JP5261100B2 - Die for forming honeycomb structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mouthpiece for molding a honeycomb structure that can suppress the deformation of grid-like groove parts formed in a first plate member when the first plate member formed with back holes and the grid-like groove parts is joined to a second plate member formed with slits for forming honeycomb in a manufacturing process. <P>SOLUTION: The mouthpiece 1 for molding the honeycomb structure includes: the first plate member 2 formed with a plurality of back holes opened to at least one face side; a second plate member 3 with slits 12 disposed on the other face side of the first plate member 2 and formed in grid shape to form a ceramic raw material. The slit-like groove parts formed in grid shape to overlap with the slits 12 formed in the second plate-like member 3 and communicating with at least part of the plurality of back holes, are formed on the face side, joined to the second plate-like member 3, of the first plate-like member 2. The back holes are formed in a similar region to the outer peripheral shape of the first plate-like member 2 around the center of the first plate-like member 2. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a die for forming a honeycomb structure, and more specifically, in a manufacturing process, a first plate-like member in which a back hole and a lattice-like groove are formed, and a second member in which a slit for forming a honeycomb is formed. The present invention relates to a die for forming a honeycomb structure capable of suppressing deformation of a lattice-shaped groove formed in a first plate-like member when the plate-like member is joined.

  Conventionally, a die for forming a honeycomb structure has, for example, a first plate-shaped member formed with a plurality of back holes that open to at least one surface side, and communicated with the back hole on the other surface of the first plate-shaped member. The slit-like groove portion to be formed is formed in a lattice shape, the other surface of the first plate-like member is joined to the second plate-like member by hot pressing, and the first plate-like shape is joined to the second plate-like member. It is manufactured by forming slits in a lattice shape so as to overlap the groove formed in the member and communicate with the groove (see, for example, Patent Documents 1 and 2). Usually, the back hole is provided at a position corresponding to an intersection position in the lattice shape of the groove portion (slit formed in the lattice shape) formed in the lattice shape. Such a die for forming a honeycomb structure is used as a die for extrusion forming for manufacturing a ceramic honeycomb structure by extruding a ceramic raw material.

Since the first plate-like member is usually formed of a hard member such as stainless steel, ECM machining (electrolytic machining) is adopted as a method for forming a back hole in the first plate-like member. . According to the ECM processing, it is possible to accurately open a narrow and deep hole in a hard member such as stainless steel. And as a method of ECM processing, in order to improve production efficiency, usually, back holes are sequentially formed using electrodes arranged in one or several rows so as to open a desired range. FIG. 7 shows a die for forming a honeycomb structure 102 provided with the first plate-like member 101 having a back hole opened by such a method. FIG. 7 is a plan view of a conventional honeycomb structure forming die 102 as viewed from the first plate-like member 101 side where the back hole 103 is formed.
JP 2006-051682 A JP 2006-263865 A

  However, when the honeycomb structure forming die 102 is manufactured using the first plate-like member 101 as shown in FIG. 7, the first plate-like member and the second plate-like member usually have different materials ( When the first plate-like member 101 and the second plate-like member are joined by hot pressing, the first plate-like member 101 is made of a material having a different coefficient of thermal expansion / shrinkage. There was a problem that the lattice-shaped groove portion formed in the first plate member was deformed and deformed. The first plate-like member 101 expands when heated by hot pressing and then shrinks when cooled, but the first plate-like member 101 shown in FIG. 7 is an area where the back hole 103 is not formed. Are dispersed in four places, and there are a direction in which the surface of the first plate-like member 101 contracts greatly at the time of contraction and a direction in which it does not contract so much. Specifically, the shrinkage is greatly reduced in the direction P where many back holes 103 are formed, and the shrinkage is small in the direction Q where few back holes 103 are formed. For this reason, it is considered that the lattice shape of the groove portion of the first plate-like member 101 is deformed.

  When the lattice-shaped groove portion formed in the first plate member is deformed, when the slit is formed in the second plate member after joining the first plate member and the second plate member, In some cases, the blade of the slicer used for forming the slit is out of the space of the groove and comes into contact with the first plate-like member, so that the slit cannot be formed. Usually, when a slit is formed in the second plate-shaped member, the blade of the slicer for slit formation is placed along the groove formed in the first plate-shaped member and in the groove that is a space. In a state where a part (tip portion) is inserted, the second plate member is moved while being cut. Therefore, when the blade of the slicer for forming the slit comes into contact with a portion other than the groove portion of the first plate-like member, the blade of the slicer cannot be further advanced, and the slit cannot be formed.

  The present invention has been made in view of the above-described problems. In the manufacturing process, the first plate-like member in which the back holes and the lattice-like grooves are formed, and the second in which the slits for forming the honeycomb are formed. It is characterized by providing a die for forming a honeycomb structure capable of suppressing deformation of a lattice-shaped groove formed in the first plate-like member when the plate-like member is joined.

  In order to achieve the above object, the present invention provides the following die for forming a honeycomb structure.

[1] A first plate-like member formed with a plurality of back holes extending in the thickness direction opened on at least one surface side, and a ceramic disposed on the other surface side of the first plate-like member A slit for forming the raw material into a honeycomb shape includes a second plate-like member formed in a lattice shape, and a surface of the first plate-like member joined to the second plate-like member On the side, a slit-like groove portion is formed so as to overlap with the slit formed in the second plate-like member and communicates with at least a part of the plurality of back holes, and the back hole is formed A honeycomb structure forming die formed in a region having a shape similar to the outer peripheral shape of the first plate member, with the center of the first plate member as the center.

[2] For forming a honeycomb structure according to [1], an area of the region where the back hole is formed is 70 to 100% of an area of a cross section orthogonal to the thickness direction of the first plate member. Base.

[3] All the back holes are through back holes communicating with the groove portions of the first plate-like member, and the area of the region where the through back holes are formed is 70 to 100% [1] or The die for forming a honeycomb structure according to [2].

[4] A part of the back hole is the through-hole, and the remaining part of the back hole is a pseudo back hole that opens only on the one surface side and does not communicate with the groove [1] or [2] 2. A die for forming a honeycomb structure according to 1.

[5] The honeycomb structure according to [4], wherein a depth of the pseudo back hole in a thickness direction of the first plate member is 50 to 99% of a thickness of the first plate member. Body molding die.

[6] The area of the region where the back hole is formed is 100% of the area of the cross section perpendicular to the thickness direction of the first plate member, and the pseudo back hole is the first plate member. The die for forming a honeycomb structure according to [4] or [5], wherein the die is formed in a region including the outer periphery of the first plate member, and the through back hole is formed in one region including the center of the first plate member.

[7] The first plate-shaped member is disk-shaped, and the through-back hole has four quadrangular apex portions of the first plate-shaped member along the outer periphery of the first plate-shaped member. The die for forming a honeycomb structure according to [6], which is formed in an octagonal region which is a shape cut out by cutting.

  According to the honeycomb structure forming die of the present invention, the back hole is formed in a region similar to the outer peripheral shape of the first plate-like member, centered on the center of the first plate-like member, When the first plate-like member and the second plate-like member are joined by hot pressing and then cooled, the distortion of the first plate-like member is reduced, and the lattice formed on the first plate-like member It is possible to suppress the deformation of the lattice shape of the groove portion.

  BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the best mode for carrying out the present invention will be specifically described. However, the present invention is not limited to the following embodiment, and is within the scope of the present invention without departing from the spirit of the present invention. It should be understood that design changes, improvements, and the like can be made as appropriate based on the knowledge.

(1) Honeycomb structure forming die An embodiment of the honeycomb structure forming die of the present invention will be described. FIG. 1 schematically shows an embodiment of a honeycomb structure forming die according to the present invention, and is a perspective view seen from the side of a second plate-like member in which slits are formed. FIG. 1 is a perspective view schematically showing an embodiment of a die for forming a honeycomb structure of the invention, as viewed from the side of a first plate member in which a back hole is formed. FIG. 3 is an enlarged plan view showing a part of the surface on the second plate-like member side of the die for forming a honeycomb structure shown in FIG. FIG. 4 is a schematic diagram showing an AA ′ cross section of the die for forming a honeycomb structure shown in FIG.

  As shown in FIG. 1 to FIG. 4, the honeycomb structure forming die 1 of the present embodiment is a first plate in which a plurality of back holes 11 extending in the thickness direction opened on at least one surface 4 side are formed. And a second plate member 3 in which slits 12 for forming a ceramic raw material disposed on the other surface 5 side of the first plate member 2 into a honeycomb shape are formed in a lattice shape, The surface of the first plate member 2 that is joined to the second plate member 3 (the other surface 5) is overlapped with the slit 12 formed in the second plate member 3. A slit-shaped groove portion 13 is formed which is formed in a lattice shape and communicates with at least a part of the plurality of back holes 11, and the back hole 11 is centered on the center of the first plate-like member 2. The plate-like member 2 is formed in a region 14 similar to the outer peripheral shape.

  Thus, since the back hole 11 was formed in the area | region similar to the outer periphery shape of the 1st plate-shaped member 2 centering on the center of the 1st plate-shaped member 2, the 1st plate-shaped member 2 and the second plate-like member 3 are joined by hot pressing and then cooled, the distortion of the first plate-like member 2 is reduced, and the lattice-like shape formed on the first plate-like member 2 is reduced. It is possible to suppress deformation of the lattice shape of the groove portion 13. When the back hole 11 is formed in a region similar to the outer peripheral shape of the first plate member 2 with the center of the first plate member 2 as the center, the entire first plate member 2 is formed. Since it expands and contracts relatively uniformly, the lattice shape of the groove 13 is difficult to deform.

  Here, the “center of the first plate-like member” corresponds to the center of gravity of the first plate-like member when the first plate-like member is a single plate having a uniform thickness. This means the position, and when the outer peripheral shape of the first plate-like member is circular, it is the center of the circle, and when it is rectangular, it is the intersection of diagonal lines. In addition, the “region similar to the outer peripheral shape of the first plate member centered on the center of the first plate member” is a region where a back hole is formed, and the center of the region is It means that it is at the same position as the center of the first plate member, and the outer peripheral shape of the region is similar to the outer peripheral shape of the first plate member. In this case, the “region similar to the outer peripheral shape of the first plate-shaped member centered on the center of the first plate-shaped member” includes the same as the outer peripheral shape of the first plate-shaped member. That is, the case where the back hole is formed in the entire first plate-like member is also included. Further, when the back hole is formed in the “region”, it means that the back hole is formed in the entire “region”. Further, “the groove 13 is formed so as to overlap the slit 12” means that when the honeycomb structure forming die is viewed from a direction perpendicular to the surface on which the slit is formed, the groove 13 and the slit 12 are formed. It means that and are overlapped.

  A ceramic honeycomb structure extruded by using the honeycomb structure forming die 1 of the present embodiment is a ceramic honeycomb structure including porous partition walls that partition and form a plurality of cells extending in the fluid flow direction. . The ceramic raw material used when manufacturing the ceramic honeycomb structure using the honeycomb structure forming die 1 of the present embodiment is a raw material in which water, a binder, a pore forming agent and the like are mixed with ceramic powder.

  In the honeycomb structure forming die 1 of the present embodiment, the back plate 11 penetrating from one surface 4 to the other surface 5 has a first plate shape centered on the “center of the first plate member”. It is formed in a region 14 similar to the shape on the outer periphery of the member 2. And it is preferable that the area of the area | region (similar-shaped area | region 14) in which the back hole 11 is formed is 70 to 100% of the area of the cross section orthogonal to the thickness direction of a 1st plate-shaped member, 75- More preferably, it is 100%. If it is less than 70%, the lattice shape of the groove portion may be easily deformed.

  In the honeycomb structure forming die 1 of the present embodiment, as shown in FIG. 4, the back hole 11 penetrates from one surface 4 to the other surface 5 of the first plate-like member 2, and the groove 13 is on the back. It is formed so as to communicate with the hole 11. As described above, the back hole 11 communicating with the groove portion 13 including the back hole 11 penetrating the first plate-like member 2 is referred to as a through back hole 11a. A back hole that opens only on one surface 4 side of the first plate-like member 2 and does not communicate with the groove 13 is referred to as a pseudo back hole 11b (see FIGS. 5 and 6).

  In the honeycomb structure forming die 1 of the present embodiment, as shown in FIGS. 1 to 4, the entire back hole 11 may be a through back hole 11 a, or the back hole 11 may be a through back hole and a pseudo back. It may contain a hole. When all of the back holes 11 are through back holes 11a communicating with the grooves 13 of the first plate-like member 2, the area of the region where the through back holes 11a are formed is preferably 70 to 100%. More preferably, it is 75 to 85%. If it is less than 70%, the lattice shape of the groove portion may be easily deformed. On the other hand, if it is larger than 85%, the adhesive strength between the first plate-like member 2 and the second plate-like member 3 may be lowered. Therefore, in order to maintain a high adhesive strength between the first plate-like member 2 and the second plate-like member 3, the area of the region where the through back hole 11a is formed is preferably 85% or less.

  The through back hole 11a in the back hole 11 forms a through hole for introducing a forming raw material (ceramic raw material). The shape of the through back hole 11 a is not particularly limited as long as the introduced forming raw material can be guided to the slit 12. In the honeycomb structure forming die 1 shown in FIGS. 1 to 4, the through back hole 11 a is formed at a position overlapping the intersection (intersection) of the slit 12. “The through-hole is formed at a position where it intersects with the intersection of the slit” means that when the honeycomb structure forming die is viewed from the direction perpendicular to the surface on which the slit is formed, It means that the intersection is overlapped. With this configuration, when extrusion molding is performed using the honeycomb structure forming die 1 of the present embodiment, the forming raw material introduced into the through back hole 11a can be uniformly spread over the entire slit 12. High moldability can be realized. More preferably, the center of the back hole 11 overlaps the intersection of the slits 12. As in the case of the honeycomb structure forming die 1 shown in FIGS. 1 to 4, the back holes 11 are formed so as to overlap every other intersection of the slits 12 (or the groove portions 13). Preferably it is.

  The size or the like of the opening diameter of the back hole 11 can be appropriately determined depending on the size of the honeycomb structure forming die 1 and the shape of the honeycomb structure to be extruded. For example, the opening diameter of the back hole 11 is preferably 0.1 to 10 mm, and more preferably 0.5 to 3 mm. Such a back hole 11 can be formed by a method such as electric field machining (ECM machining), electric discharge machining (EDM machining), laser machining, drilling, or other machining methods. Among these, a drill is used. It is preferable. By using a drill, it is possible to efficiently form a highly accurate back hole.

  As shown in FIGS. 1 to 4, the honeycomb structure forming die 1 of the present embodiment has a surface side (the other end surface 5) of the first plate-like member 2 to be joined to the second plate-like member 3. A slit-shaped groove portion 13 is formed on the side), which has the same lattice shape as the lattice shape of the slit 12 and overlaps the slit 12. When the slit 12 is formed, the slit 12 is formed in a lattice shape along the lattice shape of the groove portion 13 so that the slit 12 and the groove portion 13 overlap each other. Further, the groove 13 is formed so that the back hole 11 is located at the intersection of the groove 13.

  Moreover, since the groove part 13 formed in the 1st plate-shaped member 2 functions also as a buffer part (buffer) for guiding the shaping | molding raw material introduce | transduced from the through back hole 11a to the 2nd slit 12, a honeycomb structure When extrusion molding is performed, the molding raw material introduced from the through back hole 11a can be smoothly moved without hindrance, and the honeycomb structure can be molded with high accuracy.

  In addition, the honeycomb structure forming die 1 of the present embodiment has a groove 13 and a back surface on the surface side (the other surface 5 side) of the first plate member 2 joined to the second plate member 3. A columnar portion 15 is formed which is surrounded (partitioned) by the hole 11 (through back hole 11a). Therefore, the first plate-like member 2 and the second plate-like member 3 are joined via the columnar portion 15. That is, the honeycomb structure forming die 1 of the present embodiment has a structure in which the columnar portion 15 of the first plate-like member 2 and the second plate-like member 3 are joined, as shown in FIG. The cell block 16 is supported by the columnar portion 15. Here, the cell block 16 is a columnar portion that is partitioned by the slit 12 in the first plate-like member 2 in which the slit 12 is formed.

  In the honeycomb structure forming die 1 of the present embodiment, the depth L of the groove portion 13 (the height of the columnar portion 15) L of the first plate-like member 2 is preferably 0.1 to 3.0 mm, and 0.3. More preferably, it is -1.5 mm. If it is smaller than 0.1 mm, high moldability may not be realized, and if it is larger than 3.0 mm, the cell block 16 may easily fall down. The width of the groove 13 is preferably 0.15 to 1.0 mm. If it is smaller than 0.15 mm, high formability may not be realized, and if it is larger than 1.0 mm, processing may take time.

  In the honeycomb structure forming die 1 of the present embodiment, the material of the first plate-like member 2 is not particularly limited, but is preferably stainless steel.

  In the honeycomb structure forming die 1 of the present embodiment, the second plate-like member 3 is formed on the other surface 5 side of the first plate-like member 2 to form a ceramic raw material into a honeycomb shape. The slits 12 are formed in a lattice shape. The slit 12 has the same lattice shape as the lattice shape of the slit-shaped groove 13 and is formed so as to overlap the slit 12. The width of the slit 12 can be appropriately determined according to the partition wall thickness of the honeycomb structure to be manufactured. For example, in order to produce a honeycomb structure forming die for extruding a general honeycomb structure for an exhaust gas filter or a catalyst carrier, the width of the slit is preferably 5 to 5000 μm, More preferably, it is 10-500 micrometers. Although the material of the 2nd plate-shaped member 3 is not specifically limited, It is preferable that it is a tungsten carbide group cemented carbide. By using a tungsten carbide-based cemented carbide, the wear resistance can be improved, and the cell block can be prevented from falling.

There is no restriction | limiting in particular about the thickness of the 1st plate-shaped member 2, and the thickness of the 2nd plate-shaped member 3, For example, considering the shape of the slit 12 and the back hole 11, it can determine suitably. For example, when manufacturing a honeycomb structure forming die for forming a cylindrical honeycomb structure having a partition wall thickness of 25 to 500 μm and a cell density of 20 to 200 cells / cm ² , the first plate-like member 2 is used. The thickness of the second plate-like member 3 is preferably 0.1 to 200 times, and more preferably 1 to 20 times the thickness.

  Further, in the honeycomb structure forming die 1 of the present embodiment, a bonding material (brazing material) is disposed between the first plate-like member 2 and the second plate-like member 3, and the first plate It is preferable that the shaped member 2 and the second plate-like member 3 are joined.

  Examples of the bonding material include a metal or an alloy including at least one selected from the group consisting of copper (Cu), silver (Ag), gold (Au), nickel (Ni), and aluminum (Al). A “brazing material” can be preferably used.

  Such bonding materials include, for example, palladium (Pd), silicon (Si), tin (Sn), cobalt (Co), phosphorus (P), manganese (Mn), zinc (Zn), and boron (B). It may further contain an additive such as. What further contains such an additive can improve bonding reliability.

  In another embodiment of the die for forming a honeycomb structure of the present invention, as shown in FIG. 5, the first plate-like member 2 has a disk shape, and the through back hole 11 a has the first plate-like member 2. Are formed in an octagonal (pseudo-octagon) region 22 in which the four apex portions of the quadrilateral are cut along the outer periphery of the first plate-like member 2, and the pseudo back hole 11b is formed. Is formed in the other four “regions 23 including the outer periphery”. The honeycomb structure forming die 21 of the present embodiment is such that the back hole 11 is formed on the entire first plate member 2 in this way (the area where the back hole is formed is the first area). When the first plate-like member 2 and the second plate-like member are joined together by hot pressing, and then cooled, it is 100% of the cross-sectional area perpendicular to the thickness direction of the plate-like member. The distortion of one plate-like member 2 is reduced, and it is possible to suppress the deformation of the lattice shape of the lattice-like groove portion formed in the first plate-like member 2. And since the back hole 11 is formed in the whole 1st plate-shaped member 2, it is not necessary to process according to the shape of the area | region which forms a back hole, and the electric field which processes a back hole by several electrodes By processing (STEM processing), it is possible to efficiently and accurately form the back hole. In the honeycomb structure forming die of the present embodiment, the shape of the through back hole region is the octagonal eight sides, and four sides arranged every other side of the first plate-like member are arranged. It has an arc shape along the outer periphery (circular shape). In the present specification, such “a shape in which every other four sides are arranged in an arc shape among the eight sides of the octagon” is expressed as “octagon” or “pseudo octagon”. To do. FIG. 5 is a plan view schematically showing another embodiment of the die for forming a honeycomb structure of the present invention, as viewed from the first plate member side.

  The honeycomb structure forming die 21 of the present embodiment has the regions 23 including the four outer peripheries where the pseudo back holes 11b are formed, but the pseudo back holes 11b may be formed in the regions 23 including the outer periphery. It is not limited to four places. The through back hole 11 a is formed in the pseudo-octagonal region 22, but the through back hole 11 a may be formed in one region including the center of the first plate-like member 2. As the shape of the region where the through back hole 11a is formed, for example, a quadrangle in which four vertices are in contact with the outer periphery of the first plate-like member 2, a quadrangle in which all four vertices are not in contact with the outer periphery of the plate-like member 2, A circular shape or the like excluding a ring-shaped region including the outer periphery can be given.

  Moreover, it is preferable that the depth of the thickness direction of the 1st plate-shaped member 2 is 50 to 99% of the thickness of the 1st plate-shaped member 2, and the pseudo back holes 11b are 90 to 97%. More preferably it is. If it is less than 50%, the degree of deformation of the region where the pseudo back hole 11b is formed during heating and cooling is smaller than the degree of deformation of the region where the through back hole 11a is formed (the pseudo back hole 11b is Therefore, the lattice shape of the groove part may be easily deformed. If it exceeds 99%, cracks may occur due to thermal stress generated after joining. Moreover, since the joint area between the first plate-like member and the second plate-like member becomes small when the pseudo back hole 11b penetrates, the first plate-like member and the second plate-like member Bond strength may decrease.

  In still another embodiment of the die for forming a honeycomb structure of the present invention, as shown in FIG. 6, the first plate-like member 2 has a disc shape, and the through back hole 11a has a ring-like “periphery”. It is formed in a circular region 25 excluding the region 24 including, and the pseudo back hole 11b is formed in the region 24 including the ring-shaped outer periphery. The through back hole 11a is formed in a region similar to the outer peripheral shape of the first plate-like member with the center of the first plate-like member as the center, and the pseudo back hole 11b is a through back hole. It is formed in a ring-shaped region excluding the region where 11a is formed. As described above, the honeycomb structure forming die 31 of the present embodiment has a back hole formed in the entire first plate-like member 2, and the through-hole 11a is centered on the center of the first plate-like member. Since the first plate-like member is formed in a region similar to the outer peripheral shape of the first plate-like member, there is a direction in the deformation of the region where the pseudo back hole 11b is formed and the region where the through back hole 11a is formed. No (isotropically deformed around the center of the first plate-like member), and deformation of the lattice shape of the groove portion is less likely to occur. FIG. 6 schematically shows another embodiment of the die for forming a honeycomb structure of the present invention, and is a plan view seen from the first plate-like member side.

(2) Manufacturing Method of Honeycomb Structure Forming Die Next, a manufacturing method of the honeycomb structure forming die of the present invention will be described. The manufacturing method of the honeycomb structure forming die of the present embodiment is a method of manufacturing an embodiment (honeycomb structure forming die 1) of the honeycomb structure forming die of the present invention shown in FIGS. is there.

  In the method for manufacturing a die for forming a honeycomb structure of the present embodiment, first, the other surface 5 (see FIG. 4) of the disc-shaped first plate-like member formed of stainless steel is grid-like. A groove is formed (step (1)). The material of the first plate member is preferably stainless steel, but is not particularly limited.

  As a method for forming the groove portion, for example, a conventionally known method such as grinding with a diamond grindstone or electric discharge machining (EDM machining) can be suitably used.

  Further, in the method for manufacturing a honeycomb structure forming die of the present embodiment, a back hole may be formed before forming the groove portion on the other surface 5 (see FIG. 4) of the first plate-like member. After forming the groove portion, a back hole communicating from one surface 4 (see FIG. 4) of the first plate member to the groove portion may be formed.

  In the method for manufacturing a die for forming a honeycomb structure of the present embodiment, the groove and the back hole are in a region similar to the outer peripheral shape of the first plate-like member with the center of the first plate-like member as the center. Form. In the present embodiment, the area is a circular area.

  Although there is no restriction | limiting in particular about the method of forming a back hole, For example, methods, such as machining, such as electrolytic processing (ECM processing), electrical discharge machining (EDM processing), laser processing, and a drill, can be used suitably. Among these, it is preferable to use a drill. By using a drill, it is possible to efficiently form a back hole with high dimensional accuracy.

  The back hole may penetrate between both surfaces of the first plate-like member and communicate with the groove portion on the other surface 5 (see FIG. 4) side (see FIG. 4) or to the other surface side. It may be formed so as to communicate with the groove formed on the other surface side without penetrating.

  Next, a second plate member formed of a tungsten carbide base cemented carbide (a cemented carbide) is laminated on the surface of the first plate member on which the groove is formed, and the first plate member And the second plate member are joined (step (2)). The material of the first plate member is preferably a cemented carbide, but is not particularly limited.

  Further, in the method for manufacturing a honeycomb structure forming die of the present embodiment, when the first plate member and the second plate member are laminated, the first plate member and the second plate are stacked. A bonding material may be provided between the first plate-like member and the second plate-like member. As such a bonding material, the “brazing material” described in the embodiment of the honeycomb structure forming die of the present invention can be suitably used.

  When laminating and joining the first plate-like member and the second plate-like member, the first plate-like member and the second plate-like member are heated to 900 to 1200 ° C. by hot pressing. It is preferable to join, and it is preferable to join by heating to 1000-1150 degreeC. By heating at such a temperature, the first plate-like member and the second plate-like member can be bonded satisfactorily and strength reduction of the second plate-like member can be prevented. The heating time is preferably 1 minute to 1 hour, more preferably 10 to 45 minutes. If it is shorter than 1 minute, the first plate-like member and the second plate-like member may not be joined with a strong joining strength. If it is longer than 1 hour, the first and second plate-like members are deteriorated in the base material. Phases are likely to occur. As an apparatus for performing hot pressing, for example, FVHP-R manufactured by Fuji Denpa Kogyo Co., Ltd. can be used.

  In the manufacturing method of the die for forming a honeycomb structure of the present embodiment, the joined first plate-like member and second plate-like member are at least at a temperature drop rate of 0.1 to 100 ° C./min. It is preferable to cool to 500 ° C.

  Next, a grid-like slit that corresponds to the shape (formation pattern) of the groove and communicates with the groove 13 from the surface of the second plate-like member on the side opposite to the joint surface with the first plate-like member. To obtain the honeycomb structure forming die 1 (see FIGS. 1 to 4) (step (3)). In the manufacturing method of the die for forming a honeycomb structure of the present embodiment, the back hole is formed in a region similar to the outer peripheral shape of the first plate member, with the center of the first plate member as the center. The distortion of the first plate-like member after joining the first plate-like member and the second plate-like member is reduced, and the lattice-shaped deformation of the lattice-like grooves formed in the first plate-like member is reduced. Can be suppressed. Thereby, when forming a slit in a 2nd plate-shaped member, it can prevent that the blade (grinding stone) for slit formation contacts a 1st plate-shaped member.

  Although there is no restriction | limiting in particular about the method of forming a slit in the surface of a 2nd plate-shaped member, For example, conventionally well-known methods, such as a grinding process with a diamond grindstone, can be used suitably. In addition, in the honeycomb structure forming die 1 shown in FIG. 1, the cell block 16 formed by the slit 12 has a quadrangular cross-sectional shape (cross-sectional shape perpendicular to the thickness direction of the second plate-like member). In the method for manufacturing the honeycomb structure forming die of the present embodiment, the cross-sectional shape of the cell block 16 formed on the second plate member is not limited to a quadrangle, and may be other polygonal shapes. Good.

  Further, the width of the slit formed in the second plate-like member can be appropriately determined depending on the shape of the honeycomb structure to be formed. For example, in order to produce a die for forming a honeycomb structure for extruding a general ceramic honeycomb structure for an exhaust gas filter or a catalyst carrier, the width of the slit is preferably 5 to 5000 μm. More preferably, it is -500 micrometers.

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

Example 1
A first plate-like member having a plurality of back holes that are open on one surface side and a lattice-shaped groove portion that is in communication with all of the plurality of back holes on the other surface side; A honeycomb having a structure as shown in FIGS. 1 to 4, provided with a second plate-like member arranged on the other surface side of the plate-like member and having slits formed in a lattice shape so as to overlap the groove portion. A die for forming a structure was manufactured.

  The material of the first plate member was stainless steel (SUS630), and the material of the second plate member was a tungsten carbide base cemented carbide with a cobalt content of 16% by mass. The first plate-like member has a disk shape with a diameter of 160 mm and a thickness of 15 mm, and the second plate-like member has a disk shape with a surface size of 156 mm in diameter. The thickness was 2.5 mm.

  First, on the one surface side of the first plate-like member, a back hole having an opening diameter of 1.4 mm penetrating to the other end surface side was formed by electrolytic processing (EDM processing). The range in which the back hole (through back hole) was formed was a circle range (region) having a diameter of 129 mm centered on the center of the first plate-like member. The pitch of the back holes was 1.37 mm. Then, a grid-like groove having a depth of 0.5 (mm) was formed with a precision grinder so that every other grid intersection was located at the center of the back hole. The width of the groove was 0.3 mm.

  Next, after laminating the first plate-like member and the second plate-like member with a brazing material disposed between them, the first plate-like member and the first plate-like member are heated at 1100 ° C. for 0.75 hours, The 2nd plate-shaped member was joined. And after cooling down what joined the 1st plate-shaped member and the 2nd plate-shaped member to normal temperature, the slit was formed in the 2nd plate-shaped member and the die for honeycomb structure formation was obtained. . The slits were formed in a square lattice shape with a diamond grindstone. The slit width was 0.15 mm, and the slit pitch was 1.37 mm.

  With respect to the honeycomb structure forming die thus obtained, the bending state of the groove portion was measured by the following method. The results are shown in Table 1. In Table 1, “Ratio of back hole region” is a region where a back hole is formed with respect to the area of the cross section perpendicular to the thickness direction of the first plate member (the surface area of the first plate member). The area ratio. Further, the “ratio” of the “through back hole region” is the ratio of the area of the region where the through back hole is formed to the area of the cross section perpendicular to the thickness direction of the first plate-like member. The “maximum bend amount” is the maximum value of the “bend amount” in the “measurement of the bent state of the groove”. The maximum value of the “bending amount” is preferably as small as possible.

(Measurement of the bending state of the groove)
From the surface of the second plate member, with respect to the base (before the first plate member and the second plate member are joined) before the slit processing is performed on the second plate member. Then, the shape of the groove after bonding was measured using an ultrasonic flaw detection video apparatus (FineSAT, manufactured by Hitachi Construction Machinery Finetech Co., Ltd.), and the amount of bending was calculated.

(Example 2)
Like the honeycomb structure forming die 31 shown in FIG. 6, the back hole 11 is formed in the entire cross section orthogonal to the thickness direction of the first plate member 2, and the through back hole 11 a is formed on the first plate. A die for forming a honeycomb structure was obtained in the same manner as in Example 1 except that it was formed in a circle range (region 25) with a diameter of 129 mm centered on the center of the shaped member. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

(Example 3)
The first plate-like member has a disk shape with a diameter of 215 mm and a thickness of 20 mm. The range where the back hole (through-hole) is formed is the center of the first plate-like member. The second plate-shaped member having a diameter of 163 mm in the center is the same as in Example 1 except that the second plate-shaped member has a disk shape with a diameter of 210 mm and a thickness of 2.5 mm. A body molding die was obtained. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

Example 4
Like the honeycomb structure forming die 21 shown in FIG. 5, the back hole 11 is formed in the entire cross section orthogonal to the thickness direction of the first plate-like member 2, and the through back hole 11a is formed on the first plate. Except that the four apexes of the quadrilateral (square) of the shaped member 2 are formed in the octagonal (pseudooctagonal) region 22 which is a shape cut along the outer periphery of the first plate-like member 2 In the same manner as in Example 1, a die for forming a honeycomb structure was obtained. The first plate-like member has a disk shape with a diameter of 290 mm and a thickness of 25 mm, and the second plate-like member has a disk shape with a surface size of 286 mm in diameter, The thickness was 3.3 mm, and the four regions including the outer periphery other than the through back hole were pseudo back holes. As the size of the pseudo octagonal region in which the through back hole was formed, the distance between the long sides extending in parallel (sides that do not constitute the outer periphery of the first plate-like member) was 235 mm. Further, the center of the pseudo octagonal region is set to the same position as the center of the circular first plate member. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

(Comparative Example 1)
A die for forming a honeycomb structure was obtained in the same manner as in Example 2 except that “four pseudo back holes including the outer periphery” were not formed. The obtained honeycomb structure forming die has a structure like the honeycomb structure forming die 102 shown in FIG. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

(Comparative Example 2)
The first plate-like member and the second plate-like member have a diameter of 215 mm, and the long sides extending in parallel in the pseudo-octagonal region in which the through-back holes are formed (sides that do not constitute the outer periphery of the first plate-like member) A honeycomb structure forming die was obtained in the same manner as in Comparative Example 1 except that the distance between them was 163 mm. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

(Comparative Example 3)
The first plate-like member and the second plate-like member have a diameter of 290 mm, a thickness of 25 mm, and a long side extending in parallel in the pseudo-octagonal region in which the through-hole is formed (the outer periphery of the first plate-like member) A die for forming a honeycomb structure was obtained in the same manner as in Comparative Example 1 except that the distance between the sides not constituting) was 235 mm. About the obtained honeycomb structure forming die, the bending state of the groove was measured in the same manner as in Example 1. The results are shown in Table 1.

  From Table 1, in the honeycomb structure forming die of Example 1, the back holes are all through back holes, and the region where the back holes are formed is the first centered on the center of the first plate member. Therefore, the amount of bending of the groove after heating and cooling in the manufacturing process was about 30% smaller than that of Comparative Example 1, respectively. In addition, since the amount of bending of the groove portion increases as the diameter of the first plate-like member increases, it is necessary to evaluate the first plate-like member having the same diameter as that of the example and the comparative example. There is. Further, in the die for forming a honeycomb structure of Example 2, the back hole was formed in the entire first plate-like member, so that the amount of bending of the groove after being heated and cooled in the manufacturing process was even smaller. . In the honeycomb structure forming die of Example 3, the region where the back hole was formed was a region similar to the outer peripheral shape of the first plate member centered on the center of the first plate member. However, since the ratio of the back hole region was smaller than that in Comparative Example 2, it was only about 19% smaller. Further, in the honeycomb structure forming die of Example 4, a back hole is formed in the entire first plate member, and a region where the through back hole is formed is centered on the first plate member. Since it is a region similar to the outer peripheral shape of the first plate-like member at the center, the amount of bending of the groove after heating and cooling in the manufacturing process was about 35% smaller than that of Comparative Example 3. Moreover, since the area | region in which the through back hole was formed in Comparative Examples 1-3 is not an area | region similar to the outer periphery shape of a 1st plate-shaped member, the bending amount of the groove part was large. Also, from the results of Comparative Examples 1 to 3, it can be seen that the larger the diameter of the honeycomb structure forming die, the larger the amount of bending of the groove portion.

  The die for forming a honeycomb structure of the present invention collects fine particles in a honeycomb-shaped catalyst carrier that utilizes catalytic action of an internal combustion engine, a boiler, a chemical reaction device, a fuel cell reformer, and the like, and exhaust gas. It can be used when forming a honeycomb-shaped filter or the like.

1 is a perspective view schematically showing an embodiment of a die for forming a honeycomb structure of the present invention, as viewed from the side of a second plate member having a slit formed therein. FIG. 1 is a perspective view schematically showing an embodiment of a die for forming a honeycomb structure of the present invention, as viewed from the side of a first plate member in which a back hole is formed. FIG. 3 is an enlarged plan view showing a part of the surface on the second plate-like member side of the die for forming a honeycomb structure shown in FIG. 1. Fig. 4 is a schematic diagram showing an A-A 'cross section of the die for forming a honeycomb structure shown in Fig. 3. FIG. 5 is a plan view schematically showing another embodiment of a die for forming a honeycomb structure of the present invention, as viewed from the first plate member side. FIG. 6 is a plan view schematically showing still another embodiment of the die for forming a honeycomb structure of the present invention, as viewed from the first plate member side. It is the top view which looked at the die for conventional honeycomb structure formation from the 1st plate-like member side in which a back hole was formed.

Explanation of symbols

1, 21, 31, 102: Honeycomb structure forming die, 2, 101: First plate member, 3: Second plate member, 4: One surface, 5: Other surface, 11, 103 : Back hole, 12: Slit, 13: Groove, 14: Similar area, 15: Columnar part, 16: Cell block, 22: Octagon (pseudo octagon) area, 23, 24: Area including outer periphery, 25: Circular region, L: Depth of groove (height of columnar part).

Claims (7)

A first plate-like member having a plurality of back holes extending in the thickness direction that is open on at least one surface side, and a ceramic raw material disposed on the other surface side of the first plate-like member are honeycombed. The slit for forming the shape comprises a second plate-like member formed in a lattice shape,
The first plate-like member is formed in a lattice shape on the surface side to be joined to the second plate-like member so as to overlap a slit formed in the second plate-like member, and the plurality of the plate-like members. A slit-shaped groove portion communicating with at least a part of the back hole is formed,
A die for forming a honeycomb structure, wherein the back hole is formed in a region similar to the outer peripheral shape of the first plate-like member with the center of the first plate-like member as the center.   The die for forming a honeycomb structure according to claim 1, wherein an area of the region where the back hole is formed is 70 to 100% of an area of a cross section orthogonal to the thickness direction of the first plate-like member.   The entire back hole is a through back hole communicating with the groove portion of the first plate-like member, and an area of the region where the through back hole is formed is 70 to 100%. A die for forming a honeycomb structure.   The honeycomb structure according to claim 1 or 2, wherein a part of the back hole is the through-hole, and a remaining part of the back hole is a pseudo back hole that opens only on the one surface side and does not communicate with the groove. Body molding die.   The honeycomb structure forming element according to claim 4, wherein a depth of the pseudo back hole in a thickness direction of the first plate member is 50 to 99% of a thickness of the first plate member. Base.   The area of the region where the back hole is formed is 100% of the area of the cross section perpendicular to the thickness direction of the first plate member, and the pseudo back hole covers the outer periphery of the first plate member. The die for forming a honeycomb structure according to claim 4 or 5, wherein the die for forming a honeycomb structure is formed in one region including the center of the first plate-like member. The first plate-like member is disc-shaped;
The said back hole is formed in the octagonal area | region which is the shape where the four vertex parts of the square of the said 1st plate-shaped member were cut off along the outer periphery of the said 1st plate-shaped member. Item 7. A die for forming a honeycomb structure according to Item 6.

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