射线CT，对蜂窝结构体100有无裂纹进行调查。
此外，进行即将进入空转状态之前(全油门状态)的烟灰的燃烧评价。具体而言，根据基于实测温度数据得到的烟灰燃烧模型，计算出即将进入空转状态之前的烟灰的燃烧率。
将上述的结果示于表1。另外，将表示根据隔壁13的热传导率及气孔率、以及接合层20的热传导率及平均厚度计算出的热传导因子x与蜂窝结构体100的最高温度之间的关系的曲线图示于图3。应予说明，表1中，将没有发现裂纹的情形表示为〇，将发现了裂纹的情形表示为×。
表1
Figure BDA0002915921940000071
如表1及图3所示，利用上述的式(1)～(3)表示的范围内的蜂窝结构体100(本发明例)在再生处理中没有产生裂纹，与此相对，利用上述的式(1)～(3)表示的范围外的蜂窝结构体100(比较例)在再生处理中产生了裂纹。
另外，关于烟灰的燃烧评价，产生了裂纹的蜂窝结构体100(比较例)的即将进入空转状态之前(全油门状态)的烟灰的燃烧率较高。DTI试验中，在即将进入空转状态之前的全油门状态下，烟灰也进行燃烧，但是，如果在全油门状态下烟灰大量燃烧，则蜂窝结构体100被其燃烧热加热。然后，被加热的蜂窝结构体100在空转状态下被烟灰的燃烧热进一步加热，因此，蜂窝结构体100的最高温度升高，结果容易产生裂纹。即将进入空转状态之前的烟灰的燃烧率的评价基准根据蜂窝结构体100的直径及长度以及柱状蜂窝单元10的隔壁13的平均厚度的条件而不同。在这些条件相同的样品No.A－1～A－9中，如果烟灰的燃烧率为15.7％以下，在样品No.B－1～B－9中，如果烟灰的燃烧率为0.83％以下，在样品No.C－1～C－9中，如果烟灰的燃烧率为0.54％以下，则可以说即将进入空转状态之前的烟灰的燃烧率较低(将评价结果表示为“〇”)。通过在即将进入空转状态之前使烟灰的燃烧率降低，使得蜂窝结构体100的加热温度降低，因此，能够降低空转状态下的蜂窝结构体100的加热温度(最高温度)。例如，根据即将进入空转状态之前的烟灰的燃烧率较低的(烟灰的燃烧评价的结果为“〇”的)样品No.A－1、A－2、A－6及A－8和即将进入空转状态之前的烟灰的燃烧率较高的(烟灰的燃烧评价的结果为“×”的)样品No.A－4及A－9的对比，通过满足式(2)y≤717.92x-0.095，能够使即将进入空转状态之前的烟灰的燃烧率降低，从而抑制裂纹的产生。
对于样品No.A－7、B－2、B－7、C－2、C－7及C－9，即将进入空转状态之前的烟灰的燃烧率较低，尽管如此，也产生了裂纹。对其理由进行说明。
样品No.A－7的空转状态下的温度(最高温度)较高(超过1000℃)。此处，将空转状态下的蜂窝结构体100的温度与样品No.A－7同样较高的样品No.B－5的蜂窝结构体100的温度分布图作为参考，示于图4。样品No.B－5与样品No.A－7同样地，隔壁13的热传导率较低，因此，热滞留在蜂窝结构体100内，并且，热逐渐扩散到整个蜂窝结构体100。并且，如图4所示，在空转状态下，蜂窝结构体100的长度方向上的中央部附近达到最高温度。结果，在蜂窝结构体100的长度方向上的中央部附近，容易与废气的流动方向正交地产生由热膨胀引起的拉伸应力，认为是因此而产生环状裂纹。所以，通过满足式(1)y≤1000，能够抑制环状裂纹的产生。
另一方面，对于样品No.B－2、B－7、C－2、C－7及C－9，空转状态下的蜂窝结构体100的温度较低。此处，将样品No.B－2的蜂窝结构体100的温度分布图作为一例示于图5。样品No.B－2、C－2及C－9由于隔壁13的热传导率较高，所以，热在蜂窝结构体100的废气入口的端面附近瞬间地扩散。并且，如图5所示，在空转状态下，蜂窝结构体100的废气入口的端面附近达到最高温度。结果，在蜂窝结构体100的废气入口的端面附近，容易在蜂窝结构体100的长度方向上产生由热膨胀引起的拉伸应力，认为是因此而产生端面裂纹。另外，对于B－7及C－7，隔壁13的热传导率较低，但是，接合层20的热传导率较高，处于容易产生柱状蜂窝单元10的中心部与外周部的隔壁13之间的温度差的状态。结果，产生由柱状蜂窝单元10的中心部与外周部的隔壁13之间的热膨胀差所引起的拉伸应力，在端面附近产生端面裂纹。
应予说明，样品No.B－1、B－4、B－6及B－8与样品No.B－2相比，蜂窝结构体100的轴向(长度方向)上的温度分布平缓。因此，在废气入口的端面附近，蜂窝结构体100的轴向上的热膨胀引起的拉伸应力降低，认为是因此而没有产生端面裂纹。因此，通过满足式(3)y≥462.4x-0.153，能够降低端面裂纹的产生。
根据以上的结果，通过满足上述的式(1)～(3)，能够在蜂窝结构体100的再生处理时抑制裂纹的产生。
蜂窝结构体100优选进一步满足以下的式(4)。
(4)x≤2.3
式(4)与式(1)～(3)同样地是通过实验导出的关系式。通过满足式(4)，能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。热传导因子x更优选为1.5以下，进一步优选为1.0以下，特别优选为0.3以下。
隔壁13的热传导率没有特别限定，优选为0.8～34W/m·K。通过将隔壁13的热传导率控制在该范围内，能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。作为将隔壁13的热传导率控制在上述范围内的方法，例如可以举出：控制气孔率、制造蜂窝结构体100时有无氧化处理以及控制处理时间等。如果提高气孔率或者进行氧化处理，则存在热传导率降低的趋势。
此处，本说明书中，“热传导率”是指：采用激光闪光法于室温(25℃)测定的热传导率。
隔壁13的气孔率没有特别限定，优选为30～70％。通过将隔壁13的气孔率控制在该范围内，能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。
此处，本说明书中，“气孔率”是指：采用压汞仪测定的气孔率。作为压汞仪，可以举出：Micromeritics公司制的商品名Autopore 9500的压汞仪。
作为与隔室12延伸的方向垂直的柱状蜂窝单元10的截面形状，没有特别限定，可以采用三角形、四边形、六边形、八边形等各种形状。其中，柱状蜂窝单元10的截面形状优选为四边形(正方形或长方形)。通过采用像这样的形状的柱状蜂窝单元10，使得蜂窝结构体100的制造变得容易。
作为与隔室12延伸的方向垂直的隔室12的截面形状，没有特别限定，可以为三角形、四边形、六边形、八边形、圆形等各种形状。其中，隔室12的截面形状优选为四边形(正方形或长方形)。
另外，隔室12可以为：具有规定开口面积的第一隔室和开口面积与第一隔室的开口面积不同的第二隔室交替地配设。
柱状蜂窝单元10的隔室密度没有特别限定，优选为23～62个/cm2，更优选为31～52个/cm2。通过使隔室密度为23个/cm2以上，能够确保作为集尘用过滤器的强度。另外，通过使隔室密度为62个/cm2以下，能够抑制压力损失上升。
柱状蜂窝单元10可以按照本技术领域中的公知方法来制造。具体而言，如下制造。首先，在含有硅及碳化硅的陶瓷原料中添加粘合剂、分散剂(表面活性剂)、造孔材料、水等，进行混合及混炼，制成坯土。接下来，将该坯土挤出成型为规定的蜂窝形状，切成所期望的长度，然后，利用微波、热风等使其干燥。针对这样得到的柱状蜂窝成型体，将1个隔室12的2个端面中的任一个端面的开口端部封孔。通常，按一个端面(第一端面11a)和另一个端面(第二端面11b)呈互补的棋盘格状的方式，将相邻的隔室12交错封孔。作为封孔方法，可以采用本技术领域中的公知方法。具体而言，在柱状蜂窝成型体的端面粘贴片材后，在该片材的与待封孔的隔室12对应的位置开孔。然后，在粘贴有该片材的状态下，将柱状蜂窝成型体的端面浸渍于使封孔材料浆料化得到的封孔用浆料中，使该封孔用浆料通过在片材所开的孔，向待封孔的隔室12的开口端部内填充封孔用浆料，将其干燥和/或烧成而使其固化即可。封孔材料采用成分与用于柱状蜂窝成型体的材料相同的材料，以使隔壁13与封孔部14之间的热膨胀差减小。然后，对已封孔的柱状蜂窝成型体进行烧成，由此得到柱状蜂窝单元10。应予说明，可以在对隔室12进行封孔之前进行柱状蜂窝成型体的烧成。另外，在烧成后可以根据需要进行磨削等，以使其成为规定形状。
作为粘合剂，没有特别限定，可以举出：胶体二氧化硅(二氧化硅溶胶)、氧化铝溶胶、膨润土、蒙脱石这样的粘土等无机粘合剂；甲基纤维素、羧甲基纤维素、羟丙氧基纤维素、羟乙基纤维素、聚乙烯醇(PVA)、聚乙烯醇缩丁醛(PVB)、其他各种吸水性树脂等有机粘合剂。这些粘合剂可以单独使用，或者可以2种以上组合使用。
作为分散剂(表面活性剂)，没有特别限定，可以举出：油酸PEG、乙二醇、糊精、脂肪酸皂、多元醇等。这些分散剂可以单独使用，或者可以2种以上组合使用。
作为造孔材料，在烧成后成为气孔即可，没有特别限定，可以举出：淀粉、发泡树脂、吸水性树脂、硅胶、碳等。这些造孔材料可以单独使用，或者可以2种以上组合使用。
作为将柱状蜂窝单元10的侧面彼此接合的接合层20，没有特别限定，可以含有无机粉末、无机纤维、造孔材料、粘合剂及分散剂等成分。其中，用于接合层20的成分优选与用于柱状蜂窝单元10的成分相同。通过采用像这样的构成，能够使柱状蜂窝单元10与接合层20之间的热膨胀差减小，从而能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。
应予说明，采用含有上述成分的糊料状的接合材料来形成接合层20。
接合层20的平均厚度没有特别限定，优选为0.5～3.0mm。通过将接合层20的平均厚度控制在该范围内，能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。
接合层20的热传导率没有特别限定，优选为0.1～1.0W/m·K。通过将接合层20的热传导率控制在该范围内，能够在蜂窝结构体100的再生处理时稳定地抑制裂纹的产生。作为将接合层20的热传导率控制在上述范围内的方法，例如可以举出气孔率的控制等。如果使气孔率提高，则存在热传导率降低的趋势。
蜂窝结构体100采用上述的柱状蜂窝单元10及接合材料来制造。其制造方法没有特别限定，可以利用本技术领域中的公知方法来进行。具体而言，在柱状蜂窝单元10的侧面涂布接合材料而将柱状蜂窝单元10的侧面间接合后，使其干燥，由此能够使接合材料固化而形成接合层20。作为干燥条件，没有特别限定，根据接合材料的组成适当调整即可。另外，可以通过从外部施加压力而使柱状蜂窝单元10彼此压接，同时进行干燥。
蜂窝结构体100可以用作DPF、GPF等集尘用过滤器。这种情况下，对于蜂窝结构体100，包含粒子状物质的废气从一个端面的未设置封孔部14的隔室12向内部流入，通过隔壁13，进入其他隔室12。此时，废气中的粒子状物质被隔壁13捕捉。然后，粒子状物质被捕捉后的废气从另一个端面的未设置封孔部14的隔室12排出。
对于蜂窝结构体100，可以使催化剂担载于隔壁13的表面或细孔内。作为催化剂，没有特别限定，可以根据蜂窝结构体100的用途来选择。例如，将蜂窝结构体100用作DPF的情况下，可以采用用于将废气中的烟灰等氧化除去的氧化催化剂、用于将废气中包含的NOx等有害物质分解除去的NOx选择还原催化剂(SCR)、NOx吸储还原催化剂等。催化剂的担载方法没有特别限定，可以采用本技术领域中的公知方法。
对于具有上述特征的本发明的实施方式所涉及的蜂窝结构体100，即便使柱状蜂窝单元10的隔壁13的厚度减小，也能够在再生处理时抑制裂纹的产生。
符号说明
10 柱状蜂窝单元
11a 第一端面
11b 第二端面
12 隔室
13 隔壁
14 封孔部
20 接合层
30 外周涂层
100 蜂窝结构体

Claims (5)

1.一种蜂窝结构体，其具备：多个柱状蜂窝单元、以及配置成将所述柱状蜂窝单元的侧面彼此接合的接合层，
所述柱状蜂窝单元具有：隔壁，该隔壁区划形成多个隔室，该多个隔室从第一端面延伸至第二端面而形成流体的流路；以及封孔部，该封孔部将规定的隔室的第一端面侧的开口端部及剩余的隔室的第二端面侧的开口端部封孔，
所述蜂窝结构体的特征在于，
所述隔壁含有硅及碳化硅，且平均厚度为0.152～0.254mm，
所述蜂窝结构体满足以下的式(1)～(3)，
(1)y≤1000
(2)y≤717.92x-0.095
(3)y≥462.4x-0.153
式中，y为蜂窝结构体的使用所容许的最高温度，单位为℃，x为利用以下的式子表示的热传导因子，
热传导因子＝(隔壁的热传导率×接合层的热传导率)/(接合层的平均厚度×隔壁的气孔率)，
所述隔壁的热传导率为0.8～34W/m·K，
所述接合层的热传导率为0.1～1.0W/m·K，
所述接合层的平均厚度为0.5～3.0mm，
所述隔壁的气孔率为30～70％。
2.根据权利要求1所述的蜂窝结构体，其特征在于，
所述蜂窝结构体满足以下的式(4)，
(4)x≤2.3。
3.根据权利要求1或2所述的蜂窝结构体，其特征在于，
与所述隔室延伸的方向垂直的所述隔室的截面形状为四边形。
4.根据权利要求1或2所述的蜂窝结构体，其特征在于，
所述隔室中，具有规定开口面积的第一隔室和开口面积与所述第一隔室的开口面积不同的第二隔室交替地配设。
5.根据权利要求1或2所述的蜂窝结构体，其特征在于，
所述蜂窝结构体的隔室密度为31～52个/cm2。
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