JP2008055308A - Method of manufacturing exhaust gas purification filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce defects of an exhaust gas purification filter by surely boring aternate mask tapes in a zigzag arrangement at both end faces of a honeycomb structure. <P>SOLUTION: A rod-like matter 9 is inserted through a predetermined open cell 8 of the bored mask tape 6 in a zigzag arrangement at one end 4 stuck with the masking tape 6 of the honeycomb structure 1. At the other end 5 stuck with the masking tape 7, the cell 8 is sensed by recognizing the rod-like matter 9, the masking tape 7 of a cell 10 adjacent to the sensed cell 8 is bored, a reference pin 11 is inserted through the opened cell 10 subjected to opening, the cell masked with the tape of the other end 5 is opened staggeredly being displaced by one cell from the staggered disposition opened at one end 4 with the reference pin 11 as a base point. Then, the plugging materials of the open cell of both ends 4, 5 are plugged and fired. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing an exhaust gas purifying filter, and is suitable for a filter that collects particulate matter (DP) in diesel exhaust gas.

  Conventionally, the process for producing an exhaust gas purification fill is performed by forming a ceramic honeycomb structure 2 having an outer peripheral wall 21, partition walls 22 and a plurality of cells 23 as shown in FIG. Next, as shown in FIG. 5, the masking tape 5 is applied to the entire end face 241 of the honeycomb structure 2 and then masked in a staggered arrangement in the openings 231 of the cells 23 as shown in FIG. As shown in FIG. 8, the end face 241 is dipped in the plug material paste 41 as shown in FIG. 8, and the openings of the cells 23 other than the cells blocked by the mask tape 5 are shown in FIG. The plugging which forms the plug material 4 in the part 231 is performed. Further, as shown in FIGS. 10 and 11, the plug member 4 is similarly formed on the other end surface 242 of the honeycomb structure 2.

  In the honeycomb structure 2 manufactured in this way, the cells 23 plugged (closed) with the plug material 4 on one end surface 241 are open on the other end surface 242. That is, the cells 23 are alternately plugged with the plug material on the both end surfaces 241 and 242. The dipping step may be performed after the mask tape is punched on both end surfaces.

  As described above, in the honeycomb structure, it is necessary to perforate the mask tape alternately in the cells on the other end face after the holes on the one end face are staggered in the staggered arrangement. That is, it is necessary to prevent the plugging material plugged into one cell from overlapping on both end faces of the central portion of the honeycomb structure (the cells are not blocked by the plugging material at both ends).

  However, in an actual honeycomb structure, the pitch of one cell is about 1 to 4 mm, and the cells having the same shape and color are formed in a lattice shape. The tape tape is also perforated on the other end face of the tape perforated cell (open cell on one end face), that is, the mask tape is perforated on both end faces of one cell, There is a problem that plugging with a plug material is performed on both end faces of one cell.

Therefore, the inventor paid attention to making the cells on the other end face perceive the position of a predetermined cell in which the mask tape was perforated on one end face of the honeycomb structure.
JP 2004-154768 A

  The present invention has been made in view of the above points, and the position of a predetermined cell in which the mask tape is perforated on one end face of the honeycomb structure masked on the other end face on which the mask tape is applied. By making the cells perceive and perforating the mask tape to the staggered arrangement with the perceived cell as the base point, alternate mask tape perforation at the both end faces of the honeycomb structure can be ensured, and consequently An object of the present invention is to provide a method for manufacturing an exhaust gas purification filter capable of reducing defects in the exhaust gas purification filter.

The invention according to claim 1 has a honeycomb structure having a large number of lattice-like cells penetrating between both end faces and partitioned by partition walls, and the cells on the both end faces are staggered and alternately plugged. An exhaust gas purification filter plugged with a material,
Forming the honeycomb structure, then applying a mask tape to the cells on both end faces and punching the mask tape attached to the cells on one end face of the both end faces in the staggered arrangement, The rod-shaped object is inserted from the opening of the predetermined cell to the vicinity of the other end surface of the both end surfaces, and then the rod-shaped object is perceived from the outside of the cell to which the mask tape is attached on the other end surface. Next, the mask tape of the reference cell adjacent to the cell in which the rod-like object is perceived is drilled, then a reference pin is inserted into the drilled reference cell, and then the reference pin is used as a reference. Then, the staggered arrangement in which the mask tape of the other end face is affixed alternately is punched in the staggered arrangement in which the one end face is perforated, and then the both end faces are perforated. In the cell Plugged, the firing is carried out in the wood.

  According to the above configuration, the rod-like object inserted through the cell with the hole in the one end face can perceive the position of the cell with the hole in the one end face at the other end face, and the cell adjacent to the perceived cell. Since the reference pins are inserted into the holes and the holes are drilled with reference to the reference pins, the holes in the staggered arrangement of the cells on the other end face are staggered with the staggered arrangement of the holes in the one end face. You can be sure. Therefore, defects in the manufacturing process of the exhaust gas purification filter can be reduced.

  In the invention which concerns on Claim 2, the said mask tape is made into the transparent tape.

  According to the said structure, the presence position of the said rod-shaped object can be recognized and perceived reliably.

  In the invention according to claim 3, the drilling with the reference pin as a reference is performed by photographing the reference pin with a camera and performing image processing.

  According to the above configuration, it is possible to automatically recognize the drilling positions of a large number of cells, and to improve workability.

  In the invention according to claim 4, the reference pin has an identification structure that allows the camera to distinguish and recognize the reference pin from other objects in the imaging region.

  According to the above configuration, the camera can recognize the position of the reference pin reliably by distinguishing and recognizing other objects in the vicinity of the imaging region with the identification structure.

  In the invention according to claim 5, the identification structure makes the color of the reference pin complementary to the color of the other object.

  According to the said structure, the said camera can distinguish from other objects, such as a chip and dust, and can recognize the position of the said reference pin reliably.

  In the invention which concerns on Claim 6, the said identification structure is made into the spherical form formed in the head of the said reference | standard pin.

  According to the above configuration, since the head of the reference pin is formed in a spherical shape, the brightness of the reflected light from the spherical shape is not uniform in the spherical surface, and the brightness at the center is strong and the brightness increases as it goes to the periphery. Since the brightness of the spherical surface changes due to the weakness, the camera can recognize the position of the reference pin by distinguishing the reference pin from other peripheral objects such as chips and dust.

  In the invention which concerns on Claim 7, gold plating is given to the spherical form formed in the head part of the said reference | standard pin.

  According to the above configuration, by applying gold plating, the brightness of the reflected light is very strong, and the reference pin of the reference pin is surely secured even if the color of other objects in the photographing area is not only black but also light. The position can be reliably recognized.

  According to an eighth aspect of the present invention, at least the tip of the rod-like object has a color that is complementary to the color of other surrounding objects.

  According to the above configuration, it is possible to easily perceive and recognize the presence position of the rod-like object from the other end surface from the other end surface.

  Next, an embodiment of a method for producing an exhaust gas purification filter according to the present invention will be described with reference to FIGS. FIGS. 1-10 is a figure where each uses for description of the manufacturing process of the filter which concerns on this invention.

  First, as shown in FIG. 1, a honeycomb structure 1 having a large number of lattice-like cells 3 penetrating between both end faces 4 and 5 and partitioned by partition walls 2 is formed. The honeycomb structure 1 is a ceramic honeycomb structure made of cordierite and is almost black. The size of each part of the honeycomb structure 1 is a diameter of 160 mm, a length of 100 mm, a pitch of the cells 3 of 1 and 4 mm (inner width of the cells 3, height of 1 and 1 mm), and a wall thickness of the partition wall 2 of 0 and 3 mm.

  Next, as shown in FIG. 2, thin transparent mask tapes 6 and 7 are affixed to the cells 3 on one end face 4 and the other end face 5 of the both end faces. The mask tapes 6 and 7 are preferably transparent tapes, but may be cloudy enough to show through. The mask tapes 6 and 7 are made of a material that is easily melted by heat.

  Next, as shown in FIG. 3, the mask tape 6 is punched in a regular staggered arrangement in each lattice-like cell 3 to which the mask tape 6 on one end face 4 side is attached. That is, one perforated cell 8 is provided in the vertical and horizontal directions. In addition, about two cells on the inner side of the entire outer periphery of the honeycomb structure 1, a mask tape is punched for plugging, which will be described later, to ensure strength and the like. Drilling of the mask tape 6 is performed in a staggered arrangement by reading the drilling position with a camera (not shown) and laser processing. The one end face 4 is an end face that first performs punching of the mask tape as described above.

  In the description of the above process, the mask tape 6, 7 is applied to one end face 4 and the other end face 5 and then the mask tape 6 is perforated on the one end face 4. Alternatively, the mask tape 6 may be attached to the other end surface 5 after the mask tape 6 is attached to the hole and the mask tape 6 is perforated. That is, it is only necessary that the mask tape 6 is perforated on one end face 4 and the mask tape 7 is stuck on the other end face 5 (state of FIG. 3).

  Next, as shown in FIG. 4, at one end face 4, one of the cells 8 (opened cells) on which the mask tape 6 is perforated (the base cell 8 perforated on one end face 4 becomes the center cell 8). The rod-shaped object 9 is inserted into the cell of the part). At least the tip of the rod-like object 9 is provided with a color complementary to the color (black) of the honeycomb structure 1 (light color such as white), and becomes a color complementary to the color around the rod-like object 9. Yes. The rod-like object 9 itself may have the color. If at least the tip of the rod-shaped object 9 has a color complementary to the surrounding color of the rod-shaped object 9, the presence position of the rod-shaped object 9 can be easily perceived and recognized.

  Then, as shown in FIG. 5, the tip of the rod-like object 9 is perceived and recognized through the mask tape 7 from the other end face 5 side, and the position of the cell 8 through which the rod-like object 9 is inserted is recognized. That is, the mask tape 6 on one end face 4 is drilled, and the position of the opening cell 8 can be recognized on the other end face 5 side. Note that the position of the rod-like object 9 may be recognized by camera photography.

  Next, as shown in FIGS. 6 and 7, the cell 10 adjacent to the cell 8 (the position of the cell in which the rod-like object 9 is recognized) on the one end surface 4 recognized on the other end surface 5 side is drilled. . The position of the cell 10 becomes the reference position of the drilling position on the other end face 5 (the drilling origin point cell 10 on the other end face 5). The punching of the cell 10 may be performed manually by a soldering iron or the like, or by machining such as laser processing. Note that the above-described adjacent cell 10 may be adjacent to the upper and lower and left and right directions of the opening cell 8 on one end surface 4 recognized on the other end surface 5 side, and as shown in FIG. , B and c.

  The reference pin 11 is inserted into the opened cell 10 (reference cell) serving as a reference position on the other end face 5 side. The reference pin 11 serves as a recognition point and a base point of the staggered arrangement on the other end face 5. The shape of the reference pin 11 is such that the diameter of the head 111 is 1, 2 to 1, 3 mm larger than the inner width 1, 1 mm of the cells 3, 8, 10, and the diameter of the foot 112 is 0, 6 to 6 as shown in the figure. The inner width of the cells 3, 8, 10 is smaller than 1 mm at 0, 7 mm, the foot portion 112 is inserted into the cell, and the head portion 111 projects outward from the other end surface 6. Further, the head 111 of the reference pin 11 has a hemisphere as an identification structure so that the recognition of the reference pin 11 by photographing with the camera can be distinguished from the surrounding color such as the partition wall 2 of the cell 3 and the chips adhering to the partition wall 2. Surface shape is applied and gold-plated. As an identification structure, paint may be applied to the tip of the head 111 such that the brightness of reflected light gradually changes (desirably becomes weaker) from the center to the periphery. The hemispherical shape may not be a complete hemispherical shape, but may be a spherical shape that is a part of an arc.

  Next, the mask pins 7 of cells arranged in a staggered pattern are punched one by one in the vertical and horizontal directions with the reference pin 11 as a base point. On the other end face 5, the staggered arrangement of cells with holes opened is shifted up and down (left and right) by one cell from the staggered arrangement of cells with holes opened on one end face 4 described above. Have become staggered. That is, the other end face of the cell opened at one end face 4 is a cell closed by the mask tape 7, and the other end face of the cell closed by the mask tape 6 is opened at the one end face 4. It is a cell.

  On the other end face 5, when the cell mask tape 7 is punched in a staggered arrangement with the reference pin 11 as a base point, in the present invention, a staggered pattern to be drilled by photographing with a camera (not shown) and image processing is performed. This is done by detecting the position of placement. The drilling of the mask tape 7 is performed by laser processing.

  When taking a picture with a camera and processing the image, the reference pin 11 is provided with a hemispherical shape as an identification structure so that the camera can easily recognize the reference pin 11. Therefore, the reflected light from the hemispherical shape is the center. The part is bright and the peripheral part is weak, and the position where the reference pin 11 is present can be recognized with certainty from the color of the peripheral area of photographing. Further, since the head 111 of the reference pin 11 is gold-plated, the brightness of the reflected light is very strong, and the color of other objects in the shooting area is not only black but also light. The position of the reference pin can be surely recognized. The identification structure in the reference pin 11 may be any shape or color that emits reflected light from the color surrounding the camera photographing region such as the honeycomb structure 1 or the like or a color that emits reflected light from the surrounding color. The camera recognizes the reference pin 11. be able to.

  After the holes 3 having the staggered arrangement are alternately formed in the cells 3 on both end faces 4 and 5 of the honeycomb structure 1, the plugs are formed in the cells (opened cells) as shown in FIGS. 12 is plugged by dipping treatment and baked to obtain an exhaust gas purification filter. Note that the mask tape remaining without being drilled is incinerated when the honeycomb structure 1 is fired.

  The filter that is a target product of the manufacturing method of the present invention is not limited to the above-described shape, size, material, and the like, and may be another filter that is applied to exhaust gas purification. The filter may be a filter applied to exhaust gas purification other than the filter applied to exhaust gas purification of an automobile diesel engine.

FIG. 5 is a longitudinal sectional view of a central portion of a formed honeycomb structure for use in explaining the process of the manufacturing method of the present invention. FIG. 2 is a longitudinal cross-sectional view illustrating a state in which a mask tape is applied to both end faces of the honeycomb structure of FIG. 1 for explaining the process of the manufacturing method of the present invention. FIG. 3 is a longitudinal cross-sectional view showing a state in which a mask tape is perforated on one end face of the honeycomb structure of FIG. 2 for explaining the process of the manufacturing method of the present invention. FIG. 4 is a longitudinal sectional view illustrating a state in which a rod-like object is inserted from an open cell on one end face of the honeycomb structure of FIG. 3 for use in explaining the process of the manufacturing method of the present invention. FIG. 5 is a left side view of FIG. 4. FIG. 5 is a longitudinal cross-sectional view showing a state in which a reference pin is inserted from an open cell on the other end face of the honeycomb structure of FIG. 4 for explaining the process of the manufacturing method of the present invention. FIG. 7 is a left side view of FIG. 6. FIG. 4 is a longitudinal sectional view of a honeycomb structure (exhaust gas purification filter) plugged with plugs on both end faces of the honeycomb structure for explaining the process of the manufacturing method of the present invention. FIG. 9 is a left side view of FIG. 8. It is a right view of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Honeycomb structure 2 Partition 3 Cell 4 One end surface 5 The other end surface 6, 7 Mask tape 8 Open cell (base cell) in one end surface 4
9 Bar-shaped object 10 Open cell (base cell) at the other end face 5
11 Reference Pin 111 Head 12 of Reference Pin 11 Plug Material

Claims (8)

A honeycomb structure having a large number of lattice-like cells penetrating between both end faces and partitioned by partition walls, and the cells on both end faces are staggered and alternately plugged with a plug material. An exhaust gas purification filter,
Forming the honeycomb structure,
Next, a mask tape is affixed to the cells on both end faces and a mask tape affixed to the cells on one end face of the both end faces is punched in the staggered arrangement,
Next, a rod-shaped object is inserted from the opening of the predetermined cell to the vicinity of the other end face of the both end faces,
Next, the bar-like object is perceived from the outside of the cell to which the mask tape on the other end face is attached,
Next, the mask tape of the reference cell next to the cell that perceived the rod-like object is punched,
Next, a reference pin is inserted into the drilled reference cell,
Next, perforating the staggered arrangement on the cells on which the mask tape of the other end face is affixed alternately with the staggered arrangement where the cells are drilled on the one end face with respect to the reference pin,
Then, the manufacturing method of the exhaust gas purification filter characterized by performing plugging and baking with the plug material in the cell in which the both end surfaces are perforated.   The exhaust gas purification filter manufacturing method according to claim 1, wherein the mask tape is a transparent tape.   3. The method for manufacturing an exhaust gas purification filter according to claim 1, wherein the drilling with the reference pin as a reference is performed by photographing the reference pin with a camera and processing the image.   4. The method of manufacturing an exhaust gas purification filter according to claim 3, wherein the reference pin has an identification structure that allows the camera to distinguish and recognize the reference pin from other surrounding objects.   The exhaust gas purification filter manufacturing method according to claim 4, wherein the identification structure has a complementary color relationship between the color of the reference pin and the color of the other object.   6. The method for manufacturing an exhaust gas purification filter according to claim 4, wherein the identification structure is a spherical shape formed on a head of the reference pin.   The method for manufacturing an exhaust gas purification filter according to claim 6, wherein the spherical shape formed on the head of the reference pin is plated with gold. The method for manufacturing an exhaust gas purification filter according to any one of claims 1 to 7, wherein at least a tip of the rod-like object has a color complementary to a color of other surrounding objects. .