JP2011079730A - Method for producing honeycomb structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a honeycomb structure which can efficiently produce a honeycomb structure. <P>SOLUTION: The method for producing a honeycomb structure includes: a step of producing a columnar honeycomb molded body 16 in which a plurality of cells are arranged side by side in a longitudinal direction across a cell wall; a step of performing firing and producing a honeycomb fired body; and a step of producing a honeycomb block made of a plurality of the honeycomb fired bodies. The method for producing the honeycomb structure includes: a joining stage of joining the respective edge faces of the honeycomb fired bodies via a joining material 30 and producing a honeycomb joined body longer than the length of one honeycomb fired body; an adhesion stage of adhering the respective side faces of the plurality of honeycomb joined bodies via adhesive paste 19 so as to form the aggregate of the honeycomb joined bodies; a drying and solidifying stage of drying and solidifying the adhesive paste and producing the honeycomb block; and a separation stage of separating the honeycomb block at the position of the joining material so as to form at least two honeycomb blocks in which the respective side faces of the plurality of honeycomb fired bodies are adhered. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

The present invention relates to a method for manufacturing a honeycomb structure.

Conventionally, exhaust gas discharged from an internal combustion engine such as a diesel engine contains particulate matter (hereinafter also referred to as PM). In recent years, it has been a problem that this PM is harmful to the environment and the human body. ing.
Therefore, various types of honeycomb filters made of a honeycomb structure using a porous ceramic have been proposed as filters for collecting PM in the exhaust gas and purifying the exhaust gas.

Further, in recent years, downsizing of a filter for purifying such exhaust gas is desired. Therefore, there is a demand for a honeycomb structure having a small size, that is, a honeycomb structure having a short length in the longitudinal direction (hereinafter also simply referred to as a length).

Patent Document 1 discloses a ceramic filter assembly (honeycomb structure) in which filters are integrated by bonding the outer peripheral surfaces of a plurality of filters made of a porous ceramic sintered body through a sealing material layer. Has been.

Such a honeycomb structure can be manufactured by the following method.
First, a ceramic powder, a binder, a dispersion medium liquid, and the like are mixed to prepare a wet mixture.
Next, the wet mixture is extruded and cut into a predetermined length to produce a columnar honeycomb formed body.
Thereafter, a predetermined paste of each cell is filled with a sealing material paste so that any one end of each cell of the honeycomb formed body is sealed. Next, the honeycomb formed body filled with the sealing material paste is subjected to a degreasing process and a firing process to produce a porous ceramic sintered body (honeycomb fired body) that functions as a filter.
Next, side surfaces of a plurality of honeycomb fired bodies are bonded to each other through a sealing material to produce an aggregate of honeycomb fired bodies, and the sealing material is dried and solidified to form a sealing material layer. A honeycomb block is manufactured in which the side surfaces of a plurality of honeycomb fired bodies are bonded to each other through the material layer. Thereafter, if necessary, the honeycomb structure is manufactured by cutting the outer periphery of the honeycomb block or forming a coat layer on the outer periphery of the honeycomb block.

JP 2001-162121 A

In the method for manufacturing a honeycomb structure described in Patent Document 1, a honeycomb fired body having substantially the same length as the honeycomb structure to be manufactured is manufactured, and a plurality of side surfaces of the honeycomb fired body are bonded to each other, thereby firing the honeycomb fired body. An assembly of bodies is made.
In such a method for manufacturing a honeycomb structured body, when manufacturing a honeycomb structured body using the same number of honeycomb fired bodies, the time for producing an aggregate of one honeycomb fired body depends on the length of the honeycomb fired body. does not change. Therefore, in order to produce more honeycomb structures, it is necessary to produce an aggregate of honeycomb fired bodies many times, resulting in an increase in production time.
That is, in the method for manufacturing a honeycomb structure described in Patent Document 1, the number of honeycomb structures that can be manufactured per unit time cannot be increased regardless of the length of the honeycomb structure to be manufactured. There was a problem.
In particular, when a honeycomb structure having a short length is manufactured, a method for manufacturing the honeycomb structure efficiently is desired.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a method for manufacturing a honeycomb structure that can efficiently manufacture a honeycomb structure.

The present inventors diligently studied a method for efficiently manufacturing a honeycomb structure. As a result, an end face of the honeycomb fired body is joined to produce a honeycomb joined body longer than the length of one honeycomb fired body, and an assembly of the honeycomb joined body is produced using the honeycomb joined body. By performing the above, it is possible to produce a plurality of aggregates of honeycomb fired bodies in a single bonding step, so that the number of honeycomb structures that can be manufactured per unit time can be increased. The headline and the present invention were completed.

That is, the manufacturing method of the honeycomb structure according to claim 1,
Forming a columnar honeycomb formed body in which a plurality of cells are arranged in parallel in the longitudinal direction across the cell wall by molding a ceramic raw material;
A step of producing a honeycomb fired body by firing the honeycomb formed body;
A method of manufacturing a honeycomb structure including a step of manufacturing a honeycomb block including a plurality of honeycomb fired bodies,
The step of manufacturing the honeycomb block includes:
A joining step of producing a honeycomb joined body longer than the length of one honeycomb fired body by joining the end faces of at least two honeycomb fired bodies through a joining material;
An adhesion process for producing an aggregate of honeycomb bonded bodies by bonding side surfaces of a plurality of honeycomb bonded bodies through an adhesive paste;
A drying and solidifying step of producing a honeycomb block composed of an aggregate of honeycomb joined bodies by drying and solidifying the adhesive paste;
Separating the honeycomb block composed of the aggregate of the honeycomb bonded bodies at the position of the bonding material, thereby separating at least two honeycomb blocks in which the side surfaces of the plurality of honeycomb fired bodies are bonded to each other. Features.

As described above, in the conventional method for manufacturing a honeycomb structure, the number of honeycomb structures that can be manufactured per unit time is substantially constant regardless of the length of the honeycomb structure to be manufactured.
On the other hand, in the method for manufacturing a honeycomb structured body according to claim 1, since at least two aggregates of honeycomb fired bodies can be manufactured together in one bonding step, the honeycomb structure is manufactured per unit time. The number of honeycomb structures that can be increased can be increased. Therefore, a honeycomb structure can be manufactured efficiently.

In the method for manufacturing a honeycomb structured body according to claim 2, the bonding material includes a double-sided tape.
By using a double-sided tape as the bonding material, the end faces of the honeycomb fired body can be reliably bonded to each other.

In the method for manufacturing a honeycomb structured body according to claim 3, the bonding material further includes a spacing member provided with the double-sided tape on both surfaces thereof.
If the bonding material further includes a spacing member, the honeycomb fired bodies are not in direct contact with each other when the end faces of the honeycomb fired bodies are bonded to each other.

In the method for manufacturing a honeycomb structured body according to claim 4, the spacing member is a combustible spacing member.
Further, as in the method for manufacturing a honeycomb structured body according to claim 5, the combustible spacing member may be cardboard.
When the spacing member is a flammable spacing member (especially cardboard), the flammable spacing member can be burned or carbonized by heating the flammable spacing member. Therefore, it is possible to easily separate a honeycomb block formed of an aggregate of honeycomb joined bodies.

In the method for manufacturing a honeycomb structured body according to claim 6, the spacing member is a nonflammable spacing member.
Further, as in the method for manufacturing a honeycomb structured body according to claim 7, the nonflammable spacing member may be fiber paper, inorganic filler paper, ceramic, glass, or metal.

In the method for manufacturing a honeycomb structured body according to claim 8, in the drying and solidifying step of the adhesive paste, the adhesive paste is dried and solidified, and the double-sided tape and / or the spacing member is burned or carbonized.
By heating the bonding material, at least one of the double-sided tape and the spacing member can be burned out or carbonized. Therefore, at least one of the double-sided tape and the spacing member can be removed from the honeycomb bonded body. As a result, it becomes easy to separate the honeycomb block formed of the aggregate of honeycomb bonded bodies at the position of the bonding material (surface including the bonding material).

Further, in the method for manufacturing a honeycomb structure according to claim 8, the heating for burning or carbonizing the double-sided tape and / or the spacing member uses the heating for drying and solidifying the adhesive paste, There is no need to perform a separate heating step for the bonding material.

In the method for manufacturing a honeycomb structured body according to claim 9, the bonding material is made of a bonding material paste containing an inorganic sol.
When the bonding material paste used as the bonding material contains an inorganic sol, the end surfaces of the honeycomb fired bodies can be firmly bonded to each other, so that the honeycomb fired bodies can be fixed more reliably.

The method for manufacturing a honeycomb structured body according to claim 10, wherein the bonding material paste is made of the same material as the adhesive paste.
When an adhesive paste is used as the bonding material paste, the honeycomb structure can be manufactured without separately preparing the bonding material paste.

The method for manufacturing a honeycomb structure according to claim 11 further includes a step of drying and solidifying the bonding material paste, and the step of drying and solidifying the bonding material paste is performed before the bonding step.
When the step of drying and solidifying the bonding material paste is performed before the bonding step, a honeycomb bonded body in which the end faces are bonded more firmly can be manufactured. Therefore, when the bonding process is performed using such a honeycomb bonded body, the honeycomb bonded body is separated during the bonding process, and it is difficult to cause a problem that the honeycomb fired body is displaced.

In the method for manufacturing a honeycomb structured body according to claim 12, in the drying and solidifying step of the adhesive paste, the adhesive paste is dried and solidified, and the bonding material paste is dried and solidified.
When the adhesive paste is dried and solidified, and the bonding material paste is dried and solidified, the honeycomb structure can be manufactured without separately performing a step of drying and solidifying the bonding material paste.

14. The method for manufacturing a honeycomb structured body according to claim 13, wherein a coating material paste is applied to an outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies after the drying and solidifying step of the adhesive paste and before the separating step. And a coating layer forming step of forming a coating layer by drying and solidifying the coating material paste.
A coating material paste is applied to the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies, and the coating material paste is dried and solidified, thereby forming a coating layer in at least two honeycomb blocks in one coating layer forming step. Therefore, the honeycomb structure can be manufactured efficiently.

In the method for manufacturing a honeycomb structured body according to claim 13, the coating material paste is dried and solidified before the separation step. Therefore, it is possible to separate the honeycomb block made of the aggregate of honeycomb bonded bodies at the position of the bonding material in a form close to the final product.

15. The method for manufacturing a honeycomb structured body according to claim 14, wherein, in the separation step, an external force is applied to the honeycomb block composed of the aggregate of honeycomb joined bodies to thereby form the honeycomb block composed of the aggregate of honeycomb joined bodies. Separate at the position of the bonding material.
Using a machine, a jig, or manually, an external force such as vibration or bending is applied to the honeycomb block formed of the aggregate of honeycomb bonded bodies, thereby bonding the honeycomb block formed of the aggregate of honeycomb bonded bodies to the bonding material. It is possible to separate more easily at the position.

16. The method for manufacturing a honeycomb structured body according to claim 15, wherein in the separation step, a portion including the bonding material is cut along a plane parallel to an end face of the honeycomb fired body.
By cutting the portion including the bonding material along a plane parallel to the end face of the honeycomb fired body, the bonding material can be removed from the honeycomb bonded body, and as a result, the honeycomb block formed of the aggregate of the honeycomb bonded body is bonded. It can be separated at the position of the material.

The method for manufacturing a honeycomb structured body according to claim 16, wherein one end portion of the cell is sealed after the step of manufacturing the honeycomb formed body and before the step of manufacturing the honeycomb fired body. A sealing step of filling the sealing material paste is further included.

Fig.1 (a) is sectional drawing which shows typically an example of the shaping | molding process in 1st embodiment. FIG.1 (b) is sectional drawing which shows typically an example of the sealing process in 1st embodiment. FIG.1 (c) is sectional drawing which shows typically an example of the baking process in 1st embodiment. FIG.1 (d) and FIG.1 (e) are sectional drawings which show typically an example of the joining process in 1st embodiment. FIG. 2 is a perspective view schematically showing a part of an example of the bonding step in the first embodiment. Fig.3 (a) is a perspective view which shows typically a part of example of the adhesion process in 1st embodiment, FIG.3 (b) is sectional drawing in the AA cross section of Fig.3 (a). It is. Fig.4 (a) is a perspective view which shows typically an example of the drying solidification process in 1st embodiment, FIG.4 (b) is sectional drawing in the BB sectional view of Fig.4 (a). . Fig.5 (a) is a perspective view which shows typically an example of the outer periphery process in 1st embodiment. FIG.5 (b) is a perspective view which shows typically an example of the coating layer formation process in 1st embodiment. FIG.5 (c) is a perspective view which shows typically an example of the isolation | separation process in 1st embodiment. FIG. 6 is a perspective view schematically showing an example of a honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention. Fig.7 (a) is a perspective view which shows typically an example of a honeycomb fired body, FIG.7 (b) is CC sectional view taken on the line of Fig.7 (a). Fig.8 (a) is sectional drawing which shows typically an example of the shaping | molding process in 3rd embodiment. FIG.8 (b) is sectional drawing which shows typically an example of the sealing process in 3rd embodiment. FIG.8 (c) is sectional drawing which shows typically an example of the baking process in 3rd embodiment. FIG.8 (d) and FIG.8 (e) are sectional drawings which show typically an example of the joining process in 3rd embodiment. Fig.9 (a) is a perspective view which shows typically an example of the drying solidification process in 3rd embodiment, FIG.9 (b) is sectional drawing in the DD sectional view of Fig.9 (a). . Fig.10 (a) is a perspective view which shows typically an example of the outer periphery process in 3rd embodiment. FIG.10 (b) is a perspective view which shows typically an example of the coating layer formation process in 3rd embodiment. FIG.10 (c) is a perspective view which shows typically an example of the isolation | separation process in 3rd embodiment. FIG. 11 is a partially enlarged cross-sectional view schematically showing an example of a method for cutting a honeycomb block made of an aggregate of honeycomb bonded bodies. 12 (a) and 12 (b) are perspective views schematically showing another example of the separation step in the present invention. Fig.13 (a) is a perspective view which shows typically another example of the outer periphery process in this invention. FIG.13 (b) is a perspective view which shows typically another example of the coating layer formation process in this invention. FIG. 14A and FIG. 14B are perspective views schematically showing still another example of the separation step in the present invention. FIG.14 (c) is a perspective view which shows typically another example of the coating layer formation process in this invention. FIG. 15 is a partially enlarged cross-sectional view schematically showing another example of a method for cutting a honeycomb block formed of an aggregate of honeycomb bonded bodies. FIG. 16 is a partially enlarged cross-sectional view schematically showing still another example of a method for cutting a honeycomb block formed of an aggregate of honeycomb joined bodies. Fig. 17 (a) is a perspective view schematically showing another example of the honeycomb fired body, and Fig. 17 (b) is a cross-sectional view taken along the line H-H in Fig. 17 (a). FIG. 18A to FIG. 18C are perspective views schematically showing another example of the honeycomb fired body.

(First embodiment)
Hereinafter, a first embodiment, which is an embodiment of a method for manufacturing a honeycomb structure of the present invention, will be described with reference to the drawings. In the present embodiment, a method for manufacturing two honeycomb structures will be described.

In the present specification, a structure in which the side surfaces of a plurality of honeycomb fired bodies are bonded to each other via an adhesive paste is referred to as an “aggregate of honeycomb fired bodies”. Further, the aggregate of the honeycomb fired bodies after the adhesive paste is dried and solidified is referred to as “honeycomb block”. Of the honeycomb blocks, those having a coating layer formed on the outer peripheral surface of the honeycomb block are referred to as “honeycomb structures”.

First, by forming a ceramic raw material, a forming step is performed in which a columnar honeycomb formed body in which a plurality of cells are arranged in parallel in the longitudinal direction with cell walls interposed therebetween is performed.
Fig.1 (a)-FIG.1 (e) are sectional drawings which show typically a part of example of the manufacturing process of the honeycomb structure in 1st embodiment.
Fig.1 (a) is sectional drawing which shows typically an example of the shaping | molding process in 1st embodiment.
Specifically, first, a ceramic raw material (wet mixture) for manufacturing a honeycomb formed body is prepared by mixing a silicon carbide powder as a ceramic powder, an organic binder, a liquid plasticizer, a lubricant, and water.
Next, after the wet mixture is put into an extrusion molding machine and extruded, a raw honeycomb molded body having a predetermined shape is manufactured by performing a cutting process of cutting to a predetermined length.
Subsequently, by performing a drying process of drying the raw honeycomb formed body using a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer, etc., FIG. The dried honeycomb formed body 16 shown in FIG.

Then, the sealing process which fills with a sealing material paste is performed so that either one edge part of the cell of the dried honeycomb molded object may be sealed.
FIG.1 (b) is sectional drawing which shows typically an example of the sealing process in 1st embodiment.
The honeycomb molded body 16 that has been subjected to the drying process is subjected to a sealing process in which one end of the cell 21 is filled with a sealing material paste 29 serving as a sealing material, and the cell 21 is sealed.

Next, a firing process for producing a honeycomb fired body is performed by firing the honeycomb formed body subjected to the sealing treatment.
FIG.1 (c) is sectional drawing which shows typically an example of the baking process in 1st embodiment.
After the sealing step, a degreasing process is performed in which the organic matter in the honeycomb molded body in which the end portions of the cells are sealed is removed by heating in a degreasing furnace, and then a firing process is performed, whereby FIG. A honeycomb fired body 20 shown in FIG.
In addition, the sealing material paste with which the edge part of the cell was filled is solidified by heating, and becomes the sealing material 22.
Moreover, the conditions conventionally used when manufacturing a honeycomb fired body can be applied to the conditions of the cutting treatment, the drying treatment, the sealing treatment, the degreasing treatment, and the firing treatment.

Next, a joining step for producing a honeycomb joined body longer than one honeycomb fired body is performed by joining the end faces of the two honeycomb fired bodies to each other through the joining material.
Note that the end face of the honeycomb fired body refers to the face on which the cells exist among the faces of the honeycomb fired body.
In the present embodiment, a flammable gap maintaining material having double-sided tapes on both sides is used as the bonding material.
FIG.1 (d) and FIG.1 (e) are sectional drawings which show typically an example of the joining process in 1st embodiment.
First, as shown in FIG. 1 (d), the bonding material 30 is produced by sticking the double-sided tapes 31 a and 31 b to both sides of the combustible spacing member 32.
Next, the end surface 24a of one honeycomb fired body 20a and one surface of the combustible spacing member 32 are bonded with a double-sided tape 31a. Then, the end face 24b of the other honeycomb fired body 20b and the other face of the combustible spacing member 32 are bonded with a double-sided tape 31b.
By such a method, as shown in FIG. 1E, a bonded honeycomb body 40 having a length longer than the length of one honeycomb fired body 20a or 20b is manufactured.

As the double-sided tape, for example, an acrylic foam bonding tape in which an acrylic adhesive is provided on a base material made of a foam such as acrylic foam is used.
The thickness of the double-sided tape is preferably 0.1 to 5.0 mm.

As the combustible spacing material, for example, a spacing material made of cardboard or the like is used.
In addition, in this specification, a flammable space | interval holding material means the space | interval holding material which burns down or carbonizes at 100-200 degreeC.
Moreover, it is desirable that the thickness of the combustible spacing member is 1.0 to 5.0 mm.

In this specification, “burning out” means that most of the organic matter disappears when the organic matter is heated, and “carbonization” means that the organic matter is converted into carbon by heating the organic matter. “Burn or carbonize” means that most of the organic matter disappears, part of the organic matter disappears and the rest remains as carbon, or most of the organic matter remains as carbon. Say.

Next, an adhesion step is performed in which the side surfaces of the plurality of honeycomb bonded bodies are bonded to each other through an adhesive paste to produce an aggregate of honeycomb bonded bodies.
FIG. 2 is a perspective view schematically showing a part of an example of the bonding step in the first embodiment.
Fig.3 (a) is a perspective view which shows typically a part of example of the adhesion process in 1st embodiment, FIG.3 (b) is sectional drawing in the AA cross section of Fig.3 (a). It is.
In the bonding step, for example, as shown in FIG. 2, first, on the base 100 whose upper cross section is configured in a V shape so that the honeycomb bonded body 40 can be stacked in an inclined state, The honeycomb bonded body 40 is placed in an inclined state. Thereafter, the adhesive paste 19 is applied to the two side surfaces 25a and 25b of the honeycomb bonded body 40 facing upward in a uniform thickness. At this time, the adhesive paste 19 is also applied onto the bonding material 30. And the process of laminating | stacking another honeycomb joined body 40 on this adhesive paste 19 one by one is repeated.
By the above method, an aggregate 41 of the honeycomb joined body in which the adhesive paste 19 is applied to the side surface of the honeycomb joined body 40 as shown in FIGS. 3A and 3B is manufactured.
3 (a) and 3 (b), an assembly 41 of honeycomb joined bodies composed of a total of 16 honeycomb joined bodies 40 of 4 vertical and 4 horizontal is produced.

That is, in the aggregated body 41 of the honeycomb bonded body, the aggregated body 45a of the honeycomb fired bodies formed by bonding the side surfaces of a total of 16 honeycomb fired bodies 20a, 4 in length and 4 in width, through the adhesive paste 19. And the aggregated body 45b of the honeycomb fired bodies formed by adhering the side surfaces of the 16 honeycomb fired bodies 20b in total of 4 in the vertical direction and 4 in the lateral direction through the adhesive paste 19 are part of the adhesive paste 19 And the bonding material 30 (the bonding material and the cell wall of the honeycomb fired body are bonded) are connected in the longitudinal direction (the direction of the arrow a in FIGS. 3A and 3B).

As the adhesive paste, for example, a paste containing inorganic fibers such as alumina fibers, inorganic particles such as silicon carbide, and an inorganic binder such as silica sol is used. The adhesive paste may further contain whiskers.

Subsequently, the honeycomb joined body aggregate is heated at 100 to 200 ° C. for 15 to 240 minutes to dry and solidify the adhesive paste, thereby producing a honeycomb block composed of the honeycomb joined body aggregate. A solidification process is performed.

In the present specification, an aggregate of honeycomb bonded bodies after the adhesive paste is dried and solidified is referred to as “honeycomb block including an aggregate of honeycomb bonded bodies”. Therefore, in this specification, the honeycomb block refers to a honeycomb block made of an aggregate of honeycomb joined bodies (state before the separation step) and a honeycomb block (a honeycomb block made of an aggregate of honeycomb joined bodies). ) State).

Fig.4 (a) is a perspective view which shows typically an example of the drying solidification process in 1st embodiment, FIG.4 (b) is sectional drawing in the BB sectional view of Fig.4 (a). .
By drying and solidifying the adhesive paste, an adhesive layer 11a is formed between the side surfaces of the honeycomb fired body 20a, and an adhesive layer 11b is formed between the side surfaces of the honeycomb fired body 20b. Further, by drying and solidifying the adhesive paste, a connecting portion 13 that is continuous with the adhesive layers 11a and 11b and connects the adhesive layer 11a and the adhesive layer 11b is formed.

In the present embodiment, the adhesive paste is dried and solidified, and the double-sided tape and the combustible spacing member constituting the bonding material are burned out or carbonized by heating at this time. In addition, after the adhesive paste is dried and solidified, a degreasing process is performed to burn or carbonize the double-sided tape and the combustible gap maintaining material constituting the bonding material.

As shown in FIGS. 4 (a) and 4 (b), in the honeycomb block 42 formed of an aggregate of honeycomb joined bodies, a total of 16 honeycombs, 4 in length and 4 in width through the adhesive layer 11a. A honeycomb block 14a in which the side surfaces of the fired body 20a are bonded to each other, and a honeycomb block 14b in which the side surfaces of a total of 16 honeycomb fired bodies 20b in length and four in total are bonded via the adhesive layer 11b. Are connected in the longitudinal direction (the direction of the arrow b in FIGS. 4A and 4B) by the connecting portion 13.

In addition, in the honeycomb block 42 formed of the aggregate of honeycomb joined bodies as shown in FIGS. 4A and 4B, the double-sided tape and the combustible spacing member constituting the joining material are burned out or carbonized. Therefore, although the honeycomb bonded body does not exist, in this specification, the honeycomb block 42 composed of the aggregate of the honeycomb bonded bodies as shown in FIGS. 4A and 4B is also referred to as “honeycomb bonded body”. It is assumed that it is a “honeycomb block made of an aggregate”.

Thereafter, an outer peripheral machining step is performed in which a honeycomb block made of an aggregate of honeycomb bonded bodies is cut.
Fig.5 (a)-FIG.5 (c) are perspective views which show typically a part of example of the manufacturing process of the honeycomb structure in 1st embodiment.
Fig.5 (a) is a perspective view which shows typically an example of the outer periphery process in 1st embodiment.
A set of honeycomb bonded bodies whose outer periphery has been processed by cutting along a broken line in FIG. 4 (a) using a diamond cutter or the like on a honeycomb block composed of the aggregate of honeycomb bonded bodies A honeycomb block 43 made of a body is produced.
As shown in FIG. 5A, in the honeycomb block 43 formed of the aggregate of honeycomb joined bodies whose outer periphery is processed, the honeycomb blocks 15 a and 15 b whose outer periphery is processed are connected by the connecting portion 13. .

Subsequently, a coating layer forming step of forming a coating layer by applying a coating material paste to the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb bonded bodies whose outer periphery is processed, and drying and solidifying the coating material paste. Do.
FIG.5 (b) is a perspective view which shows typically an example of the coating layer formation process in 1st embodiment.
First, a coating material paste is applied to the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies that has been peripherally processed. Next, by drying and solidifying the coating material paste under conditions of 80 to 130 ° C. and 5 to 60 minutes, a honeycomb structure 44 made of an aggregate of honeycomb joined bodies in which the coating layer 12 is formed on the outer peripheral surface is manufactured. To do.
As shown in FIG. 5 (b), in the honeycomb structure 44 formed of an aggregate of honeycomb joined bodies, the honeycomb structures 10 a and 10 b are connected by the connecting portion 13.
Here, the coating material paste is made of the same material as the adhesive paste.

And the separation process which isolate | separates into two honeycomb structures is performed by isolate | separating the honeycomb structure which consists of an aggregate | assembly of a honeycomb joined body in the position of a joining material.

FIG.5 (c) is a perspective view which shows typically an example of the isolation | separation process in 1st embodiment.
The connecting portion 13 fixing the honeycomb structure 44 composed of the aggregate of honeycomb joined bodies shown in FIG. 5 (b) is folded by hand and the connecting portion attached to the end surface (near the end of the cell wall) By removing the residue (carbonized organic matter contained in the bonding material) with a brush, removing with a high-pressure water flow, etc., the honeycomb structure 44 formed of the aggregate of the honeycomb bonded bodies is converted into two honeycomb structures. Separate into 10a and 10b.
The connecting portion is obtained by drying and solidifying the adhesive paste. However, since the connecting portion has a small thickness and a small amount, the connecting portion can be easily folded by hand.
Examples of the method for folding the connecting portion by hand include methods such as bending, twisting, or pulling by hand. Further, the connecting portion may be similarly broken using a machine.
As described above, two honeycomb structures can be manufactured.

Next, a honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present embodiment will be described with reference to the drawings.
FIG. 6 is a perspective view schematically showing an example of a honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention.
Fig.7 (a) is a perspective view which shows typically an example of a honeycomb fired body, FIG.7 (b) is CC sectional view taken on the line of Fig.7 (a).

As shown in FIG. 6, the honeycomb structure 10 includes a honeycomb block 15 in which a plurality of honeycomb fired bodies 20 are bound via an adhesive layer 11, and a coat layer 12 is formed on the outer periphery of the honeycomb block 15. Is formed.
The honeycomb fired body 20 has a shape shown in FIGS. 7 (a) and 7 (b).

In the honeycomb fired body 20 shown in FIGS. 7 (a) and 7 (b), a large number of cells 21 are arranged in parallel in the longitudinal direction (in the direction of arrow c in FIG. 7 (a)) with a cell wall 23 therebetween. One end of the cell 21 is sealed with a sealing material 22. Therefore, the exhaust gas G that has flowed into the cell 21 with one end face opened always flows out from the other cell 21 with the other end face opened after passing through the cell wall 23 separating the cells 21.
Accordingly, the cell wall 23 functions as a filter for collecting PM and the like.

The honeycomb structure can be used in an exhaust gas purification device that purifies exhaust gas discharged from an internal combustion engine.

Hereinafter, the function and effect of the method for manufacturing the honeycomb structure of the present embodiment will be described.
(1) In the method for manufacturing a honeycomb structured body of the present embodiment, the end surfaces of two honeycomb fired bodies are bonded to each other through a bonding material to produce a honeycomb bonded body longer than the length of one honeycomb fired body. In addition, an adhesion step for producing an aggregate of honeycomb bonded bodies using the honeycomb bonded body is performed. Therefore, an aggregate of two honeycomb fired bodies can be manufactured together in a single bonding step, so that the number of honeycomb structures that can be manufactured per unit time can be increased. Therefore, a honeycomb structure can be manufactured efficiently.

(2) In the method for manufacturing a honeycomb structure of the present embodiment, a flammable gap maintaining material having double-sided tapes on both sides is used as a bonding material.
When the double-sided tape is included in the bonding material, the end faces of the honeycomb fired body can be reliably bonded to each other.
Further, if the bonding material contains a flammable spacing member, the honeycomb fired bodies are not directly in contact with each other when the end faces of the honeycomb fired bodies are joined to each other. .

(3) In the method for manufacturing a honeycomb structured body of the present embodiment, the adhesive paste is dried and solidified, and the double-sided tape and / or the combustible gap maintaining material is burned out or carbonized.
By heating the bonding material, at least one of the double-sided tape and the flammable spacing member can be burned out or carbonized. Therefore, at least one of the double-sided tape and the flammable gap maintaining material can be removed from the honeycomb joined body, and as a result, the honeycomb structure composed of the aggregate of honeycomb joined bodies is separated at the position of the joining material. It becomes easy to do.
Further, in the method for manufacturing a honeycomb structure of the present embodiment, the heating for burning or carbonizing at least one of the double-sided tape and the combustible spacing member is performed when the adhesive paste is dried and solidified. Since it uses, it is not necessary to perform the process of heating a joining material separately.

(4) In a honeycomb block made of an aggregate of honeycomb bonded bodies manufactured by the method for manufacturing a honeycomb structure of the present embodiment, two honeycomb blocks are connected by a connecting portion.
Since the thickness of the connecting portion is small and the amount thereof is small, the connecting portion can be folded by hand. As a result, a honeycomb structure (honeycomb block) composed of an aggregate of honeycomb bonded bodies can be easily separated at the position of the bonding material.

(5) In the method for manufacturing a honeycomb structure of the present embodiment, the coating material paste is applied to the outer peripheral surface of the honeycomb block formed of the aggregate of honeycomb joined bodies after the drying and solidifying step of the adhesive paste and before the separation step. Then, a coating layer forming step for drying and solidifying the coating material paste is performed.
The coating material paste is applied to the outer peripheral surface of the honeycomb block composed of the aggregate of the honeycomb bonded bodies, and the coating material paste is dried and solidified, thereby forming the coating layer in two honeycomb blocks in one coating layer forming step. Since it can form, a honeycomb structure can be manufactured efficiently.
Further, since the coating material paste is dried and solidified before the separation step, the honeycomb structure (honeycomb block) composed of the aggregate of the honeycomb bonded bodies can be separated at the position of the bonding material in a form close to the final product. .

Examples that more specifically disclose the first embodiment of the present invention will be described below. In addition, this invention is not limited only to this Example.
Example 1
A mixture of 52.8% by weight of silicon carbide coarse powder having an average particle diameter of 22 μm and 22.6% by weight of fine powder of silicon carbide having an average particle diameter of 0.5 μm was obtained. 0.1% by weight, 4.6% by weight of organic binder (methylcellulose), 2.8% by weight of lubricant (Unilube manufactured by NOF Corporation), 1.3% by weight of glycerin and 13.8% by weight of water and kneaded. To obtain a wet mixture. Then, by extruding the wet mixture and then cutting, a raw honeycomb molding having substantially the same shape as that shown in FIGS. 7 (a) and 7 (b) and without sealing the cells. The body was made. Next, the raw honeycomb formed body was dried using a microwave dryer, thereby manufacturing a honeycomb formed body.

A predetermined cell of the honeycomb formed body was filled with a sealing material paste having the same composition as that of the raw honeycomb formed body to seal the cells.

After placing the honeycomb molded body with the cells sealed on a firing jig, degreasing treatment is performed at 400 ° C., and further, firing treatment is performed under conditions of 2200 ° C. and 3 hours in an atmospheric pressure of argon. Therefore, the porosity is 45%, the average pore diameter is 15 μm, the size is 34.3 mm × 34.3 mm × 101.6 mm (4 inches), and the number of cells (cell density) is 46.5 cells / cm ² (300 cells). / Inch ² ), a honeycomb fired body made of a silicon carbide sintered body having a cell wall thickness of 0.25 mm (10 mil) was produced.

Next, double-sided tape (acrylic foam bonding tape, adhesive: acrylic, base material: acrylic foam, thickness 0.40 mm) is applied to both sides of a flammable spacing material (thickness 3.0 mm) made of cardboard. A bonding material (thickness 3.8 mm) was produced by pasting.
And as shown in FIG.1 (d), the end surface of one produced honeycomb fired body and one surface of the combustible space | interval maintenance material were adhere | attached with the double-sided tape. Next, the end face of the other honeycomb fired body and the other face of the combustible spacing member were bonded with a double-sided tape.
By the above method, a honeycomb bonded body in which two honeycomb fired bodies were bonded via a bonding material made of a double-sided tape and a combustible gap maintaining material as shown in FIG.

Next, 30% by weight of alumina fibers having an average fiber length of 20 μm and an average fiber diameter of 4 μm, 21% by weight of silicon carbide particles having an average particle diameter of 0.6 μm, 15% by weight of silica sol (solid content of 30% by weight), carboxymethylcellulose 5.6 An adhesive paste containing wt% and 28.4 wt% water was prepared.
Then, using the method shown in FIG. 2, an adhesive paste is applied to the side surface of the honeycomb bonded body, and a total of 16 pieces of the above-mentioned honeycomb bonded body, 4 in length and 4 in width, are bonded through the adhesive paste. As a result, an aggregate of honeycomb joined bodies as shown in FIG. Furthermore, the aggregate of honeycomb bonded bodies is heated at 180 ° C. for 45 minutes to dry and solidify the adhesive paste, and the bonding material is burned off in the degreasing process (700 ° C., 40 minutes) after the adhesive paste is dried and solidified. Alternatively, a honeycomb composed of an assembly of bonded honeycomb bodies having a quadrangular prism shape in which an adhesive layer and a connecting portion both having a thickness of 1.0 mm as shown in FIG. 4A are formed by carbonization. A block was made.
In a honeycomb block made of an aggregate of manufactured honeycomb bonded bodies, two honeycomb blocks are connected by a connecting portion.

Subsequently, by using a diamond cutter, the outer periphery of the honeycomb block made of the aggregate of honeycomb bonded bodies is cut to form a honeycomb bonded body having a cylindrical outer periphery as shown in FIG. A honeycomb block made of the aggregate was prepared.
Next, a coating material paste was applied to the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies whose outer periphery was processed into a columnar shape, thereby forming a coating material paste layer. Then, this coating material paste layer is dried and solidified at 120 ° C. for 60 minutes to form a coating layer, whereby a cylindrical shape having a diameter of 143.8 mm and a length of 207.0 mm as shown in FIG. 5B. A honeycomb structure made of an aggregate of honeycomb joined bodies having a coating layer formed on the outer periphery was prepared.
At this time, a paste having the same composition as the adhesive paste was used as the coating material paste.

Then, the connecting part that fixes the honeycomb structure composed of the aggregate of honeycomb joined bodies is manually folded, and a residue of the connecting part attached to the end surface (near the end of the cell wall) (included in the joining material) By removing the carbonized organic matter) with a brush, the honeycomb structure composed of the aggregate of honeycomb joined bodies was separated into two honeycomb structures.
Thus, two cylindrical honeycomb structures having a diameter of 143.8 mm and a length of 101.6 mm as shown in FIG. 5C were manufactured.

In Example 1, the number of honeycomb structures that can be manufactured per unit time can be increased as compared with the conventional honeycomb structure manufacturing method, and the characteristics (pressure loss and collection) of the manufactured honeycomb structures can be increased. The efficiency) was comparable to that of the honeycomb structure manufactured by the conventional method for manufacturing a honeycomb structure.

(Second embodiment)
Hereinafter, a second embodiment which is an embodiment of a method for manufacturing a honeycomb structure of the present invention will be described.
The method for manufacturing a honeycomb structure according to the present embodiment is different from the first embodiment in that only the double-sided tape is used as the bonding material without using the combustible gap maintaining material.

In the present embodiment, in the joining step, the end surfaces of the two honeycomb fired bodies are bonded to each other using a double-sided tape thicker than the double-sided tape used in the first embodiment, thereby manufacturing a honeycomb joined body.
Specifically, a double-sided tape having a thickness of 1.0 to 5.0 mm is used as the bonding material.

In the present embodiment, the effects (1), (4), and (5) described in the first embodiment can be exhibited, and the following effects can be exhibited.
(6) In the manufacturing method of the honeycomb structure of the present embodiment, only the double-sided tape is used as the bonding material, so that the bonding material can be easily manufactured.

Examples that more specifically disclose the second embodiment of the present invention will be described below. In addition, this invention is not limited only to this Example.
(Example 2)
First, using the same method as in Example 1, the porosity was 45%, the average pore diameter was 15 μm, the size was 34.3 mm × 34.3 mm × 101.6 mm (4 inches), and the number of cells (cell density). Was 46.5 cells / cm ² (300 cells / inch ² ), and a honeycomb fired body made of a silicon carbide sintered body having a cell wall thickness of 0.25 mm (10 mil) was produced.

Next, the end faces of the two honeycomb fired bodies are attached to each other using a double-sided tape (acrylic foam bonding tape, adhesive: acrylic, base material: acrylic foam, thickness 2.0 mm). A honeycomb joined body in which two honeycomb fired bodies were joined through the joining material thus formed was produced.

Next, an aggregate of honeycomb joined bodies was produced using the same method as in Example 1.
Subsequently, the aggregate of honeycomb bonded bodies is heated under the same conditions as in Example 1, the adhesive paste is dried and solidified, and the bonding material is degreased after drying and solidifying the adhesive paste (700 ° C., 40 minutes). By burning or carbonizing the double-sided tape, a honeycomb block made of an aggregate of honeycomb joined bodies having a quadrangular prism shape in which an adhesive layer and a connecting portion both having a thickness of 1.0 mm were formed.

Subsequently, in the same manner as in Example 1, the outer periphery of the honeycomb block formed of the aggregate of honeycomb joined bodies was processed into a columnar shape. In the same manner as in Example 1, a coating layer is formed on the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies whose outer periphery is processed into a columnar shape, thereby forming a honeycomb structure made of an aggregate of honeycomb joined bodies. The body was made.
After that, as in Example 1, the connecting part that fixes the honeycomb structure composed of the aggregate of honeycomb joined bodies is manually folded, and the remaining part of the connecting part adhered to the end face (near the end of the cell wall) The honeycomb structure formed by the aggregate of the honeycomb bonded bodies was separated into two honeycomb structures by removing the objects (carbonized organic substances contained in the bonding material) with a brush.
Thus, two cylindrical honeycomb structures having a diameter of 143.8 mm and a length of 101.6 mm were manufactured.

In Example 2, the number of honeycomb structures that can be manufactured per unit time can be increased as compared with the conventional honeycomb structure manufacturing method, and the characteristics (pressure loss and collection of the manufactured honeycomb structures) can be increased. The efficiency) was comparable to that of the honeycomb structure manufactured by the conventional method for manufacturing a honeycomb structure.

(Third embodiment)
Hereinafter, a third embodiment, which is an embodiment of a method for manufacturing a honeycomb structure of the present invention, will be described with reference to the drawings.
The method for manufacturing a honeycomb structure according to the present embodiment differs from the first embodiment in that a bonding material paste containing an inorganic sol is used as a bonding material, and in the separation step.
The thickness of the bonding material paste is desirably 1.0 to 5.0 mm.

Fig.8 (a)-FIG.8 (e) are sectional drawings which show typically a part of example of the manufacturing process of the honeycomb structure in 3rd embodiment.
Fig.8 (a) is sectional drawing which shows typically an example of the shaping | molding process in 3rd embodiment. Moreover, FIG.8 (b) is sectional drawing which shows typically an example of the sealing process in 3rd embodiment. And FIG.8 (c) is sectional drawing which shows typically an example of the baking process in 3rd embodiment.
First, as shown in FIG. 8A, a honeycomb formed body 16 is produced in the same manner as in the first embodiment. Next, as shown in FIG. 8B, a sealing process is performed in which any one end of the cell 21 is filled with a sealing material paste 29. Thereafter, as shown in FIG. 8C, the honeycomb formed body 16 is fired to produce a honeycomb fired body 20.

Next, a joining step for joining the end faces of the two honeycomb fired bodies is performed by the following method.
In the present embodiment, a bonding material paste containing an inorganic sol is used as the bonding material. Here, as the bonding material paste, one made of the same material as the adhesive paste used in the first embodiment is used.
FIG.8 (d) and FIG.8 (e) are sectional drawings which show typically an example of the joining process in 3rd embodiment.
As shown in FIG. 8D, the bonding material paste 35 is applied to the end face 24a of one honeycomb fired body 20a. Next, the end face 24b of another honeycomb fired body 20b is bonded to the bonding material paste 35.
By such a method, the joined honeycomb body 60 shown in FIG.

Further, when the bonding material paste 35 is applied to the end face 24a of the honeycomb fired body 20a and the end face 24b of the honeycomb fired body 20b, as shown in FIG. 8E, a part of the bonding material paste 35 is sealed at the end. It enters into the cell 21 which is not done.
The bonding material paste 35 that has entered the cell 21 can be removed by cutting together with the bonding material in a separation step described later. Therefore, in the present embodiment, it is desirable to produce a honeycomb fired body having a length longer than the length of the honeycomb structure to be manufactured in consideration of the length of the honeycomb fired body to be cut.

Next, as in the first embodiment, a bonding step is performed in which the side surfaces of a plurality of honeycomb bonded bodies are bonded to each other via an adhesive paste to produce an aggregate of honeycomb bonded bodies.
Subsequently, the honeycomb joined body assembly is heated under the same conditions as in the first embodiment to dry and solidify the adhesive paste, and to dry and solidify the adhesive paste, thereby forming a honeycomb composed of the joined honeycomb joined body. A drying and solidifying step for producing a block is performed. The degreasing step may be performed after the adhesive paste is dried and solidified.
Fig.9 (a) is a perspective view which shows typically an example of the drying solidification process in 3rd embodiment, FIG.9 (b) is sectional drawing in the DD sectional view of Fig.9 (a). .
Similar to the first embodiment, by drying and solidifying the adhesive paste, the adhesive layer 11a is formed between the side surfaces of the honeycomb fired body 20a, and the adhesive layer 11b is formed between the side surfaces of the honeycomb fired body 20b. Is done.
Moreover, the bonding material layer 36 is formed between the end surface 24a of the honeycomb fired body 20a and the end surface 24b of the honeycomb fired body 20b by drying and solidifying the bonding material paste.

From the above, as shown in FIGS. 9 (a) and 9 (b), in the honeycomb block 62 formed of the aggregate of honeycomb joined bodies, a total of 16 vertical and horizontal 4 pieces are provided via the adhesive layer 11a. The side surfaces of 16 honeycomb fired bodies 20b in total, 4 in length and 4 in width, are bonded to each other through the honeycomb block 14a in which the side surfaces of the individual honeycomb fired bodies 20a are bonded to each other and the adhesive layer 11b. The honeycomb block 14 b is joined by the joining material layer 36.
Since the bonding material layer 36 is formed between the end surface 24a of the honeycomb fired body 20a and the end surface 24b of the honeycomb fired body 20b, the bonding material layer is bonded more firmly than the connecting portion formed in the first embodiment. be able to.

Fig.10 (a)-FIG.10 (c) are perspective views which show typically a part of example of the manufacturing process of the honeycomb structure in 3rd embodiment.
Fig.10 (a) is a perspective view which shows typically an example of the outer periphery process in 3rd embodiment. Moreover, FIG.10 (b) is a perspective view which shows typically an example of the coating layer formation process in 3rd embodiment.
As shown in FIG. 10 (a), after a honeycomb block made of an aggregate of honeycomb joined bodies was manufactured, the outer periphery was processed as in the first embodiment, and the honeycomb block 63 made of an aggregate of honeycomb joined bodies was processed. Is made. Thereafter, as shown in FIG. 10 (b), by forming a coating layer 12 on the outer peripheral surface of the honeycomb block made of the aggregate of honeycomb joined bodies whose outer periphery is processed, the honeycomb made of the aggregate of honeycomb joined bodies is formed. The structure 64 is produced.

And the separation process which isolate | separates into two honeycomb structures is performed by isolate | separating the honeycomb structure which consists of an aggregate | assembly of a honeycomb joined body in the position of a joining material.

FIG.10 (c) is a perspective view which shows typically an example of the isolation | separation process in 3rd embodiment.
A portion including the bonding material layer 36 (portion indicated by a broken line in FIG. 10B) in the honeycomb structure 64 formed of the aggregate of honeycomb bonded bodies illustrated in FIG. 10B is parallel to the end face of the honeycomb fired body. By cutting along a flat surface, as shown in FIG. 10 (c), the honeycomb structure formed of the aggregate of honeycomb joined bodies is separated into two honeycomb structures 10a and 10b. As described above, the two honeycomb structures 10a and 10b can be manufactured.

Hereinafter, the separation process of the honeycomb block composed of the aggregate of honeycomb joined bodies in the present embodiment will be specifically described.
FIG. 11 is a partially enlarged cross-sectional view schematically showing an example of a method for cutting a honeycomb block made of an aggregate of honeycomb bonded bodies.
As shown in FIG. 11, the thickness is larger than the distance (represented by a double arrow E in FIG. 11) between the end face 24a of the honeycomb fired body 20a and the end face 24b of the honeycomb fired body 20b. Using a blade 71 having a double arrow F in FIG. 11, a honeycomb block 62 made of an aggregate of honeycomb bonded bodies is cut so as to include the bonding material layer 36. Thereby, the honeycomb block 62 formed of the aggregate of honeycomb bonded bodies can be separated into two honeycomb blocks.
In addition, by this method, the end face 24a of the honeycomb fired body 20a or the end face 24b of the honeycomb fired body 20b (the boundary surface between the bonding material layer 36 and the honeycomb fired body 20a or 20b) is also cut and removed. Therefore, the bonding material layer 36 that has entered the cell 21 can be removed.

Cutting of the honeycomb structure formed of the aggregate of bonded honeycomb bodies is performed using, for example, a diamond cutter, an outer peripheral diamond grindstone, an inner peripheral diamond grindstone, a multi-wire, a multi-blade, a water jet, a high-pressure washing machine, or the like.

In the present embodiment, the effects (1) and (5) described in the first embodiment can be exhibited, and the following effects can be exhibited.
(7) In the method for manufacturing a honeycomb structure of the present embodiment, a bonding material paste containing an inorganic sol is used as the bonding material. When the bonding material paste contains an inorganic sol, the end faces of the honeycomb fired bodies can be firmly bonded to each other, so that the honeycomb fired bodies can be more reliably fixed.

(8) In the method for manufacturing a honeycomb structure of the present embodiment, the bonding material paste is made of the same material as the adhesive paste. When an adhesive paste is used as the bonding material paste, the honeycomb structure can be manufactured without separately preparing the bonding material paste.
Further, the honeycomb block made of the aggregate of honeycomb joined bodies produced in the present embodiment is fixed more firmly than the honeycomb block made of the aggregate of honeycomb joined bodies produced in the first embodiment. Further, the honeycomb block made of the aggregate of honeycomb joined bodies manufactured in the present embodiment is fixed more firmly than the honeycomb block made of the aggregate of honeycomb joined bodies manufactured in the first embodiment. A coat layer can be formed more easily than in one embodiment.

Hereinafter, examples that more specifically disclose the third embodiment of the present invention will be described. In addition, this invention is not limited only to this Example.
(Example 3)
First, using the same method as in Example 1, the porosity was 45%, the average pore diameter was 15 μm, the size was 34.3 mm × 34.3 mm × 102.6 mm, and the number of cells (cell density) was 46. A honeycomb fired body made of a silicon carbide sintered body having a thickness of 5 / cm ² (300 / inch ² ) and a cell wall thickness of 0.25 mm (10 mil) was produced.
In consideration of the portion to be cut in the separation step, a honeycomb fired body having a length 1.0 mm longer than the length of the honeycomb structure to be manufactured was manufactured.

And as shown in FIG.8 (d), the joining material paste was apply | coated to the end surface of one produced honeycomb baked body. Next, the end face of another honeycomb fired body was bonded to this bonding material paste.
Here, as the bonding material paste, one made of the same material as the adhesive paste used in Example 1 was used.
By the above method, a honeycomb joined body in which two honeycomb fired bodies were joined via the joining material paste as shown in FIG.

Next, an aggregate of honeycomb joined bodies was produced using the same method as in Example 1.
Subsequently, the aggregate of honeycomb joined bodies is heated under the same conditions as in Example 1 to dry and solidify the adhesive paste, to dry and solidify the adhesive paste, and to degrease step after drying and solidifying the adhesive paste (700 , 40 minutes), a honeycomb composed of an assembly of bonded honeycomb bodies having a quadrangular prism shape in which an adhesive layer having a thickness of 1.0 mm and a bonding material layer having a thickness of 3.0 mm are formed. A block was made.

Thereafter, in the same manner as in Example 1, the outer periphery of the honeycomb block composed of the aggregate of honeycomb joined bodies was processed into a cylindrical shape. In the same manner as in Example 1, a coating layer is formed on the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies whose outer periphery is processed into a columnar shape, thereby forming a honeycomb structure made of an aggregate of honeycomb joined bodies. The body was made.

Then, using an outer peripheral diamond grindstone having a thickness of 5.0 mm, the bonding material layer in the honeycomb structure formed of the aggregate of honeycomb bonded bodies, and the end face of the honeycomb fired body (the bonding material layer and the honeycomb fired body) By cutting a 1.0 mm portion from the (boundary surface), the honeycomb structure composed of the aggregate of honeycomb joined bodies was divided into two equal parts.
Thus, two cylindrical honeycomb structures having a diameter of 143.8 mm and a length of 101.6 mm were manufactured.

In Example 3, the number of honeycomb structures that can be manufactured per unit time can be increased as compared with the conventional honeycomb structure manufacturing method, and the characteristics (pressure loss and collection) of the manufactured honeycomb structures can be increased. The efficiency) was comparable to that of the honeycomb structure manufactured by the conventional method for manufacturing a honeycomb structure.

(Fourth embodiment)
Hereinafter, a fourth embodiment which is an embodiment of a method for manufacturing a honeycomb structure of the present invention will be described.
The method for manufacturing a honeycomb structure of the present embodiment is different from the first embodiment in that a non-combustible gap maintaining material provided with double-sided tapes on both sides is used as a bonding material and the method of the separation step.

In this embodiment, a joining material is produced by sticking a double-sided tape on both surfaces of a nonflammable space holding material in the joining step.
Next, the end surface of one honeycomb fired body and one surface of the nonflammable spacing member are bonded with a double-sided tape. Subsequently, an end face of another honeycomb fired body and the other face of the nonflammable spacing member are adhered with a double-sided tape, thereby manufacturing a honeycomb joined body.

As the double-sided tape, the same double-sided tape as used in the first embodiment is used.
As the nonflammable spacing material, for example, a spacing material made of fiber paper or the like is used.
In addition, in this specification, a nonflammable space | interval holding material means the space | interval holding material which does not burn out or carbonize at 100-200 degreeC.
Moreover, it is desirable that the thickness of the nonflammable spacing member is 1.0 to 5.0 mm.

Next, as in the first embodiment, the side surfaces of the plurality of honeycomb bonded bodies are bonded to each other through an adhesive paste to produce an aggregate of honeycomb bonded bodies.
Subsequently, as in the first embodiment, the aggregate of honeycomb joined bodies is heated and dried at 100 to 200 ° C. for 15 to 240 minutes to dry and solidify the adhesive paste. A honeycomb block made of The degreasing step may be performed after the adhesive paste is dried and solidified.
By drying and solidifying the adhesive paste, the adhesive layer and the connecting portion are formed as in the first embodiment.
Moreover, the double-sided tape which comprises a joining material is burnt down or carbonized by the heating at the time of drying and solidifying an adhesive paste.
Therefore, in the honeycomb block formed of the aggregate of honeycomb bonded bodies, the two honeycomb blocks are connected by the connecting portion as in the first embodiment.
In addition, since the nonflammable gap retaining material included in the bonding material does not burn out or carbonize at 100 to 200 ° C., the nonflammable gap retaining material is also used for the end faces of the two honeycomb blocks after the adhesive paste is dried and solidified. And it will remain in the space enclosed by the connection part.

Subsequently, as in the first embodiment, the outer peripheral processing step and the coat layer forming step are performed to produce a honeycomb structure including an aggregate of honeycomb joined bodies.
Thereafter, in the same manner as in the third embodiment, a separation process is performed in which a honeycomb structure formed of an aggregate of honeycomb bonded bodies is cut into two honeycomb structures by using a diamond cutter or the like.
As described above, two honeycomb structures are manufactured.

In the present embodiment, the effects (1), (4), and (5) described in the first embodiment can be exhibited, and the following effects can be exhibited.
(9) In the method for manufacturing a honeycomb structure according to the present embodiment, a nonflammable gap maintaining material having double-sided tapes on both sides thereof is used as a bonding material.
When the non-combustible spacing member is included in the bonding material, the honeycomb fired bodies are easily bonded in parallel.

Hereinafter, examples that more specifically disclose the fourth embodiment of the present invention will be described. In addition, this invention is not limited only to this Example.
Example 4
First, as in Example 3, the porosity was 45%, the average pore diameter was 15 μm, the size was 34.3 mm × 34.3 mm × 102.6 mm, and the number of cells (cell density) was 46.5 cells / cm. ² (300 / inch ² ), and a honeycomb fired body made of a silicon carbide sintered body having a cell wall thickness of 0.25 mm (10 mil) was produced.
In consideration of the portion to be cut in the separation step, a honeycomb fired body having a length 1.0 mm longer than the length of the honeycomb structure to be manufactured was manufactured.

Next, a nonflammable spacing material was prepared by the following method.
A glass fiber was the main component, glass fiber, wood pulp, feldspar, and aluminum hydroxide were placed in water, and the agitated slurry was made and dehydrated into a sheet.
Further, the obtained sheet was dried to produce a sheet having a thickness of 2.7 mm.
Then, it punched using the metal mold | die, it processed into length 35mm x width 35mm x thickness 2.7mm, and it was set as the nonflammable space | interval holding material.
And it joins by sticking the double-sided tape (Acrylic foam joining tape, Adhesive: Acrylic type, Base material: Acrylic foam, Thickness 0.15mm) on both sides of a nonflammable space maintenance material (Thickness 2.7mm) A material (thickness: 3.0 mm) was produced.

Subsequently, in the same manner as in Example 1, the end face of one manufactured honeycomb fired body and one face of the nonflammable spacing member were bonded with a double-sided tape. Next, the end face of the other honeycomb fired body and the other face of the nonflammable spacing member were bonded with a double-sided tape.
By the above method, a honeycomb bonded body in which two honeycomb fired bodies were bonded via a bonding material composed of a double-sided tape and a nonflammable gap maintaining material was produced.

Next, an aggregate of honeycomb joined bodies was produced using the same method as in Example 1.
Subsequently, the aggregate of honeycomb bonded bodies is heated under the same conditions as in Example 1, the adhesive paste is dried and solidified, and the bonding material is degreased after drying and solidifying the adhesive paste (700 ° C., 40 minutes). By burning or carbonizing the double-sided tape contained in the honeycomb block, a honeycomb block made of an aggregate of honeycomb joined bodies having a quadrangular prism shape in which an adhesive layer and a connecting portion both having a thickness of 1.0 mm were formed. .
In a honeycomb block made of an assembly of manufactured honeycomb bonded bodies, two honeycomb blocks are connected by a connecting portion. In addition, the nonflammable spacing member included in the bonding material remains in the space surrounded by the end faces of the two honeycomb blocks and the connecting portion without being burned out or carbonized after the adhesive paste is dried and solidified. It was.

Subsequently, in the same manner as in Example 1, the outer periphery of the honeycomb block formed of the aggregate of honeycomb joined bodies was processed into a columnar shape. In the same manner as in Example 1, a coating layer is formed on the outer peripheral surface of a honeycomb block made of an aggregate of honeycomb joined bodies whose outer periphery is processed into a columnar shape, thereby forming a honeycomb structure made of an aggregate of honeycomb joined bodies. The body was made.
Thereafter, using an outer peripheral diamond grindstone having a thickness of 5.0 mm, the bonding material in the honeycomb structure formed of the aggregate of honeycomb bonded bodies and the end face of the honeycomb fired body (boundary between the bonding material layer and the honeycomb fired body) A portion of 1.0 mm from the surface) was cut to divide the honeycomb structure formed of the aggregate of honeycomb joined bodies into two equal parts.
Thus, two cylindrical honeycomb structures having a diameter of 143.8 mm and a length of 101.6 mm were manufactured.

In Example 4, the number of honeycomb structures that can be manufactured per unit time can be increased as compared with the conventional manufacturing method of honeycomb structures, and the characteristics (pressure loss and collection) of the manufactured honeycomb structures can be increased. The efficiency) was comparable to that of the honeycomb structure manufactured by the conventional method for manufacturing a honeycomb structure.

(Other embodiments)
Although the length of the honeycomb structure manufactured in the manufacturing method of the honeycomb structure of the present invention is not particularly limited, it is preferably 203.2 mm or less. Thus, the method for manufacturing a honeycomb structure of the present invention is suitable for manufacturing a honeycomb structure having a short length in the longitudinal direction.
In the method for manufacturing a honeycomb structure of the present invention, the thickness of the bonding material is preferably 1.0 to 5.0 mm.

In the method for manufacturing a honeycomb structure shown in the first to fourth embodiments, a honeycomb joined body is manufactured by joining the end faces of two honeycomb fired bodies. The number is not particularly limited.
In particular, the shorter the honeycomb structure to be manufactured, the more honeycomb fired bodies can be joined.
As the number of honeycomb fired bodies to be joined increases, the number of aggregates of honeycomb fired bodies that can be manufactured in one bonding step can be increased. As a result, the number of honeycomb structures that can be manufactured per unit time can be increased.

In the manufacturing method of the honeycomb structure shown in the first embodiment to the fourth embodiment, a honeycomb bonded body is manufactured by each method, and a honeycomb structure including an aggregate of honeycomb bonded bodies is manufactured, and then a separation step. Thus, the honeycomb structure formed of the aggregate of the honeycomb joined bodies is separated into the honeycomb structures. However, in the method for manufacturing a honeycomb structured body of the present invention, the separation step may be performed at any time after the honeycomb block made of the aggregate of honeycomb joined bodies is produced using the honeycomb joined body. Hereinafter, another embodiment of the separation process of the honeycomb block made of the aggregate of honeycomb bonded bodies will be described.

12 (a) and 12 (b) are perspective views schematically showing another example of the separation step in the present invention.
12 (a) and 12 (b), after preparing a honeycomb block 42 composed of an aggregate of honeycomb joined bodies, the honeycomb block 42 composed of an aggregate of honeycomb joined bodies is separated into two honeycomb blocks 14a and 14b. To do.

Fig.13 (a) is a perspective view which shows typically another example of the outer periphery process in this invention. FIG. 13B is a perspective view schematically showing another example of the coating layer forming step in the present invention.
After the two honeycomb blocks 14a and 14b are manufactured by the separation process shown in FIGS. 12 (a) and 12 (b), a diamond cutter or the like is used for the honeycomb blocks 14a and 14b. By performing cutting along the inner broken line, as shown in FIG. 13A, two honeycomb blocks 15a and 15b whose outer periphery is processed are manufactured. After that, as in the first embodiment, a coat layer is formed on the outer peripheral surfaces of the two honeycomb blocks 15a and 15b whose outer periphery is processed, thereby forming the coat layer 12 on the outer peripheral surface as shown in FIG. 13 (b). The two honeycomb structures 10a and 10b formed with are manufactured.

FIG. 14A and FIG. 14B are perspective views schematically showing still another example of the separation step in the present invention. Moreover, FIG.14 (c) is a perspective view which shows typically another example of the coating layer formation process in this invention.
14 (a) and 14 (b), a honeycomb block 43 made of an aggregate of honeycomb bonded bodies whose outer periphery is processed is manufactured, and then a honeycomb formed of an aggregate of honeycomb bonded bodies whose outer periphery is processed. The block 43 is separated into two honeycomb blocks 15a and 15b whose outer periphery is processed. After that, by forming a coat layer on the outer peripheral surfaces of the two honeycomb blocks 15a and 15b whose outer periphery is processed, two honeycomb structures in which the coat layer 12 is formed on the outer peripheral surface as shown in FIG. The bodies 10a and 10b are manufactured.

Among the embodiments of the separation step, as shown in the first embodiment to the fourth embodiment, after the honeycomb structure including the aggregate of honeycomb bonded bodies is manufactured, the honeycomb structure including the aggregate of honeycomb bonded bodies is manufactured. A step of separating the honeycomb structure into a honeycomb structure is desirable. This is because the number of times of outer periphery processing and the number of times of forming the coat layer can be reduced.

In the method for manufacturing a honeycomb structured body of the present invention, the method for separating the honeycomb block composed of the aggregate of the honeycomb joined bodies into the honeycomb blocks is not limited to the method described in the first embodiment to the fourth embodiment. .
In the first embodiment and the second embodiment, the connecting portion is broken off by hand. For example, the connecting portion may be broken by applying an external force using a machine or a jig, or a diamond cutter or the like. You may use and cut | disconnect the part containing a connection part.
In the third embodiment, the portion including the bonding material layer is cut using a diamond cutter or the like. For example, the bonding material layer may be broken by applying an external force using a machine or a jig. .
Also, in the fourth embodiment, as in the third embodiment, the honeycomb block made of the aggregate of honeycomb joined bodies is cut using a diamond cutter or the like. For example, an external force is used using a machine or a jig. You may fold a connection part by adding.
Examples of the method of applying an external force include a method of applying vibration, bending, twisting, tension, or load.

In the method for manufacturing a honeycomb structured body of the present invention, when the honeycomb block composed of the aggregate of honeycomb joined bodies is cut into honeycomb blocks by cutting, the method of cutting the honeycomb block composed of the aggregate of honeycomb joined bodies is shown in FIG. The method is not limited to the method shown in FIG. Hereinafter, another embodiment of a method for cutting a honeycomb block composed of an aggregate of honeycomb bonded bodies will be described.

FIG. 15 is a partially enlarged cross-sectional view schematically showing another example of a method for cutting a honeycomb block formed of an aggregate of honeycomb bonded bodies. FIG. 16 is a partial enlarged cross-sectional view schematically showing still another example of a method for cutting a honeycomb block formed of an aggregate of honeycomb bonded bodies.
FIG. 15 shows a cutting method using a blade having a thickness smaller than the thickness of the blade used in the cutting method shown in FIG. 11 and the distance between the end faces of the honeycomb fired body.
First, the blade 72a is put at a position spaced a predetermined distance from the end face 24a of the one honeycomb fired body 20a (the boundary surface between the bonding material layer 36 and the one honeycomb fired body 20a). Subsequently, the blade 72b is put at a position spaced a predetermined distance from the end face 24b of the other honeycomb fired body 20b (the boundary surface between the bonding material layer 36 and the other honeycomb fired body 20b). Thereby, the honeycomb block 62 formed of the aggregate of honeycomb bonded bodies can be separated into two honeycomb blocks. Further, the bonding material layer 36 that has entered the cell 21 can also be removed.
Specifically, when the distance E between the end face 24a of the honeycomb fired body 20a and the end face 24b of the honeycomb fired body 20b is 3.0 mm, the outer peripheral diamond having a thickness F of 2.0 mm to 3.0 mm Using a grindstone, cutting is performed at positions spaced 1.0 mm from the end face 24a of one honeycomb fired body 20a and the end face 24b of another honeycomb fired body 20b.

FIG. 16 shows a cutting method using a blade having the same thickness as the distance between the end faces of the honeycomb fired body.
Using the blade 73 having the same thickness F as the distance E between the end face 24a of the honeycomb fired body 20a and the end face 24b of the honeycomb fired body 20b, cutting is performed so as to remove the bonding material layer 36. Thereby, the honeycomb block 62 formed of the aggregate of honeycomb bonded bodies can be separated into two honeycomb blocks. In this case, the bonding material layer 36 that has entered the cell 21 may be removed separately after cutting.
Specifically, when the distance E between the end face 24a of the honeycomb fired body 20a and the end face 24b of the honeycomb fired body 20b is 3.0 mm, an outer peripheral diamond grindstone having a thickness F of 3.0 mm is used. Disconnect.

In the method for manufacturing a honeycomb structured body of the present invention, the method for joining the end faces of the honeycomb fired body is not limited to the method shown in the first embodiment to the fourth embodiment. The end faces of the honeycomb fired bodies may be joined to each other using a material paste and a spacing member as follows.
First, a bonding material paste is applied to the end face of one honeycomb fired body to adhere one surface of the spacing member. Next, a bonding material paste is applied to the end face of another honeycomb fired body. Thereafter, the other surface of the spacing member is bonded to the bonding material paste applied to the end face of another honeycomb fired body. Even with such a method, the end faces of the two honeycomb fired bodies can be joined to each other.

In the method for manufacturing a honeycomb structure of the present invention, when the bonding material includes a double-sided tape, examples of the adhesive for the double-sided tape include an acrylic adhesive, a rubber adhesive, and a silicone adhesive. Among these, an acrylic adhesive is desirable.
Moreover, as a base material (space | interval holding material) of a double-sided tape, a foam, a plastic film, a nonwoven fabric, paper etc. are mentioned, for example. Among the substrates of the double-sided tape, foam is desirable, and acrylic foam is more desirable among them. Moreover, the double-sided tape should just have an adhesive agent, and does not need to have a base material.

In the method for manufacturing a honeycomb structured body of the present invention, when the bonding material includes a flammable spacing member, examples of the flammable spacing member include cardboard, cloth, plastic, wood, and the like. Among the flammable spacing materials, cardboard is desirable. This is because it is easily available and easily burned or carbonized by heating.

Further, in the method for manufacturing a honeycomb structure of the present invention, when the bonding material includes a nonflammable spacing member, examples of the incombustible spacing member include fiber paper, inorganic filler paper, ceramic, glass, metal, and the like. It is done. Among nonflammable spacing materials, fiber paper or inorganic filled paper is desirable.
The fiber paper or the inorganic filled paper is preferably composed of fibers and inorganic particles. The fiber paper is processed into a so-called sheet shape of paper, mat, or felt with inorganic fibers as a main component, and the inorganic paper is a sheet with inorganic particles and / or fine fibers as main components. It is processed into a shape.
The fiber is at least selected from the group consisting of alumina fiber, zirconia fiber, alumina-silica fiber, silica fiber, glass fiber, calcium silicate fiber, magnesium silicate fiber, rock wool, glass wool, mineral fiber, and synthetic fiber. It is desirable to use one type.
The inorganic particles are at least selected from the group consisting of silica, titania, alumina, zirconia, spinel, magnesia, aluminum hydroxide, calcium carbonate, talc, calcium silicate, magnesium silicate, perlite, vermiculite, and diatomaceous earth. It is desirable to use one type.
In addition, inorganic fibers such as MgO, CaO and feldspar, organic matter such as wood pulp and organic binder, and inorganic fillers other than the inorganic particles may be added to the fibers, the inorganic particles, or the fibers and the inorganic particles. Good.

In the method for manufacturing a honeycomb structure of the present invention, when the end faces of the honeycomb fired bodies are bonded to each other via the bonding material paste, the method for drying and solidifying the bonding material paste is not particularly limited. In the third embodiment, the adhesive paste is dried and solidified, and the bonding material paste is also dried and solidified. However, a step of drying and solidifying the bonding material paste may be performed separately.
For example, when the step of drying and solidifying the bonding material paste is performed before the bonding step, it is possible to produce a bonded honeycomb body in which the end surfaces are bonded more firmly. Therefore, when the bonding process is performed using such a honeycomb bonded body, the honeycomb bonded body is separated during the bonding process, and it is difficult to cause a problem that the honeycomb fired body is displaced.

In the method for manufacturing a honeycomb structure of the present invention, when a bonding material paste is used, the bonding material paste may be made of the same material as the adhesive material paste, or may be made of a different material. When using a coating material paste, the coating material paste may be made of the same material as the adhesive paste, or may be made of a different material. Further, the bonding material paste and the coating material paste may be made of the same material.
Among these, it is desirable that the adhesive paste, the bonding material paste, and the coating material paste are all made of the same material. This is because if pastes made of the same material are used, there is no need to prepare each paste.
Moreover, in order to make it difficult to enter the inside of the cell, the bonding material paste preferably has a high viscosity and low fluidity.

In the method for manufacturing a honeycomb structured body of the present invention, the bonding process for producing an aggregate of honeycomb bonded bodies by bonding the side surfaces of a plurality of honeycomb bonded bodies with an adhesive paste is shown in FIG. The method is not limited.
A plurality of honeycomb joined bodies are juxtaposed vertically and horizontally through a spacer designed to have a thickness equivalent to the thickness of the adhesive layer formed between the honeycomb joined bodies. Therefore, a gap corresponding to the thickness of the spacer is formed between the honeycomb bonded bodies.
For example, a total of 16 honeycomb joined bodies of 4 in length and 4 in width are juxtaposed to produce a parallel joined body of honeycomb joined bodies, and an adhesive paste is used in the gaps between the joined honeycomb joined bodies using a filling device. Fill.
By doing in this way, the aggregate | assembly of the honeycomb joined body by which the adhesive paste is filled between 16 honeycomb joined bodies can also be produced.

In the honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention, the shape of the cross section perpendicular to the longitudinal direction of the honeycomb fired body of each cell is not particularly limited. In the honeycomb structure manufactured by the method for manufacturing a honeycomb structure according to the first to fourth embodiments, the shapes of the cross sections perpendicular to the longitudinal direction of the honeycomb fired body of each cell are all the same, and 4 Although it is a square, for example, it may be an octagon or a quadrangle.

Fig. 17 (a) is a perspective view schematically showing another example of the honeycomb fired body, and Fig. 17 (b) is a cross-sectional view taken along the line H-H in Fig. 17 (a).
In the honeycomb fired body 80 shown in FIGS. 17 (a) and 17 (b), a large number of cells 81a and 81b are arranged in parallel in the longitudinal direction (in the direction of arrow d in FIG. 17 (a)) with the cell wall 83 therebetween. One end of each of the cells 81 a and 81 b is sealed with a sealing material 82.
Here, the shape of the cross section perpendicular to the longitudinal direction of the cell 81a is a tetragon, and the shape of the cross section perpendicular to the longitudinal direction of the cell 81b is an octagon.

In the method for manufacturing a honeycomb structure according to the first embodiment to the fourth embodiment, a plurality of rectangular pillar-shaped honeycomb joined bodies are bundled to produce an aggregate of honeycomb joined bodies, and the adhesive paste is dried and solidified. After a honeycomb block made of an aggregate of honeycomb joined bodies is manufactured, the honeycomb block made of the aggregate of honeycomb joined bodies is cut. However, in the method for manufacturing a honeycomb structure of the present invention, a plurality of honeycomb bonded bodies using a honeycomb fired body manufactured in a predetermined shape are bundled to prepare an aggregate of honeycomb bonded bodies, and an adhesive paste is used. By drying and solidifying, a honeycomb block made of an aggregate of honeycomb joined bodies may be produced without performing cutting.

FIG. 18A to FIG. 18C are perspective views schematically showing another example of the honeycomb fired body.
That is, as shown in FIGS. 18A to 18C, a honeycomb fired body in which a plurality of cells 221, 231, and 241 are formed with cell walls 223, 233, and 243 separated from each other (two straight lines and 1 A honeycomb fired body comprising two arcs 220, a honeycomb fired body (honeycomb fired body comprising three straight lines and one arc) 230, and a honeycomb fired body (honeycomb fired body comprising four straight lines) 240. An aggregate of honeycomb joined bodies may be produced by manufacturing and binding a predetermined number of these honeycomb joined bodies. By drying and solidifying the adhesive paste with respect to the aggregate of the manufactured honeycomb joined body, it is possible to manufacture a honeycomb block made of the aggregate of honeycomb joined bodies having a columnar shape without performing a cutting process. .
When the honeycomb block 15 shown in FIG. 6 is manufactured, four honeycomb fired bodies 220 and 240 and eight honeycomb fired bodies 230 may be used.

In the first to fourth embodiments, it is not described that the catalyst is supported on the manufactured honeycomb structure, but the catalyst is supported on the honeycomb structure manufactured by the method for manufacturing the honeycomb structure of the present invention. May be.
As a method for supporting the catalyst on the honeycomb structure, for example, an oxide film made of alumina or the like having a high specific surface area is formed on the surface of the honeycomb structure, and noble metal, alkali metal, alkaline earth is formed on the surface of the oxide film. Examples thereof include a method of applying a catalyst containing a similar metal, an oxide or the like.

Regarding the adhesive paste used in the embodiment of the present invention, examples of the inorganic particles contained in the adhesive paste include carbide particles and nitride particles. Specific examples include silicon carbide particles, silicon nitride particles, and boron nitride particles. These may be used alone or in combination of two or more. Among the inorganic particles, silicon carbide particles having excellent thermal conductivity are desirable.
Examples of the inorganic binder contained in the adhesive paste include silica sol and alumina sol. These may be used alone or in combination of two or more. Among inorganic binders, silica sol is desirable.
Examples of the inorganic fibers contained in the adhesive paste include ceramic fibers such as silica-alumina, mullite, alumina, and silica. These may be used alone or in combination of two or more. Among inorganic fibers, alumina fiber is desirable.

The shape of the honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention is not limited to the columnar shape shown in FIG. 6, and may be any columnar shape such as an elliptical column shape or a polygonal column shape. .

The porosity of the honeycomb fired body manufactured by the method for manufacturing a honeycomb structure of the present invention is not particularly limited, but is preferably 35 to 60%.
The average pore diameter of the honeycomb fired body is preferably 5 to 30 μm.
The porosity and pore diameter can be measured by a conventionally known method such as a mercury intrusion method, an Archimedes method, or a measurement using a scanning electron microscope (SEM).

The cell density in the cross section perpendicular to the longitudinal direction of the honeycomb fired body manufactured by the method for manufacturing a honeycomb structure of the present invention is not particularly limited, but a desirable lower limit is 31.0 cells / cm ² (200 cells / inch ^2). ), The desirable upper limit is 93.0 pieces / cm ² (600 pieces / inch ² ), the more desirable lower limit is 38.8 pieces / cm ² (250 pieces / inch ² ), and the more desirable upper limit is 77.5 pieces. / Cm ² (500 pieces / inch ² ).
Further, the thickness of the cell wall of the honeycomb fired body is not particularly limited, but is desirably 0.1 to 0.4 mm.

The main component of the constituent material of the honeycomb fired body is not limited to silicon carbide. Other ceramic raw materials include, for example, nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, and titanium nitride, zirconium carbide, and carbonized Examples thereof include ceramic powders such as carbide ceramics such as titanium, 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 mixed with the above-mentioned ceramics, and ceramics in which the above-described ceramics are bonded with silicon or a silicate compound can be cited as constituent materials. Those containing silicon (silicon-containing silicon carbide) are desirable.
In particular, a silicon-containing silicon carbide ceramic containing 60% by weight or more of silicon carbide is desirable.

In the method for manufacturing a honeycomb structure of the present invention, the organic binder contained in the wet mixture to be extruded is not particularly limited, and examples thereof include methyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, and polyethylene glycol.
Moreover, it does not specifically limit as a plasticizer contained in the said wet mixture, For example, glycerol etc. are mentioned.
Moreover, it does not specifically limit as a lubricant agent contained in the said wet mixture, For example, polyoxyalkylene type compounds, such as polyoxyethylene alkyl ether and polyoxypropylene alkyl ether, etc. are mentioned.
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 wet mixture.

In preparing the wet mixture, a dispersion medium liquid may be used. Examples of the dispersion medium liquid include water, an organic solvent such as benzene, and an alcohol such as methanol.
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.

Although the embodiment of the present invention has been described using a honeycomb structure in which either one end of the cell is sealed, the honeycomb structure in the embodiment of the present invention has the cell end sealed. There may be no honeycomb structure. In the honeycomb structure in which the end portions of the cells are not sealed, it is considered that the effect of the present invention can be obtained in the same manner as the honeycomb structure in which any one end portion of the cells is sealed.

10, 10a, 10b Honeycomb structure 11, 11a, 11b Adhesive layer 12 Coat layer 14a, 14b, 15, 15a, 15b Honeycomb block 16 Honeycomb molded body 19 Adhesive paste 20, 20a, 20b, 80, 220, 230, 240 Honeycomb fired bodies 21, 81a, 81b, 221, 231, 241 Cells 23, 83, 223, 233, 243 Cell walls 24a, 24b End faces 25a, 25b of honeycomb fired bodies 29 Side faces of honeycomb joined bodies 29 Sealant paste 30 Joining Materials 31a, 31b Double-sided tape 32 Interval holding material (flammable interval holding material)
35 Bonding material paste 40, 60 Honeycomb bonded body 41 Honeycomb bonded body aggregate 42, 43, 62, 63 Honeycomb block comprising a honeycomb bonded body aggregate

Claims (16)

Forming a columnar honeycomb formed body in which a plurality of cells are arranged in parallel in the longitudinal direction across the cell wall by molding a ceramic raw material;
Firing the honeycomb formed body to produce a honeycomb fired body;
A method of manufacturing a honeycomb structure including a step of manufacturing a honeycomb block including a plurality of honeycomb fired bodies,
The step of manufacturing the honeycomb block includes:
A joining step of producing a honeycomb joined body longer than the length of one honeycomb fired body by joining the end faces of at least two honeycomb fired bodies through a joining material;
An adhesion process for producing an aggregate of honeycomb bonded bodies by bonding side surfaces of a plurality of honeycomb bonded bodies through an adhesive paste;
Drying and solidifying the adhesive paste to produce a honeycomb block composed of an aggregate of honeycomb joined bodies; and
A separation step of separating at least two honeycomb blocks in which side surfaces of a plurality of honeycomb fired bodies are bonded to each other by separating a honeycomb block formed of the aggregate of the honeycomb bonded bodies at the position of the bonding material. A method for manufacturing a featured honeycomb structure. The method for manufacturing a honeycomb structured body according to claim 1, wherein the bonding material includes a double-sided tape. The method for manufacturing a honeycomb structured body according to claim 2, wherein the bonding material further includes a spacing member provided with the double-sided tape on both surfaces thereof. The method for manufacturing a honeycomb structured body according to claim 3, wherein the spacing member is a combustible spacing member. The method for manufacturing a honeycomb structured body according to claim 4, wherein the combustible spacing member is cardboard. The method for manufacturing a honeycomb structure according to claim 3, wherein the spacing member is a nonflammable spacing member. The method for manufacturing a honeycomb structure according to claim 6, wherein the nonflammable spacing member is fiber paper, inorganic filler paper, ceramic, glass, or metal. The manufacturing of the honeycomb structure according to any one of claims 2 to 7, wherein in the drying and solidifying step of the adhesive paste, the adhesive paste is dried and solidified, and the double-sided tape and / or the spacing member is burned or carbonized. Method. The method for manufacturing a honeycomb structure according to claim 1, wherein the bonding material is made of a bonding material paste containing an inorganic sol. The method for manufacturing a honeycomb structure according to claim 9, wherein the bonding material paste is made of the same material as the adhesive paste. The method for manufacturing a honeycomb structured body according to claim 9 or 10, further comprising a step of drying and solidifying the bonding material paste, wherein the step of drying and solidifying the bonding material paste is performed before the bonding step. The method for manufacturing a honeycomb structure according to claim 9 or 10, wherein in the drying and solidifying step of the adhesive paste, the adhesive paste is dried and solidified, and the bonding material paste is dried and solidified. After the drying and solidifying step of the adhesive material paste and before the separating step, the coating material paste is applied to the outer peripheral surface of the honeycomb block composed of the aggregate of honeycomb joined bodies, and the coating material paste is dried and solidified. The method for manufacturing a honeycomb structured body according to any one of claims 1 to 12, further comprising a coat layer forming step of forming a layer. 14. The separation step according to any one of claims 1 to 13, wherein in the separation step, an external force is applied to the honeycomb block made of the aggregate of honeycomb joined bodies to separate the honeycomb block made of the aggregate of honeycomb joined bodies at the position of the bonding material. A method for manufacturing a honeycomb structure according to claim 1. The method for manufacturing a honeycomb structure according to any one of claims 1 to 13, wherein, in the separation step, a portion including the bonding material is cut along a plane parallel to an end face of the honeycomb fired body. After the step of manufacturing the honeycomb formed body, and before the step of manufacturing the honeycomb fired body, a sealing step of filling a plug material paste so that either one end of the cell is sealed Furthermore, the manufacturing method of the honeycomb structure in any one of Claims 1-15.

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