DE102014008269B4 - honeycomb structure - Google Patents

Abstract

A honeycomb structure (100) comprising: a honeycomb substrate (4) having porous partition walls (1) defining a plurality of cells (2) extending from a first end face (3) as one end face to a second end face (5) as the other end face and become passage channels for a fluid, anda bulging portion (10) continuously or intermittently surrounding at least a part of the outer periphery of the honeycomb substrate (4) in a ring shape, characterized in that the bulging portion (10) is arranged so as to protrudes outwardly from the outer periphery of the honeycomb substrate (4) and covers part of the outer periphery of the honeycomb substrate (4), the shape of at least one end of the bulging portion (10) is a conical shape having a conical surface (11) facing a connecting portion (13) is an inclined surface on the outer circumference, in the cross section perpendicular to the direction of extension of the cells (2) the maximum thickness of the curved portion (10) is 1 to 20 mm, in the cross section parallel to the cell cell extending direction, the width of the bulging portion (10) is 1% or more of the total length of the honeycomb substrate (4), and the inclination angle, which is an angle made between the tapered surface (11) and the cell extending direction, is 80 degrees or less, a part of surface of the curved section (10) is a planar section (15) which is a planar surface parallel to the cell extending direction, the planar section (15) having one or more stress relief sections (17) having columns each with an open end (18) in of the surface, and the sum of the lengths of all the stress relieving portions (17) is 3% or more of the circumferential length of the honeycomb substrate (4).

Description

BACKGROUND OF THE INVENTION

field of invention

The present invention relates to a honeycomb structure. More specifically, it refers to a honeycomb structure in which a ring crack is not easily generated.

background technique

Heretofore, an exhaust gas purification device including a diesel particulate filter (DPF), a catalyst body, or the like has been mounted in an exhaust system for an exhaust gas. The DPF is a filter for collecting particulate matter (PM), which mainly consists of soot. The catalyst body purifies harmful substances such as carbon monoxide (CO), hydrocarbons (HC), and nitrogen oxides ( _NOx ) contained in the exhaust gas. Moreover, a honeycomb structure has been used as a catalyst carrier constituting the catalyst body or the DPF.

A cause of failure of the exhaust gas purification device is, for example, generation of a ring-shaped crack in the honeycomb structure. Such a crack, as it is generated in the honeycomb structure, is referred to as a "ring crack". As in 7 shown, this annular crack is a crack (annular crack 50) which is formed essentially perpendicularly to the direction in which the cells 2 extend in a honeycomb structure 200. Moreover, the ring crack 50 is formed so as to extend in a circumferential direction in the outer periphery of the honeycomb structure. 7 14 is a perspective view schematically showing a state where the ring crack has been generated in a conventional honeycomb structure.

It is considered that the common factor for this ring crack is generation of tensile stress over the entire length direction (cell extending direction) of the honeycomb structure. The tensile stress is a stress caused by a difference between the coefficient of thermal expansion of the ceramic material constituting the honeycomb structure and the coefficient of thermal expansion of the metal case body accommodating the honeycomb structure. This tensile stress is generated when the honeycomb structure is placed in an environment where heating and cooling are repeated. The tensile stress will tend to increase as the ratio (A/B) increases, where A is the length (overall length (A)) of the honeycomb structure in the cell extending direction and B is the diameter (outer diameter (B)) of the honeycomb structure in the cross section perpendicular to the cell direction is. That is, the larger A/B, the more easily the ring crack is generated. Here, the total length (A) is “the length in the cell extending direction” of the honeycomb structure. Further, the outer diameter (B) is the diameter "in the cross section perpendicular to the cell extending direction" of the honeycomb structure.

Thus, as a method for inhibiting the generation of the ring crack, there is known a method in which the outer diameter is increased to decrease A/B. Moreover, a honeycomb structure in which A/B is in a predetermined range has been proposed (see, for example, Patent Document 1).

Patent Document 2 discloses a honeycomb structure that hardly generates ring cracks, the honeycomb structure comprising a honeycomb base body having porous partitions and an annular convex portion. Patent Document 3 describes a grinding method for manufacturing a related honeycomb structure having an annular convex portion.

• [Patent Document 1] JP H09- 299 811 A
• [Patent Document 2] DE 10 2013 015 626 A1
• [Patent Document 3] EP 2 724 814 A2

SUMMARY OF THE INVENTION

A problem, however, is that as the outer diameter of the honeycomb structure is increased, the degree of difficulty in manufacturing also increases. Further, when the honeycomb structure is used as a catalyst carrier, as the outer diameter becomes larger, the amount of noble metal to be loaded also increases. Moreover, as the outer diameter of the honeycomb structure increases, the entire exhaust gas purification device also increases in size. When the honeycomb structure is mounted in a car, the mounting space is limited, such as a space closest to the engine, or a space at the bottom of the body. Therefore, there is a limitation on increasing the outer diameter of the honeycomb structure.

The present invention was developed in view of the above-mentioned problems. In the present invention, there is provided a honeycomb structure in which a ring crack is not easily generated.

1. [1] Eine Wabenstruktur, umfassend ein Wabensubstrat mit porösen Trennwänden, die mehrere Zellen definieren, die von einer ersten Endfläche als eine Endfläche zu einer zweiten Endfläche als die andere Endfläche verlaufen und zu Durchgangskanälen für ein Fluid werden, und einen gewölbten Abschnitt, der durchgängig oder unterbrochen in Ringform zumindest einen Teil des Außenumfangs des Wabensubstrats umgibt, wobei der gewölbte Abschnitt so angeordnet ist, dass er nach außen vom Außenumfang des Wabensubstrats absteht und einen Teil des Außenumfangs des Wabensubstrats bedeckt, die Form von mindestens einem Ende des gewölbten Abschnitts eine konische Form mit einer konischen Fläche ist, die eine zu einem Verbindungsabschnitt am Außenumfang geneigte Fläche ist und im Querschnitt senkrecht zur Verlaufsrichtung der Zellen die maximale Dicke des gewölbten Abschnitts 1 bis 20 mm beträgt und im Querschnitt parallel zur Zellenverlaufsrichtung die Breite des gewölbten Abschnitts 1 % oder mehr der Gesamtlänge des Wabensubstrats beträgt und der Neigungswinkel, der ein zwischen der konischen Fläche und der Zellenverlaufsrichtung erzeugter Winkel ist, 80 Grad oder weniger beträgt, ein Teil der Fläche des gewölbten Abschnitts ein ebener Abschnitt ist, der eine ebene Fläche parallel zur Zellenverlaufsrichtung ist, der ebene Abschnitt ein oder mehrere Spannungsentlastungsabschnitte aufweist, die Spalten mit jeweils einem offenen Ende in der Oberfläche sind, und die Summe der Längen aller Spannungsentlastungsabschnitte 3 % oder mehr der Umfangslänge des Wabensubstrats beträgt.
2. [2] Die Wabenstruktur gemäß [1] oben, wobei die Summe der Längen aller Spannungsentlastungsabschnitte 10 % oder mehr der Umfangslänge des Wabensubstrats beträgt.
3. [3] Die Wabenstruktur gemäß [1] oder [2] oben, wobei die Summe der Längen der Spannungsentlastungsabschnitte, in denen die Breite des offenen Endes jeweils 10 µm oder mehr beträgt, 50 % oder mehr der Summe der Längen aller Spannungsentlastungsabschnitte beträgt.
4. [4] Die Wabenstruktur gemäß einem von [1] bis [3] oben, wobei im Querschnitt parallel zur Zellenverlaufsrichtung die Breite des gewölbten Abschnitts 1 bis 80 % der Gesamtlänge des Wabensubstrats beträgt und der Neigungswinkel 10 bis 80 Grad beträgt.
5. [5] Die Wabenstruktur gemäß einem von [1] bis [4] oben, wobei das Wabensubstrat aus mindestens einem, ausgewählt aus der Gruppe, bestehend aus Cordierit, Siliciumcarbid, Mullit, Aluminiumtitanat und Aluminiumoxid, gefertigt ist.
6. [6] Die Wabenstruktur gemäß einem von [1] bis [5] oben, ferner umfassend: Verschlussabschnitte, die ein offenes Ende auf der Seite der ersten Endfläche einer ersten Zelle als jede der vorbestimmten Zellen der mehreren Zellen und ein offenes Ende auf der Seite der zweiten Endfläche einer zweiten Zelle als jede der übrigen Zellen der mehreren Zellen verschließen.

According to the present invention, there is provided a honeycomb structure as described below.

1. [1] A honeycomb structure comprising a honeycomb substrate having porous partition walls defining a plurality of cells extending from a first end face as one end face to a second end face as the other end face and becoming passage channels for a fluid, and a bulging portion which is continuous or intermittently in a ring shape surrounding at least a part of the outer periphery of the honeycomb substrate, the bulged portion being arranged to protrude outwardly from the outer periphery of the honeycomb substrate and covering a part of the outer periphery of the honeycomb substrate, the shape of at least one end of the bulged portion being a conical shape having a conical surface which is a surface inclined to a connecting portion on the outer periphery and in the cross section perpendicular to the cell extending direction the maximum thickness of the bulging portion is 1 to 20 mm and in the cross section parallel to the cell extending direction the width of the bulging portion is 1% or more of Ge total length of the honeycomb substrate and the inclination angle, which is an angle created between the conical surface and the cell extending direction, is 80 degrees or less, part of the surface of the bulging portion is a flat portion, which is a flat surface parallel to the cell extending direction, the flat Section has one or more stress relieving sections which are gaps each having an open end in the surface, and the sum of the lengths of all the stress relieving sections is 3% or more of the circumferential length of the honeycomb substrate.
2. [2] The honeycomb structure according to [1] above, wherein the sum of the lengths of all the stress relieving portions is 10% or more of the circumferential length of the honeycomb substrate.
3. [3] The honeycomb structure according to [1] or [2] above, wherein the sum of the lengths of the stress relieving portions in which the width of the open end is 10 μm or more each is 50% or more of the sum of the lengths of all the stress relieving portions.
4. [4] The honeycomb structure according to any one of [1] to [3] above, wherein, in the cross section parallel to the cell extending direction, the width of the bulging portion is 1 to 80% of the total length of the honeycomb substrate and the inclination angle is 10 to 80 degrees.
5. [5] The honeycomb structure according to any one of [1] to [4] above, wherein the honeycomb substrate is made of at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate and alumina.
6. [6] The honeycomb structure according to any one of [1] to [5] above, further comprising: sealing portions having an open end on the first end face side of a first cell as each of the predetermined cells of the plurality of cells and an open end on the side the second end face of a second cell than each of the remaining cells of the plurality of cells.

The honeycomb structure of the present invention includes the above “bulging portion”, and therefore a ring crack is not easily generated. Further, in the honeycomb structure of the present invention, defects such as chips are not easily generated in the above “bulged portion” even if an external force is applied to the above “bulged portion” during conveyance or the like. Further, the honeycomb structure of the present invention has “the stress relieving portions”, and therefore the honeycomb structure is excellent in thermal shock resistance.

character list

• 1 Fig. 14 is a perspective view schematically showing a honeycomb structure of an embodiment of the present invention;
• 2 Fig. 12 is a schematic view showing a cross section parallel to the extending direction of cells of the honeycomb structure of one embodiment of the present invention;
• 3 is a plan view of the in 1 shown honeycomb structure viewed from a first end face side;
• 4 is a plan view showing schematically that several of the in 1 shown honeycomb structures are stored in an existing packaging container;
• 5 Fig. 14 is a perspective view schematically showing another embodiment of the honeycomb structure of the present invention;
• 6 Fig. 12 is a schematic view showing a cross section parallel to the extending direction of cells of a honeycomb structure of another embodiment of the present invention; and
• 7 14 is a perspective view schematically showing that a ring crack has been generated in a conventional honeycomb structure.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

1. (1) Wabenstruktur:
   • Wie in 1 bis 3 gezeigt, umfasst eine Wabenstruktur 100a einer Ausführungsform der vorliegenden Erfindung ein Wabensubstrat 4 und einen gewölbten Abschnitt 10. Das Wabensubstrat 4 weist poröse Trennwände 1 auf, die mehrere Zellen 2 definieren, die von einer ersten Endfläche 3 als eine Endfläche zu einer zweiten Endfläche 5 als die andere Endfläche verlaufen und zu Durchgangskanälen für ein Fluid werden. Der gewölbte Abschnitt 10 umgibt durchgängig oder unterbrochen in Ringform zumindest einen Teil des Außenumfangs des Wabensubstrats 4. Ferner ist der gewölbte Abschnitt 10 so angeordnet, dass er nach außen vom Außenumfang des Wabensubstrats 4 absteht und einen Teil des Außenumfangs des Wabensubstrats 4 bedeckt. Die Form mindestens eines Endes des gewölbten Abschnitts 10 ist eine konische Form mit einer konischen Fläche 11, die eine zu einem Verbindungsabschnitt 13 am Außenumfang geneigte Fläche ist. In einem Querschnitt senkrecht zur Verlaufsrichtung der Zellen (nachstehend einfach als „Z-Richtung“ bezeichnet) „beträgt die maximale Dicke (H) des gewölbten Abschnitts 10“ 1 bis 20 mm. In einem Querschnitt parallel zur Z-Richtung beträgt die „Breite L des gewölbten Abschnitts 10“ 1 % oder mehr der Gesamtlänge des Wabensubstrats 4, und „der Neigungswinkel“, der ein zwischen der konischen Fläche 11 und der Z-Richtung erzeugter Winkel ist, beträgt 80 Grad oder weniger. Ein Teil der Fläche des gewölbten Abschnitts 10 ist ein ebener Abschnitt 15, der eine ebene Fläche parallel zur Z-Richtung ist. Der ebene Abschnitt 15 weist ein oder mehrere Spannungsentlastungsabschnitte 17 auf, die Spalten sind, die jeweils ein offenes Ende 18 in der Oberfläche aufweisen. Ferner beträgt die Summe der Längen aller Spannungsentlastungsabschnitte 17 3 % oder mehr der Umfangslänge des Wabensubstrats 4. Es versteht sich, dass 1 eine perspektivische Ansicht ist, die schematisch die Wabenstruktur 100a der einen Ausführungsform der vorliegenden Erfindung zeigt. 2 ist eine schematische Ansicht, die den Querschnitt parallel zur Z-Richtung der Wabenstruktur 100a der einen Ausführungsform der vorliegenden Erfindung zeigt. 3 ist eine Draufsicht der Wabenstruktur 100a der einen Ausführungsform der vorliegenden Erfindung, betrachtet von der Seite der ersten Endfläche.

Embodiments of the present invention will be described below with reference to the drawings. The present invention is not limited to the following embodiments, and changes, modifications, or improvements can be made without departing from the gist of the present invention.

1. (1) Honeycomb structure:
   • As in 1 until 3 As shown, a honeycomb structure 100a of one embodiment of the present invention comprises a honeycomb substrate 4 and a bulged portion 10. The honeycomb substrate 4 has porous partition walls 1 defining a plurality of cells 2 extending from a first end face 3 as an end face to a second end face 5 as the other end surface and become passage channels for a fluid. The bulging portion 10 surrounds at least a part of the outer periphery of the honeycomb substrate 4 continuously or intermittently in a ring shape. The shape of at least one end of the bulging portion 10 is a conical shape having a conical surface 11 which is a surface inclined toward a connecting portion 13 on the outer periphery. In a cross section perpendicular to the cell extending direction (hereinafter simply referred to as “Z direction”), “the maximum thickness (H) of the bulging portion 10” is 1 to 20 mm. In a cross section parallel to the Z-direction, the "width L of the bulging portion 10" is 1% or more of the total length of the honeycomb substrate 4, and "the inclination angle", which is an angle made between the tapered surface 11 and the Z-direction, is 80 degrees or less. A part of the surface of the bulging portion 10 is a flat portion 15 which is a flat surface parallel to the Z-direction. Planar portion 15 includes one or more stress relief portions 17, which are columns each having an open end 18 in the surface. Further, the sum of the lengths of all the stress relieving portions 17 is 3% or more of the circumferential length of the honeycomb substrate 4. It goes without saying that 1 12 is a perspective view schematically showing the honeycomb structure 100a of one embodiment of the present invention. 2 12 is a schematic view showing the cross section parallel to the Z-direction of the honeycomb structure 100a of one embodiment of the present invention. 3 12 is a plan view of the honeycomb structure 100a of one embodiment of the present invention viewed from the first end face side.

Here, “the conical shape” is a shape in which the outer diameter of a ring shape decreases toward the tip. Further, it can be assumed that "the maximum thickness (H) of the bulging portion" is the distance between "a line parallel to the outer periphery of the honeycomb substrate arranged so as to align with the outer periphery (not like a tapered portion) of the bulging portion comes into contact” and “the outer periphery of the honeycomb substrate” is parallel to the Z-direction of the honeycomb structure in cross section”. Further, when the outer peripheral cladding layer is arranged on an outer peripheral surface of the honeycomb substrate 4, “the maximum thickness (H) of the bulged portion” is the thickness of the surface of the outer peripheral cladding layer as in FIG 2 and 3 shown.

The bulging portion 10 is arranged to “protrude outward from the outer periphery of the honeycomb substrate 4 and cover a part of the outer periphery of the honeycomb substrate 4”. That is, the outer diameter of part of the honeycomb structure 100a is large. Thus, in the honeycomb structure 100a, resistance to tensile stress is improved. As a result, a ring crack is not easily generated in the honeycomb structure 100a even if tensile stress is generated.

Further, in the honeycomb structure 100a, the bulged portion 10 has “an annular shape continuously or discontinuously surrounding at least part of the outer periphery of the honeycomb substrate 4”. So will in of the honeycomb structure 100a improves resistance to tensile stress. This is because "at least a part of the outer periphery of the honeycomb substrate 4 is surrounded continuously and discontinuously" with the tensile stress being applied uniformly. Consequently, the ring crack is not easily generated even if tensile stress is generated in the honeycomb structure 100a.

In the present specification, “the circumferential length of the honeycomb substrate 4” is the circumferential length of the honeycomb substrate 4 in a cross section vertical to the Z direction.

“The stress relieving portions 17” are columns each having the open end (open end of the stress relieving portion 17) 18 in the planar portions 15 of the bulging portion 10. FIG. The stress relieving portions 17 are present in the flat portions 15 of the bulging portion 10, so that the tensile stress can be relaxed and the ring crack is not easily generated. More specifically, the sum of the lengths of all the stress relieving portions 17 is 3% or more of the circumferential length of the honeycomb substrate 4, whereby a ring crack inhibiting function can be developed by the stress relieving portions 17.

There is no particular limitation on “the depth of the gap” in each of the stress relieving portions 17 . When the outer periphery of the bulging portion 10 is formed by an outer periphery cladding layer 7, "the depth of the gap" of the stress relieving portion 17 is preferably such an extent that the gap remains in the outer periphery cladding layer 7, as shown in FIG 2 shown. When “the gap” remains in the outer peripheral skin layer 7, the structural strength of the bulging portion 10 can be maintained.

In the honeycomb structure 100a, the sum of the lengths of all the stress relief portions 17 is preferably 10% or more of the circumferential length of the honeycomb substrate 4. When the sum of the lengths of all the stress relief portions 17 is 10% or more of the circumferential length of the honeycomb substrate 4, the tensile stress can be relaxed and the ring crack can occur cannot easily be produced further. Further, the sum of the lengths of all the stress relieving portions 17 is preferably 15% or more, and especially most preferably 25 to 90% of the circumferential length of the honeycomb substrate 4. When the sum of the lengths of all the stress relieving portions 17 is up to 90% of the circumferential length of the honeycomb substrate 4, the effect can be increased the inhibition of the ring crack can be exercised sufficiently. Further, when the sum of the lengths of all the stress relieving portions 17 is 90% or less of the circumferential length of the honeycomb substrate 4, manufacturing time of the stress relieving portions (e.g., drying time with an industrial dryer) can be saved.

In the honeycomb structure 100a, the sum of the lengths of the stress relieving portions 17 in which the width of the open end is 10 μm or more is preferably 50% or more of the sum of the lengths of all the stress relieving portions 17. When the sum of the lengths of the stress relieving portions 17 is each of which the width of the open end is 10 µm or more, 50% or more of the sum of the lengths of all the stress relieving portions 17, the tensile stress can be relaxed and further the ring crack cannot easily be generated. Further, the sum of the lengths of the stress relieving portions 17 each having an open end width of 10 µm or more is more preferably 55% or more, and especially most preferably 65 to 95% of the sum of the lengths of all the stress relieving portions 17. In the present Description, "the width of the open end 18 of the stress relieving portion 17" is the width of the gap measured along a direction vertical to the extending direction of the slit in the surface of the outer periphery of the honeycomb substrate 4. Is the sum of the lengths of the stress relieving portions 17 where the width of the open end is 10 µm or more each, up to 95% of the sum of the lengths of all the stress relieving portions 17, the effect of inhibiting the ring crack can be sufficiently exerted. Further, when the sum of the lengths of the stress relieving portions 17 each of which the width of the open end is 10 µm or more is 95% or less of the sum of the lengths of all the stress relieving portions 17, manufacturing time of the stress relieving portions (e.g. drying time with the industrial dryer ) are saved.

The maximum thickness (H) of the bulging portion 10 in the cross section perpendicular to the Z direction is 1 to 20 mm, preferably 3 to 15 mm, and more preferably 5 to 10 mm. If the maximum thickness (H) of the bulged portion 10 in the cross section perpendicular to the Z direction is less than 1 mm, the bulged portion is excessively thin, and so the ring crack is generated to an extent that the trapping function of a DPF is impaired. If the thickness is over 20 mm, the honeycomb structure cannot be mounted in a limited mounting space in a car or the like.

At least one end of the bulging portion 10 in the Z direction is tapered. Therefore, defects such as chips are not easily generated in the bulged portion 10 even if an external force is applied to the bulged portion 10 during conveyance or the like.

In the cross section parallel to the Z-direction of the honeycomb structure 100a, “the inclination angle”, which is the angle formed between the tapered surface 11 and the Z-direction, is 80 degrees or less. If “the inclination angle” is larger than 80 degrees, an end (the outermost peripheral portion) of the bulging portion will sometimes chip. "The angle of inclination" is preferably 10 to 80 degrees, and more preferably 20 to 60 degrees. When “the angle of inclination” is less than 10 degrees, there is a disadvantage that the honeycomb structure 100a cannot be mounted in the limited mounting space in a car or the like. It should be noted that "the inclination angle" is an acute angle α among the angles formed between the conical surface 11 and the Z direction (see 2 ). "The conical surface 11" is a conical end surface of the bulging portion 10.

The width L of the bulging portion 10 is 1% or more, preferably 1 to 80%, and more preferably 5 to 20% of the length of the honeycomb structure 100a in the Z direction (entire length of the honeycomb substrate 4). When the width L of the bulging portion 10 is in the above range, the honeycomb structure can be suitably mounted in the limited mounting space in a car or the like. Further, the bulging portion 10 is not excessively large, and therefore the honeycomb structure 100a can be made lighter. If the width L of the bulging portion 10 is less than 1%, there is a fear that the ring crack cannot be prevented appropriately. Further, when the width L of the bulging portion 10 is more than 80%, the honeycomb structure 100a increases in size, which poses a risk that the honeycomb structure 100a cannot be mounted in the limited mounting space in an automobile or the like. "The width L of the bulging portion 10" is the length of the bulging portion in the Z direction. That is, "the width L of the bulging portion 10" is the distance between the two tops of the two tapered ends.

There is no particular limitation on the arrangement position of the bulging portion 10 as long as the bulging portion is arranged to cover part of the outer periphery of the honeycomb substrate 4 . That is, the bulging portion can be arranged in a central portion or an end portion of the honeycomb substrate 4 as long as generation of the ring crack can be prevented. The central portion of the honeycomb substrate 4 is the central portion of the honeycomb substrate 4 in the Z direction. When cracks are easily generated in the central portion of the honeycomb substrate 4 , the bulging portion 10 is preferably arranged in the central portion of the honeycomb substrate 4 . When "the bulged portion 10 is arranged in the central portion of the honeycomb substrate 4", it means that "the bulged portion 10 is arranged so that at least a part of the bulged portion is the center of the honeycomb substrate 4 in the Z direction (the center of the honeycomb substrate 4) covered". That is, when "the bulging portion 10 is arranged in the central portion of the honeycomb substrate 4", it includes the following two cases. That is, this includes both the case where “the center of the bulging portion 10 in the Z direction (the center of the bulging portion 10)” overlays (covers the center) the center of the honeycomb substrate 4 and the case where which a portion of the bulging portion 10 other than the center of the bulging portion overlays (covers the center) the center of the honeycomb substrate 4 . Note that in the honeycomb structure 100a, the crack (the ring crack) is easily generated at the center of the honeycomb substrate 4 as the ratio (A/B) between the total length (A) and the outside diameter (B) increases.

In the honeycomb structure 100a, a crack (an end face crack) is easily generated in the end face of the honeycomb substrate 4 as the ratio (A/B) between the overall length (A) and the outside diameter (B) decreases. More specifically, the end face crack is easily generated in the end face on the exhaust gas outlet side. As described above, when the crack is easily generated in the end face of the honeycomb substrate 4, the bulged portion 10 is preferably arranged in the end portion of the honeycomb substrate 4 having the end face where the crack is easily generated.

The number of the bulging portions 10 is not limited to one and may be plural. When plural bulging portions 10 are arranged, the bulging portions 10 are preferably arranged in at least both the end portion of the exhaust gas outlet side and the central portion.

As in 2 As shown, the bulging portion 10 preferably has the porous partition walls 1 defining the plurality of cells 2 parallel to the Z-direction. When the cells 2 are formed in the bulging portion 10, the honeycomb structure 100a can be lightened while preventing the generation of the ring crack. The bulging portion 10 is preferably formed integrally with the honeycomb substrate 4 forms. As a result, the bulged portion 10 can be firmly bonded to the honeycomb substrate 4 . Here, when “the bulging portion 10 is formed integrally with the honeycomb substrate 4”, the following is meant. That is, this means that the partition wall 1 of the bulging portion 10 is bonded to the partition wall 1 of the honeycomb substrate 4 such that between the partition wall 1 forming the bulging portion 10 and the partition wall 1 forming the honeycomb substrate 4 Limit is present and the materials of the respective partitions 1 are continuous. In this way, the honeycomb structure 100a in which "the bulging portion 10 and the honeycomb substrate 4 are integrally formed" can be obtained by forming a honeycomb body "comprising a portion that becomes the bulging portion 10 and a portion that becomes the honeycomb substrate 4 is obtained” and then performing drying, firing and processing and the like. It is not necessary to load the partition walls 1 defining “the cells 2 formed in the bulging portion 10” with a noble metal that becomes a catalyst. This is because the exhaust gas does not easily flow into “the cells 2 formed in the bulging portion 10”. A method for loading the honeycomb structure 100a with the catalyst is preferably a method in which one end portion of the honeycomb structure 100a is dipped in a catalyst slurry and the other end portion sucks the catalyst slurry. According to this method, the honeycomb structure 100a in which no catalyst is loaded on "the cells 2 formed in the bulging portion 10" can be easily manufactured.

The honeycomb structure 100a preferably includes the outer peripheral cladding layer 7 made of an outer peripheral covering material on "an outer peripheral surface including the surface of the bulging portion 10" of the honeycomb substrate 4 . The outer peripheral covering layer 7 is contained so that leakage of the above catalyst slurry can be prevented when the catalyst slurry is sucked up. As also in 1 until 3 1, the outer peripheral covering layer 7 is preferably formed so that the open ends of "the cells 2 formed in the bulging portion 10" are closed. When the outer peripheral cladding layer 7 is formed so that the open ends of "the cells 2 formed in the bulging portion 10" are closed, the exhaust gas that could flow into "the cells 2 formed in the bulging portion 10" can be prevented from flowing , is discharged from the open ends of "the cells 2 formed in the bulging portion 10". That is, the exhaust gas can be prevented from flowing out of the honeycomb structure 100a. As described above, no catalyst is loaded on the partition walls 1 defining “the cells 2 formed in the bulging portion 10”. In this case, if the outer peripheral cladding layer 7 is not formed as described above, the insufficiently purified exhaust gas will be discharged. That is, when the exhaust gas flows out from the open ends of "the cells 2 formed in the bulging portion 10", there is a fear that the purification performance will deteriorate. Therefore, when the outer peripheral covering layer 7 is formed so that the open ends of "the cells 2 formed in the bulging portion 10" are closed, deterioration in cleaning performance can be prevented. The outer peripheral covering material is obtained, for example, by adding additives such as an organic binder, a resin balloon and a dispersant to an inorganic raw material such as inorganic fibers, colloidal silica, clay or SiC particles and adding water thereto, followed by kneading.

The thickness of the outer peripheral cladding layer 7 is preferably 1 to 5000 μm, and more preferably 10 to 3000 μm. When the thickness of the outer peripheral coating layer 7 is in the above range, drying can be performed in a uniform state after the outer peripheral coating layer 7 is applied. Thus, generation of “unwanted cracks” in the outer peripheral skin layer 7 after drying shrinkage can be prevented. If the thickness of the outer peripheral cladding layer 7 is less than 1 μm, there is a fear that the slurry for the catalyst leaks out from the honeycomb substrate 4 during the loading of the catalyst. When the thickness of the outer peripheral cladding layer 7 is more than 5000 μm, the ratio of the cross section of a portion having no exhaust gas purification function is large, and therefore the purification performance sometimes deteriorates. A method of forming the crevices of the stress-relief portions 17 is, for example, a method of intentionally generating cracks in the outer peripheral cladding layer 7. The “unwanted cracks” mentioned herein are cracks that do not correspond to the crevices of the stress-relief portions 17.

Further, when the bulged portion 10 having a part of the surface in a planar shape is included as in the honeycomb structure 100a, the maximum thickness (H) of the bulged portion 10 is small (the thickness of the planar portion 15 is small). . Thus, a small container can be used as a packaging container for use during transportation of the honeycomb structure 100a.

In the honeycomb structure 100a, the bulging portion 10 preferably has a uniform shape in a circumferential direction in portions other than portions where the flat portions 15 are formed are. "The uniform shape in the circumferential direction" means that the shape of a cross section perpendicular to the circumferential direction is the same in each section. Note that in the honeycomb structure 100a, the portions other than the portions where the planar portions 15 are formed in the bulging portion 10 need not be formed in the uniform shape in the circumferential direction.

In the honeycomb structure in which "a part of the surface of the bulging portion 10 is the flat portion 15" as in FIG 1 As shown in the honeycomb structure 100a, the thickness of the bulged portion 10 in the flat portion 15 is small. Therefore, as in 4 1, the honeycomb structures 100a can be stored in an existing packaging box 20 even if the packaging box is not of a particularly large size for the presence of annular bulging portions. Therefore, the existing packaging case 20 can be used. In 4 the partition walls of the honeycomb structures 100a were omitted. 4 FIG. 12 is a plan view schematically showing that the plural honeycomb structures 100a are stored in the existing packaging container 20. FIG.

In the curved section 10, two flat sections 15 are preferably formed parallel to one another. As also in 3 1, two pairs of flat portions 15 are preferably formed parallel to each other in the bulging portion 10, and one pair of flat portions 15 is preferably formed perpendicular to the other pair of flat portions 15. When the flat portions 15 are formed like this, thin portions (the flat portions 15) are formed in the bulging portion 10, and so the storage space can be small compared to a case where the flat portions 15 are not formed. Thus, the honeycomb structure 100a can be properly assembled even in a place where the assembly space is small, such as in an automobile or the like.

The distance (the shortest distance) T (see 3 ) between the flat portion 15 (surface) and the outer periphery of the honeycomb substrate 4 (a portion covered with the bulging portion 10) preferably ranges from 1 to 15 mm, and more preferably from 2.5 to 10 mm. When the distance T between the planar portion 15 and the outer periphery of the honeycomb substrate 4 is in the above range, the generation of the ring crack can be prevented. Furthermore, even in a place where the mounting space is small, such as in a car or the like, the honeycomb structure 100a can be properly mounted. It can be assumed that the distance T between the flat portion 15 (surface) and the outer periphery of the honeycomb substrate 4 is the thickness of the thinnest portion in the flat portion 15 of the bulging portion 10 . Note that when the honeycomb structure 100a includes an outer peripheral cladding layer 7, the distance T is a value obtained by subtracting the thickness of the outer peripheral cladding layer 7 from the distance (the shortest distance) between the planar portion 15 (the area) and the outer periphery of the honeycomb substrate 4 is obtained.

In the honeycomb structure 100a of the present embodiment, the material of the honeycomb substrate 4 preferably includes at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate, and alumina as a main component. Further, the material of the honeycomb substrate 4 is preferably formed of at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate and alumina. Here, “the main component” is a component that accounts for more than 50% by mass of the entire material.

In the honeycomb structure 100a of the present embodiment, the average pore diameter of the partition walls 1 is preferably 5 to 100 μm, and more preferably 8 to 50 μm. When the average pore diameter is less than 5 µm, the pressure loss sometimes becomes large. When the average pore diameter is larger than 100 μm, the strength of the honeycomb structure 100a sometimes becomes low. The average pore diameter is a value measured with a mercury porosimeter.

In the honeycomb structure 100a of the present embodiment, the porosity of the partition walls 1 is preferably 25 to 80%, and more preferably 35 to 75%. When the porosity is less than 25%, the pressure loss sometimes becomes large. When the porosity is more than 80%, the strength of the honeycomb structure 100a sometimes becomes low. The porosity is a value measured with the mercury porosimeter.

The thickness of the partition walls 1 is preferably 40 to 600 μm and particularly preferably 150 to 400 μm. When the thickness is less than 40 µm, the strength of the honeycomb structure 100a sometimes becomes low. When the thickness is more than 600 µm, the pressure loss sometimes becomes large.

In the honeycomb structure 100a of the present embodiment, there is no particular limitation on the shape of the honeycomb substrate 4. The shape of the honeycomb substrate 4 is preferably cylindrical shape, a tubular shape having elliptical end faces, or a polygonal tubular shape having end faces each having a polygonal shape, such as "a square, rectangular, triangular, pentagonal, hexagonal or octagonal shape". in the in 1 In the honeycomb structure 100a shown, the shape of the honeycomb substrate 4 is the cylindrical shape.

In the honeycomb structure 100a of the present embodiment, there is no particular limitation on the cell shape (the cell shape in the cross section perpendicular to the Z direction) of the honeycomb substrate 4. Examples of the cell shape include a triangular shape, a quadrangular shape, a hexagonal shape, an octagonal shape , a round shape, and any combination of these shapes. The quadrangular shape is preferably a square or a rectangular shape.

In the honeycomb structure 100a of the present embodiment, there is no particular limitation on the cell density of the honeycomb substrate 4. The cell density of the honeycomb substrate 4 is preferably 15 to 200 cells/cm ² and more preferably 30 to 100 cells/cm ² . When the cell density is less than 15 cells/cm ² , sometimes in a short time, the pressure loss or the strength of the honeycomb structure 100a during the flow of the exhaust gas becomes low. When the cell density is more than 200 cells/cm ² , the pressure loss sometimes becomes large.

In another embodiment (the honeycomb structure 100b) of the honeycomb structure of the present invention, the bulging portion 10 is arranged in an end portion (an end portion) of a honeycomb substrate 4 in the above one embodiment (the honeycomb structure 100a) of the honeycomb structure of the present invention. In the 5 The honeycomb structure 100b shown is the other embodiment of the honeycomb structure of the present invention. As described above, the bulging portion 10 is disposed in the one end portion of the honeycomb structure 100b, whereby generation of an end face crack can be prevented. Further, in the honeycomb structure 100b, stress relief portions 17 are also formed in the vicinity of one end portion. Thus, by the action of the stress relieving portions 17, generation of the end face crack can be prevented. When the honeycomb structure is used as a DPF, an end face crack is sometimes generated in an end face on the exhaust gas outlet side. This end face crack is generated as follows. A large amount of soot contained in exhaust gas from an engine of an automobile or the like is deposited in the exhaust-side end portion of the honeycomb structure. Therefore, when the soot or the like is burned for processing the honeycomb structure, the temperature of the outlet-side end portion of the honeycomb structure is higher than that of other portions due to the burning of the soot or the like. As a result, stress is generated in the end portion of the honeycomb structure. As a result, a crack (the end face crack) is generated in the outlet-side end face of the honeycomb structure. 5 14 is a perspective view schematically showing the other embodiment of the honeycomb structure of the present invention.

6 12 is a schematic view showing a cross section of a honeycomb structure 100c of still another embodiment of the present invention parallel to the Z direction. The honeycomb structure of the present invention may include, as in the honeycomb structure 100c, plugging portions 23 disposed at open ends of predetermined cells (first cells 2a) in a first end face 3 and open ends of the remaining cells (second cells 2b) in a second end face 5 are. The first cells 2a and the second cells 2b are preferably arranged alternately. Further, in both end faces of the honeycomb structure 100c, tessellated patterns are preferably formed by the plugging portions 23 and “the open ends 25 of the cells”. The material of the sealing portions 23 is preferably a material which is considered preferable as the material for a honeycomb substrate 4 (partition walls 1). The material of the sealing portions 23 may be the same as the material of the honeycomb substrate 4 or different from the material of the honeycomb substrate 4 .

(2) Manufacturing method of honeycomb structure:

The honeycomb structure of the present invention can be manufactured by the following method. That is, the honeycomb structure of the present invention can be manufactured by a method including a honeycomb fired body manufacturing step of manufacturing a honeycomb fired body and a cutting step of cutting an outer peripheral portion of this honeycomb fired body to form a bulged portion. When the honeycomb structure includes the outer peripheral cladding layer, the method preferably further comprises a step of forming an outer peripheral cladding layer after cutting the outer peripheral portion of the honeycomb fired body. “The fired honeycomb mass” is the fired honeycomb mass, which includes porous partition walls formed by firing a ceramic raw material and defines a plurality of cells that become passageways for a fluid.

According to such a method, the honeycomb structure of the present invention can be easily manufactured.

For example, when “a part of the surface of the bulging portion forms a planar portion having a planar shape parallel to the Z direction” (the planar portion is formed in the bulging portion), the honeycomb structure can be manufactured by the following method. That is, the honeycomb structure "in which the planar portion is not formed in the bulging portion" is manufactured. Thereafter, a part of the bulged portion of this honeycomb structure is cut so that the planar portion is formed, whereby the honeycomb structure in which the planar portion is formed in the bulged portion as shown in FIG 1 shown. Moreover, in the case that "a part of the surface of the bulging portion has the planar shape parallel to the Z-direction", the honeycomb structure of the present invention can also be manufactured by the following method. That is, the method comprises the above honeycomb fired body manufacturing step and the above cutting step, and in the above honeycomb fired body manufacturing step, the honeycomb fired body having a polygonal columnar shape is manufactured. Further, in the cutting step, the honeycomb fired body is cut so that a part of the side surface of the honeycomb fired body remains, and this remaining part of the side surface forms the flat portion of the bulged portion. In this case, the planar portion does not need to be formed again after the cutting step, and the manufacturing process can be streamlined.

Each step of the manufacturing method of the honeycomb structure of the present invention will be explained below.

(2-1) Honeycomb fired mass manufacturing step:

The manufacturing step of the honeycomb fired body is a step of manufacturing the honeycomb fired body including porous partition walls formed by firing the ceramic raw material. There is no particular limitation on the method for producing the honeycomb fired body. Hereinafter, the manufacturing step of the honeycomb fired body will be described in stages.

(2-1-1) formation step:

First, in the forming step, a ceramic-forming raw material containing the ceramic raw material is preferably formed so as to obtain a honeycomb body including the partition walls (not fired) that define the plural cells that become passageways for the fluid. The honeycomb body is a molded body having a honeycomb structure.

The ceramic raw material contained in the ceramic forming raw material is preferably at least one selected from the group consisting of a cordierite forming raw material, cordierite, silicon carbide, a silicon-silicon carbide composite material, mullite and aluminum titanate. It should be noted that the cordierite-forming raw material is a ceramic raw material which is mixed so as to obtain a chemical composition in which silica is in a range of 42 to 56% by mass, alumina in a range of 30 to 45% by mass. % is present and magnesium oxide is present in a range of 12 to 16% by mass. Moreover, the cordierite-forming raw material is burned to become cordierite.

Moreover, the ceramic-forming raw material is preferably prepared by mixing the above ceramic raw material with a dispersion medium, an organic binder, an inorganic binder, a pore former, a surface active agent or the like. There is no particular limitation on the composition ratio for each raw material, and the composition ratios are preferably determined according to the structure, material or the like of the honeycomb structure to be produced.

In the formation of the ceramic-forming raw material, the ceramic-forming raw material is preferably first kneaded to obtain a kneaded material, and the obtained kneaded material is preferably formed into a honeycomb shape. There is no particular limitation on the method of kneading the ceramic-forming raw material to form the kneaded material, and an example of the method is a method using a kneader, a vacuum clay kneader or the like. There is no particular limitation on the method of molding the kneaded material to obtain the honeycomb body, and therefore a known molding method such as extrusion or Injection forms are used. An example of a suitable method is a method in which a raw material is extruded using a die having desired cell shape, partition wall thickness and cell density to obtain the honeycomb body. The material of the nozzle is preferably cemented carbide, which is not easily worn.

Examples of the shape of the honeycomb body include a columnar shape, an elliptical shape, and a polygonal columnar shape having end faces of “a square shape, a rectangular shape, a triangular shape, a pentagonal shape, a hexagonal shape, or an octagonal shape”. In manufacturing the honeycomb structure including “the bulging portion in which the planar portion is formed”, the honeycomb body having a polygonal columnar shape is preferably used. If part of the side surface of a polygonal column remains, this remaining part of the side surface can be the flat portion of the curved portion. That is, the process of forming the planar portion can be omitted. The honeycomb body particularly preferably has a square columnar shape.

Moreover, after the above shaping, the obtained honeycomb body can be dried. There is no particular limitation on the drying method. Examples of the drying method include hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, freeze drying and the like. Of these methods, dielectric drying, microwave drying or hot air drying alone or any combination of these methods is preferably carried out.

(2-1-2) Burning step:

Next, the honeycomb body is fired to prepare a honeycomb fired body.

The honeycomb body is preferably calcined before firing (main firing) of the honeycomb body. Calcination is performed for degreasing. There is no particular limitation on the method for calcining the honeycomb body, and any method can be used as long as organic materials (the organic binder, the surfactant, the porogen, etc.) can be removed. As a rule, the firing temperature of the organic binder is about 100 to 300°C and the firing temperature of the pore former is about 200 to 800°C. Therefore, as the calcination conditions, heating is preferably carried out at about 200 to 1000°C under an oxidation atmosphere for about 3 to 100 hours.

Firing (main firing) of the honeycomb body is performed to sinter and compact the molding raw material constituting the calcined honeycomb body to obtain a predetermined strength. The firing conditions (temperature, time, atmosphere, etc.) vary depending on the kind of the molding raw material, and therefore appropriate conditions can be selected according to the kind. For example, when the cordierite-forming raw material is used, the firing temperature is preferably 1410 to 1440°C. Moreover, the firing time, as the time for keeping the highest temperature, is preferably 4 to 8 hours. There is no particular limitation on an apparatus for performing the calcination and main firing, but an electric furnace, a gas furnace, or the like can be used.

(2-2) Cutting step:

The cutting step is a step of cutting the outer peripheral portion of the honeycomb fired body. There is no particular limitation on the method of cutting the honeycomb fired mass. As the method for cutting the outer peripheral portion of the honeycomb fired body, an already known method can be suitably employed, but preferably the method is a technique in which a diamond-coated grinding stone is pressed onto the honeycomb fired body while the honeycomb fired body rotates. In the cutting step, the thickness of “the outer peripheral portion of the honeycomb fired body that is cut” is the same thickness of the bulged portion formed after cutting.

When the honeycomb structure in which “the planar portion parallel to the Z-direction” is formed in the bulging portion is manufactured as described above, the honeycomb fired mass is preferably cut as follows. That is, the fired honeycomb mass is preferably cut so that part of the sides surface of the honeycomb fired mass is left with a polygonal columnar shape and the remained part of the side surface becomes the flat portion of the bulging portion. In this case, the planar portion does not need to be formed again after cutting.

Note that the cutting may be performed before or after the honeycomb body is fired, but the cutting is preferably performed after the firing. The cutting is performed after the firing, and the shape of the honeycomb fired is fixed by the cutting even if the honeycomb fired is deformed by the firing.

(2-3) Closure step:

In manufacturing the honeycomb structure including the sealed portions, the following sealing step is preferably performed after the cutting step. In this sealing step, the sealed portions in the open ends of "the predetermined cells (the first cells)" in one end face (the first end face) and the open ends of "the remaining cells (the second cells)" in another end face (the second End face) of the fired honeycomb mass arranged. This step is described in detail below.

First, a plugging material is loaded into the open ends 25 of the cells of an end face (the first end face) of the honeycomb fired mass (the honeycomb substrate). As the method for loading the sealing material into the open ends of the cells of the one end face (the first end face), a method including a capping step and a press-fitting step is preferable. The covering step is a step of applying a film to one end face of the honeycomb fired body and then making holes at positions "overlying the cells in which the sealed portions are to be formed" in the film. The pressing step is a step of inserting, under pressure, "the end portion of the honeycomb fired to which the layer has been applied" into a container in which the sealing material is stored, thereby forcing the sealing material into the cells of the honeycomb fired. When the plugging material is pressed into the cells of the fired honeycomb mass, the plugging material passes through the holes created in the layer and is thus filled only in the cells connected to the holes created in the layer.

The sealing material can be prepared by appropriately mixing raw materials which are examples of constituent elements of the above ceramic-forming raw material. The ceramic raw material contained in the sealing material is preferably the same as the ceramic raw material for use as the raw material of the partition walls.

Next, the plugging material to be filled in the honeycomb fired body is preferably dried.

In the one end face (the first end face) of the honeycomb fired body, the cells in which the closed portions are formed and the cells in which the closed portions are not formed are preferably alternately arranged. In this case, in the one end face where the closed portions are formed, the closed portions and “the open ends of the cells” form a tessellated pattern.

Next, the closed portions in the open ends of "the remaining cells (the second cells)" in another end face (the second end face) of the honeycomb fired mass are arranged preferably in the same manner as in the one end face (the first end face). It is noted that the drying of the sealing material may be performed after filling both end faces of the honeycomb fired mass with the sealing material. Moreover, the firing step can be performed after filling the honeycomb body with the sealing material.

(2-4) Outer Periphery Cladding Layer Forming Step:

Preferably, an outer periphery wrapping material is coated on the outer periphery of the cut honeycomb fired body to form the outer periphery cladding layer. By forming the outer peripheral cladding layer, the bulging portion can be prevented from being chipped. The outer peripheral covering material can be obtained, for example, by adding additives such as an organic binder, a resin balloon and a dispersant to an inorganic raw material such as inorganic fibers, colloidal silica, clay or SiC particles, etc. and adding water thereto, followed by kneading. An example of a method of applying the outer peripheral wrapping material is a method of wrapping the material on the “cut honeycomb fired” using a rubber spatula or the like while rotating the body on a potter's wheel.

The stress relieving portion can be formed, for example, by grinding the outer peripheral portion of the honeycomb fired mass so that the bulging portion is formed, applying the outer peripheral wrapping material to the ground outer peripheral portion, and then partially flash drying a part of the planar portion in the bulging portion with an industrial dryer or the like. As for another portion where no stress relieving portions are formed, the outer peripheral wrapping material can be dried by ordinary drying. The reason why the stress relieving portion can be formed by the aforementioned quick drying is that a temperature difference is generated between the surface of the outer peripheral covering material and an inner portion thereof by the quick drying, and as a result, a drying shrinkage difference is generated therebetween. To regulate the width or length of each stress relieving portion, the quick drying time, the object area, the amount of water content in the outer peripheral wrapping material, or the like can be changed.

examples

Hereinafter, the present invention is described in more detail based on examples, but the present invention is not limited to these examples.

(Example 1)

As a ceramic raw material, a material obtained by mixing silicon carbide (SiC) powder and metallic silicon (Si) powder was used. Then, hydroxypropylmethyl cellulose as a binder and a pore-forming agent were added, and water was further added, thereby preparing the molding raw material. Then, the molding raw material was kneaded with a vacuum clay kneader, thereby preparing a kneaded material. The proportion of the binder was 7 parts by mass with a total of the silicon carbide powder (SiC powder) and the metallic silicon powder (Si powder) being 100 parts by mass. The proportion of the pore former was 3 parts by mass with a total of the silicon carbide powder (SiC powder) and the metallic silicon powder (Si powder) being 100 parts by mass. The proportion of water was 42 parts by mass with a total of the silicon carbide powder (SiC powder) and the metallic silicon powder (Si powder) being 100 parts by mass. The average particle diameter of the silicon carbide powder was 20 μm, and the average particle diameter of the metallic silicon powder was 6 μm. Moreover, the average particle diameter of the pore builder was 20 µm. The average particle diameters of the silicon carbide powder, the metallic silicon powder and the pore former were values measured by a laser diffraction method.

The obtained kneaded material was molded using an extrusion molding machine to obtain a quadrangular columnar honeycomb body. The obtained honeycomb body was subjected to high frequency dielectric heating and then dried at 120°C for 2 hours using a hot air dryer.

The dried honeycomb body was degreased and fired to obtain a quadrangular columnar honeycomb fired body. The degreasing conditions were 550°C and 3 hours. The firing conditions were that firing was performed at 1450°C under an argon atmosphere for 2 hours.

Next, an outer peripheral portion of the obtained quadrangular columnar honeycomb fired body was cut so that "a bulging portion having a ring shape was formed and a part of each side surface of the honeycomb fired body was left as a flat portion formed at the bulging portion of the ring shape". The bulging portion of the ring shape was formed in "a central portion in the Z direction" of the honeycomb fired body. Thereafter, an outer periphery covering material was applied to the outer periphery of the cut honeycomb fired body to form an outer periphery skin layer. In this way, a like in 1 obtained honeycomb structure shown.

In addition, as a method for cutting the outer peripheral portion of the honeycomb fired, a method was used in which a diamond-coated grinding stone was pressed at an angle of 35 degrees to the Z-direction on the outer peripheral portion of the honeycomb fired while rotating the honeycomb fired. Thus, a honeycomb structure was obtained with the bulging portion in which "four planar portions were formed and both ends were tapered". The angle (“the inclination angle”) of inclination of the bulged portion in this honeycomb structure was 35 degrees at both ends. In the bulged portion of the honeycomb structure of the present example, two pairs of flat portions were formed parallel to each other (four flat portions in total) as shown in FIG 3 shown.

Further, in the above-mentioned step, the outer peripheral covering material was applied, and then a part of each flat portion in the bulging portion was partially flash dried with an industrial drier or the like, thereby forming stress relieving portions. As for the other portions where no stress-relief portions were formed, the outer peripheral covering material was dried by natural drying, so that no stress-relief portions were formed.

The bottom of the obtained honeycomb structure had a round shape with a diameter of 14.4 cm, and the length of the honeycomb structure in the Z-direction was 20.3 cm. Furthermore, the thickness of the partition walls was 305 µm, and the cell density was 46.5 cells/cm ² . The maximum thickness (H) of the bulged portion was 10 mm, the width (L) of the bulged portion was 20 mm, the ratio of the width of the bulged portion to the total length of the honeycomb structure (honeycomb substrate) was 10%, and the inclination angle was 35 degrees . The depth of the flat section (D) (four sections) was 5 mm. In addition, "the depth of the flat portion (D)" is the difference between the maximum thickness (H) of the bulged portion and "the distance T from the flat portion (the surface) to the outer periphery of the honeycomb substrate" (see 3 ). The bulging portion was located at a position where "the distance from one end portion of the honeycomb structure to the end of the bulging portion that was close to this one end portion" was 6.4 cm.

The maximum thickness (H) of the bulging portion is the distance between "a line parallel to the outer periphery of the honeycomb substrate arranged so as to come into contact with the outer periphery of the bulging portion (but excluding tapered portions)" and "the outer periphery of the honeycomb substrate” in cross section parallel to the Z-direction of the honeycomb structure. The width (L) of the bulging portion is the length of the bulging portion in the Z-direction of the honeycomb structure.

In Table 1, the column "Attachment location for the bulged portion" shows the location where the bulged portion is located. “Center” indicates that the bulging portion is located in a central portion of the Z-direction of the honeycomb structure. “End portion” indicates that the bulging portion is located in the Z-direction end portion of the honeycomb structure. "Inclination angle (degrees)" indicates an acute angle from the angles generated between the conical surfaces of both ends of the bulging portion and the Z direction.

As for the obtained honeycomb structure, "position of each stress relief portion", "length of the stress relief portion", "width of the stress relief portion", "ring crack", "strength of the bulging portion" and "assembly properties" were each evaluated by the following methods. The results are shown in Table 1.

(Location, length and width of stress relief section)

The position, length and width of the stress relief section were measured using a ruler or calipers. As for the width of the stress relief portion, a stress relief portion having a width of 10 µm or more was specified to be 10 µm using a thickness gauge (JIS B 7524).

(ring crack)

First, the honeycomb structure was attached to a burning tester. Next, the following operations were carried out by this burning tester. Specifically, the following temperature raising/cooling process was one cycle. The temperature raising/cooling process was a process in which “a high-temperature gas heated to 800°C at a position of 20 mm in front of the inlet end face of the honeycomb structure is allowed to flow through the honeycomb structure at 2 Nm ³ /min for 10 minutes, and then a cooling gas reaching 150°C at a position of 20 mm before the inlet end face of the honeycomb structure at 2 Nm ³ /min for 10 minutes can flow through the honeycomb structure". Then, the temperature raising/cooling operations were performed for 100 cycles. Thereafter, the presence of a ring crack formed in the honeycomb structure was visually confirmed and evaluated according to the following standards. When a ring crack was generated in the honeycomb structure to such a degree that the function of a DPF was deteriorated, the evaluation was "C". When a ring crack was generated in the honeycomb structure to such a degree that the performance of a DPF was not deteriorated, the evaluation was "B". When no ring crack was generated in the honeycomb structure, the evaluation was "A". "A" and "B" passed and "C" failed. It should be noted that, as for "the function of the DPF", if the PM (soot) collection efficiency in one treatment (an exhaust gas treatment by the DPF) is 90% or more, it can be considered that the ring crack " was generated to such a degree that the function of the DPF does not deteriorate." Further, when the PM (soot) trapping efficiency is less than 90%, it can be considered that the ring crack "was generated to such a degree that the function of the DPF deteriorates". In the measurement of the PM (soot) capture efficiency, as described below, the PM (soot) contained in the gas passing through the honeycomb structure was captured by the filter paper, and the weight (W1) of PM (soot) was measured. Specifically, the honeycomb structure was first attached to a soot generator that generates PM (soot) with a burner in which diesel oil is the fuel honeycomb structure a gas, in which PM (soot) had been generated from the soot generator and which reached 200°C at a position of 190 mm before the inlet end face of the honeycomb structure, was passed at 3 Nm ³ /min for 2 minutes. Thus, the weight (W1) was measured. Further, the gas in which the PM (soot) was generated was not passed through the honeycomb structure but caught by the filter paper for the same period of time, and the weight (W2) of the PM (soot) was measured. Next, the weights (W1) and (W2) obtained respectively were substituted into the following formula to obtain the collection efficiency. $$\left(\text{W2}-\text{w1}\right)/\left(\text{W2}\right)\times 100$$

(Strength of arched section)

First, a pendulum with a cord (length 75 cm) comprising an iron ball with a diameter of 11 mm (weight 5.4 g) at its tip was prepared. Next, this pendulum was arranged so that the iron ball struck the end (outermost peripheral portion) of the bulged portion of the honeycomb structure at the lowest point of the iron ball (i.e., in a state where the pendulum was not swinging). Next, the iron ball of the pendulum swung up and struck the end of the curved section. Thereafter, the end of the bulged portion was visually observed. Then, the evaluation was made in terms of the following standards. When the iron ball swung up to a height of 80% of the length of the cord such that the iron ball hit the end of the bulged portion, it produced a defect like chips in the end of the bulged portion. In this case the rating was "C". When the iron ball swung up to a height of 100% of the length of the string such that the iron ball hit the end of the ring-shaped bulged portion, it produced a defect like chips in the end of the bulged portion. In this case, the rating was "B". When no defects were generated at all, the evaluation was "A". Ratings "A" and "B" passed and rating "C" failed.

(Mounting Properties)

As for the honeycomb structure in which no bulging portion was formed (Comparative Example 1), the assembling properties were evaluated by the maximum thickness (H) and the width (L) of the bulging portion. The evaluation related to the maximum thickness (H) of the bulged portion is sometimes referred to as "the diameter direction" evaluation. Further, the evaluation related to the width (L) of the bulged portion is sometimes referred to as the "entire length direction" evaluation. The evaluation regarding the maximum thickness (H) of the bulging portion was as follows: When the maximum thickness of the bulging portion was 10 mm or less, the rating was “A”, and when the maximum thickness was more than 10 mm and 20 mm or less, the rating was “A”. Rating "B" When the maximum thickness was more than 20 mm, the rating was "C". The rating regarding the width (L) of the bulging portion was as follows: When the width of the bulging portion was more than 80% of the length of the honeycomb structure in the cell extending direction, the evaluation was "B", and when the width was 80% or less of the length of the honeycomb structure in the cell extending direction, the evaluation was "A". after affected the honeycomb structure. In the case of "A", the assembling properties of the honeycomb structure were not impaired.

Further, as for the assembling property, an overall evaluation was made considering each of the maximum thickness (H), the width (L), and the angle (α) of the bulging portion. When both “diameter direction evaluation” and “overall length direction evaluation” were “A”, the overall evaluation was also “A”. When at least one of “diameter direction evaluation” and “overall length direction evaluation” was “B”, the overall evaluation was also “B”. When “diameter direction rating” was “C”, the overall rating was also “C”. In the overall evaluation of mounting properties, the ratings "A" and "B" passed, and the rating "C" failed. Further, "A" rating is most preferred, and then "B" rating is preferred. Further, of the A, B, and C ratings, rating "C" is the worst. Note that the honeycomb structure of Comparative Example 1 is the honeycomb structure in which the thickness of the bulging portion (the maximum thickness of the bulging portion) was “0 mm”. The results are shown in Table 1.

As for the honeycomb structures (Examples 1 to 18 and Comparative Examples 2 to 7) each having the bulged portion in which the flat portion was formed, the evaluation was made as follows (the effect of the flat portion). First, an outer tube was assumed in which the shape in cross section perpendicular to the central axis of the honeycomb structure provided with the planar portion (hereinafter referred to as “honeycomb structure X”) is analogous to the shape of the above honeycomb structure X and the space between the outer tube and the honeycomb structure X is 5 mm uniformly. Next, in the cross section perpendicular to the central axis of this outer tube, a line a passing through the center of the outer tube and connecting two points of the outer peripheral portion of the outer tube, a line b perpendicular to the line a, and a line c diverging at 45° to the line a tends, drawn. Each of the routes b and c was a route that passed through the center of the outer tube and connected two points of the outer peripheral portion of the outer tube. It is assumed that the lines a and b were perpendicular to a flat surface formed in the outer tube. Next, the total number of routes a, b, and c was calculated. Next, a honeycomb structure (hereinafter referred to as “honeycomb structure Y”) having no bulged portion in the honeycomb structure X was adopted.

Next, similarly to the honeycomb structure X, an outer tube was adopted in which the shape was analogous to the shape of the honeycomb structure Y and the space between the outer tube and the honeycomb structure Y was uniformly 5 mm. Next, similarly to the corresponding honeycomb structure X, lines a, b and c were drawn. Next, the total number of routes a, b, and c was calculated. Thereafter, evaluation was made in terms of the following standards. When a ratio of “the total number of routes a, b and c” calculated in the honeycomb structure X relative to “the total number of the routes a, b and c” calculated in the honeycomb structure Y was 104% or less, the evaluation was “ A". When the ratio of “the total number of routes a, b and c” calculated in the honeycomb structure X to “the total number of the routes a, b and c” calculated in the honeycomb structure Y was 106% or less, the evaluation was “ B". When the ratio of “the total number of routes a, b and c” calculated in honeycomb X to “the total number of routes a, b and c” calculated in honeycomb Y was more than 106%, the evaluation was “ C". It is noted that the above evaluation regarding the honeycomb structure having the bulging portion in which the planar portion was formed corresponded to the "diameter direction evaluation". Moreover, as for the honeycomb structure with the bulged portion in which the planar portion was formed, "the evaluation of the overall length direction" and "the overall evaluation" were made in the same manner as the honeycomb structure with the bulged portion in which no planar portion was formed was formed. The results are shown in Table 1. Table 1 Attachment position arched section Inclination angle [degree] max. thickness of curved section (H) [mm] Wide arched section (L) Depth of flat section (D) [mm] Sum of the lengths of the SEAs* Sum of the lengths of the SEAs' each having a width of 5 µm or more ring crack Strength arched section mounting properties judgement [mm] Ratio to overall length* ¹ [mm] Ratio to the circumferential length [%]* ² [mm] Ratio [%]* ³ diameter direction overall length direction in total Ex 1 center 35 10 20 10% 5 16 4% 6 38% B B A A A ◯ Ex 2 center 35 10 20 10% 10 14 3% 5 36% B B A A A ◯ Ex 3 center 35 20 20 10% 20 18 4% 8th 44% B B B A B ◯ Ex 4 center 35 10 20 10% 5 44 10% 17 39% B B A A A ◯ Ex 5 center 35 10 20 10% 5 48 11% 20 42% A B A A A ⊚ Ex 6 center 35 10 20 10% 5 320 71% 270 84% A B A A A ⊚ Ex 7 center 35 10 20 10% 5 40 9% 23 58% A B A A A ⊚ Ex 8 center 35 1 20 10% 1 19 4% 6 32% B A A A A ◯ Ex 9 center 35 20 20 10% 5 16 4% 5 31% B B B A B ◯ Ex 10 center 35 10 3 1 % 5 21 5% 8th 38% B B A A A ◯ Ex 11 center 35 10 160 79% 5 19 4% 7 37% B A A A A ◯ Ex 12 center 35 10 165 81% 5 41 9% 17 41% A A A B B ◯ Ex 13 center 8th 10 20 10% 5 26 6% 8th 31% B A A B B ◯ Ex 14 center 11 10 20 10% 5 16 4% 5 31% B A A A A ◯ Ex. 15 center 80 10 20 10% 5 36 8th % 23 64% A B A A A ⊚ Ex. 16 end section 35 10 20 10% 5 43 10% 16 37% B B A A A ◯ Ex 17 end section 35 10 20 10% 5 151 33% 42 28% A B A A A ⊚ Ex. 18 end section 60 1 15 7% 1 35 8th % 16 46% B A A A A ◯ Comp. Ex. 1 - - - - - - - - - - C - A A A × Comp. Ex. 2 center 35 10 20 10% 3 - - - - C B A A A × Comp. Ex. 3 center 35 10 20 10% 5 13 3% 8th 62% C B A A A × Comp. Ex. 4 center 35 0.5 20 10% 0.5 49 11% 26 53% C A A A A × Comp. Ex. 5 center 35 21 20 10% 5 32 7% 17 53% A B C A C × Comp. Ex. 6 center 35 10 1 0% 5 70 15% 16 23% C B A A A × Comp. Ex. 7 center 85 10 20 10% 5 25 6% 9 36% B C A A A ×
* SEA = Stress Relief Section
*1 Ratio (%) of width of bulged portion (L) to total length of honeycomb structure (honeycomb substrate)
*2 Ratio (%) of the sum of the lengths of all the stress relieving portions to the circumferential length of the honeycomb structure (honeycomb substrate)
*3 Ratio (%) of the lengths of the stress-relief portions each having a width of 5 µm or more to the sum of the lengths of all the stress-relief portions

(Examples 2 to 18 and Comparative Examples 1 to 7)

The procedures of Example 1 to obtain the honeycomb structures were repeated except that the conditions were changed as shown in Table 1. In addition, when the width and the length of each stress relieving portion were adjusted, the time for quick drying of the outer periphery covering material, the object area, the amount of water content in the outer periphery covering material, and the like were changed. As for the obtained honeycomb structures, "position of the stress relieving portion", "length of the stress relieving portion", "width of the stress relieving portion", "ring crack", "strength of the bulging portion" and "assembling properties" were each evaluated by the above methods. The results are shown in Table 1.

(Judgement)

When "ring crack" and "overall evaluation of assembly property" were A, and "strength of bulged portion" was A or B, the result was evaluated as "good" (indicated by a double circle in Table 1). When one of “ring crack” and “overall evaluation of assembly property” was B, the other was A or B, and “strength of bulged portion” was A or B, the result was evaluated as “pass” (indicated by a circle mark in Table 1). When any one of “ring crack”, “overall evaluation of mounting property” and “bulge portion strength” was C, the result was evaluated as “not passable” (indicated by a cross mark in Table 1).

It can be seen from Table 1 that the evaluation results of the honeycomb structures of Examples 1 to 18 were "good" or "fair". On the other hand, with the honeycomb structures of Comparative Examples 1 to 7, the evaluation results were "unfair".

The honeycomb structure of the present invention can be suitably used as a filter for purifying a gas discharged from an internal combustion engine such as a diesel engine or a gasoline direct injection engine, any type of combustion device, or the like.

reference list

1

Partition wall,

2

Cell,

2a

first cell

2 B

second cell,

3

first end face,

4

honeycomb substrate,

5

second end face,

7

outer perimeter cladding layer,

10

arched section,

11

conical surface,

13

connection section,

15

flat section,

17

stress relief section,

18

open end of stress relief section,

20

packaging container,

23

closure section,

25

open end of cell,

50

ring crack,

100, 100a to 100c

honeycomb structure and

200

honeycomb structure.

Claims (6)

A honeycomb structure (100) comprising: a honeycomb substrate (4) having porous partition walls (1) defining a plurality of cells (2) extending from a first end face (3) as one end face to a second end face (5) as the other end face and become passage channels for a fluid, and a bulging portion (10) continuously or intermittently surrounding at least part of the outer periphery of the honeycomb substrate (4) in a ring shape, characterized in that the bulging portion (10) is arranged so that it protrudes outward from the outer periphery of the honeycomb substrate (4) and covers part of the outer periphery of the honeycomb substrate (4), the shape of at least one end of the bulging portion (10) is a conical shape having a conical surface (11) facing one to one Connecting section (13) is an inclined surface on the outer circumference, the maximum thickness of the curved section (10) is 1 to 20 mm in cross section perpendicular to the direction of extension of the cells (2), in cross section parallel z In the cell extending direction, the width of the bulging portion (10) is 1% or more of the total length of the honeycomb substrate (4), and the inclination angle, which is an angle made between the conical surface (11) and the cell extending direction, is 80 degrees or less, one part the surface of the domed portion (10) is a flat portion (15) which is a flat surface parallel to the cell extending direction, the flat portion (15) having one or more stress relief portions (17) having columns each having an open end (18) are in the surface, and the sum of the lengths of all the stress relieving portions (17) is 3% or more of the circumferential length of the honeycomb substrate (4). honeycomb structure (100) after claim 1 , wherein the sum of the lengths of all the stress relief portions (17) is 10% or more of the circumferential length of the honeycomb substrate (4). honeycomb structure (100) after claim 1 or 2 wherein the sum of the lengths of the stress relief portions (17) in each of which the width of the open end (18) is 10 µm or more is 50% or more of the sum of the lengths of all the stress relief portions (17). Honeycomb structure (100) according to one of Claims 1 until 3 , wherein in the cross section parallel to the cell extending direction, the width of the bulging portion (10) is 1 to 80% of the total length of the honeycomb substrate (4) and the inclination angle is 10 to 80 degrees. Honeycomb structure (100) according to one of Claims 1 until 4 wherein the honeycomb substrate (4) is made of at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate and alumina. Honeycomb structure (100) according to one of Claims 1 until 5 further comprising: sealing portions (23) having an open end (25) on the first end surface (3) side of a first cell (2a) as each of predetermined cells of the plurality of cells (2) and an open end (25). the second end surface (5) side of a second cell (2b) than each of the remaining cells of the plurality of cells (2).

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