JP2015148152A - honeycomb structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a honeycomb structure excellent in production efficiency and hardly causing deviation in a peripheral direction when being stored in a can body.SOLUTION: A honeycomb structure 100 includes a columnar honeycomb base material 3 having a porous partition wall 1 defining a plurality of cells 2 functioning as a flow passage of fluid, and a solid flange 23 formed to surround an outer periphery of the honeycomb base material 3 and to protrude outward from the outer periphery of the honeycomb base material 3, and the whole gravity center which is the gravity center of the whole outer peripheral shape is separated from the honeycomb base material gravity center which is the gravity center of the outer peripheral shape of the honeycomb base material 3 when viewed from a center axis direction D3 of the honeycomb base material 3. Preferably, a distance between the whole gravity center and the honeycomb base material gravity center is 0.3-3.0 mm when viewed from the center axis direction D3 of the honeycomb base material 3.

Description

  The present invention relates to a honeycomb structure. More specifically, the present invention relates to a honeycomb structure that has high production efficiency and is less likely to be displaced in the circumferential direction when stored in a can body.

  Conventionally, as a catalyst carrier used by carrying a catalyst for purifying exhaust gas such as an internal combustion engine of a vehicle or a ship, or as a filter element of a dust collector, a honeycomb-shaped inner cylinder portion (honeycomb base material), A honeycomb structure having a flange portion formed on the outer periphery of the inner cylinder portion is known (see, for example, Patent Documents 1 and 2).

JP 2010-185414 A JP 2012-153538 A

  The honeycomb structure described in Patent Document 1 has low production efficiency because two or more vertical slits are formed. The “longitudinal slit” is a slit extending in the same direction as the cell extending direction of the honeycomb structure. In addition, the honeycomb structures described in Patent Document 1 and Patent Document 2 cannot sufficiently prevent circumferential displacement when stored in a can body. In particular, when the diameter of the honeycomb structure (honeycomb substrate) exceeds 200 mm, a problem due to deviation in the circumferential direction has become apparent.

  The present invention has been made in view of the above-described problems. The present invention provides a honeycomb structure that has high production efficiency and is less likely to be displaced in the circumferential direction when stored in a can body.

[1] A columnar honeycomb base material having a porous partition wall that forms a plurality of cells serving as fluid flow paths, and an outer periphery of the honeycomb base material so as to protrude outward from the outer periphery of the honeycomb base material A solid flange portion formed, and an overall center of gravity that is the center of gravity of the overall outer peripheral shape when viewed from the central axis direction of the honeycomb base material, and a honeycomb that is the center of gravity of the outer peripheral shape of the honeycomb base material A honeycomb structure in which the center of gravity of the substrate is separated.

[2] The honeycomb structure according to [1], wherein a distance between the overall center of gravity and the center of gravity of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate is 0.3 to 3.0 mm. .

[3] The honeycomb structure according to [1] or [2], wherein a shape of at least one end of the flange portion is a tapered shape.

[4] The honeycomb structure according to any one of [1] to [3], wherein a maximum value of a thickness of the flange portion in a cross section orthogonal to the cell extending direction is 1 to 40 mm.

[5] Any of the above [1] to [4], wherein the honeycomb substrate has a honeycomb substrate coat layer having a thickness of 0.05 to 8 mm disposed so as to form an outer peripheral surface of the honeycomb substrate. A honeycomb structure according to any one of the above.

[6] The method according to any one of [1] to [5], wherein the entire outer peripheral shape and the outer peripheral shape of the honeycomb base material are similar when viewed from the central axis direction of the honeycomb base material. Honeycomb structure.

  The honeycomb structure of the present invention includes a columnar honeycomb base material and a solid flange portion formed so as to protrude outward from the outer periphery of the honeycomb base material. The honeycomb structure of the present invention has an overall center of gravity that is the center of gravity of the entire outer peripheral shape, and a center of gravity of the honeycomb base that is the center of gravity of the outer peripheral shape of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate. Are separated. Therefore, the honeycomb structure of the present invention has good production efficiency and is less likely to be displaced in the circumferential direction when stored in a can body.

1 is a perspective view schematically showing an embodiment of a honeycomb structure of the present invention. 1 is a plan view schematically showing an embodiment of a honeycomb structure of the present invention. 1 is a front view schematically showing an embodiment of a honeycomb structure of the present invention. It is a mimetic diagram showing a section parallel to a cell extension direction of one embodiment of a honeycomb structure of the present invention. It is a top view which shows typically other embodiment of the honeycomb structure of this invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 6 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention.

  Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings. The present invention is not limited to the following embodiments. It should be understood that modifications and improvements as appropriate to the following embodiments are also included in the scope of the present invention based on ordinary knowledge of those skilled in the art without departing from the spirit of the present invention. It is.

(1) Honeycomb structure:
As shown in FIGS. 1 to 4, an embodiment of the honeycomb structure of the present invention surrounds a columnar honeycomb base material 3 and an outer periphery 4 of the honeycomb base material 3, and extends outward from the outer periphery 4 of the honeycomb base material 3. The honeycomb structure 100 is provided with a solid flange portion 23 formed so as to protrude from the center. The honeycomb substrate 3 has a porous partition wall 1 that partitions and forms a plurality of cells 2 that serve as fluid flow paths. The honeycomb structure 100 includes an overall center of gravity G1 that is the center of gravity of the entire outer peripheral shape and the honeycomb base material that is the center of gravity of the outer peripheral shape of the honeycomb substrate 3 when viewed from the central axis direction D3 of the honeycomb substrate 3. The center of gravity G2 is spaced apart.

  Note that “the center of gravity of the entire outer peripheral shape” means the center of gravity of the outer peripheral shape of the entire honeycomb structure. "The center of gravity of the outer peripheral shape when viewed from the central axis direction of the honeycomb substrate" and "The center of gravity of the outer peripheral shape of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate" are different. For example, it is the center of gravity in the projection map obtained as follows. That is, a light source is arranged on the extended line of the central axis of the honeycomb base material, and the honeycomb structure is illuminated from the light source to obtain a projection view of the honeycomb structure. The center of gravity of the obtained honeycomb structure in the projected view corresponds to “the center of gravity of the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate”. Further, assuming that there is no flange portion in the honeycomb structure (only the honeycomb base material), this “honeycomb structure without flange” is illuminated with the light source to obtain a projection view. The center of gravity of the obtained “honeycomb structure having no flange portion” in the projected view corresponds to “the center of gravity of the outer peripheral shape of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate”.

  FIG. 1 is a perspective view schematically showing an embodiment of a honeycomb structure of the present invention. FIG. 2 is a plan view schematically showing an embodiment of the honeycomb structure of the present invention. Fig. 3 is a front view schematically showing one embodiment of the honeycomb structure of the present invention. FIG. 4 is a schematic diagram showing a cross section parallel to the cell extending direction of an embodiment of the honeycomb structure of the present invention.

  As described above, the honeycomb structure 100 of the present embodiment includes the columnar honeycomb substrate 3 and the solid flange portion 23 formed so as to protrude outward from the outer periphery 4 of the honeycomb substrate 3. The honeycomb structure 100 of the present embodiment has an overall center of gravity G1 that is the center of gravity of the overall outer peripheral shape and the center of gravity of the outer peripheral shape of the honeycomb base 3 when viewed from the central axis direction D3 of the honeycomb base 3. A certain honeycomb base material gravity center G2 is separated. Therefore, the honeycomb structure 100 of the present embodiment has high production efficiency, and is less likely to be displaced in the circumferential direction (after being stored in the can body) when stored in the can body. Specifically, for example, in the honeycomb structure described in Patent Document 1, the number of steps increases because a honeycomb base material is disposed on the outer periphery and two or more vertical slits are formed. On the other hand, since the honeycomb structure 100 of the present embodiment forms a solid flange portion, the waste and the number of steps as described above are unlikely to occur. Therefore, the honeycomb structure 100 of the present embodiment has good production efficiency.

  As shown in FIGS. 1 and 2, the honeycomb structure 100 of the present embodiment is a segment type honeycomb structure. That is, the honeycomb structure 100 of the present embodiment is obtained by bonding a plurality of honeycomb segment fired bodies 12 with the bonding material 13. The material of the bonding material is not particularly limited, but is preferably ceramic, and more preferably the same as the material of the honeycomb segment fired body. In other embodiments, it is needless to say that an integral type composed of one honeycomb structure may be used instead of the segment type.

  In the honeycomb structure 100, the distance between the overall center of gravity G1 and the honeycomb substrate center of gravity G2 (center of gravity shift (Z)) is preferably 0.3 to 3.0 mm, and preferably 0.5 to 3.0 mm. More preferably. If the displacement (Z) of the center of gravity is less than 0.3 mm, the effect of preventing the displacement in the circumferential direction when stored in a can body may not be sufficiently obtained. On the other hand, if it exceeds 3.0 mm, the external pressure received from the can body is biased when stored in the can body, and the honeycomb structure may be destroyed when stored in the can body.

  The entire outer peripheral shape of the honeycomb structure 100 when viewed from the central axis direction D3 of the honeycomb substrate 3 is circular, but the entire outer peripheral shape of the honeycomb structure of the present invention is not limited to a circular shape. For example, as the overall outer peripheral shape, an ellipse, a substantially elliptical shape (including a track shape and an egg shape), a shape in which two circles are superimposed (double circle shape), or a shape in which a part of the circle is cut off (A deformed circular shape), a shape obtained by superimposing a circle and a deformed circular shape, and the like. The “track shape” is a shape in which one (one set) of two pairs of “opposite sides” of a quadrangle (square or rectangle) protrudes outward. .

  Specifically, FIG. 5 shows a honeycomb structure 101 whose entire outer peripheral shape is substantially elliptical (track shape) when viewed from the central axis direction of the honeycomb substrate 3. FIG. 7 shows a honeycomb structure 103 whose entire outer peripheral shape is a double circular shape when viewed from the central axis direction of the honeycomb substrate 3. FIG. 8 shows a honeycomb in which the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate 3 is an irregular circular shape (particularly, a shape in which four portions of a circle are cut off (specific irregular circular shape)). A structure 104 is shown. 9 and 10, the honeycomb structure 105, in which the entire outer peripheral shape when viewed from the central axis direction of the honeycomb base material 3 is a shape in which a circle and a deformed circular shape (specifically deformed circular shape) are superimposed. 106 is shown. In addition, the “specific deformed circular shape” that is the overall outer peripheral shape of the honeycomb structure 104 shown in FIG. 8 can be specifically referred to as the following shape. That is, the outer peripheral portion of the circle is cut by a pair of straight lines (first pair of straight lines) facing each other across the center of the circle, and further, the centers of the circles orthogonal to the first pair of straight lines are sandwiched. It is the shape obtained by cutting off with another pair of straight lines (second pair of straight lines) facing each other.

  FIG. 5 is a plan view schematically showing another embodiment of the honeycomb structure of the present invention. FIG. 7 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 8 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 9 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 10 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention.

  As shown in FIG. 2, the flange portion 23 is preferably formed in a ring shape (continuous ring shape) disposed over the entire circumferential direction of the outer periphery 4 of the honeycomb substrate 3. It is also preferable that the flange portion is formed in an “intermittent ring shape” in which a part of the “continuous ring shape” is cut out. The honeycomb structures 102, 103, 105, and 106 shown in FIGS. 6, 7, 9, and 10 are examples in which the flange portion 23 is formed in an “intermittent ring shape”. Specifically, the honeycomb structures 102, 103, and 105 shown in FIGS. 6, 7, and 9 have an “intermittent ring shape” in which the flange portion 23 is cut out at one portion of the “continuous ring shape”. It is an example formed. A honeycomb structure 106 shown in FIG. 10 is an example in which the flange portion 23 is formed in an “intermittent ring shape” in which three portions of “continuous ring shape” are cut out. FIG. 6 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention. These “intermittent ring-shaped” flange portions 23 are formed at ½ or more of the circumferential direction of the outer periphery 4 of the honeycomb base material 3 in terms of preventing the circumferential shift favorably. preferable.

  In the honeycomb structure of the present invention, the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate is preferably a shape that does not include a straight line (in other words, a shape drawn only by a curve). . Thus, when the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate is a shape that does not include a straight line, there is an advantage that it becomes easy to manufacture a can body that houses the honeycomb structure. . For example, in the honeycomb structures shown in FIGS. 2, 6, and 7, the overall outer peripheral shape when viewed from the central axis direction of the honeycomb substrate is a shape that does not include a straight line.

  The flange portion 23 has a solid structure inside. If the inside of the flange portion 23 is solid, there is an advantage that it is difficult to be damaged by an external impact or the like. The “solid flange portion” does not include a case where the inside is hollow or a honeycomb shape in which a plurality of cells are partitioned.

  In the honeycomb structure 100, the flange portion 23 has both end faces in the cell 2 extending direction orthogonal to the cell 2 extending direction. That is, in the honeycomb structure 100, the flange portion 23 has both end surfaces (25, 25) in the cell 2 extending direction orthogonal to the cell 2 extending direction (see FIGS. 3 and 4). Thus, when the end faces 25, 25 of the flange portion are orthogonal to the direction in which the cells 2 extend, the honeycomb structure can be easily fixed to the exhaust gas flow path, and further, the flange portion can be easily grasped manually or by a robot. . Further, as shown in FIG. 12, the flange portion 23 may have a shape in which both end surfaces in the cell extending direction do not go perpendicular to the cell extending direction. That is, the shape of at least one end 25 in the cell extending direction may be a shape (tapered) (see FIG. 12) in which the distance between both end surfaces in the cell extending direction becomes shorter toward the tip. Since the shape of at least one end portion in the cell extending direction is a tapered shape, damage to the flange portion can be suppressed.

  The honeycomb structure 100 includes a honeycomb substrate coat layer (outer peripheral wall) 31 having a thickness of 0.05 to 8 mm, in which the honeycomb substrate 3 is disposed so as to form the outer peripheral surface of the honeycomb substrate 3 (see FIG. 4). ). More preferably, the thickness of the honeycomb base coat layer 31 is 0.2 to 3 mm. By having the honeycomb base coat layer 31, the structural strength of the honeycomb structure increases. If the thickness is less than 0.05 mm, there is a possibility that a defect such as chipping of the outer peripheral surface easily occurs. When it is thicker than 8 mm, there is a possibility that a problem that it becomes difficult to form a coat layer may occur.

  The material of the honeycomb base coat layer 31 is “inorganic raw material such as inorganic fiber, colloidal silica, clay, SiC particles” or “same material as plugging material described later”, organic binder, foamed resin, dispersant, etc. What added water and knead | mixed the thing etc. which added this additive material is preferable.

  The honeycomb structure 100 can have a flange portion coat layer in which the flange portion 23 is disposed so as to form the surface of the flange portion 23. By having the flange coat layer, the strength of the flange increases.

  The thickness of the flange coat layer is preferably 8 mm or less, and more preferably 0.2 to 3 mm. If it is thicker than 8 mm, it may be difficult to form the flange coat layer. If no problem such as strength occurs, the flange coat layer need not be formed.

  The material of the flange coat layer can be the same as the material of the honeycomb substrate coat layer 31 and the bonding material 13.

  In the honeycomb structure 100, it is preferable that the overall outer peripheral shape and the outer peripheral shape of the honeycomb base material are similar when viewed from the central axis direction D3 of the honeycomb base material 3. If it does in this way, it will become easy to process when the perimeter shape of a honeycomb substrate is processed by grinding processing etc. Specifically, it is preferable that the entire outer peripheral shape and the outer peripheral shape of the honeycomb substrate when viewed from the central axis direction D3 of the honeycomb substrate 3 are circular. When each of the outer peripheral shapes is circular, the outer peripheral shape can be easily processed.

  The maximum value H (see FIG. 2) of the thickness (the thickness of the flange portion, that is, the length in the diameter direction) in the cross section perpendicular to the extending direction of the cell 2 of the flange portion 23 is 1 to 40 mm. preferable. And the maximum value H of the thickness of the flange part 23 is still more preferably 1 to 25 mm, and particularly preferably 1 to 15 mm. If the maximum value H of the thickness of the flange portion 23 is less than 1 mm, the flange portion may be thin and the strength of the flange portion may be reduced. On the other hand, if it exceeds 40 mm, it may be difficult to assemble to the can or be difficult to handle.

  In the plane including the central axis of the honeycomb substrate 3, the angles α and β between the end face 25 of the flange portion 23 and the side surface (outer periphery) 4 of the honeycomb substrate 3 are preferably 90 to 160 °, respectively 90 to 150 °. Is more preferable, and 90 to 140 ° is particularly preferable. Furthermore, 90 to 135 ° is most preferable. As shown in FIG. 3, the angle α is an angle between one end face 25 of the flange portion 23 and the side face 4 of the honeycomb substrate 3 in a plane including the central axis of the honeycomb substrate 3. As shown in FIG. 3, the angle β is an angle between the other end face 25 of the flange portion 23 and the side face 4 of the honeycomb substrate 3 in a plane including the central axis of the honeycomb substrate 3. Note that the angles α and β between the end surface of the flange portion and the side surface of the honeycomb substrate are 90 ° when the end surface of the flange portion is orthogonal to the cell extending direction. In addition, the angles α and β between the end face of the flange portion and the side surface of the honeycomb base material may or may not be constant over the entire circumference of the flange portion (that is, may change sequentially). Good). When the angles α and β are not constant, the “angle α” and “angle β” are the maximum angles.

  FIG. 12 shows a honeycomb structure 201 in which the flange portion 23 is formed in a ring shape (continuous ring shape) arranged over the entire circumferential direction of the outer periphery 4 of the honeycomb substrate 3. In the honeycomb structure 201 shown in FIG. 12, the angles α and β between the end surface 25 of the flange portion 23 and the side surface 4 of the honeycomb substrate 3 are sequentially changed over the entire circumference of the flange portion 23. . FIGS. 13 and 14 show honeycomb structures 202 and 203 in which the flange portion 23 is formed in a ring shape (continuous ring shape) arranged over the entire circumferential direction of the outer periphery 4 of the honeycomb substrate 3. Is shown. The honeycomb structures 202 and 203 shown in FIGS. 13 and 14 have angles α and β between the end surface 25 of the flange portion 23 and the side surface 4 of the honeycomb substrate 3 over the entire circumference of the flange portion 23, respectively. It is constant.

  Fig. 12 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 13 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention. FIG. 14 is a front view schematically showing still another embodiment of the honeycomb structure of the present invention.

  The width L of the flange portion 23 is preferably 1 to 90% of the length of the honeycomb structure 100 in the cell extending direction, more preferably 3 to 50%, and more preferably 5 to 30%. Particularly preferred. The “width L of the flange portion” is the length of the flange portion in the cell extending direction of the honeycomb structure. When the width L of the flange portion 23 is within the above range, the honeycomb structure 100 can be satisfactorily fixed in a limited space. Further, since the flange portion 23 is not too large, the honeycomb structure 100 can be reduced in weight. If the width L of the flange portion 23 is less than 1%, the strength of the flange portion may decrease. If it exceeds 90%, the honeycomb structure 100 may be increased in size, and the honeycomb structure 100 may not be fixed favorably in a limited space. In addition, when the edge part of a flange part is a taper shape, as shown in FIG. 12, "width L of a flange part" is the distance between both front-end | tips of a taper-shaped both ends. The width L of the flange portion 23 may be constant over the entire circumference of the flange portion or may not be constant (that is, it may change sequentially). In the honeycomb structures 201 and 202 shown in FIGS. 12 and 13, the width L of the flange portion 23 is constant over the entire circumference of the flange portion 23. In the honeycomb structure 203 illustrated in FIG. 14, the width L of the flange portion 23 sequentially changes over the entire circumference of the flange portion 23 (not constant).

  The flange portion 23 may be disposed at any position of the honeycomb substrate 3 in the extending direction of the cells 2. For example, you may arrange | position in the center part of the honeycomb base material 3, and may arrange | position in an edge part. The flange portion 23 is preferably disposed in the central portion of the honeycomb substrate 3. The central part of the honeycomb base material is the central part of the honeycomb base material in the cell extending direction. Specifically, the shortest distance X (see FIGS. 3 and 14) between one end face of the honeycomb base material and the end face of the flange portion facing the same direction as the one end face of the honeycomb base material is 1 mm or more. It is preferable. The shortest distance X is more preferably 2 mm or more, and particularly preferably 3 mm or more. If the shortest distance X is less than 1 mm, it may be difficult to set a holding material (a member for holding the honeycomb structure and fixing it in the can) during canning. “The shortest distance between one end face of the honeycomb substrate and the end face of the flange portion facing the same direction as the one end face of the honeycomb substrate” is formed by the flange portion based on the one end face of the honeycomb substrate. It can also be said that the position has been made.

  The material of the flange portion 23 is preferably mainly composed of at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate, zeolite, vanadium and alumina. The material of the flange portion 23 is at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate, zeolite, vanadium, and alumina (impurities contained unavoidably may be included). Is more preferable. Here, the “main component” in the present specification means a component exceeding 50 mass% in the whole.

  In the honeycomb structure 100 of the present embodiment, the average pore diameter of the partition walls 1 is preferably 5 to 100 μm, and particularly preferably 7 to 50 μm. When the average pore diameter is smaller than 5 μm, the pressure loss may increase. If the average pore diameter is larger than 100 μm, the strength of the honeycomb structure may be lowered. The average pore diameter is a value measured with a mercury porosimeter.

  In the honeycomb structure 100 of the present embodiment, the porosity of the partition walls 1 is preferably 30 to 80%, and particularly preferably 35 to 75%. If the porosity is less than 30%, the pressure loss may increase. If the porosity is higher than 80%, the strength of the honeycomb structure 100 may be lowered. The porosity is a value measured by a mercury porosimeter.

  The thickness of the partition wall 1 is preferably 40 to 600 μm, and particularly preferably 100 to 400 μm. If it is thinner than 40 μm, the strength of the honeycomb structure 100 may be lowered. If it is thicker than 600 μm, the pressure loss may increase.

  In the honeycomb structure 100 of the present embodiment, the shape of the honeycomb substrate 3 is not particularly limited. As the shape of the honeycomb substrate 3, a cylindrical shape, a cylindrical shape having an elliptical end surface, a polygonal cylindrical shape having an end surface of “square, rectangular, triangular, pentagonal, hexagonal, octagonal, etc.” are preferable. In the honeycomb structure 100 shown in FIGS. 1 to 4, the honeycomb substrate 3 has a cylindrical shape.

  In the honeycomb structure 100 of the present embodiment, the cell shape of the honeycomb substrate 3 (cell shape in a cross section orthogonal to the cell extending direction) is not particularly limited. Examples of the cell shape include a triangle, a quadrangle, a hexagon, an octagon, a circle, or a combination thereof. Among the squares, a square or a rectangle is preferable.

In the honeycomb structure 100 of the present embodiment, the cell density of the honeycomb substrate 3 is not particularly limited. The cell density of the honeycomb substrate 3 is preferably 15 to ²⁰⁰ cells / cm ² and particularly preferably 30 to 120 cells / cm ² . When the cell density is lower than 15 cells / cm ² , when exhaust gas is circulated, pressure loss may increase in a short time or the strength of the honeycomb structure 100 may decrease. When the cell density is higher than 200 cells / cm ² , the pressure loss may increase.

  The material of the honeycomb substrate 3 is preferably composed mainly of at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate, zeolite, vanadium and alumina. The material of the honeycomb substrate 3 is at least one selected from the group consisting of cordierite, silicon carbide, mullite, aluminum titanate, zeolite, vanadium, and alumina (impurities that are inevitably contained may be included). More preferably.

  In the honeycomb structure 100 of the present embodiment, the honeycomb base material 3 has the plugging portions 5 disposed in the openings of at least some of the cells 2. More specifically, the honeycomb structure 100 of the present embodiment has an opening of a predetermined cell (first cell) on one end face and an opening of a remaining cell (second cell) on the other end face. An arranged plugging portion 5 is provided. The first cells and the second cells are alternately arranged. Thus, a checkered pattern is formed on each of the one end surface 11a and the other end surface 11b of the honeycomb structure 100 by the plugged portions 5 and the “cell opening portions”.

  The material of the plugging portion 5 and the material of the honeycomb substrate may be the same material or different materials. The material of the plugging portion 5 is preferably a material that is preferable as a material of the honeycomb substrate (partition wall).

  In addition, the length of the plugged portion 5 in the cell extending direction is preferably 0.3 to 8 mm, and more preferably 1 to 7 mm.

  In the honeycomb structure of the present invention, the plugged portions 5 do not have to be formed on the honeycomb substrate 3. When there is no plugging portion 5 or the number is small, the collection efficiency may be reduced, but the pressure loss is reduced, which is preferable in terms of increasing the engine output. Further, when a three-way catalyst or the like is carried and used as an exhaust gas catalyst carrier, plugging is not formed in many cases.

  In another embodiment of the honeycomb structure of the present invention, as in the honeycomb structure 300 shown in FIG. 11, the flange body coat layer 26 in which the flange body 27 is disposed so as to form the surface of the flange body 27. have. In this honeycomb structure 300, the thickness of the flange coat layer 26 is partially different when viewed from the central axis direction D3 of the honeycomb substrate 3. In such a honeycomb structure 300, by changing the thickness of the flange portion coat layer 26, a distance is provided between the overall center of gravity and the center of gravity of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate. Can do. FIG. 11 is a plan view schematically showing still another embodiment of the honeycomb structure of the present invention.

  The honeycomb structure 300 of the present embodiment has the same configuration as that of the above-described embodiment of the honeycomb structure of the present invention (honeycomb structure 100 (FIGS. 1 to 4)) except that the configuration is the above. Preferably there is.

  In the honeycomb structure 300 of the present embodiment, the center of gravity of the portion of the flange portion 23 excluding the flange portion coat layer 26 (flange main body 27) and the honeycomb substrate 3 are not separated. That is, when viewed from the center axis direction D3 of the honeycomb base material 3, the flange main body center of gravity G3 that is the center of gravity of the outer peripheral shape of the flange main body 27, and the honeycomb base material center of gravity G2 that is the center of gravity of the outer peripheral shape of the honeycomb base material 3 , Match without spacing. That is, in the honeycomb structure 300 of the present embodiment, the overall gravity center G1 and the honeycomb substrate gravity center G2 are separated from each other by making the flange portion coat layer 26 partially different in thickness. .

  Such a honeycomb structure 300 can be manufactured as follows. That is, first, a “honeycomb structure before forming the flange coat layer” in which the flange main body gravity center G3 and the honeycomb base material gravity center G2 coincide with each other is manufactured. Thereafter, a flange coat layer is formed on the “honeycomb structure before formation of the flange coat layer” so as to partially differ in thickness. In this way, a honeycomb structure as shown in FIG. 11 can be manufactured.

(2) Manufacturing method of honeycomb structure:
The honeycomb structure of the present invention can be manufactured by the following method. That is, in the method for manufacturing a honeycomb structured body of the present invention, a honeycomb fired body manufacturing step for manufacturing a plurality of honeycomb fired bodies is performed. Next, a joined body manufacturing step is performed in which the obtained plurality of honeycomb segment fired bodies are joined with a joining material to obtain a joined honeycomb segment joined body. Next, a flange portion forming step is performed in which a flange portion forming material is applied to the outer periphery of the joined honeycomb segment assembly to form a solid flange portion. In this way, the honeycomb structure of the present invention can be manufactured. The “honeycomb fired body” is a honeycomb fired body having porous partition walls formed by firing a ceramic raw material, which defines a plurality of cells serving as fluid flow paths.

  When the honeycomb structure includes a plugged portion, the plugged portion that forms the plugged portion in the honeycomb segment fired body before being bonded with the bonding material or in the honeycomb segment bonded body in which the flange portion is formed. A stopping process can be performed. Moreover, in order to make the honeycomb structure into a desired shape, a grinding step of grinding the outer peripheral portion of the joined honeycomb segment assembly can be performed. In addition, it is not necessary to grind the outer peripheral part of this bonded honeycomb segment assembly. In order to form an outer peripheral wall composed of the flange portion coat layer and the honeycomb substrate coat layer, an outer peripheral wall forming step of applying an outer peripheral coat material to the outer periphery of the joined honeycomb segment assembly can be performed.

  Hereinafter, the manufacturing method of the honeycomb structure of the present invention will be described for each step.

(2-1) Honeycomb fired body manufacturing process:
The honeycomb fired body manufacturing process is a process of manufacturing a honeycomb fired body having porous partition walls formed by firing a ceramic raw material. The method for producing the honeycomb fired body is not particularly limited. Hereinafter, the honeycomb fired body manufacturing process will be described step by step.

(2-1-1) Molding process:
First, in the forming step, it is preferable that a ceramic forming raw material containing a ceramic raw material is formed to form a honeycomb formed body having partition walls (unfired) that partition and form a plurality of cells that serve as fluid flow paths. The honeycomb formed body is a formed body having a honeycomb structure.

  The ceramic raw material contained in the ceramic forming raw material is at least one selected from the group consisting of a cordierite forming raw material, cordierite, silicon carbide, silicon-silicon carbide based composite material, mullite, aluminum titanate, zeolite, and vanadium. Is preferred. The cordierite forming raw material is a ceramic raw material blended so as to have a chemical composition that falls within the range of 42 to 56% by mass of silica, 30 to 45% by mass of alumina, and 12 to 16% by mass of magnesia. And the cordierite-forming raw material is fired to become cordierite.

  The ceramic forming raw material is preferably prepared by mixing the ceramic raw material with a dispersion medium, an organic binder, an inorganic binder, a pore former, a surfactant and the like. The composition ratio of each raw material is not particularly limited, and is preferably a composition ratio in accordance with the structure and material of the honeycomb structure to be manufactured.

  When the ceramic forming raw material is formed, it is preferable to first knead the ceramic forming raw material to form a kneaded material, and the obtained kneaded material is formed into a honeycomb shape. The method for kneading the ceramic forming raw material to form the kneaded material is not particularly limited, and examples thereof include a method using a kneader, a vacuum kneader or the like. A method for forming a kneaded clay to form a honeycomb formed body is not particularly limited, and a known forming method such as extrusion molding or injection molding can be used. For example, a method of forming a honeycomb formed body by extrusion molding using a “die” that forms a honeycomb formed body having a desired cell shape, partition wall thickness, and cell density can be cited as a suitable example. As the material of the die, a cemented carbide which does not easily wear is preferable.

  Examples of the shape of the honeycomb formed body include a cylindrical shape, an elliptical shape, and a polygonal column shape whose end face is “square, rectangular, triangular, pentagonal, hexagonal, octagonal, etc.”.

  Further, after the above forming, the obtained honeycomb formed body may be dried. The drying method is not particularly limited. For example, hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, freeze drying and the like can be mentioned. Among these, it is preferable to perform dielectric drying, microwave drying, or hot air drying alone or in combination.

(2-1-2) Firing step:
Next, the honeycomb formed body is fired to produce a honeycomb fired body.

  Prior to firing (main firing) the honeycomb formed body, it is preferable to calcine the honeycomb formed body. Calcination is performed for degreasing. The method for calcining the honeycomb formed body is not particularly limited as long as organic substances (organic binder, surfactant, pore former, etc.) can be removed. Generally, the combustion temperature of the organic binder is about 100 to 300 ° C., and the combustion temperature of the pore former is about 200 to 800 ° C. Therefore, it is preferable to heat at about 200 to 1000 ° C. for about 3 to 100 hours in an oxidizing atmosphere as a condition for calcination.

  The firing (main firing) of the honeycomb formed body is performed in order to sinter and densify the forming raw material constituting the calcined honeycomb formed body to ensure a predetermined strength. Since the firing conditions (temperature, time, atmosphere, etc.) vary depending on the type of the forming raw material, appropriate conditions may be selected according to the type. For example, when a cordierite forming raw material is used, the firing temperature is preferably 1410 to 1440 ° C. The firing time is preferably 4 to 8 hours as the keep time at the maximum temperature. An apparatus for performing calcination and main firing is not particularly limited, and an electric furnace, a gas furnace, or the like can be used.

(2-2) Assembly production process:
The joined body manufacturing step is a step of joining the obtained plurality of honeycomb fired bodies with a joining material to obtain a joined honeycomb segment body.

  The material of the bonding material is not particularly limited, but an organic binder, a foamed resin, a dispersant, and the like are added to ceramic particles such as inorganic fibers, colloidal silica, clay, SiC particles and cordierite particles, and water is further added and kneaded. A slurry or the like is preferable.

  The thickness of the bonding material can be 0.05 to 3 mm.

(2-3) Plugging step:
When a honeycomb structure including a plugged portion is manufactured, a plugging process may be performed on the honeycomb segment fired body before bonding with the bonding material, and the plugging described below may be performed after the bonded body manufacturing process. A process may be performed. Moreover, when performing the following plugging process after a conjugate | zygote preparation process, a plugging process may be performed before the below-mentioned grinding process, and a plugging process may be performed after a grinding process. In this plugging step, plugging portions are formed in the openings of “predetermined cells” on one end face and the “remaining cells” on the other end face of the honeycomb segment fired body or the bonded honeycomb segment assembly. Arrange. This will be specifically described below.

  First, the plugging material is filled into the cell opening on one end face of the joined honeycomb segment assembly (honeycomb substrate). As a method of filling the plugging material into the cell opening on one end face, a method having a masking step and a press-fitting step is preferable. The masking step is a step in which a sheet is attached to one end face of the joined honeycomb segment assembly, and a hole is formed in the sheet at a position overlapping with “cells for forming plugged portions”. The press-fitting process is performed by press-fitting “the end of the honeycomb segment bonded body on which the sheet is pasted” into a container in which the plugging material is stored, and the plugging material is inserted into the cells of the honeycomb segment bonded body. It is a process of press-fitting into When the plugging material is press-fitted into the cells of the joined honeycomb segment assembly, the plugging material passes through the holes formed in the sheet and is filled only in the cells communicating with the holes formed in the sheet. .

  The plugging material can be prepared by appropriately mixing the raw materials listed as the constituent elements of the ceramic forming raw material. The ceramic raw material contained in the plugging material is preferably the same as the ceramic raw material used as the raw material for the partition walls.

  Next, it is preferable to dry the plugging material filled in the joined honeycomb segment assembly.

  It is preferable that cells having plugged portions and cells having no plugged portions are alternately arranged on one end face of the joined honeycomb segment assembly. In this case, a checkered pattern is formed by the plugged portion and the “cell opening” on one end face where the plugged portion is formed.

  Next, it is preferable to dispose a plugging portion in the opening portion of “remaining cells” on the other end face of the bonded honeycomb segment assembly in the same manner as in the case of one end face. The plugging material may be dried after filling the plugging material on both end faces of the joined honeycomb segment assembly.

  When a honeycomb structure is formed from one honeycomb fired body instead of combining a plurality of honeycomb fired bodies, the firing process is performed after filling the honeycomb formed body in the honeycomb fired body manufacturing process with a plugging material. Also good.

(2-4) Grinding process:
The grinding step is a step of grinding the outer peripheral portion of the joined honeycomb segment assembly so that the honeycomb structure has a desired shape.

  As a method for grinding the outer peripheral portion of the joined honeycomb segment assembly, a method of pressing a grindstone coated with diamond while rotating the joined honeycomb segment assembly can be employed. Alternatively, an arbitrary shape may be formed by fixing the honeycomb segment bonded body, rotating only the grindstone, and moving around the honeycomb segment bonded body while grinding the outer periphery of the honeycomb segment bonded body.

(2-5) Flange portion forming step:
The flange portion forming step is a step of forming a solid flange portion by coating the flange portion forming material on the outer periphery of the joined honeycomb segment assembly. The same material as the ceramic forming raw material described above can be adopted as the flange portion forming material.

  In the flange part forming step, instead of coating the flange part forming material, the flange part forming material is poured into a mold frame containing the joined honeycomb segment assembly and dried to form a solid flange part. It is good as well.

  Moreover, after forming a protrusion part larger than the flange part of a desired shape, this protrusion part may be ground by a method similar to the above grinding step to form a flange part of a desired shape. When the protruding portion is formed, the overall center of gravity and the honeycomb substrate center of gravity may coincide with each other or may be separated from each other. When the total center of gravity and the honeycomb substrate center of gravity coincide with each other, in the step of grinding the protrusion, the protrusion is ground so that the entire center of gravity and the honeycomb substrate center of gravity are separated from each other.

(2-6) Outer peripheral wall forming step:
An outer peripheral coating material is applied to the outer periphery (side surface of the honeycomb substrate and the surface of the flange portion) of the obtained “bonded honeycomb segment assembly having a flange portion” to form an outer peripheral wall, and a honeycomb having a solid flange portion A structure can be manufactured. By forming the outer peripheral wall, the flange portion can be prevented from being chipped.

  Further, in the outer peripheral wall forming step, instead of applying the outer peripheral coating material, the outer peripheral coating material is poured into a mold containing the “honeycomb segment joined body having a flange portion” and dried to form the outer peripheral wall. It is good as well.

  In other words, “center-of-gravity shift” occurs when adjusting the coating thickness of the flange forming material, adjusting the coating thickness of the outer peripheral wall, or pouring the flange forming material or outer coating material into the mold. It can be adjusted according to the shape of the mold. Further, if necessary, the flange portion may be made larger than the final shape, and the final shape may be obtained by adjusting the shape by grinding or the like.

  As the outer periphery coating material, water is added to the same inorganic raw materials and plugging materials as inorganic fibers, colloidal silica, clay, SiC particles, etc. plus additives such as organic binder, foamed resin and dispersant. In addition, those kneaded can be mentioned. Examples of the method of applying the outer periphery coating material include a method of coating a “bonded honeycomb segment having a flange portion” with a rubber spatula or the like while rotating on a potter's wheel.

  Note that the distance between the overall center of gravity and the honeycomb substrate center of gravity can be adjusted by adjusting the thickness of the outer peripheral wall. In this case, the amount of the outer periphery coating material applied to the outer periphery of the flange portion is appropriately adjusted.

  Note that, as described above, the honeycomb structure of the present invention may be composed of a single honeycomb fired body instead of combining a plurality of honeycomb fired bodies.

  In the case of a single honeycomb fired body, grinding may be performed before or after firing the honeycomb formed body, but is preferably performed after firing. By grinding after firing, even if the honeycomb fired body is deformed by firing, the shape of the honeycomb fired body can be adjusted by grinding.

  In the case of a single honeycomb fired body, the outer peripheral wall (honeycomb substrate coating layer) can be extruded integrally with the partition walls of the honeycomb substrate. As described above, when the honeycomb formed body is extruded and fired in the state having the outer wall on the outermost periphery, the outer periphery of the honeycomb fired body does not need to be ground, and the outer peripheral coating material for the honeycomb base material It is not necessary to perform the application. However, in the obtained honeycomb structure, it is necessary that the overall center of gravity and the honeycomb base material are separated from each other.

  Hereinafter, the present invention will be described more specifically with reference to examples. The present invention is not limited in any way by these examples.

Example 1
A ceramic raw material was prepared by mixing 80 parts by mass of SiC powder and 20 parts by mass of metal Si powder. A porcelain material, a binder, a surfactant, and water were added to the obtained ceramic raw material to prepare a clay. Starch was used as the pore former. As the binder, methyl cellulose and hydroxypropoxyl methyl cellulose were used. As the surfactant, sodium laurate was used. The obtained kneaded material was extruded using a die for forming a honeycomb formed body, and dried with microwaves and hot air to obtain a dried honeycomb body.

  Next, the obtained dried honeycomb body was degreased at 550 ° C. in an air atmosphere. After that, the degreased honeycomb dried body was fired at 1450 ° C. in an argon inert atmosphere, and SiC crystal particles were bonded with Si to obtain a honeycomb segment fired body.

The obtained honeycomb segment fired body had a square cross section perpendicular to the cell extending direction having a side of 45 mm, and the length in the cell extending direction was 254 mm. The ceramic honeycomb segment fired body had a cell density of 70 cells / cm ² and a partition wall thickness of 100 μm.

  About the obtained 25 honeycomb segment fired bodies, the respective side surfaces are joined together with a bonding material, dried, and a honeycomb segment joined body (5 vertical × 5 horizontal) having a square cross section perpendicular to the central axis. Obtained). As the bonding material, alumina powder added with silica fiber, organic binder and water was used. In addition, the thickness of the bonding material between the honeycomb segment fired bodies was set to 1 mm.

  Next, the outer peripheral portion of the obtained rectangular columnar honeycomb segment bonded body was ground to obtain a cylindrical honeycomb segment bonded body. As a method of grinding the outer peripheral portion of the bonded honeycomb segment assembly, a method of pressing the outer peripheral portion of the bonded honeycomb segment assembly while rotating the grindstone coated with diamond while rotating the bonded honeycomb segment assembly about its central axis. It was.

  Next, in the obtained cylindrical honeycomb segment bonded body, plugged portions were formed at one end portion of a predetermined cell and the other end portion of the remaining cells. The predetermined cells and the remaining cells are arranged alternately (alternately) so that a checkered pattern is formed on both end faces by the opening portions of the cells and the plugging portions. As the plugging filler, the same raw material as that for the honeycomb segment fired body was used.

  Thereafter, a flange portion forming material was applied to the outer periphery of the plugged honeycomb segment bonded body to form a solid flange portion. At this time, the flange portion forming material was coated so that the thickness was different in the circumferential direction so that the entire center of gravity and the honeycomb base material were separated from each other in the obtained honeycomb structure. In this way, a solid honeycomb segment bonded body was obtained. The same raw material as that of the honeycomb segment fired body was used as the flange portion forming material.

  Thereafter, an outer periphery coating material is applied to the outer periphery (side surface of the honeycomb substrate and the surface of the flange portion) of the obtained solid honeycomb segment joined body to form outer peripheral walls (the honeycomb substrate coat layer and the flange portion coat layer). A honeycomb structure having a solid flange portion was obtained.

  Thereafter, drying was performed at 140 ° C. for 2 hours.

  In addition, you may adjust a flange part etc. by methods, such as grinding, as needed so that it may become a desired shape.

  The honeycomb substrate of the obtained honeycomb structure had a cylindrical shape with a diameter of 210 mm in a cross section perpendicular to the cell extending direction and a length of 254 mm in the cell extending direction.

  The length L of the flange portion in the extending direction of the flange cell (width of the flange portion) L was 15 mm. The maximum thickness H of the flange portion in the cross section perpendicular to the cell extending direction (the thickness of the flange portion; the length in the diameter direction) was 7.8 mm. The minimum thickness h of the flange portion in the cross section orthogonal to the cell extending direction (thickness of the flange portion; length in the diameter direction) was 7.2 mm.

  Further, the shortest distance between one end face of the honeycomb substrate and the end face of the flange portion facing in the same direction as the one end face of the honeycomb substrate (the flange portion is formed on the basis of the one end face of the honeycomb substrate). X) was 60 mm.

The partition wall thickness was 100 μm. The cell density was 70 cells / cm ² . Moreover, the shape of the cross section orthogonal to the cell extending direction of the cells of the honeycomb substrate was a square.

  The overall outer peripheral shape of the obtained honeycomb structure was a circle having a diameter of 225 mm (see FIG. 2). “The entire outer peripheral shape of the honeycomb structure” is the entire outer peripheral shape of the honeycomb structure as viewed from the central axis direction of the honeycomb substrate. The drawings in the present application are all schematically shown. That is, it indicates the state of the structure of the honeycomb structure, and does not indicate the exact number of honeycomb segments, for example.

  The resulting honeycomb structure had a distance between the overall center of gravity and the center of gravity of the honeycomb substrate (shift of center of gravity (Z)) of 0.3 mm when viewed from the central axis direction of the honeycomb substrate.

  The thickness of the outer peripheral wall (that is, the thickness of each of the honeycomb substrate coat layer and the flange coat layer) was 1 mm.

  The obtained honeycomb structure was subjected to a “heating vibration test” by the method shown below. The results are shown in Table 1.

(Heating vibration test)
First, a non-thermally expandable ceramic mat having a length of 110 mm is wound around the honeycomb structure. The ceramic mat is wound around the flange portion. Then, the honeycomb structure wound with the ceramic mat is accommodated in a stainless steel (SUS430) can divided into two parts, and then welded to obtain a test can that accommodates the honeycomb structure in the can. assemble. Next, the can body (can body for test) containing the honeycomb structure is attached to the heating vibration test apparatus. Next, propane combustion gas is continuously supplied into the can body by a heating vibration test apparatus so that the gas temperature at the inlet end face of the honeycomb structure is 950 ° C. and the gas flow rate is 12 Nm ³ / min. Next, in a state where the combustion gas is continuously supplied into the can body, vibration in a direction orthogonal to the cell extending direction of the honeycomb structure body is given to the can body (honeycomb structure body). The vibration condition applied to the can body is that 200 Hz, 40 G vibration is applied for 10 hours, and then the can body (honeycomb structure) is rotated by 90 ° about its central axis. This operation is performed four times in total. That is, the test time is 10 hours × 4 times for a total of 40 hours. After the test, the presence or absence of breakage in the honeycomb structure and the circumferential displacement of the honeycomb structure (deviation of the positional relationship in the circumferential direction between the can body and the honeycomb structure before and after the test) were confirmed. Evaluate by criteria.

  In the stainless steel can, the diameter of the portion corresponding to the flange portion of the honeycomb structure was increased so that the surface pressure of the gripping material (ceramic mat or the like) was substantially constant.

  When the deviation (movement amount) in the circumferential direction of the honeycomb structure is 0.2 mm or less at the outermost peripheral portion of any end face of the honeycomb structure, “A”, and when it is more than 0.2 mm and 0.4 mm or less “B”, “C” when 0.4 mm or more and 0.6 mm or less. When the deviation in the circumferential direction of the honeycomb structure exceeded 0.6 mm, or when the honeycomb structure was damaged, “D” was given. In addition, there is no practical problem if the circumferential displacement (movement amount) of the honeycomb structure is 0.6 mm or less, but 0.4 mm or less is preferable.

  In addition, the column of “total outer peripheral shape” in Tables 1 to 6 indicates the entire outer peripheral shape of the honeycomb structure when viewed from the central axis direction of the honeycomb substrate. And the drawing number (for example, FIG. 2) in the column of “overall outer peripheral shape” means that the entire outer peripheral shape of the honeycomb structure is an outer peripheral shape as shown in the drawing of the drawing number.

  In Tables 1 to 6, the column “center-of-gravity shift (Z)” indicates the distance (center-of-gravity shift) between the overall center of gravity and the honeycomb base material center when viewed from the central axis direction of the honeycomb base material. The “flange portion distance (X)” column indicates the shortest distance (mm) between one end face of the honeycomb base material and the end face of the flange portion facing the same direction as the one end face of the honeycomb base material. The column “Flange length (L)” indicates the length of the flange portion in the direction in which the flange cell extends (the width of the flange portion) (mm). The column “Flange portion thickness (H)” indicates the maximum thickness (mm) of the flange portion in a cross section perpendicular to the cell extending direction. The column of “flange portion inclination angle (α)” indicates the inclination angle of one end surface of the flange portion (angle between one end surface of the flange portion and the side surface of the honeycomb substrate) (°). The column of “flange portion inclination angle (β)” indicates the inclination angle of the other end surface of the flange portion (angle between the other end surface of the flange portion and the side surface of the honeycomb substrate) (°).

(Examples 2-34, Comparative Examples 1-5)
A honeycomb structure was obtained in the same manner as in Example 1 except that the conditions were changed as shown in Tables 1 to 3. The obtained honeycomb structure was subjected to a “heating vibration test” by the above method. The results are shown in Tables 1 to 3.

  The overall outer peripheral shape of the honeycomb structure manufactured in each example and comparative example is as shown in Tables 1 to 3. The overall outer peripheral shape of the honeycomb structure is “the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate”. Specifically, in the honeycomb structures of Examples 2 to 8, 11 to 14, 22 to 29, and Comparative Examples 1 to 3, the entire outer peripheral shape was a circle having a diameter of 225 mm (see FIGS. 2 and 11). It was. In the honeycomb structure of Example 9, the entire outer peripheral shape was a circle having a diameter of 211 mm (see FIG. 7). In the honeycomb structure of Example 10, the entire outer peripheral shape was a circle having a diameter of 215 mm (see FIG. 7). In the honeycomb structures of Examples 15 to 21 and Comparative Examples 4 and 5, the entire outer peripheral shape was “a shape obtained by cutting four circular portions having a diameter of 225 mm into a straight shape” (see FIG. 8). In the honeycomb structures of Examples 30 to 34, the entire outer peripheral shape is such that one circular portion having a diameter of 225 mm is cut and the flange portion is only part of the outer periphery of the honeycomb substrate (see FIG. 10). there were.

  In the honeycomb structures of Examples 6 to 8 and 22 to 29, the entire outer peripheral shape was as shown in FIG. 2, and the front view was a honeycomb structure as shown in FIG.

  In Examples 2 to 10, 22 to 29, the thickness of the flange portion forming material was adjusted to obtain the deviation (Z) of the respective center of gravity.

  In Examples 11 to 14, as shown in FIG. 11, the coat layer of the flange portion was thickly coated so that the center of gravity shift (Z) was 0.2 to 1.5 mm. In Examples 15 to 21, 30 to 34, and Comparative Examples 4 and 5, each flange part was produced by pouring the flange part forming material into a previously formed mold.

  In Tables 1 to 6, in the “Flange portion arrangement range” column, “the entire circumference of the honeycomb substrate” is a ring in which the flange portion is arranged over the entire circumferential direction of the outer periphery of the honeycomb substrate. It shows that it is formed in a shape (continuous ring shape). “50%, 80%, 90% of the entire circumference of the honeycomb substrate” indicates “intermittent ring shape” in which a part of “continuous ring shape” is cut out.

(Example 35)
A honeycomb structure was produced using a cordierite forming raw material as a ceramic raw material. First, 10 parts by mass of water as a dispersion medium, 12 parts by mass of graphite as a pore former, and 5 parts by mass of an organic binder were added to 100 parts by mass of a cordierite forming raw material to obtain a forming raw material. Silica, talc and alumina were used as cordierite forming raw materials. Methylcellulose was used as the organic binder. The forming raw materials were mixed and kneaded to prepare a cylindrical clay. As the mixing device, a Laedige mixer was used, and as the kneading device, a kneader and a vacuum kneader were used.

  The obtained kneaded material was extrusion-molded to obtain a cylindrical honeycomb formed body. The obtained honeycomb formed body was microwave-dried.

  The dried honeycomb formed body was fired at a maximum temperature of 1420 ° C. for 100 hours to obtain a honeycomb fired body. Next, the outer periphery of the honeycomb fired body was ground with a grindstone to obtain a honeycomb fired body having a diameter of 208 mm.

  About the obtained honeycomb fired body, plugged portions were formed at one end of a predetermined cell and the other end of the remaining cells. The predetermined cells and the remaining cells are arranged alternately (alternately) so that a checkered pattern is formed on both end faces by the opening portions of the cells and the plugging portions. The same raw material as that for the honeycomb fired body was used as the plugging filler.

  Thereafter, a flange portion forming material was applied to the outer periphery of the plugged honeycomb fired body in the same manner as in Example 1 to form a solid flange portion. In this manner, a solid flange honeycomb fired body was obtained. The same raw material as that of the honeycomb fired body was used as the flange portion forming material.

  Thereafter, an outer peripheral coating material is applied to the outer periphery (side surface of the honeycomb substrate and the surface of the flange portion) of the obtained solid flange honeycomb fired body to form outer peripheral walls (the honeycomb substrate coat layer and the flange portion coat layer). A honeycomb structure having a solid flange portion was obtained.

  The honeycomb substrate of the obtained honeycomb structure had a cylindrical shape with a diameter of 210 mm in a cross section perpendicular to the cell extending direction and a length of 254 mm in the cell extending direction.

  Further, one end face of the honeycomb base material and the end face of the flange part facing in the same direction as the one end face of the honeycomb base material have a shortest distance (a flange part is formed with reference to one end face of the honeycomb base material). The position X was 60 mm. The length (width of the flange portion) L in the extending direction of the flange cell of the flange portion was 15 mm. The maximum thickness H of the flange portion in the cross section perpendicular to the cell extending direction (the thickness of the flange portion; the length in the diameter direction) was 7.8 mm. The minimum thickness h of the flange portion in the cross section orthogonal to the cell extending direction (thickness of the flange portion; length in the diameter direction) was 7.2 mm.

The partition wall thickness was 100 μm. The cell density was 70 cells / cm ² . Moreover, the shape of the cross section orthogonal to the cell extending direction of the cells of the honeycomb substrate was a square.

  The overall outer peripheral shape of the obtained honeycomb structure was a circle having a diameter of 225 mm (for example, see FIG. 2).

  The resulting honeycomb structure had a distance between the overall center of gravity and the center of gravity of the honeycomb substrate (shift of center of gravity (Z)) of 0.3 mm when viewed from the central axis direction of the honeycomb substrate.

  The thickness of the outer peripheral wall (that is, the thickness of each of the honeycomb substrate coat layer and the flange coat layer) was 1 mm.

  The obtained honeycomb structure was subjected to the “heating vibration test” by the above method. The results are shown in Table 4.

(Examples 36 to 68, Comparative Examples 6 to 10)
A honeycomb structure was obtained in the same manner as in Example 35 except that the conditions were changed as shown in Tables 4-6. The obtained honeycomb structure was subjected to a “heating vibration test” by the above method. The results are shown in Tables 4-6.

  The overall outer peripheral shape of the honeycomb structure manufactured in each example and comparative example is as shown in Tables 4-6. Specifically, the honeycomb structures of Examples 36 to 42, 45 to 48, 56 to 63, and Comparative Examples 6 to 8 had a circular outer shape with a diameter of 225 mm as a whole. The honeycomb structure of Example 43 had an overall outer peripheral shape of a circle having a diameter of 211 mm. In the honeycomb structure of Example 44, the entire outer peripheral shape was a circle having a diameter of 215 mm. In the honeycomb structures of Examples 49 to 55 and Comparative Examples 9 and 10, the entire outer peripheral shape was “a shape obtained by linearly cutting four circular portions having a diameter of 225 mm”. The honeycomb structures of Examples 64 to 68 were shaped such that one circular portion having a diameter of 225 mm was cut and the flange portion was only part of the outer periphery of the honeycomb substrate.

  In the honeycomb structures of Examples 40 to 42 and 56 to 63, the entire outer peripheral shape was as shown in FIG. 2, and the front view was a honeycomb structure as shown in FIG.

  In Examples 35 to 44 and 56 to 63, the thickness of the flange portion forming material was adjusted to obtain the deviation (Z) of the respective center of gravity.

  In Examples 45 to 48, as shown in FIG. 11, the flange portion coat layer of the flange portion was thickly coated, and the deviation (Z) in the center of gravity was set to 0.2 to 1.5 mm. In Examples 49 to 55, 64 to 68, and Comparative Examples 9 and 10, each flange part was produced by pouring the flange part forming material into a previously formed mold.

  From Tables 1 to 6, the honeycomb structures of Examples 1 to 68 have a better evaluation of the heating vibration test than the honeycomb structures of Comparative Examples 1 to 10, and the circumferential structure when stored in a can body It can be seen that the shift is difficult to occur. In addition, the honeycomb structures of Examples 1 to 68 have good production efficiency.

  The honeycomb structure of the present invention can be suitably used as a filter element of a dust collector.

1: partition wall, 2: cell, 3: honeycomb substrate, 4: outer periphery, 5: plugged portion, 11a: one end surface, 11b: the other end surface, 13: bonding material, 23: flange portion, 25: flange 26: flange part coat layer, 27: flange main body, 31: honeycomb substrate coat layer, 100, 101, 102, 103, 104, 105, 106, 201, 202, 203, 300: honeycomb structure, D1: Cell extending direction of honeycomb substrate, D3: Center axis direction, G1: Overall gravity center, G2: Honeycomb substrate gravity center, G3: Flange body gravity center, H: Maximum thickness of flange portion, h: Flange portion L: the width of the flange portion, l: the length of the side surface of the flange portion, X: the distance.

Claims (6)

A columnar honeycomb substrate having a porous partition wall that forms a plurality of cells serving as fluid flow paths, and the outer periphery of the honeycomb substrate are formed so as to protrude outward from the outer periphery of the honeycomb substrate. With a solid flange,
A honeycomb structure in which the overall center of gravity, which is the center of gravity of the entire outer peripheral shape when viewed from the central axis direction of the honeycomb substrate, and the center of gravity of the honeycomb substrate, which is the center of gravity of the outer peripheral shape of the honeycomb substrate, are separated from each other body.   2. The honeycomb structure according to claim 1, wherein a distance between the overall center of gravity and the center of gravity of the honeycomb substrate when viewed from the central axis direction of the honeycomb substrate is 0.3 to 3.0 mm.   The honeycomb structure according to claim 1 or 2, wherein a shape of at least one end portion of the flange portion is a tapered shape.   The honeycomb structure according to any one of claims 1 to 3, wherein a maximum value of a thickness of the flange portion in a cross section orthogonal to the cell extending direction is 1 to 40 mm.   The honeycomb substrate according to any one of claims 1 to 4, wherein the honeycomb substrate has a honeycomb substrate coat layer having a thickness of 0.05 to 8 mm arranged so as to form an outer peripheral surface of the honeycomb substrate. Honeycomb structure.   The honeycomb structure according to any one of claims 1 to 5, wherein the entire outer peripheral shape and the outer peripheral shape of the honeycomb base material are similar when viewed from the central axis direction of the honeycomb base material. .

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