JP2009256187A - Honeycomb structure, and method for producing honeycomb structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a honeycomb structure in which the positional deviation and falling-off of honeycomb fired bodies are not generated, and the leakage of exhaust gas does not occur, and to provide a method for producing the honeycomb structure. <P>SOLUTION: Disclosed is a honeycomb structure composed of a ceramic block where a plurality of honeycomb fired bodies in which many cells are arranged in the longitudinal direction with cell walls separated are banded via a binding material layer. At least one projecting part is formed at the respective confronted side faces of the honeycomb fire bodies adjacent via the binding material layer, and when viewed from the edge face side of the honeycomb structure, the respective projecting parts formed at the honeycomb fired bodies are formed so as to be superposed, and also, the projecting parts formed at the adjoining honeycomb fired bodies are formed so as to be adjacent. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a honeycomb structure and a method for manufacturing a honeycomb structure.

The exhaust gas discharged from an internal combustion engine such as a diesel engine contains particulate matter (hereinafter also referred to as PM). In recent years, there is a problem that this PM may cause harm to the environment and the human body. It has become.
Accordingly, various honeycomb filters using a honeycomb structure made of silicon carbide or the like have been proposed as exhaust gas filters that collect PM in exhaust gas and purify the exhaust gas.

In such a honeycomb structure, when a certain amount of PM is collected, the honeycomb structure is heated to a high temperature (about 600 to 1000 ° C.), and a regeneration process for burning the collected PM is performed. Here, PM tends to be accumulated in a biased manner in the longitudinal direction of the honeycomb structure constituting the honeycomb filter. Then, a temperature difference occurs along the longitudinal direction of the honeycomb structure along with the combustion of PM, and as a result, thermal stress is generated in the honeycomb structure. In particular, in a honeycomb structure obtained by adhering a plurality of honeycomb fired bodies with an adhesive layer, a load may be applied to the adhesive layer due to the influence of the thermal stress, and cracks may occur.

After that, when cracks spread to a wide range of the adhesive layer due to further regeneration treatment or vibration during operation, the force for bonding and fixing the honeycomb fired bodies decreases, and the position of some of the honeycomb fired bodies may shift, In some cases, the honeycomb fired body may come off. In addition, exhaust gas may leak from the honeycomb fired body as the position shifts or comes off.

In order to prevent such a honeycomb fired body from being displaced or removed, there has been proposed a honeycomb structure in which fine irregularities are formed on the outer peripheral surface of the honeycomb fired body to enhance the adhesive strength with the adhesive layer. (Patent Document 1).

JP 2000-279729 A

However, although the bonding strength of the honeycomb structure described in Patent Document 1 is improved, the honeycomb fired body may be misaligned or dropped, particularly in the honeycomb fired body located in the center. This is especially true for large honeycomb structures where the ratio of the area of the exhaust gas inflow surface to the total length is larger than that of conventional products, in which the honeycomb fired body in the vicinity of the center is bonded and fixed via several adhesive layers. In view of this, there has been a demand for a honeycomb structure in which the honeycomb fired body is less likely to be displaced or lost.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a honeycomb structure in which the honeycomb fired body is not misaligned or removed, and exhaust gas does not leak, and a method for manufacturing such a honeycomb structure. And

In order to achieve the above object, the honeycomb structure according to claim 1 is a ceramic in which a plurality of honeycomb fired bodies in which a large number of cells are arranged in parallel in the longitudinal direction with a cell wall interposed therebetween are bound through an adhesive layer. Each of the opposing side surfaces of the honeycomb fired body which is made of blocks and is adjacent to each other through the adhesive layer has at least one convex portion, and when viewed from the end face side of the honeycomb structure, the honeycomb fired body The protrusions formed on the adjacent honeycomb fired bodies are adjacent to each other, and the protrusions formed on the adjacent honeycomb fired bodies are adjacent to each other.
In addition, seeing from an end surface side means seeing through the convex part in a different position when it sees from an end surface side in the direction parallel to a longitudinal direction.

As a result, cracks develop in the adhesive layer, the adhesive strength is reduced, and even when the honeycomb fired body is about to move, the adjacent convex portions formed on the side surfaces of the honeycomb fired body are caught together to fire the honeycomb. Since the movement of the body is hindered, it is possible to prevent the honeycomb fired body from being displaced or removed. In particular, in the case of a large honeycomb structure in which the influence of the positional deviation of the honeycomb fired body at the center is large, it is ensured that the honeycomb fired body is displaced or removed by the above-mentioned convex portions between adjacent honeycomb fired bodies. Can be prevented.

As in the honeycomb structure according to claim 2, in one of the adjacent honeycomb fired bodies, one honeycomb fired body has a first protrusion on a side surface, and the other honeycomb fired body has a first surface on a side surface. Convex portions and second convex portions are formed, and the first convex portion formed on the side surface of one honeycomb fired body is the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body. The first convex portion formed on the side surface of one honeycomb fired body and the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body are adjacent to each other. The convex part may be formed so that it may fit.
Also in this case, since the movement of the honeycomb fired body in the longitudinal direction is hindered by the adjacent convex portions formed on the side surfaces of the honeycomb fired body, cracks and the like develop in the adhesive layer due to the thermal stress generated during the regeneration process. Even so, it is possible to prevent the honeycomb fired body from being displaced or lost. In particular, in the invention according to claim 2, the convex portions of one honeycomb fired body and the first convex portions and the second convex portions of the other honeycomb fired body are as if the concaves and convexes fitted to each other. Since it is formed, it is possible to prevent the honeycomb fired body from being displaced and removed in the longitudinal direction more firmly.

As in the honeycomb structured body according to claim 3, the thickness of the cell wall at the outer peripheral portion of the honeycomb fired body may be substantially the same as the thickness of the cell wall other than the outer peripheral portion. In this case, in order to form the convex portion on the side surface of the honeycomb fired body, the convex portion is formed by attaching a plate-like body or the like made of substantially the same material as the constituent material of the honeycomb fired body to the side surface of the honeycomb fired body. Can be formed.

As in the honeycomb structured body according to claim 4, the thickness of the cell wall at the outer peripheral portion of the honeycomb fired body may be thicker than the thickness of the cell wall other than the outer peripheral portion.
When the outer peripheral cell wall thickness is thicker than the inner cell wall thickness, for example, the honeycomb formed body is dried and then the outer peripheral cell wall is cut to form a convex portion. Can do. The convex part formed in this way can be made into a convex part integrated with the honeycomb fired body through a subsequent firing step.

As in the honeycomb structured body according to the fifth aspect, an outer peripheral coat layer may be further formed on the outer periphery of the ceramic block.

According to the method for manufacturing a honeycomb structured body according to claim 6, a forming step of forming a columnar honeycomb formed body in which a ceramic raw material is formed and a large number of cells are arranged in parallel in a longitudinal direction with a cell wall therebetween, An end face of a honeycomb structure including a firing step of firing a honeycomb formed body to produce a honeycomb fired body and a binding step of binding a plurality of honeycomb fired bodies through an adhesive layer paste to form a ceramic block When viewed from the side, one honeycomb formed body so that the respective convex portions formed on the honeycomb fired body overlap each other and the convex portions formed on each of the adjacent honeycomb fired bodies are adjacent to each other The convex part formation process which forms a convex part in each of the side surface of this and the side surface of another honeycomb molded object is included.

In the honeycomb formed body, the constituent materials are not yet sintered and are relatively easy to process. By forming convex portions on the honeycomb formed body, a honeycomb fired body having predetermined convex portions can be efficiently manufactured.

In the method for manufacturing a honeycomb structured body according to claim 7, in the honeycomb fired body, a first convex portion is formed on one side of the honeycomb fired body, and a first convex is formed on the side surface of the other honeycomb fired body. And the second convex part are formed, and the first convex part and the second convex part are formed on the side face of the other honeycomb fired body. The first convex portion formed on the side surface of one honeycomb fired body and the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body are adjacent to each other. The convex part is formed.
According to this, the convex portion formed on the side surface of one honeycomb fired body has a relationship that fits between the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body. Thus, irregularities can be formed on the side surface of the honeycomb fired body. When a honeycomb structure is manufactured using the honeycomb fired body thus manufactured, it is possible to prevent positional deviation in the longitudinal direction of the honeycomb fired body.

The outer peripheral coat in which the outer peripheral coat layer paste is applied to the outer peripheral portion of the ceramic block and dried and solidified to form the outer peripheral coat layer, as in the honeycomb structure manufacturing method according to claim 8. A layer forming step may be included.

As in the method for manufacturing a honeycomb structured body according to claim 9, in the projecting portion forming step, a plate-like body is disposed on the side surface of the honeycomb formed body, and then the firing step is performed on the side surface of the honeycomb fired body. A convex portion may be formed.
By firing the plate-like body disposed on the side surface of the honeycomb formed body, the protrusions can be formed on the honeycomb fired body. Since this plate-like body is formed through a firing step, a sintering reaction occurs between the honeycomb fired body and the plate-like body, and the protrusions from the honeycomb fired body are formed by integration. Separation of the plate-like body is also suppressed, and a honeycomb structure that can maintain the catching between the convex portions for a long period can be manufactured.

The shaped body or fired body made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste as in the method for manufacturing a honeycomb structure according to claim 10. The plate-shaped body which consists of may be sufficient.
When using the above materials as the material of the plate-like body, it becomes substantially the same material as the constituent material of the honeycomb molded body or the honeycomb fired body. Are integrated, and the strength against the stress to be displaced is good. Thereby, the honeycomb structure which prevents the positional deviation of the honeycomb fired body for a long time can be manufactured.

As in the method for manufacturing a honeycomb structured body according to claim 11, by disposing the plate-like body via the paste, the honeycomb molding is performed regardless of the state of the plate-like body (unsintered, pre-sintered, etc.). A plate-like body can be disposed on the side surface of the body or the honeycomb fired body.
In the method for manufacturing the honeycomb structure, it is desirable that the paste is made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste.

As in the method for manufacturing a honeycomb structured body according to claim 12, in the projecting portion forming step, the projecting portion is formed on the side surface of the honeycomb formed body with a paste, and then the firing step is performed on the side surface of the honeycomb fired body. A convex portion may be formed.
In the method for manufacturing the honeycomb structure, it is desirable that the paste is made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste.
When the constituent material of the honeycomb structure is applied and the convex portions are formed by subsequent firing, a sintering reaction occurs between the applied constituent material and the honeycomb molded body, so that the obtained convex portions are integrated with the honeycomb fired body. Can be Since this convex part is a part of the honeycomb fired body, the strength against the stress generated when the convex parts are caught is high, and therefore it is possible to prevent damage to the convex part and displacement of the honeycomb fired body over a long period of time. A honeycomb structure can be manufactured.

In the method for manufacturing the honeycomb structure, it is desirable that the paste is made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste.

In the method for manufacturing a honeycomb structured body according to the fourteenth aspect, the convex portion may be formed by cutting a side surface of the honeycomb formed body in the convex portion forming step.
Since the convex portions are formed on the honeycomb formed body that is easily cut, a honeycomb fired body having the convex portions can be manufactured more easily and with high production efficiency. In addition, the convex portions that are overlapped and adjacent to each other when viewed from the end face direction are integrated with the honeycomb fired body to become a part of the honeycomb fired body, and thus have high strength against stress when displacement occurs. Therefore, it is possible to manufacture a honeycomb structure in which the honeycomb fired body is not misaligned or detached for a long time.

It is a perspective view showing typically an example of the honeycomb structure of the present invention. (A) is the perspective view which showed typically an example of the honeycomb fired body which comprises the honeycomb structure of this invention, (b) is the sectional view on the AA line of Fig.2 (a). (A) is a side view schematically showing the positional relationship between protrusions formed on adjacent honeycomb fired bodies, and (b) is a partial perspective view of the honeycomb fired body of (a) as viewed from the end face side. FIG. It is a side view which shows the positional relationship of a convex part at the time of laminating | stacking the honeycomb fired body which formed the convex part. (A) is a perspective view which shows typically the part which applies a punching load among the end surfaces of a honeycomb structure in a punching strength test, (b) is a side view which shows a punching strength tester typically. FIG. (A) is a side view schematically showing another positional relationship between convex portions formed on adjacent honeycomb fired bodies, and (b) is a view of the honeycomb fired body of (a) as viewed from the end face side. FIG. It is a side view which shows another positional relationship of the convex part at the time of laminating | stacking the honeycomb fired body in which the convex part was formed. It is a side view which shows another positional relationship of the convex part at the time of laminating | stacking the honeycomb fired body in which the convex part was formed. (A) is a side view schematically showing a honeycomb formed body before being subjected to cutting, and (b) is a side view schematically showing a honeycomb formed body having a convex portion after being subjected to cutting. It is. It is a side view which shows the positional relationship of a convex part at the time of laminating | stacking the honeycomb fired body which formed the convex part by cutting.

(First embodiment)
Hereinafter, a first embodiment which is an embodiment of a honeycomb structure and a method for manufacturing a honeycomb structure of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view schematically showing an example of the honeycomb structure of the present invention, and FIG. 2A is a perspective view schematically showing an example of the honeycomb fired body constituting the honeycomb structure of the present invention. FIG. 2B is a cross-sectional view taken along line AA in FIG.

In the honeycomb structure 10 shown in FIG. 1, a plurality of honeycomb fired bodies 20 made of porous silicon carbide and shaped as shown in FIGS. 2A and 2B are bonded through an adhesive layer 11 to form a ceramic. A block 12 is configured, and an outer peripheral coat layer 13 is formed on the outer periphery of the ceramic block 12.

In the honeycomb fired body 20 shown in FIGS. 2 (a) and 2 (b), a large number of cells 21 are arranged in parallel in the longitudinal direction (direction a in FIG. 2 (a)) with a cell wall 23 therebetween. Either end of the cell 21 is sealed with a sealing material 22. Therefore, the exhaust gas G that has flowed into the cell 21 opened at one end face 25 always passes through the cell wall 23 separating the cells 21 and then flows out from the other cell 21 opened at the other end face. In this way, the cell wall 23 functions as a filter for collecting PM and the like.
Of the surfaces of the honeycomb fired body and the honeycomb structure, a surface in which cells are open is referred to as an end surface, and a surface other than the end surface is referred to as a side surface.

Here, as shown in FIG. 2A, one convex portion 28 a is formed on one side surface 26 of the honeycomb fired body 20. The convex portion 28a is made of silicon carbide, and is integrated with the honeycomb fired body by substantially the same constituent material as the honeycomb fired body 20. That is, the convex portion 28 a constitutes a part of the honeycomb fired body 20. In the honeycomb fired body 20 shown in FIG. 2A, one convex portion 28a is formed on one side surface 26, and one convex portion 28b, 28c, and 28d is provided on each of the other three side surfaces. Is formed.

The length of the convex portion 28a along the longitudinal direction a of the honeycomb fired body may be 10 to 50% with respect to the total length in the longitudinal direction of the honeycomb fired body, and specifically 10 to 80 mm. Good. In addition, the height b from the side surface of the convex portion 28a may be 2 to 5% of the height d of the honeycomb fired body, and specifically 0.5 to 1.5 mm. These values can also be changed in accordance with the degree of protrusion catching required for the final honeycomb structure and the thickness of the adhesive layer.

In the honeycomb structure of the present invention, when viewed from the end face side of the honeycomb structure, the protrusions formed on the honeycomb fired body are formed so as to overlap with each other, and formed on each of the adjacent honeycomb fired bodies. The convex portions are formed so as to be adjacent to each other. This aspect will be described with reference to FIGS. 3 (a) and 3 (b). Fig.3 (a) is a side view which shows typically the positional relationship of the convex part formed in the adjacent honeycomb fired body, FIG.3 (b) is an end surface of the honeycomb fired body of Fig.3 (a). It is a partial perspective view seen from the side.

As shown in FIG. 1, the plurality of honeycomb fired bodies 20 constituting the honeycomb structure 10 are adjacent to each other on the side surfaces with the adhesive layer 11 interposed therebetween. FIG. 3A shows two adjacent honeycomb fired bodies 30a and 30b. In FIG. 3 (a), one convex portion 38a is formed on the side surface of the upper honeycomb fired body 30a that faces the lower honeycomb fired body 30b. One convex portion 38b is also formed on the side surface facing the honeycomb fired body 30a.

In the honeycomb structure of the present invention, the convex portions 38a and the convex portions 38b are formed on the side surface of the honeycomb fired body 30a and the side surface of the honeycomb fired body 30b so as to be adjacent to each other. In FIG. 3A, the convex portion 38a and the convex portion 38b are not in contact with each other, and an adhesive layer is actually interposed therebetween. In the present invention, although not actually in contact with each other, the adjacent protrusions through the adhesive layer are also treated as adjacent protrusions.

Moreover, FIG.3 (b) is a partial perspective view seen from the end surface side of the right side of the adjacent honeycomb fired body shown to Fig.3 (a). In FIG. 3 (b), the convex portion 38a formed on the side surface of the honeycomb fired body 30a is located on the near side as viewed from the paper surface side, and the convex portion 38b formed on the side surface of the honeycomb fired body 30b is located on the other side. ing. As shown in FIG. 3B, the convex portions 38a and the convex portions 38b overlap each other when viewed from the end surface 15 side of the honeycomb structure (the same side as the end surfaces 35a and 35b of the honeycomb fired body). Part 39 is provided. The range of the portion 39 where the convex portions 38a and the convex portions 38b overlap is changed depending on the degree of catching between the convex portions formed on the side surfaces of the honeycomb fired body and the required thickness of the adhesive layer. That's fine.

The protrusions 38a and protrusions 38b shown in FIG. 3A are formed closer to the right end face of the honeycomb fired body 30a and the honeycomb fired body 30b in the longitudinal direction of the honeycomb fired body. Has been. However, in this embodiment, the convex portion is not limited to being formed closer to the end face as described above, and may be formed at any position along the longitudinal direction as necessary. Moreover, the formation positions of the convex portions may be reversed so that the convex portion 38a is formed on the left side of the convex portion 38b and the convex portion 38b is formed on the right side of the convex portion 38a.

In particular, as for the formation position of the convex portion, it is desirable to form the convex portion at a position where the honeycomb fired body does not come off due to the catching of the convex portions when an external force is applied to the honeycomb fired body from the exhaust gas inflow side. Specifically, the position shown in FIG. 4 is desirable. FIG. 4 is a side view showing the positional relationship of the convex portions when the honeycomb fired bodies having the convex portions are stacked. As shown in FIG. 4, the position of the convex portion 48a formed on one side surface (for convenience, the first side surface is the same for other honeycomb fired bodies), and the side surface opposite to this one side surface. (For convenience, it is the second side surface. The same applies to other honeycomb fired bodies.) When the position of the convex portion 48b formed in the longitudinal direction is shifted and the two honeycomb fired bodies face each other. In addition, a convex portion 48c formed on the first side surface of another honeycomb fired body is located at a position corresponding to the convex portion 48a on the second side surface, and the convex portion on the second side surface of one honeycomb fired body. It is desirable that the respective convex portions are formed so that 48b and the convex portion 48c on the first side surface of another honeycomb fired body are adjacent to each other. When the honeycomb fired bodies having protrusions formed at such positions are arranged, the protrusions formed on the first side surface of one honeycomb fired body and the protrusions formed on the first side surface of another honeycomb fired body Are aligned in the same direction and in a row, and similarly, the convex portion formed on the second side surface of one honeycomb fired body and the convex portion formed on the second side surface of another honeycomb fired body. Are aligned in the same direction and in a row. By adopting such an arrangement, the positional deviation in the longitudinal direction of one honeycomb fired body is necessarily hindered by the convex portions formed in the adjacent honeycomb fired bodies in any direction in the longitudinal direction. become.
In the honeycomb fired body positioned in the outer peripheral portion of the honeycomb structure, the convex portions are formed only on the side surfaces in contact with the other honeycomb fired bodies.

When the honeycomb structure 10 is constituted by a plurality of honeycomb fired bodies 20 having convex portions, particularly with respect to one or a plurality of side surfaces of the honeycomb fired body located in a portion where the honeycomb fired body is likely to be displaced or dropped. By forming the convex portions so as to have the above-described relationship, it is possible to obtain a honeycomb structure in which the adjacent convex portions are caught and the honeycomb fired body is prevented from being displaced.

Next, a method for manufacturing the honeycomb structure of the present embodiment will be described.
First, a forming process for producing a honeycomb formed body is performed by extruding a raw material paste containing ceramic powder and a binder.

First, a raw material paste for manufacturing a honeycomb formed body is prepared by mixing silicon carbide powder having different average particle sizes, an organic binder, a liquid plasticizer, a lubricant, and water as ceramic raw materials.

Subsequently, the raw material paste is put into an extrusion molding machine.
When the raw material paste is put into an extrusion molding machine, the raw material paste becomes a honeycomb formed body having a predetermined shape by extrusion molding. Next, the extruded continuous honeycomb formed body is cut into a predetermined length.

Next, the honeycomb formed body is dried using a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer or the like.

In the method for manufacturing a honeycomb structured body of the present embodiment, after the honeycomb formed body is dried, a projecting portion forming step of forming a projecting portion on the side surface of the honeycomb formed body is performed.
In this convex portion forming step, the convex portion is formed by applying the raw material paste constituting the honeycomb molded body to the position where the convex portion on the side surface of the honeycomb molded body is to be formed.

In order to form the convex portion 28a shown in FIG. 2A, a plate-like jig (mask) made of SUS having a hole is placed on the side surface of the honeycomb formed body, and the hole is filled with the raw material paste. Can be done. Thereafter, the raw material paste protruding from the plate-shaped jig is removed, and the plate-shaped jig is removed, whereby the convex portions 28a and the like are formed.

By performing such a procedure on each side surface of the honeycomb molded body that requires the formation of convex portions, a honeycomb molded body having convex portions formed on the side surfaces can be manufactured.

In the present embodiment, since the material constituting the convex portion is substantially the same as the material constituting the honeycomb molded body (that is, the raw material paste), in the subsequent firing step, the constituent material of the convex portion and the honeycomb molded body The constituent materials are sintered to each other, and the convex portion is integrated with the honeycomb fired body. Thereby, the convex part which became a part of the honeycomb fired body has extremely high strength against the displacement of the honeycomb fired body, and can prevent the honeycomb fired body from being displaced over a long period of time.

After forming the convex portions on the side surfaces of the honeycomb formed body, a sealing process is performed in which predetermined cells are filled with a sealing material paste as a sealing material and the cells are plugged.
In addition, the conditions conventionally used when manufacturing a honeycomb fired body can be applied to the conditions of the cutting process, the drying process, and the sealing process.

Next, a degreasing process is performed in which the organic matter in the honeycomb formed body is removed by heating in a degreasing furnace, and the honeycomb fired body is transported to the firing furnace and the firing process is performed to produce a honeycomb fired body.
A honeycomb fired body can be manufactured through the above steps.
In addition, as conditions for the degreasing step and the firing step, the conditions conventionally used when manufacturing a honeycomb fired body can be applied.

Then, an adhesive layer paste is applied to the side face of the obtained honeycomb fired body to form an adhesive layer paste layer, and other honeycomb fired bodies are sequentially stacked through the adhesive layer paste layer. . This procedure is repeated to produce an aggregate of honeycomb fired bodies in which a predetermined number of honeycomb fired bodies are bundled. In addition, as an adhesive layer paste, what consists of an inorganic binder, an organic binder, an inorganic fiber, and / or an inorganic particle can be used, for example.

When forming the aggregate of the honeycomb fired bodies, the convex portions formed on the side surface of one honeycomb fired body and the convex portions formed on the side surfaces of the other honeycomb fired body are on the end face side of the honeycomb structure. When viewed from above, the honeycomb fired bodies are stacked so as to overlap each other and be adjacent to each other. Therefore, the positions in the longitudinal direction of the protrusions formed on the side surfaces of the honeycomb fired body are not the same in all the honeycomb fired bodies, and are formed at positions where the respective protrusions do not face each other as shown in FIG. Will be.

Further, the thickness of the adhesive layer needs to be set so as not to prevent the overlapping of the convex portions when the honeycomb fired bodies are adjacent to each other via the adhesive layer. Such a thickness is not particularly limited, but when the honeycomb fired bodies are adjacent to each other via the adhesive layer, the shortest distance between the side surface of one honeycomb fired body and the protrusions of the other honeycomb fired body is What is necessary is just to provide an adhesive material layer so that it may become smaller than the height of a convex part. The shortest distance may be 20 to 80% of the height b of the convex portion from the side surface of the honeycomb fired body. Specifically, the thickness of the adhesive layer at the shortest distance portion may be 0.2 to 0.8 mm.

The aggregate of the honeycomb fired bodies is heated to dry and solidify the adhesive layer paste layer to form an adhesive layer, thereby producing a ceramic block. Furthermore, the outer periphery processing process which processes the side surface of a ceramic block using a diamond cutter etc. and makes it cylindrical form is performed.

Next, an outer peripheral coat layer forming step is performed in which the outer peripheral coat layer paste is applied to the outer periphery of the cylindrical ceramic block, dried and solidified to form the outer peripheral coat layer.
In addition, as a material which comprises the said outer periphery coating layer paste, the material similar to the said adhesive material layer paste can be used suitably, and a different material may be used.

Through the above-described steps, a cylindrical honeycomb structure in which an outer peripheral coat layer is provided on the outer peripheral portion of a ceramic block formed by bonding a plurality of honeycomb fired bodies through an adhesive layer can be manufactured.
Note that the outer peripheral coat layer is not necessarily provided, and may be provided as necessary.

Hereinafter, the effects of the honeycomb structure of the present embodiment and the method for manufacturing the honeycomb structure will be listed.
(1) In the honeycomb structure of the present embodiment, at least one convex portion is formed on each of the opposing side surfaces of the honeycomb fired bodies adjacent to each other with the adhesive layer interposed therebetween, from the end face side of the honeycomb structure. When viewed, the protrusions formed on the honeycomb fired body are formed so as to overlap each other, and the protrusions formed on each of the adjacent honeycomb fired bodies are formed adjacent to each other.
As a result, cracks develop in the adhesive layer, the adhesive strength is reduced, and even when the honeycomb fired body is about to move, the adjacent convex portions formed on the side surfaces of the honeycomb fired body are caught together to fire the honeycomb. Since the movement of the body is hindered, it is possible to prevent the honeycomb fired body from being displaced or removed. In particular, in the case of a large honeycomb structure in which the influence of the positional deviation of the honeycomb fired body at the center is large, it is ensured that the honeycomb fired body is displaced or removed by the above-mentioned convex portions between adjacent honeycomb fired bodies. Can be prevented.

(2) When the thickness of the cell wall at the outer peripheral portion of the honeycomb fired body is substantially the same as the thickness of the cell wall other than the outer peripheral portion, A convex portion can be formed on the side surface by applying substantially the same material as the constituent material of the honeycomb formed body, that is, a raw material paste.

(3) According to the method for manufacturing a honeycomb structured body of the present embodiment, a ceramic raw material is molded to form a columnar honeycomb molded body in which a large number of cells are arranged in parallel in the longitudinal direction across the cell wall; A firing step of firing a honeycomb formed body to produce a honeycomb fired body, and a binding step of binding a plurality of honeycomb fired bodies through an adhesive layer paste to form a ceramic block. When viewed from the end surface side, one honeycomb molding is performed so that the respective convex portions formed on the honeycomb fired body overlap each other and the convex portions formed on each of the adjacent honeycomb fired bodies are adjacent to each other. A convex portion forming step of forming convex portions on each of the side surface of the body and the side surface of another honeycomb formed body is included.

A honeycomb formed body that has not undergone the firing step is relatively easy to process because its constituent material is unsintered. A honeycomb fired body having predetermined protrusions can be efficiently manufactured by forming protrusions on the honeycomb formed body using a raw material paste, an adhesive paste, or the like.

(4) In the method for manufacturing a honeycomb structured body of the present embodiment, in the projecting portion forming step, the projecting portion is formed on the side surface of the honeycomb formed body with paste, and then the firing step is performed to project the projecting side surface of the honeycomb fired body. Forming part.
Since the constituent material of the honeycomb structure is applied to the side surface of the honeycomb molded body and the convex portions are formed by subsequent firing, a sintering reaction occurs between the applied constituent material and the honeycomb molded body. Can be integrated with the honeycomb fired body. Since this convex part is a part of the honeycomb fired body, the strength against the stress generated when the convex parts are caught is high, and therefore it is possible to prevent damage to the convex part and displacement of the honeycomb fired body over a long period of time. A honeycomb structure can be manufactured. In the method for manufacturing a honeycomb structure of the present embodiment, it is desirable that the paste is made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste.

Examples that more specifically disclose the first embodiment of the present invention are shown below, but the present invention is not limited to these examples.

Example 1
A mixture of 52.8% by weight of silicon carbide coarse powder having an average particle diameter of 22 μm and 22.6% by weight of fine powder of silicon carbide having an average particle diameter of 0.5 μm is obtained. 2.1% by weight, organic binder (methylcellulose) 4.6% by weight, lubricant (Unilube manufactured by NOF Corporation (Nippon Oil & Fats Co., Ltd.)) 2.8% by weight, glycerin 1.3% by weight, and water 13.8% After adding the weight percent to knead to obtain a raw material paste, extrusion molding and cutting are performed, and the cross-sectional shape is substantially the same as the cross-sectional shape shown in FIGS. An unprocessed raw honeycomb formed body was produced. The honeycomb formed body was dried using a microwave dryer.

Subsequently, the convex part formation process which forms a predetermined convex part in the side surface of a honeycomb molded object was performed. The convex portion is formed by applying a 0.8 mm thick SUS mask having a hole portion of 20 × 30 mm in plan view to the side surface of the honeycomb molded body and applying a raw material paste having the same composition as that of the honeycomb molded body to the side surface of the honeycomb molded body. Then, the hole was filled so as to have a shape as shown in FIG. This procedure was repeated to form one convex portion on each side surface of the honeycomb formed body.

Further, the above procedure was repeated for other honeycomb molded bodies, and a plurality of honeycomb molded bodies each having one convex portion formed on each side surface were produced. In the case of this example, even if an external force is applied from the exhaust gas inflow side of the honeycomb fired body (that is, the direction in which the load from the punching jig is applied in the punching strength test described later), the convex portions are caught with each other. Thus, convex portions were formed so that the honeycomb fired body could not be removed. Specifically, the positions of the protrusions formed on the side surfaces of the plurality of honeycomb formed bodies are as shown in FIGS. 2A and 4 when forming an aggregate of honeycomb fired bodies. The convex portions formed on the side surfaces of the two opposing honeycomb fired bodies were formed adjacent to each other.

A predetermined cell of the honeycomb formed body in which the convex portion was formed was filled with a sealing material paste having the same composition as that of the generated shaped body, the cell was sealed, and again dried using a dryer.

The dried honeycomb formed body was degreased at 400 ° C. and fired under a normal pressure argon atmosphere at 2200 ° C. for 3 hours to obtain a porosity of 45%, an average pore diameter of 15 μm, and a height of 34.3 mm × A honeycomb fired body made of a silicon carbide sintered body having a width of 34.3 mm × a length of 150 mm, a cell number (cell density) of 46.5 cells / cm ² , and a cell wall thickness of 0.25 mm (10 mil) is manufactured. did. On the side surface of the honeycomb fired body, a convex portion having a height of 0.8 mm in a plan view of 20 × 30 mm was formed.

Heat resistance including 30% by weight of alumina fiber having an average fiber length of 20 μm, 21% by weight of silicon carbide particles having an average particle diameter of 0.6 μm, 15% by weight of silica sol, 5.6% by weight of carboxymethylcellulose, and 28.4% by weight of water A large number of honeycomb fired bodies were bonded using the adhesive layer paste. At this time, the honeycomb fired bodies were bonded so that the protrusions formed in the protrusion forming step overlap with each other when viewed from the end face side of the honeycomb fired body. The thickness of the applied adhesive paste is 1.0 mm between the side surfaces of the adjacent honeycomb fired bodies, and 0.2 mm between the side surface of one honeycomb fired body and the protrusions of the other honeycomb fired bodies. there were.

Furthermore, this aggregated body of honeycomb fired bodies was dried at 120 ° C., and then cut using a diamond cutter to produce a cylindrical ceramic block.

Next, an outer peripheral coat layer paste layer having a thickness of 0.2 mm was formed on the outer peripheral portion of the ceramic block using the outer peripheral coat layer paste having the same composition as the adhesive layer paste. And this outer periphery coating layer paste layer was dried at 120 degreeC, and the cylindrical honeycomb structure of diameter 143.8mm x length 150mm in which the outer periphery coating layer was formed in the outer periphery was manufactured.

(Comparative Example 1)
A honeycomb structure was manufactured in the same manner as in Example 1 except that the convex portions were not formed on the side surfaces of the honeycomb fired body.

(Comparative Example 2)
Instead of forming convex portions on the side surface of the honeycomb fired body, the honeycomb structure is the same as in Example 1 except that the surface roughness (ten-point average roughness) Rz of the side surface of the honeycomb fired body is 60 μm. Manufactured. The surface roughness was adjusted by a known sand blasting process for the side surface of the honeycomb fired body. The surface roughness Rz was measured according to JIS B0601.

(Punching strength test)
The punching strength of the honeycomb structures manufactured in Example 1 and Comparative Examples 1 and 2 was measured.
Specifically, as shown in FIGS. 5A and 5B, after the honeycomb structure 10 in which a plurality of the honeycomb fired bodies 20 are bound through the adhesive layer is placed on the base 51, The honeycomb fired body 20 is pushed by applying a punching load (pressing speed 1 mm / min) to the honeycomb fired body 20 near the center (shaded portion in FIG. 5A) with an aluminum jig 50 having a diameter of 30 mm. The load at the time when the honeycomb fired body 20 was pulled out or destroyed was measured, and the result was taken as the punching strength of the portion where the honeycomb fired body 20 was bonded by the adhesive layer. Fig. 5 (a) is a perspective view schematically showing a portion of the end face of the honeycomb structure to which a punching load is applied in the punching strength test, and (b) schematically shows a punching strength tester. FIG.
In addition, an Instron universal testing machine (model 5582) was used for the measurement of strength.

As a result, the punching strength in the honeycomb structure of Example 1 was not able to be measured because the punching load was high (even if a load of 6 kN, which is about three times that of Comparative Example 2, was applied) There was no misalignment of the body). This is presumably because the convex portions formed on the side surfaces of the honeycomb fired body were caught and the strength against the punching load was very high.

On the other hand, the punching strength of the honeycomb structure of Comparative Example 1 was 1.47 kN, and the punching strength of the honeycomb structure of Comparative Example 2 was 2.04 kN. In any of the honeycomb structures, the punching strength is weak, and it is estimated that the honeycomb fired body may be displaced from the honeycomb structure during use.

(Second embodiment)
Hereinafter, a second embodiment which is an embodiment of the present invention will be described with reference to the drawings.
In the honeycomb structured body of the second embodiment, in the adjacent honeycomb fired bodies, one honeycomb fired body is formed with the first convex portion on the side surface, and the other honeycomb fired body has the first convex portion on the side surface and A second convex portion is formed, and the first convex portion formed on the side surface of one honeycomb fired body is between the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body. And the first convex portion formed on the side surface of one honeycomb fired body and the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body are adjacent to each other. Protrusions are formed.

Fig.6 (a) is a side view which shows typically another positional relationship of the convex parts formed in the adjacent honeycomb fired body, FIG.6 (b) is the honeycomb fired body of Fig.6 (a). It is a partial perspective view which looked at from the end surface side. In FIG. 6A, one convex portion 68a is formed on the side surface of the upper honeycomb fired body 60a that faces the lower honeycomb fired body 60b. On the other hand, two convex portions 68b and 68c are formed on the side surface of the honeycomb fired body 60b facing the honeycomb fired body 60a.

Also in the honeycomb structure of the present embodiment, convex portions are formed on the side surface of the honeycomb fired body 60a and the side surface of the honeycomb fired body 60b so that one convex portion 68a and two convex portions 68b and 68c are adjacent to each other. Has been. In FIG. 6 (a), the convex portion 68a and the convex portions 68b and 68c are not in contact with each other, but in reality, they are adjacent to each other with an adhesive layer interposed therebetween. Become.

FIG. 6B is a partial perspective view seen from the right end face side of the adjacent honeycomb fired body shown in FIG. 6A, and the convex portion 68b formed on the side surface of the honeycomb fired body 60b. A convex portion 68a formed on the side surface of the honeycomb fired body 60a is located on the far side as viewed from the paper surface side. Further, although not shown, a convex portion 68c exists on the rear side of the convex portion 68a when viewed from the paper surface side. When these protrusions 68a and protrusions 68b and 68c are viewed from the end face 15 side of the honeycomb structure (the same side as the end faces 65a and 65b of the honeycomb fired body), as shown in FIG. It has the part 69 which mutually overlaps. Due to the overlapping of the convex portions, positional displacement in the longitudinal direction of the honeycomb fired body is prevented. In addition, the range of the part 69 where the convex part 68a and the convex parts 68b and 68c overlap with each other is based on the degree of catching between the convex parts formed on the side surface of the honeycomb fired body and the thickness of the required adhesive layer. It may be changed accordingly.

In the honeycomb structured body of the second embodiment, when the honeycomb fired body formed with the first protrusions and the honeycomb fired body formed with the first and second protrusions are stacked, as shown in FIG. As described above, the convex portion 78c formed on one side surface of the one honeycomb fired body 70b (for convenience, the first side surface is the same for the other honeycomb fired bodies) is the first portion of the other honeycomb fired body 70a. What is necessary is just to laminate | stack so that it may fit between the two convex parts 78a and 78b formed in the side surface (For convenience, it is set as the 2nd side surface. The same also applies to other honeycomb fired bodies). . Even when another honeycomb fired body is laminated, the first and second protrusions formed on the first side surface of the other honeycomb fired body are formed on the second side surface of the honeycomb fired body 70b. What is necessary is just to laminate | stack so that it may fit between convex parts. Thus, a ceramic block can be formed by sequentially laminating new honeycomb fired bodies. Further, by adopting such an arrangement, the positional deviation in the longitudinal direction of one honeycomb fired body is always hindered by the convex portions formed in the adjacent honeycomb fired bodies in any direction in the longitudinal direction. Will be.
In the honeycomb fired body positioned in the outer peripheral portion of the honeycomb structure, the convex portions are formed only on the side surfaces in contact with the other honeycomb fired bodies.

In order to manufacture the honeycomb structure of the second embodiment, in the convex portion forming step, a raw material paste is applied so that one convex portion is formed on one side surface using a plate frame having a hole portion. The raw material paste may be applied so that two convex portions are formed on the side surface opposite to the one side surface. The honeycomb structure of the present embodiment can be manufactured by performing this procedure on other side surfaces or other honeycomb molded bodies.

Range in which the three convex portions occupy the side surface of the honeycomb fired body when the first convex portion of one honeycomb fired body is fitted between the first and second convex portions of another honeycomb fired body As the convex portions 78a, 78b, 78c shown in FIG. 7, it may be a range over a part of the side surface of the honeycomb fired body, or, as the convex portions 78a, 78b, 78c shown in FIG. It may be a range extending over the entire length of the honeycomb fired body on the side surface of the honeycomb fired body when the three convex portions are adjacent to each other.

Also in the honeycomb structure of the second embodiment, the same effects (1) to (4) as in the first embodiment can be obtained.
(5) Furthermore, in the honeycomb structure of the second embodiment, the protrusions of one honeycomb fired body and the first protrusions and the second protrusions of the other honeycomb fired body are fitted together. Since it is formed like irregularities, it is not necessary to consider the position of the convex part so that it can be formed at a position where all of the honeycomb fired body does not come out, easily and more firmly In addition, it is possible to prevent positional deviation and disconnection in the longitudinal direction of the honeycomb fired body.

(Third embodiment)
So far, the embodiment has been described in which the raw material paste having substantially the same composition as the honeycomb molded body is applied to the side surface of the honeycomb molded body to form the convex portions, but the method for forming the convex portions is not limited to this, and the honeycomb A convex part can be formed by arrange | positioning a plate-shaped object to the side surface of a molded object.

As such a plate-like body, a plate having a size (thickness, width, length) corresponding to the convex portion having a desired size (height, width, length) is formed. A body can be used. The material constituting the plate-like body is not particularly limited, and forms a raw material paste having substantially the same composition as the honeycomb formed body, an adhesive layer paste used when bonding a plurality of honeycomb fired bodies, and an outer peripheral coating layer. The outer periphery coating layer paste or the like can be used. Since these pastes have almost the same composition, good adhesiveness can be obtained in terms of adhesiveness to the side surfaces of the plate-shaped honeycomb formed body or honeycomb fired body.

When the plate-like body is made of the paste as described above, the plate-like body in any state of an undried state, a state after drying, or a state after sintering may be used. Use a plate-like body that has not been sintered, that is, in an undried state or in a dried state, so that the material forming the honeycomb formed body can be sintered and integrated in the firing step of Is desirable.

In addition, it is not always necessary to integrate the plate-like body and the honeycomb formed body through a direct sintering reaction, and the plate-like body in a sintered state is not formed through any of the pastes described above. You may integrate both by sticking to the side surface of this, and performing a baking process after that. Also by such a method, it is possible to manufacture a honeycomb structure that can prevent displacement for a long period of time.

In the honeycomb structure of the third embodiment, the same effects (1) and (3) as in the first embodiment can be obtained.
(6) Furthermore, a convex part can be easily formed by forming a convex part using a plate-shaped object.

(Fourth embodiment)
Next, a fourth embodiment which is an embodiment of the present invention will be described with reference to the drawings.
In the present embodiment, as a method for forming the convex portion, a method is employed in which the side surface of the honeycomb formed body is cut to form the convex portion. As described above, a honeycomb structure that can prevent displacement in the longitudinal direction even when the convex portions are formed through the cutting process can be manufactured.

FIG. 9A is a side view schematically showing a honeycomb formed body before being subjected to cutting, and FIG. 9B is a schematic view showing a honeycomb formed body having a convex portion after being subjected to cutting. It is the side shown.
Note that the honeycomb molded body has an undried state after being extruded and cut, and a dried state after a drying step. However, after considering the ease of cutting and handling, It is preferable to cut the honeycomb formed body.

First, a portion to be cut on the side surface of the honeycomb formed body is determined. Specifically, as shown in FIG. 9 (a), a portion 84a on which one side surface of the honeycomb formed body 80 is cut and a side surface opposite to the one side surface are cut. The parts 84b and 84c are determined in advance. The portion to be cut may be arbitrarily determined in consideration of the size, shape, number, etc. of the target convex portion.

Next, a cutting process is performed on the portion to be cut. The cutting process is not particularly limited, and processes such as milling, planing, and end milling can be employed. Of these processes, end milling is preferable in consideration of the ease of the dried honeycomb formed body and the degree of freedom of the forming position.

By cutting the side surface of the honeycomb molded body in this way, as shown in FIG. 9B, two convex portions 88a and 88b are formed on one side surface, and 1 is formed on the side surface opposite to the one side surface. A honeycomb formed body in which two convex portions 88c are formed can be manufactured. Since these three convex portions 88a, 88b, 88c constitute a part of the side surface of the honeycomb formed body, they constitute a part of the honeycomb fired body as it is through a subsequent firing step. Since the convex portions formed in this way have a very high strength against the positional deviation of the honeycomb fired body, it is possible to prevent the positional deviation of the honeycomb fired body for a long period of time.

By the way, in this embodiment, the side surface of the honeycomb formed body is cut to form a convex portion, so that the thickness of the cell wall (that is, the outer peripheral cell wall) constituting the side surface of the honeycomb formed body is formed. Becomes thinner. The thickness of the outer peripheral cell wall and the thickness of the cell wall other than the outer peripheral cell wall (that is, the inner cell wall) may be substantially the same as long as the outer peripheral cell wall can withstand cutting. . However, since the strength may decrease in the thinned portion of the outer peripheral cell wall, the thickness of the outer peripheral cell wall is preferably thicker than the thickness of the inner cell wall. This is because, even after the side surface of the honeycomb formed body is cut, the thickness of the cell wall in the cut portion has sufficient strength from the viewpoint of strength. . In addition, in order to produce a honeycomb molded body in which the outer peripheral cell wall is thicker than the inner cell wall, the width of the portion corresponding to the outer peripheral cell wall corresponds to the inner cell wall in the mold used for extrusion molding. It may be thicker than the width of the part to be done.

After the above-described cutting process was performed on another honeycomb molded body to form similar convex portions, one convex portion formed on the side surface of one honeycomb fired body was formed on the other honeycomb fired body. By fitting between the two convex portions, a plurality of honeycomb fired bodies can be easily stacked in a relationship that does not shift each other. This procedure will be described with reference to FIG. FIG. 10 is a side view showing the positional relationship of the convex portions when the honeycomb fired body having the convex portions formed by cutting is stacked.

In the honeycomb structure of the fourth embodiment, when the honeycomb fired body formed with the first protrusions and the honeycomb fired body formed with the first and second protrusions are stacked, as shown in FIG. As described above, the convex portion 98a formed on one side surface of the one honeycomb fired body 90a (for convenience, the first side surface is the same for the other honeycomb fired bodies) is the first portion of the other honeycomb fired body 90b. What is necessary is just to laminate | stack so that it may fit between the two convex parts 98b and 98c formed in the side surface (For convenience, it is set as the 2nd side surface. It is the same also about another honeycomb fired body.). . Even when another honeycomb fired body 90c is laminated, the first and second protrusions formed on the first side surface of the honeycomb fired body 90b are formed on the second side surface of the honeycomb fired body 90c. What is necessary is just to laminate | stack so that it may fit between convex parts. Thus, a ceramic block can be formed by sequentially laminating new honeycomb fired bodies. Further, by adopting such an arrangement, the positional deviation in the longitudinal direction of one honeycomb fired body is always hindered by the convex portions formed in the adjacent honeycomb fired bodies in any direction in the longitudinal direction. Will be.

In the honeycomb structure of the fourth embodiment, the same effects (1) and (3) as in the first embodiment can be obtained.
(7) Furthermore, in this embodiment, since the convex portion is formed on the honeycomb molded body that is easy to cut, a honeycomb fired body having the convex portion can be manufactured more easily and with high production efficiency. In addition, the convex portions that are overlapped and adjacent to each other when viewed from the end face direction are integrated with the honeycomb fired body to become a part of the honeycomb fired body, and thus have high strength against stress when displacement occurs. Therefore, it is possible to manufacture a honeycomb structure in which the honeycomb fired body is not misaligned or detached for a long time.

(Other embodiments)
The formation pattern of the convex portions is not limited to the form described so far. For example, in one honeycomb formed body, two convex portions are formed on one side surface, and also on the side surface opposite to the one side surface. Two convex portions may be formed. In this case, in another honeycomb formed body, one convex portion is formed on one side surface, and one convex portion is also formed on the side surface opposite to the one side surface.

The shape of the honeycomb structure of the present invention is not limited to the columnar shape shown in FIG. 1, and may be any columnar shape such as an elliptical column shape, a long column shape, or a polygonal column shape.

The porosity of the honeycomb structure of the present invention is desirably 30 to 70%.
This is because the strength of the honeycomb structure can be maintained and the resistance when the exhaust gas passes through the cell walls can be kept low.

On the other hand, if the porosity is less than 30%, the cell walls may be clogged at an early stage. On the other hand, if the porosity exceeds 70%, the strength of the honeycomb structure is lowered and easily broken. May be.
The porosity can be measured by a conventionally known method such as a mercury intrusion method, an Archimedes method, or a measurement using a scanning electron microscope (SEM).

The cell density in the cross section perpendicular to the longitudinal direction of the honeycomb fired body is not particularly limited, but a desirable lower limit is 31.0 cells / cm ² (200 cells / inch ² ), and a desirable upper limit is 93.0 cells / cm ^2. (600 / inch ^2), more preferably downside is 38.8 pieces ^/ cm 2 (250 cells / inch ^2), a more desirable upper limit is 77.5 cells ^/ cm 2 (500 cells / inch ^2).

The main component of the constituent material of the honeycomb fired body is not limited to silicon carbide, and as other ceramic raw materials, for example, nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, titanium nitride, zirconium carbide, It may be a carbide ceramic such as titanium carbide, tantalum carbide or tungsten carbide, a composite of metal and nitride ceramic, a composite of metal and carbide ceramic, or the like.
In addition, ceramic raw materials such as silicon-containing ceramics in which metallic silicon is mixed with the above-described ceramics, and ceramics bonded with silicon or a silicate compound are also included as constituent materials.

The main component of the constituent material of the honeycomb fired body is particularly preferably silicon carbide having excellent heat resistance, mechanical strength, thermal conductivity, and the like among the ceramic raw materials listed above.
In addition, silicon carbide containing metal silicon (silicon-containing silicon carbide) is also desirable.

The honeycomb structure may carry a catalyst for purifying exhaust gas. As the catalyst to be carried, for example, a noble metal such as platinum, palladium, rhodium or the like is desirable, and among these, platinum is more desirable. Further, as other catalysts, for example, alkali metals such as potassium and sodium, and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more.

Further, when the catalyst is supported, a catalyst support layer may be formed on the cell wall of the honeycomb structure for the purpose of highly dispersing the catalyst. The material for forming the catalyst supporting layer is preferably a material having a high specific surface area and capable of supporting the catalyst in a highly dispersed state, and examples thereof include oxide ceramics such as alumina, titania, zirconia, and silica. .
These materials may be used alone or in combination of two or more.

DESCRIPTION OF SYMBOLS 10 Honeycomb structure 11 Adhesive material layer 12 Ceramic block 13 Outer peripheral layer 20, 30a, 30b, 40a, 40b, 40c, 60a, 60b, 70a, 70b, 70c, 80, 90a, 90b, 90c Honeycomb fired body 21 Cell 23 Cell Wall 28a, 28b, 28c, 28d, 38a, 38b, 48a, 48b, 48c, 48d, 68a, 68b, 68c, 78a, 78b, 78c, 88a, 88b, 88c, 98a, 98b, 98c

Claims (14)

A honeycomb structure comprising a plurality of ceramic blocks in which a plurality of honeycomb fired bodies in which a large number of cells are arranged in parallel in the longitudinal direction across a cell wall are bound through an adhesive layer,
At least one convex portion is formed on each of the opposing side surfaces of the honeycomb fired body adjacent via the adhesive layer,
When viewed from the end face side of the honeycomb structure, the protrusions formed on the honeycomb fired body are formed so as to overlap each other, and the protrusions formed on each of the adjacent honeycomb fired bodies are adjacent to each other. A honeycomb structure characterized by being formed to fit. In the adjacent honeycomb fired body, one honeycomb fired body is formed with a first protrusion on the side surface,
The other honeycomb fired body is formed with a first convex portion and a second convex portion on the side surface,
A first convex portion formed on a side surface of the one honeycomb fired body is formed between a first convex portion and a second convex portion formed on a side surface of the other honeycomb fired body; and A convex portion is formed so that the first convex portion formed on the side surface of one honeycomb fired body and the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body are adjacent to each other. The honeycomb structure according to claim 1. The honeycomb structure according to claim 1 or 2, wherein the thickness of the cell wall at the outer peripheral portion of the honeycomb fired body is substantially the same as the thickness of the cell wall other than the outer peripheral portion. The honeycomb structure according to claim 1 or 2, wherein the thickness of the cell wall at the outer peripheral portion of the honeycomb fired body is thicker than the thickness of the cell wall other than the outer peripheral portion. The honeycomb structure according to any one of claims 1 to 4, wherein an outer peripheral coat layer is formed on an outer periphery of the ceramic block. A molding step of forming a ceramic raw material to produce a columnar honeycomb formed body in which a large number of cells are arranged in parallel in the longitudinal direction across the cell wall;
A firing step of firing the honeycomb formed body to produce a honeycomb fired body;
A method of manufacturing a honeycomb structure including a binding step of binding a plurality of the honeycomb fired bodies through an adhesive layer paste to form a ceramic block,
When viewed from the end face side of the honeycomb structure, the protrusions formed on the adjacent honeycomb fired bodies are adjacent to each other so that the protrusions formed on the honeycomb fired bodies overlap each other. Thus, the manufacturing method of the honeycomb structure characterized by including the convex part formation process which forms a convex part in each of the side surface of one said honeycomb molded object, and the side surface of another said honeycomb molded object. In the honeycomb fired body, one honeycomb fired body is formed with a first convex portion on a side surface,
The other honeycomb fired body is formed with a first convex portion and a second convex portion on the side surface,
A first convex portion formed on a side surface of the one honeycomb fired body is formed between a first convex portion and a second convex portion formed on a side surface of the other honeycomb fired body; and A convex portion is formed so that the first convex portion formed on the side surface of one honeycomb fired body and the first convex portion and the second convex portion formed on the side surface of the other honeycomb fired body are adjacent to each other. The method for manufacturing a honeycomb structured body according to claim 6. The method for manufacturing a honeycomb structure according to claim 6 or 7, further comprising an outer peripheral coat layer forming step of forming an outer peripheral coat layer by applying an outer peripheral coat layer paste to the outer peripheral portion of the ceramic block and drying and solidifying the paste. The said convex-part formation process WHEREIN: A plate-shaped object is arrange | positioned to the side surface of the said honeycomb molded body, and a convex part is formed in the side surface of the said honeycomb fired body by performing a baking process next. A method for manufacturing a honeycomb structure. The method for manufacturing a honeycomb structure according to claim 9, wherein the plate-like body is formed of a molded body or a fired body made of substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste. . The method for manufacturing a honeycomb structured body according to claim 9 or 10, wherein the plate-like body is disposed via a paste. In the convex portion forming step, a convex portion is formed with a paste on a side surface of the honeycomb formed body,
The method for manufacturing a honeycomb structured body according to claim 6 or 7, wherein a convex portion is formed on a side surface of the honeycomb fired body by performing a firing step. The method for manufacturing a honeycomb structure according to claim 11 or 12, wherein the paste is substantially the same material as the raw material paste, the adhesive layer paste, or the outer peripheral coat layer paste. The method for manufacturing a honeycomb structured body according to claim 6 or 7, wherein, in the convex portion forming step, the convex portions are formed by cutting a side surface of the honeycomb formed body.

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