JP2011194320A - Honeycomb structure and method for producing honeycomb structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a honeycomb structure preventing a portion of a barrier wall from quickly damaging filtration function and continuing the capture of the material to be caught by means of the barrier wall with a large area when being used as a filter for catching material to be caught with the barrier wall and for filtering fluid.SOLUTION: The honeycomb structure 1 includes the porous barrier wall 2, a plurality of cells 3 serving as a flow channel of the fluid G and a plugging part 6 disposed on the cells 3, wherein a resistance part 11 is disposed which gives resistance to a flow of the fluid G on an intermediate part in the axial direction X of the cells 3 on a part or all of the cells 3 where the plugging part 6 is disposed on the side of a second edge surface 5 and, at the same time, causes a part of the fluid G to pass to the side of the second edge surface 5.

Description

  The present invention relates to a honeycomb structure having a partition wall having a filtration function used for purifying exhaust gas and the like, and a plurality of cells formed in the partition wall, and a method for manufacturing the honeycomb structure.

  A honeycomb structure is composed of partition walls and a plurality of cells penetrating from one end face to the other end face. When the partition walls are porous, the honeycomb structure is for purifying exhaust gas from a diesel engine or the like. Used as an exhaust gas filter. For example, a honeycomb structure is used for a diesel particulate filter (DPF) that collects particulate matter (hereinafter, “PM”: particulate material) contained in exhaust gas by a porous partition wall.

  A honeycomb structure used as an exhaust gas filter has a configuration in which exhaust gas always passes through a porous partition wall. In a typical embodiment of such a honeycomb structure, either one of both end portions of the cell is plugged with a plugging portion. Therefore, even if the exhaust gas flows into the cell from the end of the cell without the plugged portion, it reaches the plugged portion at the cell end on the opposite side and always passes through the porous partition wall. Flow into the next cell. And when exhaust gas passes a porous partition, PM contained in exhaust gas cannot pass through the pore of a partition, but is collected by a partition as it is. Therefore, when exhaust gas is discharged to the outside of the honeycomb structure, it is purified without containing PM (see, for example, Patent Document 1).

  Further, in order to improve the filter function of the honeycomb structure as described above, a honeycomb structure in which the position of plugging is arranged or the number of plugged portions arranged in one cell is devised as follows. Patent Documents 2 to 5 disclose the above.

  In the honeycomb structures described in Patent Documents 2 and 3, the plugged portion is not exposed on the end face and is provided in the back of the cell on the side where the exhaust gas flows. In this honeycomb structure, since all the cells are opened at the inflow side end surface into which the exhaust gas flows, the inflow resistance of the exhaust gas at the inflow side end surface is reduced. Thereby, the stagnation of the exhaust gas in the cell near the inflow side end face is reduced.

  In the honeycomb structures described in Patent Documents 4 and 5, one plugged portion is provided at one end of the cell, and another plugged portion is provided at an intermediate portion of the cell in the cell penetration direction. . Therefore, in this honeycomb structure, exhaust gas is surely discharged through the partition wall twice or more.

JP 2001-269585 A JP 2004-251137 A JP 2006-272156 A JP 2005-262210 A JP 2007-289926 A

  However, in the honeycomb structure of Patent Document 1, a large amount of PM is concentrated on the partition walls at some locations in the cell. More specifically, in the vicinity of the end of the cell that opens to allow the exhaust gas to flow in, and in the vicinity of the plugged portion at the opposite end of the cell, the amount of PM deposited is larger than that in the middle portion of the cell. Very many.

  In the honeycomb structures of Patent Documents 2 and 3, although the exhaust gas stagnation is reduced in the vicinity of the end portion of the cell where the exhaust gas flows from the outside, the uneven distribution of the PM accumulation amount cannot be eliminated.

  Moreover, in the honeycomb structures of Patent Documents 2 to 5, the exhaust gas that has flowed from the end portions of the open cells hits the plugging portion in the middle portion of the cells. Therefore, in these honeycomb structures, the first exhaust gas purification is forced in the short flow path portion from the end portion of the cell on the exhaust gas inflow side to the intermediate portion where the plugging portion is provided. That is, the small-area partition walls that form the open cell end to the middle part of the cell are forced to filter untreated exhaust gas containing a large amount of PM, and PM deposition tends to concentrate.

  In view of the above problems, the object of the present invention is to collect the collected matter intensively at a part of the partition wall when the collected object (for example, PM) is used as a filter for collecting by the partition wall. An object of the present invention is to provide a honeycomb structure and a manufacturing method thereof.

  In order to solve the above-mentioned problems, the present inventors have intensively studied to complete the present invention. That is, according to the present invention, the following honeycomb structure is provided.

[1] A porous partition wall, a plurality of cells that are partitioned by the partition wall and serve as a fluid flow path in the axial direction from the first end surface to the second end surface, and the first end surface of each of the cells A honeycomb structure having a plugging portion plugging at least one of the side and the second end surface side, wherein the cell is provided with the plugging portion on the second end surface side In the middle of the cell in the axial direction in part or all of the cell, in the direction of the second end surface when flowing the fluid from the first end surface to the second end surface in the cell. A honeycomb structure provided with a resistance portion that allows a part of the fluid to pass through on the second end face side while imparting resistance to the flow of the fluid to be directed.

[2] The honeycomb structure according to [1], wherein the resistance portion is provided with a through hole serving as a flow path for the fluid.

[3] The honeycomb structure according to [2], wherein the through hole has a flow path cross-sectional area that continuously or intermittently decreases from the first end face side toward the second end face side.

[4] The resistance portion is made of a porous body having a large number of pores, and the pores serve as a flow path for the fluid at a location where the resistance portion is provided in the cell. The honeycomb structure according to any one of [3].

[5] The honeycomb structure according to any one of [1] to [4], wherein the resistance portion has a wall-like structure with a thickness of 1 to 3 mm in the axial direction.

[6] In each of the cells in which the resistance portion is provided, the porosity of the partition wall defining the cell is such that the first end surface side and the second end surface side are separated from the resistance portion. The honeycomb structure according to any one of [1] to [5], which is different from each other.

[7] The honeycomb structure according to any one of [1] to [6], wherein cross-sectional areas differ between adjacent cells in a cross section perpendicular to the axial method.

[8] The above [1] to [7], wherein the plugging portion for plugging the first end face side of the cell is provided in the cell without being exposed to the first end face. The honeycomb structure according to any one of the above.

[9] A first honeycomb structure having a porous partition wall and a plurality of cells that are partitioned by the partition wall and that serve as fluid flow paths in the axial direction from one end surface to the other end surface, and A honeycomb structure manufacturing method for forming a bonded honeycomb structure by integrating the end faces of two honeycomb structures together, the end face being one of the end faces of the first honeycomb structure A resistance portion disposing step of providing a resistance portion that reduces a flow path cross-sectional area of the flow path of the fluid at a part or all of the end portions of the cells; and the resistance portion of the first honeycomb structure. The joining hanica having the cell provided with the resistance portion at an intermediate portion in the axial direction by connecting the end face on the provided side and the end face of the second honeycomb structure to communicate with each other. A bonding step of forming a structure, and the first honeycomb structure and the first honeycomb structure and the cells so that each of the cells in the bonded honeycomb structure is plugged on at least one end side in the axial direction. A plugging step of providing plugging portions in the cells of the second honeycomb structure.

[10] In the resistance portion disposing step, a mask opened so as to correspond to the openings of some or all of the cells is provided on the end face of any one of the first honeycomb structures, and the top of the mask is provided. Alternatively, the resistance portion material is supplied on the same plane as the surface of the mask, and the pressure portion is disposed on the surface of the mask at an acute angle to pressurize the resistance portion material. By moving the pressure member, the resistance portion material is pressurized on the pressure surface to fill the end portion of the cell on the end surface with the resistance portion material, and then the end portion of the cell is filled. While the resistance portion material has fluidity, the inside of the cell filled with the resistance portion material is set to a positive pressure or a negative pressure, and the resistance portion material filled in the end portion of the cell is applied to the resistance portion material. Between the inside and outside of the cell. A method for manufacturing a honeycomb structure according to [9] with a step of forming a through hole for.

[11] In the resistance portion disposing step, after a predetermined time has elapsed since the end portion of the cell is filled with the resistance portion material, the inside of the cell filled with the resistance portion material is set to a negative pressure and the penetration is performed. The method for manufacturing a honeycomb structured body according to [10], wherein the holes are formed.

[12] The method for manufacturing a honeycomb structure according to any one of [9] to [11], wherein the first honeycomb structure and the second honeycomb structure are different in porosity of the partition walls.

  When the honeycomb structure of the present invention is used as a filter that collects the collected objects by the partition walls, the collected matter does not collect intensively at a part of the partition walls. Therefore, in the honeycomb structure of the present invention, it is possible to prevent a part of the partition walls from quickly losing the filtration function, and even when used as a filter for a long time, the trapped material is collected by almost the entire area of the partition walls. Can continue.

  In addition, as described above, the method for manufacturing a honeycomb structure of the present invention, even if it is continuously used as a filter, some portions of the partition walls do not quickly impair the filtration function, and are captured by almost the entire area of the partition walls. A honeycomb structure capable of continuing collection of the collected material can be manufactured.

Fig. 3 is a longitudinal view showing an embodiment of the honeycomb structure of the present invention. It is explanatory drawing which expands partially the longitudinal cross-sectional view shown in FIG. 1, and represents typically the flow of the fluid in a cell. FIG. 3 is a longitudinal cross-sectional view of an embodiment of the honeycomb structure of the present invention that schematically shows a state in which collected materials contained in a fluid are collected in partition walls by the fluid flow shown in FIG. 2. [Fig. 4] Fig. 4 is a longitudinal sectional view schematically showing a flow of a fluid in a cell by partially enlarging an embodiment of a conventional honeycomb structure. [Fig. 5] Fig. 5 is a longitudinal sectional view of a conventional honeycomb structure schematically showing a state in which collected materials contained in a fluid are collected in a partition wall by the fluid flow shown in Fig. 4. FIG. 3 is a longitudinal sectional view of a part of a honeycomb structure provided with a resistance portion having a through hole, and schematically shows a flow of fluid in a cell in an embodiment in which a part of an inner wall of the through hole is formed of a partition wall. It is explanatory drawing represented to. It is a longitudinal cross-sectional view of a part of a honeycomb structure in which a resistance portion made of a porous body having a large number of pores is provided in a cell, and is an explanatory view schematically showing a flow of fluid in the cell. FIG. 4 is a longitudinal sectional view of a part of a honeycomb structure in which a resistance portion having a through-hole and a resistance portion made of a porous body are provided in the same cell, and is an explanatory view schematically showing a fluid flow in the cell It is. FIG. 3 is a partial cross-sectional view of an embodiment of a honeycomb structure of the present invention, showing partition walls having different porosity between the first end face side and the second end face side with a position where the resistance portion is disposed as a boundary. It is a figure. [Fig. 3] Fig. 3 is a cross-sectional view of the honeycomb structure in which a portion where a resistance portion is provided is enlarged in an embodiment of the honeycomb structure of the present invention. [Fig. 3] Fig. 3 is a cross-sectional view of the honeycomb structure in which a portion where a resistance portion is provided is enlarged in an embodiment of the honeycomb structure of the present invention. [Fig. 3] Fig. 3 is a cross-sectional view of the honeycomb structure in which a portion where a resistance portion is provided is enlarged in an embodiment of the honeycomb structure of the present invention. 1 is a longitudinal sectional view of a part of a honeycomb structure showing a state in which plugged portions are not exposed at a first end face and are provided inside cells in an embodiment of the honeycomb structure of the present invention. 1 is a cross-sectional view of a first honeycomb structure used in an embodiment of a method for manufacturing a honeycomb structure of the present invention. 12B is a cross-sectional view of a first honeycomb structure in which a resistance portion is provided in the resistance portion arranging step in the embodiment of the method for manufacturing a honeycomb structure of the present invention with respect to the first honeycomb structure shown in FIG. 12A. . FIG. 12B is a view for explaining a joining step in an embodiment of the method for manufacturing a honeycomb structure of the present invention, in which the first honeycomb structure provided with the resistance portion and the second honeycomb structure are combined. FIG. FIG. 12C is a cross-sectional view of the bonded honeycomb structure formed by combining the first honeycomb structure and the second honeycomb structure by a bonding process following FIG. 12C. FIG. 12E is a cross-sectional view of the joined honeycomb structure in which a plugging portion is provided by a plugging process in an embodiment of the method for manufacturing a honeycomb structure of the present invention following FIG. 12E. [Fig. 3] Fig. 3 is a cross-sectional view of a first honeycomb structure provided with a plugging portion by a plugging step in an embodiment of the method for manufacturing a honeycomb structure of the present invention. FIG. 14B is a cross-sectional view of a first honeycomb structure in which a resistance portion is provided by a resistance portion arranging step in an embodiment of the method for manufacturing a honeycomb structure of the present invention with respect to the first honeycomb structure shown in FIG. 13B. . The first honeycomb structure provided with the plugging portion and the resistance portion shown in FIG. 13B is combined with the second honeycomb structure provided with the plugging portion in a separate plugging step. It is a figure for demonstrating the joining process in one Embodiment of the manufacturing method of this honeycomb structure. FIG. 13C is a cross-sectional view of the bonded honeycomb structure formed by combining the first honeycomb structure and the second honeycomb structure by a bonding process following FIG. 13C. In the resistance portion disposing step of the embodiment of the method for manufacturing a honeycomb structure of the present invention, the resistance portion material is filled in the end portion of the cell by using a pressure member, and the end portion of the cell is filled. It is a figure for demonstrating a mode that a through-hole is formed in material. FIG. 3 is a diagram schematically showing a state immediately after a resistance member material is filled in an end portion of a cell using a pressure member in a resistance portion arranging step of an embodiment of a method for manufacturing a honeycomb structure of the present invention. . FIG. 16 is a diagram for explaining a state in which a through hole is formed in the resistor portion material filled in the end portion of the cell in the resistor portion disposing step subsequent to FIG. 15. FIG. 17 is a cross-sectional view in the vicinity of an end face of an enlarged honeycomb structure in a round frame A in FIG. 16.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to the following embodiments, and changes, modifications, and improvements can be added without departing from the scope of the present invention.

1. Honeycomb structure:
1-1. Basic embodiment of the honeycomb structure of the present invention:
FIG. 1 is a cross-sectional view of a honeycomb structure 1 that belongs to the technical scope of the present invention, and is represented by a cross-section in which cells 3 are vertically cut from a first end face 4 to a second end face 5. The honeycomb structure 1 of the present invention includes a porous partition wall 2 and a plurality of cells 3 that are partitioned by the partition wall 2 and serve as a flow path for the fluid G that communicates from the first end surface 4 to the second end surface 5. Each cell 3 is provided with a plugging portion 6 that plugs at least one of the first end face 4 side and the second end face 5 side.

  Examples of the porous partition walls 2 include those formed mainly of ceramics, such as a honeycomb structure used as a DPF. Of course, the honeycomb structure 1 of the present invention is not limited to the one formed mainly of ceramics as long as the partition walls 2 are made of a porous material having a large number of pores.

  Furthermore, in the honeycomb structure 1 of the present invention, a part or all of the cells 3 in which the plugging portions 6 are provided on the second end surface 5 side are not resistant to the intermediate portion of the cells 3 in the axial direction X. Part 11 is provided.

  FIG. 2 is a partially enlarged longitudinal sectional view of the honeycomb structure 1 shown in FIG. 1 and schematically shows the flow of the fluid G in the cell 3. When the resistance part 11 flows the fluid G in the cell 3 from the first end face 4 to the second end face 5, the resistance part 11 applies a part of the fluid G while giving resistance to the flow of the fluid G toward the second end face 5. It passes through the second end face 5 in the same cell 3.

  The resistance part 11 includes one that locally reduces the flow path cross-sectional area of the cell 3. In a specific embodiment of the resistance portion 11, there is a wall-like structure that has a through hole 12 and partitions the cell 3 as shown in FIG. 2.

  Hereinafter, unless otherwise specified, the flow of the fluid G causes the fluid G to flow into the cell 3 opened on the first end surface 4 side, and the direction from the first end surface 4 to the second end surface 5 in the cell 3 It is assumed that a specific example in which the fluid G is allowed to flow is described.

  “The resistance portion 11 is provided in the middle portion of the cell 3 in the axial direction X” means that the position of the target resistance portion 11 and the cell 3 in the vicinity of the cell 3 having the resistance portion 11 are arranged. When the position of the plugging portion 21 on the end surface 4 side is compared, it means that the position of the resistance portion 11 is closer to the second end surface 5 side in the axial direction X. The position where the resistance portion 11 is provided can be determined as appropriate depending on the number of the resistance portions 11 provided in one cell 3, the magnitude of the resistance that the resistance portion 11 exerts on the fluid G, and the like.

  “The fluid G passes through the resistance portion 11” means that the fluid G passes through the portion of the cell 3 where the resistance portion 11 is provided and passes through the same cell 3 from one end face side to the other end face side. It means to flow through.

“Give resistance to the flow of the fluid G toward the second end surface 5” means that the cell 3 is moved from the first end surface 4 to the second end surface 5 in the vicinity of the portion where the resistance portion 11 is provided. This means that a part of the flowing fluid G acts to flow into the adjacent cell 3 through the partition wall 2 like the fluids G ₃ and G ₄ in FIG. In addition, even when acting to pass through the partition wall 2 and flow into the adjacent cell 3 only on the first end face 4 side from the resistance section 11 or only on the second end face 5 side from the resistance section 11, it resists the flow of the fluid G. It corresponds to giving.

In the resistance portion 11 of the embodiment shown in FIG. 2, since the flow path cross-sectional area decreases from the first end face 4 to the resistance portion 11, the fluid that has flowed through the cell 3 to the location where the resistance portion 11 is provided. A part of G cannot pass through the resistance portion 11 and flows into the adjacent cell 3 through the partition wall 2 like the fluid G ₃ .

And when passing through the through hole 12 of the opposing part 11 and going to the second end face 5 side, the flow path cross-sectional area becomes larger again, so that part of the fluid G that has passed through the through hole 12 becomes the second part of the resistance part 11. A vortex is wound in the vicinity of the wall surface 42 on the second end face 5 side to flow backward, and like the fluid G ₄ , passes through the partition wall 2 and flows into the adjacent cells 3.

Further, when the fluid G flows from the first end face 4 into the honeycomb structure 1, an inflow resistance to the fluid G is generated in the vicinity of the first end face 4, and passes through the partition wall 2 in the vicinity of the first end face 4. fluid flow G flowing in the cell 3 adjacent Te is generated (see FIG. 2, the fluid G _1).

In addition, fluid G that has reached the plugging portion 22 of the abutment is blocked the way, flow into the cells 3 adjacent through the partition wall 2 (see Figure 2, fluid G _2).

Therefore, the flow of the fluid G flowing into the adjacent cells 3 through the partition walls 2 is dispersed along the axial direction X as indicated by G _{1 to} G ₄ in FIG.

FIG. 3 is a longitudinal sectional view of the same honeycomb structure 1 as shown in FIG. 2, and the collected matter contained in the fluid G is collected in the partition wall 2 by the flow of the fluid G shown in FIG. 2. Represents. In the honeycomb structure 1 of the present invention, the collected matter is scattered on the partition wall 2 along the axial direction X as indicated by PM ₁ to PM ₄ in FIG.

FIG. 4 is a longitudinal sectional view of a conventional honeycomb structure 1 in which the resistance portion 11 is not provided in the cell 3. In the conventional honeycomb structure 1, the flow of the fluid G in the direction from the first end surface 4 to the second end surface 5 is arranged in the intermediate portion of the cell 3 in the axial direction X, and the fluid G passing through the partition wall 2 is in this intermediate portion. The flow is not noticeable. Therefore, in the conventional honeycomb structural body 1, the flow of the fluid G passing through the partition wall 2, at the side of the second end face 5 showing the first end face 4 near indicated by fluid G _1, and at fluid G ₂ plugging It becomes noticeable only in the vicinity of the portion 22.

FIG. 5 is a vertical cross-sectional view of a conventional honeycomb structure 1 and shows a state in which collected materials contained in the fluid G are collected in the partition walls 2. Corresponding to the flow of the fluid G described above, the locations where much of the collected matter is collected by the partition wall 2 are the vicinity of the first end face 4 indicated by PM ₁ and the second end face 5 indicated by PM ₂ in FIG. It is unevenly distributed in the vicinity of the sealing portion 22. Sometimes, as indicated by PM _{2 in} FIG. 4, the substantial flow path length of the cell 3 may decrease from the second end face 5 side due to the accumulation of collected substances.

  In contrast to this, in the honeycomb structure 1 of the present invention, since the collection of the collected material by the almost entire area of the partition wall 2 can be continued for a long time, the collected material collected in the partition wall 2 is burned. The time until removal, that is, the so-called combustion regeneration period can be lengthened.

  The honeycomb structure 1 of the present invention can be applied to the embodiments described below while having the configuration of the above-described basic embodiment.

1-2. Embodiment in which a resistance portion having a through hole is provided:
FIG. 6 shows an embodiment of the honeycomb structure 1 belonging to the technical scope of the present invention. In this embodiment, the resistance portion 11 having the through hole 12 is provided in an intermediate portion of the cell 3 in the axial direction X. As shown in this figure, the through hole 12 may be constituted by a partition wall 2 in which a part of the inner wall 41 forming the through hole 12 defines the cell 3.

  In the resistance portion 11 having the through hole 12, it is preferable that the edge of the through hole 12 on the first end face 4 side and / or the edge of the through hole 12 on the second end face 5 side is rounded. By adopting such a form of the through hole 12, it is possible to reduce the pressure loss of the fluid G that passes through the resistance portion 11 and flows to the second end surface 5 as compared with the case where the edge of the through hole 12 has a corner.

1-3. Embodiment in which a resistance portion made of a porous body is provided:
In the honeycomb structure 1 shown in FIG. 7, the resistance portion 11 has a porous wall-like structure and partitions the cells 3. Thus, the resistance part 11 is comprised from the porous body which has many pores, and it can also be embodiment which allows a part of fluid G to pass the 2nd end surface 5 side from a pore.

  When the resistance portion 11 is formed of a porous body, the fluid G flows through the pores connected in a mesh shape inside the opposing portion 11 and flows out from the entire wall surface 42 on the second end face 5 side. Therefore, the fluid G flowing out from the wall surface 42 does not spiral, and the fluid G hardly passes through the partition wall 2 in the vicinity of the wall surface 42.

  In the resistance part 11 comprised from a porous body, this resistance part 11 itself can also collect the collection thing contained in the fluid G. Thereby, the collection efficiency of a thing to be collected can be improved.

  When the resistance part 11 is comprised from a porous body, it is preferable that the average pore diameter of the porous body which comprises the resistance part 11 is larger than the average pore diameter of the partition 2 which forms the cell 3, and the partition 2 It is more preferable that the average pore diameter is twice or more. Thereby, the pressure loss at the time of the fluid G passing through the resistance part 11 can be made small.

1-4. Embodiment in which a resistance portion having a wall-like structure having a thickness of 1 to 3 mm is provided:
In the honeycomb structure 1 of the present invention, the resistance portion 11 preferably has a wall-like structure with a thickness in the axial direction X of 1 to 3 mm. The resistance portion 11 having a wall-like structure here includes the resistance portion 11 having a through hole 12 and the resistance portion 11 formed of a porous body.

  In the resistance part 11 of such embodiment, the pressure loss at the time of the fluid G passing through the resistance part 11 can be made small. Moreover, since the connection part of the partition 2 and the resistance part 11 becomes small, the surface of the partition 2 is exposed more widely with respect to the fluid G in the cell 3, and the collection efficiency of a collection thing increases. For example, comparing the case where the thickness of the resistance portion 11 is 3 mm and the case where the thickness of the resistance portion 11 is 30 mm, the former has a longer 27 mm channel length, and the longer the channel length, the more inside the cell 3 The surface area of the partition wall 2 exposed to the fluid G is also increased.

1-5. Embodiment in which a plurality of resistance portions are provided in the same cell:
FIG. 8 shows a partial cross section of the honeycomb structure 1 in which two resistance portions 11 are provided in the same cell 3. As shown in this figure, in the honeycomb structure 1 of the present invention, a plurality of resistance portions 11 are provided in the same cell 3 to further disperse the flow of the fluid G passing through the partition walls 2 and flowing into the adjacent cells 3. Is also possible.

  In the embodiment shown in FIG. 8, in the same cell 3 in which the second end surface 5 side is plugged by the plugging portion 6, the resistor portion 11a having the through hole 12 on the first end surface 4 side, The resistance part 11b comprised from a porous body and the two resistance parts 11 are provided in the 2 end surface 5 side. In this embodiment, the flow of the fluid G4 passing through the partition wall 2 tends to occur on the second end surface 5 side of the resistance portion 11a, whereas the fluid G passing through the partition wall 2 on the second end surface 5 side of the resistance portion 11b. The flow of is difficult to occur. Thus, the flow of the fluid G can be appropriately adjusted by selecting the form of the resistance portion 11.

1-6: Embodiment having partition walls having different porosities on the same surface with the resistance portion as a boundary:
FIG. 9 is a cross-sectional view of the honeycomb structure 1 belonging to the technical scope of the present invention. In the embodiment shown in FIG. 9, the partition wall 51 on the first end face 4 side and the partition wall 52 on the second end face 5 side have different porosities with the resistor portion 11 as a boundary.

  In this way, a difference in porosity between the partition walls 51 and 52 is generated with the resistor portion 11 as a boundary, and the cell 3 in the cell 3 between the first end surface 4 side and the second end surface 5 side with the resistor portion 11 as a boundary. By adjusting the pressure difference, the resistance generated with respect to the fluid G when passing through the resistance portion 11 can be adjusted.

  For example, in the embodiment in which the pressure of the fluid G is excessively lost when passing through the resistance portion 11, increasing the porosity of the partition wall 52 on the second end face side from the resistance portion 11 also increases the pressure in the partition wall 52. The lost fluid G can still pass easily.

  10A to 10C are enlarged cross-sectional views of the cell 3 where the resistance portion 11 is provided. The position of the interface 53 between the partition wall 51 on the first end face side and the partition wall 52 on the second end face side having different porosities is an intermediate position of the resistor portion 11 (FIG. 10A), and the end of the resistor portion 11 on the first end face 4 side. The position (FIG. 10B) or the position of the end of the resistance portion 11 on the second end face 5 side (FIG. 10C) may be used.

1-7. Embodiment in which all cells are open at the first end face:
FIG. 11 is a cross-sectional view of a part of the honeycomb structure 1 belonging to the technical scope of the present invention. In the embodiment shown in FIG. 11, a plugging portion 21 that plugs the first end surface 4 side of the cell 3 is not exposed to the first end surface 4 and is provided inside the cell 3.

  In this embodiment, the cells 3 are all open at the first end face 4, and the fluid G flows from the first end face 4 into all the cells 3. Thereby, when viewed from the whole honeycomb structure 1, the flow passage cross-sectional area of the fluid G at the first end face 4 is not reduced, and at the end of the cell 3 on the side of the first end face 4 through which the fluid G flows, the fluid G Inflow resistance is reduced.

1-8. Embodiments with different cross-sectional areas between adjacent cells:
In the honeycomb structure 1 of the present invention, it is preferable that the cross-sectional areas differ between adjacent cells 3 in a cross section perpendicular to the axial direction X. When the cross-sectional areas of the adjacent cells 3 are different, if the fluid G flows from the outside into the cells 3 having a wide cross-sectional area, the inflow resistance of the fluid G can be more reliably reduced.

1-9: Form of arrangement of plugging portions:
In the honeycomb structure 1 of the present invention, the plugging portion 6 is one of the adjacent cells 3 separated by the common partition wall 2 on either the first end face 4 side or the second end face 5 side. An embodiment provided in the cell 3 and not provided in the other cell 3 is preferable. As a specific example, in the plan view of the first end face 4 or the second end face 5 of the honeycomb structure 1, there is an embodiment in which the cells 3 provided with the plugging portions 6 appear alternately in a checkered pattern.

2. Manufacturing method of honeycomb structure:
Although any method that can be used by those skilled in the art based on the prior art can be applied to the manufacturing of the above-described honeycomb structure 1 of the present invention, as a specific embodiment, the following manufacturing method of the honeycomb structure is described. (Hereinafter, “the manufacturing method of the present invention”) can be applied.

2-1. Basic embodiment of the production method of the present invention:
Briefly, in the manufacturing method of the present invention, two honeycomb structures are prepared, and after providing a resistance portion at the end of a predetermined cell on one end face of one of the honeycomb structures, the honeycomb structure The end face on the side where the resistance portion of the body is provided and the end face of the other honeycomb structure are combined to produce a bonded honeycomb structure. In the bonded honeycomb structure, the cells of the two honeycomb structures communicate with each other in the axial direction, and a resistance portion is provided in an intermediate portion of the one communicated cell.

  The manufacturing method of the present invention includes a resistance portion providing step of providing a resistance portion, a joining step of forming two bonded honeycomb structures together to form one bonded honeycomb structure, and a plugging step of providing plugged portions in cells. , Has three steps. Hereinafter, with reference to FIG. 12A-12E which shows the outline of one Embodiment of the manufacturing method of this invention, it demonstrates in order.

2-1-1. Resistor placement process:
FIG. 12A is a cross-sectional view of the first honeycomb structure 61 used in the resistance portion arranging step in an embodiment of the manufacturing method of the present invention. In the resistance portion disposing step, as shown in FIG. 12B, a resistance that reduces the cross-sectional area of the flow path of the fluid at the end portion of some or all of the cells 3 on the end face 65 of the first honeycomb structure 61. A portion 11 is provided. In the embodiment shown in FIG. 12B, a resistance portion 11 having a through hole 12 is provided.

  Although not shown here, in the resistor portion arranging step, for example, the opening of one cell 3 is formed not on the inside of the cell 3 but on the end surface 65 so as to reduce the opening area of the predetermined cell 3 on the predetermined end surface 65. It may be a step of attaching a film having a hole smaller than the area.

2-1-2. Joining process:
FIG. 12C represents one embodiment of the joining process. As shown in this figure, in the joining step, the end surface 66 on the side where the resistance portion 11 of the first honeycomb structure is provided and the end surface 65 of the second honeycomb structure 62 are matched. As a result, a bonded honeycomb structure 71 shown in FIG. 12D is formed.

  In the bonded honeycomb structure 71, a cell 72 in which the cell 63 of the first honeycomb structure 61 and the cell 64 of the second honeycomb structure 62 communicate with each other is constructed. In the cell 72, the resistance portion 11 is provided in an intermediate portion in the axial direction X.

  When the cell 22 is constructed, the partition walls 67 of the first honeycomb structure 61 and the partition walls 68 of the second honeycomb structure 62 are integrated. In this case, the edge 81 of the partition wall 67 of the first honeycomb structure 61 and the edge 82 of the partition wall 68 of the second honeycomb structure 62 may be connected via a bonding material.

  As the bonding material, the same material as the partition walls 2 of the first honeycomb structure 61 and / or the second honeycomb structure 62 can be used.

2-1-3. Plugging process:
The plugging step is a step of providing the plugging portions 6 in the cells 72, and the plugging step in the conventional method for manufacturing a plugged honeycomb structure can be applied.

  Following the steps shown in FIGS. 12A to 12D, through a plugging step, as shown in FIG. 12E, each cell 72 of the bonded honeycomb structure 71 has at least one end side in the axial direction X. A plugging portion 6 is provided.

  13A to 13D are diagrams showing an outline of an embodiment of the manufacturing method of the present invention different from the above. In the embodiment shown in FIGS. 13A to 13D, prior to the resistance disposing step and the joining step, on the end face 65 side of any one of the predetermined cells 3 of the first honeycomb structure 61 and the second honeycomb structure 62. A plugging portion 6 is provided (see FIGS. 13A and 13C).

  In the embodiment shown in FIGS. 13A to 13D, the resistance portion 11 is provided on the end surface 66 of the first honeycomb structure 61 opposite to the end surface 65 on the side where the plugging portions 6 are provided (FIG. 13B). reference).

  In the manufacturing method of the present invention, the plugging step may be performed before or after the resistance portion arranging step and / or the bonding step.

  In the manufacturing method of the present invention, the following embodiment can be adopted while providing the above-described basic embodiment. Several embodiments are shown below, but two or more embodiments are arbitrarily selected from the plurality of embodiments, and combinations of the configurations of the selected embodiments are also included in the technical scope of the manufacturing method of the present invention. include.

2-2. Embodiment in which a resistance member material is filled into an end portion of a cell using a pressure member:
FIG. 14 schematically shows an embodiment of the resistance portion arranging step, and shows a state in which the resistance portion 11 having the through hole 12 is provided by using a resistance portion material 85 having fluidity. First, in the resistance portion disposing step of this embodiment, a mask 87 having an opening corresponding to the opening of a part or all of the cells 63 is provided on the end face 66 of the first honeycomb structure 61.

  Subsequently, a resistance portion material 85 having fluidity is supplied on the mask 87 or on the same plane as the surface of the mask 87, and the resistance portion is disposed on the surface of the mask 87 at an acute angle with respect to the surface. The pressure member 88 having the pressure surface 90 for pressing the material 85 is moved, and the resistance portion material 85 is pressed by the pressure surface 90 to fill the end portion of the cell 63 on the end surface 66 with the resistance portion material 85.

  In this embodiment, the resistance part material 85 can be filled in the cell 63 with a thickness of 3 mm or less in the axial direction X. Therefore, since the resistance portion 11 provided by this embodiment is very thin, there is an advantage that excessive resistance is not given to the fluid G.

  Next, as shown in FIG. 14, while the resistance portion material 85 filled in the end portion of the cell 63 has fluidity, the inside of the cell 63 filled with the resistance portion material 85 is set to a positive pressure or a negative pressure. To do.

  By making the inside of the cell 63 a positive pressure or a negative pressure, a part of the resistance portion material 85 filled in the end portion of the cell 63 flows out of the cell 63 or flows further into the cell 63, and the remaining resistance. The part material 85 remains attached to the partition wall 67 at substantially the same location. Therefore, the resistance part 11 having the through hole 12 that penetrates the inside of the cell 63 and the outside of the cell 63 is formed.

  In the embodiment shown in FIG. 14, the suction means 86 sucks the cells 63 one by one according to the degree of solidification of the counter part material 85 from the end 65 opposite to the side where the resistance part material 85 is filled. ing. Although not shown, suction by the suction means 86 may be performed for all the cells 63 at the same time.

2-3. Embodiment in which a resistance portion having a rounded end of a through hole is provided:
FIG. 15 shows that after filling the end portion of the cell 63 of the first honeycomb structure 61 with the resistance portion material 85 having fluidity, the pressure in the cell 63 is not changed artificially and is maintained for a predetermined time. Represents the situation. Since the resistance portion material 85 has fluidity, if the resistance portion material 85 is left as it is after being filled, the surface of the resistance portion material 85 exposed at the end face 66 is recessed near the center.

  Subsequently, as shown in FIG. 16, the inside of the cell 63 is sucked by the suction means 86 from the end portion 65 on the side opposite to the side filled with the resistance portion material 85 to form the through hole 12.

  FIG. 17 is an enlarged view in the frame A in FIG. In this embodiment, the edge of the through-hole 12 on the side that appears on the end face 66 is rounded.

  In the manufacturing method of the present invention, the first honeycomb structure 61 and / or the second honeycomb structure 62 can be made of ceramic as a main component. In this case, the first honeycomb structure 61 and the second honeycomb structure 62 may have different porosity of the partition walls 67 and 68.

  In addition, as the resistance portion material 85 having fluidity, a material mainly composed of ceramics can be used. In this case, the resistance portion 11 can be made of a porous body having a large number of pores.

  EXAMPLES Hereinafter, although this invention is demonstrated further in detail based on an Example, this invention is not limited to these Examples.

Example 1
(1) adjusted talc as a cordierite after the honeycomb structure fired, kaolin, alumina, silica, its chemical _composition, SiO 2 42 to 56 _{wt%, Al} 2 O 3 30-45% by weight, and Honeycomb forming by blending at a predetermined ratio so as to be MgO 12 to 16% by mass, adding a pore former, binder, surfactant and mixed water to this, mixing and kneading, and then performing extrusion molding Got the body.

Next, the obtained honeycomb formed body was dried at 180 ° C. for 3 minutes, and then fired at 1420 ° C. for 5 hours to obtain a honeycomb structure. The honeycomb structure had a partition wall thickness of 1 mm, a cell density of 300 cells / inch ² , a porosity (partition wall efficiency) of 45% measured by a mercury porosimeter, and an average pore diameter (partition wall average pore diameter) of 25 μm. It was. Two identical honeycomb structures were produced.

(2) Plugging step As plugging material, 40% by mass of kaolin with an average particle size of 5 μm, 40% by mass of talc with an average particle size of 40 μm, 15% by mass of aluminum oxide with an average particle size of 10 μm, and an average particle size of 5 μm 5 mass of silica was used as the main inorganic component. The viscosity of the plugging material was 250 dPa · s at 25 ° C. This plugging material was filled in one end face of each of the two honeycomb structures. The plugging material was filled by a method using a pressurizing member described in JP2009-40046A. The conditions for filling the plugging material were a pressure from the pressure member of 0.4 MPa, a pressure member driving speed of 50 mm / sec, and an angle between the honeycomb structure and the pressure surface of 15 °. The filled plugging portions had an average thickness of 3 mm and a standard deviation of 0.3 mm with respect to the average thickness of the plugging portions.

(3) Resistance part arrangement | positioning process The resistance part was formed in the end surface opposite to a plugging part in one body among the two honeycomb structures. A ceramic slurry of the same material as the honeycomb structure is used as the resistance part material, and as shown in FIG. 15, a mask is provided on the end face, and then the resistance part material is filled into the cell end part by a pressure member, and the resistance part material is filled. A resistance portion having a through hole was formed by sucking the inside of the cell from the end surface opposite to the formed side. The conditions for filling the resistance portion material were a pressure from the pressure member of 0.4 MPa, a pressure member drive speed of 100 mm / sec, and an angle between the honeycomb structure and the pressure surface of 30 °. The resistance portion thus formed had an average thickness of 1.0 mm and a standard deviation of 0.3 mm with respect to the average thickness of the resistance portion.

(4) Joining process The end face with the resistance portion of the honeycomb structure formed with the resistance portion was joined to the end face of the other honeycomb structure that was not plugged. Bonding of both end faces is performed by applying an adhesive of the same material as the resistance part to the edge of the partition wall of one of the two end faces to be joined, bonding the edges of the partition wall, and pressurizing and firing. I went. As described above, a honeycomb structure having a resistance portion provided in the middle portion of the cell in the axial direction was obtained.

(Example 2)
Example 1 except that the conditions at the time of filling the resistance portion material were set to a pressure of 0.3 MPa from the pressing member, a pressing member driving speed of 50 mm / sec, and an angle formed by the honeycomb structure and the pressing surface of 30 °. A honeycomb structure was obtained by the same method. The resistance portion had an average thickness of 2.0 mm and a standard deviation of 0.3 mm with respect to the average thickness of the resistance portion.

  INDUSTRIAL APPLICABILITY The present invention can be used as a honeycomb structure having a partition wall having a filtration function used for purification of exhaust gas and the like and a plurality of cells formed in the partition wall, and a method for manufacturing the honeycomb structure.

1: honeycomb structure, 2: partition wall, 3: cell, 4: first end face, 5: second end face, 6: plugging portion, 11: resistance portion, 11a, resistance portion, 11b: resistance portion, 12: Through-hole, 13: porous body, 21: plugged portion, 22: plugged portion, 41: inner wall, 42: wall surface on the second end face side, 51: partition wall, 52: partition wall, 53: interface, 61: 1st honeycomb structure, 62: 2nd honeycomb structure, 63: Cell, 64: Cell, 65: End face, 66: End face, 67: Partition wall, 68: Partition wall, 69: End face, 71: Bonded honeycomb structure 79: end face, 80: end face, 81: edge of partition wall, 82: edge of partition wall, 85: resistance part material, 86: suction means, 87: mask, 88: pressure member, 90: pressure face.

Claims (12)

A porous partition wall, a plurality of cells that are partitioned by the partition wall and serve as fluid flow paths in the axial direction from the first end surface to the second end surface, and the side of the first end surface of each of the cells or the A honeycomb structure having a plugging portion for plugging at least one of the second end face side,
The part of or all of the cells provided with the plugging portion on the second end face side is provided in an intermediate portion in the axial direction of the cell, and the cell is provided from the first end face into the cell. A honeycomb structure provided with a resistance portion that passes a part of the fluid on the second end face side while giving resistance to the flow of the fluid moving in the direction of the second end face when the fluid flows in the direction of the second end face body.   The honeycomb structure according to claim 1, wherein the resistance portion is provided with a through-hole serving as a flow path for the fluid.   The honeycomb structure according to claim 2, wherein the through-hole has a flow path cross-sectional area that continuously or intermittently decreases from the first end face side toward the second end face side.   The said resistance part consists of a porous body which has many pores, The said pore becomes a flow path of the said fluid in the location in which the said resistance part in the said cell is provided. The honeycomb structure according to one item.   The honeycomb structure according to any one of claims 1 to 4, wherein the resistance portion has a wall-like structure with a thickness of 1 to 3 mm in the axial direction.   In each of the cells in which the resistance portion is provided, the porosity of the partition that defines the cell is different between the first end surface side and the second end surface side with respect to the resistance portion. Item 6. The honeycomb structure according to any one of Items 1 to 5.   The honeycomb structure according to any one of claims 1 to 6, wherein cross-sectional areas differ between adjacent cells in a cross section perpendicular to the axis method.   The said plugging part which plugs the said 1st end surface side of the said cell is not exposed to the said 1st end surface, but is provided in the inside of the said cell. Honeycomb structure. A first honeycomb structure and a second honeycomb having both porous partition walls and a plurality of cells that are partitioned by the partition walls and that serve as fluid flow paths in the axial direction from one end face to the other end face A method for manufacturing a honeycomb structure in which the end faces of the structure are integrated and integrated to form a bonded honeycomb structure,
A resistance portion that provides a resistance portion that reduces a flow path cross-sectional area of the flow path of the fluid at a part or all of the end portions of the cells on any one of the end faces of the first honeycomb structure. An arrangement process;
The end face of the first honeycomb structure on the side where the resistance portion is provided and the end face of the second honeycomb structure are combined to communicate with each other in the middle portion in the axial direction. A bonding step of forming the bonded honeycomb structure having the cells with the resistance portion;
The first honeycomb structure and the second honeycomb structure are arranged so that each of the cells in the bonded honeycomb structure is plugged on at least one end side in the axial direction. And a plugging step for providing a plugged portion in the cell.   In the resistance portion disposing step, a mask opened so as to correspond to the openings of some or all of the cells is provided on the end face of any one of the first honeycomb structures, and on the mask or on the mask. A pressure member having a pressure surface for supplying the resistance portion material on the same plane as the surface and arranged on the surface of the mask at an acute angle with respect to the surface to pressurize the resistance portion material; The resistance part material is pressed by the pressure surface to fill the end part of the cell on the end face with the resistance part material, and then the end part of the cell is filled. While the cell has fluidity, the inside of the cell filled with the resistance part material is made positive pressure or negative pressure, and the resistance part material filled at the end of the cell is filled with the inside of the cell and the Through the outside of the cell A method for manufacturing a honeycomb structure according to claim 9 comprising the step of forming a hole.   The resistance portion disposing step forms the through-hole with a negative pressure inside the cell filled with the resistance portion material after a predetermined time has elapsed since the end portion of the cell was filled with the resistance portion material. The manufacturing method of the honeycomb structure according to claim 10.   The method for manufacturing a honeycomb structure according to any one of claims 9 to 11, wherein the first honeycomb structure and the second honeycomb structure are different in porosity of the partition walls.

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