JP2008168609A - Molding cutting device, cutting method of ceramic molding, and manufacturing process of honeycomb structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molding cutting device which can cut an extrusion molding while the deformation of a cutting surface after cutting and the readhesion, etc. of a constitution material are prevented. <P>SOLUTION: The molding cutting device comprises a first conveying member for conveying an extrusion molded columnar ceramic molding, a cutting member for cutting the ceramic molding in a predetermined length by moving the first conveying member in parallel with the moving direction of the first conveying member, moving also in a vertical direction and passing the interior of the ceramic molding, and a second conveying member for conveying the ceramic molding cut in a predetermined length by the cutting member. The molding cutting device is characterized in that the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel are approximately the same before the ceramic molding is cut, and in that the conveying speed of the first conveying member, the moving speed of the cutting member in parallel and the conveying speed of the second conveying member are faster in the latter one after the ceramic molding is cut. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a molded body cutting device, a method for cutting a ceramic molded body, and a method for manufacturing a honeycomb structure.

Recently, it has become a problem that particulates such as soot contained in exhaust gas discharged from internal combustion engines such as vehicles such as buses and trucks and construction machinery cause harm 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 uncut formed body is cut into a predetermined length by a formed body cutting device, thereby producing a prism-shaped honeycomb formed body.

Next, the obtained honeycomb formed body is dried, and then a predetermined cell is plugged, and after either end of the cell is sealed with a sealing material layer, a degreasing treatment and a firing treatment are performed. To produce 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 ceramic block, and finally, a seal is formed on the outer periphery of the ceramic block. The manufacturing of the honeycomb structure is completed by applying the material paste to form the sealing material layer (coat layer).

In the present specification, in any form of the honeycomb formed body, the honeycomb fired body, and the honeycomb structure, the surface where the cells are exposed among the surfaces forming the respective outer shapes is referred to as an end surface, and other than the end surfaces. A surface is called a side.

Here, as a device for cutting an uncut ceramic molded body that has been continuously extruded, a cradle is supplied to the lower surface of the molded body that is extruded from the extruder, and the extruded molded body is placed on the cradle. In this state, the cutting tool is moved at the same speed and in the same direction as the moving speed and moving direction of the extruded product while the interval detector detects the interval between the cradles, and the extruded product is cut perpendicular to the moving direction. An automatic cutting device is disclosed (for example, see Patent Document 1).

JP-A-61-241094

With the automatic cutting device described in Patent Document 1, it was possible to automate the conveyance and cutting of the extruded molded body and to cut the molded body so that the cut surface was vertical. However, since this automatic cutting device simply rises to the original position after the extrusion molded body is cut and performs the next cutting process, when the cutting tool is raised, the cut molded body and cutting tool May cause deformation and chipping of the molded body. In addition, the constituent material of the molded body that has adhered to the cutting tool when the extruded molded body is cut may adhere to the cut surface of the molded body when the cutting tool is pulled up. In particular, if the object to be cut is a honeycomb formed body having cells separated by a very thin cell wall, the cell wall may be deformed or chipped by contact with the formed body when the cutting tool rises. This causes a problem that the cell is blocked by the adhesion of the constituent material, which is a problem.

In order to solve the above-mentioned problems, the present inventors have intensively studied, and in the molded body cutting device, the conveying speed of the first conveying member, the moving speed of the cutting member, and the conveying speed of the second conveying member are predetermined. It was found that by setting so as to satisfy the relationship, the ceramic molded body can be cut while preventing deformation on the cut surface after cutting and reattachment of constituent materials, and the present invention has been completed.

That is, the formability cutting device of the present invention includes a first conveying member that conveys an extruded columnar ceramic molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body to a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.
Hereinafter, in this specification, the moving speed of the cutting member in the parallel direction refers to the moving speed when the cutting member moves in a direction parallel to the moving direction of the first conveying member.

The cutting member is preferably a linear body, and it is desirable that a resin is coated around the metal wire.

The molded body cutting device of the present invention preferably has a configuration for moving the linear body every time the ceramic molded body is cut.

The molded body cutting device of the present invention preferably includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction.

The method for cutting a ceramic molded body of the present invention is a method for cutting a ceramic molded body in which an extruded columnar ceramic molded body is cut into a predetermined length using a molded body cutting device,
The molded body cutting device includes a first conveying member that conveys an extruded uncut columnar ceramic molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body to a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.

In the method for cutting a ceramic molded body of the present invention, the cutting member is preferably a linear body, and it is preferable that a metal wire is covered with a resin.

The molded body cutting device used in the method for cutting a ceramic molded body according to the present invention preferably includes a configuration for moving the linear body every time the ceramic molded body is cut.
The molded body cutting device preferably includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction.

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 separated by extruding a ceramic raw material. A honeycomb structure manufacturing method for manufacturing a honeycomb structure made of a honeycomb fired body by cutting the honeycomb molded body into a predetermined length using a molded body cutting device, and then firing the honeycomb molded body.
The molded body cutting device includes a first conveying member that conveys an extruded uncut columnar honeycomb molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the honeycomb molded body into a predetermined length by passing through the inside of the honeycomb molded body. When,
A second conveying member that conveys the honeycomb formed body cut to a predetermined length by the cutting member,
Before cutting the honeycomb formed body, the transport speed of the first transport member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the honeycomb formed body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.

In the method for manufacturing a honeycomb structured body of the present invention, the cutting member is preferably a linear body, and it is desirable that a metal wire is covered with a resin.

Moreover, it is desirable that the molded body cutting apparatus used in the method for manufacturing a honeycomb structured body of the present invention has a configuration for moving the linear body every time the honeycomb molded body is cut.
The molded body cutting device preferably includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction.

According to the molded body cutting device of the present invention, the ceramic molded body is moved in the direction parallel to and perpendicular to the moving direction of the first conveying member, and at substantially the same speed as the moving speed of the first conveying member. Since the moving cutting member is provided, the ceramic molded body can be cut so as to form a cut surface perpendicular to the longitudinal direction.

After cutting the ceramic molded body, (1) the conveying speed of the first conveying member, (2) the moving speed of the cutting member in the parallel direction, and (3) the conveying speed of the second conveying member. Since the relationship of (1) <(2) <(3) is satisfied, the cut molded body and the cutting member do not come into contact with each other at the speed of. Therefore, problems such as deformation of the cut surface of the formed body can be prevented, and in particular, in a honeycomb formed body having cells separated by extremely thin cell walls, cell deformation or chipping does not occur. In addition, since the constituent material attached to the cutting member during the cutting does not adhere to the cut surface again and block the cell, the molded product can be cut with high accuracy and the cut surface has a well-finished surface state. Can be obtained.

If the cutting member is a linear body, the contact area with the ceramic molded body is extremely small, and unnecessary stress or the like is not applied to the ceramic molded body, so that the ceramic molded body is not deformed during cutting. Can be cut easily.
In particular, if the linear body is made of a metal wire, the durability and strength are high, so the replacement frequency due to wear can be reduced, and if the metal wire is covered with a resin, the wire is cut. Since adhesion of the constituent material of the ceramic molded body to the linear body is effectively suppressed at the time and after cutting, the adhesion of the constituent material to the cut surface can be effectively prevented.

In addition, as described above, when a linear body coated with resin is used, adhesion of the constituent materials to the cut surface is effectively suppressed. However, the molded body cutting apparatus has a configuration that further moves the linear body. In this case, since the cutting member can be completely replaced with a new cutting member, the ceramic molded body can be satisfactorily cut without causing a defective cutting product.

When the molded body cutting device of the present invention includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction, the cutting member is moved in the parallel direction and the vertical direction. Can be moved smoothly, and the efficiency of the production line including the full automation of the cutting process can be improved.

In the method for cutting a ceramic molded body of the present invention, the ceramic molded body extruded by using the molded body cutting apparatus of the present invention is cut, so that cutting in a direction perpendicular to the longitudinal direction of the ceramic molded body is efficient and It can be done easily. In addition, after cutting, each speed of the first conveying member, the cutting member, and the second conveying member satisfies a predetermined relationship, so that the cutting member and the ceramic molded body come into contact with each other when the cutting member is raised. There is no. Therefore, it is possible to suppress the occurrence of deformation, chipping or the like in the cut surface of the ceramic molded body, and when the ceramic molded body is the honeycomb molded body, it is possible to prevent the cell from being deformed or chipped. At the same time, the constituent material of the ceramic molded body can be prevented from blocking the cell.

In the method for manufacturing a honeycomb structure of the present invention, the honeycomb formed body continuous from the extruder formed in the extrusion step is cut with the formed body cutting device of the present invention, thereby having a cross section perpendicular to the longitudinal direction, In addition, since a honeycomb formed body having a cut surface can be efficiently produced, it is possible to improve the efficiency of the production line, reduce product loss, and the like.

First, a molded body cutting apparatus and a ceramic molded body cutting method of the present invention will be described with reference to the drawings.
The formability cutting device of the present invention includes a first conveying member that conveys the extruded columnar ceramic molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body to a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.

Further, the method for cutting a ceramic molded body of the present invention is a method for cutting a ceramic molded body in which an extruded columnar ceramic molded body is cut into a predetermined length using a molded body cutting device,
The molded body cutting device includes a first transport member that transports an extruded uncut ceramic molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body to a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.
In the present specification, the “columnar shape” includes an arbitrary columnar shape such as a columnar shape, an elliptical columnar shape, or a polygonal columnar shape.

The target of cutting by the molded body cutting device of the present invention is not particularly limited as long as it is a molded body obtained by extrusion molding, and may be, for example, a honeycomb molded body having a large number of cells penetrating in the longitudinal direction. Further, it may be a simple cylindrical shaped body. Below, the ceramic molded object (honeycomb molded object) which has a honeycomb structure is demonstrated as an example of a ceramic molded object.

Fig.1 (a) is a side view which shows an example of embodiment of the cutting unit which comprises the molded object cutting device of this invention, FIG.1 (b) is the cutting unit which comprises the molded object cutting device of this invention. FIG. 2: (a)-(e) is a side view which shows typically cutting operation | movement of the molded object cutting device of this invention.

As shown in FIG. 2 (a), the molded body cutting device of the present invention is a first transporter that transports an uncut ceramic molded body (hereinafter also referred to as a continuous ceramic molded body) 30 that has been continuously extruded. The continuous ceramic molded body 30 is moved to a predetermined length by moving in the direction parallel to the moving direction of the member 31 and the first conveying member 31 and also in the vertical direction and passing through the continuous ceramic molded body 30. A cutting member 28 that is cut into two pieces and a second conveying member 32 that conveys the ceramic molded body cut by the cutting member 28 are provided. Further, a passage sensor 33 (described later) for detecting the passage of the cut ceramic molded body is installed downstream in the transport direction of the second transport member.
In addition, the arrangement state of the cutting member 28 shown to Fig.2 (a)-(e) expanded the cutting member 28 and the cutting member support part 22 when the cutting unit 20 shown in FIG.1 (b) is seen from a right hand. Corresponding to the state, the cylinder 23 is omitted.

The first transport member 31 and the second transport member 32 have their upper surfaces in the same plane so that the continuous ceramic molded body 30 extruded from the extruder 40 can be transported in a direction parallel to the extrusion direction. And have the same transport direction. Further, the cutting member 28 is arranged so that a cut portion 28 a cut into the continuous ceramic molded body 30 is orthogonal to the longitudinal direction of the continuous ceramic molded body 30.

First, the cutting unit 20 including the cutting member 28 will be described with reference to FIGS. 1 (a) and 1 (b).
As an outline of the cutting unit 20, as shown in FIG. 1B, the base 21 is provided with a delivery bobbin 11 for feeding the cutting member 28 and a take-up bobbin 12 for winding the cutting member 28, and the cutting member 28. Are provided with a plurality of pulleys that guide the feed bobbin 11 to the take-up bobbin 12 through the cutting member support 22. Further, at the time of cutting the continuous ceramic molded body 30, the cutting unit 20 moves at a speed synchronized with the first transport member 31 that transports the continuous ceramic molded body 30 at the same speed as the extrusion speed of the continuous ceramic molded body 30. The cutting member 28 is moved so as to pass through the inside of the continuous ceramic molded body 30 and cut so as to be orthogonal to the longitudinal direction of the continuous ceramic molded body 30.

Specifically, the base 21 of the cutting unit 20 is provided with a delivery bobbin 11 for sending out the cutting member 28 and a take-up bobbin 12 for winding up the cutting member 28, and the cutting member 28 is separated from the sending bobbin 11 with a cutting region. A large pulley 13 that leads to the take-up bobbin 12 and six other pulleys 14, 15, 16, 17, 18, and 19 are provided.

The delivery bobbin 11 has a cylindrical shape, and a large number of cutting members 28 are wound around it. At both ends of the delivery bobbin 11, flange portions orthogonal to the axial direction of the delivery bobbin 11 are provided, so that the wound state of the cutting member 28 can be maintained, and a large amount of the wound cutting member 28 is provided. It can be sent out continuously or intermittently. The large pulley 13 has substantially the same shape as the delivery bobbin 11 and is attached at the same height. For example, when the large pulley 13 reduces the amount of the cutting member 28 wound around the delivery bobbin 11 and the cutting member 28 is delivered from a position lower than the upper portion of the large pulley 13, The cutting member 28 is naturally guided to the next pulley 14 at a low position.

A cutting member support 22 is provided on the lower left side of the base 21, and a cutting member 28 is bridged between pulleys 16 and 17 attached to the end of the cutting member support 22. Moreover, the cutting member support part 22 has the structure which straddles the ceramic molded body by which the extrusion molding was carried out by dropping the base | substrate 21. As shown in FIG. Furthermore, the pulley 14 located diagonally to the lower right of the large pulley 13 can move its position, whereby the tension of the cutting member 28 can be adjusted.

The base 21 provided with such bobbins and pulleys is fixed to a cylinder 23 that can move up and down, and the cylinder 23 is slidable back and forth (that is, parallel to the conveying direction of the ceramic molded body). Stands on the stand 25. The cylinder 23 is an air cylinder or an oil cylinder, and the base 21 can be moved in the vertical direction by adjusting the air pressure or the oil amount. Further, the slide base 25 is screwed into a horizontally provided ball screw 26 so as to move back and forth according to the rotation direction in which the ball screw 26 rotates. That is, the end of the ball screw 26 is connected to the end of the motor 27 by a belt (not shown), and the ball screw 26 rotates as the motor 27 rotates. According to the rotation direction of the ball screw 26, the cylinder 23 and the base 21 fixed to the slide base 25 and the slide base 25 move back and forth.

Thus, since the base 21 is fixed to the cylinder 23 and the cylinder 23 is fixed to the slide base 25, the base 21 can be moved in the front-rear direction and can be moved in the vertical direction. . Accordingly, the substrate 21 is moved in a direction parallel to the movement direction of the first conveying member 31 for conveying the extruded ceramic molded body and in synchronization with the movement, and the substrate 21 is lowered at a predetermined speed, thereby cutting. The member 28 passes through the inside of the ceramic molded body in a direction perpendicular to the longitudinal direction, and can cut the ceramic molded body into a predetermined length. Therefore, the cut surface of the ceramic molded body is formed so as to be orthogonal to the longitudinal direction.

Next, a series of operations for cutting a ceramic molded body using the molded body cutting apparatus of the present invention will be described with reference to FIGS. 2 (a) to 2 (e).
In the molded body cutting apparatus, before the ceramic molded body is cut, the conveying speed of the first conveying member is substantially the same as the moving speed of the cutting member in the parallel direction, and the ceramic molding is performed. After cutting the body, the relationship between the speed of the first transport member, the speed of movement of the cutting member in the parallel direction, and the speed of transport of the second transport member is as fast as the latter. Have.

First, as illustrated in FIG. 2A, the continuous ceramic molded body 30 extruded from the extruder 40 is transported by the first transport member 31 having the transport speed V ₁ that is the same as the extrusion speed. Has been. At this time, the second conveying member 32 conveys the continuous ceramic molded body 30 at the same conveying speed V _{3 as} the conveying speed V ₁ of the first conveying member 31. On the other hand, the cutting member 28 remains stopped at the original position before cutting. Needless to say, the operation of the first conveying member 31 and the second conveying member 32 can be controlled separately.

Next, as shown in FIG. 2B, when the tip of the continuous ceramic molded body 30 reaches the position of the passage sensor 33, the passage sensor 33 detects the passage of the continuous ceramic molded body 30, and passes along with the start of the passage. The start signal is transmitted to a cutting control means (not shown) that controls the operation of the cutting member 28. When the cutting control means receives this passage start signal, the operation of the cutting member 28 is started. When the operation of the cutting member 28 is started, the cutting member 28 moves in a direction parallel to the moving direction of the first conveying member 31 and also moves vertically downward to start cutting the continuous ceramic molded body 30. . In this case, the conveying speed V ₁ of the first conveying member 31, the moving speed V ₂ to said parallel direction of the cutting member 28 is in substantially the same relationship. Therefore, the cutting member 28 moves vertically downward in synchronization with the movement of the continuous ceramic molded body 30, and cuts the continuous ceramic molded body 30 so as to be orthogonal to the longitudinal direction of the continuous ceramic molded body 30. Further, the cutting member support portion 22 descends without touching the continuous ceramic molded body 30, and the cutting member 28 laid on the cutting member support portion 22 cuts the continuous ceramic molded body 30.

In the molded body cutting apparatus 10, the continuous ceramic molded body 30 passes through the passage sensor 33, and the cutting control means receives the passage start signal due to this passage, so that the cutting member 28 starts its operation, so the cutting control means passes. The distance between the passage sensor 33 and the cutting member 28 at the time when the start signal is received is the length of the continuous ceramic molded body 30 after the target cutting (hereinafter also simply referred to as cutting length. This cutting length will be described later. Corresponds to the length in the longitudinal direction of the ceramic molded body 35 shown in FIG. Therefore, the cutting length of the continuous ceramic molded body 30 can be changed to an arbitrary length by changing the arrangement position of the passage sensor 33. For example, if the disposition position of the passage sensor 33 is not the position shown in FIG. 2B but is disposed closer to the extruder 40, the cutting length of the continuous ceramic molded body 30 can be further shortened.

In this way, the cutting length of the continuous ceramic molded body 30 can be changed to an arbitrary length by changing the arrangement position of the passage sensor 33 until the cutting of the continuous ceramic molded body 30 is completed. Since the conveying speed V ₁ of one conveying member 31 and the moving speed V _{2 of the} cutting member 28 in the parallel direction are substantially the same, the cutting length of the continuous ceramic molded body 30 is determined by the passage sensor 33 and the cutting member 28. It is clear from the fact that it depends only on the passage time and does not depend on the respective conveyance speed and movement speed, and is also one of the features of the present invention.
At this time, the transport speed V ₁ of the first transport member 31, the moving speed V ₂ of the cutting member 28 in the parallel direction, and the transport speed V ₃ of the second transport member 32 are V ₁ = V ₂ = V. The relationship of ₃ is satisfied.

Next, while passing through the inside of the continuous ceramic molded body 30, the cutting member 28 moves vertically downward at a predetermined speed to the position shown in FIG. 2C to cut the continuous ceramic molded body 30. Thereafter, the cutting member 28 rises and returns to the original position for the next cutting process. Here, in the molded body cutting apparatus of the present invention, the cutting member 28 does not simply rise after cutting, but the first conveying member 31, the cutting member 28, and the second conveying member 32 have a predetermined speed relationship. Since it rises while having, it can prevent the deformation | transformation of a cell of a ceramic molded body, a chip, etc., and it can prevent that the constituent material adhering to a cutting member adheres to a cut surface, and plugs up a cell. it can. The position of the cutting member 28 immediately after the cutting of the continuous ceramic molded body 30 is defined as position I, and the position of the end portion of the second conveying member 32 facing the first conveying member 31 is defined as position II. Details of the operation of each member constituting the molded body cutting apparatus 10 after cutting 30 will be described.

In the molded body cutting device 10, after cutting the continuous ceramic molded body 30, the transport speed V _{1 of} the first transport member 31, the moving speed V _{2 of} the cutting member 28 in the parallel direction, and the second transport member. the conveying speed V ₃ of the faster the latter. That is, after the continuous ceramic molded body 30 is cut, the speed of each member has a relationship of V ₁ <V ₂ <V ₃ .

When the cutting of the continuous ceramic molded body 30 by the cutting member 28 is completed, the cutting unit 20 detects the completion of cutting (detects the completion of cutting when it has moved vertically downward by a predetermined distance), and the cutting member 28 is parallel. The moving speed in the direction is set to V ₂ that satisfies the above relationship, the cutting member 28 is started to move vertically upward, and the transfer control means (FIG. 5) controls the transfer operation of the second transfer member 32. A disconnection completion signal is transmitted to (not shown). When receiving the disconnection completion signal said conveyance control means changes the conveyance speed V ₃ of the second conveying member 32 so as to satisfy the relation of the speed.

After the continuous ceramic molded body 30 is cut, the first conveying member 31, the cutting member 28, and the second conveying member 32 have the above-described speed relationships. Due to this speed relationship, after a predetermined time t _{1 has} elapsed from the completion of cutting, as shown in FIG. 2D, the rear end portion of the cut ceramic molded body 35, the cutting member 28, and a new cutting are performed. Each of the leading end portions of the continuous ceramic molded body 36 is located at a position away from the position I by a predetermined distance in accordance with the speed in the extrusion molding direction. Specifically, the rear end portion of the ceramic molded body 35 is located at the position farthest from the position I, the distal end portion of the continuous ceramic molded body 36 is located closest to the position I, and the cutting member 28 is the ceramic molded body 35. It is located between the rear end portion and the front end portion of the continuous ceramic molded body 36.

According to the molded body cutting apparatus 10, the speed as the moving speed V ₂ of the parallel direction of the conveying speed V ₁ and the cutting member 28 and the conveyance speed V ₃ of the second conveying member 32 of the first conveyance member 31 Thus, after the continuous ceramic molded body 30 is cut, the rear end portion of the ceramic molded body 35, the cutting member 28, and the front end portion of the continuous ceramic molded body 36 that is newly continuously extruded are: The positional relationship is as described above.

Next, while satisfying the above speed relation, the first conveying member 31, the cutting member 28 and the second conveying member 32 and are actuated respectively, the ceramic molded body 35 from the cutting completion after a predetermined time t ₂ has elapsed, The cutting member 28 and the continuous ceramic molded body 36 have a positional relationship as shown in FIG. That is, in the ceramic molded body 35 conveyed by the second conveying member 32 having the highest speed, the rear end portion thereof has passed through the passage sensor 33. Moreover, in the continuous ceramic molded body 36 conveyed by the 1st conveyance member 31 with the lowest speed, the front-end | tip part is conveyed to the position of the edge part (position II in the figure) of the 2nd conveyance member 32. Yes. In the cutting member 28, the position in the direction parallel to the conveying direction is between the rear end portion of the ceramic molded body 35 and the front end portion of the continuous ceramic molded body 36, and the vertical position is as high as the original position. In the raised position.

When the passage sensor 33 no longer detects the presence of the ceramic molded body 35, in other words, when the rear end portion of the ceramic molded body 35 exits the passage sensor 33, the passage sensor 33 is connected to the second conveying member 32. A passage completion signal is transmitted to the conveyance control means for controlling the operation. When the transport control means receives this passage completion signal, the transport speed V ₃ of the second transport member 32 is changed and set to the same speed as the transport speed V _{1 of} the first transport member 31. Thereby, even if the continuous ceramic molded body 36 to be newly cut is transported by the first transport member 31, passes through the position II, and is placed on the second transport member 32, the first Since the conveying speed of the conveying member 31 and the conveying speed of the second conveying member 32 are the same speed, there is no tensile stress or compressive stress on the continuous ceramic molded body 36, so that the next cutting process can be performed smoothly. Can be provided.
As described above, the transport speed V ₃ of the second transport member 32 is desirably the same speed as the transport speed V _{1 of} the first transport member 31 before cutting, but the continuous ceramic molded body. Unless the deformation that lowers the quality of 30 and 36 occurs, the transport speed V ₃ of the second transport member 32 is greater than the transport speed V _{1 of} the first transport member 31 before and after cutting. May be.

For cutting member 28, after the time t ₂ has elapsed from completion of cutting, as shown in FIG. 2 (e), it has risen to the same height as the original position (see FIG. 2 (a)), then, to the original position Move and wait for the next disconnection process. During the movement from the position shown in FIG. 2E to the original position, the delivery bobbin 11 and the take-up bobbin 12 are operated, and the cutting member 28 used for the previous cutting process is moved by a predetermined length. Move to send and replace with new cutting member. And if the front-end | tip part of the ceramic molded body which will be cut | disconnected newly reaches | attains a passage sensor, a new cutting member will start the movement to the perpendicular downward direction, and will perform the cutting process of a ceramic molded body. The replacement of the cutting member 28 by the operation of the delivery bobbin 11 and the take-up bobbin 12 may be performed during standby for the next cutting process.
By repeating the above procedure, the ceramic molded body extruded from the extruder can be continuously cut.

The cutting member is preferably a linear body.
The cutting member 28 at the time of cutting the ceramic molded body is not particularly limited, and examples thereof include a cutter, a laser, a linear body, and the like in which a blade is formed at a cut portion. Considering the contact area, running cost, etc., a linear body is desirable. When a linear body is used, the contact area with the ceramic molded body is extremely small, so even if the cells of the ceramic molded body come into contact, cracks, shear deformation, or other deformation or chipping does not occur. Thus, it is desirable because it does not require an accessory device or the like and the running cost can be kept low.

When the cutting member is a linear body, the diameter of the linear body is not particularly limited, but is preferably 0.05 to 0.5 mm.
If the diameter of the linear body is less than 0.05 mm, the strength decreases and the durability decreases. On the other hand, if the diameter exceeds 0.5 mm, the contact area with the ceramic molded body increases and the cut surface is deformed. May occur.

Furthermore, it is desirable that the linear body has a metal wire covered with a resin.
The cutting member 28 is not particularly limited and may be a metal wire or a resin wire. However, a metal wire is preferable in consideration of durability and the like, and a resin is preferable in consideration of non-adhesiveness. Therefore, from these points, a resin wire coated around a metal wire such as SUS is preferable. The resin coated around the metal wire is not particularly limited, and examples thereof include resins such as nylon, polyester, polyvinyl alcohol, and polyacryl.

In the molded body cutting apparatus 10 having the above configuration, a thin cutting member 28 in which a resin is coated around a metal wire is used. While the cutting member 28 moves in synchronization with the extrusion speed of the ceramic molded body, the ceramic molded body is cut into a predetermined length by passing through the inside of the ceramic molded body. Therefore, the area where the cutting member 28 is in contact with the ceramic molded body at the time of cutting is extremely small. Therefore, the molded body can be cut well without affecting the shape of the molded body, the shape of the cells, and the like. it can.

Moreover, it is desirable that the molded body cutting apparatus of the present invention has a configuration for moving the linear body every time the ceramic molded body is cut.
In the cutting unit 20 including the cutting member 28, when the cutting member 28 is a linear body, a new linear body is sent out each time cutting is performed, and the next continuous body is used using the new linear body. Since the ceramic molded body 30 is cut, disconnection of the linear body can be prevented. In addition, the movement of the linear body can prevent the occurrence of defective cutting due to the adhesion of the ceramic molded body component to the cutting member 28, and the ceramic molded body adhered during the previous cutting process can be prevented. It is possible to prevent the constituent material from adhering to the ceramic molded body at the time of new cutting, and it is possible to perform cutting well. In addition, after all the cutting members 28 are wound up by the winding bobbin 12, the cutting members 28 can be reused by wiping away the constituent material of the ceramic molded body adhering to the cutting members 28. The cutting member 28 may be wiped immediately after cutting.

The molded body cutting device of the present invention preferably includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction.
As the mechanism for moving the cutting member in a direction parallel to the moving direction of the first conveying unit, the above-described ball screw is preferable, but is not limited to the ball screw, and includes, for example, a conveyor mechanism, a linear guide, a cross roller guide, A drive mechanism such as a dynamic actuator or a rotary actuator can also be used suitably. Further, the above-described cylinder is desirable as a mechanism for moving the cutting member in the vertical direction, but is not limited to the cylinder. For example, a mechanism such as a ball screw is used similarly to the mechanism for moving the cutting member in the parallel direction. Also good.

The constituent material of the contact portion of the first transport member and the second transport member with the ceramic molded body is not particularly limited, and examples thereof include natural rubber, resins such as nylon, urethane, and polyester. Further, the contact portion formed of these constituent materials may have a sponge shape or a shape in which long fibers are entangled with each other, and may have a shape that can be elastically deformed when a predetermined stress is applied. If the contact portion has such a shape, when the cutting member passes through the inside of the ceramic molded body and reaches the lower surface of the ceramic molded body, the cutting member can further sink into the contact portion. The molded body can be completely cut.

When the cutting member 28 reaches the position I, the cutting of the continuous ceramic molded body 30 is completed (see FIG. 2C). At this time, the rear end portion of the ceramic molded body 35 is on the first conveying member 31. Then, the ceramic molded body 35 is conveyed according to the conveyance speed of the second conveyance member 32 that is faster than the conveyance speed of the first conveyance member 31. Therefore, friction occurs between the rear end portion of the ceramic molded body 35 and the first transport member 31 between the position I and the end portion of the first transport member 31. However, since the contact portion of the first conveying member 31 with the continuous ceramic molded body 30 is composed of the above-described constituent material and is a smooth surface, the friction is small enough to be ignored. There is no effect on the surface of the ceramic molded body.

In addition, although the continuous ceramic molded object after continuous extrusion molding was demonstrated as a to-be-cut body as the object of cutting by the molded body cutting apparatus of the present invention, the cut object is a continuous ceramic if it is a ceramic formed body. It is not limited to a molded body, and may be any ceramic molded body having another shape.

Next, the method for cutting the ceramic molded body of the present invention will be described.
As the molded body cutting apparatus used in the method for cutting a ceramic molded body of the present invention, the above-described molded body cutting apparatus of the present invention can be suitably used. The explanation will be focused on the conditions at the time.

The lowering speed of the cutting member during cutting is preferably 0.6 to 30 m / min.
When the descending speed is less than 0.6 m / min, the ceramic molded body is deformed with respect to the stress at the time of cutting, or the cutting processing efficiency is lowered. On the other hand, if it exceeds 30 m / min, the cutting process itself is accelerated, the load on the cutting unit including the cutting member is increased, and the deterioration and consumption of the device may progress quickly.

When the cutting member is a linear body, the tension of the linear body is preferably 2 to 8N.
If the tension of the linear body is less than 2N, so-called deflection may occur in the linear body during cutting, and good cutting may not be performed. On the other hand, if it exceeds 8 N, the tensile strength of the linear body will be exceeded, so the durability will be reduced, or damage will occur due to an excessive load applied to the delivery bobbin or pulley that sends out the cutting member that is a linear body. It becomes easy to do.

In the method for cutting a ceramic molded body of the present invention, after the ceramic molded body is cut, the conveying speed V ₁ of the first conveying member (hereinafter also simply referred to as V ₁ ) and the moving speed V ₂ of the cutting member in the parallel direction. The relationship of V ₁ <V ₂ <V ₃ is established as a relationship between (hereinafter also simply referred to as V ₂ ) and the conveyance speed V ₃ of the second conveyance member (hereinafter also simply referred to as V ₃ ). Here, an example of the variation of the operation order of each member will be described with reference to FIGS.

First, as shown in FIG. 2 (c), the state of the time t = 0 the state of cutting completion of the ceramic molded body, the state as shown from which the predetermined time t ₁ after a lapse of example FIG. 2 (d) the time t = _{t 1} (hereinafter, simply referred to as _{t 1)} and the state of, further, a state as shown from the cutting completion predetermined time _{t 2} after a lapse of example FIG. 2 (e) time t = _{t 2} (hereinafter , Simply referred to as t ₂ ).

Here, in the description of the molded body cutting apparatus according to the present invention, in the state of FIG. 2D where t = t ₁ , the cutting member 28 is parallel to the moving speed V ₂ that satisfies the above-mentioned relationship at the same time as the cutting is completed. It explained that it was moving and also moving vertically.

However, the speed relationship of each member, the timing of movement, and the like are not limited to the above order. For example, when t = 0, V ₁ = V ₂ = V ₃ , and when 0 <t <t ₁ , Only the conveying speed of the second conveying member 32 is changed without moving the cutting member 28 vertically upward so that V ₁ = V ₂ <V ₃ , and when t ₁ ≦ t ≦ t ₂ , the cutting member 28 is moved vertically. may be _V 1 _<V 2 _{<V 3} by changing the moving speed _{V 2} in a direction parallel while moving upward.

In this case, first, at 0 <t <t ₁ , only the rear end portion of the ceramic molded body 35 moves away from the front end portion of the continuous ceramic molded body 36 and the cutting member 28. Therefore, the cutting member 28 remains positioned at the lower end of the tip portion of the continuous ceramic molded body 36. Thereafter, V ₂ is changed so as to satisfy the relationship of V ₁ <V ₂ <V ₃ at t ₁ ≦ t ≦ t ₂ , so that the cutting member 28 is parallel so as to be separated from the tip of the continuous ceramic molded body 36. moved and vertical parallel, the time t ₂ in the state shown in FIG. 2 (e).

In addition to the above example, for example, V ₁ = V ₂ = V ₃ at t = 0, and when 0 <t <t ₁ , V ₁ <V ₂ <while moving the cutting member 28 vertically upward. V ₃ may be set, and in the case of t ₁ ≦ t ≦ t ₂ , V ₁ = V ₂ <V ₃ while the cutting member 28 is moved vertically upward.
In any case, the cutting member 28 can be raised to the same height as the original position without contacting the ceramic molded body 35 and the continuous ceramic molded body 36, and a series of cutting processes can be performed efficiently and in a trouble. Can be done without waking up.
As described above, some of the variations in the operation order of each member after cutting have been exemplified, but the present invention is not limited to these embodiments.

Here, the ratio of the speed between the transport speed V _{1 of} the first transport member 31, the moving speed V _{2 of the} cutting member 28 in the parallel direction, and the transport speed V _{3 of} the second transport member 32 is V _{1 <V} 2 <is not particularly limited as long as it satisfies the relationship of _{V 3,} a _V 2 _{/ V} 1 = _3~7 If based on velocity _{V 1,} it is V ₃ / V 1 = 5~10 Is desirable.
When V ₁ , V ₂ , and V ₃ are set so as to satisfy the above speed ratios, the cutting member 28 is cut into the ceramic molded body 35 after cutting or the continuous ceramic molded body 36 to be newly cut. It can raise to the same height as an original position, without applying excessive load to each member which constitutes a forming object cutting device, without contacting.

Note that the conveying speed _{V 3} of the second conveying member 32, only between the cutting completion of _{t 2} may satisfy the above relationship _{(V 1 <V 2 <V} 3). As described above, the time until the ceramic molded body 35 is cut exits through the passage sensor 33 is equal to t _2, then the tip portion of the continuous ceramic molded body 36 that is to be newly cut This is because it is placed on the second conveying member 32 beyond the position II. Accordingly, a value (L / t ₂ ) obtained by dividing the length in the longitudinal direction of the ceramic molded body 35 (here, L for convenience) by the time t ₂ can be used as the set value of V _3. . Further, the size of V ₃ may be appropriately increased or decreased based on (L / t ₂ ). For example, the setting is such that a half of the total length of the ceramic molded body 35 passes through the passage sensor 33. If so, V ₃ may be halved. That is, the value of V ₃ in this case is a value obtained by dividing (L / t ₂ ) by 2.

Next, the manufacturing method of the 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 separated by extruding a ceramic raw material. A honeycomb structure manufacturing method for manufacturing a honeycomb structure made of a honeycomb fired body by cutting the honeycomb molded body into a predetermined length using a molded body cutting device, and then firing the honeycomb molded body.
The molded body cutting device includes a first conveying member that conveys an extruded uncut columnar honeycomb molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the honeycomb molded body into a predetermined length by passing through the inside of the honeycomb molded body. When,
A second conveying member that conveys the honeycomb formed body cut to a predetermined length by the cutting member,
Before cutting the honeycomb formed body, the transport speed of the first transport member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the honeycomb formed body is cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member are higher as the latter. To do.

FIG. 3 is a perspective view schematically showing an example of the honeycomb structure, and FIG. 4A is a perspective view schematically showing the honeycomb fired body constituting the honeycomb structure, and FIG. ) Is a cross-sectional view taken along line AA.

In the honeycomb structure 130, a plurality of honeycomb fired bodies 140 as shown in FIGS. 4 (a) and 4 (b) are bundled through a sealing material layer (adhesive layer) 131 to form a ceramic block 133. A sealing material layer (coat layer) 132 is formed on the outer periphery of the ceramic block 133.
In addition, as shown in FIGS. 4A and 4B, the honeycomb fired body 140 has a large number of cells 141 arranged in the longitudinal direction, and the cell walls 143 separating the cells 141 function as a filter. ing.

That is, in the cell 141 formed in the honeycomb fired body 140, as shown in FIG. 4B, either the inlet side or the outlet side end of the exhaust gas is plugged by the sealing material layer 142, and one cell The exhaust gas that has flowed into 141 always passes through the cell wall 143 that separates the cell 141 and then flows out from the other cell 141. When the exhaust gas passes through the cell wall 143, the particulates are separated from the cell wall 143. 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 the order of steps.
Here, a method for manufacturing a honeycomb structure when silicon carbide powder, which is a ceramic raw material, is used will be described, 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. Examples of other ceramic raw materials include nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, and titanium nitride, zirconium carbide And carbide ceramics such as titanium carbide, tantalum carbide, and tungsten carbide, and oxide ceramics such as alumina, zirconia, cordierite, mullite, and aluminum titanate.
Of these, non-oxide ceramics are preferred, and silicon carbide is particularly preferred. It is because it is excellent in heat resistance, mechanical strength, thermal conductivity and the like. In addition, ceramic raw materials such as silicon-containing ceramics in which metallic silicon is blended with the above-described ceramics, ceramics bonded with silicon or a silicate compound can be cited as constituent materials, and among these, silicon carbide is blended with silicon carbide. (Silicon-containing silicon carbide) is desirable.

First, as a ceramic raw material, an inorganic powder such as silicon carbide powder having a different average particle size and an organic binder are dry mixed to prepare a mixed powder, and a liquid plasticizer, a lubricant and water are mixed to prepare a mixed liquid. Then, a wet mixture for producing a molded body is prepared by 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 size of 1 to 5 is preferred.
In order to adjust the pore diameter and the like of the honeycomb fired body, it is necessary to adjust the firing temperature, but the pore diameter can be adjusted by adjusting the particle size of the inorganic 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 raw material powder.

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 8.0 to 20.0% by weight.

The wet mixture is transported after preparation and put into a molding machine.
After the wet mixture is put into an extruder, a honeycomb formed body having a predetermined shape is formed by extrusion. The honeycomb formed body is cut into a predetermined length by a formed body cutting device.

A molded body cutting apparatus used in the method for manufacturing a honeycomb structure of the present invention includes a first transport member that transports an extruded uncut columnar honeycomb molded body, and a moving direction of the first transport member. A cutting member that cuts the honeycomb formed body into a predetermined length by moving in the parallel direction and also moving in the vertical direction and passing through the inside of the honeycomb formed body, and a predetermined length by the cutting member A second conveying member that conveys the honeycomb molded body cut into two pieces, and before cutting the honeycomb molded body, the conveying speed of the first conveying member and the movement of the cutting member in the parallel direction After the honeycomb formed body is cut, the speed of the first transport member, the speed of movement of the cutting member in the parallel direction, and the speed of transport of the second transport member are substantially the same. Is faster than the latter And wherein the door.
As such a molded body cutting apparatus, the molded body cutting apparatus of the present invention can be suitably used, and as a method of cutting a honeycomb molded body using this molded body cutting apparatus, the ceramic of the present invention can be used. The cutting method of a molded object can be employ | adopted suitably. Accordingly, details of the configuration, operation, and effects are omitted here.

In the method for manufacturing a honeycomb structured body of the present invention, the cutting member is preferably a linear body.
If the cutting member is a linear body, since the contact area at the time of cutting is extremely small, excessive stress does not occur. Therefore, even if the body to be cut has plastic deformation like the ceramic molded body, It can cut well.

In addition, when the cutting member is a linear body, it is desirable that the metal wire is covered with a resin.
The constituent material of the ceramic molded body may contain a molding aid, an organic component, or the like in order to impart moldability. If such an additive is contained in the constituent material, the ceramic molded body itself becomes sticky, and the constituent material may adhere to the cutting member when it is cut. However, if the linear body is a metal wire coated with a resin, the adhesion of the above constituent materials can be minimized, and the durability can be improved because it is a metal wire. Can do.

Moreover, it is desirable that the molded body cutting device used in the method for manufacturing a honeycomb structured body of the present invention has a configuration for moving the linear body every time the ceramic molded body is cut.
With such a configuration, it is possible to prevent the occurrence of a defective cutting product during a new cutting process caused by the constituent material attached at the previous cutting, the reattachment of the constituent material to the cut surface, or the like. .

Furthermore, it is desirable that the molded body cutting device includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in the vertical direction.
This is because the cutting process of the ceramic molded body can be performed smoothly and is suitable for the promotion of full automation.

As described above, in the method for manufacturing a honeycomb structured body of the present invention, the honeycomb structure is extruded from an extruder without causing deposits or the like on the cut surface and preventing deformation or chipping of the cut surface. The ceramic molded body can be cut perpendicularly to the longitudinal direction and with a predetermined length.

Next, the honeycomb formed body is dried using a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer, or the like to obtain a dried honeycomb formed body.

Here, a cutting step of cutting both ends of the honeycomb formed body produced using the cutting device is performed, and the honeycomb formed body is cut into a predetermined length. Thereby, the shrinkage | contraction of the honeycomb molded object at the time of drying can be disregarded.

Then, if necessary, the end side of the inlet side cell group and the end side of the outlet side cell group at the inlet side are filled with a predetermined amount of sealing material paste as a sealing material, and the cells are To seal. When sealing the cells, a sealing mask is applied to the end face of the honeycomb formed body (that is, the cut surface after the cutting step), and only the cells that need to be sealed are filled with the sealing material paste.

Although it does not specifically limit as said sealing material paste, The thing from which the porosity of the sealing material manufactured through a post process becomes 30 to 75% is desirable, For example, the thing similar to the said wet mixture can be used. .

The sealing material paste may be filled as necessary. When the sealing material paste is filled, for example, a honeycomb structure obtained through a subsequent process is preferably used as a honeycomb filter. In the case where the sealing material paste is not filled, for example, a honeycomb structure obtained through a subsequent process can be suitably used as a catalyst carrier.

Next, the honeycomb molded body filled with the sealing material paste is degreased (for example, 200 to 500 ° C.) under predetermined conditions, and then fired (for example, 1400 to 2300 ° C.), so that the whole A honeycomb fired body composed of a fired body, in which a plurality of cells are arranged in parallel in the longitudinal direction across a cell wall, and either one end of the cells is sealed (FIGS. 4A and 4B). )) Can be manufactured.

As the conditions for degreasing and firing the honeycomb formed body, the conditions conventionally used when manufacturing a filter made of a porous ceramic can be applied.

Next, a sealing material paste serving as a sealing material layer (adhesive layer) is applied to the side surface of the honeycomb fired body with a uniform thickness to form a sealing material paste layer. The process of laminating other honeycomb fired bodies is repeated to produce an aggregate of honeycomb fired bodies having a predetermined size.

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.

Next, the aggregate of the honeycomb fired bodies is heated to dry and solidify the sealing material paste layer to form a sealing material layer (adhesive layer).
Next, using a diamond cutter or the like, an aggregate of honeycomb fired bodies in which a plurality of honeycomb fired bodies are bonded via a sealing material layer (adhesive layer) is cut to produce a cylindrical ceramic block.

A cylindrical shape in which a plurality of honeycomb fired bodies are bonded via a sealing material layer (adhesive layer) by forming a sealing material layer (coating material layer) on the outer periphery of the ceramic block using the sealing material paste. A honeycomb structure in which a sealing material layer (coating material layer) is provided on the outer periphery of the ceramic block can be obtained.

Thereafter, if necessary, a catalyst is supported on the honeycomb structure. The catalyst may be supported on the honeycomb fired body before producing the aggregate.
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 honeycomb structure manufactured by the method for manufacturing a honeycomb structure described so far is a collective honeycomb structure having a configuration in which a plurality of honeycomb fired bodies are bundled through a sealing material layer (adhesive layer). However, the honeycomb structure manufactured by the manufacturing method of the present invention may be an integrated honeycomb structure in which a columnar ceramic block is composed of one honeycomb fired body. Here, the main constituent material of the integral honeycomb structure is preferably cordierite or aluminum titanate.

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 method similar to that used for producing can be used. Also in this method, the honeycomb formed body is cut by the formed body cutting device to produce the honeycomb formed body.

Next, similarly to the production of the aggregated honeycomb structure, the honeycomb formed body is dried using a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer, or the like. .
Next, a cutting process for cutting both end portions of the dried honeycomb formed body is performed.

Next, a predetermined amount of a sealing material paste serving as a sealing material is filled in the outlet side end portion of the inlet side cell group and the inlet side end portion of the outlet side cell group to seal the cells.
Thereafter, in the same manner as the production of the aggregated honeycomb structure, a ceramic block is produced by performing degreasing and firing, and if necessary, a sealing material layer (coating material layer) is formed, whereby an integral honeycomb structure is produced. The body can be manufactured. Further, the above-mentioned integral honeycomb structure may be loaded with a catalyst by the method described above.

As described above, the honeycomb structure manufacturing method of the present invention described above can manufacture a honeycomb structure with high work efficiency.
Further, when a honeycomb structure is manufactured by the above-described method, the honeycomb formed body is cut using a predetermined formed body cutting apparatus, so that there is no cell deformation or chipping on the cut surface, and there is no deposit or the like. A honeycomb formed body having an appropriate cut surface can be easily produced. In addition, the cutting of the honeycomb formed body, the change of the cutting length, and the like can be performed fully automatically continuously with the extrusion molding, so that the production line can be made more efficient.

Further, here, the honeycomb structure has been described mainly with respect to a honeycomb filter used for the purpose of collecting particulates in exhaust gas. However, the honeycomb structure is also suitable as a catalyst carrier (honeycomb catalyst) for purifying exhaust gas. Can be used.

The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to these examples.

In the honeycomb molded body cutting step of the method for manufacturing a honeycomb structured body of the present invention, the method for cutting a ceramic molded body of the present invention was adopted to cut the honeycomb molded body. The cutting conditions at this time were changed, and the influence on the shape near the cut surface of the obtained honeycomb formed body was evaluated.

(Example 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 (methylcellulose) 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.
The moisture content of the wet mixture prepared here was 14% by weight.

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.
In addition, the moisture content of the wet mixture immediately before feeding the extruder was 13.5% by weight.
A continuous honeycomb molded body having a cross-sectional shape (unsealed state) shown in FIGS. 4A and 4B was produced by extrusion molding.

Next, the extruded honeycomb formed body was cut under the conditions shown in Table 1 using the formed body cutting apparatus of the present invention shown in FIGS. 1 (a) and 1 (b) and FIGS. 2 (a) to 2 (e). A honeycomb molded body was produced. Specifically, the wet mixture was extruded from the extruder 40 at an extrusion speed of 3.3 m / min, and the resulting continuous honeycomb formed body 30 was cut using a linear body as the cutting member 28.
As the linear body, seven strands made of SUS313 having a diameter of 0.03 mm were twisted into S and the periphery thereof was coated with a nylon resin. The diameter of this linear body was 0.09 ± 0.01 mm, and the twist pitch was 1.08 ± 0.10 mm.
The diameter d [mm] of the linear body at this time, the tension T [N] of the linear body, the transport speed V ₁ [m / min] of the first transport member after cutting, and the movement of the cutting member in the parallel direction Speed V ₂ [m / min], transport speed V ₃ [m / min] of the second transport member, ratio of speed V ₂ to speed V ₁ (V ₂ / V ₁ ), speed V ₃ to speed V ₁ The ratio (V ₃ / V ₁ ) is shown in Table 1.

(Examples 2 and 3)
A honeycomb formed body was cut in the same manner as in Example 1 except that the diameter of the linear body serving as the cutting member was changed to the value shown in Table 1.

(Examples 4 and 5)
Example 1 except that after the honeycomb formed body was cut, the conveyance speed of the first conveyance member, the movement speed of the cutting member in the parallel direction, and the conveyance speed of the second conveyance member were set to the values shown in Table 1. In the same manner as above, the honeycomb formed body was cut to prepare a honeycomb formed body.

(Comparative Example 1)
Similar to Example 1, except that the conveying speed of the first conveying member, the moving speed of the cutting member in the parallel direction, and the conveying speed of the second conveying member after cutting the honeycomb formed body were set to the same value. The honeycomb formed body was cut to produce a honeycomb formed body.

(Evaluation of cut surface of ceramic molded body)
The honeycomb molded bodies produced in the examples and comparative examples were each visually evaluated for the shape near the outer peripheral portion of the cut surface, cell deformation, chipping or cracking, and the presence or absence of deposits.
The results are shown in Table 1.

As is clear from Table 1, there is no cell deformation, chipping or cracking on the cut surfaces of the honeycomb formed bodies produced in Examples 1 to 5, and there are no deposits or the like. Thus, it was confirmed that the honeycomb formed body was cut well.

On the other hand, on the cut surface of the honeycomb formed body produced in Comparative Example 1, some deformation was observed at the outer peripheral portion of the cut surface, and cell deformation, chipping and cracks were slightly confirmed. It was also confirmed that there were deposits that seemed to be constituent materials when the honeycomb formed body was cut.

Fig.1 (a) is a side view which shows an example of embodiment of the cutting unit which comprises the molded object cutting device of this invention, FIG.1 (b) is the cutting unit which comprises the molded object cutting device of this invention. It is a front view showing an example of the embodiment. 2A to 2E are side views schematically showing a cutting operation of the molded body cutting apparatus of the present invention. FIG. 3 is a perspective view schematically showing an example of a honeycomb structure. FIG. 4A is a perspective view schematically showing a honeycomb fired body constituting the honeycomb structure, and FIG. 4B is a cross-sectional view taken along line AA.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Form body cutting device 11 Delivery bobbin 12 Take-up bobbin 13 Large pulley 14, 15, 16, 17, 18, 19 Pulley 20 Cutting unit 21 Base 22 Cutting member support part 23 Cylinder 25 Slide stand 26 Ball screw 27 Motor 28 Cutting member 28a Cut portions 30, 35, 36 Ceramic molded body (honeycomb molded body)
31 First conveying member 32 Second conveying member 33 Passing sensor 40 Extruder

Claims (15)

A first conveying member that conveys the extruded columnar ceramic molded body;
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body into a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the transport speed of the first transport member, the moving speed of the cutting member in the parallel direction, and the transport speed of the second transport member are higher as the latter. Forming body cutting device. The molded body cutting device according to claim 1, wherein the cutting member is a linear body. The molded body cutting apparatus according to claim 2, wherein the linear body has a metal wire coated with a resin. The molded body cutting device according to claim 2 or 3, comprising a configuration for moving the linear body each time the ceramic molded body is cut. The molded body cutting device according to any one of claims 1 to 4, further comprising: a ball screw that moves the cutting member in the parallel direction; and a cylinder that moves the cutting member in the vertical direction. A method of cutting a ceramic molded body, in which an extruded columnar ceramic molded body is cut into a predetermined length using a molded body cutting device,
The molded body cutting device includes a first conveying member that conveys an extruded uncut columnar ceramic molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the ceramic molded body into a predetermined length by passing through the inside of the ceramic molded body. When,
A second conveying member that conveys the ceramic molded body cut to a predetermined length by the cutting member;
Before cutting the ceramic molded body, the conveying speed of the first conveying member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the ceramic molded body is cut, the transport speed of the first transport member, the moving speed of the cutting member in the parallel direction, and the transport speed of the second transport member are higher as the latter. A method for cutting a ceramic molded body. The method for cutting a ceramic molded body according to claim 6, wherein the cutting member is a linear body. The method for cutting a ceramic molded body according to claim 7, wherein the linear body is formed by coating a resin around a metal wire. The method for cutting a ceramic molded body according to claim 7 or 8, wherein the molded body cutting device includes a configuration for moving the linear body every time the ceramic molded body is cut. The said molded object cutting device is equipped with the ball screw which moves the said cutting member in the said parallel direction, and the cylinder which moves the said cutting member to a perpendicular direction, The cutting method of the ceramic molded object in any one of Claims 6-9 . 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 extruding the ceramic raw material, the honeycomb formed body is formed into a predetermined length using a formed body cutting device. And then firing the honeycomb formed body to manufacture a honeycomb structure made of the honeycomb fired body,
The molded body cutting device includes a first conveying member that conveys an extruded uncut columnar honeycomb molded body,
A cutting member that moves in a direction parallel to the moving direction of the first conveying member and also moves in the vertical direction and cuts the honeycomb molded body into a predetermined length by passing through the inside of the honeycomb molded body. When,
A second conveying member that conveys the honeycomb formed body cut to a predetermined length by the cutting member,
Before cutting the honeycomb formed body, the transport speed of the first transport member and the moving speed of the cutting member in the parallel direction are substantially the same,
After the honeycomb formed body is cut, the transport speed of the first transport member, the moving speed of the cutting member in the parallel direction, and the transport speed of the second transport member are higher as the latter. A method for manufacturing a honeycomb structure. The method for manufacturing a honeycomb structured body according to claim 11, wherein the cutting member is a linear body. The method for manufacturing a honeycomb structured body according to claim 12, wherein the linear body has a metal wire coated with a resin. The method for manufacturing a honeycomb structured body according to claim 12 or 13, wherein the molded body cutting device is configured to move the linear body every time the honeycomb molded body is cut. The method for manufacturing a honeycomb structure according to any one of claims 11 to 14, wherein the molded body cutting device includes a ball screw that moves the cutting member in the parallel direction and a cylinder that moves the cutting member in a vertical direction. .

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