Honeycomb structure for supporting a catalyst and manufacturing process for it

Abstract

Columnar honeycomb structure for supporting a catalyst (100), comprising partitions (112) that partition several cells extending from a first end face (104) provided with a fluid inlet to a second end face (106) provided with a fluid outlet, wherein the partitions (112) contain a first region (501) with a high initial water absorption rate and a second region (502) with a lower initial water absorption rate than the first region (501), wherein the initial water absorption rate of the second region (502) is 15% or more and 90% or less lower than the initial water absorption rate of the first region (501), wherein the initial water absorption rate [g / s] is measured by taking a cubic sample (401) from the honeycomb structure for supporting a catalyst (100).wherein the test piece (401) measures 10 mm x 10 mm x 50 mm with a dimension of 50 mm in a vertical direction corresponding to a cell extension direction of the honeycomb structure for supporting a catalyst (100), the test piece (401) is suspended from a hanging weight gauge (402) such that a 50 mm long side is oriented in a vertical direction, and the test piece (401) is lowered at a rate of 10 mm / min until a lower end touches water, and an increase in the weight of the test piece is calculated during a period of 0.5 seconds after the lower end touches the water.

Description

TECHNICAL AREA

[0001] The present invention relates to a honeycomb structure for supporting a catalyst. The present invention also relates to a manufacturing process for the honeycomb structure for supporting a catalyst. TECHNICAL BACKGROUND

[0002] The exhaust gas emitted by an internal combustion engine, as embodied by the engine of a motor vehicle, contains pollutants such as soot, nitrogen oxides (NOx), soluble organic fraction (SOF), hydrocarbons (HC), and carbon monoxide (CO). Therefore, conventionally, columnar honeycomb structures, carrying a suitable catalyst (an oxidation catalyst, a reduction catalyst, a three-way catalyst, or the like), have often been used for the exhaust systems of internal combustion engines, depending on the pollutant.

[0003] To comply with increasingly stringent emissions regulations, it has become common practice to install multiple catalyst support honeycomb structures within a single exhaust system. However, there is a need for space-saving exhaust systems, with attention focused on a technique known as zone coating, which involves coating different areas of a single honeycomb structure with multiple catalyst types.

[0004] The Japanese patent application JP 2004-169 586 A (Patent Literature 1) discloses a technique for increasing the amount of a catalyst coating in a central section of a honeycomb structure and for decreasing the amount of the catalyst coating on an outer perimeter by masking the outer perimeter of the honeycomb structure.

[0005] The national publication of the international patent application JP 2005-530 614 A (patent literature 2) discloses a technique for zone coating a honeycomb structure by immersing one end face and another end face of the honeycomb structure in wash coating slurries containing various catalyst components. Further relevant prior art is cited in the following documents: JP 4 680 437 B2, DE 10 2016 224 370 A1, and JP 2014-124 574 A. LIST OF COUNTERPOINTS Patent Literature Patent literature 1: Japanese publication JP 2004-169586A Patent Literature 2: National Publication of the International Patent Application JP 2005-530614A SUMMARY OF THE INVENTION

[0006] Although conventionally, an area of ​​the honeycomb structure to be brought into contact with the catalyst composition slurries has been sectioned by masking or similar means to achieve zone coating, this method does not apply any device to the honeycomb structure itself when coating different parts of the structure with different catalyst composition slurries. Therefore, to improve the operational efficiency of zone coating, it may be desirable to fabricate some kind of device on the honeycomb structure itself to simplify the coating of different areas of the honeycomb structure with different catalysts.

[0007] In light of the above circumstances, one object of the present invention in one embodiment is to provide a honeycomb structure for supporting a catalyst, which facilitates zone coating. Furthermore, in another embodiment, it is an object of the present invention to provide a manufacturing method for the honeycomb structure supporting a catalyst.

[0008] After carrying out extensive investigations to solve the problems mentioned above, the inventors of the present invention found that if a honeycomb structure for supporting a catalyst is made hydrophobic, the catalysts are less prone to adhering to such a hydrophobic section. The present invention has been developed based on these findings and is illustrated below by way of example.

[0009] [1] To solve the problem described above, a columnar honeycomb structure with the features of claim 1 is specified. Furthermore, a manufacturing process for a honeycomb structure with the features of claim 14 is specified. In addition, a manufacturing process for a catalyst support honeycomb structure with the features of claim 17 is specified. Furthermore, a manufacturing process for a catalyst support honeycomb structure with the features of claim 18 is specified. In addition, a manufacturing process for a catalyst support honeycomb structure with the features of claim 19 is specified. Further advantageous embodiments are defined in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic perspective view according to an embodiment of a honeycomb structure for supporting a catalyst of the present invention; Fig.2 is a schematic perspective view according to a further embodiment of a honeycomb structure for supporting a catalyst of the present invention; Fig. Figure 3 is a schematic graphical representation of a cross-section parallel to a height direction (a cell extension direction) of the honeycomb structure for carrying a catalyst according to Fig. 2; Fig. Figure 4 is a schematic graphical representation to explain a method for measuring the initial water absorption rate; Fig. 5A and Fig. 5B are conceptual sectional views where the partitions exhibit a distribution of the initial water absorption velocity in a direction perpendicular to the vertical direction (cell extension direction) of the honeycomb structure; Fig.Figures 6A to 6C are conceptual sectional views where the partitions exhibit a distribution of the initial water absorption velocity in a direction parallel to the vertical direction (cell extension direction) of the honeycomb structure; Fig. Figure 7 is a conceptual sectional view of an integrated honeycomb body created by joining the outer circumferential sidewalls of several honeycomb structures, which differ in their initial water absorption rate, together using a bonding material; Fig. Figure 8 is a graphical representation showing the changes in the initial water absorption rate on an inlet side and an outlet side in Example 1-1 and a comparison example 1; Fig.Figure 9 is a graphical representation showing the changes in the amounts of carried catalyst on the inlet side and the outlet side in Example 1-1 and in Comparative Example 1; and Fig. Figure 10 is a graphical representation showing a relationship between a decrease rate of the initial water absorption rate and a decrease rate of the amount of carried catalyst based on the results of Examples 1-1 to 1-3 and the comparison example 2. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0010] The embodiments of the present invention are described in detail below with respect to the drawings. It should be noted that the present invention is not limited to the following embodiments and that design modifications, improvements, or the like may be carried out by those skilled in the art without departing from the inventive concept and scope of protection of the present invention. (1. The honeycomb structure for supporting a catalyst) (1-1 The overall structure)

[0011] Fig. Figure 1 shows a schematic perspective view according to an embodiment of a honeycomb structure for supporting a catalyst of the present invention. Fig. Figure 2 shows a schematic perspective view according to a further embodiment of a honeycomb structure for supporting a catalyst of the present invention. Fig.Figure 3 shows a schematic graphical representation of a cross-section parallel to a height direction (a cell extension direction) of the honeycomb structure for carrying a catalyst according to Fig. 2.

[0012] The honeycomb structure for supporting a catalyst 100 according to the embodiment shown Fig.1 is a columnar honeycomb structure for supporting a catalyst, comprising an outer circumferential side wall 102 and partitions 112 configured to partition multiple cells arranged on an inner surface of the outer circumferential side wall 102, extending from a first end face 102, which is provided with a fluid inlet, to a second end face 106, which is provided with a fluid outlet. The honeycomb structure for supporting a catalyst 100 according to the present embodiment is a flow-through type, in which the opposite ends of each cell are open to a first end face 104 and a second end face 106, and a fluid flowing in through an inlet of a cell can flow directly out through an outlet of the cell.The honeycomb structures of the flow type are widely used for the purpose of carrying catalysts, including, but not limited to, oxidation catalysts, reduction catalysts and three-way catalysts.

[0013] The honeycomb structure for supporting a catalyst 200 according to the embodiment as described in the Fig. 2 and Fig. 3 is a columnar honeycomb structure for supporting a catalyst, which contains the partitions 112 configured to accommodate several cells extending from a first end face 104, which is provided with a fluid inlet, to a second end face 106, which is provided with a fluid outlet, as in the honeycomb structure for supporting a catalyst according to the embodiment shown. Fig. 1 to partition. The honeycomb structure for supporting a catalyst 200 according to the present embodiment differs from the embodiment according to Fig.1, as the present embodiment is a wall-flow type in which the cells, open at one end and sealed at the other, are arranged alternately in a checkerboard pattern. The honeycomb structures of the wall-flow type, which can collect solid contents (PM), such as soot and SOF, in the exhaust gas, are suitable for use as diesel particulate filters (DPFs) and gasoline particulate filters (GPFs) and often incorporate SCR catalysts, oxidation catalysts, or three-way catalysts.

[0014] Specifically, the honeycomb structure for supporting a catalyst 200 according to the embodiment according to the Fig. 2 and Fig.3. An outer circumferential sidewall 102 and several first cells 108 arranged on an inner side of the outer circumferential sidewall 102 and extending from a first end face 104 to a second end face 106, wherein the first end face 104 is open and the second end face 106 is sealed, and several second cells 110 arranged on the inner side of the outer circumferential sidewall 102 and extending from the first end face 104 to the second end face 106, wherein the first end face 104 is sealed and the second end face 106 is open. Furthermore, the honeycomb structure for supporting a catalyst 200 includes porous partitions 112 configured to partition the first cells 108 and the second cells 110, the first cells 108 and the second cells 110 being arranged alternately adjacent to each other across the partitions 112.

[0015] When a gas containing suspended particles is fed to the first end faces 104 on an upstream side of the honeycomb structure to support a catalyst 200, the gas is introduced into the first cells 108, flowing downstream through them. Because the first cells 108 have sealed second end faces 106 on a downstream side, the gas flows into the second cells 110 by passing through the porous partitions 112 that divide the first cells 108 and the second cells 110. The suspended particles that cannot pass through the partitions 112 are collected and deposited in the first cells 108. After the suspended particles have been removed, the clean gas flowing into the second cells 110 flows downstream through the second cells 110, exiting through the second end faces 106 on the downstream side.

[0016] The external shape of the honeycomb structure for supporting a catalyst is not particularly restricted, as long as it is columnar, and can be, for example, a columnar shape with a circular end face (a cylindrical shape), a columnar shape with an oval end face, a columnar shape with a polygonal (square, pentagonal, hexagonal, heptagonal, octagonal, etc.) end face, or the like.

[0017] There is no particular limitation on the size of the honeycomb structure for supporting a catalyst. However, a larger size allows for a greater amount of catalyst to be carried, while conversely, an excessively large size leads to reduced thermal shock resistance. Consequently, the surface area of ​​the end face is preferably between 5,000 and 200,000 mm². 2 , preferably 6500 to 125000 mm 2 and even more preferred 8000 to 75000 mm 2 . (1-2 The partition wall)

[0018] The partitions 112 can be made of a ceramic. There is no particular restriction on the ceramic materials suitable for the partitions, although possible ceramic materials include cordierite, mullite, zirconium, aluminum titanate, silicon carbide, a silicon-silicon carbide composite, silicon nitride, zirconium dioxide, spinel, indialite, sapphire, corundum, titanium dioxide, aluminum oxide, and silicon dioxide-aluminum oxide.

[0019] The partitions may be porous. In this case, from the standpoint of enhancing the heating properties and suppressing pressure losses in the case of a filter structure, the porosity of the partitions is preferably 15% or above, more preferably 20% or above, and even more preferably 22% or above. Furthermore, from the standpoint of ensuring the strength of the honeycomb structure, the porosity of the partitions is preferably 75% or below, more preferably 70% or below, and even more preferably 68% or below. The porosity is measured by a mercury penetration test in accordance with JIS R1655:2003 using a mercury porosimeter.

[0020] If the partitions 112 are porous, from the standpoint of increasing adhesion to the catalyst, the average pore size of the partitions 112 is preferably 1 µm or above, more preferably 2 µm or above, and even more preferably 3 µm or above. Furthermore, from the standpoint of ensuring strength and increasing collection efficiency in the case of a filter structure, the average pore size of the partitions is preferably 40 µm or below, more preferably 35 µm or below, and even more preferably 30 µm or below. The average pore size is a value measured by a mercury porosimeter.

[0021] There is no particular limitation on the thickness of the partitions 112. However, from the standpoint of increasing the strength of the honeycomb structure, the thickness is preferably 0.05 mm or more, more preferably 0.12 mm or more, and even more preferably 0.15 mm or more. Furthermore, from the standpoint of suppressing pressure losses, the thickness of the partitions is preferably 0.5 mm or less, more preferably 0.45 mm or less, and even more preferably 0.4 mm or less.

[0022] To simplify the zone coating of the catalyst in a post-process, it is desirable for the partitions 112 to contain a first region with a high initial water absorption rate and a second region with a lower initial water absorption rate than the first region. A large difference in the initial water absorption rate can amplify the difference in the amount of adhering catalyst, thus enabling effective zone coating. Consequently, the initial water absorption rate of the second region is preferably 15% or more lower, more preferably 20% or more lower, and even more preferably 30% or more lower than the initial water absorption rate of the first region.There is no specific upper limit to the rate of decrease of the initial water absorption rate of the second region relative to the initial water absorption rate of the first region, although from the standpoint of production costs, the rate is generally 90% or less and typically 80% or less. According to the present invention, the initial water absorption rate of the second region is 15% or more and 90% or less lower than the initial water absorption rate of the first region.

[0023] The procedures for measuring the initial water absorption rate are described with respect to Fig.4 described. A cubic test piece 401, measuring 10 mm × 10 mm × 50 mm with a dimension of 50 mm in the height direction (the cell extension direction) of the honeycomb structure for supporting a catalyst, is taken from the honeycomb structure for supporting a catalyst to be measured. Next, the test piece is suspended from a hanging weight gauge 402 such that one 50 mm long side is oriented in a vertical direction, as described in Fig. Figure 4 shows that the sample is lowered at a rate of 10 mm / min until a lower end touches the water 403. In this way, an increase in the weight (the absorbed water weight) of the sample is found during a period of 0.5 seconds after the lower end touches the water and is referred to as the initial water absorption rate [g / s] of the sample.

[0024] There is no particular restriction on the arrangement of the first and second regions, and the arrangement can be produced as is suitable according to a desired coating pattern with different catalysts. The methods for arranging the first and second regions are described by way of example below. Fig. 5, Fig. 6 to Fig.Figure 7 illustrates this. It is stated that, although a boundary between the first region and the second region is clearly shown in the illustrated embodiment, the boundary between the first region and the second region may contain a transition region in which the initial water absorption rate decreases from the first region to the second region. Furthermore, besides the transition region, there may be another partition region that has an initial water absorption rate different from those of the first and second regions.

[0025] The Fig. 5A and Fig.Figure 5B shows a conceptual sectional view of the honeycomb structure seen in a direction perpendicular to a central axis (the top) and a conceptual sectional view of the honeycomb structure seen in a direction perpendicular to the central axis (the bottom), where the partitions exhibit a distribution of the initial water absorption velocity in a direction perpendicular to the vertical direction (the cell extension direction) of the honeycomb structure. In the embodiment according to Fig. 5A The partitions comprise a first region 501 located on an outer circumferential side, and a second region 502 located on a side closer to the central axis O than the first region 501. In the embodiment according to Fig. 5B the partitions contain the second area 502, which is located on the outer circumferential side, and the first area 501, which is located on the side closer to the central axis O than the second area 502.

[0026] The Fig. Figures 6A to 6C show conceptual sectional views of the honeycomb structure seen in a direction perpendicular to a central axis, where the partitions exhibit a distribution of the initial water absorption rate in a direction parallel to the vertical direction (cell extension direction) of the honeycomb structure. In the embodiment according to Fig. 6A the partitions contain the second area 502, which is located on the fluid inlet side, and the first area, which is located on one side closer to the fluid outlet than the second area. In the embodiment according to Fig. 6B The partitions include the first region 501, which is located on the side of the fluid inlet, and the second region 502, which is located on the side closer to the fluid outlet than the first region. In the embodiment according to Fig.6C the partitions contain a section of the second area 502 located on the fluid inlet side, another section of the second area 502 located on the fluid outlet side, and the first area 501 located between the two sections of the second area 502.

[0027] Furthermore, an integrated body equipped with the partition and having the first area 501 and the second area 502 can be constructed as a whole by connecting several honeycomb structures that differ in their initial water absorption rate. Fig.Figure 7 illustrates, by way of example, a conceptual sectional view viewed in one direction of a central axis, showing a distribution of the water absorption velocity in a cylindrical honeycomb structure, wherein the cylindrical honeycomb structure is created by connecting the outer circumferential sidewalls of several quadrilateral prismatic honeycomb structures using a bonding material and an outer perimeter of the connected honeycomb structures is machined.

[0028] There is no restriction on the method for adjusting the initial water absorption rate of the partitions. Examples of the method include a method for changing the material and porosity of the partitions on a section-by-section basis, and a method in which a hydrophobic substance is caused to adhere to a section of the partitions based on the principle that the partitions with the hydrophobic substance adhering to them will have a low initial water absorption rate. Of these methods, the method in which a hydrophobic substance is caused to adhere to a section of the partitions is preferred from the standpoint of production costs and simplicity.By causing the hydrophobic substance to adhere selectively (the term "selective" here includes the concept of "preferred") to a section of the partition walls whose initial water absorption rate is to be reduced, it is possible to divide the partition walls into zones.

[0029] Consequently, in one embodiment of the honeycomb structure for supporting a catalyst according to the present invention, a hydrophobic substance adheres to the second region. There is no particular limitation on the hydrophobic substance, as long as the hydrophobic substance achieves the effect of reducing the initial water absorption rate of the partitions. The hydrophobic substance consists, for example, of one or more types selected from a group comprising hydrophobic organosilicon compounds and hydrophobic organic compounds. Typically, the hydrophobic substance exhibits low solubility in water and can form a phase separate from the water. Preferably, the hydrophobic substance has an octanol / water partition coefficient (logP) of 1 or above, more preferably 2 or above, and even more preferably 3 or above, which may be in a range of, for example, 1 to 20.

[0030] Furthermore, in one embodiment of the honeycomb structure for supporting a catalyst according to the present invention, a difference in the initial water absorption rate between the first and second regions is reduced by heat treatment at 600 °C or below. If the catalyst coating is applied before the heat treatment, the catalyst adheres in large quantities to the first region, but is less likely to adhere to the second region. However, the subsequent heat treatment reduces the difference in the initial water absorption rate, with the catalyst readily adhering to the region that was the second region before the heat treatment. While the catalyst has already adhered to the first region, a large proportion, containing pores capable of supporting the catalyst, remains in the second region of the partitions.If the catalyst coating is performed again after heat treatment, the catalyst can therefore be selectively caused to adhere to the earlier second area.

[0031] If the heat treatment is carried out at 600 °C or below, and preferably at 200 °C to 500 °C, it is preferred that the percentage of the initial water absorption rate of the area that was the second area before the heat treatment, relative to the initial water absorption rate of the area that was the first area before the heat treatment, becomes 90% or above, more preferably 95% or above, and even more preferably 97% or above.

[0032] Heat treatment at 600 °C or below means the process of heating the honeycomb structure to support a catalyst, e.g., for one hour at 500 °C and a pressure of 1 atmosphere in an air atmosphere.

[0033] The examples of the method for configuring the honeycomb structure to carry a catalyst, such that the difference in the initial water absorption rate between the first area and the second area is reduced by heat treatment at 600 °C or below, include a method using a substance that evaporates from the partitions by heat treatment at 600 °C or below, as the hydrophobic substance whose adhesion to the second area is to be caused.

[0034] Examples of hydrophobic organosilicon compounds that can be used appropriately include silane-based, siliconate-based, silicone-based and silane composite-based hydrophobic agents.

[0035] Examples of hydrophobic organic compounds that can be used include suitable examples of both aliphatic compounds, such as alcohols, ethers, and ketones, and aromatic compounds. Among these compounds, aromatic compounds with a high molecular weight, such as 100 or above, and preferably 150 or above, are suitable for increasing hydrophobicity. (1-3 The cells)

[0036] There is no particular limitation on the length of the honeycomb structure for supporting a catalyst in the cell extension direction (the vertical direction). However, a greater length allows for a larger amount of catalyst to be supported, while, conversely, an excessively long length leads to reduced thermal shock resistance. Consequently, the length is preferably 50 to 400 mm, more preferably 60 to 350 mm, and even more preferably 70 to 310 mm.

[0037] There is no restriction on the cell shape in a cross-section orthogonal to the cell extension direction (the vertical direction of the honeycomb structure), although the cell shape is preferably square, hexagonal, octagonal, or a combination thereof. Among these shapes, square and hexagonal shapes are preferred. Such a cell shape reduces pressure losses when a gas flows through the honeycomb structure and provides excellent purification performance when the honeycomb structure is used as a filter.

[0038] There is no particular restriction on the cell spacing of the honeycomb structure for supporting a catalyst. However, from the standpoint of reducing pressure losses, the cell spacing is preferably 0.6 mm or more, more preferably 0.7 mm or more, and even more preferably 0.8 mm or more. From the standpoint of increasing the surface area of ​​the partitions and increasing the cleaning efficiency, however, the cell spacing is preferably 3.0 mm or less, more preferably 2.5 mm or less, and even more preferably 2.0 mm or less. Here, the cell spacing refers to the length of a line segment connecting the centroids of two adjacent cells in a section perpendicular to the cell extension direction (the vertical direction of the honeycomb structure). (2. The manufacturing process for the honeycomb structure to support a catalyst)

[0039] A preferred example of the manufacturing process for the honeycomb structure for supporting a catalyst according to the present invention is described below. In one embodiment, the manufacturing process for the honeycomb structure for supporting a catalyst according to the present invention comprises bringing a portion of the partitions of the columnar honeycomb structure for supporting a catalyst into contact with a hydrophobic substance, wherein the honeycomb structure for supporting a catalyst comprises the partitions that divide the multiple cells extending from the first end face, which is provided with the fluid inlet, to the second end face, which is provided with the fluid outlet. (2-1 Creating a honeycomb structure)

[0040] First, a columnar honeycomb structure is fabricated to support a catalyst. This honeycomb structure comprises the partitions that divide the multiple cells extending from the first end face, which is provided with the fluid inlet, to the second end face, which is provided with the fluid outlet. Such a columnar honeycomb structure for supporting a catalyst can itself be fabricated using any known manufacturing process.

[0041] Consequently, in one embodiment, the manufacturing process for the columnar honeycomb structure for supporting a catalyst comprises a step of manufacturing a columnar honeycomb molding, which includes an outer circumferential side wall and the partition walls that divide the multiple cells arranged on an inner side of the outer circumferential side wall and extending from the first end face to the second end face.

[0042] The columnar honeycomb mold can be produced by kneading a raw material composition containing a ceramic base, a dispersion medium, a pore-forming material, and a binder, then shaping the raw material composition into a blank, and finally extruding the blank. If required, additives, such as a dispersion medium, can be mixed into the raw material composition. A mold, which provides the desired overall shape, cell shape, partition thickness, cell density, and the like, can be used for extrusion.

[0043] The ceramic starting material remains after firing and serves as a precursor for a portion that forms the framework of the honeycomb structure, namely the ceramic. The ceramic starting material can be provided, for example, in powder form. Examples of ceramic starting materials include materials used to obtain ceramics, such as cordierite, mullite, zirconium, aluminum titanate, silicon carbide, silicon-silicon carbide composites, silicon nitrides, zirconium, spinel, indialite, sapphire, corundum, titanium dioxide, etc. Specific examples include, but are not limited to, silicon dioxide, talc, aluminum hydroxide, aluminum oxide, kaolin, serpentine, pyrophyllite, brucite, boehmite, mullite, and magnesite. One type of ceramic starting material can be used alone, or two or more types can be used in combination. For filter applications, such as...For a DPF and a GPF, cordierite, silicon carbide and a silicon-silicon carbide composite material can be used as suitable ceramics.

[0044] The pore-forming material is not particularly restricted, as long as the pores are formed after firing, and can be, for example, wheat flour, starch, foaming resin, water-absorbing resin, silica gel, carbon (e.g., graphite), a ceramic balloon, polyethylene, polystyrene, polypropylene, nylon, polyester, acrylic, phenol, foamed foaming resin, or non-foamed foaming resin. One type of pore-forming material can be used alone, or two or more types can be used in combination. From the standpoint of increasing the porosity of the honeycomb structure, the content of the pore-forming material is preferably 0.5 parts by mass or more, more preferably 2 parts by mass or more, and even more preferably 3 parts by mass or more per 100 parts by mass of the ceramic starting material.From the point of view of ensuring the strength of the honeycomb structure, the content of the pore-forming material is preferably 10 parts by mass or less, more preferably 7 parts by mass or less and even more preferably 4 parts by mass or less per 100 parts by mass of the ceramic starting material.

[0045] Examples of binders include methylcellulose, hydroxypropoxylcellulose, hydroxyethylcellulose, carboxymethylcellulose, polyvinyl alcohol, and other organic binders. Methylcellulose and hydroxypropoxylcellulose are preferably used together. Furthermore, from the standpoint of increasing the strength of the honeycomb molded part, the binder content is preferably 4 parts by mass or more per 100 parts by mass of the ceramic starting material, more preferably 5 parts by mass or more, and even more preferably 6 parts by mass or more. From the standpoint of reducing cracking caused by abnormal heat generation in a firing step, the binder content is preferably 9 parts by mass or less per 100 parts by mass of the ceramic starting material, more preferably 8 parts by mass or less, and even more preferably 7 parts by mass or less.One type of binder can be used alone, or two or more types can be used in combination.

[0046] A surfactant such as ethylene glycol, dextrin, a fatty acid soap, or a polyalcohol can be used as the dispersing agent. One type of dispersing agent can be used alone, or two or more types can be used in combination. The dispersing agent content is preferably 0 to 2 parts by mass per 100 parts by mass of the ceramic starting material.

[0047] The examples of dispersion medium contain water and mixed solvents of water and an organic solvent, such as an alcohol, whereby water in particular can be used suitablely.

[0048] The water content of the honeycomb mold before a drying step is preferably 20 to 90 parts by mass, more preferably 60 to 85 parts by mass, and even more preferably 70 to 80 parts by mass per 100 parts by mass of the ceramic starting material. If the water content in the honeycomb mold is 20 parts by mass or above per 100 parts by mass of the ceramic starting material, the advantage of easily stabilizing the quality of the honeycomb mold is readily achieved. If the water content in the honeycomb mold is 90 parts by mass or below per 100 parts by mass of the ceramic starting material, shrinkage during drying is reduced and deformation can be prevented. Here, the water content in the honeycomb mold refers to a value measured by weight loss during the drying process.

[0049] In one embodiment of the honeycomb mold, all cells can be penetrated from the first end face to the second end face. According to another embodiment, the honeycomb mold can contain several first cells, in which a first end face is open and a second end face is sealed, and several second cells, in which a first end face is sealed and a second end face is open, with the first cells and the second cells extending from the first end face to the second end face; it can have a cell structure in which the first cells and the second cells are alternately adjacent to each other across the partitions. There is no particular restriction on the method for sealing the end face of the honeycomb mold, and a known technique may be used.

[0050] There is no particular restriction on the material of the sealed section, although ceramics are preferred from the standpoint of strength and heat resistance. Preferably, the ceramic material comprises at least one type selected from the group consisting of cordierite, mullite, zirconium, aluminum titanate, silicon carbide, silicon-silicon carbide composites, silicon nitrides, zirconium, spinel, indialite, sapphire, corundum, and titanium dioxide. Preferably, the sealed section is made of a material containing this ceramic at a total of 50% by weight or more, and more preferably 80% by weight or more. Even more preferably, the sealed section has the same material composition as a main body of the honeycomb mold, because this allows for a uniform coefficient of thermal expansion during firing and improves durability.

[0051] A columnar honeycomb structure for supporting a catalyst can be produced by degreasing and firing the columnar honeycomb blank after it has dried. Regarding the conditions for the drying, degreasing, and firing steps, known conditions based on the material composition of the honeycomb blank can be applied, without requiring further explanation. However, specific examples of these conditions are given below.

[0052] In the drying step, any conventionally known drying methods can be used, including hot air drying, microwave drying, dielectric drying, reduced-pressure drying, vacuum drying, and freeze-drying. Among these methods, a drying process combining hot air drying with microwave drying or dielectric drying is preferred because the entire molded part can be dried quickly and uniformly. When forming the sealed sections, these sections are created on the opposite end faces of the dried honeycomb molded part, and then dried to obtain a dried honeycomb body.

[0053] A method for forming a sealed section is described by way of illustration. A sealing slurry is stored in advance in a storage container. Next, a mask, which has openings in a section corresponding to the cell on which a sealed section is to be formed, is attached to one of the end faces. The end face with the attached mask is immersed in the storage container, and the sealed section is then formed by filling the openings with the sealing slurry. Another sealed section can be formed on the other end face by a similar procedure.

[0054] The next step is the degreasing process. The combustion temperature of the binder is approximately 200 °C, while the combustion temperature of the pore-forming material is approximately 300 to 1000 °C. Therefore, the degreasing step can be carried out by heating the honeycomb mold within a temperature range of approximately 200 to 1000 °C. The heating period is not particularly limited, although it is typically about 10 to 100 hours. The honeycomb mold, after undergoing the degreasing step, is referred to as a calcined body.

[0055] The firing step can be carried out, for example, by heating the calcined body to 1350 to 1600 °C and holding the temperature for 3 to 10 hours, depending on the material composition of the honeycomb preform. (2-2 Contact with a hydrophobic substance)

[0056] Next, a portion of the partitions of the columnar honeycomb structure, which supports a catalyst, is brought into contact with a hydrophobic substance. There are no particular limitations to the method for contacting a hydrophobic substance, although a method for contacting a fluid containing the hydrophobic substance is simple and preferred. The fluid may, for example, be in the form of a solution, a slurry, or a vapor.

[0057] The portion of the partition walls that has become hydrophobic due to the adhering hydrophobic substance reduces the initial water absorption rate. Furthermore, the degree of reduction in the initial water absorption rate can be controlled by adjusting the deposition rate, the LogP value, and other properties of the hydrophobic substance used. Therefore, a first region with a high initial water absorption rate and a second region with a low initial water absorption rate can be created by selectively contacting the hydrophobic substance with the portion of the partition walls whose initial water absorption rate is to be reduced.

[0058] Possible methods for fabricating partitions that exhibit a distribution of the initial water absorption rate in a direction perpendicular to the vertical direction (cell extension direction) of the honeycomb structure for supporting a catalyst include, for example, a method in which a fluid containing the hydrophobic substance is caused to pass through a cell where one or both of the end faces of the honeycomb structure are masked. Because the fluid flows into and through the unmasked cells, if a section to be masked is changed, the locations of the first and second regions can be altered. If it is desired to form the first region on the outer circumferential side and the second region on a side closer to a central axis than the first region, the outer circumferential side can be masked. The converse is also true.

[0059] Furthermore, the possible methods for manufacturing the partitions, which exhibit a distribution of the initial water absorption rate in a direction parallel to the vertical direction (cell extension direction) of the honeycomb structure for carrying a catalyst, include a method for immersing a portion of the honeycomb structure vertically in a fluid containing the hydrophobic substance (preferably a fluid in a slurry mold). If the honeycomb structure is a filter structure with a sealed section, the hydrophobic substance can also be selectively caused to adhere to the outlet side by causing smoke containing the hydrophobic substance to flow from an open side of the cells, as the smoke collects on the outlet side of the sealed cells. (3 A manufacturing process for the catalyst support honeycomb structure)

[0060] According to one aspect of the present invention, a manufacturing process for a catalyst support honeycomb structure is provided, wherein the manufacturing process comprises bringing into contact at least a part of the partition walls of the honeycomb structure for supporting a catalyst according to the present invention with a catalyst composition slurry.

[0061] The honeycomb structure for supporting a catalyst according to the present invention varies from region to region in its initial water absorption rate and, accordingly, in the ease with which a catalyst adheres. Consequently, a section with a large catalyst deposit and a section with a small catalyst deposit are automatically formed without the need to selectively apply the catalyst to a section where it is desirable for a large amount of catalyst to adhere. Therefore, according to one embodiment of the manufacturing process for a catalyst-support honeycomb structure, zone coating can be achieved by bringing a catalyst composition slurry into contact with at least the first region and the second region of the partitions of the honeycomb structure for supporting a catalyst.Furthermore, according to another embodiment of the manufacturing process for a catalyst support honeycomb structure, a zone coating can be carried out by bringing a catalyst composition slurry into contact with the entire honeycomb structure for carrying a catalyst.

[0062] Furthermore, an embodiment of the manufacturing process for a catalyst support honeycomb structure according to the following invention comprises: performing step 1 for contacting at least the first region and the second region of the partitions of the honeycomb structure for supporting a catalyst according to the present invention with a first catalyst composition slurry; step 2 for removing at least a part of a hydrophobic substance adhering to the second region of the partitions of the honeycomb structure for supporting a catalyst after step 1; and step 3 for contacting the first region and the second region of the partitions of the honeycomb structure for supporting a catalyst with a second catalyst composition slurry after step 2.

[0063] Step 1 allows the first catalyst composition slurry to selectively adhere to the first region of the partitions. When the hydrophobic substance adhering to the second region is removed in Step 2, the catalyst readily adheres to the former second region because the initial water absorption rate of the second region is restored. In contrast, the first region already carries the first catalyst, making it difficult to carry more catalyst, with a large proportion of the pore space, which could potentially carry the catalyst, remaining in the second region of the partitions. Consequently, Step 3, when performed after the removal of the hydrophobic substance, allows the second catalyst composition slurry to selectively adhere to the former second region.

[0064] The examples of the process for removing at least a portion of the hydrophobic substance adhering to the second region of the partitions include a method for carrying out a heat treatment at approximately a temperature at which at least a portion of the hydrophobic substance evaporates or decomposes. This heat treatment can be carried out separately from the heat treatment performed to burn the catalyst component contained in the first catalyst composition slurry onto the partitions, but from the standpoint of manufacturing efficiency, these two heat treatments are combined. For this purpose, the heat treatment temperature is preferably 400 °C or above and more preferably 450 °C or above. However, the catalyst deteriorates if the heat treatment temperature is too high. Consequently, the heat treatment temperature is preferably 650 °C or below and more preferably 600 °C or below.

[0065] The catalyst composition slurry optionally contains a suitable catalyst according to the application. Examples of catalysts include, but are not limited to, oxidation catalysts, SCR catalysts, and three-way catalysts used to remove pollutants such as soot, nitrogen oxides (NOx), soluble organic fraction (SOF), hydrocarbons (HC), and carbon monoxide (CO). The honeycomb structure for supporting a catalyst according to the present invention facilitates the implementation of a zoned coating that incorporates different catalysts depending on the area. The catalyst can be suitable for, e.g., B. precious metals (Pt, Pd, Rh etc.), alkali metals (Li, Na, K, Cs etc.), alkaline earth metals (Ca, Ba, Sr etc.), rare earth metals (Ce, Sm, Gd, Nd, Y, Zr, Ca, La, Pr etc.) and transition metals (Mn, Fe, Co, Ni, Cu, Zn, Sc, Ti, V, Cr etc.). [Examples]

[0066] The following examples illustrate the present invention and its advantages for a better understanding, but the present invention is not limited to these examples. (The creation of the honeycomb structure)

[0067] A sufficient number of silicon carbide wall-flow honeycomb structures were fabricated for the following tests. The honeycomb structures were cylindrical with a diameter of 143.8 mm, a height of 152.4 mm, and a sealing depth of 6 mm. The partition walls of the honeycomb structure were 0.3 mm thick, had a porosity of 64%, and an average pore size of 19 µm. The cells of the honeycomb structure had a square cross-section with a cell spacing of 1.5 mm. (Example 1-1)

[0068] Using the honeycomb structure created as described above, smoke was allowed to flow from the side of the first end face through the cells to the side of the second end face for 13 minutes. The smoke, which contained a hydrophobic substance (an aromatic hydrocarbon), was produced by burning incense.

[0069] Next, a sample was taken from near the central axis on the side of the first end face of the honeycomb structure with the hydrophobic substance adhering to it, and the initial water absorption rate was measured following the measurement procedures described above. A sample was also taken from near the central axis on the side of the second end face of the honeycomb structure, and the initial water absorption rate was measured following the measurement procedures described above. The results are shown in Table 1 and Fig. 8 shown.

[0070] A honeycomb structure with the hydrophobic substance adhering to it was fabricated separately using the same procedures as described above. The entire honeycomb structure was immersed in a catalyst composition slurry containing an SCR catalyst for 10 seconds and then withdrawn. The honeycomb structure, coated in this manner with the catalyst composition slurry, was then heated in an air atmosphere at 450 °C for 3 hours, thereby calcining the catalyst onto the honeycomb structure.Using a sampling procedure identical to that used to measure the initial water absorption rate, samples were taken from both the first end face (inlet side) and the second end face (outlet side) of the honeycomb structure with the fired catalyst. The respective amounts of catalyst carried were measured by weight. The ratio of catalyst coating on the outlet side to catalyst coating on the inlet side is shown in Table 1. Fig. 9 shown. (Comparison example 1)

[0071] Using the honeycomb structure produced as described above, the initial water absorption rate was measured on the side of the first end face and on the side of the second end face, following the same procedures as in Example 1-1. The results are shown in Table 1 and Fig. 8 shown.

[0072] The catalyst composition slurry was applied to the honeycomb structure, which was prepared as described above, using the same procedures as in Example 1-1, and the catalyst was fired. Using the same procedure as in Example 1-1, samples were taken from both the first end face and the second end face of the honeycomb structure with the fired catalyst. The amounts of catalyst carried were then measured using the same procedure as in Example 1-1. The ratio of catalyst coating on the outlet side to catalyst coating on the inlet side is shown in Table 1. Fig. 9 shown. [Table 1] initial water absorption rate [g / s] Amount of catalyst carried [%] Entrance side outlet side Entrance side outlet side Example 1-1 3,2 1,5 100 33 Comparison example 1 4,7 4,5 100 103 (Comparison example 2, example 1-2, example 1-3)

[0073] Using the same procedures as in Example 1-1, except that the duration for which smoke was allowed to flow was changed to the values ​​shown in Table 2 according to the test numbers, smoke was allowed to flow through the cells in the honeycomb structures, which were prepared as described above, causing the hydrophobic substance to adhere. Using the honeycomb structure of each of the examples and the comparison example with the hydrophobic substance adhering to the honeycomb structures, the initial water absorption rate was measured on the side of the first end face and on the side of the second end face, following the same procedures as in Example 1-1.For each of the examples and the comparison example, the percentage ratio of the initial water absorption rate on the outlet side to the initial water absorption rate on the inlet side is shown in Table 2.

[0074] Furthermore, the honeycomb structures of each example / comparative example were prepared separately, and the hydrophobic substance was induced to adhere to them using the same procedures as above. The catalyst composition slurry was applied to the honeycomb structures using the same procedures as in Example 1-1, and the catalyst was fired. Using the same procedure as in Example 1-1, samples were taken from both the first end face and the second end face of the honeycomb structure with the fired catalyst. The amounts of catalyst carried were then measured using the same procedure as in Example 1-1. For each of the examples and the comparative example, the percentage ratio of catalyst coating on the outlet side to catalyst coating on the inlet side is shown in Table 2. Fig. 10 shown. [Table 2] Comparative example 2 Example 1-2 Examples 1-3 Example 1-1 Rate of decrease of initial water absorption rate (%) 9 22 38 56 Rate of decrease of the amount of catalyst carried (%) 4 42 63 78 Smoke flow time (min) 2 4 7 13 (Example 2)

[0075] Ethylbenzene was prepared as the hydrophobic substance. The honeycomb structure, prepared as described above, was immersed in a container of ethylbenzene to a depth of 30 mm in the cell extension direction (the vertical direction) from the side of the first end face for 3 seconds. The honeycomb structure, withdrawn from the ethylbenzene, was dried in an air atmosphere at room temperature for 15 minutes. Subsequently, samples were taken from the portion of the honeycomb structure immersed in the ethylbenzene and from the portion of the honeycomb structure not immersed in the ethylbenzene, and the initial water absorption rate was measured following the measurement procedures described above. The results are shown in Table 3.

[0076] A honeycomb structure was prepared separately, and the hydrophobic substance was selectively adhered to it using the same procedures as above. The catalyst composition slurry was applied to the honeycomb structure using the same procedures as in Example 1-1, and the catalyst was calcined. Subsequently, samples were taken from the portion of the honeycomb structure immersed in ethylbenzene and from the portion of the honeycomb structure not immersed in ethylbenzene, and the respective amounts of catalyst carried were measured following the measurement procedures described above. The ratio of the amount of catalyst carried in the ethylbenzene-immersed portion to the amount of catalyst carried in the non-ethylbenzene-immersed portion is shown in Table 3. [Table 3] initial water absorption rate [g / s] Amount of carried catalyst [%] non-submerged section submerged section non-submerged section submerged section 4,6 0,9 100 11 (Example 3)<Die Beschichtung mit dem ersten Katalysator>

[0077] The cells in the central regions of both end faces of the honeycomb structure, which was prepared as described above, were masked by concentrically attaching circular adhesive films with a diameter of 80 mm to each end face. The same solution containing the hydrophobic substance as in Example 2 was prepared, and the honeycomb structure with the attached films was completely immersed in the solution for 3 seconds. The honeycomb structure was then withdrawn from the solution and, after removal of the films, dried for 15 minutes at room temperature in an air atmosphere.Subsequently, samples were taken from the outer circumferential and central axis sections of the honeycomb structure for use in measuring the initial water absorption rate. The initial water absorption rate was measured following the measurement procedures described above, with the central axis section corresponding to the masked cell section and the outer circumferential section corresponding to the unmasked cell section. The results are shown in Table 4-1.

[0078] A honeycomb structure was prepared separately by masking it using the same procedures as above and selectively subjecting it to adhesion of the hydrophobic substance. The first catalyst composition slurry was applied to the honeycomb structure using the same procedures as in Example 1-1, and the catalyst was calcined. Samples were taken from a section of an outer circumferential side and a section of the central axis side of the honeycomb structure, and the respective amounts of catalyst carried were measured, following the measurement procedures described above. The central axis side section corresponded to the masked cell section, while the outer circumferential side section corresponded to the unmasked cell section.The ratio of the amount of carried catalyst of the outer circumferential section (the unmasked section) to the amount of carried catalyst of the central axis section (the masked section) is shown in Table 4-1. [Table 4-1] Coating with the first catalyst initial water absorption rate [g / s] Amount of carried catalyst [%] masked section unmasked section masked section unmasked section 4,7 1,0 100 12 <Die Beschichtung mit dem zweiten Katalysator>

[0079] A honeycomb structure was prepared separately by subjecting it to the steps up to catalyst firing using the same procedures as described above. To verify that the hydrophobic substance disappeared along with the catalyst firing, samples were taken from a section of the outer circumferential side and a section of the central axis side of the honeycomb structure with the catalyst fired onto them. The initial water absorption rate was measured using the measurement procedures described above, with the central axis side section corresponding to the masked cell section and the outer circumferential side section corresponding to the unmasked cell section. The results are shown in Table 4-2.

[0080] A honeycomb structure was fabricated separately by subjecting it to the steps leading up to the firing of the first catalyst, using the same procedures as described above. The entire honeycomb structure was immersed in a second catalyst composition slurry containing a high concentration of the SCR catalyst for 10 seconds and then withdrawn. The honeycomb structure, coated in this manner with the catalyst composition slurry, was then heated in an air atmosphere at 450 °C for 3 hours, thereby firing the catalyst onto the honeycomb structure.Samples were taken from a masked section of the central axis side and an unmasked section of the outer circumferential side of the resulting honeycomb structure. The amount of catalyst carried on the central axis side and the amount carried on the outer circumferential side were measured by weight. The results are shown in Table 4-2. [Table 4-2] Coating with the second catalyst Initial water absorption rate after burning of the first catalyst [g / s] Amount of carried catalyst [%] masked section unmasked section masked section unmasked section 4,7 4,8 100 86 List of reference symbols 100, 200 honeycomb structure for supporting a catalyst 102 outer perimeter side wall 104 first front face 106 second front face 108 first cell 110 second cell 112 Partition wall 401 cubic specimen 402 Hanging Weight Meter 403 Water 501 first area 502 second area

Claims

Columnar honeycomb structure for supporting a catalyst (100), comprising partitions (112) that partition several cells extending from a first end face (104) provided with a fluid inlet to a second end face (106) provided with a fluid outlet, wherein the partitions (112) contain a first region (501) with a high initial water absorption rate and a second region (502) with a lower initial water absorption rate than the first region (501), wherein the initial water absorption rate of the second region (502) is 15% or more and 90% or less lower than the initial water absorption rate of the first region (501), wherein the initial water absorption rate [g / s] is measured by taking a cubic sample (401) from the honeycomb structure for supporting a catalyst (100).wherein the test piece (401) measures 10 mm x 10 mm x 50 mm with a dimension of 50 mm in a vertical direction corresponding to a cell extension direction of the honeycomb structure for supporting a catalyst (100), the test piece (401) is suspended from a hanging weight gauge (402) such that a 50 mm long side is oriented in a vertical direction, and the test piece (401) is lowered at a rate of 10 mm / min until a lower end touches water, and an increase in the weight of the test piece is calculated during a period of 0.5 seconds after the lower end touches the water. Honeycomb structure for carrying a catalyst (100) according to claim 1, wherein the partitions (112) have a distribution of the initial water absorption rate in a direction perpendicular to an extension direction of the cells of the honeycomb structure and have the first region (501) located on an outer circumferential side and the second region (502) located on a side closer to a central axis than the first region (501). Honeycomb structure for carrying a catalyst (100) according to claim 1, wherein the partitions (112) have a distribution of the initial water absorption rate in a direction perpendicular to an extension direction of the cells of the honeycomb structure and have the second region (502) located on an outer circumferential side and the first region (501) located on a side closer to a central axis than the second region (502). Honeycomb structure for carrying a catalyst (100) according to one of claims 1 to 3, wherein the partitions (112) have a distribution of the initial water absorption velocity in a direction parallel to an extension direction of the cells of the honeycomb structure and have the second region (502) located on one side of the fluid inlet and the first region (501) located on one side closer to the fluid outlet than the second region (502). Honeycomb structure for carrying a catalyst (100) according to one of claims 1 to 3, wherein the partitions (112) have a distribution of the initial water absorption velocity in a direction parallel to an extension direction of the cells of the honeycomb structure and have the first region (501) located on one side of the fluid inlet and the second region (502) located on one side closer to the fluid outlet than the first region (501). Honeycomb structure for carrying a catalyst (100) according to one of claims 1 to 3, wherein the partitions (112) have a distribution of the initial water absorption velocity in a direction parallel to an extension direction of the cells of the honeycomb structure and comprise a section of the second region (502) located on one side of the fluid inlet, a further section of the second region (502) located on one side of the fluid outlet, and the first region (501) located between the two sections of the second region (502). Honeycomb structure for supporting a catalyst (100) according to any one of claims 1 to 6, wherein the initial water absorption rate of the second region (502) is 30% or more lower than the initial water absorption rate of the first region (501). Honeycomb structure for supporting a catalyst (100) according to one of claims 1 to 7, wherein a difference in the initial water absorption rate between the first area (501) and the second area (502) is reduced by heat treatment at 600°C or below. Honeycomb structure for supporting a catalyst (100) according to one of claims 1 to 8, wherein a base material of the partitions (112) is ceramic. Honeycomb structure for supporting a catalyst (100) according to one of claims 1 to 9, wherein the multiple cells comprise multiple first cells (108) in which a first end face is open and a second end face is sealed, and multiple second cells (110) in which a first end face is sealed and a second end face is open; and the first cells (108) and the second cells (110) are arranged alternately adjacent to each other via the partitions (112). Honeycomb structure for carrying a catalyst (100) according to one of claims 1 to 10, wherein a hydrophobic substance adheres to the second area (502). Honeycomb structure for supporting a catalyst (100) according to claim 11, wherein the hydrophobic substance comprises one or more types selected from a group comprising hydrophobic organosilicon compounds and hydrophobic organic compounds. Honeycomb structure for supporting a catalyst (100) according to claim 11 or 12, wherein at least a part of the hydrophobic substance adhering to the second region (502) evaporates at 600 °C or below. Manufacturing process for the honeycomb structure for supporting a catalyst (100) according to one of claims 1 to 13, wherein the manufacturing process comprises bringing into contact a part of the partitions (112) of the columnar honeycomb structure for supporting a catalyst (100) with a hydrophobic substance, wherein the honeycomb structure for supporting a catalyst (100) comprises the partitions (112) that partition the multiple cells extending from the first end face (104) provided with the fluid inlet to the second end face (106) provided with the fluid outlet. Manufacturing method for the honeycomb structure for supporting a catalyst (100) according to claim 14, wherein the manufacturing method comprises bringing into contact a part of the partitions of the columnar honeycomb structure for supporting a catalyst with a fluid containing a hydrophobic substance, wherein the honeycomb structure for supporting a catalyst (100) comprises the partitions (112) which partition the multiple cells extending from the first end face (104) which is provided with the fluid inlet to the second end face (108) which is provided with the fluid outlet. Manufacturing process for the honeycomb structure for carrying a catalyst (100) according to claim 15, wherein the fluid is in a smoke form. Manufacturing process for a catalyst support honeycomb structure, wherein the manufacturing process comprises bringing into contact at least a part of the partition walls of the honeycomb structure for supporting a catalyst (100) according to one of claims 1 to 13 with a catalyst composition slurry. Manufacturing process for a catalyst support honeycomb structure, wherein the manufacturing process comprises bringing into contact at least the first region (501) and the second region (502) of the partition walls of the honeycomb structure for carrying a catalyst according to one of claims 1 to 13 with a catalyst composition slurry. A manufacturing process for a catalyst support honeycomb structure, wherein the manufacturing process comprises: step 1 of contacting at least the first region (501) and the second region (502) of the partitions (112) of the honeycomb structure for supporting a catalyst (100) according to any one of claims 1 to 13 with a first catalyst composition slurry; step 2 of removing at least a part of the hydrophobic substance adhering to the second region (502) of the partitions (112) of the honeycomb structure for supporting a catalyst (100) after step 1; and step 3 of contacting the first region (501) and the second region (502) of the partitions (112) of the honeycomb structure for supporting a catalyst (100) with a second catalyst composition slurry after step 2. Manufacturing process for a catalyst support honeycomb structure according to claim 19, wherein step 2 is carried out together with a heat treatment which is provided to burn a catalyst component contained in the first catalyst composition slurry onto the partitions (112).

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