JP3971066B2 - Manufacturing method of filter with flange - Google Patents

Description

【００３１】
表１に示すように、実施例１−１〜１−５のフィルタには、本体及びフランジにおけるクラックや接合部分における隙間は認められなかった。
一方、比較例１−１のフィルタはフランジにクラックが発生し、比較例１−２のフィルタは接合部分に隙間が発生した。
【００３２】
【発明の効果】
本発明の製造方法によれば、本体部分とフランジ部分を別個に成形するため成形工程が単純であり、生産効率を向上させることが可能である。
また、フランジ部分が既に焼成されているため、フランジ部分の焼成収縮によって本体やフランジにクラックが発生することがない。
【００３３】
更に、ハンドリング性に優れる焼結体同士を接合するため両者の接合が容易であり生産効率を向上させることができることに加え、本体部分とフランジ部分を別個に焼成した後に接合するため、本体とフランジのいずれか一方の焼成不良により接合工程が無駄になることもない。
【００３４】
また、本発明の製造方法に係る接合材は、十分な接合力を確保しつつ接合材の焼成収縮を防止することができるため、本体やフランジにおけるクラックの発生、或いは本体とフランジとの接合部分における隙間の発生を防止することができる。
【図面の簡単な説明】
【図１】 ハニカムフィルタの一の実施例を示す斜視図である。
【図２】 （ａ）はフランジ付きフィルタの一の実施例を示す模式図であり、（ｂ）はフランジ付きフィルタの取り付け態様の例を示す模式図である。
【図３】 フィルタ本体とフランジとの接合部分における強度の評価方法を示す模式図である。
【符号の説明】
１…フィルタ、２…セル壁、３…セル、２１…フィルタ、２４…本体、２５…フランジ、２６…シール材、２７…取付枠、３１…フィルタ、３４…本体、３５…フランジ、３８…接合材、３９…スペーサ。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a dust collecting honeycomb filter used for removing dust or the like in a gas to be treated, and more particularly to a method for manufacturing a flanged filter having a flange at one end of the filter.
[0002]
[Prior art]
Honeycomb filters are used as dust collection filters to remove dust in the gas to be treated, and are used to recover products from high-temperature gas or exhaust gas in a wide range of fields such as chemical, electric power, steel, and automobile-related industries. Used to purify.
[0003]
In general, in a honeycomb filter, as shown in FIG. 1, a large number of cells 3 are formed in a honeycomb-shaped porous body, and the end portions on the inlet side B and the outlet side C of the large number of cells 3 are alternately arranged for each cell. The structure is sealed.
According to the filter 1, dust or the like larger than the pore diameter of the porous body is trapped in the pores of the cell wall 2 by sending the gas to be treated containing dust and the like from the inlet side B into the cell 3. Only the gas component that permeates the wall 2 can be recovered from the outlet side C as a processed gas.
[0004]
In the honeycomb filter, in order to prevent mixing of the gas to be processed and the processed gas, for example, a filter 21 having a structure in which a flange 25 is arranged at one end of a main body 24 as shown in FIG. Such a filter is called a “filter with flange”). Since the flanged filter 21 can hermetically join the flange 25 to the mounting frame 27 via the seal member 26, it is possible to prevent mixing of the gas to be processed and the processed gas.
[0005]
The flanged filter generally includes a cordierite for the main body and the flange. An integral molding method in which the main body portion and the flange portion are integrally molded and fired, and the sintered body of the main body portion and the flange portion are formed. Sintered body-molded body joining method, main body for joining a molded body (ie, unsintered body) with a bonding material made of cordierite raw material powder (eg, mixed powder of talc, kaolin, alumina, silica, etc.) It has been manufactured by a sintered body-sintered body joining method or the like in which a sintered body of a flange portion is joined to a sintered body of a portion by a bonding material made of cordierite raw material powder .
[0006]
[Problems to be solved by the invention]
However, the above production methods have problems in production or quality of the produced filter, and none of them is sufficient. For example, in the integral molding method, it is difficult to continuously form a complex shaped product such as a filter with a flange, so that there is a problem in that the molding process is complicated and the production efficiency is low.
[0007]
Further, in the sintered body-molded body joining method, the flange portion is fired and contracted in the subsequent firing step, so that there is a problem that cracks occur in the main body and the flange. On the other hand, in the sintered body-sintered body joining method, since cordierite raw material powder is used as a joining material, there is a problem that cracks occur in the main body and the flange due to the firing shrinkage of the joining material itself.
[0008]
In addition to the above-mentioned conventionally known methods, there is also a molded body-molded body joining method in which a molded body (unsintered body) of a main body part and a molded body of a flange part (unsintered body) are directly joined without using a joining material. Conceivable. However, when it is difficult to directly join molded products that are inferior in handling properties compared to a sintered body, production efficiency is low, and when firing failure such as cracks occurs only in one of the main body and flange However, there is a problem that the difficult joining process is completely wasted.
[0009]
The present invention has been made in view of the above-described problems of the prior art, and the object of the present invention is to generate cracks in the main body and the flange or to form a gap in the joint portion between the main body and the flange when manufacturing the filter. An object of the present invention is to provide a method of manufacturing a flanged filter that can prevent the occurrence of the flanged filter and has high production efficiency.
[0010]
[Means for Solving the Problems]
As a result of intensive studies by the present inventors, a sufficient bonding force can be obtained by using a bonding material having a predetermined composition in the sintered body-sintered body bonding method described above. As a result, the present invention was completed.
[0011]
That is, according to the present invention, in the method of manufacturing a flanged filter, the main body and the flange of which are made of the same material ceramic, the sintered body of the main body portion and the sintered body of the flange portion are made of cordierite powder and cordierite. There is provided a method for manufacturing a flanged filter, wherein the raw material powder is joined with a joining material contained in a weight ratio of 60:40 to 95: 5 .
[0012]
DETAILED DESCRIPTION OF THE INVENTION
The production method of the present invention is characterized in that the sintered body of the main body portion and the sintered body of the flange portion are joined by a joining material containing cordierite powder and cordierite raw material powder in a predetermined ratio. To do.
According to such a manufacturing method, it is possible to prevent the occurrence of cracks in the main body and the flange, or the generation of a gap in the joint portion between the main body and the flange, and further improve the production efficiency.
Hereinafter, the production method of the present invention will be described in detail.
[0013]
The manufacturing method of the present invention employs a sintered body-sintered body joining method in which the sintered body of the flange portion is joined to the sintered body of the main body portion with a joining material of the same material as the main body and the flange. In the sintered body-sintered body joining method, the main body portion and the flange portion are separately formed, so that the forming process is simple and the production efficiency can be improved, and the flange portion is already fired. For this reason, cracks are not generated in the main body or the flange due to the firing shrinkage of the flange portion.
[0014]
Furthermore, since the sintered body-sintered body joining method joins sintered bodies having excellent handling properties, it is easy to join the two and the production efficiency can be improved. In addition, the main body portion and the flange portion are separated. Since joining is performed after firing, there is an advantage that the joining process is not wasted due to defective firing of either the main body or the flange.
[0015]
However, in the conventional sintered body-sintered body joining method, a bonding material made of cordierite raw material powder (such as a paste of cordierite raw material powder ) is used as the bonding material, and thus the firing shrinkage of the bonding material itself As a result, there is a problem that cracks occur in the main body and the flange. Therefore, in the production method of the present invention, the bonding is performed using a bonding material in which the cordierite powder and the cordierite raw material powder are included in a weight ratio of 60:40 to 95: 5.
[0016]
The reason why the cordierite powder and the cordierite raw material powder were used as the ceramic to be included in the bonding material is to make the thermal expansion coefficient of the main body and the flange and the bonding material coincide, and the cordierite powder and the cordierite raw material powder This ratio is defined in order to prevent firing shrinkage of the bonding material while ensuring a sufficient bonding force. That is, when the weight ratio of the cordierite powder exceeds 95%, it is not preferable in that the bonding force is reduced and a gap is formed between the main body and the flange, while the weight ratio of the cordierite raw material powder is 40%. Exceeding this is not preferable because cracks occur in the main body and the flange due to firing shrinkage of the bonding material.
[0017]
In the present specification, the term “cordierite raw material powder” means a ceramic powder capable of synthesizing cordierite by firing. For example, a mixed powder of talc, kaolin, alumina, silica and the like corresponds to the “cordierite raw material powder” referred to in the present invention.
These powders have a particle size of about several tens to 100 μm.
[0018]
Cordierite powder and cordierite raw material powder may be newly prepared as binders, but defective products (cracked products, etc.) in the drying process after molding of the filter body and flange are pulverized to produce cordierite. It is also possible to prepare cordierite powder by pulverizing the light raw material powder with defective products (such as crack products) in the firing step. Such a method is preferable in that raw material costs can be reduced.
[0019]
In the manufacturing method of the present invention, cordierite with small firing shrinkage is used as the material constituting the main body and the flange .
[0020]
As long as the cordierite powder and the cordierite raw material powder are mixed in the above weight ratio, water and other additives may be added to the bonding material.
For example, if 25 to 30% by weight of water is added to the total weight of the cordierite powder and the cordierite raw material powder , the bonding material can be made into a pellet, and if 40% by weight or more of water is added, the bonding material Can be made into a slurry. In addition, for the purpose of securing the strength when drying and firing the bonding material portion, an organic binder (for example, about 0.5 to 1.5% by weight with respect to the total weight of the cordierite powder and the cordierite raw material powder ) It is also possible to add a water-soluble polymer or the like.
[0021]
According to the production method of the present invention, the cordierite sintered body cordierite sintered body and the flange portion of the body portion is prepared by prepared separately, in the center of the cordierite sintered body of the flange portion The cordierite sintered body of the main body is inserted into the provided opening, the pellet-like bonding material is packed into the gap between the two members, or the slurry-like bonding material is poured, and then the bonding material portion is dried and fired. Thus, a flanged filter in which the main body portion and the flange portion are joined can be obtained.
[0022]
【Example】
EXAMPLES Hereinafter, although the manufacturing method of this invention is demonstrated in detail by an Example, this invention is not limited to these Examples.
[0023]
Example 1
The fired body of the main body part and the fired body of the flange part were joined with a joining material containing cordierite powder and cordierite raw material powder to produce a flanged filter.
(Main body)
As the main body, a honeycomb structure having a structure in which a large number of cells are formed in a porous body having an average pore diameter of 15 μm as in FIG. 2, and one end and the other end of the large number of cells are alternately sealed for each cell. Used the body. The size of the honeycomb structure was 150 mm long × 150 mm wide × 150 mm long, and the material was a cordierite sintered body. In the honeycomb structure, about 300 cells having a square shape with a cross section of 6 mm × 6 mm in the longitudinal direction of the rectangular parallelepiped were formed with a cell wall thickness of 0.65 mm.
(Flange)
The flange had a frame shape in which an opening of 160 mm length × 160 mm width was provided at the center of a flat plate having a length of 190 mm × width of 190 mm × thickness of 30 mm. The material of the flange was also a cordierite sintered body like the main body.
[0026]
(Joining material)
The cordierite powder is a powder obtained by pulverizing a defective product in the firing step of the flange to a particle size of about 10 to 100 μm, and the cordierite raw material powder is a mixed powder of talc, kaolin, alumina, silica, etc. The powder which grind | pulverized the inferior goods in the drying process of the molded object (unsintered body) of a flange to the particle size of about 10-100 micrometers was used.
[0027]
The above-mentioned cordierite powder and cordierite raw material powder are mixed at a predetermined weight ratio, but by adding an organic binder and water, the weight ratio of the uncalcined powder and cordierite raw material powder is different from seven levels. A pellet-like or slurry-like bonding material was prepared. A water-soluble polymer was used as the organic binder added to the bonding material.
(Joining method)
The main body and the flange are joined by inserting the main body into an opening provided in the center of the flange and filling the gap between the two members with a pellet-shaped bonding material or pouring a slurry-shaped bonding material, The baking was performed at 1410 ° C. for 3.5 hours.
(Evaluation)
About the filter of an Example and a comparative example, it evaluated by observing generation | occurrence | production of the crack in a main body and a flange, and the generation | occurrence | production of the clearance gap in a junction part.
Further, as shown in FIG. 3, the joint strength of the joint portion was evaluated by raising the flange portion 35 with a spacer 36, applying a load to the main body portion 34 with an Amsler type material tester, and measuring the punching load. . The results are shown in Table 1.
[0030]
[Table 1]

[0031]
As shown in Table 1, in the filters of Examples 1-1 to 1-5, cracks in the main body and the flange and gaps in the joint portion were not recognized.
On the other hand, in the filter of Comparative Example 1-1, a crack occurred in the flange, and in the filter of Comparative Example 1-2, a gap occurred in the joint portion.
[0032]
【The invention's effect】
According to the manufacturing method of the present invention, since the main body portion and the flange portion are separately molded, the molding process is simple, and the production efficiency can be improved.
Further, since the flange portion has already been fired, cracks are not generated in the main body and the flange due to firing shrinkage of the flange portion.
[0033]
Furthermore, since the sintered bodies having excellent handling properties are joined together, it is easy to join the two and the production efficiency can be improved. In addition, since the body portion and the flange portion are separately fired and joined, the body and the flange are joined. The joining process is not wasted due to any one of the firing failures.
[0034]
In addition, since the bonding material according to the manufacturing method of the present invention can prevent firing shrinkage of the bonding material while ensuring a sufficient bonding force, occurrence of cracks in the main body and the flange, or a bonding portion between the main body and the flange It is possible to prevent the occurrence of gaps in
[Brief description of the drawings]
FIG. 1 is a perspective view showing an embodiment of a honeycomb filter.
FIG. 2A is a schematic diagram showing an example of a flanged filter, and FIG. 2B is a schematic diagram showing an example of an attachment mode of the flanged filter.
FIG. 3 is a schematic diagram showing a strength evaluation method at a joint portion between a filter main body and a flange.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Filter, 2 ... Cell wall, 3 ... Cell, 21 ... Filter, 24 ... Main body, 25 ... Flange, 26 ... Sealing material, 27 ... Mounting frame, 31 ... Filter, 34 ... Main body, 35 ... Flange, 38 ... Joining Material, 39: spacer.

Claims (1)

In the manufacturing method of the flanged filter whose main body and flange are made of cordierite ,
A cordierite sintered body cordierite sintered body and the flange portion of the body portion, cordierite powder and cordierite raw material powder and the weight ratio 60: 40 to 95: joint included in the range of 5 A method for manufacturing a filter with flange, characterized by joining with a material.

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