CN1836863A - Method for manufacturing ceramic - Google Patents
Method for manufacturing ceramic Download PDFInfo
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- CN1836863A CN1836863A CN 200610066170 CN200610066170A CN1836863A CN 1836863 A CN1836863 A CN 1836863A CN 200610066170 CN200610066170 CN 200610066170 CN 200610066170 A CN200610066170 A CN 200610066170A CN 1836863 A CN1836863 A CN 1836863A
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Abstract
The present invention provides a suitably method for manufacturing a ceramic having a stable quality by favorably controlling a mass of a body for shaping. The manufacturing method of the ceramic comprises mixing and kneading a body containing a ceramic material, extruding the body 1 with a kneader 6, cutting the body 1 into pieces of a predetermined length to give the body 1a for shaping, filling the body 1a for shaping in a shaping machine and shaping it to give a shaped body, and firing the shaped body to produce the ceramic, wherein a mass of the body 1a for shaping to be filled in the shaping machine is measured, and quality control of the body 1a for shaping is conducted based on the measured mass.
Description
Technical field
The present invention relates to the manufacture method of pottery, relate in particular under being shaped management quality well, be suitable for making the manufacture method of the pottery of stabilizing quality with the state of base soil.
Background technology
The structure that is made of pottery is in aspect extensive uses such as filter, catalyst carriers, particularly as the waste gas purification of internal combustion engines such as gasoline engine, diesel engine, burner with or exhaust-gas treatment be widely used with catalyst carrier, filter etc.Because from exhaust gas of internal combustion engines such as diesel engine, what contain a large amount of reasons that becomes environmental pollution is the particulate matter (particle-like substance) of main component with carbon, so in these gas extraction system, can carry the filter that is used for trap particulate matter.
Generally, the filter that is used for such purpose, use ceramic honeycomb structural body, shown in Fig. 3 (a) and Fig. 3 (b), this structure has a plurality of holes lattice of being separated by porous matter next door 17 (opening) 9 that connect on direction of principal axis, the end of the end of specific hole lattice 19a is sealed at these hole lattice 19 inner mouth-sealed portions 21 that are made of enclosed material of filling, and is similarly sealed by mouth-sealed portion 21 in the end of the other end of the opposition side of specific hole lattice 19a for remaining hole lattice 19b.
Waste gas flows into to inside from end face 13 beginnings by an end of such filter that honeycomb structured body constituted, and after the particulate matter that is contained in the gas etc. is removed, flows out from the end face 15 of the other end.Particularly, at first, waste gas flow into the hole lattice 19b that is not closed in inflow side end face 13 ends, is closed in outflow side end face 15 ends of this filter, by porous matter next door 17, move in inflow side end face 13 ends the hole lattice 19a that is closed, is not closed in outflow side end face 15 ends, lattice 19a is discharged from from this hole.At this moment next door 17 becomes filter course, thereby the particulate matter in the waste gas is caught by next door 17 and is deposited on the dividing plate 17.
Such pottery be ceramic materials such as cordierite, water and adhesive, pore-creating material etc. mixed, mixes after, by pug mill extruding ejection soil, this base soil is cut off according to desirable length, obtain being shaped and use base soil, the shaping that obtains is configured as honeycomb shape with base soil, drying, burns till and make.
In the manufacture method of in the past the structure that is made of pottery, the qualitative control with base soil of being shaped for example is to use by cutting into desirable length after the pug mill extruding, shaping is become certain volume with a part of severing of base soil and the sample strip that obtains.Specifically, the sample strip of intercepting certain volume is measured various weight, divided by the volume of sample strip, calculates density then.According to the density value of calculating like this, estimate the base soil (for example opening the 2003-327483 communique) that the back of mixing, mix is squeezed out by pug mill with reference to the spy.
Summary of the invention
But, in the manufacture method of existing pottery like this, through mixed once, mix after, the amount of the base soil that is squeezed out by pug mill is the amount that general forming machine can repeatedly be shaped, so, for resulting base soil, can there be part difference in the damage state based etc. of contained pore-creating material in the admixture of ceramic material etc., the shaping raw material, and these states can change along with the time.Therefore, even carry out the evaluation of base soil from the part intercepting sample strip of base soil, the a plurality of shapings that obtain as this base soil is cut into desired length are with the whole qualitative control of base soil, and it is insufficient, for example the meetings such as the porosity of the pottery of reality manufacturing are different with the value of prediction, have the problem that is difficult to make the stabilizing quality pottery.
And, also can cause the loss of raw material by sampling.In addition, the sample strip of intercepting is measured various weight in the atmosphere, in the water by Archimedes's method, but this Archimedes's method must be determined at the quality in the water, just must need the long period to the sample strip processing that is covered.Because water evaporates causes variable density, can not measure correct density during lining is handled, the making of sample strip also needs the long period.Because the work in-process water evaporates is so can cause variable density.Also have, the base soil that is squeezed out by pug mill produces big Density Distribution in the longitudinal direction, so just produces the problem that can not fully hold the whole density of base soil according to sampling point.
In view of so in the past situation, the invention provides under being shaped management quality well with the state of base soil, can make the process for preparing ceramic of stabilizing quality pottery aptly.
The invention provides following process for preparing ceramic.
(1) Tao Ci manufacture method, after the shaping raw material that will contain ceramic material mixes, mixes, by pug mill extruding ejection soil, described base soil is cut off according to desirable length, obtain being shaped and use base soil, described shaping is filled in the forming machine with base soil forms, obtain formed body, the described formed body that obtains is burnt till, obtain pottery, wherein, measure and be used for being filled into the quality of the described shaping of described forming machine, carry out the qualitative control of described shaping with base soil according to the quality of measuring with base soil.
(2) manufacture method of above-mentioned (1) described pottery wherein, is set the mass range of described shaping with base soil, uses the described shaping of quality in the prescribed limit to form with base soil.
(3) manufacture method of above-mentioned (2) described pottery, wherein, the value of the porosity after burning till according to the described pottery of gained is set the described scope of described shaping with the quality of base soil.
(4) manufacture method of each described pottery of above-mentioned (1)~(3), wherein, described ceramic material is at least a for what select from cordierite, carborundum, silicon nitride, mullite, aluminium oxide, silica.
(5) manufacture method of each described pottery of above-mentioned (1)~(4), wherein, described pottery is cellular.
(6) manufacture method of each described pottery of above-mentioned (1)~(5), wherein, described pottery is a particulate matter filter.
(7) manufacture method of each described pottery of above-mentioned (1)~(6) wherein, is used and is contained the material of pore-creating material as described shaping raw material.
Manufacture method according to pottery of the present invention, mensuration is actually used in the quality that base soil is used in the shaping that forms, form with the qualitative control of base soil with the quality of base soil according to the shaping of measuring and to make pottery, therefore can be under base earthy attitude for example porosity of the pottery that gets of administrative institute well, make the pottery of stabilizing quality aptly.Therefore, the manufacture method of pottery of the present invention is before being shaped with base soil, can more positively carry out the qualitative control of employed shaping with base soil.
And, compare with the process for preparing ceramic in the past that the whole evaluation of the base soil that is squeezed out by pug mill for mixed once, after mixing is judged by the sample strip of taking out from its part, can estimate respectively with base soil each shaping that is used to be filled into forming machine, therefore when the mixing of the base soil that squeezes out by pug mill, when the state that mixes is inhomogeneous, can get rid of the indivedual shapings base soil that contains inappropriate part.And then, owing to can carry out real-time mensuration,, adjust in the suitable scope with the quality of base soil being shaped so can adjust the operating condition of pug mill.
Description of drawings
Fig. 1 obtains being shaped mode declaration pattern specification figure with the operation of base soil in the embodiment of manufacture method of expression pottery of the present invention.
Fig. 2 is the mode declaration pattern specification figure with the operation of base soil of being shaped in the embodiment of manufacture method of expression pottery of the present invention.
Fig. 3 (a) is the summary description figure of structure that expression is used as the ceramic honeycomb structural body of filter, is to see plane in the past from an end face of ceramic honeycomb structural body.
Fig. 3 (b) is the sectional view at the ceramic honeycomb structural body of Fig. 3 (a) expression.
Among the figure, the 1st, base soil, 1a are to be shaped to use base soil, the 2nd, forming machine, the 3rd, ceramic honeycomb structural body, the 4th, shaping raw material, the 5th, mixer, the 6th, pug mill, the 7th, cylinder, the 8th, tube head, the 9th, hole lattice, the 13rd, end face (inflow side end face), the 15th, end face (outflow side end face), the 17th, next door, 19,19a, 19b be the hole lattice, the 21st, mouth-sealed portion.
The specific embodiment
Following with reference to accompanying drawing, as an example of the manufacture method of pottery of the present invention, the embodiment of the manufacture method of ceramic honeycomb structural body is elaborated.But the present invention is not limited to these, in the limit that does not depart from the scope of the present invention, according to those skilled in the art's knowledge, can carry out various changes, correction and improvement.
The manufacture method of the ceramic honeycomb structural body of present embodiment as shown in Figure 1, after the shaping raw material 4 that will contain ceramic material mixes, mixes, squeezes out specific shape by pug mill 6, for example cylindric base soil 1.Then, resulting base soil 1 is cut off according to desirable length, obtain being shaped with base soil 1a, as shown in Figure 2 resulting shaping is filled in the forming machine 2 with base soil 1a, obtain formed body (being to be configured as cellular ceramic honeycomb formed body 3 in the present embodiment), ceramic honeycomb formed body 3 to gained burns till, obtain ceramic honeycomb structural body as pottery, wherein, as depicted in figs. 1 and 2, mensuration is used to be filled into the quality of the shaping of forming machine 2 with base soil 1a, forms the qualitative control of using base soil 1a according to the quality of measuring.Usually, be shaped and fix according to the extruding bore of pug mill 6 with the outside dimension of base soil 1a, the length of cut-out is fixing according to the size of forming machine 2 substantially also.In the qualitative control of carrying out according to quality in the present embodiment ceramic honeycomb structural body manufacture method, preferably adopt linear mass.
Like this, by measure with base soil 1 according to desired length cut off obtain, be used to be filled into the quality of the shaping of forming machine 2 with base soil 1a, can be under this be shaped with the state of base soil 1a management quality well, can make the pottery (being ceramic honeycomb structural body in the present embodiment) of stabilizing quality aptly.
And, evaluation with base soil 1 integral body that squeezes out by pug mill 6 for mixed once, after mixing, compare by the manufacture method in the past that the sample strip of taking out with the part of base soil 1a from shaping is judged, can be shaped to each that is used to be filled into forming machine 2 and estimate with the native 1a of base, so, can only get rid of the shaping that contains inappropriate part base soil 1a when the mixing of base soil 1, when the state that mixes is inhomogeneous.And then, owing to can carry out real-time mensuration,, the quality that is shaped with base soil 1a is adjusted in the suitable scope so can adjust the operating condition of pug mill 6.
The manufacture method of the ceramic honeycomb structural body of present embodiment, as mentioned above, according to being used to be filled into the quality of the shaping of forming machine 2 with base soil 1a, this shaping is carried out qualitative control with base soil 1a, be used to be filled into the quality of the shaping of forming machine 2 so also can for example set, use the shaping of quality in the particular range to form with base soil 1a with base soil 1a.If know that the one-tenth that constitute to be shaped with the shaping raw material 4 of base soil 1a is grouped into, then, can predict for example porosity of gained ceramic honeycomb structural body according to the shaping of given shape (for example length-specific) quality with the native 1a of base.Thus, as an example that is shaped with the qualitative control of base soil 1a, can be according to the porosity after the burning till of gained pottery, promptly the target porosity is set the mass range that is shaped with base soil 1a, carries out the qualitative control of this shapings with the native 1a of base.According to formation like this, can make the ceramic honeycomb structural body of particular air holes rate aptly.
Below, the manufacture method to the ceramic honeycomb structural body of present embodiment further describes each operation.
At first, as shown in Figure 1, after the shaping raw material 4 that will contain ceramic material mixes, mixes, push, obtain base soil 1 by pug mill 6.The ceramic raw material that contains in the shaping raw material 4, the material that uses in the time of can using known in the past manufacturing ceramic honeycomb structural body for example can be enumerated select at least a from cordierite, carborundum, silicon nitride, mullite, aluminium oxide, silica.
In addition, in the shaping raw material 4 that constitutes base soil 1, contain water, and then can also contain pore-creating material, adhesive, dispersant, surfactant etc. as required as decentralized medium.The pore-creating material is burnt when Low fire ceramic honeycomb formed article 3 (with reference to Fig. 2) and is formed pore, thereby increases the porosity, is the additive that is used to obtain the ceramic honeycomb structural body of high porosity.As the pore-creating material, can enumerate the combustible of when Low fire ceramic honeycomb formed article 3 (with reference to Fig. 2), being burnt, for example graphite, wheat flour, starch, phenolic resins, Foamex, polymethyl methacrylate, polyethylene or PETG etc.
For the mixer 5 that mixes, mixes, muller and pug mill 6, can use known in the past mixer, muller and pug mill aptly.Also be not particularly limited for the method for mixing, mixing, can use known method in the past aptly.By the base soil 1 of pug mill 6 extruding, be squeezed into cylindric corresponding to the shape of the internal diameter of the cylinder 7 (with reference to Fig. 2) that constitutes forming machine 2 (with reference to Fig. 2).
After obtaining such base soil 1, base soil 1 is cut to needed length, obtains to be used to be filled into the shaping base soil 1a of forming machine 2 (with reference to Fig. 2).For example will cut into desirable length, and make it can fill the cylinder 7 (with reference to Fig. 2) that constitutes plunger type forming machine 2 shown in Figure 2 (with reference to Fig. 2) in right amount by the base soil 1 that pug mill 6 squeezes out.
Then, measure the quality that base soil 1a is used in the shaping that so obtains.The measuring method of shaping with base soil 1a is not particularly limited, for example can enumerates methods for measuring such as using steelyard, electronic balance.
And then, resemble when by the evaluation of sample strip is next base soil 1 integral body that is squeezed out by pug mill 6 being carried out qualitative control in the past, for example, if the mixing of base soil 1, the state of mixing exists inhomogeneous, the sample strip that is intercepted contains inappropriate part, it is all improper then can to judge into this base soil 1, but in the manufacture method of the ceramic honeycomb structural body of present embodiment, be used to be filled into the separately quality of each shaping of forming machine 2 owing to measure respectively with base soil 1a, carry out high-precision management so can be shaped with base soil 1a to each, for example, mixing when the base soil 1 that squeezes out by pug mill 6, the state of mixing exists when inhomogeneous, can only get rid of the shaping that contains inappropriate part with base soil 1a.
Then, as shown in Figure 2, will be shaped is filled into forming machine 2 with base soil 1a, and this shaping that is shaped obtains the ceramic honeycomb formed body 3 as formed body with base soil 1a.In Fig. 2, adopt extrusion molding to carry out the shaping of ceramic honeycomb formed body 3, but be not particularly limited for manufacturing process, can be suitable for known in the past manufacturing process.Wherein, in Fig. 2, carry out the shaping of ceramic honeycomb formed body 3 by extrusion molding, ceramic honeycomb formed body 3 as formed body, be the formed body that divide to form the hole lattice of fluid flowing path according to the next door, so be tube head 8 extrusion moldings of the slit of complementary shape by having formed the next door that has with needing form.
Also have, though omit in the drawings, the ceramic honeycomb structural body of preferred gained for example, when being used for filter applications such as diesel particulate filter, will seal at two end face parts as the end of the hole lattice of the stream of above-mentioned fluid with staggering mutually.About method for sealing, can enumerate following method: for example paste adhesion sheet etc. at the end face of an end of ceramic honeycomb formed body, by utilizing Laser Processing that image handles etc., only the part of the hole lattice (sealing the hole lattice) that seal corresponding to needs of this adhesion sheet etc. is carried out perforate, as mask, the end face of pasting the ceramic honeycomb formed body of this mask is impregnated in the slurries (ceramic slurries), the Kong Gezhong that seals at ceramic formation body fills slurries, thereby seal, also carry out same operation in the other end of ceramic honeycomb formed body.
Global shape to the ceramic honeycomb formed body is not particularly limited, and for example can exemplify cylindric, quadrangular prism shape, triangle column etc.Also have, the shape of hole lattice (with the hole lattice shape on the perpendicular cross section of the formation direction of hole lattice) is not particularly limited, for example can exemplify quadrangle, hexagon, triangle etc.
Then, above-mentioned ceramic honeycomb formed body (also may be calcined body as required) is burnt till (formally burning till), obtain ceramic honeycomb structural body thus.Formally burn till and mean, to guarantee the operation of regulation shape and target property the shaping raw material sintering.Firing condition (temperature, time, atmosphere) is different different because of the kind of shaping raw material, therefore can select suitable condition according to its kind.
Like this,, can under being shaped, carry out good quality management, produce the ceramic honeycomb structural body of stabilizing quality aptly with the state of base soil according to the manufacture method of the ceramic honeycomb structural body of present embodiment.
In addition, the manufacture method that has more than exemplified ceramic honeycomb structural body illustrates the embodiment of the manufacture method of pottery of the present invention, but process for preparing ceramic of the present invention can also be used for, the honeycomb shape structure of making by extrusion molding, tubular body structure etc., and the tableware of making by die forming (round scraper shaping), watt, the shaping that obtains from the base soil that is squeezed out by pug mill of use such as ceramic tile, insulator is with base soil, the method for the pottery of manufacturing different shape.
Embodiment
Below, according to embodiment the present invention is described in more details, but the present invention is not limited to these embodiment.
In order to make the porosity reach 59% (range of management is 56~62%), after will containing cordierite and forming the about 600kg of shaping raw material of powder, shaping additive, surfactant, pore forming agent, water and mix, mix, by pug mill in three batches (first~the 3rd batch) push ejection soil.By the base soil of such gained, the circle that each forms 5 end surface shape is 300mm, length are the cylindric shaping base soil of 1300mm.The shaping of embodiment 1~15 is measured by the steelyard of maximum 200kg with the quality (kg/m) of base soil.In the present embodiment, obtain the quality of the shaping of embodiment 1~15 with the unit length (lm) of base soil.In manufacture method in the past, carry out simultaneously, take sample strip from the shaping of resulting embodiment 1~15 with base soil simultaneously, measure density, be converted into the quality (kg/m) of the shaping of these embodiment 1~15 with base soil by Archimedes's method.The porosity is 56~62% shaping with the mass range of base soil is 88~95kg/m.The result of table 1 for measuring.
Table 1
Be shaped with the quality (kg/m) of base soil | Archimedes's density conversion is shaped with base soil property amount (kg/m) | The porosity (%) | The error of quality determination (σ) (kg) | The error of Archimedes's density conversion (σ) (kg) | ||
| First | 90.6 | 88.7 | 59.3 | 0.5 | 1.9 |
Embodiment 2 | 91.4 | 92.7 | 59.1 | |||
Embodiment 3 | 91.6 | 90.2 | 58.6 | |||
Embodiment 4 | 91.0 | 93.0 | 59.1 | |||
| 91.7 | 92.7 | 59 | |||
| Second batch | 88.4 | 91.5 | 61.8 | 0.7 | 1.5 |
Embodiment 7 | 87.1 | 88.2 | 62.5 | |||
Embodiment 8 | 86.8 | 90.5 | 63.5 | |||
Embodiment 9 | 88.0 | 88.2 | 62 | |||
Embodiment 10 | 87.5 | 88.5 | 62.4 | |||
Embodiment 11 | The 3rd batch | 89.7 | 92.1 | 60.5 | 0.3 | 1.8 |
Embodiment 12 | 90.3 | 92.4 | 60.4 | |||
Embodiment 13 | 89.7 | 90.9 | 60.5 | |||
Embodiment 14 | 90.0 | 88.6 | 60.6 | |||
Embodiment 15 | 90.1 | 88.7 | 60.7 |
The shaping separately of the above embodiments 1~15 is filled in the forming machine (extrusion moulding machine) with base soil, form, obtaining quadrangle, hole lattice density that circle that end surface shape is 160mm, cylinder that length is 200mm and hole lattice are shaped as 1.17mm * 1.17mm is 260 holes lattice/square inch (about 40.3 hole lattice/cm
2), next door thickness is the ceramic honeycomb structural body of 12mil (about 300 μ m), the ceramic honeycomb structural body of gained extracted burn till, and obtains 15 ceramic honeycomb structural bodies from the shaping separately of embodiment 1~15 with base soil.Sintered body (ceramic honeycomb structural body) is cut off, measured the porosity by the forced PORE SIZE APPARATUS FOR of mercury.The result is as shown in table 1.Also have, also shown in the table 1 according to embodiment 1~15 be shaped the result's that quality determination with base soil obtains error (error of quality determination (σ) (kg)) and Archimedes's density conversion error (σ) (kg).
As shown in Table 1, first mixes shaping raw material substantially equably with the 3rd batch, the shaping of embodiment 1~5 and embodiment 11~15 uses the quality of base soil all within range of management with the quality of base soil and the shaping separately of Archimedes's method conversion, but compare with the error of the quality of base soil with the shaping of embodiment 1~5 and embodiment 11~15, the shaping that Archimedes's method converts is bigger with the error of the quality of base soil, the steady quality of base soil of shaping separately.Second batch is, can not hold out batch situation (ロ Star ト ア ウ ト) in Archimedes's method.The shaping of embodiment 1~15 demonstrates very high correlation with the quality and the porosity of base soil, can effectively control the porosity.
The possibility of utilizing on the industry
The manufacture method of pottery of the present invention, can be under being shaped with the state of base soil management quality well, Production Example is as being used as for the catcher/filter of removing particulate material, catalyst carrier etc. aptly, the pottery of stabilizing quality.
Claims (7)
1. the manufacture method of a pottery, after the shaping raw material that will contain ceramic material mixes, mixes, by pug mill extruding ejection soil, described base soil is cut off according to desirable length, obtain being shaped and use base soil, described shaping is filled in the forming machine with base soil forms, obtain formed body, described formed body is burnt till and obtain pottery, wherein, mensuration is used for being filled into the quality of the described shaping of described forming machine with base soil, carries out the qualitative control of described shaping with base soil according to the quality of measuring.
2. the manufacture method of pottery according to claim 1 wherein, is set the scope of described shaping with the quality of base soil, uses the described shaping of quality in the prescribed limit to form with base soil.
3. the manufacture method of pottery according to claim 2, wherein, the porosity value after burning till according to the described pottery of gained is set the described scope of described shaping with the quality of base soil.
4. according to the manufacture method of each described pottery of claim 1~3, wherein, described ceramic material is at least a for what select from cordierite, carborundum, silicon nitride, mullite, aluminium oxide, silica.
5. according to the manufacture method of each described pottery of claim 1~4, wherein, described pottery is cellular.
6. according to the manufacture method of each described pottery of claim 1~5, wherein, described pottery is a particulate matter filter.
7. on the manufacture method according to each described pottery of claim 1~6, wherein, use and contain the material of pore-creating material as shaping raw material.
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JP2005088580A JP2006264237A (en) | 2005-03-25 | 2005-03-25 | Manufacturing method of ceramic |
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Cited By (1)
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CN109230411A (en) * | 2018-08-20 | 2019-01-18 | 镇江裕太防爆电加热器有限公司 | A kind of simple overturning structure for conveying for triangle magnesium pipe agglomerating plant |
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US7993561B2 (en) | 2006-09-28 | 2011-08-09 | Hitachi Metals, Ltd. | Method for producing ceramic honeycomb filter |
CN115056341B (en) * | 2022-04-25 | 2023-08-29 | 重庆安都陶瓷有限公司 | Ceramic pug stirring system and method |
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2005
- 2005-03-25 JP JP2005088580A patent/JP2006264237A/en not_active Withdrawn
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Cited By (1)
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CN109230411A (en) * | 2018-08-20 | 2019-01-18 | 镇江裕太防爆电加热器有限公司 | A kind of simple overturning structure for conveying for triangle magnesium pipe agglomerating plant |
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JP2006264237A (en) | 2006-10-05 |
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