JP2006239917A - Honeycomb structure and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a honeycomb structure reduced in its pressure loss and more reinforced in its compression strength than before in a honeycomb structure filter used in dehumidification, air purification or the like and having a plurality of sucking actions with respect to a passing substance. <P>SOLUTION: An organic/inorganic composite sheet is composed of a planar sheet 8 which contains a relatively large amount of inorganic fibers, and a corrugated sheet 9, which is formed by corrugating a sheet relatively low in the content of inorganic fibers and having relatively good processability, and the planar sheet 8 is bonded to the corrugated sheet 9 to form a single-faced corrugated molded sheet 11 which is, in turn, laminated to another single-faced corrugated molded sheet 11 to provide the honeycomb structure having high compression strength. Alternatively, different materials are formed into sheets by a papermaking method to obtain sheets, and the planar sheet 8 and the corrugated sheet 9 are respectively formed from the respective sheets and laminated to obtain the single faced corrugated molded sheet 11 in the same way while the single-faced corrugated molded sheets 11 are laminated to provide the honeycomb structure characterized in that a plurality of materials act on the passing substance. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a honeycomb structure.

  Conventionally, this type of honeycomb structure is formed by processing a sheet of ceramic fibers or glass fibers and organic fibers as components and minerals such as mountain bark (sepiolite) as a base sheet into a honeycomb shape. What was processed into the inorganic honeycomb structure by baking is known (for example, refer patent document 1).

  Hereinafter, the honeycomb structure will be described with reference to FIGS. 4, 5, and 6.

  As shown in FIG. 4, the organic-inorganic composite sheet is made of ceramic fiber, glass fiber, pulp, mountain bark, organic and inorganic binder, and is not particularly processed with the organic-inorganic composite corrugated sheet 101 processed into a wave shape. A single-wave molded body 104 is formed by adhering a planar organic-inorganic composite flat sheet 102 with an organic and inorganic mixed adhesive 103. 4 is wound up and laminated to obtain the cylindrical honeycomb laminated body 105 of FIG. Further, the prismatic honeycomb laminated body 106 of FIG. 6 can be obtained by cutting the single-wave molded body 104 of FIG. 4 with a certain length and stacking them. It is also known that an inorganic honeycomb structure can be obtained by firing each honeycomb laminate.

Also, in this type of honeycomb structure, a sheet made of ceramic fibers, pulp, organic or inorganic binder as a component is formed into a honeycomb shape, impregnated with colloidal silica or ethyl silicate, and then this silicon compound is added to silica gel. It is known that a honeycomb structure as a catalyst carrier can be obtained as a result of burning and removing organic matter in the sheet by converting and then firing (see, for example, Patent Document 2).
JP-A-5-64745 Japanese Patent Laid-Open No. 4-18896

  In such a honeycomb structure, when the base material is processed into a corrugated shape, it is necessary to have a certain degree of ease of touching and stiffness of the sheet in order to ensure the workability of the base material. Or a certain weight or more is required. However, as a honeycomb structure, it is desired to reduce the pressure loss by reducing the thickness of the base material and to save energy and reduce noise during ventilation.

  In the conventional honeycomb structure, the material is supported on the base material by impregnating the honeycomb structure of the base material sheet with a dispersion of the material and the adhesive component. In this method, when a plurality of materials are dispersed, it is difficult to carry a stable material in continuous production due to the difference in particle size and specific gravity, and it is difficult to carry a plurality of materials simultaneously. Similarly, when preparing a honeycomb structure with a sheet in which a material is mixed in a base material, in order to mix a plurality of materials into a sheet, dispersion stability is improved if the particle size and specific gravity are different in the dispersion. Because it is bad, it is difficult to stably spread the material into the sheet.

  The present invention solves such a conventional problem, and provides a honeycomb structure having a reduced pressure loss and a honeycomb structure that is formed of a plurality of materials and can exhibit various functions. is there.

  In order to achieve the above object, the honeycomb structure of the present invention is a honeycomb structure in which a corrugated sheet and a flat sheet are bonded to the flat sheet at the ridge line portion of the corrugated sheet to form a single wave molded body and laminated. In the structure, the corrugated sheet and the planar sheet are made of different materials. By this means, a hard sheet with low workability is used for a flat sheet with a small area, and it is used as an aggregate of a honeycomb structure, and a functional sheet is processed into a corrugated shape and bonded to the flat sheet. As a result, a functional filter having sufficient strength as a honeycomb structure can be obtained.

  In order to achieve the above object, the honeycomb structure of the present invention is a honeycomb structure in which a corrugated sheet and a flat sheet are bonded to the flat sheet at the ridge line portion of the corrugated sheet to form a single wave molded body and laminated. In the structure, the basis weights of the corrugated sheet and the flat sheet are different. By this means, the basis weight of the corrugated sheet is increased to increase the strength of the sheet to ensure the workability, while the flat sheet that does not require much workability does not reduce the basis weight and has a honeycomb structure. Body pressure loss can be reduced.

  Further, in order to achieve the above object, the honeycomb structure of the present invention is obtained by bonding a corrugated sheet and a flat sheet to a flat sheet at a ridge line portion of the corrugated sheet, creating a single wave molded body, and laminating them. This honeycomb structure is characterized in that the corrugated sheet and the flat sheet have different thicknesses. By this means, the corrugated sheet has a thick sheet thickness to ensure workability, and the planar sheet that does not require much workability can be thinned to reduce the pressure loss of the honeycomb structure. .

  Further, in order to achieve the above object, the honeycomb structure of the present invention is obtained by bonding a corrugated sheet and a flat sheet to a flat sheet at a ridge line portion of the corrugated sheet, creating a single wave molded body, and laminating them. The honeycomb structure is characterized in that the corrugated sheet and the flat sheet are different components. By this means, the material in the corrugated sheet is supported, and the flat sheet is supported with a material different from the corrugated sheet, so that two different materials are provided for the components passing through the honeycomb structure. By acting, a plurality of functions can be exhibited.

  In this case, the loading means that the material is mixed together at the time of sheet preparation, or the sheet is impregnated into a sheet in which the material and the binder are dispersed, and the material is bonded to the sheet together with the binder and bonded to the sheet. Is meant to do.

  Further, in order to achieve the above object, the honeycomb structure of the present invention is obtained by bonding a corrugated sheet and a flat sheet to a flat sheet at a ridge line portion of the corrugated sheet, creating a single wave molded body, and laminating them The honeycomb structure to be produced is characterized in that more fibrous inorganic substances such as glass fibers and ceramic fibers are mixed in the flat sheet than in the corrugated sheet. By this means, in an organic-inorganic composite sheet containing at least organic fibers and a fibrous inorganic substance, the inorganic honeycomb structure obtained by firing the honeycomb structure contains a large amount of fibrous inorganic substances such as glass fibers and ceramic fibers. Usually, it is difficult to process the corrugated sheet of the honeycomb structure, but if there are few fibrous inorganic substances such as glass fibers and ceramic fibers and the ratio of organic fibers is large, voids in the portion where the organic fibers exist after firing are present. The strength increases as the honeycomb structure. Therefore, the strength of the fired structure is improved by blending a large amount of fibrous inorganic substances such as glass fibers and ceramic fibers into a flat sheet that does not need to be processed.

  According to the present invention, a honeycomb structure in which a corrugated sheet and a flat sheet are formed of sheets having different thicknesses by using a thin sheet that cannot be processed into a corrugated sheet as a flat sheet only, and has a low pressure loss. Can provide.

  Further, according to the present invention, it is possible to provide a honeycomb structure in which a plurality of materials are blended, and a plurality of actions can be given to the passing substance by passing through the cells.

  In addition, a honeycomb structure with improved overall strength can be provided by using a flat sheet in which a large amount of fibrous inorganic materials such as glass fibers and ceramic fibers that are difficult to be processed into corrugations are used.

  According to the first aspect of the present invention, one is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape. After that, the honeycomb structure in which the single-wave molded bodies are laminated and the sheet materials are different from each other. The flat sheet is made of a material having poor workability but having strength. , It has the effect of obtaining a honeycomb structure having strength.

  In the invention according to claim 2 of the present invention, one is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape. After that, the honeycomb structure in which the single-wave molded bodies are laminated, and the basis weight of the sheets is different, and the corrugated sheet has workability, but the structure itself is It is light and has the effect of keeping material costs low.

  In the invention according to claim 3 of the present invention, one sheet is a flat sheet that remains flat, and the other is a corrugated sheet that is formed into a corrugated shape. After forming, the honeycomb structure is formed by laminating the one-wave shaped bodies, and the two sheets have different thicknesses. The honeycomb structure is obtained by thinning the planar sheet while maintaining the workability of the corrugated sheet. It has the effect of reducing the pressure loss of the entire body.

  In the invention according to claim 4 of the present invention, one is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape, and these are joined at the ridge line portion of the corrugated sheet to form a single-wave shaped product After that, the honeycomb structure in which the single-wave molded bodies are laminated, and the honeycomb structure is characterized in that the materials included in the sheets are different from each other, and a plurality of actions are given to the passing substance by passing through the cells. Has an effect.

  Further, in the invention according to claim 5 of the present invention, one sheet is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape. After the formation, the honeycomb structure in which the single-wave molded bodies are laminated, and the two sheets contain different types of zeolite, thereby providing an adsorption filter that can adsorb different types of adsorbate.

  The invention according to claim 6 of the present invention is an adsorption filter that can adsorb different kinds of adsorbates using not only the zeolite of claim 4 but also a layered inorganic compound such as silica gel, activated carbon, sepiolite, and smectite. Can be provided.

  The invention according to claim 7 of the present invention is not a sheet carrying only an adsorbent as shown in claim 4 or 5, but a platinum-based catalyst, a manganese-based catalyst, a palladium-based catalyst, a tin-based catalyst, A platinum-based catalyst, a manganese-based catalyst, a palladium-based catalyst, a tin-based catalyst in the form of a sheet at the same time when one or more of a cobalt-based catalyst and a titanium-based compound catalyst are supported on an adsorbent, or an adsorbent is supported on a sheet. One or more of a catalyst, a cobalt-based catalyst, and a titanium-based compound catalyst are supported. As a result, it is possible to oxidatively decompose the components adsorbed by the adsorbent with respect to the passing material of the honeycomb structure composed of the sheet carrying the adsorbent and the catalyst.

  In addition, as a supporting method, for example, titanium alkoxide is dispersed in a dispersion liquid when the base sheet is rolled, and is dispersed in the sheet. After being processed into a honeycomb shape, heating and firing are performed, and the titanium alkoxide is converted into titanium oxide. can do. As a result, paper can be produced with a liquid in which titanium alkoxide is uniformly dispersed together with the adsorbent, so that a sheet having a stable composition can be obtained, and the titanium oxide catalyst can be supported on the sheet together with the adsorbent.

  In the invention according to claim 8 of the present invention, a sheet containing a large amount of fibrous inorganic substances such as glass fiber and ceramic fiber, which is difficult to be processed into a corrugated shape through a normal corrugating machine, is used only for a flat sheet. As a result, a honeycomb structure with improved overall strength can be provided. In particular, when making an inorganic honeycomb structure obtained by sintering a honeycomb structure, the corrugated sheet requires a large amount of organic matter to ensure processability. Will decline. However, since the planar sheet has strength, the overall strength of the honeycomb structure can be ensured.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
Create a flat sheet that remains flat and a corrugated sheet that has been molded into a corrugated shape, join them at the ridges of the corrugated sheet to form a single corrugated body, and then roll up the single corrugated body A cylindrical honeycomb structure is obtained.

  At this time, the components are preferably 40 to 70% of glass fiber, or 50 to 70% in order to maintain the strength of the base material after firing, 10 to 30% of fibrous inorganic material, and 5 to 15 of organic pulp. The basis weight of 5% to 15% of organic binder is 30 to 50 g / m2, preferably strong enough to withstand the tension during processing, and the substrate is thin so that the pressure loss can be reduced. A flat sheet of 35 to 45 g / m 2 that is light and not particularly processed, and its components are 30 to 60% of glass fiber, preferably 30 to 45% for easy corrugation, and 20 to 30 of fibrous inorganic material. %, Organic pulp 20-40%, preferably 30-40% to ensure processability, organic fiber 5-15%, basis weight is 40 g to maintain substrate strength after firing / M2 or more, preferably workability In order to ensure, after joining the corrugated sheet of 50g / m2 or more at the ridge line part to obtain a single-wave molded body, a sheet having a certain length is laminated, and a prismatic honeycomb molded body or A cylindrical honeycomb structure is obtained by laminating the single-wave shaped bodies to form a cylindrical honeycomb structure.

  In addition, the honeycomb structure is immersed in a dispersion of an inorganic mineral and an inorganic binder or a liquid containing only an inorganic binder, dried, fired at a temperature of 300 ° C. or more, and burned off an organic material, thereby compressing only the inorganic material. A prismatic or cylindrical honeycomb structure having high strength and low ventilation resistance can be obtained. Inorganic minerals include layered clay compounds such as zeolite, bentonite, and sepiolite, and those having a fibrous crystalline state are particularly desirable for maintaining substrate strength. Examples of the inorganic binder include colloidal silica (for example, Snowtex-C manufactured by Nissan Chemical Industries, Ltd.) and lithium silicate (for example, lithium silicate 45 manufactured by Nissan Chemical Industries, Ltd.). May be used.

  The obtained honeycomb structure may be sliced in a direction perpendicular to the cell hole direction or in a direction shifted by 0 to 10 degrees in the vertical direction (not shown) to obtain a plurality of honeycomb structures. .

(Embodiment 2)
As shown in the first embodiment, a flat sheet that remains flat and a corrugated sheet obtained by forming a corrugated sheet are created, and the corrugated sheet is joined at a ridge line portion to form a single-wave molded body, and then the piece A cylindrical honeycomb structure laminated is obtained by winding the wave-formed body.

  At this time, different types of zeolite are used in each sheet. Different types of zeolites have different effective diameters of pores, and one sheet has an effective diameter of pores smaller than 0.3 nanometer and can selectively adsorb moisture without substantially adsorbing organic gas. Using a zeolite-supported sheet that excels in moisture absorption, and the other sheet using a zeolite-supported sheet with an effective diameter of pores of 0.3 nanometers or more, organic molecules larger than 0.3 nanometers Adsorb. Even zeolites with pores of 0.3 nanometers or more usually adsorb water, and in high humidity environments, moisture adsorption prevents odor adsorption, but there are zeolites that absorb moisture in the same cell. For this reason, the humidity decreases, and the adsorption of organic molecules proceeds advantageously. In particular, the latter zeolite having an effective diameter of pores for adsorbing organic gas of 0.3 nanometer or more is preferably a hydrophobic high silica zeolite having a silica / alumina ratio of 10 or more, and the adsorption ability of organic gas is further increased. In this case, which sheet is a flat sheet and which is a corrugated sheet may be properly selected depending on the use environment and required capacity, and the area of the sheet containing zeolite that is more adsorbed by the honeycomb structure. It is good to use for a wide corrugated sheet.

(Embodiment 3)
In the same manner as shown in Embodiment 2, by using an adsorbent such as silica gel or activated carbon in addition to zeolite, a plurality of adsorption capacities can be given to the honeycomb structure. In particular, one sheet uses a sheet carrying silica gel that has better hygroscopicity in a higher humidity environment than zeolite, and the other sheet uses activated carbon for deodorization, resulting in reduced performance in a high humidity environment. The deodorizing ability of activated carbon can be improved. In addition, you may use the zeolite for deodorizing instead of activated carbon.

(Embodiment 4)
Since the adsorbent shown in the second and third embodiments, the titanium alkoxide, and the base sheet are dispersed in the dispersion liquid, the titanium alkoxide and the adsorbent are dispersed in a constant manner. The sheet can contain a titanium oxide catalyst and an adsorbent. Each of the obtained flat sheet and corrugated sheet is processed into a honeycomb structure as shown in the first embodiment. By firing the honeycomb structure, the titanium alkoxide is heated and fired to obtain a composite sheet of titanium oxide and an adsorbent.

(Embodiment 5)
As shown in the first embodiment, a flat sheet that remains flat and a corrugated sheet that has been shaped into a corrugated sheet are created, and they are joined at the ridge line portion of the corrugated sheet to form a single corrugated body. A cylindrical honeycomb structure laminated is obtained by winding up the formed body.

  At this time, a metal sheet is used as the flat sheet, and an organic fiber sheet or a composite sheet of organic fibers and inorganic fibers is used as the corrugated sheet. Even if the indentation strength from the ridge line direction of the corrugated sheet is weak, the honeycomb structure can obtain a sufficient strength because the planar sheet is a metal.

  In addition, examples of the metal sheet at this time include iron, aluminum, nickel, and copper.

  The metal sheet may be a sheet woven with metal fibers. In this case, a certain hole is opened as a sheet, and the passage of moisture and gas can be expected, and a filter function as a filter medium can be provided.

  If the metal has a high thermal conductivity, the heat exchange efficiency is advantageous in a honeycomb filter that performs heat exchange. Examples of the metal include aluminum and copper. At this time, since the corrugated sheet functions as a spacer, a material having low thermal conductivity is preferable, and examples thereof include a vinyl chloride sheet, an organic pulp paper sheet, and a ceramic fiber sheet.

Example 1
A test sheet 1 having a composition as shown in Table 1 was prepared, and the workability into a waveform was evaluated. The evaluation method is to form various test sheets 1 of about 150 mm through a corrugating machine 2 as shown in FIG. 1, measure the length of the middle part, and form a sheet of 100 mm when flat, omitting both ends of 150 mm. Later length was measured. As a result, it was determined whether or not single wave forming was possible by joining with a flat sheet after corrugation processing as a reference for the corrugation of the sheet. At that time, the temperature of the main forming roll 3 of the corrugating machine is 80 degrees, the temperature of the upper forming roll 4 is 85 degrees, the temperature of the press roll 5 is 90 degrees, and the temperature and humidity environment is 20 ° C. and 80%. Conditioned. Further, the thickness of the sheet was 0.15 to 0.20 mm, the peak height 6 of the gear of the processing machine was 0.15 mm, and the pitch 7 that is the distance between the peaks was 2.6 mm. Table 1 shows the composition of the test sheet and the result of the single wave forming test.

  As a result, it can be seen that if the glass fiber content is high or the organic pulp is low, the spring back force is large and the workability is reduced, and even if the base material has the same composition, the workability is improved. It was. Among the five types of base materials used in this experiment, it was found that corrugated workability was not obtained for base materials A and B, and one-wave molding was not possible.

  In addition, when a single wave molded body as shown in FIG. 1 was prepared by separately bonding with a flat sheet, it was found that if the length after processing was larger than 80.7 mm, the single wave molding would not be successful. And the correlation of the workability of single wave forming.

  As shown in FIG. 2, the substrate A having a large amount of glass fibers, for which the processability was not obtained in Table 1, was used for the flat sheet 8, and E having a small amount of glass fibers was processed into the corrugated sheet 9. These were joined at the ridge line portion 10 of the corrugated sheet 9 to form a single-wave molded body 11, and then the single-wave molded body 11 was wound to form a laminated honeycomb structure AE. Also, as a comparison, a honeycomb structure EE using a base material E having good processability for both a flat sheet and a corrugated sheet but having a small amount of glass fiber was prepared, and this was impregnated with a liquid of zeolite and an inorganic binder. The one fired for 5 hours was processed into a honeycomb structure 15 having a length of 20 mm, a width of 20 mm, and a height of 20 mm as shown in FIG. 3, and the compressive strengths from 16 directions were compared. At this time, in order to compare the strength of the base material purely, the amount of zeolite and inorganic binder supported on the honeycomb structure was adjusted to be constant. Table 2 shows the compression test results of the honeycomb structure made of the base materials AE and EE.

  As a result, it can be seen that the honeycomb structure AE can obtain a compressive strength of about 1.2 times that of the honeycomb structure EE. By this method, a honeycomb structure having improved compressive strength in the direction parallel to the cells can be obtained. I understood it.

  With the honeycomb structure obtained in the present invention, it is possible to provide a honeycomb filter with lower pressure loss and higher compressive strength. In addition, a honeycomb filter in which deodorization works advantageously in a high-humidity environment can be provided using sheets containing different materials, and can be applied to uses such as deodorization, dehumidification, and air purification filters.

The figure which shows the waveform processing machine of Example 1 of this invention, and the mode of shaping | molding The figure showing the single wave molded object which consists of base material AE of Example 1 of this invention The figure which shows the compression direction at the time of a honeycomb structure of Example 1 of this invention, and a compression test Diagram showing a conventional single-wave molded body Diagram showing a conventional cylindrical honeycomb structure A diagram showing a conventional prismatic honeycomb structure

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Test sheet 2 Corrugated machine 3 Main forming roll 4 Upper forming roll 5 Press roll 6 Pile height 7 Pitch 8 Base material A (planar sheet)
9 Base material E (corrugated sheet)
10 Ridge line part 11 Single-sided wave body (Base material AE)
12 vertical 13 horizontal
14 Height 15 Honeycomb structure piece 16 Compression direction 101 Corrugated sheet 102 Flat sheet 103 Adhesive 104 Single-wave shaped body 105 Cylindrical honeycomb structure 106 Square columnar honeycomb structure

Claims (8)

A honeycomb structure comprising a flat sheet and a corrugated sheet, wherein the materials of the sheets are different from each other. A honeycomb structure comprising a flat sheet and a corrugated sheet, wherein the sheet has a different basis weight. A honeycomb structure comprising a flat sheet and a corrugated sheet and having different sheet thicknesses. A honeycomb structure comprising a flat sheet and a corrugated sheet, wherein materials carried on the sheet are different from each other. The honeycomb structure according to any one of claims 1 to 4, wherein the honeycomb structure is composed of a flat sheet and a corrugated sheet, and each of the sheets contains different types of zeolite. 5. The structure according to claim 1, wherein the sheet comprises a flat sheet and a corrugated sheet, and each of the sheets contains one or more adsorbents of zeolite, activated carbon, silica gel, and layered compound. The honeycomb structure described. Each sheet contains one or more of a platinum-based catalyst, a manganese-based catalyst, a palladium-based catalyst, a tin-based catalyst, a cobalt-based catalyst, and a titanium-based compound catalyst, and the adsorbate is oxidatively decomposed by the catalyst. The honeycomb structure according to claim 6. The honeycomb structure according to any one of claims 1 to 7, wherein the honeycomb structure has a structure including a flat sheet and a corrugated sheet, and the flat sheet contains more inorganic fibrous substances than the corrugated sheet.

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