CN100544806C - The manufacture method of formed honeycomb structure - Google Patents

Abstract

The manufacture method of The invention provides the manufacture method that effectively to use the formed honeycomb structure that is filled into the shaping raw material in the forming machine. formed honeycomb structure of the present invention is to have disposed formed honeycomb structure shaping crown cap an end, (3) shaping raw material pipeline, (2) shaping raw material is filled in inside, (5); The shaping raw material (5) of filling is shaped from formed honeycomb structure to be squeezed out and is shaped to obtain the manufacture method of the formed honeycomb structure of formed honeycomb structure (10) with crown cap (3), be near the inner formed honeycomb structure of shaping raw material pipeline (2) is shaped with crown cap (3), dispose for the screen pack (4) of the contained foreign matter of filtration shaping raw material (5) and be lowered into shape raw material pipeline (2) inner face and shaping raw material (5) between the operation of frictional resistance to obtain the formed honeycomb structure manufacture method of formed honeycomb structure (10).

Description

Manufacturing method of formed honeycomb body

technical field

The present invention relates to a method for producing a formed honeycomb body. More specifically, it relates to reducing the influence of the boundary portion of the molding raw material filled first and the molding raw material filled later on the molding in the case of subsequently adding the molding raw material to perform molding as the molding raw material filled into the molding machine decreases. A method of manufacturing a honeycomb formed body that can effectively use the forming raw material filled in the forming machine.

Background technique

As a filter (diesel particulate filter (DPF)) for trapping and removing particulate matter contained in dusty fluids such as diesel engine exhaust, or as a catalyst component for carrying and purifying harmful substances in exhaust gas ( As the catalyst carrier for purifying exhaust gas, a formed honeycomb body having partition walls forming a composite of a plurality of adjacent cells is widely used.

Such a honeycomb structure is produced by molding a forming raw material containing ceramics or the like into a honeycomb shape to obtain a honeycomb formed body, and firing the honeycomb formed body.

When forming the forming raw material to obtain the honeycomb formed body, for example, the forming raw material containing ceramics is filled into the forming raw material pipe of the molding machine, and the honeycomb forming machine is arranged from the end of the forming raw material pipe side. A method of extruding a metal cap for body molding (for example, Patent Document 1, JP-A-53-21209).

Examples of methods for extrusion molding the formed honeycomb body include piston-type or plunger-type extrusion, connection, or continuous extrusion.

As shown in Figure 7, a mixer 35 for piston-type or plunger-type extrusion is used to mix predetermined raw materials and water, then mix with a mud mill 33, etc., and then prepare the molding raw material 25 by vacuum mud refining, as shown in Figure 8 ( a) and FIG. 8(b), make the obtained predetermined amount of molding material 25 consistent with the size of the molding material pipe 22 (the inner diameter of the molding material pipe 22), and make a cylindrical clay-like block with a predetermined length. The filling molding raw material 25a is filled into the molding raw material pipe 22 constituting the molding machine 21, and the metal cover for forming the honeycomb formed body is formed by using the plunger 31 for squeezing the filled molding raw material 25. 23 extruded and shaped.

In such a conventional method for producing a formed honeycomb body, in order to efficiently manufacture the formed honeycomb body 30 from one forming material 25a for filling, first, the forming material used for the honeycomb structure, for example, obtains a honeycomb The molding raw material 25 a for filling is filled into the molding raw material pipe 22 with a sufficiently large volume of the shaped body 30 .

Therefore, the forming raw material pipe 22 for the forming raw material of the honeycomb structure consists of a cylinder 26 having a larger outer diameter than the manufactured formed honeycomb body 30 and a pipe for extruding into the formed honeycomb body 30 when the forming raw material 25 is extruded. The barrel body 27 has a large and small size (for example, a reduced barrel), and the filling molding material 25a has a larger outer diameter than the formed honeycomb body 30 and has a longer length in the extrusion direction of the molding material used for the honeycomb structure.

The junction of the cylinder 26 and the barrel 27 is provided with a filter 24 for filtering the coarse foreign matter that must be included in the forming material 25 .

The filter 24 is held by the holding portion 36 so as to withstand the pressure when the raw material 25 is extruded, and has a large thickness in the extruding direction.

A sheet-shaped metal mesh is used for the filter 24, and a disc-shaped metal perforated plate having a plurality of through holes is used for the holding part 36 thereof.

Moreover, recently, in order to meet the needs of heavy-duty diesel trucks, it is necessary to form a honeycomb formed body with a large cross-sectional area, and the barrel body 27 is enlarged toward the metal cover 23 for forming a honeycomb formed body to manufacture a larger honeycomb shape. Formed body 30 .

In addition, in the conventional manufacturing method of the formed honeycomb body using the continuous molding method, although not shown in the figure, it is a method in which each process from mixing to kneading, kneading, and extrusion molding is continuously performed in a single device. method.

The cylinder used in the manufacturing method of the existing honeycomb formed body has a long structure in the extrusion direction, and even if the size of the manufactured honeycomb formed body changes, the cylinder is fixed without changing, so that the molding for filling The size of the ingredients is also fixed.

For example, in the case of changing the outer diameter of the formed honeycomb body, for example, when it is smaller than the inner diameter of the cylinder, the cylinder and the metal cover for forming the honeycomb body are connected by reducing the barrel body. In addition, For example, if the inner diameter of the cylinder is larger than the inner diameter of the cylinder, the cylinder and the metal cover for forming the formed honeycomb body are connected to expand the barrel.

In this way, since the length of the extrusion direction of the barrel that acts to narrow or expand the path avoids sharply shrinking or expanding and becomes as gentle as possible, the angle formed between the inside of the barrel and the extrusion direction is determined by the filled forming raw material. The relationship between the outer diameter and the outer diameter of the obtained honeycomb forming is determined. Usually, the length of the extrusion direction of the barrel is long enough, which is roughly twice the length of the inner diameter of the filled forming raw material (also in the case of the inner diameter of the cylinder). .

Therefore, in the conventional manufacturing method of the formed honeycomb body, since the plunger for extruding the molding raw material can only be pressed to the front of the barrel body, the molding raw material remains inside the barrel body.

In the manufacturing method of the existing formed honeycomb body shown in Fig. 8 (a) and Fig. 8 (b), although the filter screen 24 is held by the holding part 36 on the junction of the cylinder body 26 and the barrel body 27, but in this The molding raw material 25 constricts and changes in pressure in the holding portion 36 .

Moreover, since the holding portion 36 has a thick structure in the extrusion direction to ensure the strength of the structure, when the forming material 25 passes through the filter 24, the pressure on the forming material changes within the thickness range of the holding portion 36.

In particular, when the molding is stopped, the characteristics of the molding raw material 25 are changed by the vena contracta portion of the molding raw material 25 .

In the case of restarting molding and extruding the vena contracta portion of the molding raw material 25, the obtained formed honeycomb body 30 is bent and has molding defects, so the formed honeycomb body 30 formed including this portion cannot be used as a product. .

This phenomenon occurs regardless of piston (plunger) extrusion or connecting (continuous) extrusion.

For example, when filling new molding raw material 25 with the reduction of filled molding raw material 25, once it is necessary to stop molding and fill new filling molding raw material 25, a contraction of the molding raw material 25 occurs inside the molding raw material pipeline 22. When molding is stopped in this state, the properties of the molding material 25 change.

In addition, when new filling molding raw material 25 is filled and molding is resumed, since previous molding raw material 25b remains inside filter screen 24, barrel body 27, and metal cover 23 for forming honeycomb formed body, the remaining molding raw material 25b A boundary portion 28 is formed between the new forming raw material 25 a and the boundary portion 28 remains inside the formed honeycomb formed body 30 .

Such a boundary portion 28 is discontinuous as the forming raw material 25, and voids or the like are easily formed in the formed body.

The shrinkage of the forming material 25 inside the barrel 27 causes a change in the characteristics of the forming material and a change in the velocity distribution of the forming material 25 in a vertical section with respect to the extrusion direction, the velocity distribution of the forming material 25 depicting a parabola.

The boundary portion 28 between the molding raw material 25b remaining in the molding raw material pipeline 22 and the newly filled molding raw material 25a gradually becomes a parabolic shape with the flow of the molding raw material 25 inside the barrel body 27, and is distributed longer in the extrusion direction. , Therefore, a plurality of formed honeycomb bodies 30 will be affected.

In this way, in the conventional manufacturing method of the honeycomb formed body, when the molding raw material 25a is added afterward and the molding is performed as the molding raw material 25 filled in the molding machine 21 decreases, the molding raw material 25b filled earlier is included. The molded body of the boundary portion 28 with the post-filled molding material 25a cannot be used as a plurality of products, so there is a problem that the molding material 25 is wasted until all the molding material 25 including the boundary portion 28 is extruded.

Moreover, in continuous extrusion molding, since there is no need to post-fill such molding raw materials, the boundary portion of the raw materials will not be formed. However, since the kneading process is completed by the built-in screw, the kneading of the molding raw materials is insufficient. , It is difficult to give the molding raw material viscosity. In order to improve the viscosity and ensure the formability, in order to strengthen the kneading function, there is a problem that it is necessary to increase the equipment capacity and add excess binder to the molding raw material, thereby increasing the cost.

In addition, as the outer diameter of the formed honeycomb increases, there is a problem of enlarging the size of the equipment in order to secure the extrusion pressure.

Contents of the invention

The present invention has been made in view of such a state of the art, and provides a method of manufacturing a honeycomb formed body in which molding raw materials are added for subsequent molding as the molding raw materials filled in the molding machine decrease. In this way, the influence of the boundary portion of the molding raw material filled first and the molding raw material filled later on the molding can be reduced, and the molding raw material filled into the molding machine can be effectively used.

The present invention provides the following method for producing a formed honeycomb body.

(1) A method of manufacturing a formed honeycomb body, comprising filling a forming material pipe with a metal cover for forming a formed honeycomb body at one end thereof with a forming material, and dispensing the filled forming material from the formed honeycomb body A method for manufacturing a formed honeycomb body obtained by extruding a metal cover for molding to obtain a formed honeycomb body, wherein a filter for filtering foreign substances contained in the above-mentioned forming raw material is disposed near the metal cover for forming the formed honeycomb body inside the forming material pipeline. A method of manufacturing a formed honeycomb body by performing an operation of reducing the frictional resistance between the inner surface of the forming material pipe and the forming material to obtain the above formed honeycomb formed body.

(2) The method for producing a formed honeycomb body according to (1) above, wherein the filter is arranged at a position where the distance from the metal cover for forming the formed honeycomb body is twice the inner diameter of the forming raw material pipe or less. superior.

(3) According to the manufacturing method of the formed honeycomb body described in the above (1) or (2), the operation of reducing the frictional resistance between the inner surface of the forming material pipe and the forming material is performed between the inner surface of the forming material pipe and the forming material. The operation of disposing lubricating oil or lubricating material between them, and/or the modification operation of the surface properties of the inner surface of the above-mentioned forming raw material pipeline.

(4) The method for manufacturing the formed honeycomb body according to any one of the above (1)-(3), wherein the inner diameter of the forming raw material pipeline is changed from the position where the filter net is arranged to the position where the formed honeycomb body is arranged. The above-mentioned forming raw material pipe expanded by the above-mentioned one end portion of the metal cap is used for extrusion molding.

(5) The method for producing a formed honeycomb article according to any one of (1) to (3) above, wherein the forming raw material pipe is used in which the inner diameter of the forming raw material pipe is reduced toward the one end and then enlarged. to extrude.

(6) The method for producing a formed honeycomb body according to any one of (1) to (3) above, wherein the plunger extrusion molding of extruding the forming raw material using a plunger for extruding the forming raw material In this method, the above-mentioned forming raw material pipe whose inner diameter is substantially the same as the outer diameter of the extruded formed honeycomb body is extruded.

(7) According to the manufacturing method of the formed honeycomb body described in any one of the above-mentioned (1)-(6), the above-mentioned forming raw material in an amount equivalent to one of the above-mentioned formed honeycomb bodies is filled into the above-mentioned forming raw material pipe and extruded. Press forming.

According to the manufacturing method of the honeycomb formed body of the present invention, in the case where the molding raw material is subsequently added for molding as the molding raw material filled into the molding machine decreases, the molding raw material filled first and the molding raw material filled later can be reduced. The influence of the boundary part of the raw material on the molding, and the molding raw material filled into the molding machine can be effectively used.

In addition, when the molding process is stopped, the influence of the shrinkage of the molding material such as the filter installed inside the molding material pipeline of the molding machine can be reduced, and when the molding is restarted, it can be restored more quickly. take shape.

Description of drawings

FIG. 1( a ) is an explanatory view showing an example of a step of extrusion molding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 1(b) is an explanatory view showing an example of a step of extrusion molding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 2(a) is an explanatory view showing another example of the step of extruding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 2(b) is an explanatory view showing another example of the step of extruding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 3 is an explanatory view showing another example of the process of extrusion molding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 4 is an explanatory diagram showing another example of the process of extrusion molding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 5(a) is an explanatory view showing an example of a step of extrusion molding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 5(b) is an explanatory view showing an example of a step of extrusion molding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 5(c) is an explanatory view showing an example of a process of extrusion molding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 6(a) is an explanatory view showing another example of the step of extruding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 6(b) is an explanatory view showing another example of the step of extruding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

Fig. 7 is an explanatory view showing a step of obtaining a molding raw material for filling of a conventional honeycomb formed body.

Fig. 8(a) is an explanatory diagram showing the process of extruding a molding raw material of a conventional honeycomb formed body.

Fig. 8(b) is an explanatory diagram showing the process of extruding a molding raw material of a conventional honeycomb formed body.

In the picture:

1-forming machine, 2-forming raw material pipeline, 3-metal cover for forming honeycomb shaped body, 4-screw, 5, 5a, 5b-forming raw material, 6-cylinder, 7, 7a, 7b-barrel, 8 -Boundary part, 10-Honeycomb forming body, 11-Plunger, 12-Forming raw material pipeline, 13-Mud mixer, 15, 15a, 15b-Forming raw material, 16-Holding part, 21-Forming machine, 22-Forming Raw material pipeline, 23-metal cover for honeycomb forming body, 24-screw, 25, 25a, 25b-forming raw material, 26-cylinder, 7-barrel, 28-boundary part, 30-honeycomb forming body, 31 - Plunger, 33 - Mud mixer, 35 - Mixer, 36 - Holder.

Detailed ways

Although the embodiment of the manufacturing method of the honeycomb formed body of the present invention will be described in detail below with reference to the drawings, the present invention is not limited thereto, and various changes can be made according to the knowledge of those skilled in the art without departing from the scope of the present invention. , modify, improve.

FIG. 1( a ) and FIG. 1( b ) are explanatory views schematically showing an example of a step of extrusion molding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

The manufacturing method of the formed honeycomb body of this embodiment is a method of manufacturing a formed honeycomb body which can be realized using the forming machine 1 shown in FIG. 1( a ) and FIG. 1( b ).

The molding machine 1 is a plunger type molding machine including a cylindrical body 6 and a barrel 7 constituting a molding raw material pipe 2, a metal cover 3 for forming a honeycomb formed body, a filter 4, and a plunger 11 for extruding a raw material.

In the manufacturing method of the formed honeycomb body of this embodiment, the molding material 5 is filled inside the forming material pipe 2 in which the metal cover 3 for forming the formed honeycomb body is disposed on one end, and the filled forming material 5 is removed from the formed honeycomb body. The manufacturing method of the formed honeycomb body obtained by extruding the formed metal cover 3 to obtain the formed honeycomb body 10 is to arrange a filter for filtering the formed material 5 in the vicinity of the formed metal cover 3 for forming the formed honeycomb body inside the forming material pipe 2 . A method of manufacturing a formed honeycomb body 10 by filtering the filter 4 containing foreign matter and performing an operation of reducing the frictional resistance between the inner surface of the forming material pipe 2 and the forming material 5 to obtain the formed honeycomb body 10 .

The formed honeycomb body 10 obtained by the method for producing the formed honeycomb body of the present embodiment is a cylindrical formed body in which a plurality of through holes are formed by partitioning.

By firing the obtained formed honeycomb body 10, a honeycomb structure suitable for use as, for example, a filter for dust removal and water treatment, and a catalyst carrier for exhaust gas purification can be obtained.

According to the manufacturing method of the formed honeycomb article of this embodiment, for example, the forming raw material 5 stagnating in and around the screen 4 and changing its characteristics once the forming is stopped will be squeezed faster when the forming is resumed. Therefore, the influence on the shaped formed honeycomb body 10 can be eliminated at an early stage, and the return to the normal shape can be achieved more quickly.

Furthermore, in the case of subsequently adding the molding raw material 5a to perform molding as the molding raw material 5b filled into the molding machine 1 decreases, the boundary portion 8 of the molding raw material 5b filled first and the molding raw material 5a filled later can be reduced influence on molding, and the molding raw material 5 filled in the molding machine 1 can be effectively used.

In the existing manufacturing method of the formed honeycomb body, as shown in Fig. 8(a) and Fig. 8(b), the forming raw material pipeline 22 consists of a cylinder 26 with a larger outer diameter than the manufactured formed honeycomb body 30 and a When the raw material 25 is extruded, it is composed of a barrel body 27 (such as a reduced barrel) that is squeezed into the size of the honeycomb formed body 30 , and the filter screen 24 is held by the holding portion 36 on the boundary between the cylindrical body 26 and the barrel body 27 .

The cylinder 26 used in the conventional manufacturing method has a relatively long structure. Even if the size of the formed honeycomb body 30 to be manufactured changes, the cylinder 26 remains unchanged, and thus the size of the molding material 25a for filling is also fixed.

For example, in the case of changing the outer diameter of the formed honeycomb body 30, for example, in the case of a smaller inner diameter than the cylinder 26, between the cylinder 26 and the metal cover 23 for forming the honeycomb body to narrow the barrel body 27 connection, and, for example, although not shown, but in the case of larger than the inner diameter of the cylinder, between the cylinder and the metal cover for forming the formed honeycomb body to expand the barrel connection.

Therefore, in the existing manufacturing method of formed honeycomb body, as shown in Fig. 8 (a) and Fig. 8 (b), because the plunger 31 of extruding molding raw material 25 can only be pressed before barrel body 27, so molding raw material 25b remains Inside the barrel body 27.

Therefore, in the conventional manufacturing method, the amount of molding raw material 25 remaining inside the molding raw material pipe 22 is large, and the boundary portion 28 between the molding raw material 25b filled first and the molding raw material 25a filled later has a great influence on molding, and The boundary portion 28 spans a plurality of formed honeycomb bodies 30, and much forming raw material 25 is wasted.

Furthermore, in the existing method for manufacturing a formed honeycomb body, the frictional resistance between the inner surface of the barrel body 27 and the forming material 25 is large, and the extrusion speed of the forming material 25 in the central part of the forming material pipeline 2 becomes fast. Expanding into a parabolic shape, more molding raw material 25 is wasted.

As shown in FIG. 1( a ) and FIG. 1( b ), in the manufacturing method of the formed honeycomb body of the present embodiment, a filter is arranged near the metal cover 3 for forming the formed honeycomb body inside the forming raw material pipe 2 . 4. The formed honeycomb body 10 can be obtained by reducing the frictional resistance between the inner surface of the forming raw material pipeline 2 and the forming raw material 5, which can solve the problems of the above-mentioned existing manufacturing technology, and can reduce the number of forming raw materials 5b filled first and the latter. The boundary portion 8 between the filled molding raw materials 5 a has an influence on molding and can effectively use the molding raw materials 5 filled in the molding machine 1 .

In the manufacturing method of the formed honeycomb body of the present embodiment, the forming raw material pipeline 2 is composed of a cylinder 6 and a barrel 7, and the filter screen 4 is disposed closer to the formed honeycomb body than the boundary between the cylinder 6 and the barrel 7. Inside the barrel body 7 of the metal lid 3 for forming.

For the position where the filter screen 4 is arranged, it is arranged near the metal cover 3 for forming the formed honeycomb body, so that the amount of the forming raw material 5b remaining inside the barrel 7 can be reduced compared with the conventional manufacturing method. Although there is no particular limitation, For example, it is desirable to dispose the filter screen 4 at a distance from the metal cover 3 for forming the honeycomb formed body that is twice or less than the inner diameter of the forming raw material pipe 2, specifically, twice or less than the inner diameter of the cylinder 6. position.

With this configuration, after the molding raw material 5b is squeezed to the position of the filter 4 installed inside the molding raw material pipe 2, when filling the new molding raw material 5a in the molding raw material pipe 2, it is possible to effectively reduce the molding time of post-filling. The influence of the boundary portion 8 between the raw material 5a and the remaining molding raw material 5b on molding.

In addition, although it is not particularly limited, it is desirable to set the distance between the filter screen 4 and the metal cover 3 for forming the formed honeycomb body at 2/3 or less of the distance in the conventional method for producing the formed honeycomb body, and most preferably Preferably 1/2 or less.

In addition, in the manufacturing method of the formed honeycomb body of this embodiment, the filter 4 can be arranged near the metal cover 3 for forming the formed honeycomb body by shortening the length of the barrel body 7 in the extrusion direction.

The effect of shrinkage or enlargement of the forming material pipeline 2 in the barrel 7 is the change in the properties of the forming material and the change in the velocity distribution of the forming material produced by the volumetric compression or expansion of the forming material 5 in the section of the forming material pipeline 2 .

In the case of shortening the length of the barrel 7 in the extrusion direction as described above, although the reduction or expansion of the forming raw material pipeline may become more serious, the influence on the formability will also become greater, but carefully study the forming method. In the range of the current extrusion molding speed, not only has it been fully confirmed by experiments that there is no substantial influence on the formability, but it can also be realized by clarifying the lower limit of the length of the barrel body 7 and optimizing it.

In the existing method for manufacturing a formed honeycomb body, as shown in FIG. 8( a), generally, the length of the barrel body 27 in the extrusion direction is equal to the outer diameter of the forming raw material 25a for filling (compared with the cylindrical body forming the forming raw material pipeline 22). 26 is twice or more than the inner diameter of the same meaning), for example, when the outer diameter of the molding material 25a for filling is about 300mm, the length of the barrel body 27 is 600mm or more, and from the filter screen 24 to the honeycomb The distance from the inner side of the metal cover 23 for forming a molded body is also 600 mm or more.

In the manufacturing method of the honeycomb formed body of this embodiment, by concentrating on the length of the extruding direction of the barrel body 27 which appears to be slightly long in the prior art, for example, as shown in Fig. 1(a) and Fig. 1(b) When the outer diameter of the forming raw material 25a for filling is about 300 mm, the length of the barrel body 7 is 400 mm or less, for example, 400-300 mm, and the inner side of the metal cover 3 from the filter screen 4 to the formed honeycomb body is formed. The distance can be a length of 400-300mm shorter than existing manufacturing methods.

In addition, although illustration is omitted, the case of using a connecting type forming machine is the same, and the filter can be arranged near the metal cover for forming the formed honeycomb body.

In the connection type molding machine, although the rotation of the built-in screw is used to extrude the molding material instead of the plunger, the inner diameter of the molding material pipe at the tip of the screw part is equivalent to the outer diameter of the plunger type molding material.

A barrel is arranged between the front end of the screw part and the metal cover for forming the formed honeycomb body, and a filter net is arranged between the front end of the screw part and the barrel.

Furthermore, although the operation of reducing the frictional resistance between the inner surface of the forming material pipe 2 and the forming material 5 is not particularly limited as long as it is a method for effectively reducing the frictional resistance between the inner surface of the forming material pipe 2 and the forming material 5, there are, however, examples For example, disposing lubricating oil or a lubricating material between the inner surface of the forming material pipe 2 and the forming material 5 and/or modifying the surface properties of the inner surface of the forming material pipe 2 are taken as suitable examples.

The manufacturing method of this embodiment will be described in more detail below.

In the manufacturing method of the formed honeycomb body of this embodiment, first, the molding raw material 5 for extrusion-molding the formed honeycomb body 10 is prepared.

The method of preparing the molding raw material 5 can be carried out according to the preparation method of the molding raw material 5 in the conventional manufacturing method of the honeycomb formed body.

For example, there may be mentioned a method of mixing predetermined raw material powder and water with a mixer, kneading with a kneader, followed by vacuum kneading and preparation.

Furthermore, the material of the forming raw material 5 can be appropriately selected according to the formed honeycomb article 10 to be obtained.

For example, in order to obtain the formed honeycomb body 10 used for purifying automobile exhaust, cordierite ceramics excellent in heat resistance and low thermal expansion coefficient can be suitably used as the main material of the forming material 5 .

The cordierite-based ceramics are preferably 0-20% by mass of kaolin (Al ₂ O ₃ .2SiO ₂ .2H ₂ O) with an average particle size of 5-10 μm, and talc (3MgO 4SiO ₂ . H ₂ O) 37-40% by mass, 15-45% by mass of aluminum hydroxide with an average particle size of 1-10 μm, 0-15% by mass of alumina with an average particle size of 4-8 μm, fused dihydrogen oxide with an average particle size of 3-100 μm The composition of 15-45% by mass of silicon oxide or quartz is the main raw material.

In addition, as a molding material, not only the above-mentioned cordierite ceramics, but also those made of alumina, mullite, spinel, aluminum titanate, titanium dioxide, zirconia, silicon nitride, aluminum nitride, and LAS can be suitably used. (lithium aluminosilicate) selected one or their composites, as well as adsorption materials such as stainless steel, aluminum alloy, activated carbon, silica gel and zeolite.

In addition, desired additives may be added to the molding raw material 5 used in the manufacturing method of the honeycomb formed article of this embodiment as needed.

Examples of the additive include a binder, a dispersant for promoting diffusion into the medium liquid, a pore-forming material for forming pores, and the like.

As the binder, for example, hydroxypropylmethylcellulose, methylcellulose, hydroxyethylcellulose, carboxymethylcellulose, polyvinyl alcohol, polyethylene terephthalate, etc.; Agents can include, for example, glycol, dextrin, fatty acid soap, polyhydric alcohol, etc.; As the pore-forming material used, examples can be mentioned, such as graphite, coke, wheat flour, starch, foaming resin, water-absorbing resin, phenolic resin, Polyethylene terephthalate, fly ash balls, silicon balls, silica gel, alumina gel, organic fibers, inorganic fibers, carbon fibers, solid or hollow fibers of these materials, etc.

These additives can be used alone or in combination of two or more depending on the purpose.

The molding raw material 5 is usually mixed with 10-40 parts by mass of water to 100 parts by mass of the mixed raw material powder of the above-mentioned main raw material and additives if necessary, and then kneaded to form a plastic mixture.

Each raw material may be classified or passed through a sieve to remove coarse particles prior to mixing.

Furthermore, since agglomeration of raw material particles is eliminated during mixing, it is desirable to adopt a mixing method that improves the degree of dispersion.

In addition, water may be added when mixing the respective raw material powders.

Then, the forming raw material 5 of gained predetermined amount is dropped in the vacuum puddling machine, mixes and adds with screw screw while exhausting, and the inner diameter of forming raw material pipeline 2 (the inner diameter of the cylinder 6 that constitutes forming raw material pipeline) Consistently, it is divided into the molding material 5a for filling which is a cylindrical clay-like mass of a predetermined length.

In the method for manufacturing the formed honeycomb article of the present embodiment, the outer diameter of the filling forming material 5 a is preferably formed to be slightly smaller than the inner diameter of the forming material pipe 2 .

In addition, the outer diameter of the molding raw material 5a for filling can be changed variously according to the inner diameter of the front-end metal port attached to the front-end|tip of a vacuum mud mill.

In the method for manufacturing the formed honeycomb body of the present embodiment shown in Fig. 1(a) and Fig. 1(b), in order to continuously extrude a plurality of formed honeycomb bodies 10 from one molding raw material 5a for filling, obtain Filling molding raw material 5 a having a volume sufficiently larger than the volume of the honeycomb formed body 10 to be produced.

In addition, the inner diameter of the forming raw material pipe 2 of the forming machine 1 used can be determined according to the outer diameter of the formed honeycomb body 10 to be produced and the like.

For example, the outer diameter of the formed honeycomb body 10 is in a wide range of about 50-300 mm.

The formed honeycomb body 10 having an outer diameter of about 50 to 200 mm is generally used as a formed honeycomb body for exhaust gas purification of passenger cars and small trucks with a small engine exhaust capacity.

As the exhaust capacity of the engine increases, the size of the outer diameter of the formed honeycomb body 10 also increases, and its length also becomes longer.

The formed honeycomb body 10 having an outer diameter of about 200 mm or more is generally used as a formed honeycomb body for exhaust purification of large vehicles such as diesel trucks and buses with a large displacement.

Next, the thus obtained molding raw material 5 a for filling is filled into the cylindrical body 6 of the molding raw material pipe 2 .

The forming raw material pipeline 2 is composed of a cylindrical body 6 and a barrel body 7, and the barrel body 7 is connected to the metal cover 3 for forming the honeycomb shaped body.

In addition, the filter 4 is arranged inside the barrel 7 closer to the metal cover 3 for forming the formed honeycomb body than the boundary between the cylindrical body 6 and the barrel 7 .

A sheet-shaped metal mesh can be used as the filter 4, and it is held by the holding|maintenance part 16 of the disc-shaped metal perforated plate which has many through-holes.

In addition, in the method for manufacturing the formed honeycomb article of the present embodiment, the operation of arranging lubricating oil or a lubricating material between the inner surface of the forming material pipe 2 and the forming material 5 and/or the modification of the surface properties of the inner surface of the forming material pipe 2 are performed. In operation, etc., the difference in the extrusion speed of the molding material 5 between the central part and the outer peripheral part of the molding material pipe 2 is reduced, and the range of the boundary part 8 generated when the molding material 5 is added later is reduced.

The above lubricating oil preferably contains at least one selected from the group consisting of various commercially available synthetic lubricating oils, hydrocarbons, petroleum oils, and edible oils as the main component.

In addition, examples of petroleum-based oils include kerosene and light oil, and examples of edible oils include rapeseed oil, soybean oil, corn oil, olive oil, and sesame oil.

In addition, the lubricating material preferably contains at least one selected from the group consisting of black lead, graphite, coke, carbon fiber, and molybdenum disulfide as the main component.

These lubricating oils and lubricating materials may also be used in combination.

In addition, such lubricating oil and lubricating material have the effect of preventing the outer surface of the molding material 5 from drying.

Various anti-drying agents and preservatives, PH stabilizers, etc. can also be added.

As the modification operation of the surface properties of the inner surface of the forming raw material pipe 2, it is an operation to smooth the surface roughness (Ra, Rmax, Ry, Rz, etc.) and surface characteristics quantified by fluctuations, and to reduce surface tension, and to improve wear resistance. Operations on both loss and friction characteristics.

Specifically, when the inner surface of the barrel body 7 is machined, a method of reducing the processing streaks in the circumferential direction by performing lathe cutting with a turning tool can be mentioned, and it can be ground by a grindstone as a surface finish after the cutting. Or grinding to achieve.

In addition, it can also be realized by the method of sandblasting.

Since the barrel body 7 is usually made of metal materials such as steel, stainless steel, titanium, etc., it is desirable to apply various heat treatments and surface hardening treatments to improve wear resistance.

In addition, ceramic materials such as alumina, zirconia, and silicon nitride, and non-metallic materials such as alloy ceramics can also be used.

In addition, various coating treatments such as hard chrome plating treatment can be performed on the machined surface.

In order to improve lubricity, it is desirable to have a composite coating in which dispersed material particles such as hexagonal boron nitride, molybdenum disulfide, and tungsten disulfide are uniformly dispersed in a coating matrix such as nickel (Ni).

In addition, sulfurizing treatment, sulfurizing and nitriding treatment, ion implantation treatment, CVD treatment, PVD treatment, sublimation precipitation treatment, plasma treatment, thermal spraying, etc. for forming a sulfide film can be suitably used.

These various surface treatments described above are ideally applied not only to the inner surface of the forming raw material pipe 2 but also to the surface of the screw and the like, and also play a role in preventing corrosion such as rust in steel materials.

The shape of the formed honeycomb body 10 obtained by the method for producing the formed honeycomb body of this embodiment is not particularly limited, and formed honeycomb bodies of various shapes can be obtained by using the metal cover 3 for forming the formed honeycomb body of a desired shape. 10.

For example, as the outer shape of the formed honeycomb body 10, a cylinder whose end surface shape is circular or elliptical, a prism whose end surface shape is a polygon such as three sides or four sides, and a shape in which the side surfaces of these columns and prisms are curved into a ㄑ shape, etc., as The shape of the through-holes of the formed honeycomb body 10 includes, for example, a cross-sectional shape of a polygon such as four sides and eight sides, a circle, an ellipse, or a combination of these shapes.

Next, the molding material 5 filled in the molding material pipe 2 is extrusion-molded. Although there is no particular limitation on the method of extruding the raw material 5, as shown in FIG. 1(a) and FIG. Plunger extrusion.

In this way, after extruding a molded body of a predetermined length from the metal cap 3 for forming a honeycomb molded body, the extruded molded body is cut to obtain a molded honeycomb body 10 in which a plurality of through holes are divided by partition walls.

Furthermore, in the method for manufacturing the formed honeycomb body of the present embodiment, even by, for example, using two barrels 7, for example, disposing the first barrel (shrinking or expanding the barrel) between the cylinder 6 and the screen 4 , and configure the second barrel (reducing or expanding the barrel) between the filter screen 4 and the metal cover 3 for forming the formed honeycomb body, and the filter screen 4 can also be arranged near the metal cover 3 for forming the formed honeycomb body.

And, as shown in Fig. 2 (a) and Fig. 2 (b), the metal cover 3 itself for forming the honeycomb formed body can also serve as the holding part 16 (referring to Fig. 1 (a)) of the filter screen 4, and the The filter 4 is arranged to be pasted on the inner side of the metal cover 3 for forming the formed honeycomb body, and is inserted into the metal cover 3 for forming the formed honeycomb body for extrusion molding.

Fig. 2(a) and Fig. 2(b) are explanatory diagrams showing another example of the step of extruding a raw material in one embodiment of the method for producing a formed honeycomb article of the present invention.

In Fig. 2(a) and Fig. 2(b), the same symbols are assigned to the same components as those of the molding machine shown in Fig. 1(a), and description thereof will be omitted.

In such a method, for example, water and a binder are blended into the cordierite raw material mainly composed of talc, kaolin, and alumina as raw materials, and the disperse-mixed and kneaded molding raw materials are extruded by a pulverizer. A molding material having an outer diameter of about 300 mm obtained by pressing into a cylindrical shape is extruded with a molding machine 1 to obtain a honeycomb formed body having an outer diameter of about 210 mm without a boundary portion of the molding material.

In addition, when using the formed body thus obtained to manufacture a honeycomb structure, the obtained formed body is cut into a predetermined length after drying to obtain a dried body, and the cell groups on both ends of the dried body are alternately arranged. After being sealed, it is fired to obtain a fired body.

Next, after grinding and removing the outer peripheral wall of the obtained fired body and the partition wall at a distance of about 3 cells from the outermost periphery, a cordierite honeycomb shape can be obtained by applying a ceramic coating material to the outer periphery to form the outer peripheral wall. structure.

Through this method, for example, the cross-sectional shape of the cell is quadrangular, the thickness of the partition wall is 0.3 mm, the standard cell density is 200 cpsi (31 cells/cm ² ), and the shape of the honeycomb structure after the peripheral coating is cylindrical (outer diameter: 191mm, length: 203mm) honeycomb structure.

The honeycomb structure has a porosity of 65%, an average fine porosity of 12 µm, and an axial average thermal expansion rate of about 0.4×10 ^-6 /°C at 40-800°C.

In addition, although illustration is omitted, in the method for manufacturing the formed honeycomb article of this embodiment, toner may be applied to the end surface of the formed honeycomb article forming metal cover of the post-filled forming raw material so that post-filling can be easily judged. The position of the boundary portion of the forming raw material.

In this way, the position of the boundary portion of the post-filled molding material can be easily judged visually.

In addition, in the method for manufacturing the formed honeycomb body of the present embodiment, as shown in FIG. 3 , the inner diameter of the forming raw material pipe 2 can be adjusted from the position where the filter 4 is arranged toward the metal cover 3 for forming the formed honeycomb body. Extrusion molding can be performed by expanding the forming raw material pipe 2 at one end, or by making the inner diameter of the forming raw material pipe 2 shrink toward one end and then expanding the forming raw material pipe 2 for extrusion molding.

The barrel 7 shown in FIG. 3 is composed of a reduced barrel 7a in which the inner diameter of the forming raw material pipe 2 is reduced and an enlarged barrel 7b in which the inner diameter of the forming raw material pipe 2 is enlarged.

Here, FIG. 3 is an explanatory view showing another example of the process of extrusion molding a raw material in one embodiment of the method for manufacturing a formed honeycomb article of the present invention.

The ratio (reduction ratio) of the inner diameter of the cylinder 6 (or the outer diameter of the forming raw material 5) to the inner diameter of the reduced portion is in the range of 5-95%, and the ratio of the inner diameter of the reduced portion to the outer diameter of the molding is ideally in the range of 105-200%. Inside.

The ideal setting is to reduce the length of the barrel body 7a to be within the range of 10-90 degrees between the two corners, and to expand the length of the barrel body 7b to be within the range of 5-45 degrees between the two corners, and the ideal is that the expansion angle is smaller than the reduction angle.

Such reduction rate, expansion rate, reduction angle, expansion angle, inner diameter of cylinder, inner diameter of reduction part, barrel length of reduction part and expansion part, and the optimal combination of formed outer diameter are affected by the forming process actually used on the production site. It depends on the properties of raw materials, so the most important thing in production is to set the best combination design method in experiments.

Furthermore, in FIG. 3, although the plunger-type extrusion molding process of extruding the raw material 5 using the plunger 11 for extruding the raw material 5 is shown, in other methods, for example, in the connection type In forming, the inner diameter of the forming raw material pipe can be extruded from the position where the screen is arranged toward the forming raw material pipe 2 where one end portion of the metal cover for forming the honeycomb formed body is enlarged.

In the manufacturing method of the formed honeycomb body shown in Fig. 3, since the inner diameter of the forming material pipeline 2 is not reduced after passing through the filter screen 4, the velocity distribution of the forming material 5 is improved, and the formation of the forming material 5a after filling can be effectively prevented. The boundary portion 8 between them has a long parabolic shape.

The formed honeycomb body 10 including the boundary portion 8 cannot be used as a product and must be handled after forming, so according to the manufacturing method of the formed honeycomb body of this embodiment, the formed honeycomb body 10 including such a boundary portion 8 can be reduced, Thus, the molding raw material 5 can be effectively used.

In addition, since the forming raw material 5 is supplied smoothly to the outer peripheral portion of the formed honeycomb body 10, the pressure resistance of the partition walls located at the outer peripheral portion of the formed honeycomb body 10 is improved, and the outer wall constituting the formed honeycomb body 10 Formed honeycomb body 10 with less defects and beautiful appearance can be obtained.

In such a method, for example, water and a binder are blended into the cordierite raw material mainly composed of talc, kaolin, and alumina as raw materials, and the disperse-mixed and kneaded molding raw materials are extruded by a pulverizer. The forming raw material obtained by pressing into a cylindrical shape with an outer diameter of about 300 mm is extruded with the molding machine 1 provided with the above-mentioned shrinking and expanding barrel 7 to obtain a honeycomb formed body with an outer diameter of about 250 mm.

In addition, although it does not specifically limit, in this embodiment, the inner diameter of the reduced part with a reduction ratio of 65% and an expansion ratio of 120% is 210 mm.

In addition, the length of the narrowing barrel 7a is set to be 30 degrees at both angles, and the length of the expanding barrel 7b is set to be 15 degrees at both angles.

The molded pattern during such extrusion molding is generally flat, so it is preferable, and a molded body with a good honeycomb structure without significant cell deformation can be obtained.

In addition, when using the formed body thus obtained to manufacture a honeycomb structure, the obtained formed body is cut into a predetermined length after drying to obtain a dried body, and the cell groups on both ends of the dried body are alternately arranged. After being sealed, it is fired to obtain a fired body.

Next, after grinding and removing the outer peripheral wall of the obtained fired body and the partition wall at a distance of about 3 cells from the outermost periphery, a cordierite honeycomb shape can be obtained by applying a ceramic coating material to the outer periphery to form the outer peripheral wall. structure.

Through this method, for example, the cross-sectional shape of the cell is quadrangular, the thickness of the partition wall is 0.3 mm, the standard cell density is 200 cpsi (31 cells/cm ² ), and the shape of the honeycomb structure after the peripheral coating is cylindrical (outer diameter: 229mm, length: 305mm) honeycomb structure.

The honeycomb structure has a porosity of 60%, an average pore rate of 12 µm, and an axial average thermal expansion rate of about 0.4×10 ^-6 /°C at 40-800°C.

Moreover, when the molding material 5 extruded from the plunger-type cylinder 6 or the connection-type screw part (cylinder) shrinks temporarily, and then expands toward the metal cover 3 for forming the honeycomb formed body, as shown in FIG. 3 As shown, although the filter 4 can be arranged between the reduced barrel 7a and the enlarged barrel 7b for extrusion molding, for example, although the illustration is omitted, it is also possible to arrange the filter between the cylinder and the reduced barrel. net to carry out extrusion molding, and, as shown in Fig. 4, also can not dispose filter net 4 between narrow barrel body 7a and enlarge barrel body 7b, and arrange in the inner side or inside of metal cover 3 for forming honeycomb shaped body The filter screen 4 is extruded.

In addition, in FIG. 3 and FIG. 4, the same code|symbol is attached|subjected to each member which is the same as that of the molding machine shown in FIG. 1(a), and description is abbreviate|omitted.

In addition, although not shown, when the forming raw material expands from the cylindrical body to the metal cover for forming the formed honeycomb body, extrusion molding may be performed by disposing a filter between the cylindrical body and the enlarged barrel.

In addition, extrusion molding may be performed by placing a filter in the middle of the enlarged barrel, or by arranging it on the inner side or inside of the metal cover for forming the formed honeycomb body.

As shown in FIG. 4, when the filter screen 4 is directly arranged on the inner side of the metal cover for forming the formed honeycomb body, when the forming is stopped and restarted, the forming raw material 5 of the stopped vena contracta (vena contracta) Immediately extruding together with the forming raw material 5 stopped inside the metal cap 3 for forming the formed honeycomb body has little influence on the formability, and the formed honeycomb body 10 including the boundary portion 8 is easy to handle.

In addition, the embodiment shown in FIG. 3 and FIG. 4 can be applied to any extrusion molding of a piston type (plunger type) or a connection type.

Next, another embodiment of the manufacturing method of the formed honeycomb article of this embodiment will be described.

5( a ) to 5 ( c ) are explanatory diagrams showing an example of a process of extrusion molding a raw material in another embodiment of the method for producing a formed honeycomb article of the present invention.

As shown in FIGS. 5( a ) to 5 ( c ), the method for manufacturing the formed honeycomb body of this embodiment is the filling molding of the forming raw material pipe 12 in which the metal cover 3 for forming the formed honeycomb body is disposed on one end. Raw material 15, the manufacturing method of the formed honeycomb body obtained by extruding the filled forming material 15 from the metal cover 3 for forming the formed honeycomb body and obtaining the formed honeycomb body 10 is to make the inner diameter of the forming material pipeline 12 and the extrusion The formed honeycomb formed body 10 has substantially the same outer diameter, and the filter screen 4 for filtering the foreign matter contained in the formed material 15 is arranged near the metal cover 3 for forming the formed honeycomb body inside the formed raw material pipeline 12 to perform reduced molding. A method of manufacturing a formed honeycomb body by manipulating the frictional resistance between the inner surface of the raw material pipe 12 and the forming raw material 15 to obtain the formed honeycomb body 10 .

5(b) and 5(c) show a process of arranging the filter 4 on the backside or inside of the metal cover 3 for forming the formed honeycomb body and performing extrusion molding.

In the method for manufacturing the formed honeycomb body of this embodiment, by making the inner diameter of the forming raw material pipe 12 approximately the same as the outer diameter of the extruded formed honeycomb body 10, and making the cylinder constituting the existing forming raw material pipe The integrated structure of the honeycomb body and the barrel can be cut by the plunger 11 before the metal cover 3 for forming the honeycomb formed body, thereby reducing the boundary portion generated when the forming raw material 15 is added later.

There is a discontinuity at the boundary portion of the above-mentioned molding raw material, and it is desirable not to remain inside the product.

Furthermore, in the manufacturing method of the formed honeycomb body of the present embodiment, as shown in FIG. The molding raw material 15a for filling the cylindrical clay-like block of the size of the inner diameter of the molding raw material pipeline 12 (that is, the size of the outer diameter of the extruded honeycomb formed body 10), as shown in Figure 5 (b) and Figure 5 (c) As shown, it is desirable to fill the molding raw material 15a for filling into the molding raw material pipe 12 and extrude it.

Furthermore, in the case of obtaining the filling molding raw material 15 equivalent to one formed honeycomb body 10, in practice, it is desirable to use a machined material including one formed honeycomb body 10 and the end surfaces corresponding to both sides thereof. Part of the amount of molding raw material 15 to obtain the molding raw material 15a for filling.

By exhausting the molding raw material filled into the molding raw material pipe 12 every time molding is performed, the molding raw material 15 hardly remains in the molding raw material pipe 12 , and the appearance of the boundary portion of the molding raw material 15 can be eliminated.

In addition, in the case of actual molding, although some forming raw materials 15 may remain inside the metal cover 3 for forming a formed honeycomb body, in the formed honeycomb body 10 obtained by extrusion molding next time, the residual forming The portion made of the raw material 15 becomes a machining allowance on the end face of the formed honeycomb body 10 and does not remain on the product.

In this way, when using the forming raw material 15 of the amount equivalent to one honeycomb formed body 10 to carry out forming, as shown in Figure 5 (a)-Figure 5 (c), with a clay refining machine 13 continuously obtained Filling molding raw material 15 corresponding to the honeycomb formed body 10, the obtained filling molding raw material 15a is sequentially transferred to the molding raw material pipe 12 of the molding machine 1, the transferred molding raw material 15a is filled into the molding raw material pipe 12, and Shaping is performed intermittently.

In the manufacturing method of the formed honeycomb body of the present invention, although the formed honeycomb body cannot be continuously formed like the conventional manufacturing method, the structure of one forming raw material pipe 12 becomes smaller and the filling operation of the forming raw material 15 is simplified. , so the time it takes to fill the molding raw material 15 can be significantly shortened.

In the molding raw material pipe 12, there is no configuration of a cylinder and a barrel in the conventional manufacturing method, and only the cylindrical molding raw material pipe 12 is simply constituted.

Furthermore, in the manufacturing method of the formed honeycomb body of the present embodiment, as shown in Fig. 6(a) and Fig. 6(b), the dedicated forming raw material pipe 12 which is consistent with the outer diameter of the formed honeycomb body 10 is a cylindrical shape. And prepare a plurality of them, and arrange them in a circular shape and in a row on the rotary table, and during molding by pressing one molding raw material pipe 12a filled with the molding raw material 15 with the plunger 11, the molding raw material 15 can be filled until the molding is completed. Other operations in the forming raw material pipeline 12b.

In this way, by moving the molding raw material pipe 12b filled with the molding raw material 15 to the position where the plunger 11 is for molding, extrusion molding can be performed more quickly.

In particular, the recent development of computer control technology and robotization technology not only hardly reduces the efficiency of forming work, but also realizes continuous extrusion forming substantially.

Here, FIG. 6(a)-FIG. 6(b) are explanatory views showing another example of the extrusion molding process of the molding raw material in another embodiment of the manufacturing method of the formed honeycomb body of the present invention.

In addition, in FIG.6(a)-FIG.6(b), the same code|symbol is attached|subjected to each member similar to the molding machine shown in FIG.1(a), and the description is abbreviate|omitted.

In the method for manufacturing the formed honeycomb body of this embodiment, the length of the forming raw material pipe 12 of the forming machine 1 in the extrusion direction can be shortened compared with the currently used forming raw material pipe, and accordingly, the hydraulic mechanism of the plunger 11 can be simplified and formed The compactness of the machine 1 becomes possible.

By downsizing the forming machine 1 , the forming raw material pipe 12 can be easily changed to match the outer diameter of the formed honeycomb body 10 .

Specifically, the forming raw material pipeline 12 is an integrated structure of a conventional cylindrical body and a barrel, so that it is consistent with the shape of the formed honeycomb body 10 and can be changed to a cylindrical type.

The filling forming raw material 15a of the inner diameter of the forming raw material pipeline 12 (that is, the outer diameter of the extruded formed honeycomb body 10) can be easily obtained by adding a throttle valve at the front end of the mud mill 13 or enlarging the barrel.

Furthermore, in Fig. 5(a)-Fig. 5(c), although the amount equivalent to one formed honeycomb body 10 is obtained (actually, the part corresponding to the machining allowance including one formed honeycomb body and its end face amount) of filling forming material 15a and forming the formed honeycomb body 10, but for example, although the illustration is omitted, an amount equivalent to two formed honeycomb bodies can be obtained (actually, it is equivalent to two honeycomb forming bodies). shaped body and the amount corresponding to the machining allowance of each end face), the filling forming raw material may also be an amount equivalent to three or more formed honeycomb bodies (actually, the same amount as that containing a plurality of honeycomb shaped bodies) The molding raw material for filling is equivalent to the machining allowance of the molded body and each end surface), but since the length of the molding raw material for filling becomes longer as the number of moldable pieces increases, it is ideal to use one to three honeycombs The shaped body is used as a forming raw material for forming and filling.

In particular, in the manufacturing method of the formed honeycomb body of this embodiment, the efficiency is higher when the size of the formed honeycomb body is relatively large.

Usually, although the forming raw material for filling is a long cylindrical shape with an outer diameter of about 300mm and a length of about 1200mm, if, for example, the outer diameter of the formed honeycomb body is about 280mm and the length is about 350mm, then in the existing manufacturing method, the screw The molding raw material remaining inside the barrel increases, and the number of honeycomb formed bodies obtained from one filling molding raw material decreases.

Therefore, in the conventional manufacturing method, the replacement interval of the molding raw material becomes very short, and the ratio of the replacement time of the molding raw material in the entire manufacturing time increases rapidly, and the molding work efficiency decreases.

In particular, in heavy-duty diesel trucks, a filter having a honeycomb structure of a honeycomb formed body having an outer diameter exceeding 300 mm is required, and in such a case, the efficiency of the forming work further decreases.

In the case of forming a large honeycomb formed body, it is conceivable to increase the size of the molding raw material for filling, but since the molding machine itself also needs to be enlarged, it is difficult to actually realize it.

As in the method for manufacturing a formed honeycomb body of this embodiment, the inner diameter of the forming raw material pipe 12 is substantially the same as the outer diameter of the formed honeycomb body 10 to be extruded, for example, by obtaining a Filling the forming raw material 15a with an appropriate amount and forming the formed honeycomb body 10 can improve the forming work efficiency (see FIG. 5( a ) and FIG. 5( b )).

(Example)

As a raw material, mix water and a binder in the cordierite raw material with the above-mentioned talc, kaolin, and alumina as the main raw materials, and then disperse, mix and knead the forming raw material to be extruded by a mud mill to have the same outer diameter as the honeycomb forming A molding material with an outer diameter of about 400 mm obtained in substantially the same cylindrical shape.

The obtained cylindrical forming raw material is cut at an amount including one honeycomb formed body and only the portion remaining in the forming raw material pipe of the forming machine and the portion remaining in the metal cover for forming the honeycomb formed body to obtain a formed honeycomb forming body. Forming material for machine filling.

In the molding machine used in this example, a filter for filtering foreign matter contained in the molding raw material was arranged directly inside the metal cover for molding the honeycomb molded body.

In addition, in this embodiment, lubricating oil is disposed between the inner surface of the forming material pipe and the forming material to reduce the frictional resistance between the inner surface of the forming material pipe and the forming material.

In addition, the inner diameter of the molding raw material pipe of the molding machine is slightly larger than the outer shape of the obtained formed honeycomb body so that the above-mentioned molding raw material for filling the molding machine can be easily filled.

The obtained molding raw material for filling the molding machine was filled into the molding raw material pipe of the molding machine, and extruded through the honeycomb shaped body by a plunger.

In this example, the molding raw material filled in the molding machine can be effectively used, and molding can be performed favorably.

Furthermore, in this example, the molded body obtained in this way was cut into a predetermined length after drying to obtain a dried body, and the compartment groups on both ends of the dried body were closed in a staggered manner and then fired to obtain a fired body. body.

Furthermore, the range of 2-3 compartments on the outer periphery of both ends of the drying body is not closed.

And, after grinding and removing the outer peripheral wall of the obtained fired body and the partition wall at a distance of about 5 cells from the outermost periphery, a ceramic coating material is applied to the outer periphery to form the outer peripheral wall, and the boundary portion of the forming raw material can be obtained. The cordierite honeycomb structure remaining inside the product.

The obtained honeycomb structure is that the cross-sectional shape of the cell is quadrangular, the thickness of the partition wall is 0.3 mm, the standard cell density is 200 cpsi (31 cells/cm ² ), and the shape of the honeycomb structure after the peripheral coating is cylindrical ( Outer diameter: 410mm, length: 450mm).

In addition, this honeycomb structure has a porosity of 50%, an average porosity of 12 µm, and an axial average thermal expansion rate of about 0.4×10 ^-6 /°C at 40-800°C.

The manufacturing method of the formed honeycomb article of the present invention can reduce the boundary between the forming material filled first and the forming material filled later in the case of adding the forming material to the forming machine to form it later as the forming material filled in the molding machine decreases Partial influence on molding, and the molding raw material filled into the molding machine can be effectively used.

The obtained formed honeycomb body can be fired into a honeycomb structure suitable for, for example, filters for dust removal and water treatment, and catalyst carriers for exhaust gas purification.

Claims (7)

1. the manufacture method of a formed honeycomb structure, it is to have disposed the formed honeycomb structure shaping to fill shaping raw material with the inside of the shaping raw material pipeline of crown cap on an end, the above-mentioned shaping raw material of filling is shaped from above-mentioned formed honeycomb structure to squeeze out and the manufacture method of the formed honeycomb structure that obtains formed honeycomb structure of being shaped with crown cap, it is characterized in that:

Configuration is used to filter the screen pack of the contained foreign matter of above-mentioned shaping raw material near the above-mentioned formed honeycomb structure of above-mentioned shaping raw material pipe interior is shaped with crown cap, and,

The operation that reduces frictional resistance between above-mentioned shaping raw material pipeline inner face and the above-mentioned shaping raw material obtains above-mentioned formed honeycomb structure.

2. the manufacture method of formed honeycomb structure according to claim 1 is characterized in that:

It is on the twice of above-mentioned shaping raw material internal diameter of the pipeline or the position below it that above-mentioned screen pack is disposed at the distance that is shaped with crown cap from above-mentioned formed honeycomb structure.

3. the manufacture method of formed honeycomb structure according to claim 1 and 2 is characterized in that:

The operation that reduces frictional resistance between above-mentioned shaping raw material pipeline inner face and the above-mentioned shaping raw material is the operation of configuration lubricating oil or lubriation material between above-mentioned shaping raw material pipeline inner face and above-mentioned shaping raw material, and/or the surface texture of above-mentioned shaping raw material pipeline inner face is changed operation.

4. the manufacture method of formed honeycomb structure according to claim 1 is characterized in that:

Used the internal diameter size that makes above-mentioned shaping raw material pipeline to come extrusion molding to having disposed the above-mentioned shaping raw material pipeline of above-mentioned formed honeycomb structure shaping with the above-mentioned end expansion of crown cap from the position that disposes above-mentioned screen pack.

5. the manufacture method of formed honeycomb structure according to claim 1 is characterized in that:

Used the internal diameter size that makes above-mentioned shaping raw material pipeline to come extrusion molding at the above-mentioned shaping raw material pipeline that dwindles back expansion towards an above-mentioned end.

6. the manufacture method of formed honeycomb structure according to claim 1 is characterized in that:

Push in the plunger type extrusion molding of above-mentioned shaping raw material at the plunger that uses the above-mentioned shaping raw material of extruding to use, used the internal diameter size above-mentioned shaping raw material pipeline identical that makes above-mentioned shaping raw material pipeline to come extrusion molding with the external diameter size of the above-mentioned formed honeycomb structure of extrusion molding.

7. the manufacture method of formed honeycomb structure according to claim 1 is characterized in that:

The above-mentioned shaping raw material of amount that will be suitable with above-mentioned formed honeycomb structure is filled in the above-mentioned shaping raw material pipeline and comes extrusion molding.

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