Honeycomb structure and honeycomb catalytic body

Abstract

There are disclosed a honeycomb catalytic body to which a wall flow structure is applied so that a fluid such as an exhaust gas passes through a partition wall twice or more, and a honeycomb structure for use as a catalyst carrier of the honeycomb catalytic body in which a pore characteristic and the like are appropriately adjusted as the catalytic body. In a honeycomb structure 11 including porous partition walls 4 arranged so as to form a plurality of cells 3 which communicate between two end surfaces of the honeycomb structure and having a large number of pores; and plugging portions 10 arranged so as to plug at least a part of the plurality of cells 3 at any position in a length direction of the cells, an average maximum image distance of the partition walls is larger than 40 μm, and the plugging portions 10 are arranged so that at least a part of a fluid which has entered the cells from one end surface passes through the partition wall 4 twice or more, and is then discharged from the other end portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view showing an example of an embodiment of a honeycomb structure according to the present invention;

FIG. 2 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 3 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 4 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 5 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 6 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 7 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 8 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 9 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 10 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 11 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 12 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 13 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention;

FIG. 14 is a schematic sectional view showing configurations of honeycomb structures according to Comparative Examples 2 to 4;

FIG. 15 is a schematic front view schematically showing one embodiment of a conventional honeycomb catalytic body;

FIG. 16 is a schematic sectional view schematically showing the embodiment of the conventional honeycomb catalytic body;

FIG. 17 is a partially enlarged view schematically showing the embodiment of the conventional honeycomb catalytic body;

FIG. 18 is a plan view schematically showing a partially enlarged end surface of a honeycomb structure according to one embodiment of the present invention;

FIG. 19 is an SEM photograph of a honeycomb structure showing the end surface of the honeycomb structure according to the embodiment of the present invention; and

FIG. 20 is a schematic sectional view showing an example of the embodiment of the honeycomb structure according to the present invention.

Claims

1. A honeycomb structure comprising: porous partition walls arranged so as to form a plurality of cells which communicate between two end surfaces of the honeycomb structure and having a large number of pores; andplugging portions arranged so as to plug at least a part of the plurality of cells at any position in a length direction of the cells,wherein an average maximum image distance of the partition walls is larger than 40 μm, and the plugging portions are arranged so that at least a part of a fluid which has entered the cells from one end surface passes through the partition wall twice or more, and is then discharged from the other end portion.

2. The honeycomb structure according to claim 1, at least a part of which is constituted by alternately arranging a cell including two or more arranged plugging portions and a cell disposed adjacent to the cell and including a plugging portion disposed between the plugging portions in the length direction of the cell.

3. The honeycomb structure according to claim 1, at least a part of which is constituted by alternately arranging a cell including two or more arranged plugging portions and a cell disposed adjacent to the cell and including a plugging portion disposed at an intermediate position between the plugging portions in the length direction of the cell or a position where a distance from the intermediate position is 30% or less of a distance between the plugging portions.

4. The honeycomb structure according to claim 1, wherein at least a part of the plugging portions have a through hole which extends through the cell in the length direction of the cell; and a sectional area of the through hole is 30 to 90% of that of the cell.

5. The honeycomb structure according to claim 1, wherein the average maximum image distance of the plugging portions is 200 μm or more.

6. The honeycomb structure according to claim 1, wherein a difference of a porosity between a portion close to the one end surface of the honeycomb structure and a portion close to the other end surface is 5% or more.

7. The honeycomb structure according to claim 1, wherein a bulk density of the honeycomb structure is 0.5 g/cm3 or less.

8. The honeycomb structure according to claim 1, wherein more plugging portions are arranged in the cell positioned at the central portion of the honeycomb structure in a diametric direction than in the cell positioned at an outer peripheral portion of the honeycomb structure.

9. A honeycomb catalytic body constituted by carrying a catalyst-containing catalytic layer on at least inner surfaces of the pores of the partition walls of the honeycomb structure according to claim 1.

10. The honeycomb catalytic body according to claim 9, wherein an amount of the catalytic layer to be carried per unit volume of the honeycomb structure is in a range of 10 to 250 g/L.

11. The honeycomb catalytic body according to claim 9, wherein the catalytic layer is also carried by the plugging portions.

12. The honeycomb catalytic body according to claim 9, wherein the amount of the catalytic layer to be carried per unit volume of the honeycomb structure at the portion close to the other end surface of the honeycomb structure is 5% or more larger than that at the portion close to the one end surface of the honeycomb structure.

13. The honeycomb catalytic body according to claim 9, wherein the amount of the catalytic layer to be carried per unit volume of the honeycomb structure at the portions close to the opposite end surfaces is 5% or more larger than that at the center of the honeycomb structure in the length direction.

14. The honeycomb catalytic body according to claim 9, wherein the amount of the catalytic layer to be carried per unit volume of the honeycomb structure gradually increases from the one end surface toward the other end surface of the honeycomb structure.

15. The honeycomb catalytic body according to claim 9, for use as a catalytic body to purify an exhaust gas which does not substantially include any carbon particulate.

16. The honeycomb catalytic body according to claim 9, for use as a catalytic body to purify an exhaust gas discharged from a gasoline engine.

17. The honeycomb catalytic body according to claim 9, for use as a catalytic body to purify an exhaust gas discharged from an industrial combustion apparatus.

18. The honeycomb catalytic body according to claim 9, for use as a catalytic body to purify an exhaust gas from which particulate matters have been removed by a filter, wherein the honeycomb catalytic body is disposed on a downstream side of the filter which removes the particulate matters from a dust-containing gas.

19. The honeycomb catalytic body according to claim 18, wherein the filter is a diesel particulate filter.

20. The honeycomb catalytic body according to claim 9, for use to be disposed on a downstream side of another catalytic body.