Patents by Inventor Masafumi Kunieda

Masafumi Kunieda has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 7556666
    Abstract: A honeycomb structure including a plurality of porous ceramic members which are bonded through an adhesive layer, each of the porous ceramic members has a plurality of cells, which are arranged in parallel while being separated by cell walls. The cells extend in a longitudinal direction of the honeycomb structure. In the honeycomb structure, the following relationship is satisfied: 2?B?100/3×A?10/3??(1) where A (g/cm3) designates apparent density of the porous ceramic members, and B (GPa) designates Young's modulus of the adhesive layer.
    Type: Grant
    Filed: April 5, 2006
    Date of Patent: July 7, 2009
    Assignee: Ibiden Co., Ltd.
    Inventor: Masafumi Kunieda
  • Patent number: 7553531
    Abstract: A honeycomb structure is disclosed that includes plural honeycomb units bonded together by using a sealing material layer, each of the honeycomb units including plural through-holes separated by plural partition walls and provided in parallel along a longitudinal direction. Each of the honeycomb units includes at least ceramic particles, and inorganic fibers and/or whiskers; a cross sectional area of the honeycomb unit is from about 5 cm2 to about 50 cm2; and an outer surface of each honeycomb unit and the sealing material layer satisfy: about 0.5??/d×(dc/?c+df/?f)?about 1, where, ?f (W/mK) and df (mm) represent a thermal conductivity and a thickness of the outer surface of the honeycomb units, respectively, ?c (W/mK) and dc (mm) represent a thermal conductivity and a thickness of the sealing material layer, respectively, and ? (W/mK) and d (mm) represent a thermal conductivity and a thickness of the combination of the outer surface and the sealing material layer.
    Type: Grant
    Filed: March 7, 2006
    Date of Patent: June 30, 2009
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Kazutake Ogyu
  • Patent number: 7524350
    Abstract: This honeycomb structural body is made from a sintered body having a pore structure wherein pores having a pore size ranging from 1.0 ?m to about 150 ?m are a first pore group and pores having a pore size ranging from about 0.006 or more to less than 1.0 ?m are a second pore group in a pore size distribution curve, one peak in the pore size distribution is existent in the first pore group region and plural peaks in the pore size distribution are existent in the second pore group region.
    Type: Grant
    Filed: April 10, 2007
    Date of Patent: April 28, 2009
    Assignee: Ibiden Co., Ltd.
    Inventor: Masafumi Kunieda
  • Patent number: 7521025
    Abstract: An object of the present invention is to provide a honeycomb structural body for use in a filter, which can be provided with a large amount of catalyst, can suppress an increase in pressure loss upon collecting particulates, can have a high particulate collecting capability and can efficiently carry out a regenerating process and a toxic gas purifying process. The honeycomb structural body of the present invention is a pillar-shaped honeycomb structural body that is mainly composed of inorganic fibers and has a structure in that a large number of through holes are placed in parallel with one another in the length direction with a partition wall interposed therebetween. Herein, the inorganic fibers, which form the honeycomb structural body, are arranged in such a manner that more fibers are aligned along a face perpendicular to the forming direction of the through holes rather than aligned along a face in parallel with the forming direction of the through holes.
    Type: Grant
    Filed: June 10, 2004
    Date of Patent: April 21, 2009
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Masafumi Kunieda
  • Publication number: 20090095416
    Abstract: A method for manufacturing a honeycomb structure includes molding a raw material composition to manufacture a plurality of honeycomb molded bodies. Each of the plurality of honeycomb molded bodies has a number of cells longitudinally placed substantially in parallel with one another with a cell wall interposed therebetween. The plurality of honeycomb molded bodies are fired to manufacture a plurality of honeycomb fired bodies. A water retention adhesive paste containing a water retention agent is prepared. The plurality of honeycomb fired bodies are bonded to one another by using the water retention adhesive paste and forming an adhesive layer to manufacture a honeycomb aggregated body.
    Type: Application
    Filed: August 20, 2008
    Publication date: April 16, 2009
    Applicant: IBIDEN CO., LTD.
    Inventors: Masafumi KUNIEDA, Mari KITAJIMA
  • Publication number: 20090098333
    Abstract: A honeycomb structure includes honeycomb fired bodies having cell walls extending along the longitudinal direction to define a plurality of cells, and an outer wall at the outermost peripheral face. The fired bodies are connected at the outer wall by an adhesive layer. The cell wall has a thickness of at least about 0.15 mm and at most about 0.30 mm. A thickness of a border wall is at least about 5 times greater and at most about 20 times greater than the thickness of the cell wall. The border wall includes the adhesive layer, and first and second outer walls which are connected to each other. The catalyst permeation preventive region is provided in the outer wall or between the outer wall and the adhesive layer. The catalyst permeation preventive region includes at least one of a water repellent material, a cation exchanger and water absorbing material.
    Type: Application
    Filed: September 19, 2008
    Publication date: April 16, 2009
    Applicant: IBIDEN CO., LTD.
    Inventors: Masafumi KUNIEDA, Mari KITAJIMA
  • Patent number: 7462216
    Abstract: A honeycomb unit includes a plurality of walls and a plurality of cells. The plurality of cells are defined by the plurality of walls and extend along a longitudinal direction of the honeycomb unit. Each of the plurality of cells has opposite first and second end portions along the longitudinal direction. Either one of the first and second end portions is sealed. X and Y satisfy a following relationship, 100/3·X+5?Y?100/3·X+40, wherein Y is a ratio of a weight of an unsealed region in said cells to a weight of a sealed region in said cells and X is a ratio of a length in the longitudinal direction of said honeycomb unit to an area of a cross-section perpendicular to the longitudinal direction of said honeycomb unit. X is at least about 0.1 and at most about 0.26.
    Type: Grant
    Filed: October 29, 2007
    Date of Patent: December 9, 2008
    Assignee: Ibiden Co., Ltd.
    Inventors: Masafumi Kunieda, Yuki Fujita
  • Patent number: 7455709
    Abstract: An object of the present invention is to provide a honeycomb structural body for use in a filter, which can support a large amount of catalysts, can suppress increase in pressure loss upon collecting particulates, can have a high particulate collecting capability and can efficiently carry out a regenerating process and a toxic gas purifying process. The honeycomb structural body according to the present invention is a pillar-shaped honeycomb structural body having a structure in which a plurality of through holes are placed in parallel with one another in the length direction with a partition wall interposed therebetween, wherein lamination members are laminated in the length direction so that the through holes are superposed on one another, and one of ends of each through hole is sealed.
    Type: Grant
    Filed: July 15, 2004
    Date of Patent: November 25, 2008
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Masafumi Kunieda
  • Publication number: 20080286523
    Abstract: A honeycomb structure includes a ceramic block formed by bonding a plurality of pillar-shaped honeycomb fired bodies by interposing an adhesive layer therebetween, and a sealing material layer provided on the periphery of the ceramic block. Each of the honeycomb fired bodies has a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween. The adhesive layer and the sealing material layer are integrally formed with substantially no interface to divide the two layers.
    Type: Application
    Filed: April 22, 2008
    Publication date: November 20, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige OHNO, Masafumi Kunieda, Masatoshi Okuda
  • Publication number: 20080260599
    Abstract: A honeycomb filter includes a honeycomb fired body having cells longitudinally disposed either end of each cell being sealed. The honeycomb filter includes an outlet-side catalyst supporting area, an inlet-side catalyst supporting area, and a catalyst unsupporting area formed between the catalyst supporting areas. A thermal conductivity of the catalyst unsupporting area is larger than those of the catalyst supporting areas. Y (%), Z (%), and X (%) satisfy the following inequalities, about 1?Y?about 19, (880?70Y)/9?Z?(825?15Y)/9 (about 1?Y?about 10), (330?15Y)/9?Z?(1375?70Y)/9 (about 10?Y?about 19), and X=100?Y?Z in which Y, Z, X indicate a ratio of a length of the outlet-side catalyst supporting area, the inlet-side catalyst supporting area, the catalyst unsupporting area, respectively, to an entire length of the honeycomb filter.
    Type: Application
    Filed: March 28, 2008
    Publication date: October 23, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Akihiro Ohira, Masafumi Kunieda
  • Publication number: 20080241501
    Abstract: A honeycomb structure includes a plurality of pillar-shaped honeycomb fired bodies bound with one another by interposing a adhesive layer. Each of the honeycomb fired bodies has a large number of cells longitudinally placed in parallel with one another with a cell wall therebetween. An adhesive strength A between central portion honeycomb fired bodies out of the honeycomb fired bodies measured by a three-point bending strength test is at least about 0.02 and at most about 0.2 MPa. The central portion honeycomb fired bodies are positioned at a central portion of a cross-section formed by cutting the honeycomb structure perpendicularly to the longitudinal direction. The adhesive strength A is lower than an adhesive strength B between peripheral portion honeycomb fired bodies out of the honeycomb fired bodies measured by the three-point bending strength test. The peripheral portion honeycomb fired bodies form a part of a periphery the honeycomb structure.
    Type: Application
    Filed: February 19, 2008
    Publication date: October 2, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Masatoshi Okuda
  • Publication number: 20080237941
    Abstract: A honeycomb structure is manufactured by molding a pillar-shaped honeycomb molded body having a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween by extrusion-molding a raw material composition including a ceramic powder and a binder, and carrying out a firing treatment on the honeycomb molded body to manufacture a honeycomb fired body. A plurality of the honeycomb fired bodies are provided, and both end faces of each of the plurality of the honeycomb fired bodies are hold with a holding member after positioning the plurality of the honeycomb fired bodies on a predetermined position. An adhesive paste is injected into a gap between the plurality of honeycomb fired bodies held on the predetermined position. The adhesive paste is dried and solidified to form an adhesive layer.
    Type: Application
    Filed: March 7, 2008
    Publication date: October 2, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige OHNO, Masafumi Kunieda, Masatoshi Okuda
  • Publication number: 20080241015
    Abstract: An object of the present invention is to provide a honeycomb filter for purifying exhaust gases which makes it possible to alleviate a thermal stress generated due to occurrence of a local temperature change and which is less likely to generate cracks and superior in strength and durability, an adhesive that has a low thermal capacity and is capable of alleviating the thermal stress, a coating material that has a low thermal capacity with a superior heat insulating property and is capable of alleviating the thermal stress, and a manufacturing method of the honeycomb filter for purifying exhaust gases that can improve precision in the outside dimension, and reduce damages in the manufacturing processes.
    Type: Application
    Filed: May 7, 2008
    Publication date: October 2, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Atsushi KUDO, Masafumi Kunieda
  • Publication number: 20080236394
    Abstract: A honeycomb structure includes a ceramic block formed by a plurality of pillar-shaped honeycomb fired bodies each having a large number of cells longitudinally disposed in parallel with one another with a cell wall between the cells. The plurality of honeycomb fired bodies are combined with one another by interposing an adhesive layer with a sealing material layer formed on a peripheral face of the ceramic block and include a plurality of different shapes of the honeycomb fired bodies. A thickness of a peripheral wall forming the peripheral face of the ceramic block is virtually even. A shape of a cell located at an outermost periphery of the ceramic block is virtually identical with a shape of a cell located at a place other than the outermost periphery of the ceramic block. On the peripheral wall of the honeycomb fired body, a step is provided.
    Type: Application
    Filed: March 13, 2008
    Publication date: October 2, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige OHNO, Masafumi KUNIEDA, Shigeharu ISHIKAWA
  • Publication number: 20080202086
    Abstract: A honeycomb filter includes a plurality of honeycomb fired bodies each having a longitudinal direction and a plurality of cells which are divided by cell walls and which extend in the longitudinal direction in substantially parallel with each other, each of the cells having one end sealed; and an adhesive material binding the plurality of honeycomb fired bodies. The plurality of honeycomb fired bodies includes outer peripheral honeycomb fired bodies each having a first outer wall and positioned at an outermost periphery of the honeycomb filter; and inner honeycomb fired bodies surrounded by the outer peripheral honeycomb fired bodies. Each of the inner honeycomb fired bodies has a second outer wall thinner than the first outer wall.
    Type: Application
    Filed: October 16, 2007
    Publication date: August 28, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda
  • Publication number: 20080203626
    Abstract: A method is provided that includes extrusion-molding a raw material composition containing ceramic powder and a binder to manufacture a coupled honeycomb molded body having a shape in which a plurality of pillar-shaped honeycomb molded bodies, each having a number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween, are integrated with one another by interposing a coupling portion. The method includes firing the coupled honeycomb molded body to manufacture a coupled honeycomb fired body, cutting the coupling portion to manufacture coupling-portion-cut honeycomb fired bodies, and binding a plurality of honeycomb fired bodies by interposing an adhesive layer, where at least one of the bound honeycomb fired bodies is a coupling-portion-cut honeycomb fired body.
    Type: Application
    Filed: December 14, 2007
    Publication date: August 28, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Shigeharu Ishikawa
  • Publication number: 20080202087
    Abstract: A honeycomb structure is provided that includes a plurality of pillar-shaped honeycomb fired bodies, each having a number of cells longitudinally disposed in parallel with one another with a cell wall therebetween. An adhesive layer is interposed between adjacent honeycomb fired bodies of the plurality of honeycomb fired bodies to combine the plurality of honeycomb fired bodies together, and a sealing material layer is formed on an outer peripheral face of the combined plurality of honeycomb fired bodies. At least two honeycomb fired bodies of the plurality of honeycomb fired bodies have an outer wall that forms a portion of the outer peripheral face of the combined plurality of honeycomb fired bodies. At least one of the outer walls has a protruding portion extending from a surface thereof, and the protruding portion is made from a same material as a material of the at least one outer wall.
    Type: Application
    Filed: December 12, 2007
    Publication date: August 28, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Shigeharu Ishikawa
  • Publication number: 20080176028
    Abstract: A method for manufacturing a honeycomb structure includes a molding step of manufacturing a pillar-shaped honeycomb molded body by using a raw material composition, and a firing step of carrying out a firing treatment on the honeycomb molded body to manufacture a honeycomb fired body. The pillar-shaped honeycomb molded body has a large number of cells disposed in substantially parallel with one another in a longitudinal direction with a cell wall therebetween. The raw material composition includes inorganic particles, at least one of inorganic fibers and inorganic whiskers, and an inorganic binder. The inorganic particles include secondary particles formed by an agglomeration of primary particles. An average particle diameter of the inorganic binder in the raw material composition is about 1/200 to about 1/40 of an average particle diameter of the inorganic particles.
    Type: Application
    Filed: November 14, 2007
    Publication date: July 24, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige OHNO, Masafumi Kunieda, Takahiko Ido
  • Patent number: 7387657
    Abstract: A honeycomb structural body is constituted with a ceramic block comprising a plurality of through-holes arranged in a longitudinal direction and separated from each other through partition walls, either end portions of which through-holes being sealed. The ceramic block constituting the honeycomb structural body is made of a composite material consisting of ceramic particles and crystalline silicon and having an excellent thermal conductivity, so that the honeycomb structural body is excellent in the thermal diffusibility but also excellent in the resistance to thermal shock because the storing of thermal stress is less and no crack is caused even if a temperature distribution is caused at a relatively low temperature or cool-heat cycle is repeated over a long period of time.
    Type: Grant
    Filed: October 7, 2003
    Date of Patent: June 17, 2008
    Assignee: Ibiden Co., Ltd.
    Inventors: Masafumi Kunieda, Atsushi Kudo
  • Publication number: 20080118701
    Abstract: A method for manufacturing a honeycomb structure includes manufacturing a pillar-shaped honeycomb molded body having a large number of cells disposed in substantially parallel with one another in a longitudinal direction with a cell wall therebetween by using a raw material composition. The raw material composition includes inorganic particles, at least one of inorganic fibers and inorganic whiskers, and an inorganic binder. The method further includes carrying out a firing treatment on the honeycomb molded body to manufacture a honeycomb fired body. An average particle diameter of the inorganic binder in the raw material composition is about 10 to about 50 nm.
    Type: Application
    Filed: November 12, 2007
    Publication date: May 22, 2008
    Applicant: IBIDEN CO., LTD.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Takahiko Ido