Honeycomb structure and method for manufacturing honeycomb structure
A honeycomb structure includes a ceramic block formed by combining a plurality of honeycomb fired bodies together with an adhesive layer interposed between the plurality of honeycomb fired bodies. The plurality of honeycomb fired bodies each has cell walls extending along a longitudinal direction of the honeycomb fired bodies to define cells. The honeycomb fired bodies adjacent to each other via said adhesive layer each have at least one projected portion on the opposing side faces. The projected portions formed on the honeycomb fired bodies overlap each other when seen from an end face of the honeycomb structure and the projected portions formed on the adjacent honeycomb fired bodies abut each other.
1. A honeycomb structure comprising:
a ceramic block formed by combining a plurality of honeycomb fired bodies together with an adhesive layer interposed between the plurality of honeycomb fired bodies, said plurality of honeycomb fired bodies each having cell walls extending along a longitudinal direction of the honeycomb fired bodies to define cells,
wherein
said honeycomb fired bodies adjacent to each other via said adhesive layer each have at least one projected portion on the opposing side faces,
the projected portions formed on said honeycomb fired bodies overlap each other when seen from an end face of the honeycomb structure and the projected portions formed on said adjacent honeycomb fired bodies abut each other, and
said adhesive layer is provided in a manner that a shortest distance between a side face of one of said adjacent honeycomb fired bodies and a projected portion of another of said adjacent honeycomb fired bodies is smaller than a height of said projected portion from a side face of said another of said adjacent honeycomb fired bodies when said honeycomb fired bodies are adjoined to each other via said adhesive layer.
2. The honeycomb structure according to claim 1 ,
wherein
one of said adjacent honeycomb fired bodies has a first projected portion on a side face,
another of said adjacent honeycomb fired bodies has a first projected portion and a second projected portion on a side face, and
the projected portions are formed in a manner that the first projected portion formed on the side face of said one of said adjacent honeycomb fired bodies is formed between the first and second projected portions formed on the side face of said another of said adjacent honeycomb fired bodies and the first projected portion formed on the side face of said one of said adjacent honeycomb fired bodies and the first and second projected portions formed on the side face of said another of said adjacent honeycomb fired bodies abut each other.
3. The honeycomb structure according to claim 1 ,
wherein
a thickness of cell walls of a periphery of said honeycomb fired bodies is substantially same as a thickness of cell walls other than the cell walls of the periphery.
4. The honeycomb structure according to claim 1 ,
wherein
a thickness of cell walls of a periphery of said honeycomb fired bodies is larger than a thickness of cell walls other than the cell walls of the periphery.
5. The honeycomb structure according to claim 1 ,
wherein
a peripheral coat layer is formed around a periphery of said ceramic block.
6. The honeycomb structure according to claim 5 ,
wherein
said peripheral coat layer is formed by drying and solidifying a paste for a peripheral coat layer.
7. The honeycomb structure according to claim 1 ,
wherein
a length of said projected portions along the longitudinal direction of said honeycomb fired bodies is from about 10% to about 50% of a total longitudinal length of said honeycomb fired bodies.
8. The honeycomb structure according to claim 1 ,
wherein
a height of said projected portions from the side faces of said honeycomb fired bodies is from about 2% to about 5% of a height of said honeycomb fired bodies.
9. The honeycomb structure according to claim 1 ,
wherein
said shortest distance is from about 20% to about 80% of the height of the projected portion from a side face of said another of said adjacent honeycomb fired bodies.
10. The honeycomb structure according to claim 1 ,
wherein
said adhesive layer is formed by drying and solidifying a paste for an adhesive layer.
11. The honeycomb structure according to claim 1 ,
wherein
the side faces of said ceramic block are processed into a predetermined shape through periphery processing.
12. The honeycomb structure according to claim 1 ,
wherein
one honeycomb fired body has two of said projected portions on one side face and also has two of said projected portions on a side face on a reverse side of said one side face.
13. The honeycomb structure according to claim 1 ,
wherein
materials for forming said honeycomb fired bodies comprise at least one of
a nitride ceramic;
a carbide ceramic;
a complex of a metal and a nitride ceramic;
a complex of a metal and a carbide ceramic;
a silicon-containing ceramic in which metal silicon is mixed with at least one of a nitride ceramic, a carbide ceramic, a complex of a metal and a nitride ceramic, and a complex of a metal and a carbide ceramic; and
a ceramic in which at least one of a nitride ceramic, a carbide ceramic, a complex of a metal and a nitride ceramic, and a complex of a metal and a carbide ceramic is bonded by silicon or a silicate compound.
14. The honeycomb structure according to claim 13 ,
wherein
forming material of said honeycomb fired body comprises at least one of silicon carbide and silicon-containing silicon carbide.
15. The honeycomb structure according to claim 1 ,
wherein
a catalyst for converting and/or purifying exhaust gases is supported on said honeycomb structure.
16. The honeycomb structure according to claim 15 ,
wherein
said catalyst comprises at least one of noble metals, alkali metals, and alkaline earth metals.
17. A method for manufacturing a honeycomb structure, said method comprising:
molding a ceramic raw material to manufacture honeycomb molded bodies each having cell walls extending along a longitudinal direction of the honeycomb fired bodies to define cells;
firing said honeycomb molded bodies to manufacture honeycomb fired bodies;
bonding a plurality of said honeycomb fired bodies together with a paste for an adhesive layer interposed between said honeycomb fired bodies to form a ceramic block; and
forming a projected portion on each of side faces of one piece of said honeycomb molded bodies and another piece of said honeycomb molded bodies in a manner that the projected portions formed on said honeycomb fired bodies overlap each other when seen from an end face of said honeycomb structure and the projected portions formed on said adjacent honeycomb fired bodies abut each other,
wherein said adhesive layer is provided in a manner that a shortest distance between a side face of one of said adjacent honeycomb fired bodies and a projected portion of another of said adjacent honeycomb fired bodies is smaller than a height of said projected portion from a side face of said another of said adjacent honeycomb fired bodies when said honeycomb fired bodies are adjoined to each other via said adhesive layer.
18. The method for manufacturing a honeycomb structure according to claim 17 ,
wherein
one of said honeycomb fired bodies has a first projected portion on a side face,
another of said honeycomb fired bodies has a first projected portion and a second projected portion on a side face, and
the projected portions are formed in a manner that the first projected portion formed on the side face of said one of said honeycomb fired bodies is formed between the first and second projected portions formed on the side face of said another of said honeycomb fired bodies and the first projected portion formed on the side face of said one of said honeycomb fired bodies and the first and second projected portions formed on the side face of said another of said honeycomb fired bodies abut each other.
19. The method for manufacturing a honeycomb structure according to claim 17 , the method further comprising:
applying a paste for a peripheral coat layer around a periphery of said ceramic block, and then drying and solidifying the paste to form a peripheral coat layer.
20. The method for manufacturing a honeycomb structure according to claim 17 ,
wherein
in said projected portion formation, a plate body is placed on a side face of said honeycomb molded body, which is followed by the firing to form a projected portion on the side face of said honeycomb fired body.
21. The method for manufacturing a honeycomb structure according to claim 20 ,
wherein
said plate body comprises either a molded body or a fired body manufactured by using substantially a same material as a material of a raw material paste, said paste for an adhesive layer, or a paste for a peripheral coat layer.
22. The method for manufacturing a honeycomb structure according to claim 20 ,
wherein
said plate body is placed via a paste.
23. The method for manufacturing a honeycomb structure according to claim 22 ,
wherein
said paste is prepared using a substantially same material as a material of a raw material paste, said paste for an adhesive layer, or a paste for a peripheral coat layer.
24. The method for manufacturing a honeycomb structure according to claim 20 ,
wherein
an undried or dried plate body is used as said plate body.
25. The method for manufacturing a honeycomb structure according to claim 20 ,
wherein
said plate body is arranged on the side faces of said honeycomb molded body by attaching a sintered plate body to the side faces of the honeycomb molded body via a paste.
26. The method for manufacturing a honeycomb structure according to claim 25 ,
wherein
any one of a raw material paste, said paste for an adhesive layer, and a paste for a peripheral coat layer is used as said paste.
27. The method for manufacturing a honeycomb structure according to claim 17 ,
wherein
the projected portions are formed on the side faces of said honeycomb molded body using a paste in said projected portion formation, and
then, the firing is carried out to form the projected portions on the side faces of said honeycomb fired body.
28. The method for manufacturing a honeycomb structure according to claim 27 ,
wherein
said paste is prepared using a substantially same material as a material of a raw material paste, said paste for an adhesive layer, or a paste for a peripheral coat layer.
29. The method for manufacturing a honeycomb structure according to claim 17 ,
wherein
the side faces of said honeycomb molded body are cut to form said projected portions in said projected portion formation.
30. The method for manufacturing a honeycomb structure according to claim 29 ,
wherein
said cutting is carried out on a dried honeycomb molded body.
31. The method for manufacturing a honeycomb structure according to claim 29 ,
wherein
said cutting is milling, planing, or end milling.
32. The method for manufacturing a honeycomb structure according to claim 17 , the method further comprising
drying and solidifying said paste for an adhesive layer to form an adhesive layer.
33. The method for manufacturing a honeycomb structure according to claim 17 , the method further comprising
processing side faces of said ceramic block into a predetermined shape.