Honeycomb structure, honeycomb member, and method for producing honeycomb structure

Abstract

To provide a large honeycomb structure having fine cells.SOLUTION: A honeycomb structure is formed by connecting a plurality of honeycomb members 10 having a plurality of cells 11 by a joining member 15, wherein: each honeycomb member 10 includes a reference surface 10k formed on a side surface parallel to an axial direction of the cells 11, the reference surface being parallel to the axial direction of the cells 11; and a recessed portion 10g formed on a side surface 10f on which the reference surface 10k parallel to the axial direction of the cells 11 is formed, on which the joining member 15 recessed relative to the reference surface 10k is disposed. The plurality of honeycomb members 10 are connected in a state in which the reference surfaces 11k of adjacent honeycomb members 10 are in surface contact with each other.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a honeycomb structure, a honeycomb member, and a method for manufacturing a honeycomb structure. [Background technology]

[0002] Honeycomb structures having a large number of cells are used in a variety of applications. For example, they are used as filters for capturing fine particulate matter and odors contained in exhaust gases, and as transmission members and absorbents for transmitting and absorbing heat waves and sound waves. In particular, when honeycomb structures are used as transmission members and absorbents for transmitting and absorbing heat waves and sound waves, honeycomb structures with a larger surface area can improve transmission and absorption characteristics. Therefore, honeycomb structures with a large number of cells and a short cell lattice width (honeycomb structures with fine cells) are required for transmission members and absorbents. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-88491 [Patent Document 2] Patent No. 5281733 [Patent Document 3] Japanese Patent Application Laid-Open No. 2010-12415 [Patent Document 4] Japanese Patent Application Laid-Open No. 2010-12416 Summary of the Invention [Problem to be solved by the invention]

[0004] However, honeycomb structures with short cell lattice widths are difficult to manufacture, and currently, it is not possible to manufacture honeycomb structures with cell lattice widths shorter than approximately 0.6 mm. In particular, in the case of ceramic honeycomb structures that are fired after molding, the finer the cell lattice, the more likely it is that damage will occur due to thermal shrinkage during the manufacturing process, making it extremely difficult to manufacture honeycomb structures with cell lattice widths shorter than approximately 0.6 mm.

[0005] Furthermore, large honeycomb structures with short cell lattice widths are even more difficult to manufacture. Even if the cell lattice width is, for example, about 0.7 mm, currently only structures with a side length of less than about 50 mm and a height (length along the axial direction of the cell through holes) of less than about 100 mm can be manufactured.

[0006] One method for manufacturing a large honeycomb structure with a short cell lattice width is to join small honeycomb structures with a short cell lattice width together to increase the size. For example, Patent Document 1 discloses a method for forming a large honeycomb structure by joining multiple honeycomb segments. Patent Document 1 discloses a honeycomb structure with a diameter of approximately 266 mm, formed by joining the side surfaces of honeycomb segments with a side length of approximately 40 mm, a height of approximately 300 mm, and a cell wall thickness of approximately 1 mm, using a joining paste.

[0007] However, in the techniques of Patent Documents 1 to 4, since the cells are relatively large, high accuracy is not required for the joining precision of the honeycomb segments, that is, the layout of the cells after joining. On the other hand, when joining honeycomb structures with a short cell lattice width, high accuracy is required for the layout of the cells after joining. Therefore, it is difficult to manufacture a large honeycomb structure with a short cell lattice width and sufficient accuracy with the techniques of Patent Documents 1 to 4, and currently no large honeycomb structure with a short cell lattice width exists.

[0008] In view of the above circumstances, an object of the present invention is to provide a large honeycomb structure having fine cells. Another object of the present invention is to provide a honeycomb member having fine cells that can be used to form a large honeycomb structure having fine cells. Another object of the present invention is to provide a method for manufacturing a honeycomb structure in which a large honeycomb structure having fine cells is formed using honeycomb members having fine cells. [Means for solving the problem]

[0009] <Honeycomb structure> The honeycomb structure of the first invention is formed by connecting a plurality of honeycomb members, each having a plurality of cells, with a bonding material, and the honeycomb members have connecting side surfaces having a reference plane parallel to the axial direction of the cells, and the connecting side surfaces are either sides having a recessed portion recessed from the reference plane into which the bonding material is placed, or sides having no recessed portion, and the plurality of honeycomb members are connected with each other such that the reference plane of the connecting side surface having the recessed portion of one of the adjacent honeycomb members is in face-to-face contact with the reference plane of the connecting side surface of the other honeycomb member. The honeycomb structure of the second invention is characterized in that, in the first invention, the connecting side surface of the honeycomb member having the recessed portion has the reference surface provided at each end of the axial direction of the connecting side surface, and the recessed portion is provided between the reference surfaces. The honeycomb structure of the third invention is characterized in that, in the first invention, the recessed portion of the connecting side surface is provided so as to connect both side end portions of the connecting side surface in a direction perpendicular to the axial direction of the cells. The honeycomb structure of the fourth invention is the honeycomb structure of the first invention, wherein the honeycomb member is made of a ceramic material and has a cell density of 3000 / inch 2 or more and the cell grid width is 0.6 mm or less. The honeycomb structure of the fifth invention is characterized in that, in the fourth invention, the recessed portion on the connecting side of the honeycomb member has a depth of 0.1 mm or more and a length equal to or less than the sum of the cell lattice width and the cell wall thickness. A honeycomb structure according to a sixth aspect of the present invention is the honeycomb structure according to the fourth aspect of the present invention, characterized in that the bonding material is a particulate material formed from a material that bonds to the honeycomb members by sintering. A honeycomb structure according to a seventh aspect of the present invention is the honeycomb structure according to the first aspect of the present invention, characterized in that the honeycomb member has a polygonal cross section. <Honeycomb material> The honeycomb member of the eighth invention is made of ceramic material and has a cell density of 3000 / inch 2 or more and the cell grid width is 0.6 mm or less. <Method for manufacturing honeycomb structure> The method for manufacturing a honeycomb structure of the ninth invention is to manufacture a honeycomb structure having a cell density of 3000 / inch 2 A method for manufacturing a ceramic honeycomb structure having a cell density of 3000 / inch or more and a cell lattice width of 0.6 mm or less, 2 The method is characterized in that a connecting side surface having a reference plane parallel to the axial direction of the cells is formed on the side surface of a honeycomb member having a cell lattice width of 0.6 mm or less, a recessed portion recessed below the reference plane is formed on the connecting side surface, a bonding material is placed in the recessed portion of the connecting side surface of the honeycomb member, and the reference plane of the connecting side surface on which the recessed portion of the honeycomb member is formed is in surface contact with the reference plane of the connecting side surface of the other honeycomb member, thereby connecting multiple honeycomb members together. The tenth invention is a method for manufacturing a honeycomb structure according to the ninth invention, characterized in that the bonding material comprises a bonding member which is a particulate material formed from a material which bonds to the ceramic material of the honeycomb structure by sintering, and an adhesive having fluidity, and the bonding material is placed between the recessed portions so that the reference surfaces are in surface contact with each other to form a connecting body, and the formed connecting body is then fired. An eleventh aspect of the present invention provides a method for manufacturing a honeycomb structure according to the tenth aspect of the present invention, characterized in that the viscosity of the bonding material is 5000 mPa·s (20° C.) or more. [Effects of the Invention]

[0010] <Honeycomb structure> According to the first and second aspects of the present invention, a plurality of honeycomb members can be connected with high precision, so that the honeycomb structure can be made larger while preventing a decrease in its functionality. According to the third aspect of the present invention, the bonding strength between the honeycomb members can be increased. According to the fourth aspect of the present invention, it is possible to improve functions such as filter characteristics, absorption characteristics, and transmission characteristics. According to the fifth and sixth aspects of the present invention, it is possible to increase the connection strength between a plurality of honeycomb members while preventing a decrease in performance. According to the seventh aspect of the present invention, it becomes easier to increase the size of a honeycomb structure formed by a plurality of honeycomb members. <Single> According to the eighth aspect of the present invention, it is possible to improve functions such as filter characteristics, absorption characteristics, and transmission characteristics. <Method for manufacturing honeycomb structure> According to the ninth to eleventh aspects of the present invention, a large honeycomb structure having fine cells can be manufactured easily and accurately. Moreover, the connection strength between a plurality of honeycomb members can be increased while preventing a decrease in performance. [Brief explanation of the drawings]

[0011] [Figure 1] 1A is a schematic side view of the honeycomb structure 1 of the present embodiment, and FIG. 1B is a schematic plan view of the honeycomb structure 1 of the present embodiment. [Figure 2] 1A is a schematic perspective view of a honeycomb structure 1 of the present embodiment, and FIG. 1B is a schematic enlarged view of a portion B of FIG. 1A. [Figure 3] FIG. 2 is a schematic enlarged side view seen from the direction of line III in FIG. 1(B). [Figure 4] FIG. 4 is a schematic cross-sectional view taken along line IV-IV in FIG. 1(A). [Figure 5] 1A is a schematic side view of the honeycomb member 10, and FIG. 1B is a schematic plan view of the honeycomb member 10. FIG. [Figure 6] 1A is a schematic perspective view that makes the structure of a honeycomb member 10 easier to understand. [Figure 7]1A is a schematic side view of a honeycomb structure 1 according to another embodiment, and FIG. 1B is a schematic plan view of the honeycomb structure 1 according to the present embodiment. [Figure 8] FIG. 8 is a schematic cross-sectional view taken along line VIII-VIII in FIG. 7(A). [Figure 9] FIG. 1 is a schematic perspective view of a honeycomb structure 1 of the present embodiment formed by honeycomb members 10 having different cross-sectional shapes. DETAILED DESCRIPTION OF THE INVENTION

[0012] The honeycomb structure of this embodiment will be described with reference to the drawings. As shown in Fig. 1, the honeycomb structure 1 of this embodiment is formed by connecting a plurality of honeycomb members 10 with joining members 15 (see Figs. 3 and 4). Specifically, the honeycomb structure 1 of this embodiment is formed by connecting a plurality of honeycomb members 10 with the joining members 15 in a state where the axial directions of the cells 11 (the vertical direction in Fig. 1(A)) are parallel to each other. In the honeycomb structure 1 of this embodiment, the cell density of the honeycomb members 10 is 3000 / inch 2 The honeycomb structure 1 of this embodiment has a cell lattice width of 0.6 mm or less and a large number of fine cells 11. Therefore, the honeycomb structure 1 of this embodiment has a large surface area (more specifically, the surface area of ​​the inner surface of the cells 11), so when used as an odor absorbent, it can enhance the odor absorption effect and can increase the propagation efficiency of waves such as heat waves and sound waves. In other words, the honeycomb structure 1 of this embodiment can be used as a high-performance odor absorbent or transmitter.

[0013] <Honeycomb member 10> The honeycomb member 10 constituting the honeycomb structure 1 of this embodiment will be described. As shown in FIGS. 5 and 6, the honeycomb member 10 is a structure provided with a plurality of cells 11 penetrating between both end faces 10a and 10b, and has a cell density of 3000 / inch 2 The cell grid width is 0.6 mm or less.

[0014] Note that Fig. 6 emphasizes the cell lattice width and cell wall thickness to make it easier to understand the structure of the honeycomb member 10. In Fig. 6, the width (W2 in Fig. 5) and height (H2 in Fig. 5) of the reference surface 10k and the width (W3 in Fig. 5) and height (H3 in Fig. 5) of the recessed portion 10g are approximately the same as the actual dimensions relative to the entire honeycomb member 10, but the cell lattice width and cell wall thickness are significantly different in their relative dimensions relative to the entire honeycomb member 10.

[0015] This honeycomb member 10 is a member that is formed by sintering particulate matter m (see FIG. 3) and then machined into a predetermined shape. For example, the honeycomb member 10 is a member that is formed by sintering particulate matter m of ceramics such as alumina, zirconia, cordierite, silicon carbide, or silicon nitride, or particulate matter m of metals such as stainless steel or titanium, and then machined or otherwise formed into a predetermined cross-sectional shape. For example, in FIG. 5, the honeycomb member 10 is machined into a hexagonal cross-section having six side surfaces 10f.

[0016] The cell density is 3000 / inch 2 When manufacturing a honeycomb member 10 having fine cells 11 with a cell lattice width of 0.6 mm or less, there are no particular limitations on the particle size of the particulate matter m forming the honeycomb member 10. For example, particles with an average particle size of 20 μm or less can be used.

[0017] Furthermore, the material of the particulate matter m forming the honeycomb member 10 is not limited to the materials described above, and various materials that can be bonded by sintering can be used. Furthermore, the honeycomb member 10 is not necessarily limited to being formed by sintering the particulate matter m, and may be formed by desolvation firing or the like.

[0018] As shown in FIG. 5, a reference surface 10k and a recess 10g are formed on a side surface 10f of the honeycomb member 10. Specifically, a pair of reference surfaces 10k, 10k is provided on both ends of the side surface 10f of the honeycomb member 10 (both ends in the vertical direction in FIG. 5(A)). That is, on the side surface 10f of the honeycomb member 10, a reference surface 10k that is continuous with both end surfaces 10a, 10b (in other words, forming an edge e between both end surfaces 10a, 10b) is provided on both ends in the axial direction of the cells 11. The pair of reference surfaces 10k, 10k are surfaces that are provided to connect both end edges of the side surface 10f (edges parallel to the axial direction of the cells 11, edges d, d in the left-right direction in FIG. 5(A)). Furthermore, the pair of reference surfaces 10k, 10k formed on the same side surface 10f are formed to be in the same plane parallel to the axial direction of the cells 11. The term "coplanar" as used herein includes both cases where the surfaces of the pair of reference surfaces 10k, 10k are positioned on the same plane and cases where there is a slight deviation due to manufacturing errors. A slight deviation due to manufacturing errors refers to, for example, a state where there is a slight tilt between the surfaces of the pair of reference surfaces 10k, 10k (a state where there is a tilt deviation), a state where there is a slight height deviation in the normal direction between the surfaces of the pair of reference surfaces 10k, 10k, and a state where both a tilt deviation and a height deviation occur. Note that, hereinafter, the side surface on which the pair of reference surfaces 10k, 10k are provided may be referred to as the connecting side surface 10f.

[0019] Furthermore, a recess 10g is provided between the pair of reference surfaces 10k, 10k on the connecting side surface 10f of the honeycomb member 10. This recess 10g is a portion formed so as to be recessed from the surface of the connecting side surface 10f on which the pair of reference surfaces 10k, 10k is provided. In other words, the recess 10g is a portion formed so as to be recessed from the surface of the pair of reference surfaces 10k, 10k. The recess 10g is provided so as to connect both side edges of the connecting side surface 10f. For example, the recess 10g is formed by scraping the connecting side surface 10f of the honeycomb member 10 to a predetermined depth in a direction perpendicular to the axial direction of the cells 11.

[0020] <Joint member 15> As shown in FIGS. 1 to 4, the honeycomb structure 1 of this embodiment is formed by connecting a plurality of honeycomb members 10, and as shown in FIGS. 3 and 4, a joining member 15 is provided between adjacent honeycomb members 10 to connect the adjacent honeycomb members 10. Specifically, in the honeycomb structure 1 of this embodiment, when the reference surfaces 10k of the connecting side surfaces 10f, on which the recessed portions 10g are provided, of adjacent honeycomb members 10 are brought into surface contact with each other, a space h (see FIGS. 3 and 4; hereinafter, this may be simply referred to as the space h between adjacent honeycomb members 10) is formed between the recessed portions 10g of the adjacent honeycomb members 10. A joining member 15 is disposed in this space h, and the adjacent honeycomb members 10 are connected by this joining member 15. The joining member 15 is a particulate matter formed from a material that connects the joining members 15 to each other and to the honeycomb members 10 by sintering (see FIG. 3). When the material of the honeycomb member 10 is formed from ceramic particles m such as alumina or zirconia, the joining members 15 can be made of particles made of alumina, zirconia, or the like. When the material of the honeycomb member 10 is formed by sintering particles m made of metal such as stainless steel or titanium, the joining members 15 can be made of particles made of metal such as stainless steel or titanium.

[0021] As described above, the honeycomb structure 1 of this embodiment is formed by arranging and connecting a plurality of honeycomb members 10 each having fine cells 11 so that the axial directions of the cells 11 are parallel, and therefore it is possible to manufacture a large honeycomb structure having fine cells. For example, a honeycomb structure having a cell density of 3000 / inch 2 The honeycomb member 10 has a height H (axial length H of the cell 11, hereinafter sometimes simply referred to as the length H of the honeycomb member 10, see FIG. 5(A)) of 100 mm or more and a hexagonal shape (cross-sectional area of ​​about 600 mm or more) with one side of about 15 mm or more, and a cell lattice width of 0.6 mm or less. 2 If a plurality of honeycomb members 10 having a height H1 (see FIG. 1(A)) of 100 mm or more and a diameter of 60 mm or more are used, a cylinder (with a cross-sectional area of ​​about 2800 mm 2The honeycomb structure 1 can be manufactured as described above (see FIG. 9(A)).

[0022] Furthermore, since adjacent honeycomb members 10 can be connected with a pair of reference surfaces 10k, 10k of the connecting side surfaces 10f on which the recessed portions 10g are provided being in surface contact with each other (see FIG. 3), it is possible to manufacture with high precision a honeycomb structure 1 in which the axial directions of all the cells 11 are parallel. Here, "the axial directions of all the cells 11 are parallel" includes both a state in which the axial directions of all the cells 11 are completely parallel (in other words, a state in which the axial directions of all the cells 11 are parallel to the axial direction of the honeycomb structure 1) and a case in which some cells 11 are slightly inclined with respect to the axial direction of the honeycomb structure 1.

[0023] Adjacent honeycomb members 10 are connected to each other by joining members 15 that are bonded to the material of the honeycomb members 10 by sintering, thereby firmly bonding adjacent honeycomb members 10. Therefore, although the honeycomb structure 1 is formed by connecting multiple honeycomb members 10, it can have a strength equivalent to that of a honeycomb structure formed integrally.

[0024] Note that the connecting side surfaces 10f of the honeycomb member 10, i.e., the reference surfaces 10k of the connecting side surfaces 10f, may have openings of the cells 11 (spaces between the end faces of the wall surfaces of the cells 11 (see Figure 5(B)) on their surfaces. In other words, the reference surfaces 10k of the honeycomb member 10 may not be completely flat, but the planar portions that make up the reference surfaces 10k are located on the same plane. Therefore, in this specification, the state in which the reference surfaces 10k of the connecting side surfaces 10f are in surface contact with each other means the state in which the planar portions that make up the reference surfaces 10k are in surface contact with each other (see the circled areas in Figure 1).

[0025] <Method for manufacturing honeycomb structure 1 of the present embodiment> A method for manufacturing the honeycomb structure 1 of this embodiment will be described.

[0026] First, a plurality of honeycomb members 10 having the above-described shape are formed. For example, the plurality of honeycomb members 10 are formed by extruding a material containing particulate matter m and firing the extruded material. The plurality of honeycomb members 10 are formed to have substantially the same shape and size.

[0027] The honeycomb members 10 may have the following sizes. For example, as shown in FIG. 5, the honeycomb members 10 may be formed into a hexagonal shape with a side L of 20 mm (see FIG. 4(B)) by machining a cylindrical molded body with a height H of 80 mm and a diameter of 40 mm. The honeycomb members 10 may have a pair of reference surfaces 10k, 10k formed on all side surfaces at both ends of the cells 11 in the axial direction. In other words, all side surfaces are connecting side surfaces 10f, and a recess 10g recessed from the surface of the pair of reference surfaces 10k, 10k may be formed between the pair of reference surfaces 10k, 10k. The pair of reference surfaces 10k, 10k of the connecting side surfaces 10f may have a length H2 (see FIG. 5(A)) of 16 mm in the axial direction of the cells 11, and the recess 10g may have a depth D (see FIG. 5(A)) of 0.2 mm.

[0028] After forming the plurality of honeycomb members 10, a bonding material containing bonding members 15 and a viscous adhesive is placed in the recessed portion 10g of the connecting side surface 10f, and the honeycomb members 10 with the bonding material placed thereon are arranged so that the pair of reference surfaces 10k, 10k of the connecting side surface 10f are in surface contact with each other. This forms a pre-fired honeycomb structure 1b in which the plurality of honeycomb members 10 are connected by the bonding material due to the adhesive strength of the bonding material. If the bonding material has a certain degree of fluidity (e.g., a viscosity of 5000 mPa·s (20°C)), placing a relatively large amount of bonding material in the recessed portion 10g of the connecting side surface 10f and arranging the plurality of honeycomb members 10 as described above will allow the bonding material to flow and fill the space h between adjacent honeycomb members 10. In other words, the bonding members 15 are arranged in a somewhat dispersed state within the space h between adjacent honeycomb members 10.

[0029] Once the pre-fired honeycomb structure 1b is formed, it is fired, for example, in an atmospheric firing furnace. As a result, the contacting joining members 15 are bonded together by firing, and the honeycomb members 10 that were in contact with the joining members 15 are bonded to the joining members 15. This results in the production of a honeycomb structure 1 in which adjacent honeycomb members 10 are connected to each other by the joining members 15 located in the spaces h between the adjacent honeycomb members 10. At this time, the adhesive contained in the bonding material vaporizes at the temperature at which the joining members 15 are fired, so that in the honeycomb structure 1 after firing, only the joining members 15 are present in the spaces h between the adjacent honeycomb members 10.

[0030] As described above, with the method for manufacturing the honeycomb structure 1 of this embodiment, by arranging a plurality of honeycomb members 10 formed in a predetermined shape with bonding material placed in the recessed portions 10g so that the pair of reference surfaces 10k, 10k of the connecting side surfaces 10f are in surface contact with each other, and then firing the honeycomb structure 1, it is possible to manufacture a honeycomb structure 1 that is larger than the honeycomb members 10. Moreover, since the manufactured honeycomb structure 1 can be composed entirely of particulate matter that is connected by firing, the performance of the honeycomb structure 1 can be made similar to that of a honeycomb structure having fine cells similar to those of the honeycomb member 10, which is formed as an integral unit.

[0031] Therefore, by employing the manufacturing method of the honeycomb structure 1 of the present embodiment, it is possible to manufacture a large honeycomb structure 1 having fine cells easily and accurately.

[0032] 1 and 4, the cells 11 arranged in a lattice pattern in adjacent honeycomb members 10 constituting the honeycomb structure 1 are arranged in an oblique direction. On the other hand, as shown in FIGS. 7 and 8, the cells 11 of adjacent honeycomb members 10 constituting the honeycomb structure 1 may be arranged so that they are parallel to each other. By forming the honeycomb structure 1 in this manner, the performance of the honeycomb structure 1 can be made closer to that of a honeycomb structure having fine cells similar to those of the honeycomb member 10, which is formed as an integral unit. In other words, even when the honeycomb structure 1 is manufactured by combining a plurality of honeycomb members 10, the propagation efficiency of waves such as thermal waves and sound waves can be improved.

[0033] <Cross-sectional shapes of honeycomb structure 1 and honeycomb member 10> In the above example, the cross-sectional shape of the honeycomb member 10 is hexagonal. In this case, as shown in Fig. 9(A), six honeycomb members 10 each having a hexagonal cross-sectional shape are arranged around one honeycomb member 10 having a hexagonal cross-sectional shape and joined together, and the joined assembly is then machined to form a honeycomb structure 1 having a circular cross-section.

[0034] 9(A), when the honeycomb structure 1 has a circular cross section, its outer peripheral surface is curved and is therefore usually machined so as to have no reference surface 10k or recessed portions 10g. However, depending on the use of the honeycomb structure 1, the reference surface 10k and the recessed portions 10g may be provided on the outer peripheral surface. In addition, the honeycomb member 10 may be formed to have a triangular or rectangular cross section, in which case, by arranging and joining four honeycomb members 10 together, a honeycomb structure 1 with a rectangular cross section can be formed (see Figures 9(B) and (C)).

[0035] Of course, the cross-sectional shape of the honeycomb member 10 is not limited to a hexagon, square, or triangle as shown in FIG. 9 , and may be a pentagon, etc. Any shape is acceptable as long as it allows the reference surfaces 10k of the connecting side surfaces 10f of adjacent honeycomb members 10 to be in surface contact with each other. In particular, a shape (such as an equilateral triangle, square, or regular hexagon) that allows multiple honeycomb members 10 to be arranged without gaps between the connecting side surfaces 10f (i.e., between the reference surfaces 10k) of adjacent honeycomb members 10 when viewed from the axial direction of the cells 11 is desirable. With such a shape, if multiple honeycomb members 10 are connected with the reference surfaces 10k of the connecting side surfaces 10f in surface contact with each other, when a honeycomb structure 1 is formed using multiple honeycomb members 10, the entire honeycomb structure 1 can be formed as if it were an integrated unit, making it easier to adjust the use and function of the honeycomb structure 1.

[0036] Furthermore, Figure 9 illustrates an example in which all honeycomb members 10 forming the honeycomb structure 1 have the same cross-sectional shape, but the honeycomb members 10 forming the honeycomb structure 1 do not all have to have the same cross-sectional shape, and the honeycomb structure 1 may be formed by connecting honeycomb members 10 having different cross-sectional shapes.

[0037] <About the connecting side 10f> The honeycomb member 10 only needs to have at least one connecting side surface 10f that can connect adjacent honeycomb members 10, that is, one connecting side surface 10f that has a reference surface 10k and a recessed portion 10g. For example, the honeycomb member 10 may have a semicircular or sectorial cross section, that is, one or two connecting side surfaces 10f, and the other side surfaces may be curved or have no reference surface 10k.

[0038] The honeycomb member 10 may also have connecting side surfaces 10f that have only reference surfaces 10k and no recessed portions 10g. For example, when the honeycomb member 10 has a plurality of connecting side surfaces 10f, all of the connecting side surfaces 10f may have the reference surfaces 10k and the recessed portions 10g (hereinafter, sometimes referred to as a first honeycomb member 10A), or all of the connecting side surfaces 10f may have the reference surfaces 10k and the recessed portions 10g (hereinafter, sometimes referred to as a second honeycomb member 10B). Alternatively, all of the connecting side surfaces 10f may have only the reference surfaces 10k (hereinafter, sometimes referred to as a third honeycomb member 10C).

[0039] When forming the honeycomb structure 1 using the first to third honeycomb members 10A to 10C as described above, the honeycomb structure 1 can be formed by connecting the honeycomb members 10 as follows.

[0040] For example, when joining first honeycomb members 10A together (or second honeycomb members 10B together) to form the honeycomb structure 1, the joining member 15 is placed in the recessed portion 10g of the connecting side surface 10f having the recessed portion 10g of the first honeycomb member 10A (or second honeycomb member 10B). Then, the reference surfaces 10k of the connecting side surfaces 10f having the recessed portions 10g of the first honeycomb members 10A (or second honeycomb members 10B) are brought into surface contact with each other, thereby joining the first honeycomb members 10A together (or second honeycomb members 10B together) to form the honeycomb structure 1.

[0041] Furthermore, when joining the first honeycomb member 10A and the second honeycomb member 10B (or the third honeycomb member 10C) to form the honeycomb structure 1, a bonding material is placed in the recessed portion 10g of the connecting side surface 10f of the first honeycomb member 10A, which has the recessed portion 10g. Then, the reference surface 10k of the connecting side surface 10f having the recessed portion 10g of the first honeycomb member 10A is brought into surface contact with the reference surface 10k of the connecting side surface 10f without the recessed portion 10g of the second honeycomb member 10B (or the third honeycomb member 10C), and the first honeycomb member 10A and the second honeycomb member 10B (or the third honeycomb member 10C) are joined (or fired after joining) to form the honeycomb structure 1.

[0042] Furthermore, when the second honeycomb member 10B and the third honeycomb member 10C are joined to form the honeycomb structure 1, a bonding material is placed in the recessed portion 10g of the connecting side surface 10f having the recessed portion 10g of the second honeycomb member 10B. Then, the reference surface 10k of the connecting side surface 10f having the recessed portion 10g of the second honeycomb member 10B is brought into surface contact with the reference surface 10k of the connecting side surface 10f without the recessed portion 10g of the third honeycomb member 10C, and the second honeycomb member 10B and the third honeycomb member 10C are joined (or fired after joining) to form the honeycomb structure 1.

[0043] <Regarding the reference surface 10k and the recessed portion 10g> In the above example, a pair of reference surfaces 10k, 10k is provided on both ends of the connecting side surface 10f of the honeycomb member 10, which has the recessed portion 10g. However, the number and positions of the reference surfaces 10k on the connecting side surface 10f, which has the recessed portion 10g, are not particularly limited. The number of reference surfaces 10k provided on the connecting side surface 10f may be one, or three or more. For example, a pair of reference surfaces 10k, 10k may be provided on both ends of the connecting side surface 10f of the honeycomb member 10, which has the recessed portion 10g, and one or more reference surfaces 10k may be provided between the pair of reference surfaces 10k, 10k. Furthermore, a single reference surface 10k may be provided at one end of the connecting side surface 10f of the honeycomb member 10, which has the recessed portion 10g. Alternatively, a single reference surface 10k may be provided at the axial center of the cells 11 on the connecting side surface 10f of the honeycomb member 10, which has the recessed portion 10g. In other words, there are no particular limitations on the number or positions of the reference surfaces 10k provided on the connecting side surface 10f having the recessed portion 10g, as long as the adjacent honeycomb members 10 can be accurately positioned, lined up, and connected. At least when the connecting side surface 10f has the recessed portion 10g, providing a pair of reference surfaces 10k, 10k at both ends of the connecting side surface 10f having the recessed portion 10g makes it easy to maintain high positioning accuracy between the adjacent honeycomb members 10.

[0044] The height H2 of the reference surface 10k, i.e., the length H2 of the reference surface 10k in the axial direction of the cells 11, is not particularly limited, and may be any length that allows for accurate positioning of adjacent honeycomb members 10. For example, the height H2 of the reference surface 10k (the total length of the heights H2 of all the reference surfaces 10k when there are multiple reference surfaces 10k) is preferably 20 to 80% of the length H of the honeycomb member 10. Furthermore, when multiple reference surfaces 10k are provided, the heights H2 of all the reference surfaces 10k may be the same length, or the height H2 may be different for each reference surface 10k.

[0045] In the above example, the reference surfaces 10k are formed so as to connect both ends of the side surfaces 10f on which the reference surfaces 10k are formed, that is, the width W2 (see FIG. 5(A)) of the pair of reference surfaces 10k, 10k is the same as the distance between both ends of the connecting side surfaces 10f of the honeycomb members 10 (if the honeycomb members 10 are polygonal, the length of one side (see L in FIG. 5(B))). If the reference surfaces 10k having such a width W2 are provided at both ends of the connecting side surfaces 10f of the honeycomb members 10 and the connecting side surfaces 10f on which such reference surfaces 10k are provided are brought into surface contact with each other to connect the honeycomb members 10, it is possible to reduce the gap between adjacent honeycomb members 10 when the honeycomb structure 1 is viewed from the axial direction of the cells 11, and therefore it is possible to make the honeycomb structure 1 appear as if it were formed integrally. However, the width W2 of the reference surface 10k, i.e., the length W2 of the reference surface 10k in the direction perpendicular to the axial direction of the cells 11, is not particularly limited, and may be any length that allows for accurate positioning of adjacent honeycomb members 10. For example, the width W2 of the reference surface 10k may be shorter than the distance between both ends of the connecting side surface 10f of the honeycomb members 10. Furthermore, when there are multiple reference surfaces 10k, the width W2 of all the reference surfaces 10k may be the same length, or the width W2 of each reference surface 10k may be different.

[0046] In the above example, the recessed portion 10g is formed to connect both ends of the connecting side surface 10f on which the recessed portion 10g is formed. However, the recessed portion 10g may be formed only in a portion between both ends of the connecting side surface 10f. In other words, the width W3 of the recessed portion 10g (see FIG. 4(A)) may be shorter than the distance between both ends of the connecting side surface 10f on which the recessed portion 10g is formed (or the length of one side of the polygonal honeycomb member 10 (see L in FIG. 5(B))). For example, the recessed portion 10g may be formed by forming a recessed portion between both ends of the connecting side surface 10f, or by forming a recessed portion from one end of the connecting side surface 10f to partway along the width direction. However, forming the recessed portion 10g so as to connect both ends of the connecting side surface 10f on which the recessed portion 10g is formed can strengthen the bonding strength between adjacent honeycomb members 10. Furthermore, the number of recesses 10g provided on the connecting side surface 10f is not particularly limited, and as in the example described above, only one recessed portion 10g may be provided on the connecting side surface 10f, or multiple recessed portions 10g separated by a reference surface 10k or the like may be provided on the connecting side surface 10f.

[0047] The length H3 of each recess 10g (when multiple recesses 10g are provided, the total length H3 of the multiple recesses 10g), i.e., the length H3 of the recess 10g in the axial direction of the cell 11, is not particularly limited as long as it is formed so that adjacent honeycomb members 10 can be appropriately connected to each other by the bonding material (or bonding member 15). For example, the length H3 of the recess 10g is preferably 20 to 80% of the length H of the honeycomb member 10 in the axial direction of the cell 11. If the length H3 of the recess 10g is less than 20% of the length H of the honeycomb member 10, the bonding area of ​​the bonding material will be insufficient, which may reduce the bonding strength between the honeycomb members 10. On the other hand, if the length H3 of the recess 10g is greater than 80% of the length H of the honeycomb member 10, the bonding area will be too large, and the bonding material will easily protrude into the recesses 10g between the reference surfaces 10k where they are in contact and onto both end faces 10a and 10b. This can easily cause distortion between the reference surfaces 10k of adjacent honeycomb members 10, potentially reducing the bonding strength between adjacent honeycomb members 10. Therefore, in consideration of the bonding strength between adjacent honeycomb members 10, the length H3 of the recessed portion 10g is preferably 30 to 80% of the length H of the honeycomb member 10, more preferably 40 to 80%, and even more preferably 50 to 80%. When a honeycomb member 10 has multiple recessed portions 10g on one connecting side surface 10f, the height H3 of all recessed portions 10g may be the same length, or the height H3 of each recessed portion 10g may be different.

[0048] The depth D of each recess 10g, i.e., the distance D from the inner bottom surface of each recess 10g to the surface of the pair of reference planes 10k, 10k of the connecting side surface 10f on which the recess 10g is provided (see FIG. 5(A)), is not particularly limited. The depth D of each recess 10g is preferably 0.1 mm or more and less than the sum of the cell lattice width W5 (see FIG. 4) and the cell wall thickness T (see FIG. 4). For example, if the cell lattice width W5 is 0.6 mm and the cell wall thickness T is 0.2 mm, the depth D of each recess 10g is preferably 0.1 mm or more and 0.8 mm or less, and more preferably 0.1 mm or more and 0.5 mm or less. If the depth D of each recess 10g is less than 0.1 mm, the adhesive contained in the bonding material placed in each recess 10g will seep into the honeycomb members 10, weakening the bond between the honeycomb members 10 before firing. This may result in a misalignment of the honeycomb members 10 relative to each other before firing, potentially reducing the manufacturing accuracy of the honeycomb structure 1 after firing. Furthermore, it becomes difficult to uniformly distribute the bonding members 15 in the bonding material in the recesses 10g, weakening the bonding strength between the honeycomb members 10 after firing. On the other hand, if the depth of the recesses 10g is large, a larger amount of bonding material is required, resulting in increased costs and reduced production efficiency due to the excessive use of bonding material. Furthermore, if the depth of the recesses 10g is greater than the sum of the cell lattice width W5 and the cell wall thickness T, the number of cells 11 decreases, potentially reducing the functionality of the manufactured honeycomb structure 1. Therefore, the depth D of the recesses 10g is preferably 0.1 mm or more and less than the sum of the cell lattice width W5 and the cell wall thickness T, and is preferably less than 0.5 mm.

[0049] <About bonding materials> The bonding material used to bond the honeycomb members 10 together before firing is not particularly limited, as long as it includes the bonding members 15 described above and can bond the honeycomb members 10 together with a certain degree of strength before firing. For example, the bonding material may be formed from the bonding members 15 and an adhesive made of a fluid resin or other material. In this case, the resin component forming the adhesive can be primarily a thermosetting adhesive such as an epoxy, acrylic, or cyanoacrylate adhesive. The viscosity of the bonding material formed from the bonding members 15 and the adhesive is not particularly limited, but a viscosity of 5000 mPa·s (20°C) or higher is preferred to prevent precipitation or uneven concentration of the bonding members 15 in the bonding material and ensure uniform distribution of the bonding members 15 within the space h. The bonding material may also contain components other than the bonding members 15 and adhesive described above.

[0050] <Regarding honeycomb member 10> In the above example, the honeycomb member 10 is described as a member that forms the honeycomb structure 1, but the honeycomb member 10 can also be used alone. When the honeycomb member 10 is used alone, the reference surface 10k or the recessed portion 10g does not need to be provided on its side surface. In other words, all of the side surfaces of the honeycomb member 10 may be formed as a continuous flat surface from the end surface 10a to the end surface 10b. Of course, even when the honeycomb member 10 is used alone, recesses or grooves may be provided on the side surface 10f as needed. For example, when the honeycomb member 10 is to be installed in equipment such as various measuring instruments, grooves or protrusions for positioning with the mounting portion of the equipment, or grooves or protrusions for fixing to the equipment, may be provided on the side surface. [Industrial Applicability]

[0051] The honeycomb structure of the present invention is suitable as a member used as an absorbent material for transmitting or absorbing heat waves, sound waves, etc. [Explanation of symbols]

[0052] 1 Honeycomb structure 10 Honeycomb member 10f connection side 10k reference plane 10g recess 11 cells 11w wall 15 Joint materials m Particulate matter

Claims

1. The honeycomb structure is formed by connecting a plurality of honeycomb members each having a plurality of cells with a bonding material, The honeycomb member is A connecting side surface having a reference surface parallel to the axial direction of the cell, The connecting side surface is a side surface having a recessed portion recessed from the reference surface in which the bonding material is placed, or a side surface having no recessed portion; The plurality of honeycomb members include: Adjacent honeycomb members are connected in a state in which the reference surface of the connecting side surface on which the recessed portion of one honeycomb member is formed is in surface contact with the reference surface of the connecting side surface of the other honeycomb member. A honeycomb structure characterized by:

2. The connecting side surface having the recessed portion of the honeycomb member is The reference surfaces are provided at both ends of the connecting side surface in the axial direction, The recessed portion is provided between the reference surfaces.

2. The honeycomb structure according to claim 1, wherein the honeycomb structure is a honeycomb structure having a thickness of 100 nm or less.

3. The recessed portion of the connecting side surface is The connecting side surface is provided so as to connect both end portions of the connecting side surface in a direction perpendicular to the axial direction of the cells.

2. The honeycomb structure according to claim 1, wherein the honeycomb structure is a honeycomb structure having a thickness of 100 nm or less.

4. The honeycomb member is The material is ceramic, Cell density is 3000 / inch ２ or more and the cell grid width is 0.6 mm or less 2. The honeycomb structure according to claim 1, wherein the honeycomb structure is a honeycomb structure.

5. The recessed portion on the connecting side surface of the honeycomb member is The depth is 0.1 mm or more and is equal to or less than the sum of the cell lattice width and cell wall thickness.

5. The honeycomb structure according to claim 4.

6. The bonding material is A particulate material formed by sintering that bonds to the honeycomb member.

5. The honeycomb structure according to claim 4.

7. The honeycomb member has a polygonal cross section.

2. The honeycomb structure according to claim 1, wherein the honeycomb structure is a honeycomb structure.

8. The material is ceramic, Cell density is 3000 / inch ２ or more and the cell grid width is 0.6 mm or less A honeycomb member characterized by:

9. Cell density is 3000 / inch ２ A method for manufacturing a ceramic honeycomb structure having a cell lattice width of 0.6 mm or less, Cell density is 3000 / inch ２ A connecting side surface having a reference plane parallel to the axial direction of the cell is formed on a side surface of the honeycomb member having a cell lattice width of 0.6 mm or less, and a recessed portion recessed below the reference plane is formed on the connecting side surface, A bonding material is placed in the recessed portion of the connecting side surface of the honeycomb member, and the honeycomb members are arranged so that the reference surface of the connecting side surface on which the recessed portion of the honeycomb member is formed is in surface contact with the reference surface of the connecting side surface of the other honeycomb member, thereby connecting the plurality of honeycomb members together. A method for manufacturing a honeycomb structure comprising the steps of:

10. The joining material is The honeycomb structure has a ceramic material, which is a material for the honeycomb structure, and a bonding member, which is a particulate material formed by a material that is bonded by sintering, and an adhesive having fluidity. The bonding material is placed between the recesses, and the reference surfaces are arranged to be in surface contact with each other to form a connected body, and the formed connected body is fired.

10. The method for manufacturing a honeycomb structure according to claim 9.

11. The viscosity of the bonding material is 5000 mPa·s (20°C) or more. The method for manufacturing a honeycomb structure according to claim 10.

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