WO2016039331A1 - Procédé de fabrication d'une structure en nid d'abeilles - Google Patents

Procédé de fabrication d'une structure en nid d'abeilles Download PDF

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Publication number
WO2016039331A1
WO2016039331A1 PCT/JP2015/075448 JP2015075448W WO2016039331A1 WO 2016039331 A1 WO2016039331 A1 WO 2016039331A1 JP 2015075448 W JP2015075448 W JP 2015075448W WO 2016039331 A1 WO2016039331 A1 WO 2016039331A1
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Prior art keywords
honeycomb
cell
cross
longitudinal direction
cutting
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PCT/JP2015/075448
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English (en)
Japanese (ja)
Inventor
和丈 尾久
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イビデン株式会社
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Publication of WO2016039331A1 publication Critical patent/WO2016039331A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01J35/56—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • 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
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • 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
    • 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
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/87—Ceramics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors

Definitions

  • the present invention relates to a method for manufacturing a honeycomb structure.
  • PM Particulate matter
  • an internal combustion engine such as a diesel engine.
  • CO and HC since it is also contain toxic gas components such as NO X, are growing concerns about influences of these toxic gas components on the environment and human body.
  • a honeycomb structure (exhaust gas treatment body) made of a porous ceramic such as silicon carbide or cordierite, and a honeycomb structure
  • exhaust gas purifying apparatuses comprising a casing for housing a body, and a holding sealing material disposed between the honeycomb structure and the casing have been proposed.
  • honeycomb structure for example, a honeycomb structure composed of only one unit mainly using oxide-based ceramics and a plurality of units mainly using non-oxidized ceramics are assembled. Honeycomb structures and the like are known.
  • Patent Document 1 discloses a columnar porous ceramic member in which a large number of through holes are arranged in parallel in the longitudinal direction with a partition wall therebetween.
  • a method of manufacturing a honeycomb structure having a cylindrical shape, an elliptical cylindrical shape, or a shape similar to these, which are bundled together via layers, and combining a plurality of types of porous ceramic members via an adhesive paste There is disclosed a method for manufacturing a honeycomb structure including a ceramic block manufacturing step of manufacturing a ceramic block having a shape, an elliptical column shape, or a shape similar to these shapes.
  • a plurality of types of ceramic molded bodies are fired to manufacture a porous ceramic member, and then each porous ceramic member is bound through an adhesive layer to form a honeycomb.
  • Manufactures structures Since the ceramic molded body is a relatively small molded body, thermal expansion and the like generated during firing are small and cracks hardly occur. For this reason, the method for manufacturing a honeycomb structure disclosed in Patent Document 1 has an advantage that a large honeycomb structure can be manufactured without generating cracks in the porous ceramic member.
  • the present invention has been made in view of the above problems, and an object of the present invention is to make contact between the honeycomb units constituting the honeycomb structure when manufacturing a honeycomb structure in which a plurality of honeycomb units are assembled. It is providing the manufacturing method of the honeycomb structure which can suppress that a crack generate
  • the present inventors have made extensive studies, and as a result, produced a monolith-type honeycomb fired body, cut the honeycomb structure in a direction parallel to the longitudinal direction, and a plurality of honeycomb units. And manufacturing the honeycomb structure by assembling the plurality of honeycomb units through the adhesive layer, thereby suppressing contact between the honeycomb units and reducing the thickness of the adhesive layer.
  • the present invention has been completed.
  • the method for manufacturing a honeycomb structure of the present invention includes a honeycomb in which a plurality of honeycomb units made of silicon carbide each having a plurality of cells serving as exhaust gas flow paths and porous cell partition walls defining the cells are assembled.
  • a method for producing a structure which includes extrusion molding a ceramic raw material containing silicon carbide to produce a honeycomb molded body, degreasing the honeycomb molded body to produce a honeycomb degreased body, and the above
  • the honeycomb molded body in vertical cross section in the longitudinal direction, and having a cutting area to be cut in the cutting step, and a function
  • a ceramic raw material containing silicon carbide is extrusion molded. Since silicon carbide is a material having excellent heat resistance, the honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention has excellent heat resistance.
  • a monolith type honeycomb fired body is manufactured in the firing step.
  • the fired honeycomb units are assembled by conveying or the like.
  • the honeycomb units come into contact with each other, and the honeycomb unit may be damaged.
  • the manufactured honeycomb structure has defects such as easy gas leakage.
  • the method for manufacturing a honeycomb structured body of the present invention after firing the monolith type honeycomb fired body, the fired monolith type honeycomb fired body is transported or the like.
  • the surface area of the monolith type honeycomb fired body is smaller than the total surface area of the plurality of honeycomb units constituting the honeycomb fired body of the same size. Accordingly, the monolith-type honeycomb fired body is less likely to come into contact with something than the plurality of honeycomb units. That is, the monolith type honeycomb fired body is less likely to be damaged by contact with something. Therefore, in the method for manufacturing a honeycomb structure of the present invention, defects are hardly generated in the manufactured honeycomb structure.
  • the monolith-type honeycomb fired body is cut in a direction parallel to the longitudinal direction in the cutting step. Since the monolith type honeycomb fired body is formed by sintering silicon carbide, it is very hard and hardly deformed. Therefore, when a monolith-type honeycomb fired body is cut, a honeycomb unit that is not easily deformed and has a predetermined shape can be manufactured.
  • a plurality of honeycomb units are assembled via an adhesive layer to produce a honeycomb structure.
  • honeycomb units having a distorted shape when honeycomb units having a distorted shape are assembled, a gap is easily generated between the honeycomb units in the manufactured honeycomb structure, which easily causes gas leakage. Therefore, when assembling honeycomb units having a distortion in shape, it is necessary to increase the thickness of the adhesive layer in order to absorb the distortion. Increasing the thickness of the adhesive layer increases the pressure loss.
  • the honeycomb unit manufactured in the cutting process is not easily deformed, so that the shape is hardly distorted. Therefore, it is difficult for gaps generated due to the distortion of the honeycomb unit to occur during assembly.
  • the honeycomb units can be assembled without gaps without increasing the thickness of the adhesive layer in order to absorb the strain. Furthermore, when the adhesive layer is not thickened, the pressure loss of the honeycomb structure can be reduced. In addition, the silicon carbide sintered body is very hard but brittle. When thermal stress or the like is generated inside the monolith honeycomb structure made of silicon carbide, the monolith honeycomb structure may not withstand the thermal stress and may be damaged. However, in the case of a honeycomb structure in which a plurality of honeycomb units are assembled, the generated thermal stress and the like can be absorbed by the adhesive layer or the like, and thus the honeycomb structure is not easily damaged. Therefore, the honeycomb structure manufacturing method of the present invention can manufacture a honeycomb structure that is not easily damaged by thermal stress.
  • the extrusion molding step in the extrusion molding step, extrusion molding is performed so that cutting cells cut in the cutting step and functional cells not cut in the cutting step are formed, and the cutting is performed.
  • the honeycomb unit can be manufactured by simply cutting the cell partition walls of the cutting cells in the cutting process. That is, the monolith type honeycomb fired body can be easily cut. Further, by cutting the cutting cell, a part of the cell partition wall remains on the cut surface of each honeycomb unit.
  • a part of the cell partition walls function as an anchor. Therefore, each honeycomb unit is firmly fixed in the manufactured honeycomb structure.
  • the area of the cross section perpendicular to the longitudinal direction of the cutting cell is larger than the area of the cross section perpendicular to the longitudinal direction of the functional cell. It is desirable to extrude.
  • the area of the cross section perpendicular to the longitudinal direction of the cutting cell is large, when cutting the monolith-type honeycomb fired body in the cutting process, the functional cell is not damaged even if the cutting position is slightly shifted. It becomes easy to cut the cell. Therefore, defects are less likely to occur in the manufactured honeycomb structure.
  • the cell density of the cutting cells arranged in the cutting region is made smaller than the cell density of the functional cells arranged in the functional region. It is desirable to extrude.
  • the cell density of the cutting cells arranged in the cutting region is small, the number of cell partition walls to be cut in the cutting process can be reduced. Therefore, the monolith-type honeycomb fired body can be efficiently cut.
  • the functional cell includes an outer peripheral functional cell disposed on the outer periphery of the functional region and an inner functional cell disposed on the inner side of the outer peripheral functional cell, and the extrusion molding
  • extrusion molding is performed in this manner, a honeycomb unit having a thick outer periphery can be manufactured. Therefore, the outer frame of the honeycomb unit has a mechanically strong structure, and has a sufficiently high strength against external impacts and the like. Further, since the volume of the outer periphery is large, the heat capacity of the honeycomb unit can be increased.
  • the peripheral function cell includes a first peripheral function cell disposed at an outer peripheral portion of the honeycomb formed body and a second outer periphery disposed at a position other than the outer peripheral portion of the honeycomb formed body.
  • the area of the cross section perpendicular to the longitudinal direction of the first outer peripheral functional cell is smaller than the area of the cross section perpendicular to the longitudinal direction of the internal functional cell. Extrusion is desirable.
  • the area of the cross section perpendicular to the longitudinal direction of the first outer peripheral functional cell is the area of the cross section perpendicular to the longitudinal direction of the internal functional cell. It is desirable to perform extrusion molding so as to be 60 to 80%.
  • the area of the cross section perpendicular to the longitudinal direction of the first peripheral function cell is less than 60% of the area of the cross section perpendicular to the longitudinal direction of the internal function cell, the area of the opening of the first peripheral function cell is small.
  • the exhaust gas flow path becomes narrow. Therefore, in the manufactured honeycomb structure, the gas passage resistance when the exhaust gas passes through the cell partition walls of the first outer peripheral functional cell is increased, and the pressure loss is increased.
  • the volume of the outer frame portion of the manufactured honeycomb structure is It becomes small and weak mechanically, and the heat capacity tends to decrease.
  • the cross-sectional shape perpendicular to the longitudinal direction of the internal function cell is rectangular, and the cross-sectional shape perpendicular to the longitudinal direction of the first peripheral functional cell is Two corners are chamfered from a rectangle having a cross-sectional shape perpendicular to the longitudinal direction of the internal function cell, and the cell partition wall forming the first peripheral function cell faces the outside of the function region. It is desirable to extrude so that a thick wall region where the wall thickness gradually increases is formed.
  • the internal function cell and the first peripheral function cell having such a shape can be easily formed by extrusion. Therefore, the area of the cross section perpendicular to the longitudinal direction of the first outer peripheral functional cell can be easily made smaller than the area of the cross section perpendicular to the longitudinal direction of the internal functional cell.
  • the area of the cross section perpendicular to the longitudinal direction of the second outer peripheral functional cell is greater than the area of the cross section perpendicular to the longitudinal direction of the internal functional cell. It is desirable to carry out extrusion molding so as to be small.
  • the second outer peripheral functional cell has the above shape, the volume of the outer frame portion of the entire honeycomb unit increases. Therefore, the outer frame portion of the honeycomb unit has a mechanically strong structure and has a sufficiently high strength against external impacts and the like. Further, since the volume of the outer frame portion of the honeycomb unit is increased, it is possible to suppress a decrease in heat capacity.
  • the area of the cross section perpendicular to the longitudinal direction of the second outer peripheral functional cell is equal to the area of the cross section perpendicular to the longitudinal direction of the internal functional cell. It is desirable to perform extrusion molding so as to be 60 to 80%.
  • the area of the cross section perpendicular to the longitudinal direction of the second peripheral function cell is less than 60% of the area of the cross section perpendicular to the longitudinal direction of the internal function cell, the area of the opening of the second peripheral function cell is small.
  • the exhaust gas flow path becomes narrow. Therefore, the gas passage resistance when the exhaust gas passes through the cell partition walls of the second outer peripheral function cell increases, and the pressure loss increases.
  • the volume of the outer frame portion of the manufactured honeycomb unit becomes small. It becomes mechanically weak and the heat capacity tends to decrease.
  • the cross-sectional shape perpendicular to the longitudinal direction of the internal function cell is rectangular, and the cross-sectional shape perpendicular to the longitudinal direction of the second peripheral functional cell is From the rectangle which is the cross-sectional shape of the internal functional cell, two corners are chamfered, and the wall thickness gradually increases toward the outside of the functional region on the cell partition wall forming the second outer peripheral functional cell. It is desirable to extrude such that an increased thick wall region is formed.
  • the internal function cell and the second outer peripheral function cell having such a shape can be easily formed by extrusion molding. Therefore, the area of the cross section perpendicular to the longitudinal direction of the second outer peripheral function cell can be easily made smaller than the area of the cross section perpendicular to the longitudinal direction of the internal function cell.
  • the thickness of the cell partition wall of the functional cell is 0.210 mm or less.
  • the thickness of the cell partition wall of the functional cell formed in the extrusion process is 0.210 mm or less, the thickness of the cell partition wall of the functional cell is sufficiently thin, so that PM is not deposited in the manufactured honeycomb structure.
  • the pressure loss in the initial state can be sufficiently reduced. Further, an increase in pressure loss can be suppressed even when PM is deposited.
  • the thickness of the cell partition wall of the functional cell formed in the extrusion molding process exceeds 0.210 mm, the thickness of the cell partition wall of the functional cell is too thick. The resistance when passing through the cell partition increases, and as a result, the pressure loss increases.
  • honeycomb structured body of the present invention it is preferable to further include a sealing step for sealing one end of the cell.
  • the honeycomb structure manufactured in this way functions as a honeycomb filter that removes PM in the exhaust gas.
  • the method for manufacturing a honeycomb structure of the present invention it is desirable to further include an outer peripheral coat layer forming step of providing an outer peripheral coat layer on the outer periphery of the honeycomb structure.
  • an outer peripheral coat layer By providing the outer peripheral coat layer, the mechanical strength of the manufactured honeycomb structure can be improved.
  • the method for manufacturing a honeycomb structure of the present invention preferably further includes a cutting step of cutting the outer periphery of the honeycomb structure and shaping the shape of the honeycomb structure before the outer peripheral coat layer forming step.
  • FIGS. 1A to 1E are process diagrams schematically showing an example of a method for manufacturing a honeycomb structure of the present invention in the order of processes.
  • Fig. 2 (a) is a perspective view schematically showing an example of a honeycomb formed body that is extrusion-molded in the method for manufacturing a honeycomb structure of the present invention.
  • FIG. 2B is a cross-sectional view taken along the line AA in FIG.
  • FIGS. 3-1 (a) and (b) are enlarged views schematically showing an enlarged part of the honeycomb formed body formed in the extrusion step of the method for manufacturing a honeycomb structure of the present invention.
  • FIGS. 3-2 (c) and (d) are enlarged views schematically showing an enlarged part of the honeycomb formed body formed in the extrusion step of the manufacturing method of the honeycomb structure of the present invention. It is a schematic diagram which shows typically an example of the shape of the cross section perpendicular
  • FIG. 3-3 (e) is an enlarged view schematically showing a part of the honeycomb formed body formed in the extrusion forming step of the manufacturing method of the honeycomb structure of the present invention.
  • FIG. 4 is an enlarged view schematically showing an enlarged example of the honeycomb formed body in which the cell partition walls are cut regions, which is formed in the extrusion forming step in the method for manufacturing a honeycomb structured body of the present invention.
  • FIG. 5 is an enlarged view schematically showing an example of the functional region in a cross section perpendicular to the longitudinal direction of the honeycomb formed body formed in the extrusion forming step in the method for manufacturing a honeycomb structure of the present invention. .
  • FIG. 4 is an enlarged view schematically showing an enlarged example of the honeycomb formed body in which the cell partition walls are cut regions, which is formed in the extrusion forming step in the method for manufacturing a honeycomb structured body of the present invention.
  • FIG. 5 is an enlarged view schematically showing an example of the functional region in a cross section perpendicular to the longitudinal direction of the honeycomb formed body formed in the extrusion forming step in the method for manufacturing a honeycomb structure of the present invention. .
  • FIG. 6 is a cross-sectional view schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the internal function cell.
  • FIGS. 7A to 7E are cross-sectional views schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the peripheral function cell.
  • FIGS. 8A to 8D are cross-sectional views schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the corner functional cell.
  • FIGS. 9A and 9B are schematic views schematically showing an example of a cross-sectional shape in the vertical direction of the longitudinal direction of the honeycomb formed body that is extruded in the extrusion process of the manufacturing method of the honeycomb structure of the present invention. is there.
  • FIG. 9A and 9B are schematic views schematically showing an example of a cross-sectional shape in the vertical direction of the longitudinal direction of the honeycomb formed body that is extruded in the extrusion process of the manufacturing method of the honeycomb structure of
  • FIG. 10 (a) is a perspective view schematically showing an example of a honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention.
  • FIG. 10B is a cross-sectional view taken along line BB in FIG.
  • FIGS. 11A to 11C are perspective views schematically showing a honeycomb formed body formed by extrusion molding in the method for manufacturing a honeycomb structure of Comparative Example 1.
  • FIG. 10B is a cross-sectional view taken along line BB in FIG.
  • FIGS. 11A to 11C are perspective views schematically showing a honeycomb formed body formed by extrusion molding in the method for manufacturing a honeycomb structure of Comparative Example 1.
  • a method for manufacturing a honeycomb structure according to the present invention includes a honeycomb structure in which a plurality of honeycomb units made of silicon carbide each having a plurality of cells serving as exhaust gas flow paths and porous cell partition walls defining the cells are assembled.
  • a method for producing a honeycomb molded body by extruding a ceramic raw material containing silicon carbide, a degreasing step for degreasing the honeycomb molded body to produce a honeycomb degreased body, and the honeycomb degreasing process.
  • the honeycomb unit is assembled through an adhesive layer, and a honeycomb structure is manufactured.
  • FIGS. 1A to 1E are process diagrams schematically showing an example of a method for manufacturing a honeycomb structure of the present invention in the order of processes.
  • the honeycomb structure 1 manufactured by the method for manufacturing a honeycomb structure of the present invention is manufactured, first, as shown in FIG. 1 (a), a ceramic raw material containing silicon carbide is extruded and formed. 11 is performed. Since silicon carbide is a material having excellent heat resistance, the honeycomb structure 1 manufactured through the steps described later has excellent heat resistance.
  • a degreasing step for degreasing the honeycomb formed body 11 and producing the honeycomb degreased body 12 is performed in order to remove organic substances contained in the honeycomb formed body 11.
  • the honeycomb degreased body 12 is fired to produce a monolith-type honeycomb fired body 13.
  • the fired honeycomb units are assembled by conveying or the like. When the fired honeycomb unit is transported, the honeycomb units come into contact with each other, and the honeycomb unit may be damaged.
  • the manufactured honeycomb structure has defects such as easy gas leakage.
  • the honeycomb structure 1 when the honeycomb structure 1 is manufactured, after firing the monolith type honeycomb fired body 13, the fired monolith type honeycomb fired body 13 is transported or the like.
  • the surface area of the monolith honeycomb fired body 13 is smaller than the total surface area of the plurality of honeycomb units constituting the honeycomb fired body of the same size. Accordingly, the monolith-type honeycomb fired body 13 is less likely to come into contact with something than the plurality of honeycomb units. That is, the monolith-type honeycomb fired body 13 is less likely to be damaged by contact with something. Therefore, when the honeycomb structure 1 is manufactured by the method for manufacturing a honeycomb structure of the present invention, the honeycomb structure 1 is unlikely to be defective.
  • the monolith-type honeycomb fired body 13 is cut in a direction parallel to the longitudinal direction (the direction of the arrow in FIG. 1 (d)) to produce a plurality of honeycomb units 14.
  • a cutting step is performed.
  • the monolith-type honeycomb fired body 13 is formed by sintering silicon carbide, and thus is extremely hard and hardly deformed. Therefore, when the monolith-type honeycomb fired body 13 is cut, the honeycomb unit 14 that is not easily deformed and has a predetermined shape can be manufactured.
  • a collecting step is performed in which a plurality of honeycomb units 14 are gathered through the adhesive layer 15 to produce the honeycomb structure 1.
  • honeycomb units having a distorted shape when honeycomb units having a distorted shape are assembled, a gap is easily generated between the honeycomb units in the manufactured honeycomb structure, which easily causes gas leakage. Therefore, when assembling honeycomb units having a distortion in shape, it is necessary to increase the thickness of the adhesive layer in order to absorb the distortion. Increasing the thickness of the adhesive layer increases the pressure loss.
  • the honeycomb unit 14 manufactured in the cutting process is not easily deformed, the shape is hardly distorted. Therefore, it is difficult to generate a gap caused by the distortion of the honeycomb unit 14 when assembled.
  • the honeycomb units 14 can be assembled without gaps without increasing the thickness of the adhesive layer 15 to absorb strain. Furthermore, when the adhesive layer 15 is not thickened, the pressure loss of the honeycomb structure 1 can be reduced. In addition, the silicon carbide sintered body is very hard but brittle. When thermal stress or the like is generated inside the monolith honeycomb structure made of silicon carbide, the monolith honeycomb structure may not withstand the thermal stress and may be damaged. However, in the honeycomb structure 1 in which a plurality of honeycomb units 14 are assembled, the generated thermal stress and the like can be absorbed by the adhesive layer 15 and the like, and thus the honeycomb structure 1 is not easily damaged. Therefore, the honeycomb structure manufacturing method of the present invention can manufacture the honeycomb structure 1 that is not easily damaged by thermal stress.
  • a ceramic raw material to be a raw material of a honeycomb fired body is prepared.
  • the ceramic raw material can be prepared by mixing silicon carbide powder, an organic binder, a plasticizer, a lubricant, and water. Since silicon carbide is a material having excellent heat resistance, the honeycomb structure 1 manufactured by the method for manufacturing a honeycomb structure of the present invention has excellent heat resistance.
  • a pore-forming material such as balloons, which are fine hollow spheres containing oxide ceramics, spherical acrylic particles, and graphite may be added to the ceramic raw material.
  • the balloon is not particularly limited, and examples thereof include an alumina balloon, a glass micro balloon, a shirasu balloon, a fly ash balloon (FA balloon), and a mullite balloon. Of these, alumina balloons are desirable.
  • FIG. 2 (a) is a perspective view schematically showing an example of a honeycomb formed body that is extrusion-molded in the method for manufacturing a honeycomb structure of the present invention.
  • FIG. 2B is a cross-sectional view taken along the line AA in FIG.
  • a honeycomb formed body 11 as an example of a honeycomb formed body that is extrusion-molded in the method for manufacturing a honeycomb structure of the present invention includes a plurality of cells 20, And cell partition walls 30 for partition formation. Further, as shown in FIG. 2B, the honeycomb formed body 11 has a cutting region 51 cut in the cutting step and a functional region 52 other than the cutting region 51 in a cross section perpendicular to the longitudinal direction.
  • the shape of the honeycomb formed body 11 produced by extrusion molding is preferably a columnar shape, and more preferably a column as shown in FIGS. 2 (a) and 2 (b). Further, as shown in FIG.
  • the cutting region 51 is formed in a straight line in the cross section perpendicular to the longitudinal direction of the honeycomb formed body 11, but the cutting region 51 is formed in the longitudinal direction of the honeycomb formed body 11. It is desirable to form a circle having a vertical cross-sectional shape so that it is divided into four equal parts in the vertical direction and four equal parts in the horizontal direction.
  • the size of the monolith-type honeycomb fired body is 5 to 20% larger than the size of the finished honeycomb structure. Furthermore, it is desirable to shape the honeycomb formed body 11.
  • FIGS. 3-1 (a) and (b), FIGS. 3-2 (c) and (d), and FIG. 3-3 (e) are formed in the extrusion process of the honeycomb structure manufacturing method of the present invention.
  • FIG. 3 is an enlarged view schematically showing a part of the honeycomb formed body to be enlarged, and is a schematic view schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the cutting cells and functional cells to be cut. is there.
  • FIGS. 3-1 (a) and (b), FIGS. 3-2 (c) and (d), and FIG. 3-3 (e) are formed in the extrusion process of the honeycomb structure manufacturing method of the present invention.
  • FIG. 3 is an enlarged view schematically showing a part of the honeycomb formed body to be enlarged, and is a schematic view schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the cutting cells and functional cells to be cut. is there.
  • the straight line X indicates that the honeycomb formed body 11 is formed in a later step.
  • the monolith honeycomb fired body 13 is obtained, it is a portion to be cut in the cutting process.
  • the shape of the cross section perpendicular to the longitudinal direction of the cutting cell 21 formed in the extrusion process in the method for manufacturing a honeycomb structure of the present invention, and the longitudinal direction of the functional cell 22 The shape of the cross section in the vertical direction may be the same shape. In addition, these shapes may be rectangular or square.
  • the cutting region 51 and the functional region 52 are the following regions. That is, the cutting region 51 divides the thickness of the cutting cell 21, the cell partition 30 between the cutting cells 21, and the cell partition 30 between the cutting cell 21 and the functional cell 22 into two equal parts. This is a region composed of the cell partition walls 30 on the cutting cell 21 side.
  • the functional area 52 is an area other than the cutting area 51.
  • the honeycomb unit 14 can be manufactured by simply cutting the cell partition walls 30 forming the cutting cells 21 in the cutting process. That is, the monolith type honeycomb fired body 13 can be easily cut. Furthermore, by cutting the cutting cell 21, a part of the cell partition wall 30 remains on the cut surface of each honeycomb unit 14. When the honeycomb units are assembled through the adhesive layer 15 in the assembly process, a part of the cell partition walls 30 functions as an anchor. Therefore, each honeycomb unit 14 is firmly fixed in the manufactured honeycomb structure.
  • the length perpendicular to the cutting direction of the cutting cell 21 is equal to the cutting direction of the functional cell 22 as shown in FIG. It is desirable to extrude so as to be larger than the length in the vertical direction.
  • the shape of the cross section perpendicular to the longitudinal direction of the cutting cell 21 is a shape obtained by expanding the shape of the cross section perpendicular to the longitudinal direction of the functional cell 22 in the perpendicular direction to the cutting direction. .
  • the cutting position is slightly shifted when the monolith honeycomb fired body 13 is cut in the cutting step.
  • the cutting cell 21 can be easily cut without damaging the functional cell 22. Therefore, defects are less likely to occur in the manufactured honeycomb structure 1.
  • the ratio of the length perpendicular to the cutting direction of the cutting cell 21 to the length perpendicular to the cutting direction of the functional cell 22 is determined by the cutting of the cutting cell 21.
  • the length in the direction perpendicular to the cutting direction of the functional cell 22 is preferably 1.2: 1 to 2.5: 1.
  • the cell density of the cutting cells 21 arranged in the cutting region 51 is arranged in the functional region 52 as shown in FIG. It is desirable to perform extrusion molding so that the cell density of the functional cell 22 is smaller.
  • the shape of the cross section perpendicular to the longitudinal direction of the cutting cell 21 is a shape obtained by removing the cell partition wall 30 from the shape composed of two adjacent functional cells 22 and the cell partition wall 30 between them. It is.
  • the ratio between the cell density of the cutting cells 21 arranged in the cutting area 51 and the cell density of the functional cells 22 arranged in the functional area 52 is the cell density of the cutting cells 21 arranged in the cutting area 51: function It is desirable that the cell density of the functional cells 22 arranged in the region 52 is 1: 1.2 to 1: 2.5.
  • the cell density of the functional cells 22 arranged in the functional region 52 is desirably in the range of 15.5 to 62 cells / cm 2 (100 to 400 cpsi), and 31 to 46.5 cells / cm 2 (200 to 300 cpsi). ) Is more desirable.
  • the area of the cross section perpendicular to the longitudinal direction of the cutting cell 21 is equal to the longitudinal direction of the functional cell 22 in the extrusion process, as shown in FIG. It is desirable to perform extrusion molding so as to be larger than the cross-sectional area in the vertical direction.
  • the shape of the cross section perpendicular to the longitudinal direction of the cutting cell 21 is a shape obtained by enlarging the shape of the cross section perpendicular to the longitudinal direction of the functional cell 22 without changing the aspect ratio.
  • the functional cell 22 may be damaged even if the cutting position is slightly shifted when the monolith honeycomb fired body 13 is cut in the cutting process. Therefore, the cutting cell 21 can be easily cut. Therefore, defects are less likely to occur in the manufactured honeycomb structure 1. Further, with such a shape, the cell density of the cutting cells 21 arranged in the cutting region 51 can be made smaller than the cell density of the functional cells 22 arranged in the functional region 52. Therefore, the number of cell partition walls 30 to be cut in the cutting process can be reduced. Therefore, the monolith-type honeycomb fired body 13 can be efficiently cut.
  • the area of the cross section perpendicular to the longitudinal direction of each cell can be obtained by the following method. First, the honeycomb structure 1 is cut in a direction perpendicular to the longitudinal direction. Next, an SEM image of a cross section perpendicular to the longitudinal direction of the honeycomb structure 1 is taken. The photographed SEM image is binarized to identify a skeleton portion such as the cell partition wall 30 and a space portion of each cell. And the area of the part identified as the space part of each cell in a SEM image is made into the area of each cell.
  • the thickness of the cell partition wall 30 between the cutting cell 21 and the functional cell 22 is set in the extrusion process, as shown in FIG. 3-3 (e). It is desirable to perform extrusion molding so as to be thicker than the thickness of the cell partition wall 30 that forms only the cells 22.
  • the honeycomb unit 14 having a thick outer periphery can be manufactured. Therefore, the outer frame of the honeycomb unit 14 has a mechanically strong structure, and has a sufficiently high strength against external impacts and the like. Moreover, since the volume of the outer periphery is large, the heat capacity of the honeycomb unit 14 can be increased.
  • the thickness of the cell partition wall 30 between the cutting cell 21 and the functional cell 22 is preferably 1.5 to 3 times the thickness of the cell partition wall 30 forming only the functional cell 22. It is more desirable that it is double.
  • the extrusion molding step it is desirable to perform extrusion molding so that the thickness of the cell partition wall 30 of the functional cell 22 is 0.210 mm or less, and 0.075 to 0.160 mm. It is more desirable to do.
  • the thickness of the cell partition wall 30 of the functional cell 22 formed in the extrusion molding process is 0.210 mm or less, the thickness of the cell partition wall 30 of the functional cell 22 is sufficiently thin. It is possible to sufficiently reduce the pressure loss in the initial state where no is deposited. Further, an increase in pressure loss can be suppressed even when PM is deposited.
  • the thickness of the cell partition wall 30 of the functional cell 22 formed in the extrusion molding process exceeds 0.210 mm, the thickness of the cell partition wall 30 of the functional cell 22 is too thick.
  • the resistance when the exhaust gas passes through the cell partition wall 30 of the functional cell 22 increases, and as a result, the pressure loss increases.
  • FIG. 4 is an enlarged view schematically showing an enlarged example of the honeycomb formed body in which the cell partition walls are cut regions, which is formed in the extrusion forming step in the method for manufacturing a honeycomb structured body of the present invention.
  • the honeycomb molded body is formed such that the cutting cell partition walls 31 that are cut in the cutting step and the functional cell partition walls 32 that are not cut are formed. 11 may be extruded.
  • a straight line Y is a portion that is cut in the cutting step when the honeycomb formed body 11 becomes the monolith-type honeycomb fired body 13 in the subsequent step.
  • the thickness of the cutting cell partition wall 31 is larger than the thickness of the functional cell partition wall 32. Therefore, the monolith honeycomb fired body 13 can be cut without damaging the cells 20 arranged in the functional region 52 in the cutting step.
  • FIG. 5 is an enlarged view schematically showing an example of the functional region in a cross section perpendicular to the longitudinal direction of the honeycomb formed body formed in the extrusion forming step in the method for manufacturing a honeycomb structure of the present invention.
  • the functional cells 22 of the honeycomb formed body 11 to be formed in the extrusion molding step include an outer peripheral functional cell 22 a disposed on the outer periphery 53 of the functional region 52 and an inner portion disposed on the inner side of the outer peripheral functional cell 22 a. And a functional cell 22b.
  • the functional cell 22 includes a corner functional cell 22 c arranged at the corner 54 of the functional region 52.
  • the “corner portion of the functional area” is not included in the “periphery of the functional area”. That is, the corner function cell 22c is not included in the outer peripheral function cell 22a.
  • the “corner portion of the functional region” means a portion where two line segments intersect at right angles in the outline forming the functional region 52 in the cross section perpendicular to the longitudinal direction of the honeycomb formed body. Means the neighborhood of
  • the shape of the formed honeycomb formed body has an area of a cross section perpendicular to the longitudinal direction of at least one peripheral function cell 22a. It is desirable to perform extrusion molding so as to be smaller than the area of the cross section perpendicular to the longitudinal direction of the internal function cell 22b.
  • the honeycomb unit 14 having a thick outer periphery can be manufactured. Therefore, the outer frame of the honeycomb unit 14 has a mechanically strong structure, and has a sufficiently high strength against an external impact or the like.
  • the heat capacity of the honeycomb unit 14 can be increased.
  • the area of the cross section perpendicular to the longitudinal direction of all the outer peripheral functional cells 22a is larger than the area of the cross section perpendicular to the longitudinal direction of the internal functional cells 22b.
  • the extrusion molding may be performed so as to be small.
  • the area of the cross section perpendicular to the longitudinal direction of the outer peripheral functional cell 22a is preferably 60 to 80% of the area of the cross section perpendicular to the longitudinal direction of the internal functional cell 22b.
  • the area of the cross section perpendicular to the longitudinal direction of the peripheral function cell 22a is less than 60% of the area of the cross section perpendicular to the longitudinal direction of the internal function cell 22b, the area of the opening of the peripheral function cell 22a becomes small.
  • the exhaust gas flow path becomes narrower. Therefore, the gas passage resistance when the exhaust gas passes through the cell partition wall 30 of the outer peripheral function cell 22a increases, and the pressure loss increases.
  • the volume of the outer frame portion of the manufactured honeycomb unit 14 is It becomes small and weak mechanically, and the heat capacity tends to decrease.
  • FIG. 6 is a cross-sectional view schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the internal function cell.
  • FIGS. 7A to 7E are cross-sectional views schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the peripheral function cell.
  • FIGS. 8A to 8D are cross-sectional views schematically showing an example of a cross-sectional shape perpendicular to the longitudinal direction of the corner functional cell.
  • the cross-sectional shape of the internal function cell 22b is preferably a rectangle ⁇ as shown in FIG.
  • the rectangle ⁇ is more preferably a square.
  • the cross-sectional shape of the outer peripheral function cell 22a is preferably a shape in which corners are chamfered from the rectangle ⁇ which is the cross-sectional shape of the internal function cell 22b. That is, in the extrusion molding process, two corners are chamfered from the rectangle ⁇ which is the cross-sectional shape of the internal functional cell 22b, and the cell partition wall 30 forming the outer peripheral functional cell 22a is directed to the outside of the functional region 52. It is desirable to extrude so that a thick wall region 33 with gradually increasing wall thickness is formed. Examples of such shapes include those shown in FIGS. 7 (a) to (e).
  • a shape in which corners are chamfered from a rectangle means a shape in which corners of a rectangle are cut out from a rectangle by a straight line or a curve.
  • FIG. 7A shows a cross-sectional shape of the peripheral function cell 22a in which two adjacent corners of the rectangle ⁇ are hexagons cut off by two line segments A and B, respectively.
  • the line segments A and B are not in direct contact with each other, and when the line segments A and B are extended, they intersect each other outside the rectangle ⁇ . Further, a part of the side of the rectangle ⁇ between the two cut corners forms one side of the hexagon.
  • FIG. 7B shows a cross-sectional shape of the peripheral functional cell 22a in which two adjacent corners of the rectangle ⁇ are pentagons cut off by two line segments C and D, respectively.
  • the line segment C and the line segment D intersect at the side forming the rectangle ⁇ .
  • the line segment C and the line segment D may intersect within the rectangle ⁇ . That is, there is no side that forms the pentagon between the two corners to be cut.
  • FIG. 7C is an octagon in which one of the two adjacent corners of the rectangle ⁇ is cut off by line segments E and F, and the other corner is cut off by line segments G and H.
  • the cross-sectional shape of a certain peripheral function cell 22a is shown.
  • the line segment E and the line segment F intersect each other inside the rectangle ⁇ .
  • the line segment G and the line segment H cross each other within the rectangle ⁇ .
  • a part of the side of the rectangle ⁇ between the two cut corners forms one side of the octagon.
  • FIG. 7D shows a cross-sectional shape of the peripheral function cell 22a in which two adjacent corners of the rectangle ⁇ are cut off by two curves A ′ and B ′, respectively.
  • Curves A ′ and B ′ are curves obtained by bending line segments A and B so that the corners of rectangle ⁇ are rounded.
  • a part of the side of the rectangle ⁇ between the two cut corners forms the outline of the cross-sectional shape of the outer peripheral functional cell 22a.
  • FIG. 7E shows a cross-sectional shape of the peripheral function cell 22a in which two adjacent corners of the rectangle ⁇ are cut off by two curves C ′ and D ′, respectively.
  • Curves C ′ and D ′ are curves obtained by bending the line segments C and D so that the corners of the rectangle ⁇ are rounded.
  • the curve C ′ and the curve D ′ intersect at the side forming the rectangle ⁇ .
  • the curve C ′ and the curve D ′ may intersect within the rectangle ⁇ .
  • the internal function cell 22b and the peripheral function cell 22a having such a shape can be easily formed by extrusion molding. Therefore, the area of the cross section perpendicular to the longitudinal direction of the outer peripheral functional cell 22a can be easily made smaller than the area of the cross section perpendicular to the longitudinal direction of the internal functional cell 22b.
  • the cross-sectional shape of the corner functional cell 22c is preferably a shape in which the corner is chamfered from the rectangle ⁇ which is the cross-sectional shape of the internal functional cell 22b. Examples of such shapes include those shown in FIGS. 8 (a) to 8 (d).
  • FIG. 8A shows a corner that is a heptagon in which three corners are cut out by line segments I, J, and K, respectively, except for the corner that is most inside the functional region 52 among the corners of the rectangle ⁇ .
  • the cross-sectional shape of the partial function cell 22c is shown.
  • the line segments I and J are not in direct contact with each other, and when the line segments I and J are extended, they intersect each other outside the rectangle ⁇ . Further, the line segments I and K are not in direct contact with each other, and when the line segments I and K are extended, they intersect each other outside the rectangle ⁇ .
  • a part of each side of the rectangle ⁇ between the three cut corners forms one side of a heptagon that is a cross-sectional shape of the corner functional cell 22c.
  • FIG. 8B shows a cross-sectional shape of the corner functional cell 22c, which is a pentagon in which the corner that is the innermost of the functional region 52 among the corners of the rectangle ⁇ is cut out by the line segment L.
  • FIG. 8C illustrates a corner function in which three corner portions are cut out by curves I ′, J ′, and K ′, except for the corner portion that is most inside the functional region 52 among the corner portions of the rectangle ⁇ .
  • the cross-sectional shape of the cell 22c is shown.
  • Curves I ′, J ′, and K ′ are curves obtained by bending line segments I, J, and K so that the corners of rectangle ⁇ are rounded.
  • a part of the side of the rectangle ⁇ between the three cut corners forms a cross-sectional outline of the corner functional cell 23c.
  • FIG. 8D shows a cross-sectional shape of the corner functional cell 22c in which the corner that is most inside the functional region 52 among the corners of the rectangle ⁇ is cut out by the curve L ′.
  • the curve L ′ is a curve obtained by bending the line segment L so that the corner of the rectangle ⁇ is rounded.
  • each functional cell 22 is desirably in the shape and arrangement described below.
  • FIGS. 9A and 9B are schematic views schematically showing an example of a cross-sectional shape in the vertical direction of the longitudinal direction of the honeycomb formed body that is extruded in the extrusion process of the manufacturing method of the honeycomb structure of the present invention. is there.
  • the outer peripheral function cell 22a is arranged in the outer peripheral portion 61 of the honeycomb molded body 11.
  • the volume of the outer frame portion of the entire honeycomb structure 1 to be manufactured increases. Therefore, the outer frame portion of the honeycomb structure 1 to be manufactured has a mechanically strong structure and has a sufficiently high strength against an external impact or the like. Moreover, since the volume of the outer frame portion of the entire honeycomb structure 1 to be manufactured is increased, it is possible to suppress a decrease in heat capacity.
  • the area of the vertical cross section in the longitudinal direction of the first outer peripheral functional cell 22a 1 is, in the longitudinal direction of the internal functional cell 22b in the vertical direction of the cross section It is desirable to perform extrusion molding so that the area is 60 to 80%.
  • Area vertical section in the longitudinal direction of the first outer peripheral functional cell 22a 1 is, when the longitudinal direction of the internal functional cell 22b is less than 60% of the area of the cross section in the vertical direction, the first outer peripheral functional cell 22a 1 of the opening The area of the part is reduced and the exhaust gas flow path is narrowed.
  • the shape of the internal function cell 22b may be the shape shown in FIG.
  • the shape of the first outer peripheral function cell 22a 1 may be the shape shown in FIGS. 7 (a) to (e). That is, in the extrusion step, next to the cross-sectional shape is rectangular ⁇ of internal functional cell 22b, the sectional shape of the first outer peripheral functional cell 22a 1 is, two corners of a rectangular ⁇ is a cross-sectional shape of the internal functions cell 22b is chamfered shape and become, the cell partition walls 30 which form a first outer peripheral functional cell 22a 1, that the wall thickness toward the outside of the functional area 52 is extruded as a thick wall region 33 is formed to increase gradually desirable.
  • the first outer peripheral functional cell 22a 1 having such a shape can be easily formed by extrusion molding. Therefore, it can be made smaller than the area of the vertical cross section in the longitudinal direction of the first outer peripheral functional cell 22a 1 in the longitudinal direction in the vertical direction of the cross section of the area easily internal functional cell 22b.
  • the cross-sectional shape of the second outer peripheral function cells 22a 2 are congruent shape to the rectangular alpha.
  • FIG. 9 (b) in the method for manufacturing a honeycomb structure of the present invention, in the extrusion process, the area of the vertical cross section in a second longitudinal direction of the outer peripheral functional cells 22a 2, internal functional cells You may extrusion-mold so that it may become smaller than the area of the cross section perpendicular
  • the second outer peripheral functional cell 22a 2 has the above shape, the volume of the outer frame portion of the entire honeycomb unit 14 manufactured through the cutting process is increased.
  • the outer frame portion of the honeycomb unit 14 has a mechanically strong structure and has a sufficiently high strength against external impacts and the like. Moreover, since the volume of the outer frame part of the honeycomb unit 14 is increased, it is possible to suppress a decrease in heat capacity.
  • the area of the vertical cross section in the longitudinal direction of the second outer peripheral function cells 22a 2 is the longitudinal direction of the internal functional cell 22b in the vertical direction of the cross section It is desirable to perform extrusion molding so that the area is 60 to 80%.
  • Area vertical section in the longitudinal direction of the second outer peripheral function cells 22a 2 is the longitudinal direction of the internal functional cell 22b is less than 60% of the area of the vertical cross-section, the second outer peripheral function cells 22a 2 of the opening The area of the part is reduced and the exhaust gas flow path is narrowed. Therefore, exhaust gas passing resistance when passing through the cell partition wall 30 of the second outer peripheral function cells 22a 2 is increased, the pressure loss increases.
  • the shape of the second outer peripheral functional cell 22a 2 may be the shape shown in FIGS. 7 (a) to 7 (e). That is, in the extrusion process, the cross-sectional shape in the direction perpendicular to the longitudinal direction of the second outer peripheral function cell 22a 2 is a shape in which two corners are chamfered from the rectangle ⁇ which is the cross-sectional shape of the internal function cell 22b. It is desirable to extrude the cell partition wall 30 forming the outer peripheral functional cell 22a 2 so that a thick wall region 33 whose wall thickness gradually increases toward the outside of the functional region 52 is formed.
  • the second outer peripheral functional cell 22a 2 having such a shape can be easily formed by extrusion molding. Therefore, it can be made smaller than the area of the vertical cross section in the longitudinal direction of the second outer peripheral function cells 22a 2 in the longitudinal direction in the vertical direction of the cross section of the area easily internal functional cell 22b.
  • the honeycomb molded body 11 obtained in the extrusion molding process is subjected to a microwave dryer, a hot air dryer, a dielectric dryer, a vacuum dryer, a vacuum dryer, a freeze dryer, or the like. Use to dry.
  • a microwave dryer and a hot air dryer are used in combination, or the honeycomb formed body is dried to a certain level of moisture using a microwave dryer, and then a hot air dryer is used. It may be used to completely remove moisture in the honeycomb formed body.
  • the honeycomb molded body 11 is heated at 300 to 650 ° C. for 0.5 to 3 hours to remove organic substances in the honeycomb molded body 11, thereby producing the honeycomb degreased body 12.
  • the honeycomb degreased body 12 is fired at 1800 to 2200 ° C. for 0.5 to 4 hours in an inert gas atmosphere such as a nitrogen atmosphere or an argon atmosphere, and the monolith honeycomb fired body 13 is manufactured.
  • an inert gas atmosphere such as a nitrogen atmosphere or an argon atmosphere
  • the monolith-type honeycomb fired body 13 is cut in a direction parallel to the longitudinal direction to produce a plurality of honeycomb units 14.
  • the position at which the monolith-type honeycomb fired body 13 is cut has already been described in the description of the above-described (1) extrusion molding step, and therefore description thereof is omitted here.
  • the means for cutting the monolith honeycomb fired body is not particularly limited, but can be cut using a diamond cutter or the like.
  • an adhesive paste for adhering the honeycomb unit 14 is prepared.
  • the adhesive paste for example, a paste made of an inorganic binder, an organic binder, and inorganic particles is used.
  • the adhesive paste may further contain inorganic fibers and / or whiskers.
  • the inorganic particles contained in the adhesive paste include carbide particles and nitride particles. Specific examples include silicon carbide particles, silicon nitride particles, and boron nitride particles. These may be used alone or in combination of two or more. Among the inorganic particles, silicon carbide particles having excellent thermal conductivity are desirable.
  • Examples of the inorganic fibers and / or whiskers contained in the adhesive paste include inorganic fibers and / or whiskers made of silica-alumina, mullite, alumina, silica, and the like. These may be used alone or in combination of two or more.
  • alumina fiber is desirable.
  • the inorganic fiber may be a biosoluble fiber.
  • the balloon is not particularly limited, and examples thereof include an alumina balloon, a glass micro balloon, a shirasu balloon, a fly ash balloon (FA balloon), and a mullite balloon.
  • the outer periphery of the honeycomb structure 1 may be cut to shape the shape of the honeycomb structure 1.
  • the outer periphery of the honeycomb structure 1 may be cut to shape the shape of the honeycomb structure 1.
  • the outer peripheral coat material paste is applied to the outer periphery of the honeycomb structure 1 on the outer periphery of the honeycomb structure 1 and dried and solidified to form the outer peripheral coat layer 16.
  • the said adhesive paste can be used as an outer periphery coating material paste.
  • the outer peripheral coat layer 16 is not necessarily provided, and may be provided as necessary. Further, the outer peripheral coat layer 16 may be provided after the outer periphery of the honeycomb structure 1 is cut into a predetermined shape. By providing the outer peripheral coat layer 16, the mechanical strength of the manufactured honeycomb structure 1 can be improved.
  • the honeycomb structure 1 can be manufactured through the above steps.
  • the catalyst may be supported on the cells 20 of the honeycomb structure 1.
  • a noble metal such as platinum, palladium, rhodium or the like is desirable, and among these, platinum is more desirable.
  • alkali metals such as potassium and sodium, and alkaline earth metals such as barium can be used. These catalysts may be used alone or in combination of two or more. When these catalysts are supported, toxic exhaust gas can be purified.
  • the method for supporting the catalyst is not particularly limited.
  • the honeycomb unit 14 may be immersed in the catalyst-containing solution before the assembly step (6), and then the catalyst may be supported by heating.
  • a sealing step of sealing one end of the cell 20 may be performed.
  • the method for sealing one end of the cell 20 is not particularly limited.
  • a sealing material paste that becomes a sealing material in a predetermined cell 20 of the honeycomb formed body 11 The cell 20 may be sealed by filling.
  • the ceramic raw material can be used as the sealing material paste.
  • the cells 20 may be sealed by filling a predetermined cell 20 of the honeycomb unit 14 with a sealing material paste as a sealing material. Then, you may sinter sealing material paste by degreasing and baking on the same conditions as said (3) degreasing process and (4) baking process.
  • honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention will be described.
  • FIG. 10 (a) is a perspective view schematically showing an example of a honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention.
  • FIG. 10B is a cross-sectional view taken along line BB in FIG.
  • a honeycomb structure shown in FIG. 10 (a) has a plurality of cells 120, one end of which is sealed with a sealing material 118, serving as an exhaust gas flow path, and a porous cell partition wall that defines the cells 120.
  • 130 is a honeycomb filter 101 in which honeycomb units 114 including 130 are assembled via an adhesive layer 115.
  • a peripheral coat layer 116 is formed around the honeycomb filter 101.
  • the honeycomb filter 101 the exhaust gas discharged from the internal combustion engine and flowing into the honeycomb filter 101 (in FIG. 10 (b), the exhaust gas is indicated by G and the flow of the exhaust gas is indicated by an arrow) is the honeycomb filter 101.
  • PM in the exhaust gas is collected by the cell partition wall 130 and the exhaust gas is purified.
  • the purified exhaust gas flows out from the other cells 120 opened in the exhaust gas outflow side end face 101b and is discharged to the outside.
  • the honeycomb filter manufactured by the method for manufacturing a honeycomb structure of the present invention is useful as an exhaust gas treatment body for treating exhaust gas.
  • the cell partition wall 130 preferably has a porosity of 40 to 65%.
  • the porosity of the cell partition wall is 40 to 65%, the cell partition wall 130 can collect PM in the exhaust gas well and suppress an increase in pressure loss caused by the cell partition wall 130. Can do. Therefore, the initial pressure loss is low, and even if PM is deposited, the pressure loss is unlikely to increase.
  • the porosity of the cell partition wall 130 is less than 40%, the ratio of the pores of the cell partition wall 130 is too small, so that the exhaust gas does not easily pass through the cell partition wall 130, and the pressure loss when the exhaust gas passes through the cell partition wall 130 increases. .
  • the porosity of the cell partition 130 exceeds 65%, the mechanical strength of the cell partition 130 is lowered, and cracks are likely to occur during regeneration.
  • the average pore diameter of the pores contained in the cell partition wall 130 is desirably 8 to 25 ⁇ m.
  • PM can be collected with high collection efficiency while suppressing an increase in pressure loss. If the average pore diameter of the pores contained in the cell partition 130 is less than 8 ⁇ m, the pores are too small, and the pressure loss when the exhaust gas permeates the cell partition 130 increases. On the other hand, when the average pore diameter of the pores contained in the cell partition wall exceeds 25 ⁇ m, the pore diameter becomes too large, and the PM collection efficiency is lowered.
  • the porosity and average pore diameter can be measured by mercury porosimetry.
  • the honeycomb structure manufactured by the method for manufacturing a honeycomb structure of the present invention can be used as a honeycomb catalyst for purifying exhaust gas by supporting a catalyst on a cell partition wall without sealing one of the cells. it can.
  • the exhaust gas can be purified by the catalyst when the exhaust gas passes through the cell.
  • Example 1 Preparation of ceramic raw material 52.8% by weight of silicon carbide coarse powder having an average particle size of 22 ⁇ m and 22.6% by weight of fine powder of silicon carbide having an average particle size of 0.5 ⁇ m To the resulting mixture, 4.6% by weight of organic binder (methyl cellulose), 0.8% by weight of lubricant (Unilube manufactured by NOF Corporation), 1.3% by weight of glycerin, pore former ( Acrylic resin) 1.9 wt%, oleic acid 2.8 wt%, and water 13.2 wt% were added and mixed to prepare a ceramic raw material.
  • organic binder methyl cellulose
  • lubricant Unilube manufactured by NOF Corporation
  • glycerin glycerin
  • pore former Acrylic resin
  • the honeycomb formed body was formed to be a cylinder having a bottom diameter of 145.0 mm and a length in the longitudinal direction of 150.0 mm.
  • the extruded honeycomb formed body includes a cutting cell and a functional cell, and the cutting cell is formed by dividing a circle having a cross-sectional shape perpendicular to the longitudinal direction of the honeycomb formed body into four equal parts in the longitudinal direction and in the lateral direction. It was made to arrange in the position which divides into 4 equally.
  • the cross-sectional shape of the functional cell was a square having a side of 1.7 mm.
  • the cell density of the cutting cells arranged in the cutting region was 15.5 cells / cm 2 (100 cpsi).
  • the cell density of the functional cells arranged in the functional region was 31 cells / cm 2 (200 cpsi).
  • the thickness of the cell partition wall for forming the cutting cell and the cell partition wall for forming the functional cell was 0.203 mm.
  • the honeycomb degreased body was fired under conditions of 2200 ° C. and 2 hours and 40 minutes under an atmospheric pressure of argon atmosphere to produce a monolith type honeycomb fired body.
  • the monolith type honeycomb fired body had a porosity of 45% and an average pore diameter of 15 ⁇ m.
  • Outer peripheral coat layer forming step Next, the outer periphery of the honeycomb structure was cut to shape the shape of the honeycomb structure. Thereafter, an outer peripheral coating material paste having the same composition as the adhesive paste was applied to the outer peripheral surface of the honeycomb fired body aggregate, and the outer peripheral coating material paste was dried and solidified at 120 ° C. to form an outer peripheral coating layer.
  • Comparative Example 1 Comparative example as in Example 1 except that the above “(1-2) extrusion molding” was changed to the following “(1-2 ′) extrusion molding” and the above “(5) cutting step” was not performed. A honeycomb structure according to No. 1 was produced.
  • FIGS. 11A to 11C are perspective views schematically showing a honeycomb formed body formed by extrusion molding in the method for manufacturing a honeycomb structure of Comparative Example 1.
  • 11A has a size of 34.3 mm ⁇ 34.3 mm ⁇ 150 mm, a cross-sectional shape perpendicular to the longitudinal direction of the cell, a square having a side of 1.7 mm, and a cell density of 31.
  • Piece / cm 2 (200 cpsi), and the thickness of the cell partition wall was 0.203 mm.
  • 11 (b) and 11 (c) have a shape obtained by cutting a part of the honeycomb formed body 81a, and have four honeycomb formed bodies 81a, eight honeycomb formed bodies 81b, and 4 When the two honeycomb molded bodies 81c were combined, the bottom surface had a diameter of 137.2 mm and a length in the longitudinal direction of 150.0 mm.
  • the outer periphery of the honeycomb structure is not affected even when chipping occurs on these side surfaces when carrying the honeycomb formed body, the honeycomb degreased body, and the honeycomb fired body between the steps. Since the shape of the honeycomb structure was cut and the outer peripheral coat layer was formed, it was possible to obtain a good product.
  • the method for manufacturing a honeycomb structure of Comparative Example 1 when carrying out the honeycomb formed body, the honeycomb degreased body, and the honeycomb fired body between the respective steps, it is possible to recover when chipping occurs on these side surfaces. It was not possible and became a defective product.

Abstract

La présente invention concerne un procédé de fabrication d'une structure en nid d'abeilles permettant d'empêcher la formation de fissures provoquées par le contact entre les unités en nid d'abeilles qui constituent la structure en nid d'abeilles, lors de la fabrication d'une structure en nid d'abeilles au cours de laquelle sont assemblées de multiples unités en nid d'abeilles. Ce procédé de fabrication d'une structure en nid d'abeilles permet de fabriquer une structure en nid d'abeilles dans laquelle sont assemblées de multiples unités en nid d'abeilles, lesdites unités en nid d'abeilles comprenant du carbure de silicium comportant de multiples cellules qui sont destinées à être des canaux pour les gaz d'échappement et des cloisons cellulaires poreuses qui délimitent les cellules. Ce procédé de fabrication d'une structure en nid d'abeilles comprend : une étape de moulage par extrusion consistant à mouler par extrusion une matière première céramique comprenant du carbure de silicium pour former un moulage en nid d'abeilles ; une étape de dégraissage consistant à dégraisser le moulage en nid d'abeilles pour former un corps en nid d'abeilles dégraissé ; une étape de cuisson consistant à cuire le corps en nid d'abeilles dégraissé pour former un corps cuit en nid d'abeilles monolithique ; une étape de coupe consistant à couper le corps cuit en nid d'abeilles monolithique selon une direction parallèle à la direction longitudinale pour former de multiples unités en nid d'abeilles ; et une étape d'assemblage consistant à assembler les multiples unités en nid d'abeilles par l'intermédiaire de couches adhésives pour former une structure en nid d'abeilles. Le moulage en nid d'abeilles formé au cours de l'étape de moulage par extrusion comprend, dans une section transversale verticale par rapport à la direction longitudinale, des zones de coupe qui sont destinées à être coupées au cours de l'étape de coupe et des zones fonctionnelles autres que les zones de coupe.
PCT/JP2015/075448 2014-09-08 2015-09-08 Procédé de fabrication d'une structure en nid d'abeilles WO2016039331A1 (fr)

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US10538483B2 (en) 2016-03-18 2020-01-21 Nippon Shokubai Co., Ltd. Process for producing alkanolamine

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0691632A (ja) * 1992-09-10 1994-04-05 Ibiden Co Ltd セラミックス成形体の切断方法
JPH0828246A (ja) * 1994-07-14 1996-01-30 Ibiden Co Ltd セラミック構造体
JP2009006326A (ja) * 2002-03-29 2009-01-15 Ibiden Co Ltd セラミックフィルタおよび排ガス浄化装置

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0691632A (ja) * 1992-09-10 1994-04-05 Ibiden Co Ltd セラミックス成形体の切断方法
JPH0828246A (ja) * 1994-07-14 1996-01-30 Ibiden Co Ltd セラミック構造体
JP2009006326A (ja) * 2002-03-29 2009-01-15 Ibiden Co Ltd セラミックフィルタおよび排ガス浄化装置

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