JP6711774B2 - ハニカム構造体の製造方法 - Google Patents
ハニカム構造体の製造方法 Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0006—Honeycomb structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
- B28B17/026—Conditioning ceramic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/003—Methods for mixing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
- B28C7/02—Controlling the operation of the mixing
- B28C7/022—Controlling the operation of the mixing by measuring the consistency or composition of the mixture, e.g. with supply of a missing component
- B28C7/026—Controlling the operation of the mixing by measuring the consistency or composition of the mixture, e.g. with supply of a missing component by measuring data of the driving system, e.g. rotational speed, torque, consumed power
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/195—Alkaline earth aluminosilicates, e.g. cordierite or anorthite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/62204—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products using waste materials or refuse
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62625—Wet mixtures
- C04B35/6263—Wet mixtures characterised by their solids loadings, i.e. the percentage of solids
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
- B28B2003/203—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded for multi-channelled structures, e.g. honeycomb structures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6021—Extrusion moulding
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/94—Products characterised by their shape
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
- Civil Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Catalysts (AREA)
Description
上記のハニカム成形体製造装置を用い、コージェライト(セラミックス粉体に相当)を主成分とし、押出成形可能な粘度の成形材料(坏土)の調製を行った。ここで、実施例1〜3は、前述した使用済み成形材料の再使用率を20%とし、湿式混合工程における液体の添加量(以下、「液体添加率」と称す。)を通常に比べて−2%(実施例1)、−4%(実施例2)、及び−6%(実施例3)に減らし、一方、混練工程(液体再添加工程)において、押出成形直前の成形材料(混練物)にそれぞれ+2%(実施例1)、+4%(実施例2)、及び+6%(実施例3)の液体添加率の液体を添加したものである。なお、比較例1は、再使用率を20%とし、成形材料に添加する液体を湿式混合工程において全て投入したものである。
実施例1〜5及び比較例1,2の成形材料を調製する過程で、湿式混合工程及び混練工程の試料をそれぞれ500g程度採取する。そして、採取した試料の質量を測定する。次に、メッシュ径が5mmの“ふるい”を用い、採取した試料を当該ふるいに投入し、振動を加えるふるい作業を行う。このふるい作業の後、ふるい内に残った「ふるい残試料」の質量を測定する。次に、メッシュ径が5mmの上記ふるいを通過した「一次通過試料」を、メッシュ径が2mmのふるいに投入し、振動を加える上記と同様のふるい作業”を行う。そして、メッシュ径が2mmのふるいを通過した「二次通過試料」の質量を測定する。ここで、「ふるい残試料」が5mm以上の大きさの成形材料であり、2mmメッシュのふるい内に残った「一次残試料(一次通過試料−二次通過試料)」が2mm超、5mm未満の大きさの成形材料であり、「二次通過試料」が2mm以下の大きさの成形材料である。「ふるい残試料」、「一次残試料」、及び「二次通過試料」の質量を採取した試料の質量で除した値から凝集物の存在比率を求める。湿式混合工程時の試料における凝集物の存在比率を示すグラフ(図3)、及び混練工程時の試料における凝集物の存在比率(図4)を示すグラフを示す。
ミキサー(混合機)の回転する主軸にデータ収集機器を取付け、押出スクリューによる混練時における主軸を回転させるためのモータの負荷(負荷電流)を計測した。ここで、負荷電流が大きくなること、或いは負荷電流の変動が激しくなることは、押出成形される成形材料に多くの凝集物が発生していることを示し、より強い力で回転させる必要があることを示している。ここで、図5は、使用済み成形材料の再使用率が60%で、混練工程において液体を5%添加した場合のミキサーの負荷電流と時間(経過時間)との相関関係を示すグラフである。同様に、図6は、使用済み成形材料の再使用率が60%で、混練工程における液体の添加がない場合のミキサーの負荷電流と時間(経過時間)との相関関係を示すグラフであり、図7は、使用済み成形材料の再使用率が20%未満で、混練工程における液体の添加がない場合のミキサーの負荷電流と時間(経過時間)との相関関係を示すグラフである。
Claims (2)
- ハニカム構造体を形成するための原料をバッチ処理により乾式混合する乾式混合工程と、
前記乾式混合工程によって得られた乾式混合物に水、界面活性剤、潤滑剤及び可塑剤の少なくともいずれか一種類を含む液体を添加し、湿式混合する湿式混合工程と、
前記湿式混合工程によって得られた湿式混合物を混練する混練工程と、
前記混練工程によって調製された成形材料を押出成形する成形工程と
を有し、
前記乾式混合工程は、
既に前記成形工程を通過した使用済み成形材料を、前記原料の一部として加え、乾式混合を行うものであり、
前記乾式混合物の全量に占める前記使用済み成形材料の質量比率を示す再使用率は、40質量%〜60質量%の範囲であり、
前記混練工程は、
前記湿式混合物を混練する過程で、前記液体を更に添加する液体再添加工程を有するハニカム構造体の製造方法。 - 前記液体再添加工程における前記液体の添加量の比率は、
前記乾式混合物の全量を100%とした場合に対して、2質量%〜10質量%の範囲である請求項1に記載のハニカム構造体の製造方法。
Priority Applications (4)
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JP2017059057A JP6711774B2 (ja) | 2017-03-24 | 2017-03-24 | ハニカム構造体の製造方法 |
US15/918,147 US11542205B2 (en) | 2017-03-24 | 2018-03-12 | Manufacturing method of honeycomb structure |
CN201810237066.0A CN108621285B (zh) | 2017-03-24 | 2018-03-21 | 蜂窝结构体的制造方法 |
DE102018204468.6A DE102018204468A1 (de) | 2017-03-24 | 2018-03-23 | Herstellungsverfahren einer wabenstruktur |
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JP2018161765A JP2018161765A (ja) | 2018-10-18 |
JP6711774B2 true JP6711774B2 (ja) | 2020-06-17 |
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US (1) | US11542205B2 (ja) |
JP (1) | JP6711774B2 (ja) |
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DE (1) | DE102018204468A1 (ja) |
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JP7335702B2 (ja) * | 2019-01-24 | 2023-08-30 | 日本碍子株式会社 | セラミックス成形体の製造方法及び製造装置 |
CN111941601B (zh) * | 2020-06-30 | 2021-12-14 | 滨州汇信和信息技术有限公司 | 一种多级孔径分布材料的制备装置及其制备方法 |
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JPS62207758A (ja) * | 1986-03-08 | 1987-09-12 | 日本碍子株式会社 | コージェライト・セラミック体の製造法 |
US5296423A (en) * | 1992-01-03 | 1994-03-22 | Corning Incorporated | Cordierite substrates |
JP3834842B2 (ja) * | 1994-08-25 | 2006-10-18 | 株式会社デンソー | コーディエライトセラミック体の製造方法 |
JP2004188819A (ja) * | 2002-12-12 | 2004-07-08 | Ngk Insulators Ltd | ハニカム成形体の製造方法、及びハニカム構造体 |
JP4516275B2 (ja) * | 2003-01-24 | 2010-08-04 | 株式会社デンソー | コージェライトセラミック体の製造方法 |
JP4456077B2 (ja) * | 2003-08-20 | 2010-04-28 | 日本碍子株式会社 | ハニカム成形体の製造方法、ハニカムフィルタの製造方法、及びハニカムフィルタ |
CN100526041C (zh) * | 2003-08-20 | 2009-08-12 | 日本碍子株式会社 | 蜂窝成型体的制造方法、蜂窝过滤器的制造方法及蜂窝过滤器 |
JP2005126317A (ja) * | 2003-09-30 | 2005-05-19 | Ngk Insulators Ltd | ハニカム構造体の製造方法及びハニカム構造体 |
US7132066B2 (en) | 2003-09-30 | 2006-11-07 | Ngk Insulators, Ltd. | Method for producing honeycomb structure and honeycomb structure |
US8663545B2 (en) | 2004-03-31 | 2014-03-04 | Ngk Insulators, Ltd. | Method of manufacturing honeycomb structure and honeycomb structure |
US8974724B2 (en) * | 2006-11-29 | 2015-03-10 | Corning Incorporated | Aluminum titanate batch compositions and method |
CN102378745A (zh) * | 2009-03-30 | 2012-03-14 | 住友化学株式会社 | 钛酸铝系陶瓷体的制造方法 |
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EP3075717B1 (en) | 2015-03-31 | 2019-08-21 | NGK Insulators, Ltd. | Method for manufacturing ceramic formed body |
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JP6059314B1 (ja) | 2015-09-17 | 2017-01-11 | ヤフー株式会社 | 推定装置、推定方法及び推定プログラム |
CN106365669B (zh) * | 2016-08-31 | 2019-05-21 | 山东奥福环保科技股份有限公司 | 一种以全氧化物为原料的堇青石蜂窝陶瓷载体及其制备方法 |
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- 2018-03-12 US US15/918,147 patent/US11542205B2/en active Active
- 2018-03-21 CN CN201810237066.0A patent/CN108621285B/zh active Active
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JP2018161765A (ja) | 2018-10-18 |
CN108621285B (zh) | 2021-02-19 |
US20180273433A1 (en) | 2018-09-27 |
DE102018204468A1 (de) | 2018-09-27 |
CN108621285A (zh) | 2018-10-09 |
US11542205B2 (en) | 2023-01-03 |
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