JP2013227191A - ハニカム構造体の製造方法 - Google Patents
ハニカム構造体の製造方法 Download PDFInfo
- Publication number
- JP2013227191A JP2013227191A JP2013029531A JP2013029531A JP2013227191A JP 2013227191 A JP2013227191 A JP 2013227191A JP 2013029531 A JP2013029531 A JP 2013029531A JP 2013029531 A JP2013029531 A JP 2013029531A JP 2013227191 A JP2013227191 A JP 2013227191A
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- Prior art keywords
- electrode
- honeycomb structure
- honeycomb
- formed body
- electrode paste
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- Chemical & Material Sciences (AREA)
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- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Mechanical Engineering (AREA)
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- Physics & Mathematics (AREA)
- Chemical Kinetics & Catalysis (AREA)
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Abstract
【解決手段】離型シートの表面に電極用ペーストを塗膜して、離型シートに電極用ペースト膜が配設された電極形成用シート23を作製し、複数のセルを区画形成する隔壁と外周壁とを有し、側面が曲面である筒状のセラミックハニカム成形体の側面に、電極形成用シート23を貼り付けて、電極形成用シート付きハニカム成形体110を作製する電極形成用シート付きハニカム成形体形成工程と、電極形成用シート付きハニカム成形体110を焼成するか、又は、電極形成用シート付きハニカム成形体110から離型シート22を除去して電極用ペースト付きハニカム成形体を形成した後に電極用ペースト付きハニカム成形体を焼成して、側面に電極を有するハニカム構造体を得るハニカム構造体形成工程とを有するハニカム構造体の製造方法。
【選択図】図4
Description
(1−1)電極形成用シート付きハニカム成形体形成工程;
本発明のハニカム構造体の製造方法の一の実施形態における電極形成用シート付きハニカム成形体形成工程は、以下の通りである。離型シート22の表面に電極用ペーストを塗膜して電極用ペースト膜6の一方の面に離型シート22が配設された電極形成用シート23を作製する(図1を参照)。そして、電極形成用シート23を、「側面5が曲面である筒状のセラミックハニカム成形体100の側面5」に、電極用ペースト膜6がセラミックハニカム成形体100の側面5に付着するように貼り付ける(図4〜図6を参照)。これにより、電極形成用シート付きハニカム成形体110を得る(図4〜図6を参照)。ここで、側面5が曲面である筒状のセラミックハニカム成形体100は、流体の流路となる「一方の端面11から他方の端面12まで延びる」複数のセル2を区画形成する隔壁1と、最外周に位置する外周壁3とを有するものである(図2、図3を参照)。尚、側面5は、外周壁3の表面である。
値(離型シートの質量の増加量)である。
形成する方法としては特に制限はなく、例えば、ニーダー、真空土練機等を用いる方法を
挙げることができる。
次に、電極形成用シート付きハニカム成形体110(図4〜6を参照)を焼成して、側面に電極が配設されたハニカム構造体300を作製する(図8を参照)。または、電極形成用シート付きハニカム成形体から離型シートを除去して電極用ペースト付きハニカム成形体200(図7を参照)を形成した後に当該電極用ペースト付きハニカム成形体を焼成して、側面に電極が配設されたハニカム構造体300を作製してもよい(図8を参照)。電極形成用シート付きハニカム成形体110を焼成してハニカム構造体300を作製する場合には、電極形成用シート付きハニカム成形体110を焼成する際に、離型シートが燃焼する(焼失する)。これにより、電極形成用シート付きハニカム成形体から、離型シートが除去される。図7は、本発明のハニカム構造体の製造方法の一実施形態において、ハニカム構造体の製造過程において作製される電極用ペースト付きハニカム成形体200を模式的に示す斜視図である。図8は、本発明のハニカム構造体の製造方法の一の実施形態によって製造されたハニカム構造体300を模式的に示す斜視図である。
次に、本発明のハニカム構造体の製造方法の一の実施形態で得られるハニカム構造体について説明する。
炭化珪素(SiC)粉末と金属珪素(Si)粉末とを80:20の質量割合で混合した。そして、この混合物に、バインダとしてヒドロキシプロピルメチルセルロース、造孔材として吸水性樹脂を添加すると共に、水を添加して成形原料とした。そして、成形原料を真空土練機により混練し、円柱状の坏土を作製した。バインダの含有量は、炭化珪素(SiC)粉末と金属珪素(Si)粉末の合計を100質量部としたときに7質量部であった。造孔材の含有量は、炭化珪素(SiC)粉末と金属珪素(Si)粉末の合計を100質量部としたときに3質量部であった。水の含有量は、炭化珪素(SiC)粉末と金属珪素(Si)粉末の合計を100質量部としたときに42質量部であった。炭化珪素粉末の平均粒子径は20μmであり、金属珪素粉末の平均粒子径は6μmであった。また、造孔材の平均粒子径は、20μmであった。炭化珪素、金属珪素及び造孔材の平均粒子径は、レーザー回折法で測定した値である。
離型シートの種類を、表1に示すように変更した以外は、実施例1と同様にしてハニカム構造体を作製した。実施例1の場合と同様に、電極の厚さ、「気泡」、及び電極の「剥離」、について確認した。結果を表1に示す。
印刷により離型シートに電極用ペーストを塗膜して、電極形成用シートを作製する際の、電極用ペースト31の塗布回数を合計で6回とした以外は、実施例1と同様にしてハニカム構造体を作製した。実施例1の場合と同様に、電極の厚さ、「気泡」、及び電極の「剥離」、について確認した。結果を表1に示す。
Claims (7)
- 離型シートの表面に電極用ペーストを塗膜して、前記離型シートの一方の面に電極用ペースト膜が配設された電極形成用シートを作製し、
流体の流路となる一方の端面から他方の端面まで延びる複数のセルを区画形成する隔壁と、最外周に位置する外周壁とを有し、側面が曲面である筒状のセラミックハニカム成形体の前記側面に、前記電極形成用シートを、前記電極用ペースト膜が前記セラミックハニカム成形体の側面に付着するように貼り付けて、電極形成用シートが側面に配設されたセラミックハニカム成形体である電極形成用シート付きハニカム成形体を作製する電極形成用シート付きハニカム成形体形成工程と、
前記電極形成用シート付きハニカム成形体を焼成するか、又は、前記電極形成用シート付きハニカム成形体から離型シートを除去して電極用ペースト付きハニカム成形体を形成した後に前記電極用ペースト付きハニカム成形体を焼成して、側面に電極を有するハニカム構造体を得るハニカム構造体形成工程とを有するハニカム構造体の製造方法。 - 離型シートの表面に電極用ペーストを塗膜して、前記離型シートの一方の面に、複数層の電極用ペースト層から構成された電極用ペースト膜が配設された電極形成用シートを作製する請求項1に記載のハニカム構造体の製造方法。
- 前記離型シートの表面粗さRaが、0.05〜10μmである請求項1又は2に記載のハニカム構造体の製造方法。
- 離型シートの表面粗さRaが、前記セラミックハニカム成形体の表面粗さRaよりも小さい請求項1〜3のいずれかに記載のハニカム構造体の製造方法。
- 前記離型シートの吸水性が、0.003〜0.12g/分である請求項1〜4のいずれかに記載のハニカム構造体の製造方法。
- 前記電極用ペースト付きハニカム成形体の側面に付着している電極用ペースト膜の厚さが、10〜5000μmである請求項1〜5のいずれかに記載のハニカム構造体の製造方法。
- 前記ハニカム構造体の前記セルの延びる方向に直交する断面において、前記電極の中心角の0.5倍が、15〜65°である請求項1〜6のいずれかに記載のハニカム構造体の製造方法。
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