Honeycomb structure, induction heating device and honeycomb unit

Abstract

To provide a honeycomb structure, an induction heating device and a honeycomb unit capable of adjusting the temperature in the axial direction and / or the orthogonal direction during induction heating.SOLUTION: A honeycomb structure according to the present invention includes a honeycomb structure portion 10 having an outer peripheral wall 100, and a partition wall 101 arranged inside the outer peripheral wall 100 and partitioning a plurality of cells 101a forming a flow path extending from one end face to the other end face, and magnetic material powder 11 attached to or filled in at least one of the plurality of cells 101a, in which the volume and / or weight of the magnetic material powder 11 per unit volume differs with respect to the axial direction AD and / or the axially orthogonal direction OD of the honeycomb structure portion 10.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a honeycomb structure, an induction heating device, and a honeycomb unit. [Background technology]

[0002] For example, induction heating is known, which heats an object to be heated by electromagnetic induction, as shown in the following Non-Patent Document 1. Induction heating is performed by placing an induction heating coil near an object to be heated, which includes a magnetic material and / or a conductive material, and generating a magnetic field near the induction heating coil.

[0003] An induction heating coil can be formed by winding a conductor such as a copper pipe or rectangular wire around a predetermined axis. For example, when heating a columnar object, an induction heating coil can be placed around the outer periphery of the object. A magnetic field can be generated by passing a current through the induction heating coil. The current passed through the induction heating coil can be a large current obtained by amplifying alternating current from a high-frequency inverter using a transformer. Because induction heating can heat the object without contact, it is particularly useful for heating materials with poor thermal conductivity and for heating objects under conditions where thermal contact is difficult. [Prior art documents] [Non-patent literature]

[0004] [Non-Patent Document 1] "New Edition Electroheat Handbook," edited by Japan Electroheat Center, Ohmsha, April 10, 2019 (page 263) Summary of the Invention [Problem to be solved by the invention]

[0005] When an object to be heated is placed inside the induction heating coil as described above, magnetic flux tends to concentrate on the outer periphery of the object close to the induction heating coil, which tends to cause an unintended temperature deviation between the outer periphery and the center of the object in the orthogonal direction to the axis. Furthermore, there is a need to intentionally cause a temperature deviation in the axial and / or orthogonal directions, but conventional configurations are not intended to meet such needs.

[0006] The present invention has been made to solve the above-mentioned problems, and one of its objects is to provide a honeycomb structure, an induction heating device, and a honeycomb unit that can adjust the temperature in the axial direction and / or the direction perpendicular to the axis during induction heating. [Means for solving the problem]

[0007] Item 1. In one embodiment, the present invention relates to a honeycomb structure comprising: a honeycomb structure part having an outer peripheral wall; partition walls disposed inside the outer peripheral wall and defining a plurality of cells that form flow paths extending from one end face to the other end face; and magnetic material powder adhered to or filled in at least one of the plurality of cells, wherein the volume and / or weight of the magnetic material powder per unit volume varies in the axial direction and / or the direction orthogonal to the axis of the honeycomb structure part.

[0008] Item 2. The present invention may relate to the honeycomb structure according to Item 1, wherein the plurality of cells include a plurality of magnetic cells in which magnetic material powder is filled in the cells or in which magnetic material powder is attached to partition walls, and the honeycomb structure portion has a plurality of regions in which the magnetic cells are arranged coaxially with each other on the end face or in a cross section perpendicular to the axial direction and in which the magnetic cells exist at different ratios.

[0009] Item 3. The present invention may relate to the honeycomb structure according to Item 2, wherein the axially orthogonal directions include first and second directions intersecting each other, a predetermined number of adjacent cells form a cell block including X cells (X is any positive number) in each of the first and second directions, and the number of magnetic cells included in cell blocks of the same size differs among the multiple regions.

[0010] Item 4. The present invention may relate to the honeycomb structure according to Item 2, wherein the axially orthogonal direction includes first and second directions intersecting each other, a predetermined number of adjacent cells form a cell block including X cells (X is any positive number) in each of the first and second directions, and the size of the cell block including one magnetic cell differs among the multiple regions.

[0011] Item 5. The present invention may relate to the honeycomb structure according to any one of Items 2 to 4, wherein the honeycomb structure part includes a central region including an axial center of the honeycomb structure part and a peripheral region adjacent to the peripheral wall, and the proportion of magnetic cells in the central region is greater than the proportion of magnetic cells in the peripheral region.

[0012] Item 6. The present invention may relate to the honeycomb structure according to any one of Items 1 to 5, wherein the plurality of cells include a plurality of magnetic cells in which magnetic material powder is filled in the cells or in which magnetic material powder is attached to partition walls, and the honeycomb structure portion has a plurality of regions that are arranged coaxially with one another on the end face or in a cross section perpendicular to the axial direction and have different numbers of magnetic cells per unit area.

[0013] Item 7. The present invention may relate to the honeycomb structure according to Item 6, wherein the number of magnetic cells adjacent to each other differs among the plurality of regions.

[0014] Item 8. The present invention may relate to the honeycomb structure according to Item 6 or 7, wherein the honeycomb structure includes a central region including an axial center of the honeycomb structure and a peripheral region adjacent to the peripheral wall, and the number of magnetic cells per unit area in the central region is greater than the number of magnetic cells per unit area in the peripheral region.

[0015] Item 9. The present invention may relate to the honeycomb structure according to any one of Items 1 to 8, wherein the plurality of cells include a plurality of magnetic cells filled with magnetic material powder, and the honeycomb structure portion has end faces spaced apart from each other in the axial direction or a plurality of cross sections perpendicular to the axial direction, in which the abundance ratio of the magnetic cells or the number of magnetic cells per unit area differ from each other.

[0016] Item 10. The present invention may relate to the honeycomb structure according to any one of Items 1 to 9, wherein the plurality of cells include a plurality of magnetic cells filled with magnetic material powder, and the honeycomb structure portion is arranged coaxially with one another on the end face or in a cross section perpendicular to the axial direction, and has a plurality of regions in which the filling rates of the magnetic material powder in the magnetic cells are different from one another.

[0017] Item 11. The present invention may relate to the honeycomb structure according to Item 10, wherein the honeycomb structure includes a central region including an axial center of the honeycomb structure and an outer peripheral region adjacent to the outer peripheral wall, and the filling rate of the magnetic material powder in the central region is higher than the filling rate of the magnetic material powder in the outer peripheral region.

[0018] Item 12. The present invention may relate to a honeycomb structure according to Item 11, wherein the difference between the filling rate in the central region and the filling rate in the peripheral region is 10% or more.

[0019] Item 13. The present invention may relate to the honeycomb structure according to any one of Items 1 to 12, wherein the plurality of cells include a plurality of magnetic cells filled with magnetic material powder, and the honeycomb structure portion has end faces spaced apart from each other in the axial direction or a plurality of cross sections perpendicular to the axial direction, with the magnetic cells having different filling rates of the magnetic material powder.

[0020] Item 14. The present invention may relate to the honeycomb structure according to Item 13, wherein the filling rate of the magnetic material powder on one end face side of the honeycomb structure part is higher than the filling rate of the magnetic material powder on the other end face side.

[0021] Item 15. In one embodiment, the present invention relates to a honeycomb structure including: a honeycomb structure part having an outer peripheral wall; and partition walls disposed inside the outer peripheral wall and defining a plurality of cells that form flow paths extending from one end face to the other end face; and magnetic material powder attached to or filled in at least one of the plurality of cells, wherein the magnetic material powder includes a plurality of types of magnetic material powder having different magnetic permeabilities, and the usage ratio of the plurality of types of magnetic material powder varies in the axial direction and / or the axial-orthogonal direction of the honeycomb structure part.

[0022] Item 16. The present invention may relate to the honeycomb structure according to Item 15, wherein the honeycomb structure includes, in an end face or a cross section perpendicular to the axial direction, a central region including an axial center of the honeycomb structure and a peripheral region adjacent to the peripheral wall, and the magnetic permeability of the magnetic material powder in the central region is greater than the magnetic permeability of the magnetic material powder in the peripheral region.

[0023] Item 17. The present invention may relate to a honeycomb structure according to Item 16, wherein the difference between the magnetic permeability of the magnetic material powder in the central region and the magnetic permeability of the magnetic material powder in the peripheral region is 1000 or more.

[0024] Item 18. In one embodiment, the present invention relates to a honeycomb unit comprising: a plurality of honeycomb structures each having an outer peripheral wall and partition walls disposed inside the outer peripheral wall that partition a plurality of cells that form flow paths extending from one end face to the other end face, the honeycomb structures being arranged side by side in their axial direction and / or in a direction orthogonal to the axis; and magnetic material powder adhered to or filled in at least one of the plurality of cells in at least one of the plurality of honeycomb structures, wherein the volume and / or weight of the magnetic material powder per unit volume differs in the axial direction and / or the axis-orthogonal direction of the honeycomb unit.

[0025] Item 19. In one embodiment, the present invention relates to a honeycomb unit comprising: a plurality of honeycomb structures each having an outer peripheral wall and partition walls disposed inside the outer peripheral wall to define a plurality of cells that form flow paths extending from one end face to the other end face, the honeycomb structures being aligned in their axial direction and / or the axially orthogonal direction; and magnetic material powder adhered to or filled in at least one of the plurality of cells in at least one of the plurality of honeycomb structures, wherein the magnetic material powder includes a plurality of types of magnetic material powder having different magnetic permeabilities, and the usage ratio of the plurality of types of magnetic material powder varies in the axial direction and / or the axially orthogonal direction of the honeycomb unit.

[0026] Item 20. The present invention may relate to the honeycomb unit according to Item 18 or 19, wherein a magnetic material or a metal is disposed between the honeycomb structures.

[0027] Item 21. In one embodiment, the present invention relates to an induction heating device including the honeycomb structure according to any one of Items 1 to 17 or the honeycomb unit according to any one of Items 18 to 20, and an induction heating coil that is disposed on the outer periphery of the honeycomb structure or the honeycomb unit and heats the honeycomb structure or the honeycomb unit by induction heating. [Effects of the Invention]

[0028] According to the honeycomb structure and induction heating device of the present invention, the volume and / or weight of magnetic material powder per unit volume varies in the axial direction and / or the axial-orthogonal direction of the honeycomb structure part, or the proportions of multiple types of magnetic material powder used vary, so that the temperature in the axial direction and / or the axial-orthogonal direction during induction heating can be adjusted.

[0029] Furthermore, according to the honeycomb unit of the present invention, the volume and / or weight of the magnetic material powder per unit volume varies in the axial direction and / or the axial-orthogonal direction of the honeycomb unit, or the ratio of use of multiple types of magnetic material powder varies, so that the temperature in the axial direction and / or the axial-orthogonal direction during induction heating can be adjusted. [Brief explanation of the drawings]

[0030] [Figure 1] 1 is a perspective view showing an induction heating device including a honeycomb structure according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a circuit diagram showing an example of the power supply circuit of FIG. [Figure 3] 2 is an explanatory view showing a first embodiment of the arrangement of magnetic cells in an end face or a cross section perpendicular to an axial direction AD of the honeycomb structure part of FIG. 1. FIG. [Figure 4] 1. FIG. 4 is an explanatory view showing a second embodiment of the arrangement of magnetic cells in the end face or cross section perpendicular to the axial direction AD of the honeycomb structure part of FIG. [Figure 5] 2 is an explanatory view showing a first embodiment of a region arrangement in an end face or a cross section perpendicular to an axial direction AD of the honeycomb structure part of FIG. 1. FIG. [Figure 6] 1. FIG. 4 is an explanatory view showing a second embodiment of the region arrangement in the end face or cross section perpendicular to the axial direction AD of the honeycomb structure part of FIG. [Figure 7] 1. FIG. 4 is an explanatory diagram showing a change in the arrangement of magnetic cells in the axial direction AD in the honeycomb structure part of FIG. [Figure 8] FIG. 8 is an explanatory diagram conceptually showing the arrangement of the magnetic cells in FIG. 7. [Figure 9] 2 is an explanatory view showing a first mode in which the arrangement of magnetic cells changes in the axis-orthogonal direction OD and the axial direction AD in the honeycomb structure of FIG. 1.

[0023] FIG. [Figure 10] 1. FIG. 4 is an explanatory view showing a second mode in which the arrangement of magnetic cells changes in the axis-orthogonal direction OD and the axial direction AD in the honeycomb structure of FIG. [Figure 11] FIG. 10 is an explanatory view showing a main part of a honeycomb structure according to a second embodiment of the present invention. [Figure 12] FIG. 10 is a perspective view showing an induction heating device including a honeycomb unit according to a fourth embodiment of the present invention. [Figure 13] FIG. 13 is a perspective view showing the central honeycomb structure of FIG. [Figure 14] FIG. 13 is a perspective view showing the peripheral honeycomb structure of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0031] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The present invention is not limited to each embodiment, and the components can be modified and embodied without departing from the spirit of the present invention. Furthermore, various inventions can be formed by appropriately combining multiple components disclosed in each embodiment. For example, some components may be omitted from all the components shown in the embodiments. Furthermore, components of different embodiments may be appropriately combined.

[0032] Embodiment 1 Fig. 1 is a perspective view showing an induction heating device including a honeycomb structure 1 according to a first embodiment of the present invention, and Fig. 2 is a circuit diagram showing an example of a power supply circuit 3 of Fig. 1. The induction heating device shown in Fig. 1 is configured to be able to heat the honeycomb structure 1 by induction heating. The induction heating device of this embodiment includes the honeycomb structure 1, an induction heating coil 2, and a power supply circuit 3.

[0033] The honeycomb structure 1 has a honeycomb structure portion 10 and magnetic material powder 11.

[0034] The honeycomb structure 10 has an outer peripheral wall 100 and partition walls 101 arranged inside the outer peripheral wall 100 and defining a plurality of cells 101a that form flow paths extending from one end face to the other end face. The honeycomb structure 10 may have a columnar outer shape. A columnar shape can be understood as a three-dimensional shape having a predetermined thickness in the axial direction AD. The axial direction AD may be the extension direction of the cells 101a. The ratio (aspect ratio) of the axial length of the honeycomb structure 10 to the diameter or width of the end face of the honeycomb structure 10 is arbitrary. The columnar shape may include a shape (flat shape) in which the axial length of the honeycomb structure 10 is shorter than the diameter or width of the end face. The external shape of the honeycomb structure part 10 is not particularly limited, but can be a columnar shape with circular end faces (cylindrical shape) as shown in Figure 1, a columnar shape with oval end faces, a columnar shape with polygonal end faces (quadragonal, pentagonal, hexagonal, heptagonal, octagonal, etc.), or the like.

[0035] The material of the outer peripheral wall 100 and the partition walls 101 is not particularly limited, but they are usually formed of a ceramic material. Examples include cordierite, silicon carbide, aluminum titanate, silicon nitride, mullite, alumina, silica, a silicon-silicon carbide-based composite material, a silicon carbide-cordierite-based composite material, and in particular a silicon-silicon carbide composite or a sintered body containing silicon carbide as the main component. In this specification, "silicon carbide-based" means that the outer peripheral wall 100 and the partition walls 101 contain silicon carbide in an amount of 50 mass% or more of the entire outer peripheral wall 100 and the partition walls 101. The outer peripheral wall 100 and the partition walls 101 containing a silicon-silicon carbide composite as the main component means that the outer peripheral wall 100 and the partition walls 101 contain 90 mass% or more of the silicon-silicon carbide composite (total mass) of the entire outer peripheral wall 100 and the partition walls 101. Here, the silicon-silicon carbide composite contains silicon carbide particles as an aggregate and silicon as a binder that bonds the silicon carbide particles, and it is preferable that a plurality of silicon carbide particles are bonded by the silicon so as to form pores between the silicon carbide particles. Furthermore, the statement that the outer peripheral wall 100 and the partition walls 101 are mainly composed of silicon carbide means that the outer peripheral wall 100 and the partition walls 101 contain silicon carbide (total mass) in an amount of 90 mass% or more of the entire outer peripheral wall 100 and the partition walls 101.

[0036] Preferably, the outer peripheral wall 100 and the partition walls 101 are formed of at least one ceramic material selected from the group consisting of cordierite, silicon carbide, silicon-silicon carbide composite, aluminum titanate, silicon nitride, mullite, silica, and alumina.

[0037] The shape of the cells 101a is not particularly limited, but is preferably a polygon such as a triangle, a rectangle, a pentagon, a hexagon, or an octagon, a circle, or an ellipse in a cross section perpendicular to the central axis of the honeycomb structure 1, or may be other irregular shapes. A polygon is preferable.

[0038] The thickness of the partition walls 101 is preferably 0.05 to 0.50 mm, and more preferably 0.10 to 0.45 mm from the viewpoint of ease of production. For example, when the thickness is 0.05 mm or more, the strength of the honeycomb structure 1 is further improved, and when the thickness is 0.50 mm or less, the pressure loss can be reduced. The thickness of the partition walls 101 is an average value measured by observing the cross section in the central axis direction with a microscope.

[0039] The porosity of the partition walls 101 is preferably 20 to 70%. In terms of ease of production, the porosity of the partition walls 101 is preferably 20% or more, and when it is 70% or less, the strength of the honeycomb structure 1 can be maintained.

[0040] The average pore diameter of the partition walls 101 is preferably 2 to 30 μm, and more preferably 5 to 25 μm. When the average pore diameter of the partition walls 101 is 2 μm or more, manufacturing becomes easy, and when it is 30 μm or less, the strength of the honeycomb structure 1 can be maintained. In this specification, the terms "average pore diameter" and "porosity" refer to the average pore diameter and porosity measured by mercury intrusion porosimetry.

[0041] The density of the cells 101a is not particularly limited, but is preferably 5 to 150 cells / cm. 2 The range is preferably 5 to 100 cells / cm. 2 More preferably, the range is 31 to 80 cells / cm. 2 It is more preferable that the range is:

[0042] Such a honeycomb structure 1 is produced by forming a clay containing ceramic raw materials into a honeycomb shape having partition walls 101 that define a plurality of cells 101a extending from one end face to the other end face and serving as fluid flow paths, forming a honeycomb formed body, and then drying and firing the honeycomb formed body. When the obtained honeycomb structure 1 is used for the honeycomb structure 1 of this embodiment, the peripheral wall 100 may be extruded integrally with the honeycomb structure 1 and used as the peripheral wall 100 as is, or after forming or firing, the periphery of the honeycomb structure 1 may be ground to a predetermined shape, and a coating material may be applied to the ground honeycomb structure 1 to form a peripheral coating. Note that in this embodiment, for example, a honeycomb structure 1 having a periphery without grinding the outermost periphery of the honeycomb structure 1 may be used, and the coating material may be further applied to the peripheral surface of the honeycomb structure 1 having the periphery (i.e., further outside the periphery of the honeycomb structure 1) to form a peripheral coating. That is, in the former case, only the peripheral coating made of the coating material is formed on the outer peripheral surface of the honeycomb structure 1, forming the outermost peripheral wall 100. On the other hand, in the latter case, a two-layer structured peripheral wall 100 is formed on the outer peripheral surface of the honeycomb structure 1, with an additional peripheral coating made of the coating material laminated thereon. The peripheral wall 100 may be extruded integrally with the honeycomb structure part 10 and fired as is, and used as the peripheral wall 100 without any peripheral processing.

[0043] The honeycomb structure 1 is not limited to an integrated honeycomb structure 1 in which the partition walls 101 are integrally formed, but may also be, for example, a honeycomb structure 1 (bonded honeycomb structure) having a structure in which a plurality of columnar honeycomb segments having ceramic partition walls 101 and a plurality of cells 101a formed by the partition walls 101 as fluid flow paths are combined together via a bonding material layer.

[0044] The magnetic material powder 11 is attached to or filled in at least one of the plurality of cells 101a. The magnetic material powder 11 may form a coating layer provided on the surface of the partition wall 101, or may be filled in the cells 101a to form plugging portions that plug the ends or the entire cells 101a. Fig. 1 shows an embodiment in which the magnetic material powder 11 forms plugging portions.

[0045] When the magnetic material powder 11 forms a coating layer, the coating layer may contain a binder dispersed with the magnetic material powder 11. As the binder, glass, crystallized glass, ceramics containing silicic acid, boric acid, or borosilicate, or glass, crystallized glass, ceramics, etc. containing other oxides may be used.

[0046] When the magnetic material powder 11 forms the plugging portions, the magnetic material powder 11 may have a columnar outer shape that matches the shape of the cells 101a. The magnetic material powder 11 may have such an outer shape before being filled into the cells 101a, or may have such an outer shape after being filled into the cells 101a. In other words, the magnetic material powder 11 may constitute a shaped material having a predetermined shape, or may constitute a paste-like unshaped material.

[0047] The shaped material and the unshaped material may be composed of a composite composition of magnetic material powder 11 and a binder or adhesive material. Examples of binders include materials mainly composed of metal or glass. Examples of adhesive materials include materials mainly composed of silica or alumina. In addition to the binder or adhesive material, an organic or inorganic substance may also be contained. The magnetic material powder 11 may be filled all the way from one end face to the other end face of the honeycomb structure 1. Alternatively, the magnetic material powder 11 may be filled from one end face of the honeycomb structure 1 to partway through the cells 101a.

[0048] The types of magnetic materials constituting the magnetic material powder 11 include, for example, balance Co-20 mass % Fe, balance Co-25 mass % Ni-4 mass % Fe, balance Fe-15 to 35 mass % Co, balance Fe-17 mass % Co-2 mass % Cr-1 mass % Mo, balance Fe-49 mass % Co-2 mass % V, balance Fe-18 mass %. Co-10 mass%Cr-2 mass%Mo-1 mass%Al, balance Fe-27 mass%Co-1 mass%Nb, balance Fe-20 mass%Co-1 mass%Cr-2 mass%V, balance Fe-35 mass%Co-1 mass%Cr, pure cobalt, pure iron, electromagnetic soft iron, balance Fe-0.1~0.5 mass%Mn, balance Fe-3 mass% Si, balance Fe-6.5 mass%Si, balance Fe-18 mass%Cr, balance Fe-16 mass%Cr-8 mass%Al, balance Ni-13 mass%Fe-5.3 mass%Mo, balance Fe-45 mass%Ni, balance Fe-10 mass%Si-5 mass%Al, balance Fe-36 mass%Ni, balance Fe-45 mass%Ni, balance Part Fe-35 mass % Cr, remainder Fe-13 mass % Cr-2 mass % Si, remainder Fe-20 mass % Cr-2 mass % Si-2 mass % Mo, balance Fe-20 mass % Co-1 mass % V, remainder Fe-13 mass % Cr-2 mass % Si, balance Fe-17 mass % Co-2 mass % Cr-1 mass % Mo, etc.

[0049] The induction heating coil 2 has a conductor 20 wound around a predetermined axis AL. The induction heating coil 2 is disposed on the outer periphery of the honeycomb structure 1. The axis AL of the induction heating coil 2 may be parallel to the axial direction AD of the honeycomb structure 1. The axis AL may be coaxial with the central axis of the honeycomb structure 1.

[0050] A power supply circuit 3 is connected to the induction heating coil 2. As shown in FIG. 2, the power supply circuit 3 may include a DC power supply 30, an inverter 31, a transformer 32, and a resonant capacitor 33. DC power from the DC power supply 30 is converted to AC power by the inverter 31. The transformer 32 has a primary coil 32a connected to the inverter 31 and a secondary coil 32b connected to the resonant capacitor 33 and the induction heating coil 2. The turns ratio of the primary coil 32a to the secondary coil 32b is N:1. N is a number greater than 1, and the transformer 32 can amplify the current of the AC power. The capacitance of the resonant capacitor 33 is set to adjust the resonant frequency of the power supply circuit 3. The induction heating coil 2 is connected in series to the resonant capacitor 33 and may be connected to both ends of the secondary coil 32b together with the resonant capacitor 33.

[0051] When an alternating current is supplied from the power supply circuit 3 to the induction heating coil 2, a magnetic flux is generated in the vicinity of the induction heating coil 2. The honeycomb structure 1 can be induction heated by the magnetic flux from the induction heating coil 2.

[0052] In general, the magnetic flux from the induction heating coil 2 tends to concentrate on the outer periphery of the honeycomb structure 1 close to the induction heating coil 2, which tends to cause an unintended temperature deviation between the outer periphery and the center in the axial direction orthogonal to the axial direction OD of the honeycomb structure 1. There is also a need to intentionally cause a temperature deviation in the axial direction AD and / or the axial direction orthogonal to the axial direction OD during induction heating, but until now it has been difficult to intentionally cause such a temperature deviation.

[0053] The honeycomb structure 1 of this embodiment is configured so that the volume and / or weight of the magnetic material powder 11 per unit volume varies with respect to the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure portion 10. The magnetic flux from the induction heating coil 2 is induced more in locations where the volume and / or weight of the magnetic material powder 11 per unit volume is large, i.e., locations where the magnetic permeability is high. Depending on the distribution of the magnetic material powder 11, the distribution of the magnetic flux can be designed as desired, and the temperature in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure 1 during induction heating can be adjusted. That is, in the honeycomb structure 1 of this embodiment, the temperature distribution of the honeycomb structure 1 can be made uniform, or intentional temperature deviations can be generated.

[0054] The distribution of the magnetic material powder 11 will be described in more detail below. Of the multiple cells 101a, the cells 101a that are filled with magnetic material powder 11 or have magnetic material powder 11 attached to their partition walls 101 are referred to as magnetic cells 101b. In other words, the multiple cells 101a include multiple magnetic cells 101b. The size of each cell is arbitrary, and the shape is not limited to a rectangle but can be any shape, such as a triangle, pentagon, hexagon, or octagon.

[0055] The honeycomb structure 1 of this embodiment may have a plurality of regions that are arranged coaxially with each other and have different abundance ratios of the magnetic cells 101b in the end face or cross section perpendicular to the axial direction AD. By providing such regions, the volume and / or weight of the magnetic material powder 11 per unit volume can be adjusted in the end face or cross section perpendicular to the axial direction AD, and the temperature of the honeycomb structure 1 during induction heating in the axially orthogonal direction OD can be adjusted.

[0056] As described above, more magnetic flux is induced in areas where the volume and / or weight of the magnetic material powder 11 per unit volume is large. Therefore, the proportion of magnetic cells 101b can be relatively increased in areas where it is desired to increase the temperature. The proportion of magnetic cells 101b can be calculated based on the number of magnetic cells 101b contained in a predetermined number of adjacent cells 101a. It can also be expressed as "proportion of magnetic cells 101b" = "number of magnetic cells 101b" ÷ "number of cells 101a." Here, the "number of cells 101a" includes not only the number of cells 101a that are not filled or attached with magnetic material powder 11, but also the number of magnetic cells 101b.

[0057] Next, FIG. 3 is an explanatory diagram showing a first embodiment of the arrangement of the magnetic cells 101b in a cross section perpendicular to the end face or axial direction AD of the honeycomb structure 10 of FIG. 1. Any method for adjusting the proportion of the magnetic cells 101b can be used. For example, the arrangement of the magnetic cells 101b shown in FIGS. 3(a) and 3(b) can be used. As shown in FIGS. 3(a) and 3(b), the axis-orthogonal direction OD of the honeycomb structure 1 includes first and second directions OD1 and OD2 that intersect with each other. The first and second directions OD1 and OD2 are directions extending from the center of a cell 101a toward the two different partition walls 101 that form that cell 101a. More specifically, the first and second directions OD1 and OD2 may be directions passing through the center of the cell 101a and the widthwise center of the two different partition walls 101 that form that cell 101a. The width of the partition walls 101 may be understood as the distance between the intersections of the partition walls 101. When the cells 101a are rectangular as in the illustrated embodiment, the first and second directions OD1 and OD2 may be perpendicular to each other. A predetermined number of adjacent cells 101a can form a cell block 101c including X cells 101a (X is any positive number) in each of the first and second directions OD1 and OD2. Between regions with different proportions of magnetic cells 101b, the number of magnetic cells 101b included in the cell block 101c of the same size may be different. By varying the number of magnetic cells 101b included in the cell block 101c of the same size, the proportion of magnetic cells 101b can be easily adjusted.

[0058] In Figures 3(a) and 3(b), a cell block 101c is made up of four cells 101a in each of the first and second directions OD1 and OD2. In Figure 3(a), one cell block 101c includes one magnetic cell 101b, and in Figure 3(b), one cell block 101c includes two magnetic cells 101b. In the arrangement shown in Figure 3(a), the proportion of magnetic cells 101b is 1 / 16, and in the arrangement shown in Figure 3(b), the proportion of magnetic cells 101b is 1 / 8.

[0059] The cell block 101c may include three or more magnetic cells 101b. As shown in Fig. 3(b), the magnetic cells 101b may be adjacent to each other, or one cell block 101c may include multiple magnetic cells 101b spaced apart from each other.

[0060] Next, Fig. 4 is an explanatory diagram showing a second mode of the arrangement of the magnetic cells 101b in a cross section perpendicular to the end face or axial direction AD of the honeycomb structure section 10 of Fig. 1. The abundance ratio of the magnetic cells 101b may be, for example, the arrangements of the magnetic cells 101b shown in Fig. 4(a) to (c). That is, between regions having different abundance ratios of the magnetic cells 101b, the size of the cell block 101c containing one magnetic cell 101b may be different from each other. By making the size of the cell block 101c containing one magnetic cell 101b different from each other, the abundance ratio of the magnetic cells 101b can be easily adjusted.

[0061] FIG. 4A shows a cell block 101c including three cells 101a in each of the first and second directions OD1 and OD2, and one magnetic cell 101b is included (the ratio of the magnetic cells 101b is 1 / 9). FIG. 4B shows a cell block 101c including four cells 101a in each of the first and second directions OD1 and OD2, and one magnetic cell 101b is included (the ratio of the magnetic cells 101b is 1 / 16). FIG. 4C shows a cell block 101c including five cells 101a in each of the first and second directions OD1 and OD2, and one magnetic cell 101b is included (the ratio of the magnetic cells 101b is 1 / 25). A smaller or larger cell block 101c may include one magnetic cell 101b (the ratio of the magnetic cells 101b may be greater than 1 / 9 or less than 1 / 25).

[0062] Next, FIG. 5 is an explanatory diagram showing a first embodiment of the region arrangement in a cross section perpendicular to the end face or axial direction AD of the honeycomb structure 10 of FIG. 1. As shown in FIG. 5, the honeycomb structure 10 may include a central region 12 including an axial center 10c of the honeycomb structure 10, and an outer peripheral region 13 adjacent to the outer peripheral wall 100. Although not limited thereto, the proportion of magnetic cells 101b in the central region 12 may be greater than the proportion of magnetic cells 101b in the outer peripheral region 13. This embodiment is particularly useful when it is desired to induce more magnetic flux to the central region 12 and increase the temperature of the central region 12. For example, the arrangement of the magnetic cells 101b in the central region 12 may be the embodiment shown in FIG. 3(b) or FIG. 4(a), and the arrangement of the magnetic cells 101b in the outer peripheral region 13 may be the embodiment shown in FIG. 3(a) or FIG. 4(b).

[0063] The proportion of the magnetic cells 101b in the central region 12 may be greater than the proportion of the magnetic cells 101b in the outer peripheral region 13 by 20% or more.

[0064] The diameter of the central region 12 may be 10% to 90% of the diameter of the honeycomb structure section 10, preferably 25% to 75% and more preferably 40% to 60%. The width (width on one side) of the peripheral region 13 in the axially orthogonal direction OD may be 10% to 90% of the diameter of the honeycomb structure section 10, preferably 25% to 75% and more preferably 40% to 60%.

[0065] Next, Fig. 6 is an explanatory diagram showing a second embodiment of the region arrangement in a cross section perpendicular to the end face or axial direction AD of the honeycomb structure 10 of Fig. 1. As shown in Fig. 6, the honeycomb structure 10 may include at least one intermediate region 14 between the central region 12 and the outer peripheral region 13. Although not limited thereto, the proportion of the magnetic cells 101b in the at least one intermediate region 14 may be smaller than the proportion of the magnetic cells 101b in the central region 12 and larger than the proportion of the magnetic cells 101b in the outer peripheral region 13. When two or more intermediate regions 14 are provided, the proportion of the magnetic cells 101b in the inner intermediate region 14 may be larger than the proportion of the magnetic cells 101b in the outer intermediate region 14.

[0066] The width (width on one side) of the intermediate region 14 in the axially perpendicular direction OD may be 10% or more and 80% or less of the diameter of the honeycomb structure part 10, preferably 10% or more and 60% or less, and more preferably 10% or more and 40% or less.

[0067] The proportion of the magnetic cells 101b can be changed arbitrarily, and if necessary, the proportion of the magnetic cells 101b in the inner region (e.g., the central region 12) may be smaller than the proportion of the magnetic cells 101b in the outer region (e.g., the outer peripheral region 13 or the intermediate region 14). The proportion of the magnetic cells 101b in the intermediate region 14 may be larger or smaller than both the central region 12 and the outer peripheral region 13.

[0068] Although the honeycomb structure 1 of the present embodiment has been described above based on the proportion of the magnetic cells 101b, the honeycomb structure 1 of the present embodiment can also be understood from another viewpoint as follows.

[0069] That is, the honeycomb structure 10 may have a plurality of regions that are arranged coaxially with each other on the end face or in a cross section perpendicular to the axial direction AD, and that have different numbers of magnetic cells 101b per unit area. The number of magnetic cells 101b per unit area can be calculated, for example, by the number of magnetic cells 101b per square of any plurality of cells.

[0070] Furthermore, the number of adjacent magnetic cells 101b may differ between the multiple regions. That is, in one region, one magnetic cell 101b may be arranged spaced apart as shown in Fig. 3(a), and in another region, two magnetic cells 101b may be arranged adjacently as shown in Fig. 3(b). More magnetic cells 101b may be arranged adjacently.

[0071] Furthermore, the number of magnetic cells 101b per unit area in the central region 12 may be greater than the number of magnetic cells 101b per unit area in the outer circumferential region 13.

[0072] Next, Fig. 7 is an explanatory diagram showing changes in the arrangement of the magnetic cells 101b in the axial direction AD in the honeycomb structure 10 of Fig. 1, and Fig. 8 is an explanatory diagram conceptually showing the arrangement of the magnetic cells 101b in Fig. 7. The honeycomb structure 10 may have end faces spaced apart from each other in the axial direction AD or multiple cross sections perpendicular to the axial direction AD, in which the abundance ratio of the magnetic cells 101b or the number of the magnetic cells 101b per unit area differs from each other. Hereinafter, "the abundance ratio of the magnetic cells 101b or the number of the magnetic cells 101b per unit area" may be expressed as "the abundance ratio of the magnetic cells 101b, etc."

[0073] 7 shows a state in which the abundance ratio, etc. of the magnetic cells 101b at one end face E1 is greater than the abundance ratio, etc. of the magnetic cells 101b at the cross section S1 at the intermediate position in the axial direction AD. FIG. 7 also shows a state in which the abundance ratio, etc. of the magnetic cells 101b at the cross section S1 at the intermediate position in the axial direction AD is greater than the abundance ratio, etc. of the magnetic cells 101b at the other end face E2. In other words, the abundance ratio, etc. of the magnetic cells 101b at one end face E1 side may be greater than the abundance ratio, etc. of the magnetic cells 101b at the other end face E2 side. By providing such end faces or cross sections, the volume and / or weight of the magnetic material powder 11 per unit volume in the axial direction AD can be adjusted, and the temperature of the honeycomb structure 1 during induction heating in the axial direction AD can be adjusted.

[0074] The arrangement shown in Fig. 7 can be realized by arranging the magnetic cells 101b as shown in Fig. 8. That is, as shown in Fig. 8, by making it so that some of the magnetic cells 101b present on one end face E1 do not reach the intermediate position and that the magnetic cells 101b that had reached the intermediate position do not reach the other end face E2, the arrangement shown in Fig. 7 can be realized. Although Figs. 7 and 8 illustrate the case where the magnetic cells 101b are not provided on the other end face E2, the magnetic cells 101b may be provided on the other end face E2.

[0075] Next, Fig. 9 is an explanatory diagram showing a first aspect in which the arrangement of the magnetic cells 101b changes in the axial-orthogonal direction OD and the axial direction AD in the honeycomb structure 1 of Fig. 1, and Fig. 10 is an explanatory diagram showing a second aspect in which the arrangement of the magnetic cells 101b changes in the axial-orthogonal direction OD and the axial direction AD in the honeycomb structure 1 of Fig. 1. The change in the arrangement of the magnetic cells 101b in the axial-orthogonal direction OD was explained using Figs. 3 to 6, and the change in the arrangement of the magnetic cells 101b in the axial direction AD was explained using Figs. 7 and 8. These changes in the arrangement of the magnetic cells 101b in the axial-orthogonal direction OD and the axial direction AD may be implemented in combination. This makes it possible to adjust the volume and / or weight of the magnetic material powder 11 per unit volume in the axial-orthogonal direction OD and the axial direction AD, and to adjust the temperature of the honeycomb structure 1 during induction heating in the axial-orthogonal direction OD and the axial direction AD.

[0076] 9, the central region 12 having the above-described arrangement of the magnetic cells 101b may be gradually reduced in size from one end face E1 to the other end face E2. As the central region 12 is reduced in size, the outer peripheral region 13 may be expanded.

[0077] 10, the central region 12 having the above-described arrangement of the magnetic cells 101b may be gradually reduced from one end face E1 to an intermediate position in the axial direction AD and terminated at the intermediate position. That is, such an arrangement of the magnetic cells 101b may not be provided from the intermediate position to the other end face E2. From the intermediate position to the other end face E2, the same arrangement of the magnetic cells 101b as that of the outer peripheral region 13 at one end face E1 may be provided, or a different arrangement of the magnetic cells 101b may be provided. From the intermediate position to the other end face E2, the magnetic cells 101b may not be provided.

[0078] Embodiment 2 11 is an explanatory view showing a main part of a honeycomb structure 1 according to embodiment 2 of the present invention. The overall configuration of the honeycomb structure 1 according to embodiment 2 is the same as that of embodiment 1, and FIGS. 1 to 10 can be referred to for the description thereof.

[0079] In the first embodiment, it has been described that the volume and / or weight of the magnetic material powder 11 per unit volume is varied by the arrangement of the magnetic cells 101b. However, as shown in Fig. 11, the volume and / or weight of the magnetic material powder 11 per unit volume may be varied by changing the filling rate of the magnetic material powder 11 in the magnetic cells 101b. Fig. 11(a) shows a state in which the filling rate of the magnetic material powder 11 is relatively low, and Fig. 11(b) shows a state in which the filling rate of the magnetic material powder 11 is relatively high.

[0080] The honeycomb structure portion 10 may have a plurality of regions that are arranged coaxially with each other in an end face or a cross section perpendicular to the axial direction AD, and that have different filling rates of the magnetic material powder 11 in the magnetic cells 101b. Although not limited thereto, in the second embodiment, all the cells 101a may be magnetic cells 101b, and the filling rate of the magnetic material powder 11 may be changed in the axially perpendicular direction OD. The filling rate can be determined by image analysis. More specifically, it can be measured by taking a photograph of the cross section of the magnetic cell 101b with an optical microscope or a scanning electron microscope, importing the photograph into an image analyzer, and determining the ratio of the magnetic material powder 11 to voids within the imported range.

[0081] Although not limited to this, the filling rate can be varied by changing the particle size distribution of the magnetic material powder 11 for each region. The coarser the particle size of the magnetic material powder 11, the higher the filling rate tends to be. The filling rate can be further increased by mixing magnetic material powder 11 with coarse particle size and magnetic material powder 11 with fine particle size. The particle size of the magnetic material powder 11 may be in the range of 5 to 100 μm in terms of D50 (median diameter).

[0082] As in the first embodiment, the honeycomb structure 10 may include a central region 12 including the axial center 10c of the honeycomb structure 10, and a peripheral region 13 adjacent to the peripheral wall 100 (see FIG. 5). The filling rate of the magnetic material powder 11 in the central region 12 may be higher than the filling rate of the magnetic material powder 11 in the peripheral region 13.

[0083] It is preferable that the difference in filling rate between the central region 12 and the outer peripheral region 13 be 10% or more. In other words, it is preferable that the filling rate in the central region 12 be 10% or more higher than the filling rate in the outer peripheral region 13. A difference in filling rate of 10% or more allows more magnetic flux to be induced in the central region 12. It is more preferable that the difference in filling rate be 20% or more, and even more preferable that it be 30% or more.

[0084] The honeycomb structure portion 10 may have end faces spaced apart from each other in the axial direction AD or a plurality of cross sections perpendicular to the axial direction AD, in which the filling rates of the magnetic material powder 11 in the magnetic cells 101b are different from each other. That is, instead of changing the arrangement of the magnetic cells 101b as described with reference to Figs. 7 to 10, the filling rate of the magnetic material powder 11 may be changed in the axial direction AD.

[0085] The filling rate of the magnetic material powder 11 on one end face E1 side of the honeycomb structure part 10 may be higher than the filling rate of the magnetic material powder 11 on the other end face E2 side. This makes it possible to more reliably adjust the temperature of the honeycomb structure 1 during induction heating in the axial direction AD. The other configurations are the same as those of embodiment 1.

[0086] It is also possible to combine the first and second embodiments. That is, while adjusting the arrangement of the magnetic cells 101b as in the first embodiment, the filling rate of the magnetic material powder 11 in the magnetic cells 101b may be changed in the axial direction AD and / or the direction orthogonal to the axis OD.

[0087] Embodiment 3 The overall configuration of the honeycomb structure 1 of the third embodiment is similar to that of the first embodiment, and reference can be made to FIGS. 1 to 10 for the description thereof. In the first and second embodiments, the volume and / or weight of the magnetic material powder 11 per unit volume is varied to adjust the induction of magnetic flux and thereby adjust the temperature in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure 1 during induction heating. However, it is also possible to use a plurality of types of magnetic material powder 11 having different magnetic permeabilities to adjust the induction of magnetic flux and thereby adjust the temperature in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure 1 during induction heating.

[0088] That is, in the honeycomb structure 1 of the third embodiment, the proportions of the multiple types of magnetic material powders 11 used vary with respect to the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure portion 10. For example, it is assumed that a first magnetic material powder having a first magnetic permeability and a second magnetic material powder having a second magnetic permeability are used, and the first magnetic permeability is greater than the second magnetic permeability. The cells 101a may be filled with the first magnetic material powder alone (100%), the second magnetic material powder alone (100%), or a mixture of the first magnetic material powder and the second magnetic material powder at a predetermined ratio. The greater the proportion of the first magnetic material powder used, the greater the magnetic permeability and the more magnetic flux is induced. The distribution of the proportions of the multiple types of magnetic material powders 11 used can be freely designed, and the temperature in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb structure 1 during induction heating can be adjusted.

[0089] As in the first embodiment, the honeycomb structure 10 can include a central region 12 including the axial center 10c of the honeycomb structure 10, and an outer peripheral region 13 adjacent to the outer peripheral wall 100 (see FIG. 5). The magnetic permeability of the magnetic material powder 11 in the central region 12 may be greater than the magnetic permeability of the magnetic material powder 11 in the outer peripheral region 13. For example, the above-mentioned first magnetic material powder may be used alone in the central region 12, and the above-mentioned second magnetic material powder may be used alone in the outer peripheral region 13.

[0090] The difference in magnetic permeability between the magnetic material powder 11 in the central region 12 and the magnetic material powder 11 in the peripheral region 13 is preferably 1000 or more. A difference in magnetic permeability of 1000 or more allows more magnetic flux to be induced in the central region 12. The difference in magnetic permeability is more preferably 1500 or more, and even more preferably 2000 or more.

[0091] The magnetic permeability of the magnetic material powder 11 on one end face E1 side of the honeycomb structure part 10 may be higher than the magnetic permeability of the magnetic material powder 11 on the other end face E2 side. This makes it possible to more reliably adjust the temperature of the honeycomb structure 1 during induction heating in the axial direction AD. The other configurations are the same as those of embodiment 1.

[0092] At least one of Embodiment 1 and Embodiment 2 may be combined with Embodiment 3. That is, the arrangement of the magnetic cells 101b may be adjusted as in Embodiment 1, and / or the filling rate of the magnetic material powder 11 in the magnetic cells 101b may be changed as in Embodiment 2, while changing the proportion of the multiple types of magnetic material powder 11 used.

[0093] Embodiment 4 Fig. 12 is a perspective view showing an induction heating device including a honeycomb unit 4 according to a fourth embodiment of the present invention, Fig. 13 is a perspective view showing a central honeycomb structure 41 of Fig. 12, and Fig. 14 is a perspective view showing a peripheral honeycomb structure 42 of Fig. 12. In the first to third embodiments, one honeycomb structure 1 and an induction heating device including the same have been described, but in a large plant, for example, a honeycomb unit 4 made up of a combination of a plurality of honeycomb structures 1 and an induction heating device including the same may be used. The present invention can also be applied to such honeycomb units 4 and induction heating devices.

[0094] As shown in FIG. 12, the induction heating device of this embodiment includes a honeycomb unit 4, an induction heating coil 2, and a power supply circuit 3.

[0095] The honeycomb unit 4 includes a plurality of honeycomb structures 1 arranged side by side in the axial direction AD and / or the axially orthogonal direction OD. The overall configuration of the honeycomb structure 1 is the same as that of the first to third embodiments, and the description thereof can be referred to in the description of this embodiment. That is, each of the plurality of honeycomb structures 1 has an outer peripheral wall 100 and partition walls 101 disposed inside the outer peripheral wall 100 to partition and form a plurality of cells 101a that form flow paths extending from one end face to the other end face.

[0096] As shown in the figure, the honeycomb structure 1 of this embodiment has a columnar end face with a rectangular shape. In the illustrated embodiment, the honeycomb structures 1 are arranged side by side in the axial direction AD so that their end faces face each other. The honeycomb structures 1 are also arranged side by side in the axial-orthogonal direction OD so that their outer peripheral walls 100 face each other. The axial direction AD and the axial-orthogonal direction OD of the honeycomb structure 1 may be synonymous with the axial direction AD and the axial-orthogonal direction OD of the honeycomb unit 4 as a whole.

[0097] The number of honeycomb structures 1 arranged in the axial direction AD and the axial-orthogonal direction OD is arbitrary. In the illustrated embodiment, three sets of honeycomb structures 1 are arranged in the axial direction AD, with nine honeycomb structures 1 arranged in the axial-orthogonal direction OD as one set. A larger or smaller number of honeycomb structures 1 may be arranged in the axial-orthogonal direction OD and / or the axial direction AD. For example, the number of honeycomb structures 1 arranged in the axial-orthogonal direction OD or the axial direction AD may be one, such as three honeycomb structures 1 arranged in the axial direction AD.

[0098] In each honeycomb structure 1, the volume and / or weight and usage ratio of the magnetic material powder 11 per unit volume may be adjusted as described in embodiments 1 to 3, but in embodiment 4, the volume and / or weight and usage ratio of the magnetic material powder 11 per unit volume may be constant within one honeycomb structure 1.

[0099] The honeycomb unit 4 may have a magnetic material or metal 5 arranged between the honeycomb structures 1. By arranging such a magnetic material or metal 5, heat radiation from the honeycomb unit 4 is suppressed, and the temperature at the center of the honeycomb unit 4 can be increased. In the illustrated embodiment, the magnetic material or metal 5 is formed in a flat plate shape and arranged between the outer peripheral walls 100 of each honeycomb structure 1. The magnetic material or metal 5 may be adjacent to the outer peripheral walls 100 of each honeycomb structure 1. No magnetic material or metal 5 is arranged between the end faces of each honeycomb structure 1. The magnetic material or metal 5 may be omitted overall, and the outer peripheral walls 100 of each honeycomb structure 1 may be adjacent to each other.

[0100] The overall configuration of the induction heating coil 2 and power supply circuit 3 is the same as in the first to third embodiments, and the description thereof can be referred to in the description of this embodiment. However, the induction heating coil 2 is disposed on the outer periphery of the honeycomb unit 4. The axis AL of the induction heating coil 2 can be parallel to the axial direction AD of the honeycomb unit 4. The axis AL can be coaxial with the central axis of the honeycomb unit 4. When an alternating current is supplied from the power supply circuit 3 to the induction heating coil 2, a magnetic flux is generated in the vicinity of the induction heating coil 2, and the honeycomb unit 4 can be induction heated by the magnetic flux from the induction heating coil 2.

[0101] The honeycomb unit 4 of this embodiment is configured so that the volume and / or weight of the magnetic material powder 11 per unit volume varies in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb unit 4. Depending on the distribution of the magnetic material powder 11, the distribution of the magnetic flux can be designed as desired, and the temperature in the axial direction AD and / or the axis-orthogonal direction OD of the honeycomb unit 4 during induction heating can be adjusted. That is, in the honeycomb unit 4 of this embodiment, the temperature distribution of the honeycomb unit 4 can be made uniform, or intentional temperature deviations can be generated.

[0102] In the honeycomb unit 4 of this embodiment, the proportion of the magnetic cells 101b may be different for each honeycomb structure 1 arranged in the axially orthogonal direction OD. By varying the proportion of the magnetic cells 101b in this way, the volume and / or weight of the magnetic material powder 11 per unit volume in the axially orthogonal direction OD can be adjusted, and the temperature of the honeycomb unit 4 during induction heating in the axially orthogonal direction OD can be adjusted.

[0103] Methods for adjusting the volume and / or weight of magnetic material powder 11 per unit volume in the axially orthogonal direction OD include, but are not limited to, a method of varying the number of magnetic cells 101b contained in cell blocks 101c of the same size for each honeycomb structure 1 (the method described using Figure 3), and / or a method of varying the size of cell blocks 101c containing one magnetic cell 101b for each honeycomb structure 1 (the method described using Figure 4).

[0104] As shown in Fig. 12, the honeycomb unit 4 may include a central honeycomb structure 41 arranged at a position including the axial center of the honeycomb unit 4, and a peripheral honeycomb structure 42 arranged at a position forming the outer edge of the honeycomb unit 4. Although not limited thereto, the proportion of the magnetic cells 101b in the central honeycomb structure 41 may be greater than the proportion of the magnetic cells 101b in the peripheral honeycomb structure 42. This embodiment is particularly useful when it is desired to induce more magnetic flux to the central honeycomb structure 41 and increase the temperature of the central honeycomb structure 41. Figs. 13 and 14 show an example in which the magnetic cells 101b are arranged more densely in the central honeycomb structure 41 than in the peripheral honeycomb structure 42.

[0105] Although not shown, an intermediate honeycomb structure having a different abundance ratio of magnetic cells 101b from those of the central honeycomb structure 41 and the peripheral honeycomb structure 42 may be disposed between the central honeycomb structure 41 and the peripheral honeycomb structure 42. Although not limited thereto, the abundance ratio of magnetic cells 101b in the intermediate honeycomb structure may be smaller than that of the central honeycomb structure 41 and larger than that of the peripheral honeycomb structure 42. When two or more intermediate honeycomb structures are disposed side by side in the axially orthogonal direction OD between the central honeycomb structure 41 and the peripheral honeycomb structure 42, the abundance ratio of magnetic cells 101b in the inner intermediate honeycomb structure may be larger than that of magnetic cells 101b in the outer intermediate honeycomb structure.

[0106] Furthermore, in the honeycomb unit 4, the number of magnetic cells 101b per unit area may differ for each honeycomb structure 1 arranged side by side in the axially orthogonal direction OD. The number of magnetic cells 101b adjacent to each other may differ for each honeycomb structure 1. The number of magnetic cells 101b per unit area in the central honeycomb structure 41 may be greater than the number of magnetic cells 101b per unit area in the peripheral honeycomb structure 42.

[0107] Furthermore, the honeycomb unit 4 may have different proportions of the magnetic cells 101b or different numbers of the magnetic cells 101b per unit area (such as the proportions of the magnetic cells 101b) for the honeycomb structures 1 arranged side by side in the axial direction AD. For example, in Fig. 12, the proportions of the magnetic cells 101b in the middle honeycomb structure 1 may be greater than the proportions of the magnetic cells 101b in the upper and lower honeycomb structures 1.

[0108] Similarly to the second embodiment, the honeycomb unit 4 may have different filling rates of the magnetic material powder 11 in the magnetic cells 101b for each honeycomb structure 1 arranged in the axially orthogonal direction OD. The filling rate of the magnetic material powder 11 in the central honeycomb structure 41 may be higher than the filling rate of the magnetic material powder 11 in the peripheral honeycomb structure 42. It is preferable that the difference between the filling rates in the central honeycomb structure 41 and the peripheral honeycomb structure 42 is 10% or more.

[0109] Furthermore, the honeycomb unit 4 may have different filling rates of the magnetic material powder 11 in the magnetic cells 101b for each honeycomb structure 1 arranged in the axial direction AD. The filling rate of the honeycomb structure 1 at one end side in the axial direction AD may be higher than the filling rate of the honeycomb structure 1 at the other end side.

[0110] As in the third embodiment, the proportions of the magnetic material powders 11 used may differ in the axial direction AD and / or the axially orthogonal direction OD of the honeycomb unit 4. The magnetic permeability of the magnetic material powder 11 in the central honeycomb structure 41 may be greater than that of the magnetic material powder 11 in the peripheral honeycomb structure 42. It is preferable that the difference between the magnetic permeability of the magnetic material powder 11 in the central honeycomb structure 41 and that of the magnetic material powder 11 in the peripheral honeycomb structure 42 is 1000 or more. The magnetic permeability of the magnetic material powder 11 in the honeycomb structure 1 at one end side in the axial direction AD may be greater than that of the magnetic material powder 11 in the honeycomb structure 1 at the other end side. Other configurations are the same as those in the first to third embodiments.

[0111] The present invention is not limited to the embodiments, and the components can be modified and embodied without departing from the spirit of the invention. Furthermore, various inventions can be formed by appropriately combining multiple components disclosed in each embodiment. For example, some components may be omitted from all the components shown in the embodiments. Furthermore, components from different embodiments may be appropriately combined. [Example]

[0112] The honeycomb structure 1 was fabricated as follows. In the raw material mixing step, first, a cordierite raw material was prepared as a ceramic raw material. Specifically, talc, kaolin, calcined kaolin, alumina, aluminum hydroxide, and quartz were mixed to prepare the cordierite raw material. To this cordierite raw material, methyl cellulose and hydroxypropoxyl methyl cellulose as binders, a surfactant, and water were added to prepare a molding raw material, which was then mixed to obtain a clay. Next, in the molding step, the clay was extrusion-molded using a predetermined mold to form a honeycomb molded body in the shape of partition walls forming rectangular cells. The outer periphery was also integrally molded. The obtained honeycomb molded body was then dried and then fired in the firing step. The drying was performed in a microwave dryer for 10 to 30 minutes, and the firing was performed at a maximum temperature of 1430°C for 5 to 15 hours, for a total of 40 to 60 hours, to obtain the honeycomb structure 1. The obtained honeycomb structure 1 had an end face diameter of 82 mm, an axial length of 85 mm, and a cell structure of 4 mil / 400 cpsi.

[0113] Next, Fe-18Cr powder was filled into the cells 101a in each region of the obtained honeycomb structure 1 by the method shown in Table 1 below, and heat-treated in a vacuum atmosphere at 1200°C to produce Examples 1 to 8 and Comparative Examples 1 and 2.

[0114] The heat-treated honeycomb structure 1 was placed in a quartz glass tube with a diameter of 90 mm. An induction heating coil 2, which was made by winding a copper pipe with a diameter of 100 mm three times, was placed on the outer periphery of the quartz glass tube. Then, air at room temperature was blown into the tube with a power of 4 kW, a frequency of 100 kHz, and a flow rate of 0.45 m 3The maximum temperature reached at the center (center in the longitudinal and axial directions) of the honeycomb structure 1 was measured with a thermocouple. The results are also shown in Table 1 below.

[0115] [Table 1]

[0116] In Table 1, for example, the notation "center-41 mm" refers to a circular region of 41 mm diameter centered on the end face or the axial center in a cross section perpendicular to the axial direction AD, and "41 mm-82 mm" refers to the annular region between the 41 mm diameter circle and the outer edge of the honeycomb structure 1. Furthermore, for example, the notation "1 / 25 cell" indicates that there is one magnetic cell 101b in an area of ​​5 cells x 5 cells. The notation "4 / 25 cell" in Example 5 indicates that there is a magnetic cell 101b of 2 cells x 2 cells size in an area of ​​5 cells x 5 cells.

[0117] In Comparative Examples 1 and 2, the magnetic cells 101b are uniformly arranged in the radial direction, whereas in Examples 1 to 8, the proportion of the magnetic cells 101b is varied in the radial direction. As shown in Table 1, it was confirmed that by varying the proportion of the magnetic cells 101b as in Examples 1 to 8, it is possible to adjust the induction of magnetic flux and change the maximum temperature reached at the center of the honeycomb structure 1. In particular, in Examples 1 to 8, the maximum temperature is higher than in Comparative Examples 1 and 2. This is thought to be because the proportion of the magnetic cells 101b in the central region 12 is greater than the proportion of the magnetic cells in the outer circumferential region 13. [Explanation of symbols]

[0118] 1: Honeycomb structure 10: Honeycomb structure 100: Outer wall 101: Bulkhead 101a: Cell 101b: magnetic cell 101c: Cell Block 11:Magnetic material powder 12: Central Area 13: Peripheral area

Claims

1. a honeycomb structure having an outer peripheral wall and partition walls disposed inside the outer peripheral wall to define a plurality of cells that form flow paths extending from one end face to the other end face; a magnetic material powder attached to or filled in at least one of the plurality of cells; Equipped with the volume and / or weight of the magnetic material powder per unit volume varies with respect to the axial direction and / or the axially orthogonal direction of the honeycomb structure part, the plurality of cells include a plurality of magnetic cells in which the magnetic material powder is filled, The honeycomb structure portion is The magnetic cell has a plurality of regions that are arranged coaxially with each other on the end surface or in a cross section perpendicular to the axial direction, and that have different filling rates of the magnetic material powder in the magnetic cell; or The magnetic cells have end faces spaced apart from each other in the axial direction or a plurality of cross sections perpendicular to the axial direction, and the filling rates of the magnetic material powder in the magnetic cells are different from each other, The filling rate varies depending on the particle size distribution of the magnetic material powder. Honeycomb structure.

2. the plurality of cells include a plurality of magnetic cells in which the magnetic material powder is filled in the cells or the magnetic material powder is attached to the partition walls, The honeycomb structure portion has a plurality of regions that are arranged coaxially with each other on the end face or in a cross section perpendicular to the axial direction, and that have different abundance ratios of the magnetic cells. The honeycomb structure according to claim 1 .

3. the axis-orthogonal directions include first and second directions intersecting with each other, A predetermined number of the cells adjacent to each other form a cell block including X number of the cells (X is any positive number) in each of the first and second directions, the number of magnetic cells included in the cell blocks of the same size differs among the plurality of regions; The honeycomb structure according to claim 2 .

4. the axis-orthogonal directions include first and second directions intersecting with each other, A predetermined number of the cells adjacent to each other form a cell block including X number of the cells (X is any positive number) in each of the first and second directions, The size of the cell block including one magnetic cell differs among the plurality of regions. The honeycomb structure according to claim 2 .

5. the honeycomb structure includes a central region including an axial center of the honeycomb structure and a peripheral region adjacent to the peripheral wall, a proportion of the magnetic cells in the central region is greater than a proportion of the magnetic cells in the outer circumferential region; The honeycomb structure according to claim 2 .

6. the plurality of cells include a plurality of magnetic cells in which the magnetic material powder is filled in the cells or the magnetic material powder is attached to the partition walls, The honeycomb structure portion has a plurality of regions that are arranged coaxially with each other on the end face or in a cross section perpendicular to the axial direction, and in which the number of magnetic cells per unit area is different from each other. The honeycomb structure according to claim 1 .

7. The number of adjacent magnetic cells differs among the plurality of regions. The honeycomb structure according to claim 6.

8. the honeycomb structure includes a central region including an axial center of the honeycomb structure and a peripheral region adjacent to the peripheral wall, the number of the magnetic cells per unit area in the central region is greater than the number of the magnetic cells per unit area in the outer circumferential region; The honeycomb structure according to claim 6.

9. the plurality of cells include a plurality of magnetic cells in which the magnetic material powder is filled, the honeycomb structure portion has end faces spaced apart from each other in the axial direction or a plurality of cross sections perpendicular to the axial direction, in which the existence ratio of the magnetic cells or the number of the magnetic cells per unit area are different from each other, The honeycomb structure according to claim 1 .

10. The honeycomb structure portion has a plurality of regions that are arranged coaxially with each other on the end face or in a cross section perpendicular to the axial direction, and in which the filling rates of the magnetic material powder in the magnetic cells are different from each other, the honeycomb structure includes a central region including an axial center of the honeycomb structure and a peripheral region adjacent to the peripheral wall, The filling rate of the magnetic material powder in the central region is higher than the filling rate of the magnetic material powder in the outer peripheral region. The honeycomb structure according to claim 1 .

11. the difference between the filling rate in the central region and the filling rate in the outer peripheral region is 10% or more; The honeycomb structure according to claim 10.

12. The honeycomb structure portion has end faces spaced apart from each other in the axial direction or a plurality of cross sections perpendicular to the axial direction, in which the filling rates of the magnetic material powder in the magnetic cells are different from each other, a filling rate of the magnetic material powder on the one end face side of the honeycomb structure part is higher than a filling rate of the magnetic material powder on the other end face side; The honeycomb structure according to claim 1 .

13. The magnetic material powder contains a plurality of types of magnetic material powder having different magnetic permeabilities, The proportions of the magnetic powders used vary with respect to the axial direction and / or the axially orthogonal direction of the honeycomb structure part. The honeycomb structure according to claim 1 .

14. the honeycomb structure part includes, in the end face or in a cross section perpendicular to the axial direction, a central region including an axial center of the honeycomb structure part and a peripheral region adjacent to the peripheral wall, The magnetic permeability of the magnetic material powder in the central region is greater than the magnetic permeability of the magnetic material powder in the outer peripheral region. The honeycomb structure according to claim 13.

15. a difference between the magnetic permeability of the magnetic material powder in the central region and the magnetic permeability of the magnetic material powder in the outer peripheral region is 1000 or more; The honeycomb structure according to claim 14.

16. a plurality of honeycomb structures each having an outer peripheral wall and partition walls disposed inside the outer peripheral wall to define a plurality of cells forming flow paths extending from one end face to the other end face, the honeycomb structures being arranged side by side in the axial direction and / or the axially orthogonal direction; a magnetic material powder attached to or filled in at least one of the plurality of cells in at least one of the plurality of honeycomb structures; A honeycomb unit comprising: the volume and / or weight of the magnetic material powder per unit volume varies with respect to the axial direction and / or the axially orthogonal direction of the honeycomb unit, the plurality of cells include a plurality of magnetic cells in which the magnetic material powder is filled, The honeycomb unit is The filling rates of the magnetic material powder in the magnetic cells of the honeycomb structures arranged side by side in the axis-orthogonal direction are different from each other, or The filling rates of the magnetic material powder in the magnetic cells are different for each of the honeycomb structures arranged side by side in the axial direction, The filling rate varies depending on the particle size distribution of the magnetic material powder. Honeycomb unit.

17. The magnetic material powder includes a plurality of types of magnetic material powder having different magnetic permeabilities, The proportions of the magnetic powders used vary with respect to the axial direction and / or the axially orthogonal direction of the honeycomb unit. The honeycomb unit according to claim 16.

18. A magnetic material or a metal is disposed between the honeycomb structures. The honeycomb unit according to claim 16.

19. The honeycomb structure according to any one of claims 1 to 15 or the honeycomb unit according to any one of claims 16 to 18; an induction heating coil disposed on the outer periphery of the honeycomb structure or the honeycomb unit, and configured to heat the honeycomb structure or the honeycomb unit by induction heating; An induction heating device comprising:

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