JP4872216B2 - Honeycomb structure and manufacturing method thereof - Google Patents

Description

  The present invention relates to a honeycomb structure.

  Conventionally, this type of honeycomb structure has a flat sheet that is flat in one pair of two base papers, and a corrugated sheet that is formed into a corrugated shape on the other, and these are the ridges of the corrugated sheet. It is known that a single-wave molded body is formed by bonding using an adhesive or the like and is laminated in a cylindrical shape or a prismatic shape.

  Hereinafter, a method of forming a single-wave molded body laminated in a cylindrical or prismatic shape will be described with reference to FIGS.

  As shown in FIG. 7, the single wave molded body 101 includes a flat sheet 102 and a corrugated sheet 103, and is bonded to the flat sheet 102 by applying an adhesive 104 to the ridge line portion 105 of the corrugated sheet 103.

  Further, as shown in FIG. 8, the single wave molded body 101 is rolled up and laminated in a cylindrical shape, and an adhesive 104 is applied to and joined to a line portion 105 that is a contact portion between adjacent single wave molded bodies 101. Thus, the cylindrical honeycomb structure 106 is formed.

On the other hand, for example, as shown in Japanese Patent Application Laid-Open No. 5-137937, there are some which improve the adsorption performance by mixing particles such as an adsorbent into the adhesive 104 to be used.
JP-A-5-137937

  In such a conventional honeycomb structure, the base paper of the laminated body is thin or brittle, so that the strength is not sufficient or the shape cannot be maintained. In addition, in order to ensure the strength, paper with a strength different from that of the base paper must be adhered separately to ensure the strength. When the strength paper is adhered, the honeycomb structure is dispersed in a certain functional material. When the functional material is supported on the honeycomb structure by impregnating with the liquid, it is also supported on the paper that is stuck to secure the strength. When using an expensive functional material, a large loss of material is required. Thus, there is a problem that the cost becomes high, and there is a demand for a means for providing the honeycomb structure with strength separately without impregnating the outer periphery with a material.

  The present invention solves such a conventional problem, can improve the outer peripheral strength of the laminate, and when impregnated, does not hold the liquid material to be impregnated in the outer peripheral portion. It aims at providing the honeycomb structure which can be made.

  In order to achieve the above object, the honeycomb structure of the present invention covers the outer peripheral surface parallel to the cell opening direction of the laminated honeycomb structure with a sheet having water resistance or water repellency, and impregnates the liquid of the material, After drying, the sheet is removed, and a hardener is applied to the removed surface to give the outer peripheral strength to the element.

  By this means, the outer peripheral strength of the honeycomb structure can be improved, and when the honeycomb structure includes an impregnation step into the material liquid, the liquid material to be impregnated in the outer peripheral portion is almost smaller than the inside of the cell. A honeycomb structure that can be not supported can be provided.

  Further, the honeycomb structure of the present invention covers the outer peripheral surface parallel to the cell opening direction of the honeycomb structure with a water-resistant or water-repellent and flammable sheet, impregnated with a liquid of the material, and after drying, the honeycomb structure By firing the body and burning off the sheet, the need to remove the sheet covering the outer periphery can be eliminated. In addition, an outer periphery strength can be given to the outer peripheral surface after burning off by apply | coating a hardening | curing agent.

  In addition, the curing agent can be hardened by heating or baking after applying the curing agent, and the peripheral strength can be further increased.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the honeycomb structure which strengthens the outer peripheral surface parallel to the opening direction of the cell of a honeycomb structure, and does not need the paper for shape retention can be provided.

  Further, even when the honeycomb structure is impregnated with the liquid in which the material is dispersed, the outer peripheral surface parallel to the opening direction of the cells of the honeycomb structure hardly carries the material as compared with the inner surface of the cell, and the material loss is small. A method for manufacturing a honeycomb structure can be provided.

  Moreover, the honeycomb structure produced by the above manufacturing method can be provided.

  In addition, a honeycomb-like moisture absorption filter that absorbs moisture in the air carrying zeolite or silica gel or both in the honeycomb structure can be provided by using the honeycomb structure.

  In addition, a honeycomb-shaped deodorizing filter that uses the honeycomb structure to adsorb an odor component in the air carrying zeolite or activated carbon or both in the honeycomb structure can be provided.

  According to the first aspect of the present invention, one is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape. Then, in the honeycomb structure in which these are laminated, the outer peripheral surface parallel to the opening direction of the cells of the honeycomb structure is covered with a water-resistant or water-repellent outer peripheral sheet, and an adsorbent or catalyst material such as zeolite, silica gel or activated carbon And a binder structure in which the binder component is dispersed. The honeycomb structure is formed by removing the outer peripheral sheet covering the outer periphery after being pulled up and dried. As a result, it is possible to prevent the functional material from adhering to the outer peripheral portion that does not function as a honeycomb structure filter, and to reduce the cost because unnecessary materials are not used.

  In addition, since the honeycomb structure pulled up from the impregnating solution is wet and easily deformed, it is preferable that the outer peripheral sheet is in close contact with the honeycomb structure. For this purpose, it is desirable that the outer peripheral sheet does not swell when it absorbs water, or it does not swell even when swollen, and has a smaller expansion coefficient than the honeycomb and does not generate a gap with the honeycomb structure.

  Further, according to claim 2 of the present invention, one sheet is a flat sheet that remains flat, and the other is a corrugated sheet that has been formed into a corrugated shape. Then, the outer peripheral surface parallel to the opening direction of the cells of the honeycomb structure laminated with this is covered with a water-resistant or water-repellent and flammable outer peripheral sheet, and adsorbents such as zeolite and silica gel, catalyst materials and binder components The honeycomb structure is obtained by impregnating the above dispersed liquid, drying, firing the honeycomb structure at 400 ° C. or more, and burning off the outer peripheral sheet. By burning off the outer peripheral sheet, it is not necessary to peel off the outer peripheral sheet, and the honeycomb structure can be cured and the strength can be improved by previously putting a material that cures by firing into the base material component of the honeycomb structure. It can also be made.

  According to a third aspect of the present invention, there is provided a honeycomb structure characterized in that a hardening agent is applied to the surface of the honeycomb structure from which the outer peripheral sheet is removed to give the element peripheral strength. As a result, the strength of the honeycomb structure can be improved without impairing the functions such as adsorption and catalytic action of the honeycomb structure even if the substrate alone cannot withstand the use strength as the structure. Become. Further, when the base paper is thinned in the honeycomb structure, the pressure loss is reduced and the contact efficiency with air is further improved, but there is a problem that the strength is weakened. In the present invention, since the structure is retained by applying a curing agent that reinforces the outer periphery, the substrate can be made thinner, and a more functional honeycomb structure can be provided.

  According to a fourth aspect of the present invention, the curing agent can be made harder by heating or firing the honeycomb structure. In addition, after baking, the outer periphery can be further strengthened by applying a curing agent, and the handleability of the structure can be improved.

  In the case of a honeycomb structure made of a composite substrate sheet of organic fibers and inorganic fibers, by firing at 400 degrees or more, the outer peripheral sheet wound around the outer periphery is burned off, and at the same time, in the material dispersion and the substrate sheet This manufacturing method is particularly effective because two steps can be performed simultaneously to burn off the organic matter.

  Further, in claim 5 of the present invention, water-resistant paper subjected to water-resistant processing is used for the sheet wound around the outer periphery, and the adsorbent such as zeolite, silica gel, activated carbon and the like, and dispersion of the binder component When the liquid is impregnated and pulled up and dried, the liquid does not easily adhere to the paper wound around the outer periphery, and material loss can be reduced. Further, since water resistant paper is difficult to tear even when impregnated, the process can be carried out stably. Water-resistant paper is manufactured by impregnating or painting paraffin, oils, fats, silicone resin, or astringency.

  Further, in claim 6 of the present invention, an outer peripheral sheet wound around the outer periphery is used as a film, and the raw material of the film is polyester, polyethylene terephthalate, polystyrene, polyvinylidene chloride, polypropylene, polyethylene, or other organic resin. By making it into a film, it is impregnated with an adsorbent such as zeolite, silica gel or activated carbon, or a liquid in which a catalyst material and a binder component are dispersed, and when it is pulled up and dried, the film wound around the outer periphery is difficult to adhere to the liquid, reducing material loss be able to. In addition, since the organic resin film is not easily broken even when impregnated, the process can be stably performed.

  Further, in claim 7 of the present invention, the outer peripheral sheet is in the form of a plate, and the material of the plate is either a metal or an organic resin, so that an adsorbent or a catalyst material such as zeolite, silica gel or activated carbon, When impregnated with a liquid in which the binder component is dispersed, and then pulled up and dried, the liquid hardly adheres to the plate wound around the outer periphery, and material loss can be reduced. In addition, the plate-like material is particularly hard at the time of impregnation, and the honeycomb structure is not easily deformed, so that the process can be carried out stably. In addition, as long as the plate is not burned off, it can be easily reused and can be operated at low cost.

  According to claim 8 of the present invention, the curing agent is composed of an inorganic mineral and an inorganic binder so that the inorganic binder binds the inorganic mineral and the substrate of the honeycomb structure and can be cured. In addition, the temperature can be raised to the heat resistant temperature of the inorganic binder inorganic mineral during firing.

  Further, according to claim 9 of the present invention, by including at least a silicon material in the curing agent, the outer peripheral base material of the honeycomb structure can be protected, hardened, and wear-resistant.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment 1)
As shown in FIG. 1 and FIG. 2, a corrugator 6 forms a corrugator 6 with a flat sheet 2 with the base sheet 1 kept flat, and a corrugator 6 that is formed into a corrugated shape by a main forming roll 3 and an upper forming roll 4. The corrugated sheet 5 is applied to the corrugated sheet 5 at the adhesive applying section 7, and the corrugated sheet 5 and the flat sheet 2 are joined at the ridge line section 10 of the corrugated sheet 5 with the main forming roll 3 and the press roll 9. The wave forming body 11 is formed. And the cylindrical honeycomb structure 12 laminated | stacked by winding up the said single wave molded object 11 is obtained. And as shown in FIG. 3, the outer peripheral surface parallel to the opening direction of the cell of the cylindrical honeycomb structure 12 is covered with a resin film 13. As the film material, a film made of polyester, polyethylene terephthalate, polystyrene, polypropylene, polyvinylidene chloride, or polyethylene is preferable because of good workability. The film covers the outer periphery of the honeycomb structure by rotating the cylindrical honeycomb structure 12 while applying pressure with a belt cover 15 having a weight 14 at one end so that there is no gap with the film, as shown in FIG. The tape 16 is preferably bonded with water-resistant vinyl tape or glue, preferably with water-resistant glue. It is impregnated with a liquid in which an adsorbent such as zeolite, silica gel or activated carbon, a catalyst material, or a binder component is dispersed, and the material is supported on the honeycomb structure, pulled up and dried, and then the film covering the outer periphery is removed. As a result, a honeycomb structure can be obtained in which useless material is prevented from being carried on the outer peripheral portion which has no functional influence. Depending on the desired loading, it is necessary to repeat the impregnation and drying several times.

(Embodiment 2)
Instead of the film of the first embodiment, water-resistant paper made by mixing water-resistant resin may be used (not shown).

(Embodiment 3)
On the outer periphery after the outer peripheral sheet of the cylindrical honeycomb structure obtained in Embodiments 1 and 2 is peeled off, one or more of inorganic minerals, preferably sepiolite, zeolite, montmorillonite, alumina oxide, silica, and talc are used. By applying only the inorganic binder dispersion liquid or the inorganic binder and drying, the outer periphery can be cured, and the strength and handling properties of the honeycomb structure can be improved. Examples of the inorganic binder include colloidal silica, lithium silicate, and sodium silicate, which may be diluted with water depending on the application.

(Embodiment 4)
In the case of a base sheet that includes any one or more of glass fiber, ceramic fiber, and inorganic mineral fiber, the base sheet of the honeycomb structure obtained in the third embodiment retains molding even when fired. Since the organic matter in the structure is burned off by firing to obtain an inorganic honeycomb structure, and the hardening liquid shown in the third embodiment can be further solidified by heat, and the strength of the honeycomb structure and Handleability can be improved. Here, when it is desired to further improve the structural strength, the strength can be improved by impregnating the supporting liquid again and repeating the drying step.

(Embodiment 5)
In place of the film of the first embodiment and the water-resistant paper of the second embodiment, as shown in FIG. 5, a plate 17, preferably a stainless plate if made of metal, an aluminum plate, a nickel plate, or an iron plate If it is made of resin, it is preferable to use polypropylene or vinyl chloride. Further, it is more desirable that the plate is processed so as to be rounded to some extent.

  At this time, the outer peripheral plate may be bonded with a tape as in the first and second embodiments, but when the plate is rolled, the fastener 18 preferably accommodates an error in the diameter of the honeycomb structure. If it is made to fix with the fastener 18 using a spring etc. so that it can do, it will become easier to recycle, a cost can be suppressed, and an environmental load can also be suppressed.

(Embodiment 6)
Silicon may be used in place of the mixed liquid of inorganic mineral and inorganic binder applied to the outer periphery in the third embodiment. In this case, the film on the outer peripheral surface becomes a protective film, and an effect that it is difficult to break or chip is obtained.

(Embodiment 7)
In Embodiments 1, 2 and 5, the liquid in which the adsorbent such as zeolite, silica gel and activated carbon, the catalyst material and the binder component are dispersed is impregnated, and the material is supported on the honeycomb structure. A step of pouring over the honeycomb structure and blowing off excess liquid may be used, and drying may be used, which is suitable for continuously forming a material-supporting honeycomb structure as compared with the impregnation type.

(Embodiment 8)
As shown in the first and fourth embodiments, the material liquid is impregnated, dried, baked without peeling off the sheet to burn off the outer peripheral sheet, and then coated with the outer peripheral curing liquid as shown in the third and sixth embodiments. May be. As the outer peripheral sheet, the film sheets and paper sheets of Embodiments 1 and 2 are sufficiently burned off by firing. Further, even if the metal plate of the fifth embodiment does not burn out, the outer peripheral sheet can be naturally peeled off from the honeycomb structure by using a burning tool such as rubber for the fastener portion. Is possible.

Example 1
Using a papermaking containing at least glass fiber and pulp, a single-wave molded body was formed from a flat sheet that remained flat and a corrugated sheet that had been molded into a corrugated sheet. The paper thickness of the base paper is about 0.15 mm, the shape of one-sided wave is 2.6 mm, and the height is 1.5 mm including the thickness of the base paper. did. The single-wave molded body was supplied to a winder and rotated and laminated to obtain a cylindrical honeycomb structure.

  A film, paper, or stainless steel plate as shown in Table 1 was wound around the outer peripheral surface of the cylindrical honeycomb structure with a length of about 1 to 2 rounds. At this time, the honeycomb structure and the film are not bonded, and the film or paper is restrained while being wound so that there is no gap as shown in the first embodiment, and the end of the film is shown in FIG. Affixed with vinyl tape. Further, the stainless steel plate was wound around the honeycomb structure so that there was no gap, and then fixed as shown in FIG. 5 so as not to spread.

  In addition, honeycomb structures using drawing paper (thickness 0.3 mm) and plotter paper (thickness 0.15 mm), which are generally commercially available for comparison, were also prepared and tested in the same process.

  Table 1 is a table showing the outer peripheral sheet wound around the cylindrical honeycomb structure of Example 1 of the present invention and a table showing impregnation results.

  The cylindrical honeycomb structure manufactured in the above process is impregnated with a dispersion of an inorganic binder component and zeolite, and then heated at room temperature or until the honeycomb substrate is free of moisture until it is passed through the cells of the honeycomb structure. And dried. After drying, the outer peripheral sheet was peeled off. At this time, in all sheets, the situation that the liquid of zeolite and the inorganic binder did not peel off by adhering the outer peripheral sheet and the base paper of the honeycomb structure did not occur.

  After impregnation, the drawing paper used for comparison expanded by sucking water, resulting in a gap between the honeycomb structure and the honeycomb structure deformed during ventilation drying. Also, plotter paper was torn when it was dried by ventilation after impregnation. This is considered to be because the honeycomb structure was slightly expanded by sucking water, and the plotter paper was torn and weakened.

  In addition, the honeycomb structure expanded in the same way with the film, water-resistant paper, and stainless steel plate, but its expansion rate was less than half that of the one wrapped with drawing paper, and it can be said that the shape is sufficiently retained. there were. This is because the water-resistant paper, film and stainless steel plate did not swell or did not swell as much as the honeycomb structure even after sticking, so the outer peripheral sheet adhered closely to the honeycomb structure, and as a result, even in ventilation drying etc. Indicates that the shape has been preserved.

Next, the diameter change rate before and after impregnation in Table 1 is less than 0.5%, and a curing agent as shown in Table 2 is applied to the outer periphery of the honeycomb structure obtained while maintaining the shape, and after drying, The honeycomb structure was obtained by firing at a temperature at which the pulp content in the base material was burned off at 400 ° C. or more for 5 hours. The honeycomb structure thus obtained was evaluated by appearance and indentation strength. The appearance was visually confirmed from the viewpoint of cracks and cracks. With respect to the strength, as shown in FIG. 6, the compression strength measuring machine 21 having a circular indentation surface 20 with a diameter of 5 mm with respect to the honeycomb structure outer peripheral edge surface 19 so that the circular shape with a diameter of 5 mm overlaps the honeycomb surface just half, Was compressed in the vertical direction at 9.8 mm ² , the breaking strength at that time was measured, and the outer peripheral compressive strength was 22. Moreover, it pushed with the compressive-strength measuring machine 21 which similarly has a circular pushing surface of 10 mm on an outer peripheral surface, the fracture strength at that time was measured, and it was set as outer peripheral pushing strength 23. Moreover, the outer periphery hardening | curing agent was applied even after partial baking, and the effect was also evaluated.

  Table 2 shows the composition of the liquid applied to the outer periphery of the cylindrical honeycomb structure of Example 1 of the present invention and the results.

  As a result, after the outer periphery of the cylindrical honeycomb structure is peeled off, the outer peripheral compressive strength of the honeycomb structure is improved by applying a dispersion of a mixture of zeolite or alumina oxide and an inorganic binder, in this case a mixture of lithium silicate and colloidal silica. I understood it. However, the liquid containing only colloidal silica improves the compressive strength and indentation strength, but has the disadvantage that glassy fragments are formed and the base material is chipped. I found it effective to apply.

  This is because both the plane of the honeycomb and the corrugated sheet are cured when a certain amount of the inorganic binder penetrates the base material, but if the inorganic binder content is excessive, the inorganic binder content becomes a glass film and becomes brittle due to drying, And it is thought that the crack of a base material will occur easily from the difference in shrinkage. On the other hand, a certain amount of inorganic mineral is considered to be because the shrinkage rate is close to that of the base material and cracks are reduced, and glass film formation due to the increase in the bond between the inorganic binder and the inorganic mineral is prevented. It is done.

  In addition, it was confirmed that applying the outer peripheral curing agent again after firing was particularly effective in terms of compressive strength.

  In an adsorption filter carrying an adsorbent of zeolite or activated carbon or an oxidative decomposition filter carrying a catalyst made of the honeycomb structure obtained in the present invention, an expensive adsorbent or catalyst is attached to the outer peripheral portion which does not provide a relatively function. A honeycomb filter with improved handling and strength can be provided by applying a curing agent on the outer periphery, preventing loss of material without carrying it, and can be applied as a dehumidification or air purification filter.

The figure which shows the single wave molded object manufacturing method of Embodiment 1 of this invention The figure which shows the cylindrical honeycomb structure preparation method of Embodiment 1 of this invention The figure which shows the method of winding a film around the cylindrical honeycomb structure of Embodiment 1 of this invention. The figure which wrapped and stopped the film around the cylindrical honeycomb structure of Embodiment 1 of the present invention The figure which wrapped and stopped the board around the cylindrical honeycomb structure of Embodiment 5 of the present invention The figure which shows the measurement location of the outer periphery compression indentation strength measurement of Example 1 of this invention Diagram showing a conventional single-wave molded body Diagram showing a conventional cylindrical honeycomb structure

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Substrate sheet 2 Plane sheet 3 Main forming roll 4 Upper forming roll 5 Corrugated sheet 6 Corrugator 7 Adhesive application part 8 Adhesive 9 Press roll 10 Ridge line part 11 Single wave formed body 12 Cylindrical honeycomb structure 13 Film 14 Weight 15 Belt cover 16 Tape 17 Plate 18 Fastener 19 Honeycomb structure outer peripheral edge surface 20 Circular indentation surface 21 Compressive strength measuring machine 22 Outer periphery compressive strength 23 Outer periphery indentation strength 101 Single wave molded body 102 Flat sheet 103 Corrugated sheet 104 Adhesive 105 Strand Part 106 Cylindrical honeycomb molded body

Claims (10)

A honeycomb structure in which one flat sheet is left flat, and the other is a corrugated sheet formed into a corrugated shape, which are joined at the ridge line portion of the corrugated sheet to form a single-wave compact, and then the single-wave compact is laminated The outer peripheral surface parallel to the opening direction of the body cell is covered with a water-resistant or water-repellent outer peripheral sheet, impregnated with a liquid in which adsorbent and binder components of zeolite, silica gel and activated carbon are dispersed, and after drying, the outer peripheral sheet A method for manufacturing a honeycomb structure, wherein the honeycomb structure is removed. 2. The method for manufacturing a honeycomb structure according to claim 1, wherein the outer peripheral sheet is burned out at 400 degrees or more, and the honeycomb structure is fired and removed by burning off the outer peripheral sheet. The method for manufacturing a honeycomb structure according to claim 1 or 2, wherein a curing agent is applied to a surface from which the outer peripheral sheet has been removed. The method for manufacturing a honeycomb structured body according to claim 1 or 2, wherein the surface from which the outer peripheral sheet has been removed is coated with a curing agent and further fired. The method for manufacturing a honeycomb structured body according to any one of claims 1 to 4, wherein the outer peripheral sheet is a paper subjected to water-resistant processing. The outer peripheral sheet is a film, and the material is made of polyester, polyethylene terephthalate, polystyrene, polyvinylidene chloride, polypropylene, polyethylene, or other organic resin. A method for manufacturing a honeycomb structured body according to claim 1. The method for manufacturing a honeycomb structure according to any one of claims 1 to 4, wherein the outer peripheral sheet is either a metal plate or a resin plate. The method for manufacturing a honeycomb structured body according to any one of claims 3 to 7, wherein the curing agent comprises at least an inorganic mineral and an inorganic binder. The method for manufacturing a honeycomb structured body according to any one of claims 3 to 7, wherein the curing agent contains at least a silicon material. A honeycomb structure manufactured by the method for manufacturing a honeycomb structure according to any one of claims 1 to 9, wherein a liquid material to be impregnated is not retained in an outer peripheral portion .

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