JP5132831B1 - Porous ceramic fired disk manufacturing apparatus and disk - Google Patents

Abstract

An apparatus for producing a disk of a porous ceramic fired body that can easily form a complicated shape or a fine shape and can ensure the accuracy of a product is provided.
An apparatus for manufacturing a disk of a porous ceramic fired body includes a ceramic paper making means for making a ceramic paper sheet by drawing a ceramic slurry into a paper with a mesh, and an upper disk and a lower disk of a predetermined shape from the ceramic paper sheet. And a pressing means for sandwiching a sheet-like member between the upper disk and the lower disk between the upper disk and the lower disk and assembling and pressing into a three-layer structure disk. And a drying means for drying the disk assembled by pressing, and a firing means for firing the disk in a firing furnace.
[Selection] Figure 2

Description

  The present invention relates to a disk manufacturing apparatus for a porous ceramic fired body and a disk manufactured by the manufacturing apparatus.

Ceramic refers to a substance that has been baked and solidified with an inorganic material such as clay and changed its properties. Firing means baking at high temperature to change its properties.
In recent years, by using refined materials such as alumina (Al ₂ O ₃ ), zirconia (ZrO ₂ ), and silicon carbide (SiC), the shape and process are precisely controlled to produce new functions and new properties. Ceramics that have been made to come to be made. When a material used in ceramic is fired, a phenomenon called “sintering” occurs in which the grains and the grains are baked and solidified. It is known that a porous ceramic fired body having a high porosity can be obtained by changing the type of raw materials used, the fineness of particles, and the baking method (see Patent Document 1).

FIG. 7 is a block diagram showing a conventional method of manufacturing a porous ceramic fired body, FIG. 8 shows a conventional molding method of steps 11 to 14 shown in FIG. 7, and (a) is a flow of ceramic mud. The state diagram, (b) is an explanatory view showing the disassembly of the mold after solidification.
As shown in FIG. 7, step 11 is a first step in which a ceramic slurry in which ceramic fibers and ceramic particles are dissolved in water is poured into a mold (gypsum).
As shown in FIG. 8 (a), the upper mold 9b is fixed on the form of the lower mold 9a, and various ceramic mud is poured from the inlet 9c provided on the upper surface of the upper mold 9b.
Step 12 is a second step of removing the mold and taking out the solidified molded product.
As shown in FIG. 8 (a), after solidifying for a while until solidified, as shown in FIG. 8 (b), the mold of the upper mold 9b is removed, and the solidified molded product W is taken out. .

Step 13 is a drying process for drying the molded product W. The burr 9e of the molded product W is removed, the inlet 9d is cut off to finish the product, and the molded product W is dried.
Step 14 is a firing step of firing in a kiln. A fired product is obtained at a firing temperature of 750 ° C. or higher.
The conventional gypsum casting method (Plaster Casting) using a gypsum mold for such a mold has a short lifetime of the gypsum mold, but is easy to repair and inexpensive.
In addition, the manufacturing method of the sintered compact which uses a plaster mold as a shaping | molding die is disclosed by patent document 2. FIG.

JP 2010-228424 A (paragraph 0010) JP 2011-140235 A (FIG. 2)

  However, the molding of a complicated shape or a fine shape has a problem that the mold becomes complicated and the accuracy of the mold is also required, which increases the cost of repair.

  Therefore, the present invention has been made in view of such problems, and without adopting a gypsum casting method using a gypsum mold in a conventional formwork, conventionally, complicated shapes that are difficult to mold and fine It is an object of the present invention to provide a porous ceramic fired body disk and a method of manufacturing a porous ceramic fired body disk that can easily mold the shape, secure the quality of the product, and reduce the cost. To do.

  In order to achieve the solution of the above-described problem, the porous ceramic fired disk manufacturing apparatus according to claim 1, ceramic paper making means for making a ceramic paper sheet by paper making a ceramic slurry with a screen, A die cutting means for punching an upper disk and a lower disk of a predetermined shape from a ceramic paper sheet, and a sheet-like member burnable between the upper disk and the lower disk between the upper disk and the lower disk. A pressing means for assembling and pressing a disc having a three-layer structure, a drying means for drying the pressed and assembled disc, and a firing means for firing the disc in a firing furnace. Features.

  The invention according to claim 2 is the porous ceramic fired body manufacturing apparatus according to claim 1, wherein the sheet-like member is sandwiched between the upper disk and the lower disk, and has a three-layer structure. The press means for assembling and pressing the disk includes means for applying an inorganic binder to the bonding surface of the upper disk and the lower disk.

  The invention according to claim 3 is the porous ceramic fired disk manufacturing apparatus according to claim 1 or 2, wherein the ceramic slurry includes alumina fibers of ceramic fibers and alumina particles of ceramic particles. The mixing ratio is characterized in that the alumina fibers are blended at 10 to 100% and the alumina particles at 90 to 0%.

Invention of Claim 4 is a manufacturing apparatus of the disk of the porous ceramic fired body as described in any one of Claims 1-3, Comprising: The thickness of the papermaking of the said ceramic papermaking sheet | seat is 5-10 mm It is characterized by.

The invention according to claim 5 is the porous ceramic fired disc manufacturing apparatus according to any one of claims 1 to 4, wherein the sheet-like member is an organic sheet. .

The invention according to claim 6 is a disc manufactured by the porous ceramic sintered body manufacturing apparatus according to any one of claims 1 to 5, wherein the upper disc and the lower disc And a through hole is provided in the upper disk and the lower disk.

  According to the first aspect of the present invention, the ceramic papermaking means for producing the ceramic papermaking sheet, the die cutting means for punching the disk, and the sheet-like member that can be burned out between the disks are sandwiched between the disks to form a three-layer structure. By including a pressing means for assembling and pressing, a drying means for drying the pressed and assembled disk, and a firing means for firing in a firing furnace, a formwork such as a plaster mold of the conventional construction method is completely unnecessary. In addition, since the hollow portion can be easily formed in the disk by the three-layer structure, a flow path for the permeate can be secured. Further, there is no need to lose shape or repair the mold even if it is a finely shaped pattern with a mesh pattern. Therefore, it is possible to provide an apparatus for manufacturing a disk of a porous ceramic fired body that has a good product yield, a stable quality, and can be manufactured at a low cost.

  According to the second aspect of the present invention, in the pressing means that sandwiches the sheet-like member between the upper disk and the lower disk and assembles and presses the three-layer disk, the bonding surface of the upper disk and the lower disk is inorganic. By applying the binder, it is possible to improve the bonding strength of the bonding surfaces of the outer edges of the upper disk and the lower disk.

  According to the invention of claim 3, the ceramic slurry is composed of alumina fibers of ceramic fibers and alumina particles of ceramic particles, and the mixing ratio is 10 to 100% for alumina fibers and 90 to 0% for alumina particles. By blending, the ceramic fiber material and the ceramic particle material are intertwined, and the ceramic mud can be made as if making Japanese paper.

  According to the invention which concerns on Claim 4, while the thickness of the papermaking of a ceramic papermaking sheet is 5-10 mm, while ensuring the intensity | strength of a disk, the filtration function can be exhibited.

According to the invention which concerns on Claim 5, since a sheet-like member is made into an organic sheet, since an organic sheet will become gas when burned, a hollow part can be formed reliably.

According to the invention of claim 6, the porous ceramic fired disc includes a hollow portion between the upper disc and the lower disc, and through holes are provided in the upper disc and the lower disc.
The penetrating liquid soaks into the hollow portion from the outer peripheral surfaces of the upper disk and the lower disk, and the soaked permeating liquid can be easily recovered to the outside through the through hole.

The disk of the porous ceramic sintered body of this invention is shown, (a) is a top view, (b) is sectional drawing of the AA line shown to (a). It is the figure which decomposed | disassembled the manufacturing apparatus of the disk of the porous ceramic sintered body of this invention into each manufacturing means. (A) is an enlarged sectional view showing a mixture of ceramic slurry when the ceramic slurry is squeezed with a plow net (however, moisture is not shown), and (b) is a sectional view showing a crafted ceramic sheet. It is. (A) is the layout which takes many disks from a ceramic papermaking sheet | seat, (b) is sectional drawing of the BB line shown to (a). (A) is a top view which shows an example of the mesh pattern of an osmosis | permeation flow path material, (b) is sectional drawing of CC line shown to (a), and a dashed-two dotted line shows an upper disk and a lower disk. (A) is a cross-sectional view showing a three-layer structure, (b) is an assembling means, (c) is a pressing means, (d) is a drying means, (e) is a firing means, and (f). These are each process drawing by a drilling means. It is a block diagram which shows the manufacturing method of the conventional ceramic sintered compact. The molding method by the conventional mold form is shown, (a) is the state figure which poured ceramic slurry, (b) is explanatory drawing which shows the decomposition | disassembly of the mold form after solidification.

Mud is a suspension called slurry or slime. In the present invention, it means a liquid mixture having a relatively large amount of liquid in which particles, fibers and the like are mixed. Papermaking slurry is a suspension in which floc-like aggregated particles are formed by adding alumina sol or silica sol to an aqueous slurry in which alumina fibers and alumina powder are dispersed in water, and further adding a polymer flocculant. A liquid (slurry).
Since the papermaking slurry cannot be made if it is too muddy, it has a low concentration and a moisture content of 95% or more. This is a low-viscosity suspension (slurry) in which flocculant is added and the powder and fibers dispersed in water are intertwined into a cotton lint (flock).

≪Configuration of disk of porous ceramic fired body≫
FIG. 1 shows a disk of a porous ceramic fired body according to the present invention, in which (a) is a plan view and (b) is a cross-sectional view taken along line AA shown in (a).
As shown in FIG. 1 (a), a disk 1 of a porous ceramic fired body 10 is formed by joining and connecting an upper disk 1a made of porous ceramic and an outer edge 1e of the upper disk 1a to form a hollow part in the center. The lower disk 1b is made of a porous ceramic and is opposed to the upper disk 1a via a (gap) λ (see FIG. 1B).
The disk 1 of the porous ceramic fired body 10 is disk-shaped and has a three-layer structure, its intermediate layer is a hollow portion λ, and the gap between the cavities is the permeate flow path 1d.
Further, through holes 1g and 1g are provided in the center of the upper disk 1a and the lower disk 1b in order to pass orthogonal tubes through the upper disk 1a and the lower disk 1b.
The disk shape may be circular or polygonal. As shown in FIG. 1B, for example, when the disk is circular, the outer diameter D1 of the disk 1 is, for example, 152 mm, and the outer diameter D2 of the osmotic fluid channel 1d is, for example, The inner diameter D3 (through hole 1g) of the disk 1 to 146 to 136 mm is preferably 25.0 mm, for example. Further, the thickness T1 of the disk 1 is, for example, 3.4 mm, and the gap λ is 0.4 mm.

As shown in FIG. 1 (a), the disk 1 is formed of a porous ceramic in which countless fine holes 1c are formed. The size of the fine hole 1c is φ0.5 μm to 40 μm, preferably φ4 to 8 μm. Various methods of using the disk 1 can be considered. As an example, a method of using the disk 1 will be described.
When the undiluted solution is supplied around the disk 1, the undiluted solution permeates from the minute holes 1 c on the outer surface of the disk 1, and those smaller than the size of the minute holes 1 c become the osmotic solution and pass through the holes 1 c. Do not pass anything larger than that.
That is, the disk 1 of the porous ceramic fired body 10 is suitable as a filter medium that functions as a filter. In this case, the permeate is called the filtrate. The filtrate that has permeated through the countless fine holes 1 c permeates the disk 1, passes through the permeate flow path 1 d that is the hollow portion λ, and is further recovered from the through hole 1 g of the disk 1.

≪Device for manufacturing disc of porous ceramic fired body≫
FIG. 2 is an exploded view of the porous ceramic fired disk manufacturing apparatus of the present invention into each manufacturing means.
The manufacturing method of the disk 1 which is the porous ceramic fired body 10 includes step 1 of the ceramic paper making means for making a ceramic paper sheet by making a ceramic slurry in the same way as paper making, and a disk in a predetermined shape from the ceramic paper sheet. Step 2 of the die cutting means for punching, step 3 of the press means for sandwiching the permeate flow path material between the two disks and assembling and pressing in a three-layer structure, and drying means for drying the assembled disk Step 4, step 5 as a baking means for baking in a baking furnace, and step 6 as a drilling means for processing a through hole at the center of the disk.

Before going into the explanation of each means, there is a combination of ceramic slurry as a setup.
FIG. 3 is an enlarged schematic diagram showing the structure of the ceramic slurry when the ceramic slurry is lifted up in the manner of papermaking.

≪Ceramic mud blending≫
For example, the ceramic slurry 2 is filled with water in a rectangular basket, and ceramic fibers 3a, ceramic particles 3b, an organic binder 3c, an inorganic binder 3d, a firing temperature reducing agent 3e, a polymer flocculant 3f, and the like are placed therein. Charge at a predetermined ratio and stir to make a mixed state of 95% moisture. The alumina fiber of the ceramic fiber 3a shown in FIG. 3 has AL ₂ O ₃ and SiO ₂ as main components, and the former has a content of 70% or more and the latter has a content of 30% or less. The alumina fiber is a fiber having an outer diameter of 3 to 5 μm and a length of 10 to 50 μm and a cylindrical shape.
The alumina particles of the ceramic particles 3b preferably have a particle diameter of 1 to 6 μm.
The mixing ratio of the alumina fibers 3a and the alumina particles 3b is 10 to 100% for the alumina fibers 3a and 90 to 0% for the alumina particles 3b, but the ratio of 50% for the alumina fibers 3a and 50% for the alumina particles 3b is the most. It is easy to entangle and is suitable.
It should be noted that the mixing ratio may be such that only alumina fibers (100%) and alumina particles 3b are not mixed (0%).
The organic binder 3c is preferably cationized starch, pulp, or synthetic resin emulsion (nerve) polyacrylamide or PVA.
The inorganic binder 3d is preferably colloidal silica or alumina sol.
As the firing temperature reducing agent 3e, various phosphates and submicron particle alumina are used depending on firing conditions. As the polymer flocculant 3f, polyacrylamide or the like is used.

≪Ceramic paper making means≫
As shown in FIG. 3 (a), the ceramic slurry 2 in the cocoon is crushed with a gauze 4 with a formwork so that the thickness is uniform, and the ceramic fibers 3a are entangled with each other, so that the ceramic particles 3b The plow net 4 is rotated up and down or left and right so that the thickness is adjusted.
The pavement net 4 is removed from the outer frame, the plow net 4 is inverted on the table near the ridges, and the ceramic paper sheet 5 is left on the table so that the plow net 4 is turned over. Repeat this.
In FIG. 3 (b), as a result of paper making in the same way as paper making, the thickness T1 of the ceramic paper making sheet 5 is 5 to 10 mm, preferably 7 to 8 mm.

<< Die cutting means >>
As shown in FIG. 4 (a), the size of the ceramic papermaking sheet 5 is preferably a horizontal length L1 × vertical length L2 (1300 mm × 1000 mm) with good workability for manufacturing a disk.
The ceramic papermaking sheet 5 becomes like a stretched wrinkle in a semi-dry state.
The ceramic papermaking sheet 5 becomes felt when dried. In a stage where the ceramic papermaking sheet 5 is not yet dried, the ceramic papermaking sheet 5 is punched out in a predetermined disk shape by a multi-cavity punching means. The die cutting means is performed by a die cutting tool comprising a lower die and an upper die (not shown).
As shown in FIG. 4A, a large number of upper disks 1a and lower disks 1b of the disk 1 are taken from one ceramic papermaking sheet 5, respectively. Here, the multi-cavity arrangement is a staggered arrangement, but the multi-cavity arrangement may be made by narrowing the interval to form a lattice arrangement.
The disk 1 in FIG. 4B contracts by 3 to 5% in the sintering process. In anticipation of this shrinkage rate, for example, in the case of taking a large number of pieces, the diameter D1 is φ156 mm, and it is cut out by die cutting. The finished product shrinks to φ152 mm.

≪Pressing means for assembling and pressing≫
Before describing the pressing means for assembling and pressing, the permeate channel material will be described.
≪Configuration of permeate channel material≫
Fig.5 (a) is a top view which shows an osmotic fluid flow path material, (b) is sectional drawing of CC line shown to (a). As shown in FIG. 5A, the osmotic flow path material 6 that is a sheet-like member has a gap λ (FIG. 1B) that becomes a flow path for collecting the permeated liquid that has permeated the disk 1. 1d) of the permeate flow path 1d. The permeate channel material 6 is formed from an organic material sheet such as paper, and is burned off to become a gas. The permeate channel material 6 is similar to the precision casting method by disappearance like a kind of lost wax method. The outer diameter D2 of the permeate channel member 6 is a small diameter D2 obtained by subtracting the outer edge 1e that is bonded and connected with a width of 5 to 10 mm from the outer diameter D1 from the outer peripheral edge of the disk 1, for example, in the case of a circular disk. φ146 to φ136 mm), and the thickness t2 is 0.4 mm here. The thickness t2 may be other than this, and can be selected with a width of, for example, 0.2 to 1.2 mm in accordance with the viscosity of the stock solution and the area of the disk.
The material of the osmotic flow path material 6 is not particularly limited as long as it is a material that burns down when the disk is fired, such as plastic or paper.

As shown in FIG. 5 (a), the mesh pattern of the reference osmotic fluid channel material 6 is preferably a hexagonal honeycomb shape, for example. By forming the permeated liquid flow path material 6 with a mesh pattern and widely distributing the mesh in the hollow portion, the distance of the flow path is increased, so that the filtration performance is improved and the filter effect is improved. Other lace-like or radial complicated patterns may be used.
The thickness t2 of the permeate channel material 6 shown in FIG. 5 (b) is an organic sheet such as cardboard, paper pattern, or resin net, and may be molded by stamping into a mesh pattern.

≪Pressing means to assemble and press on a three-layer disc≫
6A is a sectional view showing a three-layer structure, FIG. 6B is an assembling means, FIG. 6C is a pressing means, FIG. 6D is a drying means, FIG. 6E is a baking means, and FIG. FIG.
As shown in FIG. 6 (a), the disk 1 is assembled by placing the lower disk 1 b die-cut in a circle on the table 7. On top of this, the above-described permeate channel material 6 is placed (see FIG. 5A). An inorganic binder 3d serving as an adhesive is applied to the bonding surface between the lower disk 1b and the outer edge 1e of the upper disk 1a.
And as shown in FIG.6 (b), the upper disk 1a is mounted on the permeate flow path material 6, and it assembles | assembles into a 3 layer structure. Therefore, the disk 1 has a three-layer structure including the lower disk 1b, the permeate flow path material 6, and the upper disk 1a.
When the disk 1 is in a semi-dry state, it is in a semi-solid state such as a stretched ridge, and as shown in FIG. It will be buried in between. The press pressure at this time is preferably 0.01 to 0.1 MPa (about 1 to 10 kgf / cm ² ).

  When used in an environment of high filtration pressure or backwashing pressure, the above-mentioned inorganic binder 3d such as alumina sol is applied to the joint surface between the upper disk 1a and the lower disk 1b, and then pressed, dried and fired. As a result, the bonding strength of the disk can be improved.

≪Drying means≫
As shown in FIG. 6 (d), the drying means dries the disk 1 assembled into a three-layer structure and bonded together by pressure bonding at 80 to 120 ° C. It is just equivalent to drying before unglazed ceramic manufacturing. Dry thoroughly to prevent defective products from being handled.

≪Baking means≫
As shown in FIG. 6 (e), the firing means performs firing in a firing furnace. The firing temperature is in the range of 1200 to 1400 ° C. For example, after the temperature rise rate reaches 100 to 150 ° C per hour and reaches the firing temperature of 1350 ° C, the holding time at the same temperature is 1 to 2 hours. By the firing in this firing furnace, the disc-shaped permeate flow path material 6 of the intermediate layer of the disk is decomposed and gasified at 350 to 450 ° C.
The disk-shaped permeate flow path material 6 on the mating surface of the upper disk 1a and the lower disk 1b is burned out, and the disk 1 of the porous ceramic fired body 10 in which the permeate flow path 1d having a hollow mesh pattern is formed is fired. The The outer edge 1e of the disk 1 is baked in a state where the upper disk 1a and the lower disk 1b are bonded to each other by the adhesive of the inorganic binder 3d. Note that no adhesive may be used.

≪Drilling means≫
As shown in FIG. 6 (f), the drilling means drills a through hole 1 g (φD3) in the center of the disk 1 with, for example, an NC machine tool using a carbide blade drill or laser. When a tube is passed through the through hole 1g, the tube diameter, for example, φ25.0 mm, preferably has a loose fit. The drilling process can also be performed before firing.

The disk 1 of the present invention is a disk 1 manufactured by the manufacturing means of the above-described porous ceramic fired disk manufacturing apparatus, and is characterized in that a hollow portion λ is formed between the upper disk 1a and the lower disk 1b. Provided that a through hole 1g is provided in the upper disk 1a and the lower disk 1b. The present invention can be modified and changed in various ways within the scope of the technical idea.
The shape of the disk 1 is a disc shape, but may be other shapes such as an ellipse or a polygon. Further, the outer diameter, thickness, etc. of the disk 1 may be other dimensions.
Moreover, since ceramic slurry is synonymous with ceramic slurry, it may be replaced with ceramic slurry.
In the preparation of the ceramic slurry, for example, starch may be used as a natural viscous material, and a polyacrylamide copolymer, for example, may be used as a synthetic viscous material.
You may use the commercially available general inorganic and organic binders, and adhesives and flocculants.
Specifically, troolloi can be added as a dispersant that gives slurry viscosity so that fine fibers do not clump, acrylate latex may be used as an organic binder, and silica sol, for example, may be used instead of alumina sol as an inorganic binder. Absent.
Furthermore, polyacrylamide is used as a polymer flocculant for aggregating dispersed fibers and powders, and a sulfuric acid band is used as a flocculant, and an ionized silica sol or alumina sol liquid can be used as the flocculant. Further, other materials may be added.

1 disk 1a upper disk 1b lower disk 1c fine hole 1d permeate flow path 1e outer edge 1g through hole 2 ceramic slurry (ser)
3a Ceramic fiber (alumina fiber)
3b Ceramic particles (alumina particles)
3c Organic binder 3d Inorganic binder 3e Firing temperature reducing agent 3f Polymer flocculant 4 Peeling net 5 Ceramic paper making sheet 6 Osmotic fluid flow path material 7 Table
8 Filtration device 8a Case 8b Filtrate recovery tube (rotary shaft)
8c Small hole 8d O-ring 8f Opening 8g Nut 8h Filtrate recovery hole 8i Stock solution 10 Porous ceramic fired body λ Hollow part (void)

Claims (6)

Ceramic paper making means to make a ceramic paper sheet by paper making ceramic mud with a plow net,
From the ceramic papermaking sheet, a die cutting means for punching the upper disk and the lower disk of a predetermined shape,
A pressing means for sandwiching and burning a sheet-like member between the upper disk and the lower disk between the upper disk and the lower disk and assembling and pressing into a three-layered disk;
Drying means for drying the disk assembled by pressing;
Firing means for firing the disk in a firing furnace;
An apparatus for producing a disk of a fired porous ceramic body, comprising:   In the pressing means for sandwiching the sheet-like member between the upper disk and the lower disk and assembling and pressing into a three-layer structure disk, means for applying an inorganic binder to the bonding surface of the upper disk and the lower disk The apparatus for manufacturing a disk of a fired porous ceramic body according to claim 1, wherein:   The ceramic slurry is composed of alumina fibers of ceramic fibers and alumina particles of ceramic particles, and the mixing ratio is 10 to 100% of alumina fibers and 90 to 0% of alumina particles. An apparatus for manufacturing a disk of a fired porous ceramic body according to claim 1 or 2. The apparatus for producing a disk of a porous ceramic fired body according to any one of claims 1 to 3 , wherein a thickness of the ceramic paper sheet is 5 to 10 mm. The said sheet-like member is made into an organic sheet, The manufacturing apparatus of the disk of the porous ceramic sintered body as described in any one of Claims 1-4 characterized by the above-mentioned. A disk manufactured by the porous ceramic fired body manufacturing apparatus according to any one of claims 1 to 5,
A porous ceramic fired disk comprising a hollow portion between the upper disk and the lower disk, and a through hole provided in the upper disk and the lower disk.

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