# US 10,307,743 B2 · Honeycomb structure

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- Number: US 10,307,743 B2
- Document ID: US10307743B2
- Status: Granted
- Kind: B2
- Application number: 15/467,103
- Filed: 2017-03-23
- Published: 2017-10-05
- Granted: 2019-06-04
- Earliest claimed: 2016-03-31
- Assignees: NGK Insulators, Ltd.
- Applicants: Ngk Insulators, Ltd.
- Inventors: Satoshi Yamazaki; Toru Hayase; Kenji Morimoto
- Web page: https://patentgrep.com/patent/US10307743B2

## CPC

- B01J 29/85: Silicoaluminophosphates [SAPO compounds]
- B01D 53/0407: {Constructional details of adsorbing systems}
- B01D 53/8628: {Processes characterised by a specific catalyst}
- B01D 53/9431: {Processes characterised by a specific device}
- B01J 21/04: Alumina
- B01J 21/12: Silica and alumina
- B01J 29/084: {Y-type faujasite}
- B01J 29/146: {Y-type faujasite}
- B01J 29/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J 29/46: Iron group metals or copper
- B01J 29/7007: {Zeolite Beta}
- B01J 29/7015: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/7615: {Zeolite Beta}
- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/80: Mixtures of different zeolites
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/45: Nanoparticles
- B01J 35/57: Honeycombs
- B01J 35/63: Pore volume
- B01J 35/64: Pore diameter
- B01J 35/695: {polymodal}
- B01J 37/0018: {Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/082: {Decomposition and pyrolysis}
- B01J 37/30: Ion-exchange
- C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)}
- C04B 38/0009: {characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls}
- B01D 2253/108: Zeolites
- B01D 2253/311: Porosity, e.g. pore volume
- B01D 2255/20761: Copper
- B01D 2255/50: Zeolites
- B01D 2255/502: Beta zeolites
- B01D 2255/504: ZSM 5 zeolites
- B01D 2255/912: HC-storage component incorporated in the catalyst
- B01D 2255/9202: Linear dimensions
- B01D 2255/9205: Porosity
- B01D 2255/9207: Specific surface
- B01D 2257/404: Nitrogen oxides other than dinitrogen oxide
- B01D 2257/702: Hydrocarbons
- B01J 2229/183: in framework positions
- B01J 2229/186: not in framework positions
- B01J 2229/42: Addition of matrix or binder particles
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

The honeycomb structure includes a honeycomb structure body made of a zeolite material containing at least a coarse particle zeolite having a large average particle diameter (coarse zeolite particles). A fine particle zeolite having an average particle diameter smaller than that of the coarse particle zeolite (fine zeolite particles), and an inorganic bonding material, the coarse particle zeolite (the coarse zeolite particles) is a chabazite type zeolite in which an average particle diameter of primary particles is 2 μm or more and 6 μm or less, and in the fine particle zeolite (the fine zeolite particles), an average particle diameter of primary particles is 0.02 μm or more and smaller than 2 μm, and in the zeolite material which is comprised the honeycomb structure body, a ratio of a volume of pores having pore diameters of 0.02 to 0.15 μm to a volume of all pores is 42% or less.

## Claims

### Claim 1

A honeycomb structure comprising a honeycomb structure body made of a zeolite material containing at least a coarse particle zeolite having a large average particle diameter, a fine particle zeolite having an average particle diameter smaller than that of the coarse particle zeolite, and an inorganic bonding material,
wherein the coarse particle zeolite is a chabazite type zeolite in which an average particle diameter of primary particles is 2 μm or more and 6 μm or less,
in the fine particle zeolite, an average particle diameter of primary particles is 0.02 μm or more and smaller than 2 μm,
the zeolite material has a ratio of a volume of pores having pore diameters of 0.02 to 0.15 μm to a volume of all pores is 42% or less,
the zeolite material includes 3 vol % or more of the inorganic bonding material in a total volume of the zeolite material, and
the inorganic bonding material includes alumina derived from basic aluminum lactate at a ratio of 1 vol % or more to the total volume of the zeolite material.

### Claim 2 (depends on 1)

The honeycomb structure according to claim 1,
wherein in the zeolite material, a ratio of a volume of pores having pore diameters smaller than 0.02 μm to the volume of all the pores is from 8 to 20%.

### Claim 3 (depends on 1)

The honeycomb structure according to claim 1,
wherein in the zeolite material, a ratio of a volume of pores having pore diameters in excess of 0.15 μm to the volume of all the pores is from 40 to 60%, and a ratio of a volume of pores having pore diameters of 0.52 μm or more to the volume of all the pores is 5% or less.

### Claim 4 (depends on 1)

The honeycomb structure according to claim 1,
wherein the coarse particle zeolite and the fine particle zeolite are copper ion-exchanged zeolite.

### Claim 5 (depends on 1)

The honeycomb structure according to claim 1,
wherein the coarse particle zeolite is at least one selected from the group consisting of chabazite, SAPO-34 and SSZ-13.

### Claim 6 (depends on 1)

The honeycomb structure according to claim 1,
wherein the fine particle zeolite is at least one selected from the group consisting of a β-type zeolite, a Y-type zeolite, a ZSM-5 type zeolite, and a chabazite type zeolite.

### Claim 7 (depends on 1)

The honeycomb structure according to claim 1,
wherein the inorganic bonding material includes the alumina derived from basic aluminum lactate and alumina derived from boehmite, and
a value of A1/A2 which is a ratio of a volume A1 of the alumina derived from basic aluminum lactate to a volume A2 of the alumina derived from boehmite is 0.6 or more.

### Claim 8 (depends on 1)

The honeycomb structure according to claim 1,
wherein the zeolite material includes at least one inorganic fiber selected from the group consisting of alumina fiber, silica alumina fiber, and glass fiber.

### Claim 9 (depends on 8)

The honeycomb structure according to claim 8,
wherein the zeolite material includes 3 to 8 vol % of the inorganic fiber in a total volume of the zeolite material.