JP2008132754A - Manufacturing method of honeycomb structure, honeycomb molded object receiver and honeycomb molded object takeout machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a honeycomb structure capable of normally operating another process when a trouble occurs in either one of the processes in a manufacturing process of the honeycomb structure and capable of avoiding trouble, where an intermediate product must be discarded by the occurrence of the trouble, as a result. <P>SOLUTION: After a columnar honeycomb molded object having a large number of cells, which are provided thereto side by side in the longitudinal direction thereof so as to interpose cell walls by molding a ceramic raw material, one or a plurality of processings including at least baking processing is applied to the honeycomb molded object and the honeycomb structure is manufactured using the honeycomb baked object. After the processed honeycomb molded object to which one or a plurality of the processings are applied is housed in a molded object keeping container to be temporarily preserved therein, the processed honeycomb object housed in the molded object keeping container is taken out of the molded object keeping container to be fed to a next process. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a method for manufacturing a honeycomb structure, a honeycomb molded body receiver, and a honeycomb molded body take-out machine.

Recently, there has been a problem that soot particulates contained in exhaust gas discharged from internal combustion engines such as buses, truck vehicles and construction machines are harmful to the environment and the human body.
Thus, various honeycomb filters using a honeycomb structure made of porous ceramics have been proposed as filters for collecting particulates in exhaust gas and purifying the exhaust gas.

Conventionally, when manufacturing a honeycomb structure, for example, first, a ceramic powder, a binder, a dispersion medium liquid, and the like are mixed to prepare a wet mixture. Then, the wet mixture is continuously extruded with a die, and the extruded molded body is cut into a predetermined length to produce a prismatic honeycomb molded body.

Next, the obtained honeycomb formed body was dried using microwave drying or hot air drying, and then a predetermined cell was plugged, and either end of the cell was sealed. Thereafter, degreasing treatment and firing treatment are performed to manufacture a honeycomb fired body.

Thereafter, by applying a sealing material paste to the side surfaces of the honeycomb fired bodies and bonding the honeycomb fired bodies to each other, the honeycomb fired bodies in a state where a large number of honeycomb fired bodies are bundled through the sealing material layer (adhesive layer). Create an assembly. Next, the obtained honeycomb fired body aggregate is cut into a predetermined shape such as a cylinder or an elliptical column using a cutting machine or the like to form a honeycomb block, and finally, the outer periphery of the honeycomb block is sealed. The honeycomb structure is manufactured by applying the material paste to form the sealing material layer (coat layer) (see, for example, Patent Document 1).

JP 2002-126427 A

In the method for manufacturing a honeycomb structure as described above, in order to improve the production capacity, it is desirable to manufacture the honeycomb structure using a series of continuous manufacturing lines by continuing each process.
However, when all the processes are moving continuously in synchronization, trouble occurs in any process in a production line having a large number of processing processes, and the work in that process has to be stopped. In some cases, other processes in which trouble has not occurred must be stopped, and productivity may be significantly reduced.

In addition, depending on the process, there is a process that needs to perform the next process continuously (within a predetermined time) after the end of one process, trouble occurs in the process after these processes, and the entire production line is When stopped, even if the processing up to one step has been completed, the next step cannot be performed within a predetermined time, and eventually, the intermediate product that has finished up to one step must be discarded was there.
Specifically, for example, in a production line that must be transported to a drying process within a predetermined time after producing a honeycomb formed body by cutting the formed body into a predetermined length after extrusion molding, If trouble occurs in a later process and the entire manufacturing process including the drying process is stopped, it can be transported to the next drying process even if the production of the honeycomb formed body has been completed. After all, there were cases where the manufactured honeycomb formed body had to be discarded.

In order to solve the above-mentioned problems, the present inventors have intensively studied, and even if any trouble occurs in any process in the honeycomb structure production line, it is not necessary to stop the entire production line, and the production efficiency can be improved. The present inventors have found a method for manufacturing a honeycomb structure capable of preventing the decrease, and a honeycomb molded body receiving machine and a honeycomb molded body take-out machine used in such a manufacturing method.

That is, in the method for manufacturing a honeycomb structure of the present invention, after forming a columnar honeycomb formed body in which a large number of cells are arranged in parallel in the longitudinal direction with cell walls separated by forming a ceramic raw material, A honeycomb structure manufacturing method for manufacturing a honeycomb fired body by subjecting the body to one or a plurality of treatments including at least a firing process, and further manufacturing a honeycomb structure using the honeycomb fired body,
The treated honeycomb formed body that has been subjected to the one or more treatments is placed in a formed body storage container and temporarily stored, and then the treated honeycomb formed body placed in the formed body storage container is formed into a formed body. It is characterized by being taken out from the storage container and transported to the next process.

A method for manufacturing a honeycomb structured body of the present invention is a method for manufacturing a honeycomb structured body in which the honeycomb formed body is manufactured and then subjected to at least a drying process and a firing process on the honeycomb formed body.
The treated honeycomb formed body to be temporarily stored is preferably a honeycomb formed body that has been subjected to a drying treatment and / or a firing treatment.

Further, the method for manufacturing a honeycomb structure of the present invention is a method for manufacturing a honeycomb structure in which after the honeycomb formed body is manufactured, the honeycomb formed body is subjected to at least a drying process, a sealing process, and a firing process.
The processed honeycomb formed body to be temporarily stored is preferably a honeycomb formed body that has been subjected to at least one of a drying process, a sealing process, and a firing process.

The honeycomb molded body receiver of the present invention is a honeycomb molded body receiver used when the treated honeycomb molded body is placed in a molded body storage container in the method for manufacturing a honeycomb structure of the present invention,
A molded body non-storage container input section for stacking and holding empty molded body storage containers,
A first molded body storage container moving mechanism for moving the empty molded body storage container in the vertical direction and / or horizontal direction, and installing the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body on the transport unit via the holding unit and places the processed honeycomb formed body in an empty formed body storage container installed at the predetermined position; ,
A second molded body storage container moving mechanism for laminating the molded body storage container on which the treated honeycomb molded body is placed, with a molded body storage container on which another treated honeycomb molded body is placed;
And a molded body storage container take-out portion for stacking and holding the molded body storage container on which the treated honeycomb molded body is placed.

In the honeycomb molded body receiving machine of the present invention, when the processed honeycomb molded body is placed, the position where the empty molded body storage container is installed is the molded body storage container on which the processed honeycomb molded body is placed. It is desirable to be above the position where the layers are stacked.

Further, in the honeycomb molded body receiver of the present invention, the position where the empty molded body storage container is installed when the processed honeycomb molded body is placed holds the stacked empty molded body storage containers. It is also desirable to be above the position.

The honeycomb formed body take-out machine of the present invention is a honeycomb formed body take-out machine used when the treated honeycomb formed body is taken out from the formed body storage container in the method for manufacturing a honeycomb structure of the present invention,
A molded body storage container input section for stacking and holding the molded body storage container on which the treated honeycomb molded body is placed; and
A third molded body storage container moving mechanism for moving the molded body storage container on which the treated honeycomb molded body is placed in the vertical direction and / or the horizontal direction, and setting the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body in the formed body storage container via a holding unit, and places the processed honeycomb formed body on the transport unit;
A fourth molded body storage container moving mechanism for stacking the empty molded body storage container from which the treated honeycomb molded body has been taken out with another empty molded body storage container;
And a molded product non-storage container take-out portion for stacking and holding the empty molded product storage container.

In the honeycomb molded body take-out machine of the present invention, when the processed honeycomb molded body is lifted through the holding portion, the position where the molded body storage container is installed is above the position where the empty molded body storage containers are stacked. It is desirable to be.

Further, in the honeycomb molded body take-out machine of the present invention, when the processed honeycomb molded body is lifted via the holding portion, the position where the molded body storage container is installed is placed on the stacked processed honeycomb molded body. It is also desirable to be above the position where the molded body storage container is held.

In the method for manufacturing a honeycomb structure of the present invention, after the treated honeycomb formed body is placed in a formed body storage container and temporarily stored, the treated honeycomb formed body placed in the formed body storage container is Since it is taken out from the molded product storage container and placed on the transport unit to the next process, it is possible to divide a continuous manufacturing process without lowering the production efficiency, and therefore any one of a plurality of processes. Even if trouble occurs, other processes can be operated as usual. As a result, it is possible to avoid the inconvenience of having to discard the intermediate product due to the occurrence of trouble.

Further, as described above, by dividing the continuous manufacturing process, it is possible to adjust the production amount, make and store the processed honeycomb formed body, and the like.

Since the honeycomb molded body receiver of the present invention automatically performs the process of placing the processed honeycomb molded body in the molded body storage container, the processed honeycomb molded body can be efficiently and manually processed. It can be mounted on.

Since the honeycomb molded body take-out machine of the present invention automatically performs the process of taking out the processed honeycomb molded body from the molded body storage container, the processed honeycomb molded body is efficiently taken out from the molded body storage container without manpower. be able to.

First, a method for manufacturing a honeycomb structure of the present invention will be described.
The method for manufacturing a honeycomb structured body of the present invention includes forming a columnar honeycomb formed body in which a large number of cells are arranged in parallel in the longitudinal direction with cell walls being separated by forming a ceramic raw material. A method for manufacturing a honeycomb structured body, wherein a honeycomb fired body is manufactured by performing at least one treatment including a firing process, and further a honeycomb structure is manufactured using the honeycomb fired body,
The treated honeycomb formed body that has been subjected to the one or more treatments is placed in a formed body storage container and temporarily stored, and then the treated honeycomb formed body placed in the formed body storage container is formed into a formed body. It is characterized by being taken out from the storage container and transported to the next process.
In the present specification, the “columnar shape” includes various columnar shapes such as a columnar shape, an elliptical columnar shape, and a polygonal columnar shape.

In the method for manufacturing a honeycomb structured body of the present invention, a plurality of processing steps are sequentially performed.
In general, (1) a honeycomb molded body manufacturing step of adjusting a wet mixture by mixing and kneading raw materials, then extruding the wet mixture, and cutting the extruded molded body into a predetermined length (2) A honeycomb formed body drying step in which the honeycomb formed body is dried. (3) A honeycomb formed body sealing step in which a sealing treatment is performed in which a cell paste of the dried honeycomb formed body is filled with a sealing material paste ( (Also referred to as a honeycomb formed body sealing step), (4) a honeycomb formed body degreasing step for performing degreasing treatment on the honeycomb formed body, and (5) a honeycomb formed body that is subjected to firing treatment on the degreased honeycomb formed body to obtain a honeycomb fired body. A firing step, (6) a honeycomb assembly manufacturing step for manufacturing a honeycomb fired body aggregate by binding a plurality of honeycomb fired bodies through a sealing material layer (adhesive layer); ) A honeycomb block manufacturing process for processing the outer periphery of the honeycomb aggregate to form a honeycomb block having a predetermined shape, (8) A coating layer forming process for forming a sealing material layer (coat layer) around the honeycomb block, and the like are sequentially performed. Thus, a honeycomb structure is manufactured.

In the method for manufacturing a honeycomb structure of the present invention, the steps (1) to (8) do not necessarily need to be performed all, but only the steps necessary depending on the design of the honeycomb structure. Just do it.
Specifically, for example, when manufacturing a honeycomb structure that functions as a filter as a honeycomb structure, it is necessary to perform (3) a honeycomb formed body sealing step (honeycomb formed body sealing step). When manufacturing a honeycomb structure that functions as (3), the honeycomb formed body sealing step (honeycomb formed body sealing step) may not be performed.
In addition, for example, when manufacturing an aggregated honeycomb structure, it is necessary to perform the (6) honeycomb aggregate manufacturing process, but when manufacturing an integrated honeycomb structural body, (6) the honeycomb aggregate manufacturing process is performed. You don't have to. The distinction between the aggregated honeycomb structure and the integral honeycomb structure will be described later.

In the method for manufacturing a honeycomb structure of the present invention, the processed structure obtained by going through any one of the steps (2) to (8) and placed on the transport unit to be carried into the next step. The honeycomb formed body is once placed in the formed body storage container and temporarily stored, and then placed on the transport unit for the next process.
In the present specification, the treated honeycomb formed body is not only a honeycomb formed body subjected to drying treatment, degreasing treatment, and firing treatment, but also a honeycomb formed body subjected to various treatments such as sealing treatment. Furthermore, after the honeycomb formed body is subjected to a firing treatment to form a honeycomb fired body, the bundled honeycomb aggregate and the externally processed honeycomb aggregate are also included in the treated honeycomb molded body. To do.

Further, in the method for manufacturing a honeycomb structured body of the present invention, when the treated honeycomb formed body is temporarily stored, the storage time does not change in the physical properties of the treated honeycomb formed body stored at the time of storage. If it is, it will not specifically limit.
As a specific storage time, for example, when storing a honeycomb formed body that has been subjected to a drying process or a honeycomb formed body that has been subjected to a sealing process, it is preferably within one month. In addition, for example, when storing a honeycomb formed body that has been fired (honeycomb fired body), the storage time is not limited.

The formed body storage container used in the method for manufacturing a honeycomb structure is not particularly limited as long as the processed honeycomb formed body to be stored can be placed thereon, and the size thereof is arbitrary. In addition, it is desirable that the size of the molded body storage container is capable of simultaneously holding a plurality of processed honeycomb molded bodies.
Moreover, the material of the said molded object storage container is not specifically limited, either.

Further, with respect to the honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention, specifically, a columnar honeycomb formed body in which a large number of cells are arranged in parallel in the longitudinal direction with a cell wall therebetween is obtained by firing. A honeycomb structure (see FIG. 1) in which a plurality of the fired honeycomb bodies are bundled through a sealing material layer (adhesive layer), or a honeycomb molded body in which a large number of cells are arranged in parallel in the longitudinal direction with cell walls interposed therebetween. And a columnar honeycomb structure made of one honeycomb sintered body obtained by firing the above.
In the present specification, a honeycomb structure in which a plurality of the former honeycomb fired bodies are bundled through a sealing material layer (adhesive layer) is referred to as a collective honeycomb structure, and the latter is a columnar shape made of one honeycomb sintered body. This honeycomb structure is referred to as an integral honeycomb structure.

FIG. 1 is a perspective view schematically showing an example of a honeycomb structure (aggregate honeycomb structure), and FIG. 2 (a) is a perspective view schematically showing a honeycomb fired body constituting the honeycomb structure. (B) is the AA sectional view taken on the line.

In the honeycomb structure 30, a plurality of honeycomb fired bodies 40 as shown in FIG. 2A are bundled through a sealing material layer (adhesive layer) 31 to form a honeycomb block 33. A sealing material layer (coat layer) 32 is formed on the outer periphery of the substrate.
Further, as shown in FIG. 2, the honeycomb fired body 40 has a large number of cells 41 arranged in the longitudinal direction (see a in FIG. 2A), and the cell wall 43 separating the cells 41 functions as a filter. It is supposed to be.

That is, in the cell 41 formed in the honeycomb fired body 40, as shown in FIG. 2B, either the inlet side or the outlet side end of the exhaust gas is plugged by the sealing material layer 42, and one cell The exhaust gas that has flowed into 41 always passes through the cell wall 43 separating the cells 41 and then flows out from the other cells 41. When the exhaust gas passes through the cell wall 43, the particulates are transferred to the cell wall 43. Captured at the part, the exhaust gas is purified.

Hereinafter, the manufacturing method of the honeycomb structure of the present invention will be described in more detail in the order of steps.
Here, the manufacturing method of the honeycomb structure will be described by taking as an example the case of manufacturing a honeycomb structure whose main component is silicon carbide.
Of course, the main component of the constituent material of the honeycomb structure is not limited to silicon carbide. Other examples include nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, and titanium nitride, zirconium carbide, and titanium carbide. And carbide ceramics such as tantalum carbide and tungsten carbide, and oxide ceramics such as alumina, zirconia, cordierite, mullite, and aluminum titanate.
Moreover, the silicon-containing ceramic which mix | blended metallic silicon with the ceramic mentioned above, the ceramic couple | bonded with the silicon and the silicate compound, etc. are mentioned as a constituent material.
The above-mentioned constituent material is preferably silicon carbide or silicon-containing silicon carbide in which metal silicon is mixed with silicon carbide when manufacturing a collective honeycomb structure, and cordierite or silicon carbide when manufacturing an integral honeycomb structure. Aluminum titanate is desirable.

In the method for manufacturing a honeycomb structure of the present invention,
(1-1) First, an inorganic powder such as silicon carbide powder having different average particle diameters and an organic binder are dry mixed to prepare a mixed powder, and a liquid plasticizer, a lubricant and water are mixed and mixed. A wet mixture for molding is prepared by preparing a liquid and subsequently mixing the mixed powder and the mixed liquid using a wet mixer.

The particle size of the silicon carbide powder is not particularly limited, but it is preferable to have less shrinkage in the subsequent firing step, for example, 100 parts by weight of powder having an average particle size of 0.3 to 50 μm and 0.1 to 1.0 μm. A combination of 5 to 65 parts by weight of a powder having an average particle diameter of 5 to 65 parts by weight is preferred.
In order to adjust the pore size and the like of the honeycomb fired body, it is usually necessary to adjust the firing temperature, but the pore size can also be adjusted by adjusting the particle size of the silicon carbide powder.

The organic binder is not particularly limited, and examples thereof include methyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, and polyethylene glycol. Of these, methylcellulose is desirable.
The amount of the binder is usually preferably 1 to 10 parts by weight with respect to 100 parts by weight of the inorganic powder.

It does not specifically limit as said plasticizer, For example, glycerol etc. are mentioned.
The lubricant is not particularly limited, and examples thereof include polyoxyalkylene compounds such as polyoxyethylene alkyl ether and polyoxypropylene alkyl ether.
Specific examples of the lubricant include polyoxyethylene monobutyl ether and polyoxypropylene monobutyl ether.
In some cases, the plasticizer and the lubricant may not be contained in the mixed liquid.

Moreover, when preparing the said wet mixture, you may use a dispersion medium liquid, As said dispersion medium liquid, alcohol, such as water, organic solvents, such as benzene, methanol, etc. are mentioned, for example.
Furthermore, a molding aid may be added to the wet mixture.
The molding aid is not particularly limited, and examples thereof include ethylene glycol, dextrin, fatty acid, fatty acid soap, polyalcohol and the like.

Furthermore, a pore-forming agent such as balloons that are fine hollow spheres containing oxide-based ceramics, spherical acrylic particles, and graphite may be added to the wet mixture as necessary.
The balloon is not particularly limited, and examples thereof include an alumina balloon, a glass micro balloon, a shirasu balloon, a fly ash balloon (FA balloon), and a mullite balloon. Of these, alumina balloons are desirable.

Moreover, it is desirable that the temperature of the wet mixture using the silicon carbide powder prepared here is 28 ° C. or less. It is because an organic binder may gelatinize when temperature is too high.
The organic content in the wet mixture is desirably 10% by weight or less, and the water content is desirably 8 to 20% by weight.

(1-2) Next, this wet mixture is extruded by an extrusion method or the like. Then, by cutting the molded body obtained by extrusion molding with a cutting machine or the like, a columnar honeycomb molded body having a predetermined length and a large number of cells arranged in parallel in the longitudinal direction across the cell wall Make it.

(2) Next, the honeycomb formed body is dried.
The drying treatment can be performed using, for example, a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer, or the like.
In addition, what is necessary is just to perform this drying process as needed.

(3) Next, if necessary, the end portions of the cells of the honeycomb formed body are filled with a predetermined amount of a sealing material paste, and a sealing process is performed to seal the cells.
Although it does not specifically limit as said sealing material paste, What the porosity of the sealing material layer formed through a post process becomes 30 to 75% is desirable, For example, using the thing similar to the said wet mixture is used. it can.
Moreover, when the sealing material paste is filled, it is desirable to dry the filled sealing material paste.

(4) Next, if necessary, the honeycomb formed body filled with the sealing material paste is subjected to a degreasing treatment under a predetermined condition (for example, 200 to 500 ° C.).

(5) Further, the degreased honeycomb formed body is fired at a predetermined temperature (for example, 1400 to 2300 ° C.).
As a result, it is possible to manufacture a columnar honeycomb fired body in which a large number of cells are arranged in parallel in the longitudinal direction across the cell wall.

(6) Next, on the side surface of the honeycomb fired body, a sealing material paste to be a sealing material layer is applied with a uniform thickness to form a sealing material paste layer. The process of laminating the honeycomb fired body is repeated, and after a predetermined number of layers are stacked, the sealing material paste layer is dried and solidified by heat treatment, and the honeycomb fired body of a predetermined size is bound by the sealing material layer (adhesive layer) An aggregate (honeycomb aggregate) is produced.

As said sealing material paste, what consists of an inorganic binder, an organic binder, an inorganic fiber, and / or an inorganic particle etc. are mentioned, for example.
Examples of the inorganic binder include silica sol and alumina sol. These may be used alone or in combination of two or more. Among the inorganic binders, silica sol is desirable.

Examples of the organic binder include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, and the like. These may be used alone or in combination of two or more. Among the organic binders, carboxymethyl cellulose is desirable.

Examples of the inorganic fiber include ceramic fibers such as silica-alumina, mullite, alumina, and silica. These may be used alone or in combination of two or more. Among the inorganic fibers, alumina fibers are desirable.

Examples of the inorganic particles include carbides and nitrides, and specific examples include inorganic powders made of silicon carbide, silicon nitride, and boron nitride. These may be used alone or in combination of two or more. Among the inorganic particles, silicon carbide having excellent thermal conductivity is desirable.

Furthermore, a pore-forming agent such as a balloon, which is a fine hollow sphere containing an oxide-based ceramic, spherical acrylic particles, or graphite, may be added to the sealing material paste as necessary.
The balloon is not particularly limited, and examples thereof include an alumina balloon, a glass micro balloon, a shirasu balloon, a fly ash balloon (FA balloon), and a mullite balloon. Of these, alumina balloons are desirable.

(7) Next, using a diamond cutter or the like, the honeycomb aggregate in which a plurality of honeycomb fired bodies are bonded via a sealing material layer (adhesive layer) is cut to produce a cylindrical honeycomb block.

(8) Next, if necessary, a plurality of honeycomb fired bodies are formed through the sealing material layer (adhesive layer) by forming a sealing material layer on the outer periphery of the honeycomb block using the sealing material paste. A honeycomb structure in which a sealing material layer (coat layer) is provided on the outer periphery of a bonded cylindrical honeycomb block can be manufactured.

(9) Thereafter, if necessary, a catalyst may be supported on the honeycomb structure. The catalyst may be supported on the honeycomb fired body before the honeycomb aggregate is produced.
When the catalyst is supported, it is desirable to form an alumina film having a high specific surface area on the surface of the honeycomb structure, and to apply a promoter such as platinum and a catalyst such as platinum to the surface of the alumina film.

As a method for forming an alumina film on the surface of the honeycomb structure, for example, a method in which a honeycomb structure is impregnated with a solution of a metal compound containing aluminum such as Al (NO ₃ ) ₃ and heated, an alumina powder is contained. For example, the honeycomb structure may be impregnated with a solution to be heated and heated.
Examples of a method for applying a promoter to the alumina film include a method in which a honeycomb structure is impregnated with a solution of a metal compound containing a rare earth element such as Ce (NO ₃ ) ₃ and heated. .
As a method for imparting a catalyst to the alumina membrane, for example, a dinitrodiammine platinum nitric acid solution ([Pt (NH ₃ ) ₂ (NO ₂ ) ₂ ] HNO ₃ , platinum concentration 4.53% by weight) or the like is applied to the honeycomb structure. Examples of the method include impregnation and heating.
Alternatively, the catalyst may be applied by a method in which a catalyst is applied to the alumina particles in advance, and the honeycomb structure is impregnated with a solution containing the alumina powder to which the catalyst is applied and heated.

Further, the manufacturing method of the honeycomb structure described so far is a manufacturing method of the aggregated honeycomb structure, but the honeycomb structure manufactured by the manufacturing method of the honeycomb structure of the present invention is an integral honeycomb structure. May be.

When manufacturing such an integral honeycomb structure, first, the aggregated honeycomb structure is formed except that the size of the honeycomb molded body formed by extrusion molding is larger than that when manufacturing the aggregated honeycomb structure. A honeycomb formed body is manufactured using the same method [the above-mentioned steps (1-1) and (1-2)] as in the case of manufacturing.

Next, as in the production of the aggregated honeycomb structure, a drying process and a sealing process [the above steps (2) and (3)] are performed as necessary. Similarly, a honeycomb block is manufactured by performing a degreasing treatment and a firing treatment [the above steps (4) and (5)], and if necessary, a sealing material layer (coat layer) is formed [the above step (8)]. By performing the above, an integrated honeycomb structure can be manufactured. Further, the step of supporting the catalyst by the above-described method [the above step (9)] may also be performed on the above-mentioned integral honeycomb structure.

In the honeycomb structure manufacturing method of the present invention, the processed honeycomb formed body placed on the transport unit is appropriately placed in the formed body storage container and temporarily stored in the series of steps described above. Thereafter, the processed honeycomb formed body placed in the formed body storage container is taken out of the formed body storage container and placed on the conveying member for the next process.

Specifically, when the method for manufacturing a honeycomb structure of the present invention performs the drying process [the above step (2)] and the firing process [the above step (5)], the honeycomb structure is once placed in a molded body storage container. The processed honeycomb formed body is preferably a honeycomb formed body that has been subjected to a drying treatment [the above step (2)] and / or a firing treatment [the above step (5)].
This is because these processed honeycomb molded bodies are particularly suitable for holding once. This is because, for example, if an undried honeycomb formed body prepared through the step (1) is stored before it is dried, a liquid binder exists in the stored honeycomb formed body. The shape may not be retained by the above, and the dimensions may change.On the other hand, the honeycomb molded body that has been subjected to the drying treatment or the honeycomb molded body that has been subjected to the firing treatment should be stored for a long time. However, there is very little possibility that the physical properties will change.

Further, in the method for manufacturing a honeycomb formed body of the present invention, when manufacturing a honeycomb structure that functions as a filter (that is, a honeycomb structure in which a sealing material layer is formed at one end of a cell). The processed honeycomb molded body once placed in the molded body storage container is subjected to a drying process [above step (2)], a sealing process [above step (3)] and a firing process [above step (5)]. Desirably, the honeycomb formed body is subjected to any treatment.
This is because the honeycomb structure subjected to these treatments is particularly suitable for holding once because it is very unlikely to change its dimensions even when stored for a long period of time.
For example, as described above, if an undried honeycomb formed body produced through the step (1) is stored once before it is dried, a liquid binder exists in the stored honeycomb formed body. The shape cannot be maintained and the dimensions may change, whereas the honeycomb molded body subjected to the drying treatment, the honeycomb molded body subjected to the sealing treatment, and the firing treatment This is because the applied honeycomb formed body is very unlikely to change its physical properties even when stored for a long period of time.

Here, the honeycomb structure to be manufactured has been described mainly with respect to a honeycomb filter used for the purpose of collecting particulates in exhaust gas. However, the honeycomb structure manufactured in the present invention is a catalyst carrier (honeycomb for purifying exhaust gas). It can also be suitably used as a catalyst.

In such a method for manufacturing a honeycomb structured body of the present invention, the operation of temporarily holding the honeycomb molded body can be performed using the honeycomb molded body receiving machine and the honeycomb molded body taking-out machine of the present invention described below.
In the honeycomb molded body receiving machine of the present invention, the operation of placing the processed honeycomb molded body on the molded body storage container can be suitably performed. In the honeycomb molded body take-out machine of the present invention, the processed honeycomb molded body is formed into an adult. The operation of taking out from the storage container can be suitably performed.

First, the honeycomb molded body receiver of the present invention will be described with reference to the drawings.
The honeycomb molded body receiver of the present invention is a honeycomb molded body receiver used when the treated honeycomb molded body is placed in a molded body storage container in the method for manufacturing a honeycomb structure of the present invention,
A molded body non-storage container input section for stacking and holding empty molded body storage containers,
A first molded body storage container moving mechanism for moving the empty molded body storage container in the vertical direction and / or horizontal direction, and installing the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body on the transport unit via the holding unit and places the processed honeycomb formed body in an empty formed body storage container installed at the predetermined position; ,
A second molded body storage container moving mechanism for laminating the molded body storage container on which the treated honeycomb molded body is placed, with a molded body storage container on which another treated honeycomb molded body is placed;
And a molded body storage container take-out portion for stacking and holding the molded body storage container on which the treated honeycomb molded body is placed.
Here, the honeycomb molded body receiver of the present invention will be described by taking as an example the case where the treated honeycomb molded body is a dried honeycomb molded body.

Fig. 3 (a) is a front view schematically showing a honeycomb molded body receiver of the present invention, and (b) shows a storage container lifting device constituting the honeycomb molded body receiver shown in (a). It is a front view shown, (c) is a side view of the storage container lifting device shown in (b), (d) is a storage container support constituting the honeycomb molded body receiver shown in (a) It is a top view of an apparatus, and (e) is a side view of a storage container support device shown in (d).
4 is a plan view of the honeycomb molded body receiver shown in FIG. 3 (a), and FIG. 5 is a side view of the honeycomb molded body receiver shown in FIG. 3 (a). FIG. 5 is an enlarged perspective view showing the vicinity of a storage container lifting device and a storage container moving device constituting the honeycomb molded body receiver shown in FIG. 4.

As shown in FIG. 3A and FIGS. 4 to 6, the honeycomb formed body receiver 140 mainly plays a role of lifting and moving the dried honeycomb formed body (processed honeycomb formed body) 11. A belt arm 144a, 144b, 144c, and 144d for moving the molded body storage container 143 while stacking and holding the molded body storage container 143 inside the robot arm 141 and the honeycomb molded body receiver 140, and the stacked molded body When pulling out one molded body storage container 143 from the storage container 143, or when stacking one molded body storage container 143 on the stacked molded body storage container 143, other than the one molded body storage container 143. A storage container lifting device 145 for lifting the molded body storage container 143, and the processed honeycomb molded body 11 are sequentially placed inside the molded body storage container 143. A storage container support device 150 that supports the molded product storage container 143 and a storage container moving device that functions when only the lowermost molded product storage container 143 is moved from the stacked molded product storage container 143. 155 (see FIG. 4) and a storage container lifting device 149 capable of moving up and down with one or a plurality of molded body storage containers 143 placed thereon.

4 and 5, the belt conveyor 142 on which the processed honeycomb molded body 11 is placed and moves the processed honeycomb molded body 11 to the honeycomb molded body receiver 140 is close to the honeycomb molded body receiver 140. Are arranged. Further, the molded body storage container 143 has a rectangular shape in plan view, and as shown in FIGS. 3A and 6, four cutouts 143a are provided on the side surface corresponding to the short side. When the molded body storage container 143 is stacked, a member for lifting the molded body storage container 143 stacked thereon can be inserted.

Here, first, the molded body storage container 143 stacked on the upper belt conveyors 144a and 144b of the honeycomb molded body receiver 140 has not yet received the processed honeycomb molded body 11 and is empty. There will be described a case where the formed body storage containers 143 stacked on the lower belt conveyors 144c and 144d are in a state in which a prescribed number of processed honeycomb formed bodies 11 are accommodated therein.
In this case, the storage container support device 150 is provided with one molded body storage container 143 from the empty molded body storage container 143 carried from the outside and held in a state of being stacked on the belt conveyors 144a and 144b. The processed honeycomb molded body 11 is stored in the molded body storage container 143 at that position, and then the molded body storage container 143 is stacked on the storage container lifting device 149, and then the molded body is stored. The laminated body of containers 143 is moved and held on the lower belt conveyors 144c and 144d, and further moved to an appropriate storage location for storage.
Therefore, in the honeycomb molded body receiver 140 in which the molded body storage container moves in such a direction, the upper belt conveyor 144b functions as a molded body non-storage container input unit, and the lower belt conveyor 144d functions as a molded body stored container. It will function as an extraction part.
In this case, the procedure for placing the processed honeycomb formed body in the formed body storage container 143 will be described in detail below.

An empty molded body storage container 143 carried in from the outside and held on the upper belt conveyor 144b functioning as a molded body non-storage container input section is transported to the position of the storage container lifting device 145 by the belt conveyors 144a and 144b. Is done.

As shown in FIGS. 3 (b), 3 (c) and 6, this storage container lifting device 145 has a holding part 147 for directly lifting the molded body storage container 143 and a moving part 147 for moving the holding part 147 in the vertical direction. An air cylinder 146 and a base 148 that supports the air cylinder 146 are provided on both sides of the passage of the molded product storage container 143. In addition, although not shown, an air cylinder is also provided in the holding portion 147 so that the holding portion 147 can be moved in the horizontal direction.

When lifting the molded product storage container 143, the holding parts 147 of the storage container lifting device 145 located on both sides of the molded product storage container 143 are moved in the horizontal direction, and the tips of the holding parts 147 are stacked. It is inserted into the bottom notch of the storage container 143, and the air cylinder 146 is further driven to raise the holding portion 147. As a result, the second and subsequent molded body storage containers 143 are lifted upward, and the lowermost molded body storage container 143 is separated from the second and subsequent molded body storage containers 143.

Next, the compact storage container 143 is moved using the storage container moving device 155. As shown in FIGS. 4 and 6, the storage container moving device 155 includes a hooking portion 157 on which the molded body storage container 143 is hooked when it protrudes upward and moves in the direction of the molded body storage container 143. A motor 156 and a ball screw 158 for moving the motor 156 are driven to rotate the ball screw 158 so that the hook portion 157 screwed to the ball screw 158 is moved in the direction of the molded product storage container 143 or in the opposite direction. It is configured to be movable.

Accordingly, the motor 156 is driven to rotate the ball screw 158, the hooking portion 157 is moved in the direction of the molded product storage container 143, and the hooking portion 157 is hooked on the molded product storage container 143, and two units shown in FIG. It moves so that it may be located between the storage container support apparatuses 150. At this time, the belt conveyor 144a also rotates to assist the movement of the compact storage container 143.
Therefore, when the honeycomb molded body receiver 140 is operated in this procedure, the storage container moving device 155 moves the empty molded body storage container in the horizontal direction and installs the molded body storage container at a predetermined position. It will function as the first compact storage container moving mechanism.

As shown in FIGS. 3D and 3E, the storage container support device 150 supports the storage container support unit 152 for supporting the moved molded body storage container 143 and the molded body storage container 143. The air cylinder 151 for moving the storage container support 152 in the direction approaching the molded body storage container 143 and moving away from the molded body storage container 143 when the supported molded body storage container 143 is opened, and the air It comprises a cylinder support portion 153 that supports the cylinder 151 and the like, and as shown in FIG. 4, two storage container support devices 150 are provided on both sides of the area where the molded body storage container 143 moves.

Further, the two storage container support devices 150 keep the two storage container support portions 152 at a predetermined interval so that they can be supported in advance when the compact storage container 143 moves. Therefore, when the molded body storage container 143 moves to the position of the storage container support device 150 due to the movement of the hooking portion 157, the storage container support device 150 supports the molded body storage container 143 from both sides, and the air cylinder. 151 is driven, and the storage container support 152 is further advanced toward the molded body storage container 143 to hold the molded body storage container 143 firmly.

Next, the processed honeycomb molded body 11 is placed and stored in the molded body storage container 143 by the robot arm 141.
The robot arm 141 includes a suction part (not shown) that performs suction by air and a gripping part 141a made of a plate member for clamping. The robot arm 141 uses the suction part and the gripping part 141a to The processed honeycomb molded body 11 placed and transported is lifted, and the robot arm 141 is moved to the molded body storage container 143 installed in the honeycomb molded body receiver 140, and then suction is performed by the suction unit. While stopping, the holding part 141a is expanded and the processed honeycomb molded body 11 is sequentially placed in the molded body storage container 143.

Then, when the processed honeycomb formed body 11 is placed in the entire inside of the formed body storage container 143 and the storage process of the processed honeycomb formed body 11 is completed, the storage container positioned between the two storage container support devices 150 is stored. The elevating device 149 rises and supports the compact storage container 143. Thereafter, the storage container support device 150 drives the air cylinder 151 to retract the storage container support portion 152 from the molded body storage container 143, and releases the support of the molded body storage container 143. Thereby, the molded object storage container 143 will be in the state supported only by the storage container raising / lowering apparatus 149. FIG. Thereafter, the storage container lifting / lowering device 149 is lowered to allow the new molded product storage container 143 to move to a position between the two storage container support devices 150.
Therefore, the storage container lifting / lowering device 149 functions as a second molded body storage container.

Thereafter, by repeating the above steps, the molded body storage container 143 in which a predetermined number of processed honeycomb molded bodies 11 are accommodated is stacked on the storage container lifting device 149, but the molded body storage container 143 is stored. Is a predetermined value (for example, 15 levels), the storage container lifting device 149 is lowered to the bottom, and the stacked molded body storage containers 143 are placed on the belt conveyor 144c. Subsequently, when the belt conveyor 144a is driven, the stacked molded body storage containers 143 are moved to secure a place where the next stacked body of the molded body storage containers 143 is placed.

Thereafter, the stacked molded body storage containers 143 are held on the belt conveyors 144c and 144d, and are sequentially moved to the outlet side by the movement of the belt conveyors 144c and 144d. Thereafter, the stacked molded body storage containers 143 are further moved to an appropriate storage location outside the honeycomb molded body receiver 140 and stored.
In the honeycomb molded body receiver of the present invention, an empty molded body storage container 143 is installed when the processed honeycomb molded body is placed like the honeycomb molded body receiver 140 operating in the above-described procedure. The position is preferably above the position where the formed body storage container 143 on which the processed honeycomb formed body is placed is stacked.
This is because the honeycomb molded body receiver can be made compact by adopting such a configuration. In addition, when the molded body storage container stacked below the empty molded body storage container is positioned, the distance for moving the molded body storage container on which the treated honeycomb molded body is placed is short or moved. Since there is no need, the conveyance work of a molded object storage container becomes easy.

In the honeycomb molded body receiver 140 shown in FIG. 3A and FIGS. 4 to 6, the storage container lifting device 145 is also provided in the lower stage, so that the lamination process of the molded body storage container 143 is performed in the lower stage. You may go.
The operation procedure of the honeycomb molded body receiver 140 in this case will be briefly described below.
When performing the lamination process of the molded body storage container in the lower stage, the processed honeycomb molded body is placed on the molded body storage container 143 supported by the storage container support device 150 in the same manner as described above. The compact storage container 143 is supported by the storage container lifting device 149.
Then, with the storage container lifting device 149 supporting one molded body storage container 143, the storage container lifting apparatus 149 is lowered to the bottom, and the molded body storage container 143 is placed on the belt conveyor 144c. Thereafter, the compact storage container 143 is moved between the two lower storage container lifting devices 145 by the belt conveyor 144c.

Subsequently, by performing the same process, the next molded body storage container 143 is placed on the belt conveyor 144c, and is further moved between the two storage container lifting devices 145 by the belt conveyor 144c.
At this time, the molded body storage container 143 transported first is lifted by the storage container lifting device 145 to a height at which the next molded body storage container 143 can be fed into the lower part.
And after conveying the 2nd molded object storage container 143 to the predetermined position with the belt conveyor 144c, the 1st molded object storage container 143 is stacked on it.
By repeating such a process, the lamination | stacking process of the molded object storage container 143 can be performed in a lower stage.
Also in this case, when the molded product storage containers 143 having a predetermined number of stages are stacked, they are sent to the belt conveyor 144d side.
In addition, when performing the lamination | stacking process of a molded object storage container in such a procedure, the lower storage container lifting apparatus 145 and the belt conveyor 144c will function as a 2nd molded object storage container moving mechanism.

By using the honeycomb molded body receiver having such a configuration in the above-described procedure, the operation of placing the processed honeycomb molded body on the molded body storage container can be suitably performed.

Further, in the procedure described above, a molded product storage container is stacked on each of the upper belt conveyor and the lower belt conveyor, and an empty molded product storage container is placed on the upper belt conveyor. The formed body storage container on which the processed honeycomb formed body is placed is stacked on the belt conveyor, but the operation procedure of the honeycomb formed body receiver 140 of the present invention is not limited to such a procedure, You may operate according to the following procedure.

For example, the moving direction of the molded product storage container 143 may be the reverse direction.
Specifically, first, the lower belt conveyor 144d is used as a molded body non-storage container input unit, and empty molded body storage containers 143 stacked on the lower belt conveyors 144d and 144c are held to hold the lower storage container. While the upper unit 145 lifts the molding storage container 143 other than the lowermost stage, the lowermost molding storage container 143 is supported by the storage container lifting / lowering device 149 by the belt conveyor 144c.
Next, the storage container lifting / lowering device 149 is raised, the molded body storage container 143 is supported by the storage container support device 150, and the processed honeycomb molded body is placed in the molded body storage container 143 by the robot arm 141.
Thereafter, the formed body storage container 143 on which the processed honeycomb formed body is placed is placed on the belt conveyor 144a.

Then, by repeating this process, the formed body storage container 143 on which the processed honeycomb formed body is placed is placed on the belt conveyor 144a.
When the molded product storage container 143 is stacked on the belt conveyor 144a, the subsequent molded product storage container 143 is lifted by the upper storage container lifting device 145 while the molded product storage container 143 transported previously is lifted. The molded product storage container 143 may be stacked on the belt conveyer 144a by sequentially feeding them into the lower part.
Furthermore, when the molded product storage containers 143 having a predetermined number of layers are stacked, they are further conveyed to the belt conveyor 144b. Therefore, when the processed honeycomb molded body is placed in the molded body storage container 143 in such a procedure, the belt conveyor 144b functions as a molded body stored container take-out portion.
In this procedure, the belt conveyor 144c and the storage container lifting device 149 function as a first molded body storage container moving mechanism, and the belt conveyor 144a functions as a second molded body storage container moving mechanism.
As described above, the honeycomb molded body receiver 140 shown in FIGS. 3A and 4 to 6 includes an empty molded body storage container on the lower belt conveyor and a molded body on the upper belt conveyor. You may use so that the stored molded object storage container may be laminated | stacked, respectively.

Further, for example, in the honeycomb molded body receiver 140 shown in FIGS. 3A and 4 to 6, the stacked empty molded body storage containers 143 held on the belt conveyor 144 a are moved to the storage container support device 150. When forming, the molded body storage container 143 positioned at the bottom of the empty molded body storage containers 143 stacked on the belt conveyor 144a is sequentially moved to the storage container support device 150. When moving the empty molded body storage container 143 stacked on the belt conveyor 144a to the storage container support device 150, the body receiver sequentially moves from the molded body storage container 143 stacked at the uppermost stage. It may be configured.
In this case, for example, a robot arm that moves the uppermost molded body storage container 143 among the empty molded body storage containers 143 stacked on the belt conveyor 144a to the storage container support device 150 may be provided.

In addition, the honeycomb molded body receiver of the present invention may have a configuration as shown in FIGS. 7 (a) and 7 (b).
FIGS. 7A and 7B are explanatory views for explaining another configuration of the honeycomb molded body receiver of the present invention.
In the honeycomb molded body receiver 240, empty molded body storage containers stacked on the lower belt conveyors 244d and 244c are held, and the processed honeycomb molded body is placed on the upper belt conveyors 244a and 244b. A molded body storage container is held.

In the honeycomb molded body receiver 240, first, empty molded body storage containers conveyed from the outside are held on the lower belt conveyors 244d and 244c in a stacked state.
Therefore, in the honeycomb molded body receiver 240, the belt conveyor 244d functions as a molded body non-storage container input unit.

When the processed honeycomb molded body is received, the uppermost molded body storage container among the empty molded body storage containers stacked on the lower belt conveyor 244c is moved to a predetermined position by the storage container support device 250. Lift up (see white arrow A in FIG. 7A).
Therefore, in the honeycomb molded body receiver 240, the storage container support device 250 moves the empty molded body storage container 243 in the vertical direction, and moves the first molded body storage container that places the molded body storage container 243 at a predetermined position. Acts as a mechanism.
Next, the processed honeycomb molded body placed on a transport member (not shown) is placed in a molded body storage container supported by the storage container support device 250 by a robot arm (not shown) (in FIG. 7 (a), (See black arrow B).

Next, the molded body storage container storing the processed honeycomb molded body is moved onto the belt conveyor 244a, and the molded body storage container 243 storing the processed honeycomb molded body is stacked on the belt conveyor 244a (FIG. 7A). ), See white arrow C).
At this time, on the belt conveyor 244a side, the already stacked laminated product storage container is lifted by the storage container lifting device 245 so that the molded product storage container storing the processed honeycomb formed product can be placed at the lowermost stage. Keep it.
Therefore, in the honeycomb molded body receiver 240, the belt conveyor 244a and the storage container lifting device 245 function as a second molded body storage container moving mechanism.

As described above, the molded body storage containers storing the processed honeycomb molded bodies are sequentially stacked on the belt conveyor 244a. When the predetermined number of molded body storage containers are stacked, the stacked molded body storage containers are On the belt conveyor 244b, and further carried out to the outside.
Therefore, in the honeycomb molded body receiver 240, the belt conveyor 244b functions as a molded body stored container take-out portion.
In FIG. 7A, the white arrow indicates the movement of the molded body storage container, and the black arrow indicates the movement of the processed honeycomb molded body.

The honeycomb molded body receiving machine of the present invention, like the honeycomb molded body receiver 240 shown in FIG. 7A, is a position where the molded body storage container 243 is mounted when the processed honeycomb molded body is mounted. However, it is also desirable to be above the position where the empty molded body storage containers 243 are stacked.
This is because the honeycomb molded body receiver can be made compact by adopting such a configuration. In addition, when the molded body storage container laminated below the empty molded body storage container is located, the distance to move the molded body storage container up and down is small or it is not necessary to move the molded body storage container. This makes it easy to transport.

In addition, in the honeycomb molded body receiver 340 shown in FIG. 7B, the belt conveyor 344a that holds the stacked empty molded body storage containers and the processed honeycomb molded body are stored, and the stacked molded body storage is performed. The belt conveyor 344b for holding the containers is not disposed on each of the upper and lower stages as in the honeycomb molded body receiver shown in FIGS. 3A, 4 to 6, and 7A, and the belt conveyor 344a and 344b are formed in the same plane.

In the honeycomb molded body receiver 340, first, the empty molded body storage containers conveyed from the outside are held on the belt conveyor 344a in a stacked state.
When receiving the processed honeycomb molded body, first, among the empty molded body storage containers stacked on the belt conveyor 344a, the molded body storage container 343 other than the lowest stage is lifted by the storage container lifting device 345a. At the same time, the lowermost molded body storage container 343 is installed on the belt conveyor 350 (see the white arrow A in FIG. 7B).
In the honeycomb molded body receiving machine 340, the belt conveyor 350 is similar to the storage container support devices 150 and 250 in the honeycomb molded body receiving machines 140 and 240 when the processed honeycomb molded body is held in the molded body storage container. It has a function to support the storage container.

Next, the processed honeycomb molded body placed on the conveying member (not shown) is placed in the molded body storage container placed on the belt conveyor 350 by a robot arm (not shown) (in FIG. 7B). , See black arrow B).

Next, the formed body storage container storing the processed honeycomb formed body is moved onto the belt conveyor 344b, and the formed body storage container 343 storing the processed honeycomb formed body is stacked on the belt conveyor 344b (FIG. 7B). ), See white arrow C).
At this time, on the side of the belt conveyor 344b, the already stacked stacked body storage container is lifted by the storage container lifting device 345b so that the formed body storage container storing the processed honeycomb formed body can be placed at the lowermost stage. deep.
In this way, the molded body storage containers storing the processed honeycomb molded bodies are sequentially stacked on the belt conveyor 344b, and when the predetermined number of molded body storage containers are stacked, the stacked molded body storage containers are moved. To the outside.
In FIG. 7B, the white arrow indicates the movement of the molded body storage container, and the black arrow indicates the movement of the processed honeycomb molded body.

In the honeycomb molded body receiver 340 shown in FIG. 7B, the belt conveyor 344a functions as a molded body non-storage container input section, and the belt conveyor 344b functions as a molded body stored container take-out section.
In the honeycomb molded body receiver 340, the belt conveyor 344a and the belt conveyor 350 function as a first molded body non-storage container moving mechanism, and the belt conveyor 344b and the storage container lifting device 345b serve as the second molded body storage container. Functions as a moving mechanism.
The honeycomb molded body receiver of the present invention may have a configuration as shown in FIGS. 7 (a) and 7 (b).

In such a honeycomb molded body receiving machine, the process of placing the processed honeycomb molded body in the molded body storage container is automatically performed, so that the processed honeycomb molded body can be efficiently and manually processed without any manpower. It can be mounted on.

Next, the honeycomb molded body take-out machine of the present invention will be described.
The honeycomb formed body take-out machine of the present invention is a honeycomb formed body take-out machine used when the treated honeycomb formed body is taken out from the formed body storage container in the method for manufacturing a honeycomb structure of the present invention,
A molded body storage container input section for stacking and holding the molded body storage container on which the treated honeycomb molded body is placed; and
A third molded body storage container moving mechanism for moving the molded body storage container on which the treated honeycomb molded body is placed in the vertical direction and / or the horizontal direction, and setting the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body in the formed body storage container via a holding unit, and places the processed honeycomb formed body on the transport unit;
A fourth molded body storage container moving mechanism for stacking the empty molded body storage container from which the treated honeycomb molded body has been taken out with another empty molded body storage container;
And a molded product non-storage container take-out portion for stacking and holding the empty molded product storage container.

The honeycomb molded body take-out machine of the present invention is an invention relating to an apparatus for taking out a processed honeycomb molded body from a molded body storage container. This honeycomb molded body take-out machine is the same as the honeycomb molded body receiver of the present invention already described. It is a device that performs a completely reverse operation, except that the direction of movement of the processed honeycomb molded body is completely reversed, the transport direction of the molded body storage container is the same as that of the honeycomb molded body receiver, and the same apparatus Can be used.
That is, the honeycomb molded body take-out machine of the present invention includes the robot arm having the suction mechanism and the gripping mechanism, and the third and fourth molded body storage container moving mechanisms. Here, the robot arm is the present invention. The third and fourth molded body storage container moving mechanisms have a configuration similar to that of the robot arm constituting the honeycomb molded body receiver of the first embodiment. And it has the structure similar to the 2nd molded object storage container moving mechanism.

In the honeycomb molded body take-out machine of the present invention, the molded body non-storage container input section in the honeycomb molded body receiver of the present invention functions as the molded body stored container input section, and the molding in the honeycomb molded body receiver of the present invention. The body storage completed container extraction portion functions as a molded body unstorage container extraction portion.

Here, the case where a device similar to the honeycomb molded body receiver 140 shown in FIG. 3A and FIGS. 4 to 6 is used as the honeycomb molded body take-out machine is used as an example. A procedure for taking out the honeycomb formed body will be described.
In this case, the reference numerals used in FIG. 3A and FIGS. 4 to 6 are used as they are.
Further, here, an empty molded body in which a molded body storage container on which the processed honeycomb molded body is placed is stacked and held on the upper belt conveyor, and the processed honeycomb molded body is taken out on the lower belt conveyor. A case where the storage containers are stacked and held will be described as an example.

When the honeycomb molded body receiver 140 is used as a honeycomb molded body take-out machine, the molded body storage container on which the processed honeycomb molded body is placed is stacked on the upper belt conveyor 144b, and is further loaded. It conveys to the position of the storage container lifting device 145 on the belt conveyor 144a.
Then, while lifting the molded body storage container 143 other than the lowermost molded body storage container 143, the lowermost molded body storage container 143 is moved by the storage container moving device 155 and supported by the storage container support device 150.

Next, the processed honeycomb formed body 11 in the formed body storage container 143 supported by the storage container support device 150 is taken out by the robot arm 141, and the taken out processed honeycomb formed body 11 is moved onto the belt conveyor 142. The processed honeycomb formed body 11 is conveyed to the next process apparatus by the belt conveyor 142.
On the other hand, when the processed honeycomb molded body is taken out and the molded body storage container 143 that has been emptied is sequentially stacked on the storage container lifting and lowering device 149, a predetermined number of empty molded body storage containers 143 are stacked. The stacked empty compact storage containers 143 are moved onto the belt conveyor 144c, further conveyed onto the belt conveyor 144d, and then carried out to the outside.
When an apparatus similar to the honeycomb molded body receiver 140 shown in FIG. 3A and FIGS. 4 to 6 is used as a honeycomb molded body take-out machine, for example, the processed honeycomb molded body is molded according to the above procedure. Can be removed from the storage container.

In addition, when a device similar to the honeycomb molded body receiver 140 is used as the honeycomb molded body take-out machine, the molded body storage containers may be stacked on the lower belt conveyor 144c. A formed body storage container on which the processed honeycomb formed body is placed is installed on the conveyors 144c and 144d, and after the processed honeycomb formed body is taken out by the robot arm, an empty formed body storage container is placed on the upper belt conveyor 142. May be held.

Further, the honeycomb molded body take-out machine of the present invention is an invention other than the honeycomb molded body receiver 140, such as an apparatus having the same configuration as the honeycomb molded body receivers 240 and 340 shown in FIGS. 7 (a) and 7 (b). It may be the same device as the honeycomb molded body receiver.

In the honeycomb molded body take-out machine of the present invention, when the processed honeycomb molded body is lifted through the holding portion, the position where the molded body storage container is installed is above the position where the empty molded body storage containers are stacked. It is desirable to be.
This is because with such a configuration, the honeycomb molded body take-out machine can be made compact. In addition, when the molded body storage container laminated below the molded body storage container is located, the distance to move the molded body storage container up and down is small or it is not necessary to move the molded body storage container. Work becomes easy.

Further, in the honeycomb molded body take-out machine of the present invention, when the processed honeycomb molded body is lifted via the holding portion, the position where the molded body storage container is installed is placed on the stacked processed honeycomb molded body. It is also desirable to be above the position where the molded body storage container is held.
This is because the honeycomb molded body take-out machine can be made compact even in such a configuration. In addition, when the molded body storage container laminated below the molded body storage container is located, the distance to move the molded body storage container up and down is small or it is not necessary to move the molded body storage container. Work becomes easy.
In such a honeycomb molded body take-out machine, since the process of taking out the processed honeycomb molded body from the molded body storage container is automatically performed, the processed honeycomb molded body is efficiently removed from the molded body storage container without manpower. be able to.
The conveyor of the honeycomb molded body receiving machine and the honeycomb molded body take-out machine is not limited to a belt conveyor, and may be a chain conveyor, a roller conveyor, a pallet conveyor, or the like.

The present invention will be described in more detail with reference to examples below, but the present invention is not limited to these examples.
(Example 1)
(1) 250 kg of α-type silicon carbide powder having an average particle size of 10 μm, 100 kg of α-type silicon carbide powder having an average particle size of 0.5 μm, and 20 kg of an organic binder (methyl cellulose) were mixed to prepare a mixed powder.
Next, separately, 12 kg of lubricant (Unilube manufactured by NOF Corporation), 5 kg of plasticizer (glycerin), and 65 kg of water are mixed to prepare a liquid mixture, and this liquid mixture and the mixed powder are mixed in a wet mixer. And mixed to prepare a wet mixture.

Next, this wet mixture was conveyed to an extrusion molding machine using a conveyance device, and charged into a raw material inlet of the extrusion molding machine.
Then, the extruded molded body was cut to produce a honeycomb molded body having the same shape as that shown in FIG. 2A except that the end portions of the cells were not sealed.

(2) Next, the honeycomb formed body was dried using a dryer using both microwaves and hot air.
Thereafter, the dried honeycomb formed body was placed in a formed body storage container using the honeycomb formed body receiver 140 shown in FIGS. 3A and 4 to 6 and stored for about one week.
Thereafter, using the honeycomb molded body take-out machine having the same configuration as the honeycomb molded body receiver 140, the stored honeycomb molded body subjected to the drying treatment was taken out and conveyed to the next step.

(3) Next, the plug material paste having the same composition as that of the wet mixture is applied to the predetermined cells of the honeycomb molded body so that either one of the cells of the honeycomb molded body is filled with the plug material paste. Filled.
Subsequently, the filled plug material paste was dried by irradiating both ends of the honeycomb formed body with hot air of 130 ° C.

(4) Next, the honeycomb formed body filled with the sealing material paste was put into a degreasing furnace and subjected to a degreasing treatment.
Here, the degreasing conditions were set to 400 ° C. for 3 hours.

(5) Next, the degreased honeycomb formed body was put into a firing furnace and fired.
Here, the firing conditions were 3200 hours at 2200 ° C. in an atmospheric argon atmosphere.
By such firing treatment, the porosity is 40%, the average pore diameter is 12.5 μm, the size is 34.3 mm × 34.3 mm × 254 mm, and the number of cells (cell density) is 46.5 cells / cm ^2. A honeycomb fired body made of a silicon carbide sintered body having a cell wall thickness of 0.25 mm was produced.

(6) Next, 30% by weight of alumina fiber having an average fiber length of 20 μm, 21% by weight of silicon carbide particles having an average particle diameter of 0.6 μm, 15% by weight of silica sol, 5.6% by weight of carboxymethyl cellulose, and 28.4% of water. A number of honeycomb fired bodies were bonded using a heat-resistant sealing material paste containing wt%, and further dried at 120 ° C. to prepare a honeycomb aggregate.
Here, the thickness of the sealing material layer (adhesive layer) was 1.0 mm.

(7) Subsequently, the outer periphery of the honeycomb aggregate was cut using a diamond cutter to produce a cylindrical honeycomb block.

(8) Next, silica-alumina fiber (average fiber length 100 μm, average fiber diameter 10 μm) 23.3 wt% as inorganic fibers, silicon carbide powder 30.3 wt% with an average particle diameter 0.3 μm as inorganic particles, inorganic A sealing material paste was prepared by mixing and kneading 7% by weight of silica sol (content of SiO _{2 in} the sol: 30% by weight) as a binder and 0.5% by weight of carboxymethylcellulose and 39% by weight of water as an organic binder.

Thereafter, a sealing material paste layer having a thickness of 0.2 mm was formed on the outer periphery of the honeycomb block using the sealing material paste. And this sealing material paste layer was dried at 120 degreeC, and the cylindrical honeycomb structure of diameter 143.8mm x length 254mm in which the sealing material layer (coat layer) was formed in the outer periphery was manufactured.

(Example 2)
In the step (2) of Example 1, after the honeycomb formed body was dried, the honeycomb molded body was not temporarily stored, and then the next step was performed. Further, after the step (3) was completed, the sealing material paste was used. The honeycomb molded body that has been filled and dried is placed in the molded body storage container using the honeycomb molded body receiver 140 shown in FIGS. 3A and 4 to 6 and stored for about one week. A honeycomb molded body take-out machine having the same configuration as the honeycomb molded body receiving apparatus 140 was used, and the honeycomb molded body that had been stored and subjected to the drying treatment was taken out and transported to the next process, as in Example 1. A honeycomb structure was manufactured.

(Example 3)
In the step (2) of Example 1, after the honeycomb formed body was subjected to a drying treatment, the honeycomb formed body was not stored temporarily, and then the next step was performed. Further, after the step (5) was completed, the honeycomb formed body was fired. After the body (honeycomb fired body) is placed in the compact storage container and stored for about one week using the honeycomb compact receiver 140 shown in FIGS. 3 (a) and 4-6, the honeycomb compact is received. A honeycomb structure was manufactured in the same manner as in Example 1 except that the honeycomb formed body taking-out machine having the same configuration as the machine 140 was taken out and the stored honeycomb fired body was taken out and transported to the next step.

The honeycomb structures manufactured by the methods of Examples 1 to 3 were provided with the same quality as the honeycomb structures manufactured by a normal method (a method of continuously transporting without storing temporarily). .

FIG. 1 is a perspective view schematically showing an example of a honeycomb structure. FIG. 2A is a perspective view schematically showing a honeycomb fired body constituting the honeycomb structure, and FIG. 2B is a cross-sectional view taken along the line AA. Fig. 3 (a) is a front view schematically showing a honeycomb molded body receiver of the present invention, and (b) shows a storage container lifting device constituting the honeycomb molded body receiver shown in (a). It is a front view shown, (c) is a side view of the storage container lifting device shown in (b), (d) is a storage container support constituting the honeycomb molded body receiver shown in (a) It is a top view of an apparatus, and (e) is a side view of a storage container support device shown in (d). FIG. 4 is a plan view of the honeycomb molded body receiver shown in FIG. FIG. 5 is a side view of the honeycomb molded body receiver shown in FIG. FIG. 6 is an enlarged perspective view showing the vicinity of the storage container lifting device and the storage container moving device constituting the honeycomb molded body receiver shown in FIG. FIGS. 7A and 7B are explanatory views for explaining another configuration of the honeycomb molded body receiver of the present invention.

Explanation of symbols

140, 240, 340 Honeycomb molded body receiver 141 Robot arm 142 Belt conveyors 143, 243, 343 Molded body storage containers 144a, 244a, 344a Belt conveyors 144b, 244b, 344b Belt conveyors 144c, 244c Belt conveyors 144d, 244d Belt conveyors 145 245, 345a, 345b Storage container lifting device 146 Air cylinder 147 Lifting portion 148 Base portion 149 Storage container lifting device 150, 250 Storage container support device 151 Air cylinder 152 Storage container support portion 153 Cylinder support portion 350 Belt conveyor

Claims (9)

After forming a columnar honeycomb formed body in which a large number of cells are arranged in parallel in the longitudinal direction across the cell wall by forming a ceramic raw material, the honeycomb formed body is subjected to one or more treatments including at least a firing treatment. To produce a honeycomb fired body, and further to produce a honeycomb structure using the honeycomb fired body,
The processed honeycomb formed body subjected to the one or more treatments is placed in a formed body storage container and temporarily stored, and then the processed honeycomb formed body placed in the formed body storage container is formed into a formed body. A method for manufacturing a honeycomb structure, wherein the honeycomb structure is taken out from a storage container and conveyed to the next process. A method for manufacturing a honeycomb structured body, wherein after the honeycomb formed body is manufactured, the honeycomb formed body is subjected to at least a drying process and a firing process.
The method for manufacturing a honeycomb structured body according to claim 1, wherein the treated honeycomb formed body to be temporarily stored is a honeycomb formed body that has been subjected to a drying process and / or a firing process. After producing the honeycomb formed body, the honeycomb formed body is at least a drying process, a sealing process and a firing process, a manufacturing method of a honeycomb structure,
The method for manufacturing a honeycomb structured body according to claim 1, wherein the treated honeycomb formed body to be temporarily stored is a honeycomb formed body that has been subjected to at least one of a drying process, a sealing process, and a firing process. The method for manufacturing a honeycomb structure according to any one of claims 1 to 3, wherein the honeycomb formed body receiver is used when the treated honeycomb formed body is placed in a formed body storage container.
A molded body non-storage container input section for stacking and holding empty molded body storage containers,
A first molded body storage container moving mechanism for moving the empty molded body storage container in a vertical direction and / or a horizontal direction, and installing the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body on the transport unit via the holding unit and places the processed honeycomb formed body in an empty formed body storage container installed at the predetermined position; ,
A second molded body storage container moving mechanism that stacks the molded body storage container on which the processed honeycomb molded body is placed, with a molded body storage container on which another processed honeycomb molded body is placed;
A honeycomb molded body receiver, comprising: a molded body stored container take-out unit that stacks and holds the molded body storage containers on which the processed honeycomb molded bodies are placed. The position where the empty molded body storage container is placed when the treated honeycomb molded body is placed is above the position where the molded body storage container on which the treated honeycomb molded body is placed is stacked. 4. A honeycomb molded body receiver according to 4. The honeycomb according to claim 4, wherein a position where the empty molded body storage container is installed when the treated honeycomb molded body is placed is above a position where the stacked empty molded body storage container is held. Molded product receiver. A method for manufacturing a honeycomb structured body according to any one of claims 1 to 3, wherein the honeycomb molded body take-out machine is used when the treated honeycomb molded body is taken out from the molded body storage container.
A formed body storage container input section for stacking and holding the formed body storage container on which the processed honeycomb formed body is placed;
A third molded body storage container moving mechanism for moving the molded body storage container on which the treated honeycomb molded body is placed in the vertical direction and / or the horizontal direction, and setting the molded body storage container at a predetermined position;
A robot arm that lifts and moves the processed honeycomb formed body in the formed body storage container via a holding unit, and places the processed honeycomb formed body on a transport unit;
A fourth molded body storage container moving mechanism for stacking an empty molded body storage container from which the processed honeycomb molded body has been taken out with another empty molded body storage container;
A honeycomb molded body take-out machine, comprising: a molded body non-storage container take-out portion that stacks and holds the empty molded body storage containers. The honeycomb formed body according to claim 7, wherein a position where the formed body storage container is installed when the treated honeycomb formed body is lifted through a holding portion is above a position where the empty formed body storage container is stacked. Unloader. When the processed honeycomb formed body is lifted through the holding unit, the position where the formed body storage container is installed is above the position where the stacked formed body storage container is placed. The honeycomb formed body take-out machine according to claim 7.

Images