JP2005280168A - Honeycomb element and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enhance the capacity of a honeycomb element by enhancing the support ratio of a catalyst or an adsorbent in the honeycomb element having the catalyst or adsorbent used in a filter and to obtain a cost merit by having the use of an adhesive material in a manufacturing process thereof. <P>SOLUTION: When a single-faced corrugated sheet 1 is wound to form a cylindrical honeycomb 2, a cylindrical shape is held by a winding clamping force without applying a catalyst impregnated in a rear process or an adhesive which inhibits the impregnation of the effective component of an adsorbent. Further, the corrugated sheet 1 immersed in an impregnation of the catalyst or the adsorbent containing a binder component to support the catalyst or the adsorbent to obtain the structurally strong cylindrical honeycomb element enhanced in support ratio. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a honeycomb element substrate used as a catalyst or adsorbent support substrate and a method for producing the same.

  Conventionally, this type of honeycomb-shaped element uses a paper or nonwoven fabric containing ceramic fibers, glass fibers, or a mixture thereof as a base paper, and one of the pair of base papers remains flat. A flat sheet and the other corrugated sheet with a corrugated sheet are processed and joined to each other at the ridge line of the corrugated sheet using an adhesive or the like to form a single-stage sheet, which is laminated in a substantially cylindrical or prismatic shape. (For example, see Japanese Patent Application Laid-Open No. 5-137937).

  Hereinafter, a method for forming a single-stage sheet laminated in a cylindrical shape or a prismatic shape will be described with reference to FIGS.

  As shown in FIG. 4, the single-stage sheet 101 includes a flat sheet 102 and a corrugated sheet 103, and is bonded to the flat sheet 102 by applying an adhesive 104 to the ridge line portion 105 of the corrugated sheet 103.

  Further, as shown in FIG. 5, the single-stage sheet 101 is wound into a cylindrical shape and laminated, and an adhesive 104 is applied to and joined to the cross-line portion 105 which is a contact portion between the adjacent single-stage sheets 101 to form a cylinder. The honeycomb 106 is formed.

  In this way, when the catalyst or adsorbent is supported on the formed honeycomb and has functions such as air cleaning, deodorization, and dehumidification, the component of the adhesive 104 used when forming the honeycomb includes catalyst or adsorption. There is no function of the agent, on the contrary, it acts to inhibit the loading of these functional materials.

On the other hand, for example, as shown in Japanese Patent Application Laid-Open No. 5-137937, there are some which improve the adsorption performance by mixing particles such as an adsorbent into the adhesive 104 to be used.
JP-A-5-137937

  In the case where a honeycomb element is formed by laminating single-stage sheets manufactured by such a conventional single-stage sheet manufacturing method, the adhesive applied to the joint between the flat sheet and the corrugated sheet covers the surface of the base paper and There is a problem that the supporting rate of the catalyst or the adsorbent in the adhesive application portion is lowered by penetrating the inside of the fiber of the paper, and it is required to improve the supporting rate of the impregnating liquid.

  In addition, when the joint strength of adjacent single-stage sheet joints is weak, there is a problem that the product strength of the honeycomb element is not satisfied, and the strength of the impregnating liquid is improved while the strength of the honeycomb element is satisfied. It is requested.

  The present invention solves such a conventional problem, can satisfy the strength of the honeycomb-shaped element, and at the same time, improves the supporting rate of the impregnating liquid of the catalyst or the adsorbent. An object of the present invention is to provide a honeycomb-shaped element that can improve the performance and reduce the manufacturing cost and a manufacturing method thereof.

  In order to achieve the above object, the honeycomb element of the present invention uses paper or nonwoven fabric containing ceramic fibers, glass fibers, or a mixture thereof as a base paper, and one of the two base paper pairs. Is a flat sheet that remains flat, and the other is a corrugated sheet that is formed into a corrugated shape, and after joining them at the ridges of the corrugated sheet, a single-stage sheet is formed, and then the single-stage sheet is laminated to form a honeycomb In a process, it laminates | stacks, without apply | coating an adhesive agent to the contact part of an adjacent single stage sheet and a single stage sheet. However, simply laminating adjacent single-stage sheets does not have a bonding force and does not form a honeycomb shape.Therefore, in the forming process of a cylindrical honeycomb, the single-stage sheet is wound while tension is applied, and the cylindrical shape is held by the tightening force. The winding end is fixed with an adhesive tape or an adhesive.

  By this means, it is possible to reduce the manufacturing cost by reducing the man-hour and the adhesive material cost for applying the adhesive when forming the honeycomb, and also in the manufacturing apparatus, by using no adhesive adhesive There is a big merit in cleaning or maintenance.

  When the catalyst or adsorbent component is supported on the honeycomb, the binder component is mixed in the impregnating solution of the catalyst or adsorbent to impregnate the honeycomb.

  By this means, the honeycomb structure is strengthened and the supporting rate of the catalyst or adsorbent component is improved to improve the catalyst or adsorption performance.

  According to the present invention, the supporting rate of the catalyst or the adsorbent on the base material is improved. As a result, it is possible to provide a honeycomb element having an effect of improving the performance of the product or reducing the size, and a manufacturing method thereof.

  Further, according to the present invention, it is possible to reduce the use of an adhesive in the process of manufacturing a honeycomb-shaped element, and to provide a honeycomb-shaped element that has an effect of reducing processing costs and a method for manufacturing the same.

  Also in the manufacturing apparatus, there is a great merit in cleaning or maintenance of the apparatus by not using a sticky adhesive.

  According to the first aspect of the present invention, a paper sheet or nonwoven fabric containing ceramic fiber glass fibers or a mixture thereof is used as a base paper, and one of the two base paper pairs is a flat sheet that remains flat. In the manufacturing process in which the other is formed into a corrugated sheet obtained by forming a corrugated sheet and joined to each other at a ridge line portion of the corrugated sheet to form a single-stage sheet, the single-stage sheets are laminated to form a honeycomb, The structural strength is improved by supporting a catalyst or adsorbent containing a binder component in the subsequent impregnation step without applying an adhesive to the contact portion of the single-stage sheet. Since the adhesive is not applied to the joint of the sheet, the adhesive does not cover the surface of the base paper and does not penetrate into the fibers of the base paper. There has the effect of improving loading ratio because it does not inhibit the loading of the adsorbent.

  Moreover, it has the effect | action of reducing the operation man-hour of the adhesive agent application at the time of shape | molding a honeycomb, and adhesive material material cost.

  The invention according to claim 2 is the honeycomb forming method according to claim 1, wherein the single-stage sheet is wound while being wound into a substantially cylindrical shape, and is bonded to a contact portion between the adjacent single-stage sheet and the single-stage sheet. The base paper coated with adhesive is wound multiple times only on the central axis and the outermost peripheral surface, which are subject to a concentrated load and are likely to be damaged. There is an action to improve.

  The invention described in claim 3 uses an adhesive tape for joining the base paper and the single-stage sheet wound around the central axis and the outermost peripheral surface, and has an effect of improving workability.

  Further, the invention according to claim 4 is the one in which the material of the adhesive tape used in claim 3 is limited to paper. By not using the synthetic resin component, the component of the synthetic resin tape is dissolved and supported during firing. In addition, the function of the catalyst or adsorbent to be supported is not adversely affected.

  In the invention according to claim 5, a belt having a width equal to or larger than the width of the single-stage sheet to be wound is brought into contact with the outer peripheral surface of the cylindrical honeycomb in the winding process at an angle of 90 degrees to 180 degrees. The belt is wound while tension is applied to both ends of the belt, whereby a load can be applied from the outer peripheral surface of the cylindrical honeycomb toward the center of the take-up shaft, there is no local load, and the load is evenly distributed from the outer peripheral surface of the honeycomb. The cell can be pressed, the cell is not crushed, and no looseness or sagging occurs between the wound single-stage sheets.

(Embodiment 1)
1 and 2 show a single-stage sheet 1 and a cylindrical honeycomb 2. The single-stage sheet 1 is composed of a flat sheet 3 and corrugated sheet 4 made of paper or nonwoven fabric containing ceramic fiber, glass fiber, or a mixture thereof, and has a structure similar to that of a corrugator used in the production of corrugated cardboard. It is molded by the device.

  The cylindrical honeycomb 2 is the one-stage sheet 1 formed in a substantially cylindrical shape without applying the adhesive 104. However, the central axis and the outermost peripheral part are fixed by using an adhesive for fixing the end of the single-stage sheet 1 and reinforcing the strength, and when the catalyst or adsorbent is supported on the honeycomb, the binder component is added. The structural strength of the cylindrical honeycomb 2 is improved by mixing with the impregnation liquid. Lithium silicate or sepiolite is fried as the binder to be blended, but other binders may be used.

(Embodiment 2)
FIG. 3 shows a winding device 5 which is a manufacturing device for the cylindrical honeycomb 2. The take-up shaft 6 of the take-up device 5 serves as a central axis for winding the single-stage sheet 1 into a substantially cylindrical shape, and has a structure that is driven to rotate by a motor. The tension belt 7 applies tension when the single-stage sheets 1 are wound into a substantially cylindrical shape so that the adjacent single-stage sheets 1 are in close contact with each other and can be wound without any gaps. The belt is brought into contact with the outer peripheral surface at an angle of 90 degrees or more and 180 degrees or less, and one end of the belt is fixed, and a weight 8 is attached to the other end. 6 can be applied in the center direction, there is no local load, and it can be pressed evenly from the outer peripheral surface of the honeycomb, and the collapse of the cell shape of the honeycomb can be suppressed.

  For the base paper used in this example, paper making containing glass fiber and pulp was used, and a single-stage sheet 1 was formed by a corrugator similar to a corrugated board manufacturing apparatus. The base paper has a thickness of 0.15 mm, a width of 155 mm, a single-stage shape has a pitch of 2.6 mm, which is the distance between the peaks of the corrugated peaks, and the height includes the thickness of the base paper. It was 5 mm. In this embodiment, the corrugator and the winder are installed in a series of lines, and the single sheet 1 formed by the corrugator can be continuously supplied to the winder, but the corrugator and the winder are manufactured in separate processes. Alternatively, the single-stage sheet 1 formed with a corrugator may be temporarily stocked and a separate winding process may be performed. The single-stage sheet 1 supplied to the winder is corrected in position and angle by a meandering correction guide so that it can be inserted at right angles to the winding shaft 6.

  The single-stage sheet 1 inserted perpendicularly to the take-up shaft 6 is rotated and laminated by the take-up shaft 6, and a honeycomb strength reinforcing sheet is previously wound on the take-up shaft 6 by two turns and bonded with an adhesive. . As the base paper, paper making containing glass fibers of the same material as the single-stage sheet 1 was used. Although a thickness of 0.25 mm was used, paper having the same thickness of 0.15 mm as the base paper of the single-stage sheet 1 or another thickness may be used.

  The end of the single-stage sheet 1 is adhered to the outer peripheral surface around which the reinforcing sheet is wound using a paper tape, fixed to the winding shaft 6, and the winding shaft 6 is rotated to perform winding. During winding of the single-stage sheet 1, a belt wider than the base paper in the range of 90 ° to 180 ° is formed on the outer peripheral surface of the cylindrical honeycomb 2 in order to avoid the generation of gaps in the laminated single-stage sheets 1. The one end of the belt is fixed, and a weight 8 is attached to the other end to apply tension. By applying tension to the outer peripheral surface of the cylindrical honeycomb 2 on the surface of the belt, a uniform load is applied in the center direction, so that the honeycomb cell shape is less likely to be deformed or crushed.

  When winding up to a predetermined outer dimension or number of winding steps is completed, the rotational driving of the winding shaft 6 is stopped, the supplied single-stage sheet 1 is cut, and the single-stage sheet 1 wound up using a paper adhesive tape is cut. The end was fixed on the circumference. Next, a strength reinforcing sheet made of the same material as that of the sheet attached to the inner periphery of the cylindrical honeycomb 2 was attached to the outer peripheral surface twice using an adhesive. Again, the sheet material may be 0.15 mm thick or other thickness as the base paper.

  The cylindrical honeycomb 2 manufactured in the above process was immersed in an adsorbent liquid containing an adsorbent containing a binder component, and then dried at room temperature or by heating until the moisture disappeared from the honeycomb substrate. Here, in the experiment of the present embodiment, lithium silicate was used as the binder to be blended in the impregnation liquid, and zeolite was used as the adsorbent. Next, the cylindrical honeycomb element 2 is formed by firing the cylindrical honeycomb 2 and burning the pulp component in the base paper. Here, in order to further improve the structural strength, it is possible to improve the strength by impregnating the supporting liquid again and repeating the drying process. There is an optimum value for each honeycomb substrate, and it is necessary to control the concentration of the supporting liquid in order to improve strength and performance.

  In the manufacturing process of the honeycomb-shaped element supporting the catalyst or the adsorbent, improving the supporting rate leads to improvement of the performance of the product, thinning or compacting of the product. In addition, it is clear that reducing the use of adhesives has an advantage in terms of cost, and also in manufacturing equipment, it is a great advantage in cleaning and maintenance of equipment by not using sticky adhesive There is.

The figure of the single stage sheet | seat of Embodiment 1 of this invention Figure of cylindrical honeycomb The figure of the winding device of Embodiment 2 of this invention Figure of conventional single-stage sheet of honeycomb substrate Structural diagram of a conventional cylindrical honeycomb

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Single sheet | seat 2 Cylindrical honeycomb 3 Plane sheet 4 Corrugated sheet 5 Winding device 6 Winding shaft 7 Tension belt 8 Weight 101 Single stage sheet 102 Flat sheet 103 Corrugated sheet 104 Adhesive 105 Edge line part 106 Cylindrical honeycomb

Claims (10)

Paper or nonwoven fabric containing ceramic fiber, glass fiber, or a mixture thereof is used as a base paper, and one of the two base paper pairs is formed into a flat sheet while the other is corrugated. In the manufacturing process in which the corrugated sheets are joined at the ridge line portions of the corrugated sheets to form a single-stage sheet, and then the single-stage sheets are laminated to form a honeycomb, an adhesive is applied to the contact portion between the adjacent single-stage sheets and the single-stage sheets. Without coating, the honeycomb is loaded with a catalyst or adsorbent containing a binder component to improve the structural strength, and by not using an adhesive that impedes the loading of the impregnating liquid, the catalyst or adsorbent Honeycomb element with improved loading. The honeycomb forming method according to claim 1, wherein the single-stage sheet is wound while being wound into a substantially cylindrical shape, and the adjacent single-stage sheet and the single-stage sheet are laminated without applying an adhesive, and compared. Cylindrical honeycomb with improved structural strength by wrapping base paper coated with adhesive multiple times only on the central axis and the outermost peripheral surface, which are subject to concentrated loads and are easily damaged. The cylindrical honeycomb according to claim 2, wherein an adhesive tape is used to join the base paper wound around the central axis and the outermost peripheral surface and the single-stage sheet to improve workability. The material of the adhesive tape is paper, and the component of the synthetic resin tape is dissolved at the time of firing by not using the synthetic resin component, so that the function of the supported catalyst or adsorbent is not adversely affected. Cylindrical honeycomb. A belt having a width equal to or larger than the width of the single-stage sheet to be wound is brought into contact with the outer peripheral surface of the cylindrical honeycomb in the winding process at an angle of 90 degrees or more and 180 degrees or less and wound while applying tension to both ends of the belt. By this, it is possible to apply a load from the outer peripheral surface of the cylindrical honeycomb toward the center of the winding shaft, there is no local load, and the cells can be uniformly pressed from the outer peripheral surface of the honeycomb, so that the cells are not crushed, and The cylindrical honeycomb according to claim 2, wherein there is no looseness or sagging between the wound single-stage sheets. Paper or nonwoven fabric containing ceramic fiber, glass fiber, or a mixture thereof is used as a base paper, and one of the two base paper pairs is formed into a flat sheet while the other is corrugated. In the manufacturing process in which the corrugated sheets are joined at the ridge line portions of the corrugated sheets to form a single-stage sheet, and then the single-stage sheets are laminated to form a honeycomb, an adhesive is applied to the contact portion between the adjacent single-stage sheets and the single-stage sheets. Improves structural strength by supporting a catalyst or adsorbent containing a binder component without coating, and improves catalyst or adsorbent loading by not using an adhesive that impedes the impregnation liquid. The method for manufacturing a honeycomb-shaped element according to claim 1. The honeycomb forming method according to claim 1, wherein the single-stage sheet is wound while being wound into a substantially cylindrical shape, and the adjacent single-stage sheet and the single-stage sheet are laminated without applying an adhesive, and compared. 3. A method for manufacturing a cylindrical honeycomb according to claim 2, wherein a base paper coated with an adhesive is wound a plurality of times only on the central axis and the outermost peripheral surface, which are subject to concentrated load and easily damaged, to improve the structural strength. . 4. The method for manufacturing a cylindrical honeycomb according to claim 3, wherein an adhesive tape is used to join the base paper wound around the central axis and the outermost peripheral surface and the single-stage sheet to improve workability. The material of the adhesive tape is paper, and the synthetic resin component is not dissolved during firing by using no synthetic resin component, so that the function of the supported catalyst or adsorbent is not adversely affected. A method for manufacturing a cylindrical honeycomb element. A belt having a width equal to or larger than the width of the single-stage sheet to be wound is brought into contact with the outer peripheral surface of the cylindrical honeycomb in the winding process at an angle of 90 degrees or more and 180 degrees or less and wound while applying tension to both ends of the belt. Thus, a load can be applied from the outer peripheral surface of the cylindrical honeycomb toward the center of the take-up shaft, and since there is no local load, the cells are not crushed and there is no looseness or sagging between the single-stage sheets to be taken up. The manufacturing method of the cylindrical honeycomb of Claim 5.

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