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WO2009088079A1 - Procédé de fabrication d'une structure d'étanchéité en nid d'abeille - Google Patents

Procédé de fabrication d'une structure d'étanchéité en nid d'abeille Download PDF

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Publication number
WO2009088079A1
WO2009088079A1 PCT/JP2009/050230 JP2009050230W WO2009088079A1 WO 2009088079 A1 WO2009088079 A1 WO 2009088079A1 JP 2009050230 W JP2009050230 W JP 2009050230W WO 2009088079 A1 WO2009088079 A1 WO 2009088079A1
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WO
WIPO (PCT)
Prior art keywords
press
honeycomb structure
plugging material
fitting
spacer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2009/050230
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English (en)
Japanese (ja)
Inventor
Takeshi Tokunaga
Koichi Miyashita
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NGK Insulators Ltd
Original Assignee
NGK Insulators Ltd
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Filing date
Publication date
Application filed by NGK Insulators Ltd filed Critical NGK Insulators Ltd
Priority to JP2009548970A priority Critical patent/JPWO2009088079A1/ja
Publication of WO2009088079A1 publication Critical patent/WO2009088079A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/003—Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
    • B28B11/006—Making hollow articles or partly closed articles

Definitions

  • the present invention relates to a method for manufacturing a plugged honeycomb structure, and more specifically, a plugged honeycomb structure capable of manufacturing a plugged honeycomb structure with a uniform depth of plugged portions by a simple method.
  • the present invention relates to a method for manufacturing a body.
  • Ceramic plugged honeycomb structure with excellent heat resistance and corrosion resistance as a support or filter for catalyst devices used for environmental measures and recovery of specific materials in various fields such as chemistry, electric power and steel
  • the body is adopted.
  • plugged honeycomb structures have been increasingly demanded as diesel particulate filters (DPFs) that collect particulate matter (PM) discharged from diesel engines.
  • DPFs diesel particulate filters
  • the plugged honeycomb structure 41 is provided at the end of the cell 44 of the honeycomb structure 43 including the porous partition walls 42 that define a plurality of cells 44 that serve as fluid flow paths.
  • a plugging portion 46 is formed.
  • FIG. 9 is a sectional view schematically showing the structure of the plugged honeycomb structure, taken along a plane including the central axis.
  • the plugging portion 46 is disposed at one opening end of the predetermined cell 44 and is disposed at the other opening end of the remaining cell 44.
  • the sealing portions 46 are formed alternately (see, for example, Patent Document 1). Japanese Patent Laid-Open No. 2001-300922
  • the plugged honeycomb structure 41 when used as a DPF and the gas to be treated G1 is introduced into the cell 44 from the end face B on the inlet side, the porous partition wall 42 is permeated into the adjacent cell 44 to be treated.
  • the exhaust gas G2 is discharged from the end face C on the outlet side. Then, when the gas to be processed G1 passes through the partition wall 42, dust and particulates contained in the gas to be processed G1 are captured by the partition wall 42.
  • the plugged honeycomb structure 41 as described above is obtained by extruding and obtaining a cylindrical unfired honeycomb structure having porous partition walls that define a plurality of cells serving as fluid flow paths. It can be manufactured through the plugging process shown below.
  • a mask is attached to one end face of the unfired honeycomb structure.
  • the mask is attached by sticking an adhesive film to one end face of the unfired honeycomb structure, and by laser processing using image processing, only the part corresponding to the cell to be plugged is perforated. Do by opening.
  • one end face of the unfired honeycomb structure to which the mask is attached is immersed in a slurry-like plugging material (ceramic slurry) stored in a container to form a plugging portion.
  • a slurry-like plugging material ceramic slurry
  • the plugging material is filled in the cells where the plugging portions are to be formed on the other end face of the unfired honeycomb structure. Then, if the unfired honeycomb structure filled with the plugging material is dried and fired, the plugged honeycomb structure 41 is obtained.
  • the depth of the plugged portion tends to be uneven.
  • the depth of the plugged portion refers to the length of the plugged portion in the axial direction of the plugged honeycomb structure.
  • One of the reasons why such a problem occurs is that it is difficult to level the ceramic slurry that is the plugging material in the container. If there is variation in the depth of the plugging member, the filtration area decreases when the plugging member is used as a DPF, for example. The problem of rising.
  • the present invention has been made in view of the above-described problems, and manufacturing a plugged honeycomb structure capable of manufacturing a plugged honeycomb structure having a uniform depth of plugged portions by a simple method. Providing a method.
  • the present invention provides the following method for manufacturing a plugged honeycomb structure.
  • a method for manufacturing a plugged honeycomb structure comprising: a press-fitting base having a flat press-fitting surface; and a height from the press-fitting surface to the upper surface when placed on the press-fitting surface.
  • a spacer having a height corresponding to the depth of the plugged portion of the structure was stored in the storage tank with the press-fitting surface facing upward and the spacer being placed on the press-fitting surface.
  • the press-fitting table on which the spacer is placed is immersed in the slurry-like plugging material and the plugging material located on the press-fitting surface is held on the press-fitting surface.
  • a member is placed in contact with the upper surface of the spacer and arranged parallel to the press-fitting surface, and the leveling member is moved along the upper surface of the spacer to level the plugging material to a uniform thickness.
  • a plugging material layer having a uniform thickness is formed on the press-fitting surface, and the honeycomb structure is applied to the press-fitting table while pressing one end face of the plugging material layer onto the press-fitting surface.
  • the plugging step after placing the honeycomb structure on the press-fitting table and press-fitting the plugging material into an end portion of the cell, the end face of the honeycomb structure
  • the method for manufacturing a plugged honeycomb structure according to [1], wherein the plugged honeycomb structure is a step of taking out from the press-fitting table while sliding on the press-fitting surface while being in contact with the press-fitting surface.
  • the honeycomb structure can be placed between the two spacers and the two spacers.
  • the method for manufacturing a plugged honeycomb structure according to any one of [1] to [3], wherein the plugged honeycomb structure is placed on the press-fitting surface so as to form a region.
  • the leveling member has a leveling portion that comes into contact with the spacer when moved along the upper surface of the spacer, and the leveling portion is planar or linear.
  • the manufacturing method of the plugged honeycomb structure in any one of.
  • the plugging material layer having a uniform thickness formed on the press-fitting surface by the spacer and the leveling member is pressed into the cells of the honeycomb structure. Since the plugged portion is formed, the depth of the plugged portion can be made uniform.
  • FIG. 1 is a perspective view schematically showing a plugged honeycomb structure to be manufactured.
  • FIG. 2 is a diagram (cross-sectional view) showing a part of a cross section of the plugged honeycomb structure shown in FIG. 1 cut along a plane including a central axis.
  • 1 is a perspective view showing a honeycomb structure that is first manufactured in order to manufacture a plugged honeycomb structure in one embodiment of a method for manufacturing a plugged honeycomb structure of the present invention.
  • FIG. 1 is a cross-sectional view showing a honeycomb structure with a mask in one embodiment of a method for manufacturing a plugged honeycomb structure according to the present invention.
  • the press-fitting table is in a slurry state stored in the storage tank in a state where the spacer is placed on the press-fitting surface. It is a top view which shows typically the place immersed in the plugging material.
  • FIG. 6 is a cross-sectional view taken along line A-A ′ in FIG. 5. It is explanatory drawing which shows typically the plugging process of one Embodiment of the manufacturing method of the plugged honeycomb structure of this invention. It is explanatory drawing which shows typically the plugging process of one Embodiment of the manufacturing method of the plugged honeycomb structure of this invention.
  • FIG. 6 is a B-B ′ sectional view in FIG. 5. It is explanatory drawing which shows typically the plugging process of other embodiment of the manufacturing method of the plugged honeycomb structure of this invention. It is explanatory drawing which shows typically the plugging process of other embodiment of the manufacturing method of the plugged honeycomb structure of this invention. It is explanatory drawing which shows typically the plugging process of other embodiment of the manufacturing method of the plugged honeycomb structure of this invention. It is explanatory drawing which shows typically the plugging process of other embodiment of the manufacturing method of the plugged honeycomb structure of this invention. It is a top view which shows typically the state which mounted two spacers on the press-fit surface so that a honeycomb structure can be mounted in the area
  • Fig. 3 is a cross-sectional view schematically showing the structure of a plugged honeycomb structure, cut along a plane including the axial direction.
  • FIG. 1 is a perspective view schematically showing a plugged honeycomb structure to be manufactured.
  • FIG. 2 is a diagram (cross-sectional view) showing an example of a cross section obtained by cutting the plugged honeycomb structure shown in FIG. 1 along a plane including the central axis.
  • a plugged honeycomb structure 1 shown in FIG. 1 is plugged at an end portion of a cell 5 of a honeycomb structure 2 including porous partition walls 4 that partition and form a plurality of cells 5 serving as fluid flow paths.
  • the plugged portion 3 is formed at one open end 6a of a predetermined cell 5a and the other open end 6b of the remaining cell 5b. It is formed.
  • the end face of the plugged portion 3 is flat at the end face of the honeycomb structure 2, and the plugged honeycomb structure 1 is plugged.
  • the depth D of the stop member 3 is adjusted to a desired value (see FIG. 2).
  • Honeycomb structure manufacturing process In one embodiment of the method for manufacturing a plugged honeycomb structure of the present invention, in order to produce the plugged honeycomb structure 1, first, an unfired honeycomb structure as shown in FIG. 3 is produced. .
  • a honeycomb structure 12 shown in FIG. 3 is a cylindrical structure having a honeycomb structure in which a plurality of cells 15 serving as fluid flow paths are partitioned by porous partition walls 14.
  • Such an unfired honeycomb structure 12 can be obtained by extruding a molding raw material containing ceramic and drying it.
  • Molding raw materials including ceramics include cordierite raw materials, mullite, alumina, spinel, silicon carbide, silicon nitride, lithium aluminum silicate, aluminum titanate and other ceramic powders, water and other dispersion media, binders, pore formers, and dispersions. What knead
  • mixed by adding a medium etc. can be used conveniently.
  • hydroxypropylmethylcellulose, methylcellulose, hydroxyethylcellulose, carboxymethylcellulose, polyvinyl alcohol or the like can be used. These may be used individually by 1 type, and may be used in combination of 2 or more type.
  • the pore former any material that can be scattered and disappeared by the firing process may be used.
  • An inorganic substance such as coke, a polymer compound such as foamed resin, an organic substance such as starch, etc. may be used alone or in combination. it can.
  • dispersant ethylene glycol, dextrin, fatty acid soap, polyalcohol and the like can be used. These may be used individually by 1 type, and may be used in combination of 2 or more type.
  • the extrusion molding method is not particularly limited, and for example, a conventionally known method such as extrusion molding using a vacuum extrusion molding machine can be used.
  • the drying method is not particularly limited, and conventionally known drying methods such as hot air drying, microwave drying, dielectric drying, reduced pressure drying, vacuum drying, freeze drying, and the like can be used.
  • the drying method which combined hot air drying, microwave drying, or dielectric drying is preferable at the point which can dry the whole molded object rapidly and uniformly.
  • the predetermined cell 15a is a cell that forms a plugging portion on one end face 12a, and its arrangement on the end face 12a is not particularly limited and can be arbitrarily determined depending on the purpose of use. For example, the predetermined cells 15a can be made every other cell so that a checkered pattern is formed on the end face 12a (predetermined cells and remaining cells are alternately arranged).
  • the mask 19 is for introducing the ceramic slurry only into the predetermined cell 15a, and a conventional mask means can be suitably used.
  • a conventional mask means can be suitably used.
  • an adhesive film is attached to the entire surface of one end face 12a of the unfired honeycomb structure 12, and a hole is formed in a predetermined portion of the adhesive film (mask) covering the predetermined cell 15a by laser processing using image processing.
  • a mask is formed only in the remaining cells. Note that when a mask is provided (applied) to a cell, the mask covers the open end of the cell so that the plugging material is not press-fitted. The mask is applied to a part of the open end of the cell.
  • the cell is not provided with the mask.
  • the “opening area of the holes” is 30 to 100% of the opening area of each cell, so that the slurry for plugging can be satisfactorily penetrated.
  • the opening area is more preferably 40 to 100%, and particularly preferably 50 to 100%.
  • a mask covering the open end of the predetermined cell 15a is disposed on the other end face of the unfired honeycomb structure 12 by the same method. Specifically, an adhesive film is attached to the other end face of the unfired honeycomb structure 12, and holes are formed in predetermined portions corresponding to the remaining cells 15b by laser processing using image processing or the like.
  • the type of the mask film is not particularly limited, but for example, a film that can be melted by heating and can be perforated by laser light irradiation is preferable. Moreover, it is preferable to use a film having an adhesive layer so as to be fixed on the end face of the unfired honeycomb structure. Specific examples of such films include a base material made of a polymer material such as polyester, polyolefin, halogenated polyolefin and the like, and a pressure-sensitive adhesive layer having an adhesive layer made of an acrylic pressure-sensitive adhesive material and laminated on the base material. A film can be mentioned.
  • the thickness of the mask film is preferably about 10 to 100 ⁇ m from the viewpoints of strength, ease of opening holes, and the like.
  • the method for opening the slurry intrusion hole in the mask film is not particularly limited.
  • a method for forming the perforation by the laser irradiation a method for forming the perforation one by one with one needle
  • examples thereof include a method of forming a large number of slurry intrusion holes by using a sword-shaped needle having a predetermined shape corresponding to the cell pitch.
  • the end surface of the honeycomb substrate is image-processed, and the position of the cell where the slurry intrusion hole is to be opened is determined.
  • a method (laser processing using image processing) in which slurry is extracted and a slurry intrusion hole is formed in a portion corresponding to the extracted position by a laser marker is preferable.
  • the remaining cells on one end face and the predetermined cells on the other end face are masked, and then the predetermined cells on one end face are plugged, and the masking on one end face is performed.
  • the remaining cells on the other end face are plugged after peeling off, but after masking the remaining cells on one end face and plugging on predetermined cells on one end face, The masking of one end face may be peeled off, a predetermined cell on the other end face may be masked, and the remaining cells on the other end face may be plugged.
  • FIG. 5 is a diagram illustrating a plugging step in one embodiment of the method for manufacturing a plugged honeycomb structure of the present invention, in which the press-fitting table is stored in a storage tank in a state where the spacer is placed on the press-fitting surface. It is a top view which shows typically the place immersed in the slurry-like plugging material made.
  • 6A is a cross-sectional view taken along the line AA ′ in FIG. 6B to 6D are cross-sectional views corresponding to the cross section AA ′ in FIG.
  • FIGS. 6B and 7B, FIGS. 6C and 7C, and FIGS. 6D and 7D show the same state.
  • a press-fitting table 22 having a flat press-fitting surface 23 and a height from the press-fitting surface 23 to the upper surface 26a when placed on the press-fitting surface 23 are the plugged portions of the “plugged honeycomb structure”.
  • the spacer 26 having a height corresponding to the depth is plugged in the form of a slurry stored in the storage tank 21 with the press-fitting surface 23 facing upward and the spacer 26 placed on the press-fitting surface 23.
  • Immerse in material 25 see FIGS. 5, 6A and 7A.
  • the “plugged honeycomb structure” is the “plugged honeycomb structure to be manufactured” by the manufacturing method of the plugged honeycomb structure of the present embodiment, that is, “the plugged finally obtained” It means “honeycomb structure”.
  • the press-fit surface 23 faces upward means that the press-fit surface 23 faces the same direction as the liquid surface of the plugging material 25 (upward in the vertical direction), and the spacer 26 slides down from the press-fit surface 23. Including the state tilted in the range.
  • the press-fitting base 22 and the spacer 26 are immersed in the plugging material 25
  • the press-fitting base 22 may be immersed in a state where the spacer 26 is placed, or after the press-fitting base 22 is immersed, the spacer 26 is immersed. And may be placed on the press-fitting table 22 in the plugging material 25.
  • it is preferable to vibrate the plugging material 25 By vibrating, the slurry viscosity of the plugging material 25 is lowered, and the press-fitting base 22 and the spacer 26 are easily immersed.
  • the press-fitting table 22 is a member having a flat press-fitting surface 23, and the shape thereof is not particularly limited. For example, it is preferable to use a plate-like member whose one surface (press-fit surface 23) is planar.
  • the term “planar” refers to a flatness tolerance range of up to 500 ⁇ m.
  • the flatness tolerance range is a value measured by expanding the laser beam by an oblique incidence method using “FlatMaster FM40” manufactured by S-Oell.
  • the plugging step when the operation of immersing the press-fitting table 22 out of the plugging material 25 and immersing it again in the plugging material 25 is performed, the press-fitting table 22 is immersed in the plugging material 25.
  • the lower surface side may be formed in a cone shape with the central portion of the lower surface protruding (for example, a conical shape when the lower surface is circular).
  • the central portion of the lower surface protruding for example, a conical shape when the lower surface is circular.
  • the size of the press-fit base 22 is not particularly limited as long as the entire bottom surface of the honeycomb structure 12 can be pressed against the press-fit surface 23.
  • the material of the press-fit base 22 is not specifically limited, Synthetic resins, such as stainless steel, aluminum, MC nylon, Duracon, etc. can be mentioned.
  • the press-fitting base 22 supports the outer edge portion with a support rod 24.
  • a support rod 24 is mounted on an elevator (not shown) and configured so that the press-fitting table 22 can be raised and lowered and stopped at a predetermined position.
  • the honeycomb structure 12 is placed on the press-fit base 22 while pressing the press-fit surface 23, the press-fit base 22, the support rod 24 and the elevator (not shown) that support the press-fit base 22 can withstand the pressing force at that time. It is preferable to have strength.
  • the support bar 24 is a member having such strength, the material and shape thereof are not particularly limited.
  • the shape of the support rod 24 is preferably a shape that does not hinder the placement and removal of the honeycomb structure.
  • the height from the press-fit surface 23 to the upper surface 26a of the spacer 26 is the depth of the plugged portion of the plugged honeycomb structure (see FIG. 2 (see a depth D of 2). That is, the height D1 of the spacer 26 from the bottom surface 26b in contact with the press-fit surface 23 to the top surface 26a is the depth of the plugged portion of the plugged honeycomb structure to be manufactured (see depth D in FIG. 2).
  • the upper surface 26a is preferably a plane parallel to the bottom surface 26b, but may be a ridge line parallel to the bottom surface 26b.
  • the cross section of the spacer 26 perpendicular to the direction in which the ridge line extends may be a polygon such as a triangle or a curve such as a semicircle. Also good.
  • the cross-sectional shape perpendicular to the direction in which the ridgeline of the spacer 26 extends is a semicircular shape
  • the straight line portion constituting the semicircular shape corresponds to the bottom surface 26b
  • the top portion of the arc corresponds to the upper surface 26a.
  • the spacer 26 is preferably a member whose longitudinal direction is one direction parallel to the bottom surface 26b.
  • one of the side surfaces is a rod-shaped member having a bottom surface 26b.
  • the cross section perpendicular to the longitudinal direction is a rectangular rod shape (square A columnar member or the like is preferable.
  • the size of the spacer 26 is such that the height D1 is the same as the depth of the plugged portion of the plugged honeycomb structure to be manufactured, and can be placed on the press-fit surface 23 together with the honeycomb structure. If there is no particular limitation.
  • the height D1 varies in a suitable range depending on the size of the plugged honeycomb structure to be manufactured. For example, a cylindrical plugged honeycomb structure having a bottom diameter of 14.4 cm and a height of 15.2 cm Is preferably 1 to 15 mm.
  • the material of the spacer 26 is not particularly limited, and examples thereof include synthetic resins such as stainless steel, aluminum, MC nylon, and Duracon.
  • the length of the spacer 26 in the longitudinal direction is such that when the leveling member 28 is moved from one end of the spacer 26 to the other end, the entire area where the honeycomb structure is placed is equalized by the leveling member 28. It is preferable that the length be able to pass through.
  • the length in the longitudinal direction of the spacer 26 is preferably longer than the diameter of the bottom surface of the honeycomb structure.
  • FIG. 8 is a plan view schematically showing a state in which the two spacers 26 and 26 are placed on the press-fit surface 23 so that the honeycomb structure 12 can be placed in the region S between the two spacers 26 and 26. It is. FIG. 8 shows a state where the honeycomb structure 12 is placed in the region S for reference. The region S is a region sandwiched between two spacers 26 and 26 as shown in FIG.
  • the two spacers 26, 26 are arranged at a predetermined interval, and the leveling member 28 is placed on the upper surfaces of both of the two spacers 26, 26.
  • the heights of the two spacers 26, 26 from the bottom surface 26b to the top surface 26a are preferably the same.
  • the plugging material layer 27 having a uniform thickness is formed in the region S between the two spacers 26, 26, by placing the honeycomb structure 12 in this region S, the plugging material layer 27 is formed in the region S.
  • the plugging material of the formed plugging material layer 27 having a uniform thickness is press-fitted into the honeycomb structure 12 to form a plugging portion having a uniform depth.
  • the two spacers 26 and 26 are preferably arranged so as to be parallel to each other, but may not be parallel to each other.
  • the two spacers 26 and 26 sandwiching the region S may be two independent spacers, for example, one end portion is connected. May be integrated into a “U” shape, a “V” shape, a “Y” shape, or the like.
  • portions other than the portions corresponding to the two spacers 26 and 26 sandwiching the region S are used as the spacers used in the present embodiment. It is not necessary to satisfy the conditions.
  • the slurry-like plugging material (ceramic slurry) 25 stored in the storage tank 21 is not particularly limited.
  • a ceramic powder such as cordierite is kneaded with a binder, a dispersion medium, or the like. Can be suitably used.
  • the type of ceramic powder there are no particular restrictions on the type of ceramic powder, and for example, the same ceramic powder contained in the forming raw material for extruding the unfired honeycomb structure 12 described above may be used, or a different one may be used. May be.
  • the plugging material preferably has thixotropic properties from the viewpoint of penetration into the cell and retention of the slurry near the inner end of the cell.
  • the slurry concentration of the plugging material is preferably 30 to 60% by volume, more preferably 40 to 50% by volume.
  • the slurry viscosity of the plugging material at 25 ° C. is preferably 1 to 1000 dPa ⁇ s, more preferably 5 to 500 dPa ⁇ s, and particularly preferably 10 to 100 dPa ⁇ s. If the pressure is lower than 1 dPa ⁇ s, the plugging material may not easily enter the cell due to high fluidity, and if it is higher than 1000 dPa ⁇ s, the plugging material may be hard to press into the cell. There is.
  • the viscosity is a value measured with a vibration viscometer. As the vibration viscometer, for example, FVM-80A manufactured by CBC Materials can be used.
  • the dispersion medium for example, organic solvents such as acetone, methanol, ethanol and the like, water and the like can be mentioned as suitable examples.
  • the binder for example, a resin such as polyvinyl alcohol (PVA) can be used, and it is preferable to use a thermal gel curable binder having a property of gelation by heating.
  • PVA polyvinyl alcohol
  • methylcellulose can be suitably used.
  • the reservoir 21 is not particularly limited, and the diameter and depth can be appropriately determined according to the size of the honeycomb structure to be plugged.
  • a bottomed cylindrical container having a diameter of 5 to 100 cm and a depth of 5 to 20 cm can be used.
  • the shape of the bottom surface may be any shape such as a circle, an ellipse, a polygon such as a quadrangle, and other irregular shapes.
  • the material of the storage tank 21 is not particularly limited, and examples thereof include synthetic resins such as stainless steel, aluminum, MC nylon, and Duracon.
  • the plugging material 25 is preferably a high-concentration slurry, in this case, the fluidity is usually high in a vibration state, but is solidified in a stationary state, and the press-fitting table 22 and the spacer 26 are immersed. Because it may be difficult.
  • the vibration condition is not particularly limited, but it is preferable to vibrate vertically and vertically with a vibration frequency of 1 to 1,000,000 Hz and an amplitude of 0.001 to 50 mm.
  • the press-fitting base 22 on which the spacer 26 is placed is plugged in the plugging material 25 stored in the storage tank 21.
  • the press-fitting table 22 is immersed in the plugging material 25 stored in the storage tank 21
  • plugging having a thickness from the press-fitting surface 23 to the liquid surface of the plugging material 25 is formed on the press-fitting surface 23.
  • Material 25 is present. Therefore, for example, when the press-fit table 22 immersed in the plugging material 25 is moved upward in the vertical direction and out of the plugging material 25, the press-fit table 22 is positioned on the press-fit surface 23 in the storage tank 21.
  • At least a part of the plugging material 25 that has been removed is taken out while being held on the press-fit surface 23.
  • the plugging material 25 is held on the press-fitting surface 23
  • the plugging material 25 is placed on the press-fitting surface 23 without dropping from the press-fitting surface 23.
  • the plugging base 22 is taken out of the plugging material 25 while the plugging material 25 is held on the press-fitting surface 23, thereby using the leveling member 28 to seal the plugging on the press-fitting surface 23.
  • the moving direction of the press-fit table 22 is not limited to the upward direction in the vertical direction as described above, and may be an obliquely upward direction or the like as long as the plugging material 25 is held on the press-fit surface 23. .
  • the press-fitting surface 23 is kept horizontal (the normal line of the press-fitting surface 23 faces upward in the vertical direction). It may be put out in a slightly tilted state, that is, in a state where it is tilted within a range that does not slide down when the plugging material 25 is placed on the press-fitting surface 23.
  • the plugging material is preferably not vibrated in order to hold the plugging material 25 on the press-fitting surface 23. Further, when the press-fitting base 22 is raised, the bottom part of the press-fitting base 22 is stopped in contact with the plugging material 25, and the following operation is performed. This is preferable in that air is not caught between the stopper material 25.
  • a leveling member 28 for leveling the plugging material 25 on the press-fit surface 23 is brought into contact with the upper surface 26 a of the spacer 26 and arranged parallel to the press-fit surface 23.
  • the plugging material 25 is moved along the upper surface 26a and the plugging material 25 is evened to form a uniform plugging material layer 27 on the press-fit surface 23 (see FIGS. 6B and 7B).
  • the thickness of the plugging material layer 27 is the same as the height D1 of the spacer 26.
  • the leveling member 28 is in contact with the upper surface 26 a of the spacer 26 in a state parallel to the press-fit surface 23, and the leveling member 28 is in contact with the upper surface 26 a of the spacer 26 parallel to the press-in surface 23.
  • the leveling member 28 can be stably moved in a state parallel to the press-fit surface 23.
  • the plugging material 25 on the press-fit surface 23 is leveled so that the thickness becomes uniform.
  • the plugging material layer 27 having a uniform thickness can be obtained.
  • the plugging material layer The thickness of 27 can be made the same as the depth of the plugged portion of the “plugged honeycomb structure to be manufactured”.
  • the leveling member 28 has a leveling portion 28a that comes into contact with the spacer 26 when moving along the upper surface 26a of the spacer 26, and the leveling portion 28a is preferably flat or linear.
  • the “plane” or “straight line” of the flat or linear leveling portion 28 a is parallel to the press-fit surface 23. It means arranging.
  • the shape of the leveling member 28 preferably has a flat or linear leveling portion 28a, and the shape of other portions is not particularly limited.
  • the cross section perpendicular to the longitudinal direction is a rectangular columnar (plate-shaped) member.
  • a triangular prism-shaped member having a triangular cross section perpendicular to the longitudinal direction may be used. In this case, one of the ridge lines of the triangular prism may be used as the “linear leveling portion 28a”, or one side surface of the triangular prism may be used as the “planar leveling portion 28a”.
  • the cross-sectional shape is not limited to the above-described triangle or quadrangle, and may be any other shape such as a polygon, a circle, or a semicircle. Moreover, it is preferable that the leveling member 28 has a length in the longitudinal direction that can level the entire region where the honeycomb structure 12 is placed. When placing the two spacers 26, 26 on the press-fit surface 23, the leveling member 28 is preferably longer than the distance between the two spacers 26, 26.
  • the material of the leveling member 28 is not particularly limited, and examples thereof include urethane rubber and stainless steel.
  • the honeycomb structure 12 is placed on the press-fitting table 22 while pressing one end face of the plugging material layer 27 onto the press-fitting surface 23 to form the plugging material layer 27.
  • the stopper material 25 is press-fitted from the end of the cell (see FIGS. 6C and 7C).
  • To press one end face of the honeycomb structure 12 onto the press-fit surface 23 from above the plugging material layer 27 is to press the end face of the honeycomb structure 12 against the press-fit face 23 via the plugging material layer 27.
  • One end face of the honeycomb structure 12 is brought into contact with the surface of the plugging material layer 27, and the plugging material layer 27 is pressed downward (toward the press-fitting surface 23) as it is.
  • the end face of the honeycomb structure 12 is moved toward the press-fit surface 23 while the sealing material is press-fit from the end of the cell to reach the press-fit surface 23.
  • the end face of the honeycomb structure 12 is pressed from above the plugging material layer 27 onto the press-fit surface 23, the end face to be pressed is maintained in a state parallel to the plugging material layer 27 and the press-fit surface 23. It is preferable to press against the press-fitting surface 23 in order to form a plugging having a uniform depth.
  • the plugging material of the plugging material layer 27 having a uniform thickness is obtained by pressing the end face of the honeycomb structure 12 onto the press-fitting surface 23 from above the plugging material layer 27.
  • a plugged portion having a uniform depth is formed in the honeycomb structure 12 by being press-fitted from the end portion of the cell. The depth of the plugging portion is the same as the thickness of the plugging material layer 27.
  • the pressure when one end face of the honeycomb structure 12 is pressed from above the plugging material layer 27 onto the press-fit surface 23 is not particularly limited as long as the plugging member is press-fit from the end of the cell. 310 kPa is preferable, and 30 to 250 kPa is more preferable. If it is lower than 15 kPa, the plugging material may be difficult to be press-fitted into the cell. If it is higher than 310 kPa, the honeycomb structure may be damaged or unnecessary pressure may be applied to the press-fitting table.
  • the method for moving, pressing, etc. the honeycomb structure 12 is not particularly limited.
  • the honeycomb structure 12 has a holding part for holding the honeycomb structure, the holding part can be moved up and down, and can be pressed when lowered.
  • a moving / pressing device that can move in a horizontal plane can be used.
  • the moving / pressing device may be a single device having both a moving function and a pressing function, or may be a combination of a moving device and a pressing device.
  • a robot for example, a Yaskawa Electric robot
  • a cylinder for example, a cylinder manufactured by SMC
  • SMC a cylinder manufactured by SMC
  • the plugging material is press-fitted only from the open end of the cell where the mask is not provided.
  • the honeycomb structure 12 is taken out from the press-fit table 22.
  • a method for removing the honeycomb structure 12 from the press-fit base 22 is not particularly limited, but the honeycomb structure 12 is placed on the press-fit base 22 and the plugging material 25 is press-fitted into the end of the cell. It is preferable to remove the honeycomb structure 12 from the press-fitting table 22 while sliding sideways along the press-fitting surface 23 with the end face of the honeycomb structure 12 being in contact with the press-fitting surface 23 (see FIGS. 6D and 7D).
  • the honeycomb structure 12 is removed from the press-fitting table 22 by moving upward (moving without sliding), the end surface of the plugging portion may protrude or dent, and the plugging with a uniform depth may occur.
  • the honeycomb structure 12 is taken out from the press-fitting table 22 while sliding, the end surface of the plugged portion becomes flat and the plugged portion has a uniform depth as described above. A stop can be formed.
  • the press-fitting base 22 After taking out the honeycomb structure in which the plugging portions are formed, the press-fitting base 22 is immersed in the plugging material 25 stored in the storage tank 21 while vibrating the plugging material 25. In order to plug the next honeycomb structure or to further plug the other end face of the honeycomb structure having one end face plugged, the spacers 26 are arranged at predetermined positions. To do. Thus, after taking out the plugged honeycomb structure from the press-fitting table 22, the press-fitting table 22 is immersed again in the plugging material 25 and the next plugging process is started. In addition, since the plugging process can be continuously performed, it is not necessary to clean the press-fit table 22 and the spacer 26, and the production efficiency can be improved.
  • Plugging portion drying step When the plugging process on the one end face 12a side is finished, the plugging portion formed by press-fitting the plugging material 25 is dried. By this drying, the plugging material 25 is cured to the extent that the shape is not deformed in the subsequent drying and baking processes.
  • the means for drying the plugging material 25 is not particularly limited.
  • the honeycomb structure 12 filled with the plugging material is directed with its one end face 12a facing down. It is possible to employ a method of placing and drying on a hot plate in a state, hot air drying by blowing hot air, microwave drying, or the like.
  • the drying temperature of the plugged portion is not particularly limited, but is preferably 10 to 300 ° C, more preferably 20 to 200 ° C, and particularly preferably 50 to 150 ° C. If the drying temperature is less than 10 ° C., it may take too much time to sufficiently dry. On the other hand, if it exceeds 300 ° C., the honeycomb structure may be altered by heat.
  • Plugging step of the other end face of the honeycomb structure, plugging portion drying step Next, the masking disposed on one end face is peeled off, and the other end face of the honeycomb structure 12 is plugged at the open end of the remaining unmasked cells 15b in the same manner as described above. The material 25 is filled to form a plugged portion, and the formed plugged portion is dried.
  • a honeycomb structure having plugged portions on both end faces is fired to obtain a plugged honeycomb structure.
  • the means to bake It can carry out according to a conventionally well-known baking method and conditions. For example, there is a method of calcining before firing (main firing) to prepare a calcined body, followed by main firing.
  • the “calcination” means an operation for burning and removing organic substances (organic binder, dispersant, pore former, etc.) in the honeycomb base material.
  • the combustion temperature of the organic binder is about 100 to 300 ° C.
  • the combustion temperature of the pore former is about 200 to 800 ° C.
  • the calcining temperature may be about 200 to 1000 ° C.
  • the calcination time is not particularly limited, but is usually about 10 to 100 hours.
  • the firing conditions (temperature and time) for the main firing vary depending on the type of the forming raw material, and therefore, appropriate conditions may be selected according to the type. It is preferable to fire. Further, it is preferable to bake for about 3 to 10 hours.
  • the forming raw material in the calcined body can be sintered and densified to ensure a predetermined strength. Note that the mask 19 disappears at the same time as firing when firing, or is removed before firing.
  • the plugged honeycomb structure 1 as shown in FIG. 1 obtained as described above has an inner surface of the partition walls 4, pores inside the partition walls 4, or inner surfaces of the partition walls 4 and pores inside. Both can be used as a catalyst device by supporting the catalyst. Even when the plugged honeycomb structure 1 is used as a DPF, it is preferable to support a catalyst having a function of promoting the combustion of the deposit (particulate matter) trapped in the partition walls 4.
  • Preferred examples of the catalyst include noble metal Pt, Pd, Rh and the like, and nonmetal perovskite catalysts.
  • a conventionally known catalyst supporting method can be adopted.
  • Example 1 (Honeycomb structure production) A cordierite raw material mixed with alumina, kaolin, and talc was used as a ceramic raw material, methyl cellulose was used as a binder, and water was used as a dispersion medium. 5 parts by mass of the binder and 20 parts by mass of the dispersion medium were mixed and kneaded with respect to 100 parts by mass of the ceramic raw material to obtain a clay. The obtained clay was extruded to obtain a cylindrical honeycomb structure having a bottom diameter of 14.4 cm and a height of 15.2 cm. The cell density of the obtained honeycomb structure was 300 cells / cm 2 , the partition wall thickness was 0.3 mm, and the cross-sectional shape of the cell perpendicular to the central axis was a square.
  • a pressure-sensitive adhesive film was adhered to one whole end face of the obtained unfired honeycomb structure.
  • a tape adheresive strength: 5.3 N / cm, thickness: 25 ⁇ m, trade name “Masking Tape”, manufactured by 3M Company
  • an acrylic pressure-sensitive adhesive on a polyester base material was used.
  • a predetermined cell so that holes are formed in a checkered pattern by laser processing using image processing (cells in which holes are formed and cells in which holes are not formed are alternately arranged)
  • a hole was made in a predetermined part of the adhesive film, and the remaining cells were masked. In the same manner, the predetermined cell on the other end face was also masked.
  • plugging material As a plugging material, a slurry obtained by adding and kneading 1.5 parts by mass of methylcellulose, 8 parts by mass of starch, and 40 parts by mass of water to 100 parts by mass of cordierite powder was used. The viscosity of the obtained plugging material was 50 dPa ⁇ s (25 ° C.).
  • the operations schematically shown in FIGS. 5A to 5D were performed. Specifically, a rectangular press-fit with a flat press-fitting surface filled with a plugging material up to a height of 5 cm in a bottomed cylindrical stainless steel storage tank having a bottom diameter of 40 cm and a height of 10 cm.
  • a table (20 cm ⁇ 20 cm, thickness 1 cm) was immersed in the plugging material so that the press-fitting surface and the liquid surface of the plugging material face the same direction (upward) (see FIG. 5A).
  • the plugging material was vibrated (frequency 60 Hz).
  • the plugging material was vibrated by attaching a vibration device (Dalton, trade name: vibration sieve) to the storage tank. Further, the press-fitting table was supported by the support bars at the four corners, and the press-fitting table was moved up and down while controlling the four support bars by the lifting device.
  • the press-fitting table was moved to the upper side in the vertical direction to get out of the plugging material stored in the storage tank. At this time, the press-fitting table was moved while the plugging material located on the press-fitting surface was held on the press-fitting surface.
  • a leveling member for leveling the plugging material on the press-fit surface is brought into contact with the upper surface of the spacer (thickness 3 mm) and arranged in parallel to the press-fit surface, and the leveling member is arranged along the upper surface of the spacer.
  • the plugging material was moved to a uniform thickness to form a plugging material layer having a uniform thickness on the press-fit surface (see FIGS. 6B and 7B).
  • As the leveling member a rectangular plate (50 cm ⁇ 20 cm, thickness 10 cm) was used, and the material was urethane rubber.
  • the honeycomb structure is placed on a press-fitting table while pressing one end surface of the plugging material layer from above the plugging material layer, and the plugging material forming the plugging material layer is placed in the cell. It press-fitted from the edge part (refer FIG. 6C and FIG. 7C).
  • the movement and pressing of the honeycomb structure has a holding part for holding the honeycomb structure, the holding part can be moved up and down, can be pressed when lowered, and can be moved in a horizontal plane.
  • a certain moving / pressing device (moving device: manufactured by Yaskawa Electric Co., Ltd., trade name: industrial robot, pressing device: manufactured by SMC Corp., trade name: air cylinder) was used.
  • the pressing pressure when the honeycomb structure was placed on the press-fitting table was 125 kPa.
  • the honeycomb structure was taken out from the press-fitting table while being slid along the press-fitting surface in a state where the end surface thereof was in contact with the press-fitting surface (see FIGS. 6D and 7D).
  • the plugged portion was dried by a method of blowing hot air on the end face. Drying conditions were 150 ° C. and 2 minutes.
  • the honeycomb structure having the plugged portions was fired to obtain a plugged honeycomb structure.
  • an electric furnace was used, and the firing conditions were 1410 to 1440 ° C. and 5 hours.
  • the plugging portion depth was measured by the method described below, and the uniformity of the plugging depth was calculated. As a result, the average value of the plugging portion depth was 3 mm, and the sample standard deviation was 0.2 mm.
  • the plugging portion depth was measured by a method using a height gauge, and the average value and sample standard deviation were calculated to evaluate the uniformity of the plugging portion depth.
  • the average value is a value obtained by selecting 17 locations from the plugged portions formed on one end face without deviation, measuring the depth, and calculating the average.
  • the sample standard deviation is a standard deviation with respect to the 17 plugging depths at which the average value is calculated. The case where the sample standard deviation was 0.5 mm or less was regarded as acceptable.
  • Example 1 A plugged honeycomb structure was manufactured in the same manner as in Example 1 except that the plugging material storage tank was immersed without being provided with a press-fitting base. About the obtained plugged honeycomb structure, the plugged portion depth was measured by the above method, and the uniformity of the plugged depth was calculated. As a result, the average value of the plugging portion depth was 3.9 mm, and the sample standard deviation was 1.4 m.
  • Comparative Example 3 A plugged honeycomb structure was manufactured in the same manner as in Comparative Example 2 except that the orches used in Comparative Example 2 were used without washing as the substitute used in place of the storage tank. About the obtained plugged honeycomb structure, the plugged portion depth was measured by the above method, and the uniformity of the plugged depth was calculated. As a result, the average plugging depth was 4.1 mm, and the sample standard deviation was 2.8 mm.
  • the method for producing a plugged honeycomb structure according to the present invention is suitably used as a means for producing a plugged honeycomb structure used as a carrier for a catalyst device or a filter such as a DPF.

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Filtering Materials (AREA)

Abstract

Procédé de fabrication d'une structure d'étanchéité en nid d'abeille comprenant les étapes suivantes: étanchéification consistant à immerger une base à ajustement serré (22) qui présente une surface d'ajustage plane et un entretoise (26) dans un matériau d'étanchéité (25) contenu dans un récipient de stockage (21) de telle sorte que la surface à ajustage serré est tournée vers le haute et que l'entretoise (26) est montée sur cette surface; extraction de la base à ajustement serré sur laquelle est montée l'entretoise (26) hors du récipient (21) contenant le matériau d'étanchéité (25); mise en place d'un élément de mise à niveau (28) parallèlement à la surface à ajustement serré et en contact avec la surface supérieure de l'entretoise (26); formation d'une couche de matériau d'étanchéité (27) par déplacement de l'élément de mise à niveau (28) le long de la surface supérieure de l'entretoise (26) et mise à niveau du matériau d'étanchéité (25) pour qu'il présente une épaisseur uniforme, montage d'une structure en nid d'abeille sur la base à ajustement serré (22) tout en plaquant une face d'extrémité de la structure en nid d'abeille contre la surface à ajustement serré depuis le dessus de la couche de matériau d'étanchéité (27) et ajustement serré du matériau d'étanchéité depuis l'extrémité d'une cellule, puis séparation de la structure en nid d'abeille de la base à ajustement serré (22). Ce procédé de fabrication permet d'obtenir de façon simple une structure présentant une épaisseur uniforme dans la partie d'étanchéité.
PCT/JP2009/050230 2008-01-10 2009-01-09 Procédé de fabrication d'une structure d'étanchéité en nid d'abeille Ceased WO2009088079A1 (fr)

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Cited By (4)

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Publication number Priority date Publication date Assignee Title
JP2015009205A (ja) * 2013-06-28 2015-01-19 京セラ株式会社 ハニカム構造体およびこれを用いたガス処理装置
JP2019521021A (ja) * 2016-07-13 2019-07-25 コーニング インコーポレイテッド セラミックハニカム体を施栓するためのシステムおよび方法
CN112621135A (zh) * 2020-12-23 2021-04-09 河北亿利康纳利亚环保科技有限公司 后处理无导向模载体封装工艺
US20210146574A1 (en) * 2018-07-31 2021-05-20 Corning Incorporated Methods of plugging a honeycomb body

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JPS62174102A (ja) * 1985-11-07 1987-07-30 シ−、ジ−、ベバン、アソ−シエイツ、リミテツド 建材製品の製造方法およびその方法を実施する装置
JPH06190218A (ja) * 1992-12-28 1994-07-12 Ibiden Co Ltd ハニカムフィルタの封口方法
WO2006062141A1 (fr) * 2004-12-08 2006-06-15 Ngk Insulators, Ltd. Procede de fabrication d’un corps a structure alveolaire etanche
JP2006272183A (ja) * 2005-03-29 2006-10-12 Hitachi Metals Ltd セラミックハニカムフィルタの製造方法

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Publication number Priority date Publication date Assignee Title
JPS62174102A (ja) * 1985-11-07 1987-07-30 シ−、ジ−、ベバン、アソ−シエイツ、リミテツド 建材製品の製造方法およびその方法を実施する装置
JPH06190218A (ja) * 1992-12-28 1994-07-12 Ibiden Co Ltd ハニカムフィルタの封口方法
WO2006062141A1 (fr) * 2004-12-08 2006-06-15 Ngk Insulators, Ltd. Procede de fabrication d’un corps a structure alveolaire etanche
JP2006272183A (ja) * 2005-03-29 2006-10-12 Hitachi Metals Ltd セラミックハニカムフィルタの製造方法

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015009205A (ja) * 2013-06-28 2015-01-19 京セラ株式会社 ハニカム構造体およびこれを用いたガス処理装置
JP2019521021A (ja) * 2016-07-13 2019-07-25 コーニング インコーポレイテッド セラミックハニカム体を施栓するためのシステムおよび方法
US11472061B2 (en) 2016-07-13 2022-10-18 Corning Incorporated System and methods of plugging ceramic honeycomb bodies
US20210146574A1 (en) * 2018-07-31 2021-05-20 Corning Incorporated Methods of plugging a honeycomb body
US11919194B2 (en) * 2018-07-31 2024-03-05 Corning Incorporated Methods of plugging a honeycomb body
CN112621135A (zh) * 2020-12-23 2021-04-09 河北亿利康纳利亚环保科技有限公司 后处理无导向模载体封装工艺

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