Patents by Inventor Shuichi Ichikawa
Shuichi Ichikawa 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).
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Publication number: 20060101747Abstract: The honeycomb structure of the present invention has a construction wherein a plurality of cells 5 each functioning as a passage of a fluid, surrounded by porous partition walls 6 are arranged so as to be parallel to each other in the central axis direction of the honeycomb structure, and has such a constitution that a plurality of honeycomb segments 2 are bonded integrally by a bonding material 9 containing a ceramic as a main component and a particulate filler. In the honeycomb structure, generation of drawbacks such as peeling of bonded area, cracking and the like is suppressed reliably, and the honeycomb structure is superior in durability.Type: ApplicationFiled: November 11, 2004Publication date: May 18, 2006Applicant: NGK INSULATORS, LTD.Inventors: Naoshi Masukawa, Shuichi Ichikawa
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Patent number: 7037477Abstract: A silicon carbide-based porous material containing silicon carbide particles (1) as an aggregate and metallic silicon (2), wherein the average particle diameter of the silicon carbide-based porous material is at least 0.25 time the average particle diameter of the silicon carbide particles (1), or the contact angle between the silicon carbide particles (1) and the metallic silicon (2) is acute, or a large number of secondary texture particles each formed by contact of at least four silicon carbide particles (1) with one metallic silicon (2) are bonded to each other to form a porous structure. This silicon carbide-based porous material can be sintered, in its production, at a relatively low firing temperature and, therefore, can be provided at a low production cost, at a high yield and at a low product cost.Type: GrantFiled: March 27, 2002Date of Patent: May 2, 2006Assignee: NGK InsulatorsInventors: Takahiro Tomita, Yuichiro Tabuchi, Shuichi Ichikawa, Takashi Harada
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Patent number: 7029511Abstract: A honeycomb structure 1 has a large number of through-holes 3 divided by partition walls 2 and extending in the axial direction, characterized in that the honeycomb structure contains a Si phase having a lattice constant controlled at 0.54302 to 0.54311 nm at room temperature. A process for producing the honeycomb structure 1, includes a firing step of firing a precursor of honeycomb structure, wherein the precursor contains a Si phase and the firing step is conducted using a furnace material free from any boron-containing compound. A process for producing the honeycomb structure 1, includes a firing step of firing a precursor of honeycomb structure, wherein a reduction percentage of Si content in Si phase after firing step relative to Si content in Si phase before firing step is suppressed at 10% by mass or less. Having an improved thermal conductivity, the honeycomb structure is superior in thermal shock resistance.Type: GrantFiled: January 24, 2003Date of Patent: April 18, 2006Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Takashi Harada, Aiko Otsuka, Yukihisa Wada, Yoshinori Yamamoto
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Publication number: 20060062961Abstract: There is disclosed a honeycomb structure 1 having a plurality of cells 4 partitioned by cell walls 2 to function as fluid passages, a predetermined cell 4 being plugged by a plugging material at one end face, a remaining cell 4 being plugged by the plugging material at the other end face, wherein a Young's modulus of the plugging material is lower than that of the cell wall 2. A strength of the plugging material is lower than that of the cell wall. A porosity of the plugging material is 97% or more of that of the cell wall. There is provided a honeycomb structure whose end face is not easily cracked and which is superior in durability.Type: ApplicationFiled: November 7, 2003Publication date: March 23, 2006Applicant: NGK Insulators, Ltd.Inventors: Atsushi Kaneda, Naoshi Masukawa, Shuichi Ichikawa
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Publication number: 20060057330Abstract: A method for manufacturing a porous honeycomb structure of the present invention comprises the steps of: mixing at least an aggregate raw material, water, an organic binder, a pore-forming agent, and an alkali metal source, wherein the aggregate raw material comprises metal silicon and/or a non-oxide ceramic containing silicon; kneading the mixture to form clay; forming the clay into a honeycomb shape having a plurality of cells as passages for fluid; drying the formed body to obtain a honeycomb formed body; calcinating the honeycomb formed body to obtain a calcinated body; and firing the calcinated body to obtain a porous honeycomb structure.Type: ApplicationFiled: October 21, 2003Publication date: March 16, 2006Applicant: NGK Insulators, Ltd.Inventors: Yasushi Uchida, Aiko Otsuka, Shuichi Ichikawa
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Patent number: 7011803Abstract: A honeycomb structure having a large number of channels through along the axial direction and being defined by partition walls. A honeycomb structure containing a refractory particle to be an aggregate and metallic silicon and being porous. This honeycomb structure can be suitably used under high SV conditions as a filter for purifying automobile exhaust gas by treatment such as clogging or catalyst supporting.Type: GrantFiled: April 12, 2001Date of Patent: March 14, 2006Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
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Publication number: 20060014636Abstract: A catalyst body of the present invention includes: a porous carrier in which a large number of aggregate particles containing a main component of a nonoxide ceramic are bonded to one another while a large number of pores are disposed; and a catalyst layer carried on the porous carrier and containing a compound of an alkali metal, wherein the porous carrier has an oxide film unavoidably formed on a part of the surface of the aggregate particles, and an oxide film protective layer formed of a material which does not form low-melting glass with the alkali metal is further disposed between the oxide film and the catalyst layer in such a manner as to coat at least a part of the oxide film.Type: ApplicationFiled: November 19, 2003Publication date: January 19, 2006Applicant: Nke Insulators, LtdInventors: Shuichi Ichikawa, Yasushi Uchida
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Patent number: 6984253Abstract: A honeycomb filter 1, which comprises an integral structure of a plurality of honeycomb segments 12 bonded by an adhesive 8. The honeycomb segment has numbers of through-holes 3, which are surrounded by partition walls 2 and extend in the axial direction of the segment. The honeycomb filter is characterized in that a ratio of a thermal conductivity ? s of the honeycomb segment 12 to a thermal conductivity ? a of the adhesive 8, ? s/? a, is in a range of 5 to 300 and a density ? a of the adhesive 8 is in a range of 0.1 to 4 g/cc. The honeycomb filter can prevent excessive temperature increase, can be low in non-uniformity of temperature distribution, and can be superior in durability.Type: GrantFiled: October 7, 2002Date of Patent: January 10, 2006Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Naoshi Masukawa
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Publication number: 20060003143Abstract: A method of manufacturing a porous honeycomb structure of the present invention includes the steps of: mixing and kneading at least an aggregate particle material formed of a ceramic and/or a metal, water, an organic binder, a pore former, and colloidal particles to form clay; forming the clay into a honeycomb shape having a plurality of cells constituting through channels of fluids; drying the clay to obtain a honeycomb formed body; calcining the honeycomb formed body to form a calcined body; and thereafter firing the calcined body to obtain the porous honeycomb structure.Type: ApplicationFiled: October 21, 2003Publication date: January 5, 2006Applicant: NGK INSULATORS, LTD.Inventors: Yasushi Uchida, Aiko Otsuka, Shuichi Ichikawa
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Publication number: 20050140069Abstract: There is provided a method of manufacturing a composite material, which includes: manufacturing the composite material from a raw material including metal silicon and ceramic. The method of manufacturing the composite material is characterized in that the raw material includes metal silicon whose surface is coated with an organic matter. Metal silicon in which pinhole defects are not easily generated is included in the raw material in the method of manufacturing the composite material.Type: ApplicationFiled: May 14, 2003Publication date: June 30, 2005Applicant: NGK INSULATORS, LTD.Inventor: Shuichi Ichikawa
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Publication number: 20050105584Abstract: The method for measurement of thermal conductivity of a honeycomb structure according to the present invention comprises the steps keeping the whole honeycomb structure in a steady temperature state with keeping two ends of the honeycomb structure at given different temperatures; and measuring a thermal conductivity of the honeycomb structure in the steady state. According to the present invention there is provided a method for measurement of thermal conductivity of a honeycomb structure, which can measure the thermal conductivity of a honeycomb structure in the shape of the honeycomb structure per se or in a predetermined block shape without preparing, for example, a test specimen of particular shape.Type: ApplicationFiled: March 14, 2003Publication date: May 19, 2005Applicant: NGK Insulators LtdInventors: Shuichi Ichikawa, Aiko Otsuka, Motomichi Itou, Takuma Makino
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Publication number: 20050050845Abstract: The present invention provides a honeycomb structure in which a plurality of honeycomb segments each constituted by a cell structure having a plurality of cells divided from each other by partition walls and functioning as a passage for fluid and an outer wall provided at the circumference of the cell structure are bonded to each other at the outer walls by a bonding layer made of a bonding agent and converted into one piece, which honeycomb structure is characterized in that the bonding agent does not contain inorganic particles having diameters (?m) of at least 1.1 times the average surface roughness Ra (?m) of the outer wall, in an amount exceeding 30% by mass relative to the total of the bonding agent. In the honeycomb structure, the honeycomb segments as a constituent are strongly bonded to each other by a bonding agent and converted into one piece.Type: ApplicationFiled: October 3, 2003Publication date: March 10, 2005Inventors: Naoshi Masukawa, Shuichi Ichikawa
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Publication number: 20050025933Abstract: There is disclosed a honeycomb structure in which a positional deviation is not easily occurred by vibration or the like in the honeycomb structure held in a can, of which the strength reduction is small and which can be easily produced, and a process for production of the structure. The honeycomb structure 1 comprises a cell structure portion 20 constituted of partition walls 2 arranged so as to form a plurality of cells 3 extending through an axial direction, and an outer peripheral wall 7 disposed in an outer periphery of the cell structure portion 20. A surface roughness Ra of an outer peripheral surface of the outer peripheral wall is 1 to 80 ?m.Type: ApplicationFiled: July 28, 2003Publication date: February 3, 2005Inventors: Naoshi Masukawa, Shuichi Ichikawa, Takashi Harada
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Publication number: 20040244344Abstract: A honeycomb filter 1 is constituted by integrating a plurality of honeycomb segments 12 including a large number of through channels 3 partitioned by partition walls 2 and extending through an axial direction. The honeycomb filter 1 is characterized in that a thermal conductivity, strength, or strength/Young's modulus ratio of a honeycomb segment 12I, disposed in a central portion is high, or a porosity, average pore diameter, or (porosity×(average pore diameter)2) of a wall portion is small with respect to a honeycomb segment 12O disposed in an outer peripheral portion. The honeycomb filter is used in a filter or the like for capturing particulates in an exhaust gas, superior in regeneration efficiency, and capable of simultaneously achieving durability and low pressure loss.Type: ApplicationFiled: March 30, 2004Publication date: December 9, 2004Inventor: Shuichi Ichikawa
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Patent number: 6777114Abstract: It is directed to a silicon carbide-based porous body, wherein said body is a porous one which contains silicon carbide particles as an aggregate and metallic silicon, and has an oxygen-containing phase at the surfaces of silicon carbide particles and/or metallic silicon or in the vicinity of the surfaces thereof. The silicon carbide-based porous body contains refractory particles such as silicon carbide particles or the like and yet can be produced at a relatively low firing temperature at a low cost, has a high thermal conductivity, and is superior in oxidation resistance, acid resistance, chemical resistance to ash and particulates.Type: GrantFiled: August 13, 2002Date of Patent: August 17, 2004Assignee: NGK Insulators, Ltd.Inventors: Takahiro Tomita, Shuichi Ichikawa, Shinji Kawasaki, Hiroaki Sakai
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Patent number: 6764742Abstract: A honeycomb structure body which has a number of passages partitioned with partition walls and penetrating along the axial direction. A porous honeycomb structure body which contains refractory grains as filler, one or more elements selected from the group consisting of the rare earth elements, alkaline earth elements, Al, and Si, and the crystal containing one or more kinds of these elements. The present honeycomb structure body contains refractory grains such as silicon carbide grains and the like, but it can be produced at a relatively low firing temperature at a low price, it is sufficiently porous and high in specific surface area, and it can be used as a filter for purifying automobile exhaust gas, a catalyst carrier, and the like under the high SV conditions.Type: GrantFiled: October 1, 2002Date of Patent: July 20, 2004Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
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Patent number: 6746748Abstract: A honeycomb structure made of a silicon carbide-based porous body and having a number of through-holes extending in the axial direction, separated by partition walls. The strength and Young's modulus of the silicon carbide-based porous body satisfy the following relation: Strength (MPa)/Young's modulus (GPa)≧1.1. The honeycomb structure contains refractory particles such as silicon carbide particles and the like and yet can be produced at a relatively low firing temperature at a low cost, has a high strength and a high thermal shock resistance, and can be suitably used, for example, as a filter for purification of automobile exhaust gas by a treatment such as plugging of through-channel at its inlet or outlet, or as a catalyst carrier, even under a high SV condition.Type: GrantFiled: August 12, 2002Date of Patent: June 8, 2004Assignee: NGK Insulators, Ltd.Inventors: Shuichi Ichikawa, Takahiro Tomita, Shinji Kawasaki, Hiroaki Sakai
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Publication number: 20040097370Abstract: A honeycomb structure 1 formed by bonding into one piece, via a bonding layer 8, a plurality of honeycomb segments 12, the honeycomb segment having an outer wall 7, partition walls 2 provided inside the outer wall, and a large number of through-holes 3 divided by the partition walls 2 and extending in the axial direction of the segment is provided.Type: ApplicationFiled: August 7, 2003Publication date: May 20, 2004Inventors: Shuichi Ichikawa, Naoshi Masukawa
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Publication number: 20040051196Abstract: A method for producing a porous ceramic article involves a step of kneading raw materials including a raw material for a ceramic and a processing aid, to prepare a body, a step of forming the body, to prepare a ceramic formed product, a step of drying the formed product, to prepare a ceramic dried article, and a step of firing the ceramic dried article, to preparing a porous ceramic article, characterized in that the processing aid is a starch having been subjected to a crosslinking treatment or a material comprising a starch having been subjected to a crosslinking treatment and a foamed resin. The method allows the production of a porous ceramic article which is suppressed in the deformation during drying and is excellent in dimensional accuracy.Type: ApplicationFiled: July 28, 2003Publication date: March 18, 2004Inventors: Aiko Otsuka, Shuichi Ichikawa, Takashi Harada
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Publication number: 20040045267Abstract: A honeycomb filter 1, which comprises an integral structure of a plurality of honeycomb segments 12 bonded by an adhesive 8. The honeycomb segment has numbers of through-holes 3, which are surrounded by partition walls 2 and extend in the axial direction of the segment. The honeycomb filter is characterized in that a ratio of a thermal conductivity &kgr;s of the honeycomb segment 12 to a thermal conductivity &kgr;a of the adhesive 8 , &kgr;s/&kgr;a, is in a range of 5 to 300 and a density &rgr;a of the adhesive 8 is in a range of 0.1 to 4 g/cc. The honeycomb filter can prevent excessive temperature increase, can be low in non-uniformity of temperature distribution, and can be superior in durability.Type: ApplicationFiled: July 3, 2003Publication date: March 11, 2004Inventors: Shuichi Ichikawa, Naoshi Masukawa