# US 8,147,764 B2 · Honeycomb structure and exhaust gas treating apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,147,764 B2 - Document ID: US8147764B2 - Status: Granted - Kind: B2 - Application number: 12/248,675 - Filed: 2008-10-09 - Published: 2009-10-01 - Granted: 2012-04-03 - Earliest claimed: 2008-03-27 - Assignees: Ibiden Co., Ltd. - Inventors: Yuki Fujita - Web page: https://patentgrep.com/patent/US8147764B2 ## CPC - C04B 28/24: containing alkyl, ammonium or metal silicates; containing silica sols {(reaction mixtures resulting in mineral polymers C04B28/006; polymeric reaction products of alkali metal silicates with isocyanates C08G18/3895)} - B01D 46/2455: {of the whole honeycomb or segments} - B01D 46/247: {of the cells} - B01D 46/2474: {of the walls along the length of the honeycomb} - B01D 46/2478: {Structures comprising honeycomb segments} - B01D 46/2482: {Thickness, height, width, length or diameter} - B01D 46/2484: {Cell density, area or aspect ratio} - B01D 46/2486: {characterised by the shapes or configurations} - B01D 46/2496: {Circular} - C04B 28/001: {containing unburned clay (polymer binder - clay mixtures used in well cementing C09K8/44)} - C04B 35/111: Fine ceramics - C04B 35/18: rich in aluminium oxide - C04B 35/6263: {characterised by their solids loadings, i.e. the percentage of solids} - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - C04B 38/0009: {characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls} - F01N 3/2828: {Ceramic multi-channel monoliths, e.g. honeycombs} - B01D 2279/30: for treatment of exhaust gases from IC Engines - C04B 2111/0081: {as catalysts or catalyst carriers} - C04B 2235/3218: Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol - C04B 2235/402: Aluminium - C04B 2235/5224: Alumina or aluminates - C04B 2235/526: characterised by the length of the fibers - C04B 2235/5264: characterised by the diameter of the fibers - C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron - F01N 2330/48: characterised by the number of flow passages, e.g. cell density - F01N 2450/28: by using adhesive material, e.g. cement - Y10T 428/24149: Honeycomb-like - 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 - 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) - F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A honeycomb structure includes four honeycomb units each including inorganic particles, an inorganic binder, and cell walls extending from a first end face to a second end face along a longitudinal direction to define a plurality of cells. The cell walls includes a first cell walls extending along a first direction in a cross sectional plane perpendicular to the longitudinal direction and a second cell walls extending along a second direction substantially perpendicular to the first direction in the cross sectional plane. Adhesive layers are provided between the four honeycomb units to connect the four honeycomb units. The adhesive layers extend in a first extending direction and a second extending direction substantially perpendicular to the first extending direction in the cross sectional plane. A minimum angle between the first direction and the first extending direction or the second extending direction is approximately 22.5 degrees to approximately 45 degrees. ## Claims ### Claim 1 A honeycomb structure having a longitudinal direction, comprising: a first end face; a second end face opposite to the first end face along the longitudinal direction; four honeycomb units each comprising: inorganic particles; an inorganic binder; and a plurality of cell walls extending from the first end face to the second end face to define a plurality of cells, the plurality of cell walls including a first cell walls extending along a first direction in a cross sectional plane perpendicular to the longitudinal direction and a second cell walls extending along a second direction substantially perpendicular to the first direction in the cross sectional plane; and adhesive layers provided between the four honeycomb units to connect the four honeycomb units each other, the adhesive layers extending in a first extending direction and a second extending direction substantially perpendicular to the first extending direction in the cross sectional plane, a minimum angle between the first direction and the first extending direction or the second extending direction is approximately 22.5 degrees to approximately 45 degrees, wherein each of the honeycomb units has a fan shape in the cross sectional plane, wherein: each of the cells are through holes that are open at both an upstream end and a downstream end thereof and each of the four honeycombs units forming substantially a quarter of an overall cross sectional area of the honeycomb structure. ### Claim 2 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: the inorganic particles include at least one of alumina, ceria, zirconia, titania, silica, zeolite, and mullite. ### Claim 3 (depends on 2) The honeycomb structure as claimed in claim 2, wherein: the zeolite is ion-exchanged zeolite by using Cu, Fe, Ni, Zn, Mn, or Co. ### Claim 4 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: the inorganic binder includes at least one of alumina sol, silica sol, titania sol, liquid glass, meerschaum, and attapulgite. ### Claim 5 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: the honeycomb units further comprise inorganic fibers. ### Claim 6 (depends on 5) The honeycomb structure as claimed in claim 5, wherein: the inorganic fibers include at least one of alumina, silica, silicon carbide, silica-alumina, glass, potassium titanate, and aluminum borate. ### Claim 7 (depends on 5) The honeycomb structure as claimed in claim 5, wherein: an average aspect ratio of the inorganic fibers is approximately 10 to approximately 1000. ### Claim 8 (depends on 5) The honeycomb structure as claimed in claim 5, wherein: an amount of the inorganic fibers in the honeycomb units is approximately 3 wt % to approximately 50 wt %. ### Claim 9 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: a shape of the honeycomb structure in the cross sectional plane is substantially a circle, an ellipse, or an oval. ### Claim 10 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: a catalyst is provided on the cell walls. ### Claim 11 (depends on 10) The honeycomb structure as claimed in claim 10, wherein: the catalyst includes at least one of noble metal, alkali metal, and alkali earth metal. ### Claim 12 (depends on 11) The honeycomb structure as claimed in claim 11, wherein: the catalyst includes at least one of platinum, palladium, and rhodium. ### Claim 13 (depends on 11) The honeycomb structure as claimed in claim 11, wherein: the catalyst includes at least one of potassium, magnesium, barium, and calcium. ### Claim 14 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: the honeycomb structure is formed by a cutting process for forming a peripheral surface. ### Claim 15 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: a cell density of each of the honeycomb units is approximately 15.5 pieces per cm2 to approximately 186 pieces per cm2. ### Claim 16 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: a thickness of the cell walls is approximately 0.1 mm to approximately 0.4 mm. ### Claim 17 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: a specific surface area of the honeycomb units is approximately 25000 m2/L to approximately 70000 m2/L. ### Claim 18 (depends on 1) The honeycomb structure as claimed in claim 1, wherein: an amount of the inorganic particles contained in the honeycomb units is approximately 30 wt % to approximately 90 wt %. ### Claim 19 (depends on 1) The honeycomb structure as claimed in claim 1, further comprising: a coating layer formed on a peripheral surface of the honeycomb structure. ### Claim 20 An exhaust gas treating apparatus, comprising: a honeycomb structure having a longitudinal direction, comprising: a first end face; a second end face opposite to the first end face along the longitudinal direction; four honeycomb units each comprising: inorganic particles; an inorganic binder; and a plurality of cell walls extending from the first end face to the second end face to define a plurality of cells, the plurality of cell walls including a first cell walls extending along a first direction in a cross sectional plane perpendicular to the longitudinal direction and a second cell walls extending along a second direction substantially perpendicular to the first direction in the cross sectional plane; and adhesive layers provided between the four honeycomb units to connect the four honeycomb units each other, the adhesive layers extending in a first extending direction and a second extending direction substantially perpendicular to the first extending direction in the cross sectional plane, a minimum angle between the first direction and the first extending direction or the second extending direction is approximately 22.5 degrees to approximately 45 degrees; a metal casing containing the honeycomb structure; and a holding sealing member disposed between the honeycomb structure and the metal casing to hold the honeycomb structure at a predetermined position in the metal casing, wherein each of the honeycomb units has a fan shape in the cross sectional plane, wherein: each of the cells are through holes that are open at both an upstream end and a downstream end thereof and each of the four honeycombs units forming substantially a quarter of an overall cross sectional area of the honeycomb structure. ### Claim 21 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: the inorganic particles include at least one of alumina, ceria, zirconia, titania, silica, zeolite, and mullite. ### Claim 22 (depends on 21) The exhaust gas treating apparatus as claimed in claim 21, wherein: the zeolite is ion-exchanged zeolite by using Cu, Fe, Ni, Zn, Mn, or Co. ### Claim 23 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: the inorganic binder includes at least one of alumina sol, silica sol, titania sol, liquid glass, meerschaum, and attapulgite. ### Claim 24 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: the honeycomb units further comprise inorganic fibers. ### Claim 25 (depends on 24) The exhaust gas treating apparatus as claimed in claim 24, wherein: the inorganic fibers include at least one of alumina, silica, silicon carbide, silica-alumina, glass, potassium titanate, and aluminum borate. ### Claim 26 (depends on 24) The exhaust gas treating apparatus as claimed in claim 24, wherein: an average aspect ratio of the inorganic fibers is approximately 10 to approximately 1000. ### Claim 27 (depends on 24) The exhaust gas treating apparatus as claimed in claim 24, wherein: an amount of the inorganic fibers in the honeycomb units is approximately 3 wt % to approximately 50 wt %. ### Claim 28 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: a shape of the honeycomb structure in the cross sectional plane is substantially a circle, an ellipse, or an oval. ### Claim 29 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: a catalyst is provided on the cell walls. ### Claim 30 (depends on 29) The exhaust gas treating apparatus as claimed in claim 29, wherein: the catalyst includes at least one of noble metal, alkali metal, and alkali earth metal. ### Claim 31 (depends on 30) The exhaust gas treating apparatus as claimed in claim 30, wherein: the catalyst includes at least one of platinum, palladium, and rhodium. ### Claim 32 (depends on 30) The exhaust gas treating apparatus as claimed in claim 30, wherein: the catalyst includes at least one of potassium, magnesium, barium, and calcium. ### Claim 33 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: the honeycomb structure is formed by a cutting process for forming a peripheral surface. ### Claim 34 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: a cell density of each of the honeycomb units is approximately 15.5 pieces per cm2 to approximately 186 pieces per cm2. ### Claim 35 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: a thickness of the cell walls is approximately 0.1 mm to approximately 0.4 mm. ### Claim 36 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: a specific surface area of the honeycomb units is approximately 25000 m2/L to approximately 70000 m2/L. ### Claim 37 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, wherein: an amount of the inorganic particles contained in the honeycomb units is approximately 30 wt % to approximately 90 wt %. ### Claim 38 (depends on 20) The exhaust gas treating apparatus as claimed in claim 20, further comprising: a coating layer formed on a peripheral surface of the honeycomb structure.