JP4532192B2 - MEMBER FOR PACKING FORMATION AND METHOD FOR PRODUCING DUST COLLECTION FILTER USING THE - Google Patents

Description

The present invention is suitably used as a filter medium for dust filter, it relates to a manufacturing method of the dust filter with plugging portions for plugging one of the openings of the cells, particularly, plugging The present invention relates to a plugging portion forming member used for forming a portion and a method for manufacturing a dust collecting filter using the same.

In various fields including chemical, electric power, steel, and industrial waste treatment, it is made of a porous material as a filter material for dust collection filters used for environmental measures such as pollution prevention and product recovery from high-temperature gas. A honeycomb structure is used. For example, a diesel particulate filter (DPF: Diesel Particulate Filter) is a dust collection filter that is used for collecting particulate matter (PM) discharged from a diesel engine such as an automobile diesel engine. Since it is used in a high temperature or corrosive gas atmosphere, a honeycomb structure made of a ceramic porous body having excellent heat resistance and corrosion resistance is suitably used.

As a honeycomb structure used for a dust collection filter , for example, as shown in FIGS. 1 (a) and 1 (b), it has a partition wall 2 made of a porous body, and the partition wall 2 allows a fluid flow path. A dust collecting filter 1 including a honeycomb structure 6 in which a large number of cells 4 are partitioned and formed, and a plugging portion 8 that plugs any opening of the cells 4 of the honeycomb structure 6. Is widely used. According to the dust collecting filter 1 having such a structure, when the processed gas G ₁ introduced into the fluid supply cell 4a from the inlet side end face B flows into the fluid discharge cell 4b the adjacent through the partition wall 2, In the partition wall 2, PM contained in the gas to be processed G ₁ is captured. Then, since the treated gas G ₂ which has flown into the fluid discharge cell 4b the adjacent through the partition wall 2 is discharged from the outlet-side end face C, treated gas PM of the treated gas G ₁ is separated and removed it can be obtained G _2.

However, when the dust collection filter as described above is used for a filter such as a DPF, PM or the like is deposited on the inlet side end face (for example, a plugging portion), thereby reducing the cell opening area or the cell opening. There was a problem that obstruction occurred. Such a problem is not preferable in that the pressure loss of the filter increases, leading to a decrease in the output of the diesel engine and a deterioration in fuel consumption.

As a measure for solving the above problems, there is an exhaust purification device or a ceramic honeycomb filter in which a plugged portion is formed with a protruding portion protruding in a shape narrowing toward the upstream side from the opening end surface of the honeycomb structure. It has been proposed (see, for example, Patent Documents 1 and 2). Such an exhaust purification device or the like can be expected to have a deposition suppressing effect that suppresses deposition of PM or the like on the inlet side end surface because the tapered projecting portion has a rectifying effect that smoothes the flow of the gas to be processed.
JP 2002-309922 A US Patent Application Publication No. 2003/0093982

  However, the exhaust emission control device or the like described above exhibits a sufficient deposition suppressing effect due to the fact that the exhaust gas from the diesel engine contains a sticky soluble organic component (SOF). The current situation was not reached. This is because PM and the like are fixed to the inlet side end face of the honeycomb structure by the adhesive SOF, and therefore deposition of PM and the like is easily promoted.

A dust collection filter having a dome-shaped plugging portion protruding from an end surface is considered as a measure for solving the problems caused by the above-described adhesive SOF. By making the plugged portion into a hollow dome shape in this way, in addition to obtaining the same rectifying effect as the exhaust purification device described in Patent Documents 1 and 2, the heat capacity of the plugged portion is reduced. The temperature increase rate of the plugged portion can be improved. Therefore, even when PM, SOF, or the like adheres and is deposited on the plugged portion, it can be easily heated and burned, and it can be expected to exhibit a sufficient deposition suppressing effect.

However, a manufacturing method that can easily manufacture a dust collection filter having a dome-shaped plugging portion as described above has not yet been disclosed, and the creation of such a method is eagerly desired by the industry. .

As a result of diligent research to solve the above-described problems, the present inventors have a flat substrate, and a large number of recesses capable of storing plugging portion forming slurry are formed on the surface of the substrate. The present invention has been completed by finding that the above problems can be solved by forming a plugged portion using a plugging portion forming member. That is, according to the present invention, the following plugging portion forming member and a method for manufacturing a dust collecting filter are provided.

[1] A honeycomb structure for a dust collection filter having a partition wall made of a porous body, in which a large number of cells serving as fluid flow paths are partitioned and formed by the partition wall, and the openings of any of the cells A plugging portion forming member for forming a plugging portion for plugging, comprising a flat substrate having an area equal to or larger than an end face of the honeycomb structure, and on the surface of the substrate Are formed with a large number of recesses capable of storing the plugging portion forming slurry, and each recess has an area corresponding to at least an opening (plugging opening) where the plugging portion of the cell is to be formed. And has a three-dimensional shape complementary to the plugged portion to be formed, and is disposed at a position corresponding to the plugged opening on the end surface of the honeycomb structure. Element.

[2] The plugging portion forming member according to [1], wherein the recesses and the non-recesses are alternately arranged so as to form a checkered pattern as a whole.

[3] The plugging portion forming member according to [1] or [2], wherein the concave portion has a shape in which an inner diameter gradually decreases toward a bottom portion.

[4] The plugging portion forming member according to any one of [1] to [3], which is formed of a porous body.

[5] The plugging portion forming member according to any one of the above [1] to [4], which is configured by a cured resin (resin cured product) derived from a photocurable resin.

[6] Positioning pins that can be fitted to the cells project at positions corresponding to openings (non-plugged openings) that do not form the plugged portions of the cells on the end face of the honeycomb structure. The plugging portion forming member according to any one of the above [1] to [5].

[7] A honeycomb structure for a dust collection filter having a partition wall made of a porous body, in which a large number of cells serving as fluid flow paths are partitioned and formed by the partition wall, and the opening portion of any of the cells A dust collection filter manufacturing method for forming a plugging portion for plugging and obtaining a dust collection filter , wherein the plugging portion forming member according to the above [1] is used, After injecting the plugging portion forming slurry into the recess of the portion forming member, the honeycomb structure is placed on the surface of the plugging portion forming member so that the end face thereof is in contact with the surface. A dust collecting filter for forming a plugging portion on an end surface of the honeycomb structure by attaching a slurry for forming a plugging portion to an end surface of the partition wall located at a peripheral edge of the plugging opening. Production method.

[8] As the plugging portion forming member, a member in which the concave portion has a shape whose inner diameter gradually decreases toward the bottom portion, and a convex plugging portion protruding from the end face of the honeycomb structure is provided. The manufacturing method of the dust collection filter as described in said [7] to form.

[9] The plugging portion forming member is made of a porous material, and the plugging portion forming member absorbs the dispersion medium of the plugging portion forming slurry while the plugging portion forming member absorbs the dispersion medium. The manufacturing method of the dust collection filter as described in said [7] or [8] which forms a plugging part.

[10] At least an end face of the honeycomb structure can be imaged to identify the shape and position of the plugged opening and the opening (non-plugged opening) that does not form the plugged portion of the cell. Obtaining image data, and producing a plugging portion forming member composed of a photocurable resin-derived curable resin (cured resin) by the following stereolithography based on the image data, and sealing the plug The method for producing a dust collection filter according to any one of [7] to [9], wherein the plugging portion is formed using a stopper forming member.
Stereolithography: After forming a cured resin layer by irradiating light on the surface of the photocurable resin, a new photocurable resin is supplied and the same light irradiation is applied to the upper surface of the cured resin layer. A method of obtaining a three-dimensional shaped object composed of a cured resin (resin cured product) by repeating the operation of forming a new cured resin layer and laminating the cured resin layer.

[11] As the plugging portion forming member, the cell is placed at a position corresponding to an opening (non-plugging opening) of the cell in the end face of the honeycomb structure that does not form the plugging portion. The above-mentioned [7] to [10], in which the plugging portion is formed in a state where the positioning pin is fitted to the cell, using a projecting positioning pin that can be fitted. Manufacturing method of dust collecting filter .

According to the manufacturing method of the present invention, it is extremely easy to form a convex plugged portion protruding from the end face, which is difficult to form by the conventional method. Therefore, it contributes to easy manufacture of a dust collection filter having a dome-shaped plugging portion that is excellent in the effect of suppressing accumulation of PM or the like.

Hereinafter, the best mode for carrying out the dust collection filter of the present invention and the manufacturing method thereof will be specifically described with reference to the drawings. However, the present invention is not limited to the following forms.

The method for producing a dust collection filter of the present invention comprises a flat substrate having an area equal to or larger than the end face of the honeycomb structure to be plugged, and the plugging portion forming slurry is stored on the surface of the substrate. Using a plugging portion forming member having a large number of recesses that can be formed, after injecting the plugging portion forming slurry into the recesses of the plugging portion forming member, the plugging portion forming member The honeycomb structure is mounted on the surface so that the end face thereof is in contact with the slurry, and the plugging portion forming slurry is attached to the end face of the partition located at the periphery of the plugging opening. It is a manufacturing method which forms a plugging part on the end surface of this.

(1) Plugging portion forming member The plugging portion forming member used in the production method of the present invention is composed of a flat substrate having an area equal to or larger than the end face of the honeycomb structure. By using a flat substrate, a honeycomb structure for a dust collection filter in which a plugging portion should be formed can be placed on the surface of the substrate, and the surface of the substrate can be brought into contact with the end surface of the honeycomb structure. It becomes possible. Further, by having an area equal to or larger than the end face of the honeycomb structure, all plugged portions on one end face of the honeycomb structure can be formed at a time.

  A large number of recesses capable of storing the plugging portion forming slurry are formed on the surface of the base constituting the plugging portion forming member. The number of recesses is the same as the number of plugging portions to be formed, and the plugging portion forming slurry is injected into the recesses, and the slurry stored in the recesses is adhered to the end face of the honeycomb structure. A plugged portion can be formed on the end surface of the structure.

  Each recess formed on the surface of the substrate has an area corresponding to at least an opening (plugging opening) where a plugging portion of the cell is to be formed. Each recess is formed to have a larger area. With this configuration, when the honeycomb structure is placed on the substrate surface, the plugging portion forming slurry adheres to the end face of the partition wall located at the periphery of the plugging opening, and is formed by the slurry. It is possible to integrate the plugged portion and the honeycomb structure.

  Each recess has a three-dimensional shape complementary to the plugged portion to be formed. That is, there is no restriction | limiting in particular in the shape of a recessed part, What is necessary is just to form in the shape which reversed the desired plugged part shape. In other words, it is possible to form a plugged portion having a desired shape by changing the shape of the recess.

  For example, it is possible to form a convex plugged portion protruding from the end face of the honeycomb structure by forming the concave portion in a shape in which the inner diameter gradually decreases toward the bottom portion. Such a convex plugged portion can smooth the flow of the gas to be processed on the end face of the honeycomb structure (rectifying effect). It is possible to reduce the occurrence frequency of the situation of bridging and closing the non-plugged opening.

  Examples of the “shape in which the inner diameter gradually decreases toward the bottom” include a bowl shape, an inverted quadrangular pyramid shape, and the like. By making the shape of the recess into a bowl shape, the dome-shaped plugging portion 8A as shown in FIG. 2 is made into an inverted quadrangular pyramid shape, thereby making the quadrangular pyramidal plugging portion 8C as shown in FIG. Can be formed.

Needless to say, each of the concave portions needs to be arranged at a position corresponding to the plugging opening on the end face of the honeycomb structure. Usually, a DPF dust collection filter is often alternately arranged so that the plugged openings and the non-plugged openings form a checkered pattern as a whole. Therefore, as a plugging portion forming member for obtaining such a dust collecting filter, it is possible to use a member in which concave portions and non-recessed portions are alternately arranged so as to constitute a checkered pattern as a whole. preferable.

  There is no restriction | limiting in particular about the material which comprises the member for plugging part formation. Therefore, a desired material may be appropriately selected from industrially used materials that are inexpensive and easily available (for example, resin, metal, ceramic, etc.).

  However, the plugging portion forming member is preferably constituted by a porous body. When the plugging portion forming member is composed of a porous body, the slurry of the plugging portion forming slurry is absorbed not only by the honeycomb structure but also by the plugging portion forming member. Thus, the strength of the plugged portion can be improved and the mold can be released at an early stage. That is, the plugging portion can be formed quickly.

  Moreover, when forming the convex-shaped plugging part (for example, dome-shaped plugging part) mentioned above, the thickness of the plugging part is increased by the absorbability of the plugging part forming member. It can be made uniform. By making the thickness of the plugged portion uniform, it is possible to improve the heat resistance of the plugged portion and obtain the effect of making the heat capacity uniform. Specifically, if the thickness of the plugged portion is not uniform, the strength against thermal stress is likely to decrease, and there is a risk of causing damage to the plugged portion in applications such as DPF used at high temperatures. . Further, if the heat capacity of the plugged portion is not uniform, PM combustion spots may occur during the regeneration process for burning the accumulated PM, and PM may not be completely removed. By configuring the plugging portion forming member with a porous body, such a problem can be effectively suppressed.

  It is also one of the preferable embodiments that the plugging portion forming member is constituted by a curable resin (cured resin) derived from a photocurable resin. Since such a plugging portion forming member can be manufactured by stereolithography, the recess is formed in an appropriate shape at an accurate position by using data obtained by imaging the end face of the honeycomb structure. Thus, it is possible to obtain a plugged portion forming member with high shape accuracy. Therefore, it is preferable in that the plugged portion can be accurately formed in the plugged opening of the honeycomb structure. In addition, what forms the resin cured | curing material of a porous body at the time of hardening is also marketed as a photocurable resin. When such a photocurable resin is used, it is possible to obtain a plugging portion forming member that is configured by a porous body and that is configured by a cured resin (resin cured product) derived from the photocurable resin. Is preferable.

  Further, the plugging portion forming member is a positioning pin that can be fitted into the cell at a position corresponding to an opening (non-plugging opening) that does not form the cell plugging portion on the end face of the honeycomb structure. It is preferable that is protruded. By forming the plugging portion with the positioning pins fitted to the cells of the honeycomb structure, the plugging portion can be formed with high positional accuracy even in a fine plugging pattern. Such a plugging portion forming member is particularly preferably used when forming a plugging portion of a honeycomb structure having a large number of minute cells and the plugging pattern must be extremely fine. be able to. The number of positioning pins is not particularly limited, but is preferably at least 3 or more and at most the same as the number of non-plugged openings.

  A method for producing the plugging portion forming member is not particularly limited, but a plugging portion forming member with high shape accuracy can be obtained relatively easily by using the optical modeling method. Specifically, the plugging portion forming member can be produced by the method described below.

  First, at least an end face of the honeycomb structure is imaged, and image data that can specify the shape and position of the plugging opening and the opening (non-plugging opening) that does not form the cell plugging is obtained. . Since a honeycomb structure is usually manufactured by extrusion molding of clay, the cell shape, partition wall thickness, cell density, etc. are not uniform and may be distorted. According to this, it is possible to produce a plugging portion forming member that matches the structure of the honeycomb structure.

  As an imaging device for imaging at least the end face of the honeycomb structure, for example, a charge-coupled device (CCD) camera, a computed tomography (X-ray CT) scanner, or the like can be suitably used. In particular, the X-ray CT scanner can image not only the end face of the honeycomb structure but also the inside of the honeycomb structure (cell internal shape, etc.), and a positioning pin that can be fitted to the cell protrudes. There is an advantage that it is easy to create the tomographic shape data (slice data) of the plugging portion forming member necessary for the optical modeling method when the prepared plugging portion forming member is manufactured.

  Note that the imaging of the end face and the like of the honeycomb structure is not necessarily performed for each honeycomb structure. As described above, since the honeycomb structure is usually manufactured by extrusion molding of the clay, the distortion such as the cell shape, the partition wall thickness, and the cell density depends on the conditions of the ceramic clay composition, kneading / extrusion, and the like. It is because it will become the same if it is the same. That is, for lots having the same conditions, once image data is acquired for one honeycomb structure, the plugging portion forming member produced based on the image data is used for another honeycomb structure. (I.e., reuse).

  Next, based on the acquired image data, a plugging portion forming member constituted by a cured resin (cured resin) derived from a photocurable resin is produced by an optical modeling method.

  The “stereolithography” referred to in the present specification refers to the formation of a cured resin layer by drawing light on the surface of the photocurable resin, and then supplying a new photocurable resin to perform the same light irradiation. To form a new cured resin layer on the upper surface of the cured resin layer, and by repeating the operation of laminating the cured resin layer, a three-dimensional structure formed of the cured resin (resin cured product) is obtained. Means how to get. Such a method has an advantage that a complicated three-dimensional shaped object can be obtained easily and quickly. Therefore, even if the plugging portion forming member has a complicated three-dimensional shape (for example, when the cell shape, the partition wall thickness, the cell density, etc. are not uniform and are distorted), this is simplified. And can be obtained quickly.

  The term “photo-curable resin” as used herein refers to an oligomer, monomer, etc. (so-called prepolymer) that reacts by light irradiation to form a crosslinked structure, and also activates by absorbing light with the monomer or oligomer. Also included are mixtures with (excited) photopolymerization initiators. For example, an oligomer of a radical polymerization type photocurable resin such as an unsaturated polyester resin or a cationic polymerization type photocurable resin such as an epoxy resin can be used.

  Examples of a method for producing a plugging portion forming member based on the acquired image data include the methods listed below.

  First, at least the end face of the honeycomb structure (including the internal shape of the cell in the case of the X-ray CT scanner) is imaged with a CCD camera or an X-ray CT scanner, and surface image data is acquired. Next, by binarizing the surface image data, the shapes and positions of the plugged openings and non-plugged openings are specified.

  Then, the three-dimensional shape data of the plugging portion forming member is created so that the concave portion and the positioning pin are formed in an appropriate shape at an accurate position with respect to the honeycomb structure, and further, the three-dimensional shape data described above Is converted into CAD (computer-aided design) data, and from the CAD data, tomographic shape data (slice data) formed by tombling the three-dimensional shape of the plugging portion forming mask into multiple layers is created.

  By irradiating the surface of the uncured photocuring resin in a drawing manner according to the above slice data, the tomographic cured resin layer is formed. As irradiation light at this time, ultraviolet rays or visible rays having a wavelength capable of curing the photocurable resin are used. Thereafter, a new photocurable resin is additionally supplied by one layer, and the same light irradiation is performed again to form a new cured resin layer continuous with the upper surface of the previously formed cured resin layer. By repeating the operation of laminating the layers a predetermined number of times, a plugging portion forming member made of a cured resin (resin cured product) is produced.

  Currently, in addition to a light irradiation device such as an ultraviolet laser, a supply device that supplies a photocurable resin, a storage tank that stores the photocurable resin, and a lift that can raise and lower a cured resin layer formed by light irradiation in a single unit. An optical modeling apparatus provided with an apparatus or the like is commercially available (for example, SLA7000 (trade name: manufactured by Inx Corporation)). By using such a commercially available optical modeling apparatus, it becomes possible to produce a plugging portion forming member more easily and quickly.

(2) Manufacturing method of dust collection filter In the manufacturing method of this invention, first, the slurry for plugging part formation is inject | poured into the recessed part of said plugging part forming member. As the plugging portion forming slurry, the same slurry as in the conventional manufacturing method can be used. For example, in addition to aggregate particles made of ceramic, dispersion medium (water, etc.), additives such as organic binders (polyvinyl alcohol, methylcellulose, etc.) and dispersants (special carboxylic acid type polymer surfactants, etc.) are added as necessary. In addition, the mixture can be suitably used. As the ceramic seed of the aggregate particles, the same ceramic as the honeycomb structure can be preferably used.

  The viscosity of the plugging portion forming slurry is preferably adjusted within a range of 5 to 50 Pa · s, and more preferably adjusted within a range of 10 to 30 Pa · s. If the viscosity of the slurry is too low, it is not preferable in that a sink defect tends to occur. The viscosity of the slurry can be adjusted by, for example, the ratio between the aggregate raw material particles and the dispersion medium (for example, water) or the amount of the dispersant.

  At this time, when a plugging portion forming member having a shape in which the inner diameter gradually decreases toward the bottom portion (such as a bowl shape or an inverted quadrangular pyramid shape) is projected from the end face of the honeycomb structure. This is preferable in that a convex plugged portion can be formed. Examples of the convex plugged portion include a dome-shaped plugged portion 8A as shown in FIG. 2, a tent-shaped plugged portion 8B as shown in FIG. 3, and a square spindle as shown in FIG. The shape plugging part 8C etc. are mentioned.

  Next, the honeycomb structure is placed on the surface of the plugging portion forming member so that the end face thereof is in contact, and the plugging portion forming slurry is positioned at the periphery of the plugging opening of the honeycomb structure. It adheres to the end face of the partition wall. The slurry is dried by absorbing the moisture into the porous honeycomb structure. Due to this phenomenon, the slurry is solidified to some extent and develops strength, and is fixed to the honeycomb structure, so that plugged portions are formed on the end face of the honeycomb structure. It is preferable to apply a release agent to the surface of the concave portion of the plugging portion forming member because it is easy to remove the formed plugging portion from the plugging portion forming member.

  In this case, the plugging portion forming member is made of a porous material, and the plugging portion forming slurry is absorbed by the plugging portion forming member while plugging. It is preferable to form a stop. In such a method, since the dispersion medium of the plugging portion forming slurry is absorbed by the plugging portion forming member in addition to the honeycomb structure, the plugging portion can be formed quickly. In addition, the thickness of the plugged portion can be made uniform, the heat resistance of the plugged portion can be improved, and the heat capacity can be made uniform.

  Further, at this time, as the plugging portion forming member, a member in which a positioning pin that can be fitted to the cell is projected at a position corresponding to the non-plugging opening on the end face of the honeycomb structure is used for positioning. It is also preferable to form the plugging portion with the pin fitted to the cell. Such a method is preferable in that the plugged portion can be formed with high positional accuracy even with a fine plugged pattern.

After the plugging portion is formed on one end face of the honeycomb structure as described above, the plugging portion forming member is removed, and the same process is performed on the other end face of the honeycomb structure. The honeycomb structure having the plugged portions thus formed is dried and fired under conditions according to the ceramic species contained in the slurry, whereby a dust collecting filter can be obtained. The plugged portion formed by the slurry is completely cured in the course of drying and baking, and can develop strength that can be used for filter applications such as DPF.

The “honeycomb structure” used in the manufacturing method of the present invention includes, for example, a partition wall 2 made of a porous material, such as the honeycomb structure 6 shown in FIGS. 1 (a) and 1 (b). The partition wall 2 means a honeycomb structure for a dust collection filter in which a large number of cells 4 serving as fluid flow paths are partitioned and formed. As long as these conditions are satisfied, the structure and material are not particularly limited, and any conventionally known ceramic honeycomb structure for a dust collection filter can be used without any problem. The “honeycomb structure” referred to in the present specification includes not only a fired body but also an unfired dried body (one obtained by drying only the extruded body of the clay and not yet fired).

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples.

As a honeycomb structure for a dust collection filter used in Examples and Comparative Examples, a honeycomb structure having partition walls made of a porous body, and a plurality of cells serving as fluid flow paths partitioned and formed by the partition walls. Prepared the body. This honeycomb structure is made of cordierite, has a circular end face shape of 160 mmφ, a cylindrical shape with a length of 200 mm, a cell shape of 1.17 mm × 1.17 mm, a partition wall thickness of 300 μm, and a cell density of 300 pieces / square inch. This honeycomb structure was manufactured by extruding a kneaded material adjusted to an appropriate viscosity and drying it (unfired honeycomb dried body).

  In the following examples and comparative examples, all the plugging portion forming slurries used were cordierite powder as aggregate particles, methylcellulose as a binder, and a special carboxylic acid type polymer surfactant as a dispersant. The mixture was mixed with water as a dispersion medium, and the slurry viscosity was adjusted to 20 Pa · s.

Example 1
In Example 1, the dust collection filter 1 was manufactured by the method of forming the plugging portion 8 in the honeycomb structure 6 using the plugging portion forming member 21 shown in FIG.

  The plugging portion forming member 21 was produced as follows. First, the end face of the honeycomb structure 6 is imaged with a CCD camera, surface image data is acquired, and binarization processing is performed to thereby shape the plugged openings and non-plugged openings of the cell 4. And location.

  Next, from the same surface image data, the center coordinates of the cells 4 of the honeycomb structure 6 and the cell density (inter-cell pitch) are calculated, and the recesses 25 and the non-recesses 27 are properly positioned with respect to the honeycomb structure 6. Three-dimensional shape data of the plugging portion forming member 21 was created so as to be formed in a simple shape. The three-dimensional shape data was converted into CAD data and further slice data, and a plugging portion forming member 21 made of a cured resin (cured resin) was produced using an optical modeling apparatus based on the slice data. At this time, SLA7000 (trade name: manufactured by Inx Co., Ltd.) was used as the stereolithography apparatus. In this way, it is composed of a flat substrate 23, and a large number of recesses 25 are formed on the surface of the substrate 23. The recesses 25 and the non-recesses 27 are alternately arranged so as to form a checkered pattern as a whole. The plugged part forming member 21 thus obtained was obtained. The shape of the recess 25 was a bowl having an opening having a square shape with an average value of 1.77 mm × 1.77 mm and a maximum depth of 2 mm.

  After injecting the plugging portion forming slurry 31 into the recess 25 of the plugging portion forming member 21, the honeycomb structure 6 is brought into contact with the surface of the plugging portion forming member 21. Was placed. In this state, the plugging portion forming slurry 31 was attached to the end face of the partition wall 2 located at the periphery of the plugging opening of the honeycomb structure 6.

Then, after the plugging portion forming slurry 31 was dried and the plugging portion 8 was formed, the plugging portion forming member 21 was removed. The plugged portion 8 has a dome shape as shown in FIG. This was dried and fired to produce a dust collection filter 1 in which the plugged portions 8 were formed in the honeycomb structure 6.

(Example 2)
In Example 2, the dust collection filter 1 was manufactured using the plugging portion forming member 33 having the shape shown in FIG. 6 instead of the plugging portion forming member 21 shown in FIG. The plugging portion forming member 33 is formed in the non-recessed portion 27 of the plugging portion forming member 21 used in Example 1 in a square shape having a bottom surface of 1.17 mm × 1.17 mm and a taper having a height of 2 mm. A positioning pin 29 having a shape was provided so as to be produced in accordance with the method described in Example 1. The positioning pins 29 protruded in a number corresponding to all the non-plugged openings except for the partial cells (cells whose openings are not square) (see reference numeral 4c in FIG. 1A). Example 2 is the same as Example 1 except that the plugging portion 8 is formed in a state where the positioning pins 29 of the plugging portion forming member 33 are fitted to the cells 4 of the honeycomb structure 6. A dust collection filter 1 was produced according to the method described.

(Example 3)
In Example 3, the dust collecting filter 1 was manufactured using the plugging portion forming member 35 having the shape shown in FIG. 7 instead of the plugging portion forming member 33 shown in FIG. The plugging portion forming member 35 has the same shape as the plugging portion forming member 33 shown in FIG. 3, but is composed of a porous body. The method described in Example 1 It produced according to. However, as the photocurable resin, a resin that forms a cured resin body of a porous body after curing was used. Moreover, in Example 3, it describes in Example 2 except having formed the plugging part 8 while making the plugging part forming member 35 absorb the dispersion medium of the slurry 31 for plugging part formation. The dust collection filter 1 was manufactured according to the method.

About the dust collection filter manufactured by the method of Examples 1-3, it evaluated from the viewpoint of the thickness uniformity of the formed plugging part, and a positional accuracy. The uniformity of the wall thickness was evaluated based on the wall thickness difference between the wall thickness at the top of the dome-shaped plugged portion and the wall thickness at the skirt. The positional accuracy was evaluated based on the distance (deviation) between the designed formation position and the position where the plugging portion was actually formed. The results are shown in Table 1 and FIGS.

(Evaluation)
In any of the methods of Examples 1 to 3, a dome-shaped plugging portion, which was difficult to form by the conventional method, could be formed very easily, and good results were shown. However, in the case of the method of Example 1, as shown in FIG. 5 and Table 1, there is a deviation between the design formation position and the position where the plugging portion was actually formed, and the position accuracy of the plugging portion formation. In that respect, it was slightly insufficient. Further, the thickness at the top of the dome-shaped plugged portion 8 is 1.1 mm, the thickness at the skirt is 0.2 to 0.3 mm, and the thickness difference is 0.8 to 0.9 mm. It was difficult to uniformly form the thickness of the sealing portion.

  On the other hand, in the case of the method of Example 2 using the plugging portion forming member provided with the projecting positioning pins, as shown in FIG. There was almost no deviation in the position where the portion was formed, and the position accuracy of plugging portion formation was improved. On the other hand, the thickness at the top of the dome-shaped plugging portion 8 is 1.0 mm, the thickness at the skirt is 0.3 mm, and the difference in thickness is 0.7 mm, so that the thickness of the plugging portion is uniform. It was difficult to form.

  Furthermore, in the method of Example 3 using the plugging portion forming member constituted by the porous body, as shown in FIG. 7 and Table 1, the design formation position and the actual plugging portion are formed. There was almost no deviation in the position, and this point was equivalent to Example 2. However, the thickness at the top of the dome-shaped plugged portion 8 is 0.5 mm, the thickness at the skirt is 0.3 mm, and the difference in thickness is 0.2 mm, so that the thickness of the plugged portion is uniform. The property was remarkably improved.

Method for producing a dust filter of the present invention is suitably used as a filter medium for dust filter, producing a dust filter having plugging portions for plugging one of the openings of the cells, in particular, dome It can use suitably for manufacture of a dust collection filter provided with convex-shaped plugging parts including a shape.

It is a schematic diagram which shows one Embodiment of the conventional dust collection filter , Fig.1 (a) is the front view seen from the exit side end surface direction, FIG.1 (b) is AA 'cross section of Fig.1 (a). FIG. It is a perspective view which shows typically one Embodiment of a convex-shaped plugging part. It is a perspective view which shows typically another embodiment of a convex-shaped plugging part. It is a perspective view which shows typically another embodiment of a convex-shaped plugging part. It is process drawing which shows typically one Example of the manufacturing method of the dust collection filter of this invention. It is process drawing which shows typically another Example of the manufacturing method of the dust collection filter of this invention. It is process drawing which shows still another Example of the manufacturing method of the dust collection filter of this invention typically.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Dust collection filter , 2 ... Partition, 4 ... Cell, 4a ... Fluid supply cell, 4b ... Fluid discharge cell, 4c ... Partial cell, 6 ... Honeycomb structure, 8 ... Plugging part, 8A ... Dome-shaped plug Stopping part, 8B ... Tented plugging part, 8C ... Square pyramidal plugging part, 21, 33, 35 ... Member for forming plugging part, 23 ... Base, 25 ... Recessed part, 27 ... Non-recessed part, 29 ... pinspotting, 31 ... for forming plugged portions slurry, B ... inlet end face, C ... outlet end face, G 1 _... gas to be treated, G 2 _... treated gas.

Claims (11)

A honeycomb structure for a dust collection filter having a partition wall made of a porous body, in which a large number of cells serving as fluid flow paths are partitioned and formed by the partition wall, and the openings of any of the cells are plugged. A plugging portion forming member for forming a plugging portion to be stopped,
The substrate comprises a flat substrate having an area equal to or larger than the end face of the honeycomb structure, and a plurality of recesses capable of storing a plugging portion forming slurry are formed on the surface of the substrate, and each recess has at least The honeycomb structure has an area corresponding to an opening (plugging opening) in which the plugged portion of the cell is to be formed, and has a three-dimensional shape complementary to the plugged portion to be formed. A plugging portion forming member disposed at a position corresponding to the plugging opening on the end surface of the body.   The plugging portion forming member according to claim 1, wherein the recesses and the non-recesses are alternately arranged so as to form a checkered pattern as a whole.   The plugging portion forming member according to claim 1, wherein the concave portion has a shape in which an inner diameter gradually decreases toward a bottom portion.   The plugging portion forming member according to any one of claims 1 to 3, wherein the plugging portion forming member is formed of a porous body.   The member for plugging part formation as described in any one of Claims 1-4 comprised by the curable resin (resin hardened | cured material) derived from photocurable resin.   A positioning pin that can be fitted into the cell is provided at a position corresponding to an opening portion (non-plugging opening portion) that does not form the plugging portion of the cell on the end face of the honeycomb structure. Item 6. The plugging portion forming member according to any one of Items 1 to 5. A honeycomb structure for a dust collection filter having a partition wall made of a porous body, in which a large number of cells serving as fluid flow paths are partitioned and formed by the partition wall, and the openings of any of the cells are plugged. A dust collecting filter manufacturing method for obtaining a dust collecting filter by forming a plugging portion to stop,
Using the plugging portion forming member according to claim 1, after injecting the plugging portion forming slurry into the concave portion of the plugging portion forming member, the surface of the plugging portion forming member The honeycomb structure is placed so that the end surfaces thereof are brought into contact with each other, and the plugging portion forming slurry is adhered to the end surfaces of the partition walls positioned at the periphery of the plugging openings. A method for manufacturing a dust collecting filter , wherein the plugged portion is formed on an end face of a honeycomb structure. As the plugging portion forming member, a member in which the concave portion has a shape whose inner diameter gradually decreases toward the bottom portion, and a convex plugging portion protruding from an end surface of the honeycomb structure is formed. Item 8. A method for producing a dust collection filter according to Item 7. The plugging portion forming member is made of a porous material, and the plugging portion forming slurry is absorbed by the plugging portion forming slurry while the plugging portion forming member absorbs the plugging portion forming slurry. The manufacturing method of the dust collection filter of Claim 7 or 8 which forms a part. Image data capable of identifying at least an end face of the honeycomb structure and identifying the shape and position of the plugged opening and the opening (non-plugged opening) that does not form the plugged portion of the cell. Obtaining and producing a plugging portion forming member composed of a cured resin (resin cured product) derived from a photocurable resin by the following optical modeling method based on the image data, and forming the plugging portion The manufacturing method of the dust collection filter as described in any one of Claims 7-9 which forms the said plugging part using the member for a structure.
Stereolithography: After forming a cured resin layer by irradiating light on the surface of the photocurable resin, a new photocurable resin is supplied and the same light irradiation is applied to the upper surface of the cured resin layer. A method of obtaining a three-dimensional shaped object composed of a cured resin (resin cured product) by repeating the operation of forming a new cured resin layer and laminating the cured resin layer. The plugging portion forming member is fitted to the cell at a position corresponding to an opening (non-plugging opening) of the cell in the end face of the honeycomb structure that does not form the plugging portion. The dust-collecting filter according to any one of claims 7 to 10, wherein the plugging portion is formed in a state in which the positioning pin is fitted to the cell using a projecting positioning pin to be obtained. Production method.

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