JP3032342B2 - Method for manufacturing ceramic honeycomb structure - Google Patents
Method for manufacturing ceramic honeycomb structureInfo
- Publication number
- JP3032342B2 JP3032342B2 JP3251201A JP25120191A JP3032342B2 JP 3032342 B2 JP3032342 B2 JP 3032342B2 JP 3251201 A JP3251201 A JP 3251201A JP 25120191 A JP25120191 A JP 25120191A JP 3032342 B2 JP3032342 B2 JP 3032342B2
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb structure
- ceramic honeycomb
- core material
- compression
- ceramic
- 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.)
- Expired - Fee Related
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- Press-Shaping Or Shaping Using Conveyers (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明はアイソスタティック成形
によるセラミックスハニカム構造体の製造方法に関す
る。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a ceramic honeycomb structure by isostatic molding.
【０００２】[0002]
【従来の技術】一般にセラミックス構造体の製造方法と
して、概略成形した後に切削加工・研削加工等によって
形成方法が知られている。しかし、硬化前のセラミック
スは強度が低く、加工中に破損しやすく、逆に、硬化後
のセラミックスは硬度が高く、切削・研削等の加工が極
めて困難である。特に、断面角型の空洞部を有するセラ
ミックスハニカム構造体を形成するとき、空洞部の切削
加工・研削加工はほとんど不可能である。そこで、従来
セラミックスハニカム構造体を形成するは、鋳込み成形
法と押出し成形法とが用いられている。図６は鋳込み成
形法によるセラミックスハニカム構造体を示している。
鋳込み成形法によるセラミックスハニカム構造体２１は
溝付き部材２２と板状部材２３とからなる。このセラミ
ックスハニカム構造体２１を製造するには、最初に内部
に溝付き部材２２と板状部材２３とを形成する空洞を有
する石膏型を形成すると共に、粉体のセラミックスを水
と混合してセラミックススラリーを製造する。次に前記
セラミックススラリーを溝付き部材２２と板状部材２３
の石膏型にそれぞれ流し込み、石膏型の吸水作用によっ
て溝付き部材２２と板状部材２３の中間成形品を形成す
る。この溝付き部材２２と板状部材２３の中間成形品同
士を、図６に示すように、接着部２４で互いに接着した
後に、乾燥・焼結してセラミックスハニカム構造体を形
成する。図７は押出し成形法によってセラミックスハニ
カム構造体を押出し成形している工程を示している。符
号３１は押出し成形装置を示しており、この押出し成形
装置３１は内部にセラミックススラリーを収容できる圧
縮部３２を有し、この圧縮部３２はその一の端面に、押
出し用ノズル３３を有し、この押出し用ノズル３３に対
向する圧縮部３２の端面は摺動してセラミックススラリ
ーを圧縮できる圧縮壁（図示せず）に形成されている。
前記押出し用ノズル３３はセラミックスハニカム構造体
の外形を形成するノズル開口部３４を有し、このノズル
開口部３４の内部にはセラミックスハニカム構造体の空
洞部を形成する複数の中子３５が配設されている。この
押出し成形装置３１によってセラミックスハニカム構造
体を製造するには、圧縮部３２の内部にセラミックスス
ラリーを充填し、圧縮部３２の圧縮壁を図中に示す矢印
Ｐ1 の方向に圧縮し、押出し用ノズル３３を介してセラ
ミックススラリーを押し出す。セラミックススラリーは
押出し用ノズル３３を通る際に、ノズル開口部３４と中
子３５との間の空間形状によって、図に示す方向Ｐ
2 に、セラミックスハニカム構造体の中間成形品３６と
して押し出される。このセラミックスハニカム構造体の
中間成形品３６を乾燥・焼成してセラミックスハニカム
構造体の最終成形品を得ることができる。2. Description of the Related Art In general, as a method of manufacturing a ceramic structure, a method of forming a ceramic structure by roughly forming, followed by cutting, grinding, or the like is known. However, ceramics before hardening have low strength and are easily broken during processing. Conversely, ceramics after hardening have high hardness, and processing such as cutting and grinding is extremely difficult. In particular, when forming a ceramic honeycomb structure having a hollow section having a square cross section, it is almost impossible to cut and grind the hollow section. Therefore, in order to form a ceramic honeycomb structure, a casting method and an extrusion method are conventionally used. FIG. 6 shows a ceramic honeycomb structure by a casting method.
The ceramic honeycomb structure 21 formed by the casting method includes a grooved member 22 and a plate-like member 23. In order to manufacture the ceramic honeycomb structure 21, first, a gypsum mold having a cavity in which a grooved member 22 and a plate-shaped member 23 are formed is formed, and the ceramic powder is mixed with water to form the ceramic honeycomb structure 21. Make a slurry. Next, the ceramic slurry is applied to the grooved member 22 and the plate-like member 23.
Respectively, and an intermediate molded product of the grooved member 22 and the plate-like member 23 is formed by the water absorbing action of the gypsum mold. As shown in FIG. 6, the intermediate molded products of the grooved member 22 and the plate-like member 23 are bonded to each other at a bonding portion 24, and then dried and sintered to form a ceramic honeycomb structure. FIG. 7 shows a step of extruding a ceramic honeycomb structure by an extrusion molding method. Reference numeral 31 denotes an extruder, the extruder 31 has a compression section 32 capable of containing a ceramic slurry therein, and the compression section 32 has an extrusion nozzle 33 on one end surface thereof. The end face of the compression section 32 facing the extrusion nozzle 33 is formed on a compression wall (not shown) which can slide and compress the ceramic slurry.
The extrusion nozzle 33 has a nozzle opening 34 that forms the outer shape of the ceramic honeycomb structure. Inside the nozzle opening 34, a plurality of cores 35 that form a cavity of the ceramic honeycomb structure are provided. Have been. The extrusion molding device 31 for producing a ceramic honeycomb structure, a ceramic slurry is filled in the compression section 32, a compression wall of the compression unit 32 compresses in the direction of arrow P 1 shown in the drawing, extrusion The ceramic slurry is extruded through the nozzle 33. When the ceramic slurry passes through the extrusion nozzle 33, the direction P shown in the figure depends on the shape of the space between the nozzle opening 34 and the core 35.
It is extruded as an intermediate molded product 36 of a ceramic honeycomb structure. The intermediate molded product 36 of the ceramic honeycomb structure is dried and fired to obtain a final molded product of the ceramic honeycomb structure.
【０００３】[0003]
【発明が解決しようとする課題】しかしながら上記鋳込
み成形法による従来のセラミックスハニカム構造体の製
造方法は、溝付き部材と板状部材と別々に鋳込み成形
し、接着・乾燥・焼結する工程中に、溝付き部材と板状
部材との接着部に亀裂が生じたり、セラミックスハニカ
ム構造体全体に歪みが生じたりする問題があった。さら
に、セラミックスのスラリーを石膏型に流し込んで溝付
き部材と板状部材とを形成するには、セラミックスのス
ラリーの水分の含有量や、石膏型の状態等の管理を厳密
に行う必要があり、セラミックスハニカム構造体の製造
が容易でない。一方、上記押出し成形法による従来のセ
ラミックスハニカム構造体の製造方法では、大型のセラ
ミックスハニカム構造体を歪みなく押し出すのが極めて
困難であり、かつ、上記鋳込み成形法と同様にスラリー
の水分の含有量の管理が困難である。さらに、押出し成
形法によるセラミックスハニカム構造体は、セラミック
スの密度にむらが生じやすく、このことにより、乾燥・
焼成時に亀裂や歪等が生じ、製品の歩留りが低いという
問題があった。そこで、本発明の目的は、製造中に亀裂
や歪等を生じることなく、密度が均一なセラミックスハ
ニカム構造体を一体に成形でき、切削・研削加工等によ
って高い寸法精度を得ることができるセラミックスハニ
カム構造体の製造方法を提供することにある。However, the conventional method for manufacturing a ceramic honeycomb structure by the above-mentioned casting method involves a process of separately casting and forming a grooved member and a plate-like member, and bonding, drying and sintering. In addition, there has been a problem in that a crack is generated in the bonded portion between the grooved member and the plate-shaped member, and distortion is generated in the entire ceramic honeycomb structure. Furthermore, in order to form the grooved member and the plate-shaped member by pouring the ceramic slurry into the gypsum mold, it is necessary to strictly control the water content of the ceramic slurry and the state of the gypsum mold, It is not easy to manufacture a ceramic honeycomb structure. On the other hand, in the conventional method for manufacturing a ceramic honeycomb structure by the extrusion molding method, it is extremely difficult to extrude a large ceramic honeycomb structure without distortion, and the water content of the slurry is the same as in the casting method. Is difficult to manage. In addition, the ceramic honeycomb structure formed by the extrusion molding method tends to have uneven density of the ceramic, which causes
There has been a problem that cracks, distortions, and the like occur during firing, and the yield of products is low. Therefore, an object of the present invention is to form a ceramic honeycomb structure having a uniform density without generating cracks or distortion during manufacturing, and to obtain a ceramic honeycomb having high dimensional accuracy by cutting and grinding. An object of the present invention is to provide a method for manufacturing a structure.
【０００４】上記課題を解決するために本発明に係るセ
ラミックスハニカム構造体の製造方法は、ラバー型の内
側両端部に芯材を保持する一対の芯材保持用部材を配置
し、この芯材保持用部材によってセラミックスハニカム
構造体の空洞部を形成する複数の芯材の両端を保持し、
この芯材とラバー型との間に形成された空間に粉体のセ
ラミックスを充填し、粉体セラミックスを充填したラバ
ー型を圧縮用流体で満たされた圧力容器内に配置し、ア
イソスタティック成形によってラバー型内の粉体セラミ
ックスを圧縮成形するセラミックスハニカム構造体の製
造方法であって、 芯材を剛性の高い材料によって形成
し、芯材保持用部材を圧縮方向によって異なる圧縮比を
有する加圧異方性構造材料によって形成し、セラミック
スハニカム構造体の空洞部の内側寸法および長手方向の
寸法が圧縮前と圧縮後においてほぼ等しくなり、かつ、
セラミックスハニカム構造体の空洞部の周囲の肉厚が圧
縮によって所定の寸法となるように構成したことを特徴
とするものである。[0004] In order to solve the above-mentioned problems, a cell according to the present invention is disclosed.
The manufacturing method of the rubber-mixed honeycomb structure is based on the rubber type.
A pair of core material holding members that hold the core material are arranged at both ends
Then, the ceramic honeycomb is formed by the core material holding member.
Holding both ends of a plurality of core members forming the cavity of the structure,
The space between the core material and the rubber mold
Rubber filled with Lamix and powdered ceramics
-Place the mold in a pressure vessel filled with compression fluid and
Powder ceramic in rubber mold by isostatic molding
Of ceramic honeycomb structure for compression molding
Manufacturing method, where the core material is formed of a highly rigid material
The compression ratio varies depending on the compression direction.
Formed by pressure anisotropic structural material, having ceramic
The inside dimensions and longitudinal direction of the cavity of the honeycomb structure
Dimensions are almost equal before and after compression, and
The thickness around the cavity of the ceramic honeycomb structure is
It is characterized in that it is configured to have a predetermined size by shrinking .
【０００５】[0005]
【作用】本発明のセラミックスハニカム構造体の製造方
法は、ラバー型の内部の所定位置にセラミックスハニカ
ム構造体の空洞部を形成する複数の芯材を保持し、この
芯材とラバー型との間に形成された空間に粉体のセラミ
ックスを充填し、この粉体セラミックスをアイソスタテ
ィック成形によって圧縮してセラミックスハニカム構造
体を形成するので、粉体のセラミックスがすべての方向
に等しく圧縮され、密度が均一なセラミックスハニカム
構造体の中間成形品を形成する。セラミックスの密度が
均一なことにより、セラミックスハニカム構造体を焼成
するときに、セラミックスハニカム構造体が均一に収縮
し、亀裂や歪を生じることがない。また、ラバー型の内
部に芯材を配置して粉体のセラミックスをアイソスタテ
ィック成形によってセラミックスハニカム構造体を一体
に圧縮成形するので、部品を接着する必要がなく、接着
部の亀裂を回避することができ、高い強度のセラミック
スハニカム構造体を得ることができる。また、アイソス
タティック成形後のセラミックスハニカム構造体の中間
成形品は、適当な強度を有しており、切削・研削等の加
工を行って所定の寸法に形成することができる。このこ
とにより、精密な寸法精度と良好な仕上げ面を有するセ
ラミックスハニカム構造体を得ることができる。さら
に、本発明のセラミックスハニカム構造体の製造方法に
よれば、特定の水分含有量を有するセラミックススラリ
ーを製造する必要がなく、製造工程や製造管理を容易な
ものとすることができる。According to the method for manufacturing a ceramic honeycomb structure of the present invention, a plurality of cores forming a hollow portion of a ceramic honeycomb structure are held at predetermined positions inside a rubber mold, and a plurality of cores are formed between the core material and the rubber mold. Is filled with powdered ceramics, and the powdered ceramics is compressed by isostatic molding to form a ceramic honeycomb structure, so that the powdered ceramics are compressed equally in all directions, and the density is reduced. An intermediate molded article of a uniform ceramic honeycomb structure is formed. Due to the uniform density of the ceramics, when the ceramic honeycomb structure is fired, the ceramic honeycomb structure shrinks uniformly and does not cause cracks or distortion. In addition, since the core material is placed inside the rubber mold and the ceramics of the powder is compression molded integrally with the ceramics by isostatic molding, there is no need to bond the parts, and cracks in the bonded part are avoided. Thus, a ceramic honeycomb structure having high strength can be obtained. Further, the intermediate molded article of the ceramic honeycomb structure after the isostatic molding has an appropriate strength, and can be formed into a predetermined size by performing processing such as cutting and grinding. As a result, a ceramic honeycomb structure having precise dimensional accuracy and a good finished surface can be obtained. Furthermore, according to the method for manufacturing a ceramic honeycomb structure of the present invention, it is not necessary to manufacture a ceramic slurry having a specific water content, and the manufacturing process and manufacturing management can be simplified.
【０００６】[0006]
【実施例】以下本発明の実施例について添付の図面を参
照して説明する。図１は、本発明のセラミックスハニカ
ム構造体の製造方法に使用する型部材の構造を示してい
る。ラバー型１は、箱体１ａとふた１ｂとからなり、全
体が天然ゴム、ウレタンゴム、シリコンゴム、ラテック
スゴム、ゴムアメチューブ等の弾性部材によって形成さ
れている。箱体１ａの底部には、圧縮方向によって異な
る圧縮比を有する加圧異方性構造材料からなる芯材保持
用部材２ａが配設されている。芯材保持用部材２ａの上
面には芯材の断面形状と整合する角穴３ａが形成されて
いる。各角穴３ａには、セラミックスハニカム構造体の
空洞部を形成する芯材４の下端が挿入されている。この
実施例の芯材４は炭素鋼によって形成され、断面矩形の
形状を有している。芯材４の上端は、前記芯材保持用部
材２ａと同一形状の芯材保持用部材２ｂの角穴３ｂ（図
示せず）に挿入されている。ラバー型１のふた１ｂは、
前記芯材保持用部材２ａ，２ｂと芯材４とを収容して箱
体１ａの上部開口を密封できるように形成されている。Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 shows the structure of a mold member used in the method for manufacturing a ceramic honeycomb structure of the present invention. The rubber mold 1 includes a box 1a and a lid 1b, and is entirely formed of an elastic member such as natural rubber, urethane rubber, silicon rubber, latex rubber, or a rubber tube. A core holding member 2a made of a pressurized anisotropic structural material having a different compression ratio depending on the compression direction is disposed at the bottom of the box 1a. Square holes 3a are formed on the upper surface of the core material holding member 2a so as to match the cross-sectional shape of the core material. The lower end of the core material 4 forming the cavity of the ceramic honeycomb structure is inserted into each of the square holes 3a. The core member 4 of this embodiment is made of carbon steel and has a rectangular cross section. The upper end of the core member 4 is inserted into a square hole 3b (not shown) of the core member holding member 2b having the same shape as the core member holding member 2a. The lid 1b of the rubber mold 1 is
The core holding members 2a and 2b and the core 4 are housed so that the upper opening of the box 1a can be sealed.
【０００７】図２は前記加圧異方性構造材料からなる芯
材保持用部材２ａ，２ｂの一例を示している。図に示す
ように、加圧異方性構造材料からなる芯材保持用部材２
ａ，２ｂは平面状の塑性板５と波板状のゴム板６とを交
互に積層して形成されている。平面状の塑性板５と波板
状のゴム板６の板厚と、波板状ゴム板６の波の間隔や波
の高さを調整することにより、図中に示す方向Ｘ，Ｙ，
Ｚの圧縮力に対して、それぞれ所望の異なる圧縮比を有
するようにすることができる。FIG. 2 shows an example of the core material holding members 2a and 2b made of the above-described pressure anisotropic structural material. As shown in the figure, a core material holding member 2 made of a pressure anisotropic structural material
Reference numerals a and 2b are formed by alternately stacking planar plastic plates 5 and corrugated rubber plates 6. By adjusting the thickness of the flat plastic plate 5 and the corrugated rubber plate 6 and the interval between the waves and the height of the corrugated rubber plate 6, the directions X, Y, and
For a compression force of Z, each may have a different desired compression ratio.
【０００８】以下に、上記型部材に用いてセラミックス
ハニカム構造体を形成する本発明のセラミックスハニカ
ム構造体の製造方法の各工程について説明する。図３
は、ラバー型１に型部材の一部を固定して、粉体のセラ
ミックスを充填している工程を示している。最初にラバ
ー型１の箱体１ａの底部に上記芯材保持用部材２ａを配
設し、この芯材保持用部材２ａの各角穴３ａに芯材４の
下端を挿入し、芯材保持用部材２ａの上面に芯材４を立
設する。次に図３に示すように、芯材４とラバー型１と
の間に形成された空間に、セラミック・バインダーを含
むスプレードライ処理品である粉体のセラミックス７を
充填する。この粉体のセラミックス７を充填する際に、
ラバー型１と芯材４の全体に振動を与えながら充填する
ことにより、芯材４とラバー型１との間の狭い空間に前
記粉体のセラミックス７を隙間なく充填することができ
る。所定量の粉体のセラミックス７を充填した後は、芯
材４の上端に芯材保持用部材２ｂを嵌合させ、さらにふ
た１ｂによってラバー型１を密封する。Hereinafter, each step of the method for manufacturing a ceramic honeycomb structure of the present invention for forming a ceramic honeycomb structure by using the above-mentioned mold member will be described. FIG.
Shows a process in which a part of the mold member is fixed to the rubber mold 1 and the ceramic powder is filled. First, the core material holding member 2a is disposed at the bottom of the box 1a of the rubber mold 1, and the lower end of the core material 4 is inserted into each square hole 3a of the core material holding member 2a. The core 4 is erected on the upper surface of the member 2a. Next, as shown in FIG. 3, a powder ceramic 7 which is a spray-dried product containing a ceramic binder is filled in a space formed between the core material 4 and the rubber mold 1. When filling this powdered ceramic 7,
By filling the entire rubber mold 1 and the core material 4 while applying vibration, the narrow space between the core material 4 and the rubber mold 1 can be filled with the ceramic powder 7 without gaps. After a predetermined amount of powdered ceramics 7 is filled, the core material holding member 2b is fitted to the upper end of the core material 4, and the rubber mold 1 is sealed with the lid 1b.
【０００９】図４は、上記の粉体セラミックス７を充填
したラバー型１をアイソスタティック成形法によって圧
縮する工程を示している。上述したようにラバー型１の
内部に芯材保持用部材２ａ，２ｂと芯材４と粉体のセラ
ミックス７とを密封した後に、このラバー型１を圧力容
器８の内部に配置し、圧力容器８の底部の注水口９から
水を注入する。圧力容器８は加圧用蓋８ａを有し、この
加圧用蓋８ａの重量によって圧力容器内の水は所定の圧
力に上昇してこの圧力に維持される。図中の矢印Ａは注
入される加圧水を示している。圧力容器８内の水の圧力
によって、ラバー型１の外面には図中に示すように均一
な圧力Ｐが作用し、ラバー型１内の粉体のセラミックス
７をすべての方向に等しく圧縮し、粉体セラミックス７
を均一な密度で互いに一体に結合させ、所定の形状のセ
ラミックスハニカム構造体の中間成形品を形成する。FIG. 4 shows a step of compressing the rubber mold 1 filled with the powder ceramics 7 by an isostatic molding method. After sealing the core material holding members 2a and 2b, the core material 4 and the powdered ceramic 7 inside the rubber mold 1 as described above, the rubber mold 1 is placed inside the pressure vessel 8 and Water is injected from the water inlet 9 at the bottom of the nozzle 8. The pressure vessel 8 has a pressure lid 8a, and the water in the pressure vessel rises to a predetermined pressure by the weight of the pressure lid 8a and is maintained at this pressure. Arrow A in the figure indicates the pressurized water to be injected. Due to the pressure of the water in the pressure vessel 8, a uniform pressure P acts on the outer surface of the rubber mold 1 as shown in the figure, and the powder ceramics 7 in the rubber mold 1 is compressed equally in all directions, Powder ceramics 7
Are bonded together at a uniform density to form an intermediate molded article of a ceramic honeycomb structure having a predetermined shape.
【００１０】図５は、上記のセラミックスハニカム構造
体の中間成形品を取り出す工程を示している。アイソス
タティック成形法によって粉体のセラミックス７を圧縮
した後に、ラバー型１を圧力容器８から取り出し、図５
に示すように、ラバー型１から、芯材保持用部材２ａ，
２ｂと芯材４とセラミックスハニカム構造体の中間成形
品１０とを取り出す。次にに芯材４の両端の芯材保持用
部材２ａ，２ｂを取り去り、セラミックスハニカム構造
体の中間成形品１０から芯材４を抜き取る。このセラミ
ックスハニカム構造体の中間成形品１０は粉体のセラミ
ックス７が圧縮によって互いに結合し、高い強度を有し
ているので、必要に応じて切削・研削等の加工を行って
精密な所定の寸法に形成することができる。次に、この
セラミックスハニカム構造体の中間成形品１０を、従来
知られた方法により、最終製品に焼成する。この場合、
セラミックスハニカム構造体の中間成形品１０のセラミ
ックスの密度が均一なことにより、焼成中に亀裂や歪が
生じることなく、脱脂・焼成が容易である。FIG. 5 shows a step of taking out an intermediate molded product of the ceramic honeycomb structure. After compressing the powdered ceramics 7 by the isostatic molding method, the rubber mold 1 is taken out of the pressure vessel 8 and is pressed as shown in FIG.
As shown in FIG.
2b, the core material 4, and the intermediate molded product 10 of the ceramic honeycomb structure are taken out. Next, the core material holding members 2a and 2b at both ends of the core material 4 are removed, and the core material 4 is extracted from the intermediate molded product 10 of the ceramic honeycomb structure. Since the powdery ceramics 7 are bonded to each other by compression and have high strength, the intermediate molded product 10 of the ceramic honeycomb structure has a predetermined size by performing machining such as cutting and grinding as necessary. Can be formed. Next, the intermediate molded article 10 of the ceramic honeycomb structure is fired into a final product by a conventionally known method. in this case,
The uniform density of the ceramics in the intermediate molded article 10 of the ceramic honeycomb structure facilitates degreasing and firing without cracking or distortion during firing.
【００１１】この実施例においては、縦４５０ｍｍ横１
２０ｍｍ高さ１９００ｍｍのラバー型１の内部に、予め
計算した所定の圧縮比を有する保持用部材２ａ，２ｂを
配置し、この保持用部材２ａ，２ｂの角穴３ａ，３ｂに
４本の炭素鋼の芯材４の両端部を挿入して固定し、各芯
材４の間の間隔が１４ｍｍとなるように型部材を構成し
た。ラバー型１と芯材４との間の空間に粉体セラミック
ス７を充填したところ、粉体セラミックス７の高さは１
６００ｍｍあった。この粉体セラミックス７を１０００
ｋｇｆ／ｃｍ2 でアイソスタティック圧縮した結果、縦
３４０ｍｍ横９２ｍｍ高さ１５２０ｍｍのセラミックス
ハニカム構造体の中間成形品１０を得た。アイソスタテ
ィック成形による圧縮比は縦１．３、横１．３、高さ
１．０５であった。圧縮後、前記中間成形品１０を切削
加工によって肉厚が１４ｍｍとなるように切削した。こ
のセラミックスハニカム構造体の中間成形品１０は充分
な強度を有し、切削中に破損することもなく、かつ、切
削を容易に行うことができた。切削加工後、１０時間の
脱脂と、１０時間の焼成とを行った結果、縦２８３ｍｍ
横７７ｍｍ高さ１２６６ｍｍのセラミックスハニカム構
造体の最終成形品を得た。焼成中に亀裂・歪等が生じる
ことがなく、強度、寸法精度とも良好なセラミックスハ
ニカム構造体を得ることができた。In this embodiment, the height is 450 mm and the width is 1
Holding members 2a and 2b having a predetermined compression ratio calculated in advance are placed inside a rubber mold 1 having a height of 20 mm and a height of 1900 mm, and four carbon steels are provided in square holes 3a and 3b of the holding members 2a and 2b. Both ends of the core material 4 were inserted and fixed, and a mold member was configured such that the interval between the core materials 4 was 14 mm. When the space between the rubber mold 1 and the core 4 was filled with the powder ceramics 7, the height of the powder ceramics 7 was 1
It was 600 mm. This powder ceramics 7
As a result of isostatic compression at kgf / cm 2 , an intermediate molded product 10 of a ceramic honeycomb structure having a length of 340 mm, a width of 92 mm and a height of 1520 mm was obtained. The compression ratio by isostatic molding was 1.3 in length, 1.3 in width, and 1.05 in height. After compression, the intermediate molded product 10 was cut by a cutting process so as to have a thickness of 14 mm. The intermediate molded article 10 of the ceramic honeycomb structure had sufficient strength, was not damaged during cutting, and was easily cut. After cutting, degreasing for 10 hours and baking for 10 hours resulted in a length of 283 mm.
A final molded product of a ceramic honeycomb structure having a width of 77 mm and a height of 1266 mm was obtained. A ceramic honeycomb structure having good strength and dimensional accuracy without cracking, distortion, or the like during firing was obtained.
【００１２】[0012]
【発明の効果】上記の説明から明らかなように本発明の
セラミックスハニカム構造体の製造方法によれば、ラバ
ー型の内側両端部に芯材を保持する一対の芯材保持用部
材を配置し、この芯材保持用部材によってセラミックス
ハニカム構造体の空洞部を形成する複数の芯材の両端を
保持し、この芯材とラバー型との間に形成された空間に
粉体のセラミックスを充填し、この粉体セラミックスを
アイソスタティック成形によって圧縮してセラミックス
ハニカム構造体の中間成形品を形成するようしたので、
密度が均一なセラミックスハニカム構造体の中間成形品
を一体に形成できる。このことにより、前記中間成形品
を焼成してセラミックスハニカム構造体の最終成形品を
製造する間に亀裂や歪を生じることがない。また、前記
セラミックスハニカム構造体の中間成形品は、適当な強
度を有しており、必要に応じて切削・研削等の加工を行
うことができ、精密な寸法精度と良好な仕上げ面を有す
るセラミックスハニカム構造体を得ることができる。こ
の場合、前記芯材を剛性の高い材料によって形成し、前
記芯材保持用部材を圧縮方向によって異なる圧縮比を有
する加圧異方性構造材料によって形成することにより、
所望の寸法のセラミックスハニカム構造体の中間成形品
を得ることができ、切削・研削等の加工をさらに容易な
ものにすることができる。さらに、本発明のセラミック
スハニカム構造体の製造方法は、特定の水分含有量を有
するセラミックススラリーを製造する必要がなく、ま
た、セラミックスハニカム構造体を構成する部品を別々
に製造して接着する必要がないので、セラミックスハニ
カム構造体の製造工程や製造管理を容易なものとするこ
とができる。As is apparent from the above description, according to the method for manufacturing a ceramic honeycomb structure of the present invention, a pair of core material holding members for holding a core material are disposed at both inner ends of a rubber mold. The core material holding member holds both ends of a plurality of core materials forming the cavity of the ceramic honeycomb structure, and fills a space formed between the core material and the rubber mold with powdered ceramics, Since this powder ceramic was compressed by isostatic molding to form an intermediate molded product of the ceramic honeycomb structure,
An intermediate molded article of a ceramic honeycomb structure having a uniform density can be integrally formed. Thus, cracks and distortions do not occur during firing of the intermediate molded product to produce a final molded product of the ceramic honeycomb structure. In addition, the intermediate molded product of the ceramic honeycomb structure has appropriate strength, and can be subjected to machining such as cutting and grinding if necessary, and has a high dimensional accuracy and a good finished surface. A honeycomb structure can be obtained. In this case, the core material is formed of a material having high rigidity, and the core material holding member is formed of a pressurized anisotropic structural material having a different compression ratio depending on a compression direction.
An intermediate molded product of the ceramic honeycomb structure having a desired size can be obtained, and processing such as cutting and grinding can be further facilitated. Furthermore, the method for producing a ceramic honeycomb structure of the present invention does not require the production of a ceramic slurry having a specific water content, and also requires the components constituting the ceramic honeycomb structure to be separately produced and bonded. Since there is no ceramic honeycomb structure, the manufacturing process and manufacturing management of the ceramic honeycomb structure can be made easy.
【図１】本発明のセラミックスハニカム構造体製造方法
の型部材を分解して示した斜視図。FIG. 1 is an exploded perspective view showing a mold member of a method for manufacturing a ceramic honeycomb structure of the present invention.
【図２】本発明のセラミックスハニカム構造体製造方法
の保持用部材の一部を拡大して示した斜視図。FIG. 2 is an enlarged perspective view showing a part of a holding member in the method for manufacturing a ceramic honeycomb structure of the present invention.
【図３】型部材に粉体のセラミックスを充填している工
程を示した概略図。FIG. 3 is a schematic diagram showing a process of filling a mold member with powdered ceramic.
【図４】粉体セラミックスを充填したラバー型をアイソ
スタティック成形法によって圧縮する工程を示した概略
図。FIG. 4 is a schematic view showing a step of compressing a rubber mold filled with powder ceramics by an isostatic molding method.
【図５】ラバー型からセラミックスハニカム構造体の中
間成形品を取り出す工程を示した概略図。FIG. 5 is a schematic view showing a step of taking out an intermediate molded product of a ceramic honeycomb structure from a rubber mold.
【図６】従来の鋳込み成形法によって形成されたセラミ
ックスハニカム構造体を示し斜視図。FIG. 6 is a perspective view showing a ceramic honeycomb structure formed by a conventional casting method.
【図７】従来の押出し成形法によってセラミックスハニ
カム構造体の中間成形品を押出し成形している工程を示
した概略図。FIG. 7 is a schematic view showing a step of extruding an intermediate molded article of a ceramic honeycomb structure by a conventional extrusion molding method.
１ ラバー型 ２ａ 保持用部材 ２ｂ 保持用部材 ４ 芯材 ５ 平面状の塑性板 ６ 波板状のゴム板 ７ 粉体セラミックス ８ 圧力容器 １０ セラミックスハニカム構造体の中間成形品 DESCRIPTION OF SYMBOLS 1 Rubber type 2a Holding member 2b Holding member 4 Core material 5 Flat plastic plate 6 Corrugated rubber plate 7 Powder ceramics 8 Pressure vessel 10 Intermediate molded product of ceramic honeycomb structure
───────────────────────────────────────────────────── フロントページの続き (58)調査した分野(Int.Cl.7，ＤＢ名) B28B 1/00 - 1/54 B28B 3/00 - 5/12 B28B 21/00 - 23/22 ──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int. Cl. 7 , DB name) B28B 1/00-1/54 B28B 3/00-5/12 B28B 21/00-23/22
Claims (2)
対の芯材保持用部材を配置し、この芯材保持用部材によ
ってセラミックスハニカム構造体の空洞部を形成する複
数の芯材の両端を保持し、この芯材とラバー型との間に
形成された空間に粉体のセラミックスを充填し、粉体セ
ラミックスを充填したラバー型を圧縮用流体で満たされ
た圧力容器内に配置し、アイソスタティック成形によっ
てラバー型内の粉体セラミックスを圧縮成形するセラミ
ックスハニカム構造体の製造方法であって、 前記芯材を剛性の高い材料によって形成し、前記芯材保
持用部材を圧縮方向によって異なる圧縮比を有する加圧
異方性構造材料によって形成し、セラミックスハニカム
構造体の空洞部の内側寸法および長手方向の寸法が圧縮
前と圧縮後においてほぼ等しくなり、かつ、セラミック
スハニカム構造体の空洞部の周囲の肉厚が圧縮によって
所定の寸法となるように構成したことを特徴とするセラ
ミックスハニカム構造体の製造方法。1. A method for holding a core material at both inner ends of a rubber mold.
A pair of core material holding members is arranged, and the core material holding member
To form the cavity of the ceramic honeycomb structure
Hold both ends of a number of cores, and between this core and the rubber mold
Fill the formed space with powdered ceramics,
A rubber mold filled with Lamix is filled with a compression fluid
Placed in a pressure vessel, and
To compress and form powder ceramics in rubber mold
A method for manufacturing a honeycomb honeycomb structure, comprising: forming the core material from a material having high rigidity; forming the core material holding member from a pressurized anisotropic structural material having a different compression ratio depending on a compression direction; The inner dimensions and longitudinal dimensions of the hollow portion of the structure are substantially equal before and after compression, and the thickness around the hollow portion of the ceramic honeycomb structure becomes a predetermined size by compression. A method for manufacturing a ceramic honeycomb structure, comprising:
用部材は、平面状の塑性板と波板状のゴム板とを交互に
積層して形成されていることを特徴とする請求項１記載
のセラミックスハニカム構造体の製造方法。2. A core holding member made of a pressure anisotropic structural material is formed by alternately stacking a flat plastic plate and a corrugated rubber plate. A method for manufacturing a ceramic honeycomb structure according to claim 1.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3251201A JP3032342B2 (en) | 1991-09-30 | 1991-09-30 | Method for manufacturing ceramic honeycomb structure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3251201A JP3032342B2 (en) | 1991-09-30 | 1991-09-30 | Method for manufacturing ceramic honeycomb structure |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0584713A JPH0584713A (en) | 1993-04-06 |
| JP3032342B2 true JP3032342B2 (en) | 2000-04-17 |
Family
ID=17219195
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3251201A Expired - Fee Related JP3032342B2 (en) | 1991-09-30 | 1991-09-30 | Method for manufacturing ceramic honeycomb structure |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3032342B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3290195B1 (en) * | 2016-08-29 | 2019-10-16 | The Boeing Company | Compression molding assembly and methods for molding a thermoplastic blocker door |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10028865C2 (en) * | 2000-06-10 | 2002-09-26 | Xcellsis Gmbh | Device for the catalytic generation of hydrogen from hydrocarbons |
| JP4067830B2 (en) * | 2002-01-24 | 2008-03-26 | 日本碍子株式会社 | Ceramic structure joining apparatus and joining method |
| JP7089284B2 (en) | 2016-10-17 | 2022-06-22 | 国立大学法人九州大学 | Honeycomb structure for medical use |
-
1991
- 1991-09-30 JP JP3251201A patent/JP3032342B2/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3290195B1 (en) * | 2016-08-29 | 2019-10-16 | The Boeing Company | Compression molding assembly and methods for molding a thermoplastic blocker door |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0584713A (en) | 1993-04-06 |
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