Honeycomb structure and method for producing a honeycomb structure

Abstract

A honeycomb structure (114) comprising a plurality of porous honeycomb block bodies (112) connected via connecting material layers A (113), wherein each of the porous honeycomb block bodies (112) comprises a plurality of porous honeycomb segments (110) connected via connecting material layers B (111), wherein each of the porous honeycomb segments (110) comprises: partition walls (116) defining a plurality of cells (115) to form flow paths for a fluid, each of the cells (115) extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall (117) arranged on the outermost periphery of the honeycomb segment (110), wherein at least a portion of the bonding material layers A (113) has a higher load-bearing capacity than that of the bonding material layers B (111), the load-bearing capacity being equal to the deformation volume at fracture minus the deformation volume at the fracture initiation point and being measured in accordance with the four-point flexural strength test method of JIS R1601 2008 “Flexural Strength Test Method for Fine Ceramics at Room Temperature,” and wherein the bonding material layers (A) (113) having a higher load-bearing capacity than that of the bonding material layers (B) (111) are made of a material having a higher load-bearing capacity than that of a material constituting the bonding material layers (B) (111), and the bonding material layers (A) (113) comprise bonding material layers each having a width different from that of each of the bonding material layers (B) (111), and wherein the bonding materials forming the bonding material layers (A) and (B) comprise alumina fibers, and the bonding material forming the bonding material layers (B) comprises a larger amount of alumina fibers than the bonding material forming the bonding material layers (A).

Description

TECHNICAL FIELD

[0001] The present invention relates to a honeycomb structure and a method for producing a honeycomb structure. In particular, the present invention relates to a honeycomb structure with good thermal shock resistance and a method for producing the same. BACKGROUND OF THE INVENTION

[0002] Conventionally, an internal combustion engine is equipped with a diesel particulate filter (DPF) to trap fine particulates contained in the exhaust gas of a diesel engine. In addition, the internal combustion engine may include a gasoline particulate filter (GPF) to trap fine particulates contained in an exhaust gas of a gasoline engine. The DPF and the GPF are formed by bonding a plurality of porous honeycomb segments such as silicon carbide (SiC) by a bonding material and have a structure obtained by grinding an outer periphery of a segment-bonded body with the bonded honeycomb segments to form a honeycomb structure with a suitable shape such as a circle and an ellipse, and then coating the outer peripheral surface with a coating material.

[0003] Patent Document 1 discloses a method for manufacturing a honeycomb structure by bonding a plurality of porous honeycomb segments together by a bonding material to produce a segment-bonded body. In the method for manufacturing the honeycomb structure described in Patent Document 1, as shown in Fig. As shown in Figure 1, a plurality of porous honeycomb segments 10 are stacked along an L-shaped support plate 30 via adhesive layers 20 to obtain a desired stacking structure, and then pressure is applied to the entire structure. This results in the production of a segmented composite body (porous honeycomb block body 40) in which the porous honeycomb segments 10 are stacked vertically and horizontally.

[0004] KR 10 2013 0 009 497 A relates to a porous ceramic filter and discloses a plurality of filter units and a (second) adhesion layer. The filter units comprise a plurality of segments and a first adhesion layer. The first adhesion layer connects the honeycomb segments to one another, and the second adhesion layer connects the honeycomb block bodies to the interconnected honeycomb segments.

[0005] US 2009 / 0 130 378 A1 relates to a honeycomb structure comprising a plurality of honeycomb bodies, a first adhesion layer and a second adhesion layer. CITATION LISTPatent literature

[0006] [Patent literature 1] JP 2004 - 262 670 A SUMMARY OF THE INVENTION

[0007] In recent years, the demand for a filter for collecting particulates such as DPFs and GPFs has increased due to the increase in their size in the field of heavy machinery and the like. Therefore, a large-sized honeycomb structure is manufactured by combining a plurality of the porous honeycomb block bodies 40 as shown in Fig. 1, are further stacked over layers of connecting material.

[0008] However, as the size of the honeycomb structure increases, the temperature difference between the inside and outside of the honeycomb structure increases. Such a temperature difference between the inside and outside of the honeycomb structure creates uneven thermal expansion in the honeycomb structure, which leads to problems such as reduced thermal shock resistance and easy cracking of the honeycomb structure.

[0009] An object of the present invention is to provide a honeycomb structure with good thermal shock resistance and a method for producing the same.

[0010] As a result of intensive research, the present inventors focused on the fact that when a plurality of honeycomb block bodies composed of honeycomb segments are stacked via bonding material layers into a large honeycomb structure serving as a filter, cracks are easily generated at the bonding portions between the honeycomb block bodies near the bonding material layers. Then, the present inventors found that these problems can be solved by providing the bonding material layers for bonding the honeycomb block bodies together with a thermal shock reduction function. The present invention is therefore specified by the appended claims.

[0011] According to the present invention, it is possible to provide a honeycomb structure having good thermal shock resistance and a method for producing the same. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic diagram showing a conventional honeycomb segment and the manner of manufacturing a segmented composite body by joining the honeycomb segments. Fig. 2 is a schematic external view of a porous honeycomb block and a honeycomb structure according to Embodiment 1 of the present invention. Fig. 3 is a schematic external view of a porous honeycomb segment according to Embodiment 1 of the present invention. Fig. 4(a) is a schematic external view of a honeycomb structure according to Embodiment 1 of the present invention, in which an outer circumference is formed into a circular shape by grinding the outer circumference and an outer peripheral surface is coated with a coating material. Fig. 4(b) is a cross-sectional view of a honeycomb structure according to Embodiment 1 of the present invention, which is perpendicular to a direction extending from an inflow end face to an outflow end face, wherein an outer periphery is formed into a circular shape by grinding the outer periphery and an outer peripheral surface is coated with a coating material. Fig. 5 is a schematic external view of a porous honeycomb segment according to Embodiment 1 of the present invention, in which an outer peripheral wall is formed thicker around a grinding edge. Fig. 6 is a schematic external view of a grinding device in which a disc-shaped grindstone is provided at the tip of a rotation axis. Fig. 7 is a schematic external view of a porous honeycomb block body and a honeycomb structure according to Embodiment 2 of the present invention. Fig. 8(a) is a schematic external view of a honeycomb structure according to Embodiment 2 of the present invention, in which an outer circumference is formed into a circular shape by grinding the outer circumference and then an outer circumferential surface is coated with a coating material. Fig. 8(b) is a cross-sectional view of a honeycomb structure according to Embodiment 2 of the present invention, which is perpendicular to a direction extending from an inflow end face to an outflow end face, in which an outer circumference is formed into a circular shape by grinding the outer circumference and then an outer peripheral surface is coated with a coating material. Fig. 9 is a schematic external view of a porous honeycomb block body and a honeycomb structure according to Embodiment 3 of the present disclosure. Fig. 10 (a) is a schematic external view of a honeycomb structure according to Embodiment 3 of the present disclosure, in which an outer circumference is formed into a circular shape by grinding the outer circumference and then an outer peripheral surface is coated with a coating material. Fig. 10(b) is a cross-sectional view of a honeycomb structure according to Embodiment 3 of the present disclosure, which is perpendicular to a direction extending from an inflow end face to an outflow end face, in which an outer circumference is formed into a circular shape by grinding the outer circumference and then an outer circumferential surface is coated with a coating material. Fig. Figure 11 is a schematic diagram showing a state where the “load capacity” is measured in accordance with a four-point flexural strength test method of JIS R1601 2008 “Flexural Strength Test Method for Fine Ceramics at Room Temperature”. Fig. Figure 11(a) is a schematic top plan view of a porous honeycomb segment (sample) arranged in a testing fixture. Fig. 11(b) is a schematic plan view seen from a side surface of the sample set on the test fixture. Fig. Figure 11(c) is a schematic plan view as seen from an end face of the sample on the testing fixture. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of a honeycomb structure and a method for manufacturing the same according to the present invention will be specifically described with reference to the drawings. It should be understood that the present invention is not limited to the following embodiments, and various design changes and improvements can be made based on the ordinary skill of one skilled in the art without departing from the scope of the present invention. (Embodiment 1)[Structure of the honeycomb structure 114]

[0013] Fig. 2 is a schematic external view of a porous honeycomb block body 112 and a honeycomb structure 114 according to Embodiment 1 of the present invention. The honeycomb structure 114 is formed by bonding a plurality of porous honeycomb block bodies 112 via bonding material layers A (113). The porous honeycomb block body 112 is formed by bonding a plurality of porous honeycomb segments 110 via bonding material layers B (111). Fig. 2 shows an embodiment in which a total of four porous honeycomb block bodies 112 are assembled by stacking two porous honeycomb block bodies 112 vertically and horizontally to connect them to each other, although this is not limited to this. For example, three or more porous honeycomb block bodies 112 may be stacked vertically and horizontally to connect them, and a different number of porous honeycomb block bodies may be stacked vertically and horizontally to connect them, respectively, instead of the same number. Thus, the honeycomb structure 114 having a desired size can be suitably manufactured using the porous honeycomb block bodies 112.

[0014] As in Fig. As shown in Figure 3, the porous honeycomb segment 110 includes: partition walls 116 defining a plurality of cells 115 to form flow paths for a fluid extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall 117 located at the outermost periphery. The partition walls 116 and the outer peripheral wall 117 are preferably formed from porous bodies made of SiC (silicon carbide), although they are not limited thereto. They may be formed from cordierite, mullite, alumina, aluminum titanate, silicon nitride, and cordierite-silicon carbide composite material, lithium aluminum silicate, metallic silicon, or a mixture thereof.

[0015] The honeycomb structure 114 according to Embodiment 1 of the present invention has a structure with closed portions for purifying fine particulates (carbon fine particulates and the like) in an exhaust gas, so that it can be used as a fine particulate collection filter such as a diesel engine particulate filter (DPF) and a gasoline engine particulate filter (GPF). Fig. 4(a) shows a schematic external view of the honeycomb structure 114 in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer peripheral surface is coated with a coating material 119. Fig. 4(b) shows a cross-sectional view of the honeycomb structure 114 perpendicular to a direction extending from the inflow end face to the outflow end face in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer circumferential surface is coated with the coating material 119.

[0016] At least a part of the bonding material layers A (113) for bonding the plurality of porous honeycomb block bodies 112 has a higher load-bearing capacity than that of the bonding material layers B (111) for bonding the plurality of porous honeycomb segments 110. As used herein, the "load-bearing capacity" means a toughness / load-bearing capacity of a material and is represented by the following equation (1): Load capacity = permissible bending strain = deformation volume at fracture − deformation volume at the fracture starting point (1)

[0017] The load-bearing capacity can be measured in accordance with the four-point flexural strength test method of JIS R1601 2008 “Flexural Strength Test Method for Fine Ceramics at Room Temperature”. Fig. Figure 11 is a schematic diagram showing a state in which the “load capacity” is measured in accordance with the four-point bending strength test method. Fig. 11(a) is a schematic top plan view of a porous honeycomb segment (sample) connected by the bonding material layers and arranged in a testing device. Fig. Figure 11(b) is a schematic plan view seen from a side surface of the sample. Fig. Figure 11(c) is a schematic plan view as seen from the end face of the sample on the testing fixture.

[0018] As in Fig. As shown in Figure 11, the specimen has a rectangular, columnar cross-section, and the specimen is placed on the testing fixture so that the direction of cell expansion is the thickness direction. The specimen has a thickness of 12 mm, a full length of 50 mm, and a width of 16 mm. The specimen is prepared so that the bonding layer can be positioned in the center in the full longitudinal direction.

[0019] The distance between the test fixture for arranging the specimen and the support points corresponds to the name of the test fixture: 4p-40 / 20, bending method: four-point bending method, distance between outer support points: 40 ± 0.1 mm, distance between inner support points: 20 ± 0.1 mm, as described in Table 1 - Bending method, specimen, test fixture and distance between support points of JIS R1601 2008.

[0020] The resilience of the bonding material layer is measured by attaching a load cell to a crosshead and placing it on the test fixture. Force and displacement are measured during the four-point flexural strength test method as described above to obtain a stress-strain curve (SS curve). In the above equation (1), "at failure" refers to a point where the stress in the stress-strain curve becomes zero, and the "break point" refers to a yield point in the stress-strain curve.

[0021] The larger honeycomb structure 114 leads to an increase in the temperature difference between the inside and outside of the honeycomb structure 114, which may cause thermal expansion in the honeycomb structure 114 to become uneven. To address such a problem, in the honeycomb structure 114 according to Embodiment 1 of the present invention, at least a portion of the joining material layers A (113) for joining the plurality of porous honeycomb block bodies 112 has a higher load-bearing capacity than the joining material layers B (111) for joining the plurality of porous honeycomb segments 110, so that thermal shock caused by uneven thermal expansion between the plurality of porous honeycomb block bodies 112 can be reduced.That is, even if a difference in thermal expansion occurs between the plurality of porous honeycomb block bodies 112, the joining material layers A (113) joining the porous honeycomb block bodies 112 absorb the difference in thermal expansion due to their higher load-bearing capacity, so that the thermal shock generated between the plurality of porous honeycomb block bodies 112 can be reduced and cracking at the relevant locations can be satisfactorily suppressed.

[0022] In the joining material layers A (113) for joining the plurality of porous honeycomb block bodies 112, a portion having a higher strength than that of the joining material layers B (111) for joining the plurality of porous honeycomb segments 110 can reduce the thermal shock generated between the plurality of porous honeycomb block bodies 112, even if this portion is a part of the joining material layers A described above. In particular, it is preferable to supply the joining material layers A (113) having a higher strength than that of the joining material layers B (111) to a region where cracks are likely to form due to thermal shock.For example, in a cross section perpendicular to the extending direction of the cells 115 of the honeycomb structure 114 in which the plurality of porous honeycomb block bodies 112 are vertically and horizontally stacked and connected, a transverse portion located at the vertical center and the horizontal center where cracks tend to occur is preferably the joining material layer A (113) having higher load-bearing capacity than that of the joining material layers B (111). Fig. 2 and Fig. 4 show the honeycomb structure 114 in which the connecting material layer A (113) is located at such a transverse section.

[0023] Furthermore, all the joining material layers A (113) for joining the plurality of porous honeycomb block bodies 112 preferably have a higher load-bearing capacity than the joining material layers B (111) for joining the plurality of porous honeycomb segments 110. Such a structure results in the joining material layers A (113) having a higher load-bearing capacity at all joined portions of the plurality of porous honeycomb block bodies 112 that would otherwise be prone to cracking, so that the impact resistance is improved.

[0024] In the honeycomb structure 114 according to Embodiment 1 of the present invention, the joining material layers A (113) are formed of the joining material layers having a greater width than that of the joining material layers B (111), as shown in Fig. 2 and Fig. 4. In such a structure, the bonding material layers A (113) connecting the plurality of porous honeycomb block bodies 112 have a higher load-bearing capacity than that of the bonding material layers B (111).

[0025] The width of each bonding material layer A (113) for bonding the plurality of porous honeycomb block bodies 112 may be larger than that of each bonding material layer B (111) for bonding the plurality of porous honeycomb segments 110. The width of each bonding material layer A (113) may be different from that of each bonding material layer B (111). The widths of the bonding material layers A (113) and the bonding material layers B (111) can be adjusted as needed, depending on the size of the honeycomb structure 114, the materials of the bonding material layers A (113) and the bonding material layers B (111), or the desired thermal shock resistance.For example, the width of each joining material layer A (113) for joining the plurality of porous honeycomb block bodies 112 may be a varying width in a range of 0.5 to 2.0 times the width of each joining material layer B (111) for joining the plurality of porous honeycomb segments 110.

[0026] The width of each joining material layer is a value determined by measuring a width of the joining material layer connecting the centers of one side of the segment end face using a magnifying glass with a scale or image processing measurement for the joining material layer, which can be confirmed from the end face after the porous honeycomb segments 110 are joined together. A value obtained by averaging the widths of all joining material layers of the porous honeycomb block body 112 is defined as the width of the joining material layer B (111), and the width of the joining material layer A (113) can be a varying width in a range of 0.5 to 2.0 times.

[0027] The bonding material layers B (111) and the bonding material layers A (113) are not particularly limited as long as they can bond the surfaces of the outer peripheral walls 117 to each other with good adhesive strength. The bonding materials constituting the bonding material layers B (111) and the bonding material layers A (113) may contain, for example, inorganic particles, as well as inorganic fibers and colloidal oxides as other components. Further, when bonding the porous honeycomb segments 110 and the plurality of porous honeycomb block bodies 112, in addition to these components, an organic binder such as methyl cellulose and carboxymethyl cellulose, a dispersant, water, and the like may be optionally added and mixed and kneaded with a kneader such as a mixer into a paste that can be used as a bonding material.

[0028] Examples of materials for forming the inorganic particles contained in the joining materials constituting the joining material layers B (111) and the joining material layers A (113) include ceramics selected from the group consisting of silicon carbide, silicon nitride, cordierite, alumina, mullite, zirconia, zirconium phosphate, aluminum titanate, titanium oxide, and combinations thereof, Fe-Cr-Al based metals, nickel based metals, silicon-silicon carbide based composite materials, and the like.

[0029] Examples of the inorganic fibers included in the bonding materials constituting bonding material layers B (111) and bonding material layers A (113) include ceramic fibers such as aluminum silicate and silicon carbide, and metal fibers such as copper and iron. Suitable colloidal oxides include silica sol, alumina sol, and the like. The colloidal oxides are suitable for imparting appropriate adhesive strength to the bonding material and can also be bonded to the inorganic fibers and inorganic particles by drying and degreasing them to provide a strong bonding material with improved heat resistance after drying.

[0030] It is preferable that each of the plurality of porous honeycomb block bodies 112 includes the same number of porous honeycomb segments 110 as each other. Such a structure results in each of the plurality of porous honeycomb block bodies 112 having the same size, so that the widths of the bonding material layers A (113) for bonding the plurality of porous honeycomb block bodies 112 can be uniform overall, thereby achieving good thermal shock resistance. Furthermore, since the porous honeycomb block bodies 112 can be manufactured with the same size, production efficiency is improved.

[0031] In the honeycomb structure 114, the plurality of porous honeycomb block bodies 112 are formed by connecting the same number of porous honeycomb block bodies 112 in the vertical and horizontal directions. According to such a structure, when the outer circumference is ground and formed into a circular shape, the amount of grinding and removal is reduced, and production efficiency is improved, as shown in Fig. 4 shown.

[0032] For the honeycomb structure 114, a catalyst may further be provided on the surfaces or inside of the partition walls 116 defining the plurality of cells 115. The type of catalyst is not particularly limited and can be appropriately selected depending on the intended use and application of the honeycomb structure 114. Examples of the catalyst include noble metal catalysts or other catalysts. Examples of noble metal catalysts include a three-way catalyst and an oxidation catalyst obtained by supporting a noble metal such as platinum (Pt), palladium (Pd), and rhodium (Rh) on surfaces of alumina pores and containing a co-catalyst such as cerium oxide and zirconium oxide, or a lean nitrogen oxide trapping catalyst (LNT catalyst) that uses an alkaline earth metal and platinum as storage components for nitrogen oxides (NO x). Examples of a catalyst that does not use the noble metal include a NOx selective reduction catalyst (SCR catalyst) containing a copper-substituted or iron-substituted zeolite, and the like. Furthermore, two or more catalysts from the group of these catalysts may be used. The method for supporting the catalyst is not particularly limited and can be carried out according to a conventional method for supporting the catalyst on the honeycomb structure 114. [Method for producing the honeycomb structure 114]

[0033] An example of a method for manufacturing the honeycomb structure 114 according to Embodiment 1 of the present invention will now be described.

[0034] First, the porous honeycomb segments 110, as shown in Fig. 3. As a manufacturing step of the porous honeycomb segments 110, a binder, a dispersant (surfactant), a pore-forming agent, water, and the like are first added to a ceramic raw material made of a SiC material, and these are mixed and kneaded to produce a green body. SiC material refers to a material based primarily on SiC (silicon carbide), including, for example, a material consisting solely of SiC, such as recrystallized SiC, Si-SiC-based composite materials, cordierite-SiC-based composite materials, metallic silicon-impregnated SiC, and the like.

[0035] The prepared green body is then formed into a honeycomb shape by an extrusion molding process to obtain a raw (unfired) columnar honeycomb body. The columnar honeycomb body extruded from an extruder is cut into a suitable length. The extrusion molding process can be performed using a device such as a ram extruder and a continuous biaxial screw extruder. For forming the honeycomb shape, a method using a die with a desired cell shape, partition wall thickness, and cell density is preferred. In this way, the porous honeycomb segment 110, which is the unfired honeycomb body, is manufactured.

[0036] The outer shape of each porous honeycomb segment 110 is not particularly limited and may be a columnar shape having rectangular end faces as in the present embodiment, or a columnar shape having circular end faces (circular columnar shape), or a columnar shape having polygonal (triangular, pentagonal, hexagonal, heptagonal, octagonal, etc.) end faces, excluding rectangular end faces.

[0037] Subsequently, the porous honeycomb segments 110 are dried. Drying can be performed by dielectric drying using high-frequency energy generated by passing a current through the porous honeycomb segments 110, or by hot air drying in which hot air is introduced into the porous honeycomb segments 110. Further, natural drying at room temperature, microwave drying using a microwave, freeze drying, or the like, or a combination of several drying methods can be performed. Subsequently, the porous honeycomb segments 110 are fired. In this case, plugged portions are formed in segments by sintering a plugging material on both end surfaces of the porous honeycomb segment 110 to purify fine particles (carbon fine particles, etc.) in the exhaust gas. The plugged portion is provided on each cell 115 at both end surfaces of the porous honeycomb segment 110.For a cell 115 that has the sealed portion at one end face, no sealed portion is provided at the other end face. On the other hand, if the sealed portion is not provided at the other end face of the cell 115, the sealed portion is provided at one end face. Such sealed portions can provide a filtering function.

[0038] The fired porous honeycomb segment 110 is then ground along four sides of the outer peripheral wall 117, optionally using a grinding device, so that the outer shape of the porous honeycomb segment 110 has a predetermined shape. By grinding and removing the outer peripheral wall 117, for example, the outer shapes can be made uniform among the plurality of porous honeycomb segments 110.

[0039] The bonding material is then applied to each of the plurality of porous honeycomb segments 110 between the bonding surfaces to bond them via the bonding material layers B (111). In the bonding step, a plurality of porous honeycomb segments 110 can be bonded along an L-shaped support plate via the bonding material layers B (111) using the method described in Fig. 1 to form a desired stacked structure, and then pressure is applied to the entire structure to bond them together. In this way, the porous honeycomb block body 112 is formed, in which the plurality of porous honeycomb segments 110 are arranged as shown in Fig. 2, are connected.

[0040] The bonding material is then applied to each of the plurality of porous honeycomb block bodies 112 between the bonding surfaces to bond them via the bonding material layers A (113). In the bonding step, the plurality of porous honeycomb block bodies 112 can be bonded along an L-shaped support plate via the bonding material layers A (113) using the Fig. 1 to form a desired stacked structure, and then pressure is applied to the entire structure to bond them together. In this way, the porous honeycomb structure 114 is formed, in which the plurality of porous honeycomb block bodies 112 are arranged as shown in Fig. 2. In this case, the honeycomb structure 114 is formed so that at least a part of the connecting material layers A (113) has a higher load-bearing capacity than the connecting material layers B. In Embodiment 1 of the present invention, as shown in Fig. 2 and Fig. As shown in Fig. 4, the joining material layers A (113) for joining the plurality of porous honeycomb block bodies 112 are formed to have a different width than the joining material layers B (111) for joining the plurality of porous honeycomb segments 110, thereby achieving higher load-bearing capacity than that of the joining material layers B (111). In Embodiment 1 of the present invention, the joining material layers A (113) are made of a different material than the joining material layers B (111), with a change in the width of the joining material layers B (111), thereby providing the joining material layers with higher load-bearing capacity than that of the joining material layers B (111).

[0041] For the honeycomb structure 114 thus manufactured, the outer circumference may be ground and formed into a suitable shape such as a circle or an ellipse, and the outer circumference may be coated with a coating material.

[0042] Furthermore, in the step of manufacturing the porous honeycomb block body 112, at least the outer peripheral wall 117 of the porous honeycomb segment 110, which forms the outer peripheral wall of the porous honeycomb block body 112, may be made thicker by a grinding edge 118. Furthermore, the bonding material may be applied to at least the outer peripheral wall 117 of the porous honeycomb segment 110, which forms the outer peripheral wall of the porous honeycomb block body 112, and dried to have a thickness thicker by the grinding edge 118. Fig. 5 is a schematic external view of the porous honeycomb segment 110, in which the outer peripheral wall 117 is thickened by the grinding edge 118. After the grinding edge 118 of the outer peripheral wall 117 of the porous honeycomb segment 110, which forms the outer peripheral wall of the thus-formed porous honeycomb block body 112, is ground and removed, a plurality of the porous honeycomb block bodies 112 can be bonded via the bonding material layers A (113) to form the honeycomb structure 114.

[0043] In the step of manufacturing the porous honeycomb segments 110, each porous honeycomb segment 110 having the abrasive rim 118 in the outer peripheral wall 117 can be manufactured by adding a binder, a dispersant (surfactant), a pore-forming agent, water, and the like to a ceramic raw material made of a SiC material, mixing and kneading them to produce a green body, which is then formed by an extrusion molding process. The porous honeycomb segments 110, each having the outer peripheral wall 117 with the abrasive rim 118, can be manufactured by such an extrusion molding process, or they can be manufactured by producing columnar honeycomb molded bodies by extrusion molding and then forming the outer peripheral wall 117 to be thicker around the abrasive rim 118.

[0044] The porous honeycomb segments 110 each having the grinding edge 118 in the outer peripheral wall 117 are dried and fired, and the grinding edges 118 formed on each of the four side surfaces of the outer peripheral wall 117 are ground and removed, for example, along straight lines indicated by dashed lines ab, as shown in Fig. 5. The grinding edge 118 is thus removed to produce the porous honeycomb segments 110, as shown in Fig. 3 shown. Although Fig. 5 shows an example in which the grinding edge 118 is formed on all four side surfaces of the outer peripheral wall 117 of the porous honeycomb segment 110, the present invention is not limited to this, and the grinding edge 118 may be formed only on the side surface of a part of the outer peripheral wall 117 of the porous honeycomb segment 110, for example, only on the side surface of the outer peripheral wall 117 of the porous honeycomb segment 110 that is located at the outermost periphery when the porous honeycomb block body 112 is formed.

[0045] The grinding edge 118 can be ground and removed with a grinding device. For example, as in Fig. 7, a grinding apparatus having a structure in which a disc-shaped grindstone 141 is provided at the tip of a rotation axis 140 may be used. According to the grinding apparatus, the grinding edges 118 formed respectively on the four side surfaces of the outer peripheral wall 117 of the fired porous honeycomb segment 110 can be gradually ground and removed by bringing the grindstone 114 into contact with the grinding edges 118 while rotating the grindstone 141 at high speed by a rotary drive from the rotation axis 140.

[0046] The grindstone 141 preferably has a grain size in a range of #80 to #120. By grinding the outer peripheral wall 117 using the grindstone 141 with a grain size in a range of #80 to #120, the surface roughness of the outer peripheral wall 117 after grinding and removing the grinding edge 118 is reduced, resulting in easier and more uniform machining. Therefore, in the joining step of the plurality of porous honeycomb segments 110 described later, the plurality of porous honeycomb segments 110 can be joined with smaller variations in the outer shapes.

[0047] When grinding and removing the grinding edge 118 of the outer peripheral wall 117 of the porous honeycomb segment 110, it is preferable to provide another step of grinding and removing the grinding edge 118 of the outer peripheral wall 117 of a part of the porous honeycomb segment 110, and then rotating the porous honeycomb segment 110 in a direction parallel to a direction connecting the inflow end face and the outflow end face as a direction of the rotation axis to grind and remove the grinding edge of the outer peripheral wall 117 of the other part of the porous honeycomb segment 110.Specifically, the grinding edge 118 is preferably ground and removed by attaching the porous honeycomb segment 110 such that the side surface of the segment is parallel to the direction connecting the inflow end face to the outflow end face, parallel to a flat portion of the rotating grindstone, and by bringing the grindstone 141 into contact with the porous honeycomb segment for only a fraction of the grinding edge 118. Furthermore, the porous honeycomb segment 110 is preferably ground by rotating it at a specific angle.For example, when the porous honeycomb segment 110 is a rectangular parallelepiped segment, the grinding edge can be ground by rotating the porous honeycomb segment 110 90 degrees at the end of grinding an upper surface of the porous honeycomb segment 110 using a machining center to grind the four sides, and arranging the porous honeycomb segment 110 so that an unmachined surface is the upper surface. With such a configuration, the movement of the grinding device becomes efficient, for example, when the length of the porous honeycomb segment 110 in the cell extension direction is longer, so that the grinding efficiency is improved.

[0048] The thickness of the grinding edge 118 of the porous honeycomb segment 110 after firing is preferably 20 to 80% of the thickness of the outer peripheral wall 117 before the grinding edge 118 is ground and removed. If the thickness of the grinding edge 118 is less than 20% of the thickness of the outer peripheral wall 117 before the grinding edge 118 is ground and removed, the deformation volume of the outer shape of the segment generated during firing cannot be absorbed, resulting in the problem that the outer shape of the segment may not be uniform. Furthermore, if the thickness of the grinding edge 118 is more than 80% of the thickness of the outer peripheral wall 117 before the grinding edge 118 is ground and removed, and the grinding process exceeds the thickness of the outer peripheral wall 117, a collecting part of the filter may be ground to uniform the inside of the cells, resulting in a problem that a product function (filtering performance) is reduced.The thickness of the grinding edge 118 of the porous honeycomb segment 110 after firing is preferably 30 to 70%, and more preferably 40 to 60%, of the thickness of the outer peripheral wall 117 before the grinding edge 118 is ground and removed. Although the optimal value of the thickness of the grinding edge 118 varies depending on the structure of the porous honeycomb segment 110, a greater length in the cell expansion direction tends to increase the deformation of the mold during firing. Therefore, it is preferable to increase the thickness of the grinding edge 118.

[0049] When grinding the grinding edge 118 of the porous honeycomb segment 110, it is preferable to perform the grinding so that the outer shape of the plurality of porous honeycomb segments 110 becomes uniform after grinding. The uniform outer shape of the plurality of porous honeycomb segments 110 after grinding can lead to uniformity in the thickness of the bonding layers when bonding the porous honeycomb segments 110.

[0050] The plurality of porous honeycomb segments 110, from which the grinding edges 118 have been ground and removed, can then be assembled to form the porous honeycomb block body 112, as described above. Furthermore, a plurality of the porous honeycomb block bodies 112 can be assembled to form the honeycomb structure 114, as described above.

[0051] Since the grinding edge 118 of each porous honeycomb segment 110 has been ground and removed, the outer walls 117 of the respective porous honeycomb segments 110 have uniform surface properties in the bonding step, so that variation in the outer shapes of the honeycomb segments 110 is suppressed. Therefore, in the porous honeycomb block body 112 formed by bonding the plurality of porous honeycomb segments 110, the variation in the widths of the bonding material layers B (111) used for bonding is suppressed, and the generation of displacement of the adjacently arranged porous honeycomb segments 110 is suppressed. Therefore, the porous honeycomb block bodies 112 and the honeycomb structure 114 using them have constant thermal stress transfer and suppress the problem of reducing the thermal shock resistance characteristic of the particulate filter such as DPF or GPF.Furthermore, a problem that must be addressed by reducing the production efficiency in order to improve the variation of the outer shapes of the honeycomb segments as in the prior art is eliminated, so that the production efficiency of the honeycomb structure 114 is improved. (Embodiment 2)[Structure of the honeycomb structure 124]

[0052] Fig. 7 is a schematic external view of a porous honeycomb block body 122 and a honeycomb structure 124 according to Embodiment 2 of the present invention. The honeycomb structure 124 is formed by bonding a plurality of porous honeycomb block bodies 122 via bonding material layers A (123). The porous honeycomb block body 122 is formed by bonding a plurality of porous honeycomb segments 120 via bonding material layers B (121). Fig. 7 shows an embodiment in which a total of four porous honeycomb block bodies 122 are assembled by stacking two porous honeycomb block bodies 122 vertically and horizontally to connect them to each other, although this is not limited to this. For example, three or more porous honeycomb block bodies 122 may be stacked vertically and horizontally to connect them, and a different number of porous honeycomb block bodies may be stacked vertically and horizontally to connect them instead of the same number. Thus, the honeycomb structure 124 having a desired size can be suitably manufactured using the porous honeycomb block bodies 122.

[0053] As in Embodiment 1 using Fig. 3, the porous honeycomb segment 120 includes: partition walls defining a plurality of cells to form flow paths for a fluid, extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall located at the outermost periphery. The partition walls and the outer peripheral wall are preferably formed from porous bodies made of SiC (silicon carbide), although they are not limited thereto. They may be formed from cordierite, mullite, alumina, aluminum titanate, silicon nitride, and cordierite-silicon carbide composite material, lithium aluminum silicate, metallic silicon, or a mixture thereof.

[0054] The honeycomb structure 124 according to Embodiment 2 of the present invention has a structure with closed portions for purifying fine particulates (carbon fine particulates and the like) in an exhaust gas, so that it can be used as a fine particulate collection filter such as a diesel engine particulate filter (DPF) and a gasoline engine particulate filter (GPF). Fig. 8(a) shows a schematic external view of the honeycomb structure 124 in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer peripheral surface is coated with a coating material 129. Fig. 8(b) shows a cross-sectional view of the honeycomb structure 124 perpendicular to a direction extending from the inflow end face to the outflow end face, in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer peripheral surface is coated with the coating material 129.

[0055] At least a portion of the bonding material layers A (123) for bonding the plurality of porous honeycomb block bodies 122 has a higher load-bearing capacity than that of the bonding material layers B (121) for bonding the plurality of porous honeycomb segments 120. Therefore, thermal shock caused by uneven thermal expansion between the plurality of porous honeycomb block bodies 122 can be reduced. That is, even if a difference in thermal expansion occurs between the plurality of porous honeycomb block bodies 122, the bonding material layers A (123) bonding the porous honeycomb block bodies 122 absorb the difference in thermal expansion due to their higher load-bearing capacity, so that the thermal shock generated between the plurality of porous honeycomb block bodies 122 can be reduced, and cracking at the relevant locations can be satisfactorily suppressed.

[0056] In the honeycomb structure 124 according to Embodiment 2 of the present invention, the joining material layers A (123) for joining the plurality of porous honeycomb block bodies 122 are made of a material having higher load-bearing capacity than the joining material layers B (121) for joining the plurality of porous honeycomb segments 120.

[0057] The bonding material layers B (111) are not particularly limited as long as they can bond the outer peripheral wall surfaces of the porous honeycomb segments 120 together with good bonding strength. The bonding material constituting the bonding material layers B (121) may contain, for example, inorganic particles, as well as inorganic fibers and colloidal oxides as other components. Furthermore, during bonding of the porous honeycomb segments 120, in addition to these components, an organic binder such as methyl cellulose and carboxymethyl cellulose, a dispersant, water, and the like may optionally be added, and mixed and kneaded with a kneader such as a mixer to form a paste that can be used as a bonding material.

[0058] Examples of materials for forming the inorganic particles contained in the joining material forming the joining material layers B (121) include ceramics selected from the group consisting of silicon carbide, silicon nitride, cordierite, alumina, mullite, zirconia, zirconium phosphate, aluminum titanate, titanium oxide and combinations thereof, Fe-Cr-Al based metals, nickel based metals, silicon-silicon carbide based composite materials and the like.

[0059] Examples of the inorganic fibers contained in the bonding materials forming bonding material layers B (121) include ceramic fibers such as aluminosilicate and silicon carbide, and metal fibers such as copper and iron. Suitable colloidal oxides include silica sol, alumina sol, and the like. The colloidal oxides are suitable for imparting appropriate adhesive strength to the bonding material and can also be bonded to the inorganic fibers and inorganic particles by drying and degreasing them to obtain a strong bonding material with improved heat resistance after drying.

[0060] The joining material layers A (123) are not particularly limited as long as they are made of a material with higher load-bearing capacity than the joining material layers B (121), and the surfaces of the outer peripheral walls of the porous honeycomb block bodies 122 made of SiC material can be joined with good bonding strength, and the joining material constituting the joining material layers B (121) comprises a joining material having a higher density (amount) of alumina fibers than that of the joining material constituting the joining material layers A (123). Furthermore, a joining material having alumina fibers of different lengths may be used.Furthermore, the bonding material layers A (123) may be formed by changing the ratio of the respective components contained in the bonding material constituting the bonding material layers A (123), or by adding a material other than the alumina fibers to increase the load-bearing capacity, or by replacing the alumina fibers with this material.

[0061] In the honeycomb structure 124 according to Embodiment 2 of the present invention, a portion of the joining material layers A (123) may be made of the material having higher load-bearing capacity than that of the joining material layers B (121), but all of the joining material layers A (123) are preferably made of this material. Such a structure results in the joining material layers A (123) having higher load-bearing capacity at all joined portions of the plurality of porous honeycomb block bodies 122, which would otherwise be prone to cracking, thus improving impact resistance.

[0062] In the honeycomb structure 124 according to Embodiment 2 of the present invention, it is preferable that the plurality of porous honeycomb block bodies 122 include the same number of porous honeycomb segments 120 as each other. Such a structure results in the plurality of porous honeycomb block bodies 122 having the same size, so that the widths of the joining material layers A (123) for joining the plurality of porous honeycomb block bodies 122 can be uniformly provided as a whole, thereby achieving good thermal shock resistance. In addition, since the porous honeycomb block bodies 122 can be manufactured with the same size, production efficiency is improved.

[0063] In the honeycomb structure 124, the plurality of porous honeycomb block bodies 122 are formed by connecting the same number of porous honeycomb block bodies 122 in the vertical and horizontal directions. According to such a structure, when the outer circumference is ground and formed into a circular shape, the amount of grinding and removal is reduced, and production efficiency is improved, as shown in Fig. 8 shown.

[0064] As with the honeycomb structure 114 according to Embodiment 1, the honeycomb structure 124 according to Embodiment 2 may further include noble metal-based catalysts or catalysts other than these provided on the surfaces or insides of the partition walls defining a plurality of cells. [Method for producing honeycomb structure 124]

[0065] The method for manufacturing the honeycomb structure 124 according to Embodiment 2 of the present invention can be carried out in the same manner as the method for manufacturing the honeycomb structure 114 according to Embodiment 1. That is, first, the porous honeycomb segments 120 can be prepared, and the joining material can then be applied to each of the plurality of porous honeycomb segments 120 between the joining surfaces to join them via the joining material layers B (121) to produce the porous honeycomb block body 122. The joining material can then be applied to each of a plurality of porous honeycomb block bodies 122 between the joining surfaces to join them via the joining material layer A (123) to produce the honeycomb structure 124 with the joined porous honeycomb block bodies 122, as shown in Fig. 7. At least a part of the joining material layers A (123) is formed to have a higher load-bearing capacity than that of the joining material layers B. In Embodiment 2 of the present invention, the joining material layers A (123) for joining the plurality of porous honeycomb block bodies 122 have a higher load-bearing capacity than that of the joining material layers B (121) for joining the plurality of porous honeycomb segments 120, thereby achieving a higher load-bearing capacity than that of the joining material layers B (121).

[0066] For the honeycomb structure 124 thus manufactured, the outer circumference may be ground and formed into a suitable shape such as a circle or an ellipse, and the outer circumference may be coated with a coating material.

[0067] Furthermore, in the step of manufacturing the porous honeycomb block bodies 122, as shown in the method for manufacturing the honeycomb structure 114 according to Embodiment 1 of the present invention, at least the outer peripheral wall of the porous honeycomb segment 120, which forms the outer peripheral wall of the porous honeycomb block body 122, may be ground thicker by a grinding edge, and the grinding edge may be removed before bonding. Furthermore, at least the outer peripheral wall of the porous honeycomb segment 120, which forms the outer peripheral wall of the porous honeycomb block body 122, may be coated with the bonding material and dried to make it thicker by the grinding edge, and the grinding edge may be removed. (Embodiment 3)[Structure of the honeycomb structure 134]

[0068] Fig. 9 is a schematic external view of a porous honeycomb block body 132 and a honeycomb structure 134 according to Embodiment 3 of the present disclosure. The honeycomb structure 134 is formed by joining a plurality of porous honeycomb block bodies 132 via joining material layers A (133). The porous honeycomb block body 132 is formed by joining a plurality of porous honeycomb segments 130 via joining material layers B (131). Fig. 9 shows an embodiment in which a total of four porous honeycomb block bodies 132 are assembled by stacking two porous honeycomb block bodies 132 vertically and horizontally to connect them to each other, although this is not limited to this. For example, three or more porous honeycomb bodies 132 may be stacked vertically and horizontally to connect them to each other, and a different number of porous honeycomb bodies 132 may be stacked vertically and horizontally to connect them to each other instead of the same number. Thus, the honeycomb structure 134 having a desired size can be suitably manufactured using the porous honeycomb block bodies 132.

[0069] As in Embodiment 1 using Fig. 3, the porous honeycomb segment 130 includes: partition walls defining a plurality of cells to form flow paths for a fluid, extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall located at the outermost periphery. The partition walls and the outer peripheral wall are preferably formed from porous bodies made of SiC (silicon carbide), although they are not limited thereto. They may be formed from cordierite, mullite, alumina, aluminum titanate, silicon nitride, and cordierite-silicon carbide composite material, lithium aluminum silicate, metallic silicon, or a mixture thereof.

[0070] The honeycomb structure 134 according to Embodiment 3 of the present disclosure has a structure with closed portions for purifying fine particulates (carbon fine particulates and the like) in an exhaust gas, so that it can be used as a fine particulate collection filter such as a diesel engine particulate filter (DPF) and a gasoline engine particulate filter (GPF). Fig. 10(a) shows a schematic external view of the honeycomb structure 134 in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer peripheral surface is coated with a coating material 139. Fig. 10(b) shows a cross-sectional view of the honeycomb structure 134 perpendicular to a direction extending from the inflow end face to the outflow end face in a state where the outer circumference is formed into a circular shape by grinding the outer circumference and the outer peripheral surface is coated with the coating material 139.

[0071] The connecting material layers A (133) for connecting the plurality of porous honeycomb block bodies 132 are made of the same material as the connecting material layers B (131) for connecting the plurality of porous honeycomb segments 130 and are formed by connecting material layers, at least a part of which is missing. Fig. 9, for example, the joining material having a predetermined width is provided on four sides on the side surface of the porous honeycomb block body 132 to form the joining material layers A (133), each having a rectangular cutout 136 in the center. Therefore, thermal shock caused by uneven thermal expansion among the plurality of porous honeycomb block bodies 132 can be reduced. That is, even if a difference in thermal expansion occurs among the plurality of porous honeycomb block bodies 132, the joining material layers A (133) for joining the porous honeycomb block bodies 132 have the cutout portions 136, so the cutouts 136 can reduce the thermal expansion.Therefore, the joining material layers A (133) having the cutouts 136 will absorb the difference in thermal expansion, and as a result, the thermal shock generated between the plurality of porous honeycomb block bodies 132 is reduced, so that cracking can be satisfactorily suppressed.

[0072] The size, depth, shape, position, and the like of the cutout 136 of the joining material layers A (133) are not particularly limited and can be adjusted as needed depending on the size of the honeycomb structure 134, the materials of the joining material layers A (133) and the joining material layers B (131), or the desired thermal shock resistance. Furthermore, the cutouts 136 may not be provided in all the joining material layers A (133) between the plurality of porous honeycomb block bodies 132, but they are preferably provided in a region where cracks may occur due to thermal shock.For example, in a cross section of the honeycomb structure 134 in which the plurality of porous honeycomb block bodies 132 are stacked and connected vertically and horizontally, the connecting material layers B (131) having the cutouts 136 are preferably provided in a cross-sectional portion located at the vertical center and the horizontal center where cracks may occur. Fig. 9 and Fig. 10 shows the honeycomb structure 134 in which the joining material layer A (133) is arranged with the cutouts 136 in such a transverse section. Furthermore, the cutouts 136 are preferably provided in all the joining material layers A (133) between the plurality of porous honeycomb block bodies 132 to improve the overall thermal shock resistance of the honeycomb structure 134. Furthermore, to improve the overall thermal shock resistance of the honeycomb structure 134, the cutouts 136 are preferably provided in the same size, depth, shape, and position in the joining material layers A (133) between the plurality of porous honeycomb block bodies 132. Furthermore, it is preferable that the cutouts 136 be provided at central portions of the joining material layers B (131).

[0073] The bonding material layers A (133) and the bonding material layers B (131) are not particularly limited as long as they can bond the outer peripheral wall surfaces of the porous honeycomb segments 130 with good bonding strength. The bonding material constituting the bonding material layers B (131) may contain, for example, inorganic particles, as well as inorganic fibers and colloidal oxides as other components. Furthermore, during bonding of the porous honeycomb segments 130, in addition to these components, an organic binder such as methyl cellulose and carboxymethyl cellulose, a dispersant, water, and the like may optionally be added, and mixed and kneaded with a kneader such as a mixer to form a paste that can be used as a bonding material.

[0074] Examples of materials for forming the inorganic particles contained in the joining materials constituting the joining material layers A (133) and the joining material layers B (131) include ceramics selected from the group consisting of silicon carbide, silicon nitride, cordierite, alumina, mullite, zirconia, zirconium phosphate, aluminum titanate, titanium oxide, and combinations thereof, Fe-Cr-Al based metals, nickel based metals, silicon-silicon carbide based composite materials, and the like.

[0075] Examples of the inorganic fibers contained in the bonding materials constituting bonding material layers A (133) and bonding material layers B (131) include ceramic fibers such as aluminum silicate and silicon carbide, and metal fibers such as copper and iron. Suitable colloidal oxides include silica sol, alumina sol, and the like. The colloidal oxides are suitable for imparting appropriate adhesive strength to the bonding material and can also be bonded to the inorganic fibers and inorganic particles by drying and degreasing them to obtain a strong bonding material with improved heat resistance after drying.

[0076] In the honeycomb structure 134 according to Embodiment 3 of the present disclosure, it is preferable that the plurality of porous honeycomb block bodies 132 include the same number of porous honeycomb segments 130 as each other. Such a structure results in the plurality of porous honeycomb block bodies 132 having the same size, so that the widths of the joining material layers A (133) for joining the plurality of porous honeycomb block bodies 132 can be uniformly provided as a whole, thereby achieving good thermal shock resistance. In addition, since the porous honeycomb block bodies 132 can be manufactured with the same size, production efficiency is improved.

[0077] In the honeycomb structure 134, the plurality of porous honeycomb block bodies 132 are formed by connecting the same number of porous honeycomb block bodies 132 in the vertical and horizontal directions. According to such a structure, when the outer circumference is ground and formed into a circular shape, the amount of grinding and removal is reduced, and production efficiency is improved, as shown in Fig. 10 shown.

[0078] As with the honeycomb structure 114 according to Embodiment 1, the honeycomb structure 134 according to Embodiment 3 may further include noble metal-based catalysts or catalysts other than these provided on the surfaces or insides of the partition walls defining a plurality of cells. [Method for producing the honeycomb structure 134]

[0079] The method for manufacturing the honeycomb structure 134 according to Embodiment 3 of the present disclosure can be carried out in the same manner as the method for manufacturing the honeycomb structure 114 according to Embodiment 1. That is, first, the porous honeycomb segments 130 can be prepared, and the joining material can then be applied to each of the plurality of porous honeycomb segments 130 between the joining surfaces to join them via the joining material layers B (131) to manufacture the porous honeycomb block body 132. The joining material can then be applied to each of a plurality of porous honeycomb block bodies 132 between the joining surfaces to join them via the joining material layer A (133) to manufacture the honeycomb structure 134 with the joined porous honeycomb block bodies 132, as shown in Fig.9. In this case, the joining material layers A (133) for joining the plurality of porous honeycomb block bodies are made of the same materials as those of the joining material layers B for joining the plurality of honeycomb segments 130, and are formed by the joining material layers with a portion missing. That is, in Embodiment 3 of the present disclosure, at least a portion of the joining material layers A (133) for joining the plurality of porous honeycomb block bodies 132 has the cutout 136.

[0080] The honeycomb structure 134 thus formed has a structure with closed portions for purifying fine particulates (carbon fine particulates and the like) in an exhaust gas, so that a fine particulate collection filter such as a diesel engine particulate filter (DPF) and a gasoline engine particulate filter (GPF) can be manufactured.

[0081] Furthermore, in the step of manufacturing the porous honeycomb block bodies 132, as shown in the method for manufacturing the honeycomb structure 114 according to Embodiment 1 of the present invention, at least the outer peripheral wall of the porous honeycomb segment 130, which forms the outer peripheral wall of the porous honeycomb block body 132, may be ground thicker by a grinding edge, and the grinding edge may be removed before bonding. Further, at least the outer peripheral wall of the porous honeycomb segment 130, which forms the outer peripheral wall of the porous honeycomb block body 132, may be coated with the bonding material and dried to make it thicker by the grinding edge, and the grinding edge may be removed before bonding. Description of reference symbols 10, 110, 120, 130 porous honeycomb segment 20 adhesive layers 30 mounting plate 40, 112, 122, 132 porous honeycomb block body 111, 121, 131 Connecting material layer B 113, 123, 133 Connecting material layer A 114, 124, 134 honeycomb structure 115 Cell 116 Partition wall 117 outer peripheral wall 118 grinding edge 119, 129, 139 Coating material 136 Excerpt 140 rotation axis 141 Whetstone

Claims

[1] Honeycomb structure (114) comprising a plurality of porous honeycomb block bodies (112) connected via connecting material layers A (113), wherein each of the porous honeycomb block bodies (112) comprises a plurality of porous honeycomb segments (110) connected via connecting material layers B (111), wherein each of the porous honeycomb segments (110) comprises: partition walls (116) defining a plurality of cells (115) to form flow paths for a fluid, each of the cells (115) extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall (117) arranged on the outermost periphery of the honeycomb segment (110), wherein at least a portion of the bonding material layers A (113) has a higher load-bearing capacity than that of the bonding material layers B (111), the load-bearing capacity being equal to the deformation volume at fracture minus the deformation volume at the fracture initiation point and being measured in accordance with the four-point flexural strength test method of JIS R1601 2008 “Flexural Strength Test Method for Fine Ceramics at Room Temperature,” and wherein the bonding material layers (A) (113) having a higher load-bearing capacity than that of the bonding material layers (B) (111) are made of a material having a higher load-bearing capacity than that of a material constituting the bonding material layers (B) (111), and the bonding material layers (A) (113) comprise bonding material layers each having a width different from that of each of the bonding material layers (B) (111), and wherein the bonding materials forming the bonding material layers (A) and (B) comprise alumina fibers, and the bonding material forming the bonding material layers (B) comprises a larger amount of alumina fibers than the bonding material forming the bonding material layers (A). [2] Honeycomb structure (114) according to claim 1, wherein all connecting material layers (A) (113) have a higher load-bearing capacity than that of the connecting material layers (B) (111). [3] The honeycomb structure (114) according to claim 1 or 2, wherein the plurality of porous honeycomb blocks (112) have the same number of porous honeycomb segments (110). [4] The honeycomb structure (114) according to any one of claims 1 to 3, wherein the honeycomb structure (114) is formed by joining the same number of the porous honeycomb block bodies (112) in the vertical direction and in the horizontal direction. [5] A method for producing a honeycomb structure (114) according to any one of claims 1 to 4, the method comprising the following steps Joining a plurality of porous honeycomb segments (110) via joining material layers B (111) to form porous honeycomb block bodies (112), each of the porous honeycomb segments (110) comprising: partition walls (116) defining a plurality of cells (115) to form flow paths for a fluid, each of the cells (115) extending from an inflow end face, which is an end face on a fluid inflow side, to an outflow end face, which is an end face on a fluid outflow side; and an outer peripheral wall (117) disposed at the outermost periphery; and Connecting the porous honeycomb block bodies (112) via connecting material layers A (113) to produce a honeycomb structure (114), wherein at least some of the connecting material layers A (113) have a higher load-bearing capacity than that of the connecting material layers B (111). [6] The method according to claim 5, wherein the method comprises performing the step of joining the porous honeycomb block bodies (112) via the joining material layers A (113) to produce the honeycomb structure (114) after at least the outer peripheral wall (117) of each of the porous honeycomb segments (110) constituting an outer peripheral wall (117) of each of the porous honeycomb block bodies (112) is made thicker by a grinding edge, or the joining material in the step of producing the porous honeycomb block bodies (112) is applied to at least the outer peripheral wall (117) of each of the porous honeycomb segments (110) constituting the outer peripheral wall (117) of each of the porous honeycomb block bodies (112) and dried so as to have a thickness thicker by the grinding edge, and then grinding and removing the grinding edge of the outer peripheral wall (117) of each of the porous Honeycomb segments (110),which form the outer peripheral wall (117) of each of the porous honeycomb block bodies (112).

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