JP2002136817A - Honeycomb filter and its manufacturing method - Google Patents
Honeycomb filter and its manufacturing methodInfo
- Publication number
- JP2002136817A JP2002136817A JP2000338069A JP2000338069A JP2002136817A JP 2002136817 A JP2002136817 A JP 2002136817A JP 2000338069 A JP2000338069 A JP 2000338069A JP 2000338069 A JP2000338069 A JP 2000338069A JP 2002136817 A JP2002136817 A JP 2002136817A
- Authority
- JP
- Japan
- Prior art keywords
- plugging
- honeycomb filter
- ceramic
- weight
- honeycomb
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Processes For Solid Components From Exhaust (AREA)
- Filtering Materials (AREA)
- Filtering Of Dispersed Particles In Gases (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】 本発明はハニカムフィルタ
およびその製造方法に関する。The present invention relates to a honeycomb filter and a method for manufacturing the same.
【０００２】[0002]
【従来の技術】 従来、集塵装置は紙や繊維、高分子樹
脂を使用したバグフィルタが主流であったが、近年、公
害防止等の環境対策、高温ガスからの製品回収、クリー
ンな高温エネルギー回収のため、高分子材料が使用不可
能である２５０℃以上の温度域における集塵が必要な市
場が増えてきた。2. Description of the Related Art Conventionally, dust filters have been mainly made of bag filters using paper, fiber, or polymer resin. In recent years, however, environmental measures such as pollution prevention, product recovery from high-temperature gas, and clean high-temperature energy have been developed. Markets for collecting dust in a temperature range of 250 ° C. or higher where polymer materials cannot be used for recovery have increased.
【０００３】 このような状況下、セラミックスは、耐
熱性、耐食性に優れ、高温、腐食性ガス雰囲気でのフィ
ルタ材料として好ましい特性を有している。このセラミ
ックスを材料としたセラミックスフィルタとしては、例
えば管状のもの、或いは、一方が閉じた管状であるキャ
ンドルタイプと呼ばれる形状のもの等を挙げることがで
き、現在、集塵用のハニカムフィルタは、高温ガスから
の製品の回収、環境対策を狙いとした排ガスからのダス
トの除去等を目的として、化学、電力、鉄鋼、産業廃棄
物処理産業等多岐に渡る分野において用いられている。Under such circumstances, ceramics have excellent heat resistance and corrosion resistance, and have favorable characteristics as a filter material in a high-temperature, corrosive gas atmosphere. Examples of the ceramic filter using this ceramic as a material include a tubular filter and a filter called a candle type in which one side is a closed tubular form. At present, a honeycomb filter for collecting dust has a high temperature. It is used in a wide variety of fields such as the chemical, electric power, steel, and industrial waste treatment industries for the purpose of collecting products from gas and removing dust from exhaust gas for environmental measures.
【０００４】 かかる集塵用のハニカムフィルタは、図
１に示すように、ハニカムの多数の流通路３の端部を上
流側Ｂと下流側Ｃとを逆に１マスごとに目封じ部２によ
って封じられた構造を有し、上流側Ｂから入った高温ガ
スは、多孔質の隔壁４を通って下流側Ｃの穴より抜けて
いくが、その際に、高温ガス中のダストは隔壁のフィル
タ層に捕捉されるといった仕組みを有している。As shown in FIG. 1, in such a honeycomb filter for dust collection, the ends of a large number of flow passages 3 of the honeycomb are reversely connected to the upstream side B and the downstream side C by a plugging portion 2 for each cell. The hot gas that has a sealed structure and enters from the upstream side B passes through the porous partition wall 4 and passes through the hole on the downstream side C. At this time, dust in the high-temperature gas passes through the filter of the partition wall. It has a mechanism of being captured by a layer.
【０００５】[0005]
【発明が解決しようとする課題】 ハニカムフィルタの
目封じに関して、これまで目封じに使用する目封じ材の
材質やその充填方法に工夫を凝らすといった試みはなさ
れてはいなかった。しかしながら、特別な工夫を盛り込
まずに一般的な材質等を使用して製造したハニカムフィ
ルタは、高温条件下での使用に際し、材質間の熱膨張差
に起因して目封じ部や基材にクラックが発生したり、或
いは、目封じ部の基材からの剥離や脱落等の不具合が発
生する場合があった。Regarding the plugging of the honeycomb filter, no attempt has been made to devise the material of the plugging material used for the plugging or the method of filling the plugging material. However, honeycomb filters manufactured using general materials without special measures are subject to cracks in the plugged portions and base material due to the difference in thermal expansion between materials when used under high temperature conditions. Or a defect such as peeling or falling off of the plugged portion from the base material in some cases.
【０００６】 従来、目封じ材の充填は、ハニカム状に
成形された基材をスラリー状の目封じ材に浸漬させるこ
とによって行なわれていた。しかし、目封じ材の乾燥に
よる収縮の結果、充填後の目封じ材の体積が減少してし
まい、目封じ部にクラックが発生したり目封じ部が脱落
したりするおそれがあった。また、前記目封じ材の充填
方法によれば、焼成済のハニカム状に成形された基材を
用いて目封じ材の充填を行っていたために、その後、目
封じ材の焼結のためだけに再度焼成が必要となる。した
がって、ハニカムフィルタの製造工程複雑化するととも
に、製造コストが増加するといった問題をも有してい
る。Conventionally, the plugging material has been filled by dipping a honeycomb-shaped base material into a slurry-shaped plugging material. However, as a result of shrinkage of the plugging material due to drying, the volume of the plugging material after filling is reduced, and there is a possibility that cracks may occur in the plugged portion or the plugged portion may fall off. Further, according to the method of filling the plugging material, since the plugging material is filled using the fired honeycomb-shaped base material, thereafter, only for sintering the plugging material. Baking is necessary again. Therefore, there is a problem that the manufacturing process of the honeycomb filter is complicated and the manufacturing cost is increased.
【０００７】 なお、ハニカムフィルタは、そのフィル
タ層に一定量以上のダストが捕捉されたとき、もしくは
定期的に、通常とは逆向きにエアーを送り込むことによ
って逆洗し、捕捉されたダスト等を除去する必要性があ
る。その際には、最外周に比して最外周以外のセルにお
ける逆洗エアーの流速が速くなることが一般的であり、
このとき逆洗エアーに流速分布が生ずることに起因して
最外周と最外周以外の目封じ部に応力差が発生する。一
方、ハニカムフィルタを製造するに際し、目封じ深さは
全体的に均一となるように設定して目封じ材を充填する
ことが一般的であるために、前述の発生応力差により最
外周以外の目封じ部が脱落するおそれがある。The honeycomb filter back-washes when a certain amount or more of dust is trapped in the filter layer or periodically or by blowing air in a direction opposite to the normal direction to remove the trapped dust and the like. There is a need to remove. At that time, it is general that the flow velocity of the backwash air in the cells other than the outermost circumference is higher than the outermost circumference,
At this time, a stress difference is generated between the outermost periphery and a plugged portion other than the outermost periphery due to a flow velocity distribution generated in the backwash air. On the other hand, when manufacturing the honeycomb filter, it is common to fill the plugging material with the plugging depth being set to be uniform as a whole. The plugging part may fall off.
【０００８】 本発明は、このような従来技術の有する
問題点に鑑みてなされたものであり、その目的とすると
ころは、目封じ部、および基材にクラックが発生した
り、目封じ部が基材からの剥離や脱落を起こしたりする
ことのないハニカムフィルタ、および前記特性を有し、
かつ、製造工程が短縮されるとともに製造コストの削減
もなされたハニカムフィルタの製造方法を提供すること
にある。The present invention has been made in view of the above-mentioned problems of the related art, and an object of the present invention is to generate a crack in a plugging portion and a base material, Having a honeycomb filter that does not cause peeling or falling off from the base material, and having the above characteristics,
Another object of the present invention is to provide a method for manufacturing a honeycomb filter in which the manufacturing process is shortened and the manufacturing cost is reduced.
【０００９】[0009]
【課題を解決するための手段】 すなわち、本発明によ
れば、多数の平行な流通路を有するとともに、該流通路
の端部が交互に目封じされた多孔質のセラミックス基材
からなるハニカムフィルタであって、目封じ材が該セラ
ミックス基材と同じ材質のセラミックス粉砕物から構成
されていることを特徴とするハニカムフィルタが提供さ
れる。That is, according to the present invention, a honeycomb filter comprising a porous ceramic base material having a number of parallel flow passages and the ends of the flow passages being alternately plugged. Wherein the plugging material is made of a crushed ceramic material of the same material as the ceramic base material.
【００１０】 本発明においては、セラミックス粉砕物
が、セラミックス基材の焼成粉砕物７０〜８０重量％
と、セラミックス基材の未焼成粉砕物２０〜３０重量％
からなることが好ましく、セラミックス粉砕物の最大粒
径が５００μｍであることが好ましい。In the present invention, the crushed ceramic material is 70 to 80% by weight of a baked and crushed ceramic substrate.
And 20 to 30% by weight of unfired pulverized ceramic base material
It is preferable that the maximum particle size of the pulverized ceramics be 500 μm.
【００１１】 また、本発明においては、目封じ材がセ
ラミックス粉砕物１００重量部と水３３〜４３重量部か
らなることが好ましく、最外周以外の流通路の目封じ深
さ平均値が、最外周の流通路の目封じ深さ平均値の１．
１〜１．３倍であることが好ましい。In the present invention, the plugging material is preferably composed of 100 parts by weight of the crushed ceramic material and 33 to 43 parts by weight of water. Of the average plugging depth of the flow passage of 1.
Preferably it is 1 to 1.3 times.
【００１２】 一方、本発明によれば、セラミックス粉
末から調製した坏土を多数の平行な流通路を有するハニ
カム形状に成形する成形工程と、該流通路の端部を交互
に目封じする目封じ工程と、ハニカム成形体を焼成する
焼成工程とを含む多孔質のセラミックス基材からなるハ
ニカムフィルタの製造方法であって、該セラミックス基
材と同材質のセラミックスを粉砕し、当該セラミックス
粉砕物を用いて目封じすることを特徴とするハニカムフ
ィルタの製造方法が提供される。On the other hand, according to the present invention, a forming step of forming a kneaded material prepared from ceramic powder into a honeycomb shape having a number of parallel flow passages, and a plugging process of alternately plugging ends of the flow passages. A method for manufacturing a honeycomb filter comprising a porous ceramic substrate, comprising a step of firing a formed honeycomb body, and a step of firing the formed honeycomb body. And a method for manufacturing a honeycomb filter characterized by sealing.
【００１３】 本発明においては、セラミックス粉砕物
が、セラミックス基材の焼成粉砕物７０〜８０重量％
と、セラミックス基材の未焼成粉砕物２０〜３０重量％
との混合物であることが好ましく、目開き５００μｍ以
下の篩を通したセラミックス粉砕物を用いることが好ま
しい。In the present invention, the crushed ceramic material is 70 to 80% by weight of the baked and crushed ceramic substrate.
And 20 to 30% by weight of unfired pulverized ceramic base material
It is preferable to use a crushed ceramic material which has been passed through a sieve having an opening of 500 μm or less.
【００１４】 また、本発明においては、セラミックス
粉砕物１００重量部に対し、水３３〜４３重量部を混合
した目封じ材を用いて目封じすることが好ましく、さら
には、目封じ工程に次いで焼成工程を有することが好ま
しい。In the present invention, the plugging is preferably performed by using a plugging material obtained by mixing 33 to 43 parts by weight of water with respect to 100 parts by weight of the pulverized ceramic material. It is preferable to have a step.
【００１５】[0015]
【発明の実施の形態】 以下、本発明の実施の形態につ
いて説明するが、本発明は以下の実施の形態に限定され
るものではなく、本発明の趣旨を逸脱しない範囲で、当
業者の通常の知識に基づいて、適宜、設計の変更、改良
等が加えられることが理解されるべきである。BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described. However, the present invention is not limited to the following embodiments, and is within the scope of the present invention. It should be understood that design changes, improvements, etc. may be made as appropriate based on the knowledge of
【００１６】 本発明のハニカムフィルタは、多数の平
行な流通路を有するとともに、その流通路の端部が交互
に目封じされた多孔質のセラミックス基材（以下、「基
材」という）からなるものであり、目封じのために用い
られる目封じ材が、基材と同じ材質のセラミックス粉砕
物であることを特徴としている。すなわち、基材と同じ
材質であるセラミックスを粉砕して用いるため、高温条
件下での使用に際し、材質間の熱膨張差に起因して目封
じ部や基材にクラックが発生することがなく、また目封
じ部の基材からの剥離や脱落等の不具合が発生すること
もない。The honeycomb filter of the present invention comprises a porous ceramic base material (hereinafter, referred to as “base material”) having a number of parallel flow passages and the ends of the flow passages being alternately plugged. Wherein the plugging material used for plugging is a crushed ceramic material of the same material as the base material. That is, since the same material as the base material is crushed and used, when used under high-temperature conditions, cracks do not occur in the plugging portion or the base material due to the difference in thermal expansion between the materials, In addition, problems such as peeling and dropping of the plugged portion from the base material do not occur.
【００１７】 また、本発明に係るハニカムフィルタ
は、目封じに用いるためのセラミックス粉砕物が、基材
の焼成粉砕物と基材の未焼成粉砕物からなることが好ま
しい。この場合、当該セラミックス粉砕物の組成比率
が、基材の焼成粉砕物に関しては７０〜８０重量％が好
ましく、７２〜７８重量％がさらに好ましく、７４〜７
６重量％が特に好ましい。同時に、基材の未焼成粉砕物
に関しては２０〜３０重量％が好ましく、２２〜２８重
量％がさらに好ましく、２４〜２６重量％が特に好まし
い。Further, in the honeycomb filter according to the present invention, it is preferable that the pulverized ceramics to be used for plugging comprises a pulverized product of a base material and an unpulverized product of a base material. In this case, the composition ratio of the ceramic pulverized product is preferably 70 to 80% by weight, more preferably 72 to 78% by weight, and more preferably 74 to 7% by weight with respect to the fired and pulverized substrate.
6% by weight is particularly preferred. At the same time, 20 to 30% by weight, more preferably 22 to 28% by weight, and particularly preferably 24 to 26% by weight, of the unground pulverized material of the substrate is preferred.
【００１８】 ここで、基材の焼成粉砕物は骨材として
の役割を有し、基材の未焼成粉砕物は焼結助剤としての
役割を有している。本発明においては、両方の基材の粉
砕物を当該数値範囲で混合したものを目封じ材として使
用するために、目封じ部にクラックが発生したり、基材
からの剥離・脱落が発生したりしないばかりでなく、流
通路の端部に目封じ材を充填する際の施工性に優れると
ともに、その後に焼成する際の焼結性も良好となる。Here, the fired and ground material of the base material has a role as an aggregate, and the unfired and ground material of the base material has a role as a sintering aid. In the present invention, in order to use a mixture obtained by mixing the pulverized materials of both substrates in the above numerical range as a plugging material, cracks are generated in the plugged portions, and peeling and falling off from the substrate occur. Not only is it not only slack, but also excellent in workability when filling the end of the flow passage with the plugging material, and good in sinterability when firing thereafter.
【００１９】 さらに、本発明においては、セラミック
ス粉砕物の最大粒径が５００μｍであることが好まし
く、４５０μｍであることがさらに好ましく、４００μ
ｍであることがさらに好ましい。セラミックス粉砕物の
最大粒径が５００μｍ超である場合には、良好な目封じ
を施すことができないおそれがある。したがって、上記
の最大粒径に規定した本発明に係るハニカムフィルタお
よびその製造方法は、優れた目封じ性能を確保すること
が可能である。Further, in the present invention, the maximum particle size of the crushed ceramic material is preferably 500 μm, more preferably 450 μm, and more preferably 400 μm.
m is more preferable. If the maximum particle size of the ceramic pulverized product is more than 500 μm, there is a possibility that good sealing cannot be performed. Therefore, the honeycomb filter and the method for manufacturing the same according to the present invention, which are defined to have the above maximum particle size, can ensure excellent plugging performance.
【００２０】 また、上記最大粒径を有するセラミック
ス粉砕物を得るために、本発明に係るハニカムフィルタ
の製造方法においては、所定の目開き寸法を有する篩を
通したセラミックス粉砕物を用いる。このとき使用する
篩は、目開き５００μｍ以下であることが好ましく、４
５０μｍ以下であることがさらに好ましく、４００μｍ
以下であることが特に好ましい。このような目開き寸法
を有する篩を使用しているために、上記好ましい粒径を
有するセラミックス粉砕物を調製することが可能であ
る。In addition, in order to obtain a crushed ceramic material having the above maximum particle size, in the method for manufacturing a honeycomb filter according to the present invention, a crushed ceramic material that has been passed through a sieve having a predetermined opening size is used. The sieve used at this time preferably has a mesh size of 500 μm or less.
More preferably 50 μm or less, more preferably 400 μm
It is particularly preferred that: Since a sieve having such an opening size is used, it is possible to prepare a pulverized ceramic having the above preferable particle size.
【００２１】 なお、本発明においては、目封じのため
に用いる目封じ材が、セラミックス粉砕物１００重量部
に対して水３３〜４３重量部を添加したものであること
が好ましく、３５〜４０重量部を添加したものであるこ
とがさらに好ましく、３６〜３８重量部を添加したもの
であることが特に好ましい。セラミックス粉砕物１００
重量部に対して水の添加量が３３重量部未満である場合
には、目封じ材の粘性が高過ぎるために、流通路の端部
に圧入することが困難である。また、セラミックス粉砕
物１００重量部に対して水の添加量が４３重量部超であ
る場合には、目封じ材の粘性が低過ぎるために、目封じ
材が一定時間、一定の形状を保持できないばかりでな
く、乾燥の際の水分蒸発による収縮率が大きく、目封じ
部にクラックが発生しやすくなってしまう。したがっ
て、前記重量部範囲内において水を添加して調製した目
封じ材を用いて製造した本発明のハニカムフィルタおよ
びその製造方法は、施工性に優れているとともに焼結性
も良好である。In the present invention, the plugging material used for plugging is preferably one obtained by adding 33 to 43 parts by weight of water to 100 parts by weight of the pulverized ceramic material, preferably 35 to 40 parts by weight. More preferably, 36 to 38 parts by weight are added. Ceramic crushed material 100
If the amount of water is less than 33 parts by weight relative to parts by weight, it is difficult to press-fit the plug into the end of the flow passage because the viscosity of the plugging material is too high. If the amount of water exceeds 43 parts by weight with respect to 100 parts by weight of the crushed ceramic material, the viscosity of the plugging material is too low, so that the plugging material cannot maintain a constant shape for a certain period of time. Not only that, the shrinkage due to evaporation of water during drying is large, and cracks tend to occur in the plugged portions. Therefore, the honeycomb filter of the present invention manufactured using the plugging material prepared by adding water in the above-mentioned weight part range and the method for manufacturing the same have excellent workability and good sinterability.
【００２２】 また、本発明においては、最外周以外の
流通路の目封じ深さ平均値が、最外周の流通路の目封じ
深さ平均値の１．１〜１．３倍であることが好ましく、
１．２〜１．３倍であることがさらに好ましく、１．２
５倍であることが特に好ましい。すなわち、全ての目封
じ部において、発生する応力によって脱落や剥離を生ず
ることのない充分な目封じ深さを有している。したがっ
て、逆洗エアーに流速分布が生ずることに起因して発生
する最外周と最外周以外の流通路の目封じ部における応
力差によって最外周以外の流通路の目封じ部が脱落する
おそれがない。In the present invention, the average plugging depth of the flow passages other than the outermost circumference may be 1.1 to 1.3 times the average plugging depth of the outermost flow passages. Preferably
More preferably, it is 1.2 to 1.3 times,
It is particularly preferred that it be 5 times. That is, all the plugging portions have a sufficient plugging depth so that the plugs do not drop or peel due to the generated stress. Therefore, there is no danger that the plugged portions of the flow passages other than the outermost circumference will fall off due to the stress difference between the outermost circumference and the plugged portions of the flow passages other than the outermost circumference due to the occurrence of the flow velocity distribution in the backwash air. .
【００２３】 なお、多孔質の隔壁における濾過面積を
充分に確保することが好ましいために、目封じ深さは必
要以上に深く設定しないことが好ましい。本発明におい
ては逆洗エアーの流速分布に応じ、目封じ深さにも差を
設けているために、目封じ部の脱落を抑止するだけでな
く、多孔質の隔壁における濾過面積が充分に確保される
といった効果をも奏する。In addition, since it is preferable to secure a sufficient filtration area in the porous partition wall, it is preferable that the plugging depth is not set more deeply than necessary. In the present invention, a difference is also provided in the plugging depth according to the flow velocity distribution of the backwash air, so that not only the dropping of the plugged portion is suppressed, but also a sufficient filtration area in the porous partition wall is secured. It also has the effect of being done.
【００２４】 なお、本願における目封じ深さの平均値
は、以下のような方法によって測定・算出するものをい
う。すなわち、図２に示すように、流通路３の端部を流
通路の長手方向と直交するように適当な長さで切断し、
各流通路端部５から目封じ部先端６までの長さＡを測定
する。次に、最外周以外の長さＡ、および最外周の長さ
Ａの平均値をそれぞれ算出するものである。The average value of the plugging depth in the present application is measured and calculated by the following method. That is, as shown in FIG. 2, the end of the flow passage 3 is cut at an appropriate length so as to be orthogonal to the longitudinal direction of the flow passage,
The length A from each flow path end 5 to the plugging end 6 is measured. Next, the average value of the length A other than the outermost circumference and the average value of the length A of the outermost circumference are calculated.
【００２５】 次に、本発明に係るハニカムフィルタの
製造方法を例に挙げ、さらなる詳細を説明する。原材料
のセラミックスとしては、例えばコーディライト、ムラ
イト、アルミナ等を挙げることができる。一般的な処
方、および工程によって坏土を作製するが、このとき、
基材を多孔質とするために、例えばカーボングラファイ
ト等の造孔剤を適当量添加して坏土を作製する。次い
で、押出し成形法等により所定のセルピッチを有するハ
ニカム構造体を製造することができる。なお、押出し成
形に際し、種々の形状・セルピッチを有する口金を用い
ることにより、所望の開口形状・セルピッチを有するハ
ニカム構造体とすることができる。Next, a method for manufacturing a honeycomb filter according to the present invention will be described as an example, and further details will be described. Examples of the raw material ceramics include cordierite, mullite, and alumina. A kneaded clay is produced by a general prescription and a process.
In order to make the substrate porous, an appropriate amount of a pore-forming agent such as carbon graphite is added to produce a clay. Next, a honeycomb structure having a predetermined cell pitch can be manufactured by an extrusion molding method or the like. In the extrusion molding, a honeycomb structure having a desired opening shape and cell pitch can be obtained by using die having various shapes and cell pitches.
【００２６】 前記ハニカム構造体を、概ね１００〜１
３０℃、１時間程度乾燥する。ここで、本発明に係るハ
ニカムフィルタの製造方法においては、流通路の端部を
交互に目封じし、その後、焼成することが好ましい。本
発明に係るハニカムフィルタの製造方法は、従来の目封
じの方法を用いた製造方法とは異なり、従来の目封じ材
に比して水分含有量が低く、いわゆる粘土状である目封
じ材を充填するといった手法を採用している。この場
合、目封じされるハニカム状に成形された基材は焼成し
たものである必要性はなく、目封じは未焼成のハニカム
状に成形された基材に対して行うことができる。したが
って、従来の目封じ部を有するハニカムフィルタの製造
方法において必要とされていた、二回の焼成工程を一回
に減ずることが可能である。すなわち、当該ハニカムフ
ィルタの製造工程を簡略化することが可能であるととも
に、製造コストの削減にも寄与することができる。The above-mentioned honeycomb structure is generally set to 100 to 1
Dry at 30 ° C. for about 1 hour. Here, in the method for manufacturing a honeycomb filter according to the present invention, it is preferable that the ends of the flow passages are alternately plugged and then fired. The manufacturing method of the honeycomb filter according to the present invention is different from the manufacturing method using the conventional plugging method, in which the moisture content is lower than the conventional plugging material, and a so-called clay-like plugging material is used. The method of filling is adopted. In this case, the plugged honeycomb-shaped substrate does not need to be fired, and plugging can be performed on an unfired honeycomb-shaped substrate. Therefore, it is possible to reduce the two firing steps required for the conventional method for manufacturing a honeycomb filter having a plugged portion to one. That is, it is possible to simplify the manufacturing process of the honeycomb filter and to contribute to the reduction of the manufacturing cost.
【００２７】 続いて、図１に示すように、ハニカムの
多数の流通路３の片側端部、例えば上流側Ｂを１マスご
とに目封じ材を圧入することによって封じた後、再び６
０〜１００℃、１２時間程度乾燥する。なお、目封じ材
は既に述べた方法にしたがって調製すればよいが、この
とき、焼成の際の材質間の熱膨張差に起因するクラック
の発生を防止することを目的として、目封じ材にも前記
造孔剤を適当量添加することが好ましい。ただし、目封
じの効果が損なわれることがないよう、充分な目封じ深
さを設ける必要がある。したがって、目封じ深さは１５
〜３０ｍｍであることが好ましい。１５ｍｍ未満では充
分な目封じ効果を得ることができないおそれがあり、３
０ｍｍ超では充分な目封じ効果を得ることができる反
面、フィルタの濾過面積が減少してしまうために好まし
くない。Subsequently, as shown in FIG. 1, one end of each of the plurality of flow passages 3 of the honeycomb, for example, the upstream side B is sealed by press-fitting a plugging material for each square, and then the honeycomb is again sealed.
Dry at 0-100 ° C for about 12 hours. Note that the plugging material may be prepared according to the method described above, but at this time, the plugging material may also be prepared for the purpose of preventing the occurrence of cracks due to the difference in thermal expansion between the materials during firing. It is preferable to add an appropriate amount of the pore-forming agent. However, it is necessary to provide a sufficient plugging depth so that the plugging effect is not impaired. Therefore, the sealing depth is 15
It is preferably about 30 mm. If the thickness is less than 15 mm, a sufficient plugging effect may not be obtained.
If it exceeds 0 mm, a sufficient plugging effect can be obtained, but the filtering area of the filter is undesirably reduced.
【００２８】 次に、流通路３の反対側端部、例えば下
流側Ｃを、上流側Ｂとは逆に１マスごとに目封じ材を圧
入することによって封じた後、乾燥する。このときの乾
燥温度、および時間は概ね６０〜１００℃、１２時間程
度でよい。その後、約１３８０〜１４２０℃にて３．５
時間焼成を行い、多孔質のセラミックス基材からなるハ
ニカムフィルタを製造することができる。Next, the opposite end of the flow passage 3, for example, the downstream side C, is sealed by press-fitting a plugging material for each square, contrary to the upstream side B, and then dried. The drying temperature and time at this time may be about 60 to 100 ° C. for about 12 hours. Then, at about 1380-1420 ° C, 3.5
By firing for a time, a honeycomb filter made of a porous ceramic substrate can be manufactured.
【００２９】 なお、前記各工程により製造したハニカ
ムフィルタの表面には、捕捉効率を上げつつ、小圧力損
失を実現すべく、多孔質である基材よりもさらに平均気
孔径の小さいフィルタ層を設けて用いることが一般的で
あり、そのフィルタ層を設ける方法としては動加圧真空
法、気流コート法、ディッピング法、スラリー直濾過法
等を挙げることができる。いずれの方法によってもハニ
カムフィルタの表面に好適にフィルタ層を設けることが
可能であり、いずれかの方法を適宜選択すればよい。A filter layer having an average pore diameter smaller than that of a porous base material is provided on the surface of the honeycomb filter manufactured in each of the above steps so as to increase the capture efficiency and achieve a small pressure loss. The method of providing the filter layer is generally a dynamic pressure vacuum method, an air flow coating method, a dipping method, a slurry direct filtration method, or the like. The filter layer can be suitably provided on the surface of the honeycomb filter by any of the methods, and any method may be appropriately selected.
【００３０】[0030]
【実施例】 以下、本発明の具体的な実施結果を説明す
る。端面が一辺１５ｍｍの正方形状を有する長さ５００
ｍｍのハニカム構造を有する基材に、スラリー直濾過法
により、基材よりも平均気孔径の小さいフィルタ層を設
けた複層構造のハニカムフィルタを製造した。以下、そ
の実施例の詳細を説明する。EXAMPLES Specific results of the present invention will be described below. The end face has a square shape having a square shape with a side of 15 mm.
A honeycomb filter having a multilayer structure in which a filter layer having an average pore diameter smaller than that of the base material was provided on a base material having a honeycomb structure of 1 mm by a slurry direct filtration method. Hereinafter, details of the embodiment will be described.
【００３１】（実施例１〜５、比較例１〜８）原材料と
してカオリン、タルク、シリカ、アルミナ、及び造孔剤
としてカーボングラファイト、並びに成形助剤として有
機バインダー（メチルセルロース）を使用して坏土を作
製し、一般的な押出し成形法により所定のセルピッチを
有するハニカム構造体とした。乾燥後、図１に示すよう
に、ハニカムの多数の流通路３の端部を上流側Ｂと下流
側Ｃとを逆に１マスごとに所定の目封じ材を用いて封
じ、再度乾燥後、１４００℃、３．５時間焼成を行っ
て、コーディライトからなる多孔質のセラミックス基材
であるハニカムフィルタを製造した。各実施例における
セルピッチ、目封じ材原料、目封じ材を構成する焼粉と
生粉の配合割合、篩目開き寸法、調合水比、ならびに各
実施例に示す条件により製造したハニカムフィルタの目
封じ深さ、最外周と最外周以外の流通路の目封じ深さ平
均値の比を表１に示す。なお、ここでいう調合水比と
は、セラミックス粉砕物１００重量部に対して添加した
水の重量部のことであり、焼粉とは基材の焼成粉砕物、
生粉とは基材の未焼成粉砕物のことである。(Examples 1 to 5, Comparative Examples 1 to 8) Clay using kaolin, talc, silica and alumina as raw materials, carbon graphite as a pore-forming agent, and an organic binder (methyl cellulose) as a forming aid. Was prepared to obtain a honeycomb structure having a predetermined cell pitch by a general extrusion molding method. After drying, as shown in FIG. 1, the ends of a large number of the flow passages 3 of the honeycomb are reversely sealed on the upstream side B and the downstream side C with a predetermined plugging material for each cell, and after drying again, By firing at 1400 ° C. for 3.5 hours, a honeycomb filter as a porous ceramic substrate made of cordierite was manufactured. The cell pitch in each example, the plugging material, the mixing ratio of the baked powder and the raw powder constituting the plugging material, the sieve opening size, the mixing water ratio, and the plugging of the honeycomb filter manufactured according to the conditions shown in each example. Table 1 shows the depth and the ratio between the outermost circumference and the average of the plugging depths of the flow passages other than the outermost circumference. Here, the blended water ratio is a part by weight of water added to 100 parts by weight of the crushed ceramic material, and the calcined powder is a baked and crushed material of the base material,
The raw powder is an unfired pulverized product of a base material.
【００３２】 前記工程により製造した各ハニカムフィ
ルタの表面上に、平均粒子径が１０μｍのセラミックス
粒子よりなる、平均フィルタ層厚５０μｍの単一フィル
タ層を設けた。すなわち、原材料としてコーディライト
からなる基材粉砕物を使用し、一般的なスラリー直濾過
法によってフィルタ層を設け、乾燥後、１３５０℃、５
時間焼成を行って複層構造のハニカムフィルタを製造し
た。A single filter layer made of ceramic particles having an average particle diameter of 10 μm and having an average filter layer thickness of 50 μm was provided on the surface of each honeycomb filter manufactured by the above-described process. That is, a ground material of cordierite is used as a raw material, a filter layer is provided by a general slurry direct filtration method, and after drying, at 1350 ° C., 5
By firing for a time, a honeycomb filter having a multilayer structure was manufactured.
【００３３】（目封じ部強度確認試験）目封じ部に金属
棒を押し付け、流通路と平行に荷重をかけていき、当該
目封じ部が押し抜かれたときの荷重値を測定することに
よって目封じ部強度確認試験を行った。なお、荷重値は
２９４Ｎとした。次いで、目封じ部とその周辺における
クラック、剥離、脱落、および基材のクラック発生の有
無を目視観察し、また、ハニカムフィルタの品質総合評
価を行った。結果を表１に示す。なお、品質総合評価の
基準は、目封じ部におけるクラック、剥離、脱落、およ
び基材のクラックのいずれも発生しなかったものを◎、
いずれかが微小発生したものを△、いずれかが明らかに
発生したものを×とした。(Test for confirming the strength of the plugged portion) A metal rod is pressed against the plugged portion, a load is applied in parallel with the flow passage, and the load value is measured when the plugged portion is pushed out to measure the plugging. A partial strength confirmation test was performed. The load value was 294N. Next, the presence or absence of cracks, peeling, falling off, and cracks in the base material at and around the plugged portion was visually observed, and the overall quality of the honeycomb filter was evaluated. Table 1 shows the results. In addition, the criteria of the comprehensive quality evaluation were as follows: cracks in the plugged portions, peeling, falling off, and those in which neither of the base material cracks occurred
Any one of which was minutely generated was rated as Δ, and one of which was clearly generated was rated as x.
【００３４】[0034]
【表１】 [Table 1]
【００３５】（考察）比較例３〜８においては、２９４
Ｎ未満の荷重値で目封じ部が押し抜かれた。それに対
し、実施例１〜５においては、２９４Ｎの荷重値で目封
じ部が押し抜かれることはなかった。また、実施例１〜
５においては、目封じ部とその周辺に欠陥が生ずること
もなかった。目封じ材原料、目封じ材を構成する焼粉と
生粉の配合割合、篩目開き寸法、調合水比、ならびに目
封じ深さ、最外周と最外周以外の流通路の目封じ深さ平
均値の比を、本発明に示すような所定の原料および数値
範囲内に規定することによって、目封じ部において欠陥
が発生せず、また、十分な強度確保が可能であることが
判明し、本発明の優れた効果を確認することができた。(Consideration) In Comparative Examples 3 to 8, 294
The sealing portion was pushed out with a load value less than N. In contrast, in Examples 1 to 5, the plugged portion was not pushed out with a load value of 294N. Further, Examples 1 to
In No. 5, no defect occurred in the plugged portion and its periphery. Plugging material, blending ratio of roasted powder and raw powder that constitute the plugging material, sieve opening size, mixing water ratio, and plugging depth, average of plugging depth of the outermost circumference and flow passages other than the outermost circumference By defining the ratio of the values within a predetermined raw material and a numerical range as shown in the present invention, it was found that no defect occurs in the plugged portion and that sufficient strength can be ensured. The excellent effects of the invention could be confirmed.
【００３６】[0036]
【発明の効果】 以上説明したように、本発明のハニカ
ムフィルタによれば、目封じ部を構成する材質や組成、
粒径等を所定の数値範囲内に規定しているために、目封
じ部、および基材にクラックが発生したり、目封じ部が
基材からの剥離や脱落が起こり難いといった優れた特性
を有している。また、本発明のハニカムフィルタの製造
方法は、上記特性を具備するハニカムフィルタを提供す
ることが可能であるとともに、その製造工程が短縮さ
れ、かつ、製造コストの削減も効果的になされている優
れた製造方法である。As described above, according to the honeycomb filter of the present invention, the material and the composition of the plugging portion,
Since the particle size and the like are specified within a predetermined numerical range, the plugging portion and the base material have excellent characteristics such that cracks are generated and the plugging portion is unlikely to peel off or fall off from the base material. Have. In addition, the method for manufacturing a honeycomb filter according to the present invention is capable of providing a honeycomb filter having the above-described characteristics, and the manufacturing process is shortened, and the manufacturing cost is effectively reduced. Manufacturing method.
【図１】 本発明に係るハニカムフィルタの一実施態様
を説明する部分断面図である。FIG. 1 is a partial cross-sectional view illustrating one embodiment of a honeycomb filter according to the present invention.
【図２】 目封じ深さ平均値の測定・算出方法を説明す
る模式図である。FIG. 2 is a schematic diagram illustrating a method for measuring and calculating an average plugging depth.
１…ハニカムフィルタ、２…目封じ部、３…流通路、４
…隔壁部、５…流通路端部、６…目封じ部先端、７…切
断部。DESCRIPTION OF SYMBOLS 1 ... Honeycomb filter, 2 ... Sealing part, 3 ... Flow path, 4
... partition wall part, 5 ... end of flow passage, 6 ... tip of plugging part, 7 ... cutting part.
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4D019 AA01 BA05 BB06 BD10 CA01 CB06 4D058 JA32 JB06 KA11 KA23 KA25 KA27 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4D019 AA01 BA05 BB06 BD10 CA01 CB06 4D058 JA32 JB06 KA11 KA23 KA25 KA27
Claims (10)
該流通路の端部が交互に目封じされた多孔質のセラミッ
クス基材からなるハニカムフィルタであって、 目封じ材が該セラミックス基材と同じ材質のセラミック
ス粉砕物から構成されていることを特徴とするハニカム
フィルタ。1. It has a number of parallel flow paths,
A honeycomb filter comprising a porous ceramic base material in which ends of the flow passages are alternately plugged, wherein the plugging material is formed of a crushed ceramic material of the same material as the ceramic base material. And a honeycomb filter.
なる請求項１記載のハニカムフィルタ。2. The honeycomb filter according to claim 1, wherein the crushed ceramic material comprises 70 to 80% by weight of a fired and crushed ceramic base material and 20 to 30% by weight of an unfired crushed ceramic base material.
μｍである請求項１または２に記載のハニカムフィル
タ。3. The maximum particle size of the crushed ceramic material is 500.
The honeycomb filter according to claim 1, wherein the thickness of the honeycomb filter is μm.
量部と水３３〜４３重量部からなる請求項１〜３のいず
れか一項に記載のハニカムフィルタ。4. The honeycomb filter according to claim 1, wherein the plugging material comprises 100 parts by weight of the crushed ceramic material and 33 to 43 parts by weight of water.
が、最外周の流通路の目封じ深さ平均値の１．１〜１．
３倍である請求項１〜４のいずれか一項に記載のハニカ
ムフィルタ。5. The average plugging depth of the flow passages other than the outermost circumference is 1.1 to 1.
The honeycomb filter according to any one of claims 1 to 4, which is three times as large.
数の平行な流通路を有するハニカム形状に成形する成形
工程と、該流通路の端部を交互に目封じする目封じ工程
と、ハニカム成形体を焼成する焼成工程とを含む多孔質
のセラミックス基材からなるハニカムフィルタの製造方
法であって、 該セラミックス基材と同材質のセラミックスを粉砕し、
当該セラミックス粉砕物を用いて目封じすることを特徴
とするハニカムフィルタの製造方法。6. A forming step of forming a kneaded material prepared from ceramic powder into a honeycomb shape having a number of parallel flow passages, a plugging step of alternately plugging ends of the flow passages, and a honeycomb formed body. And a firing step of firing a honeycomb filter comprising a porous ceramic base material, comprising: crushing ceramics of the same material as the ceramic base material;
A method for manufacturing a honeycomb filter, comprising plugging using the crushed ceramic material.
混合物である請求項６記載のハニカムフィルタの製造方
法。7. The honeycomb filter according to claim 6, wherein the crushed ceramic material is a mixture of 70 to 80% by weight of a baked and crushed ceramic base material and 20 to 30% by weight of an unfired crushed ceramic base material. Production method.
ミックス粉砕物を用いる請求項６または７に記載のハニ
カムフィルタの製造方法。8. The method for manufacturing a honeycomb filter according to claim 6, wherein a pulverized ceramic material passed through a sieve having an opening of 500 μm or less is used.
し、水３３〜４３重量部を混合した目封じ材を用いて目
封じする請求項６〜８のいずれか一項に記載のハニカム
フィルタの製造方法。9. The method for manufacturing a honeycomb filter according to claim 6, wherein the plugging is performed using a plugging material obtained by mixing 33 to 43 parts by weight of water with respect to 100 parts by weight of the crushed ceramic material. .
請求項６〜９のいずれか一項に記載のハニカムフィルタ
の製造方法。10. The method for manufacturing a honeycomb filter according to claim 6, further comprising a firing step after the plugging step.
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005046764A (en) * | 2003-07-30 | 2005-02-24 | Asahi Glass Co Ltd | Sealing material for silicon nitride-based honeycomb filter and method for sealing silicon nitride-based honeycomb filter by using the same |
| JP2005125318A (en) * | 2003-09-29 | 2005-05-19 | Hitachi Metals Ltd | Ceramic honeycomb filter and production method therefor, and sealing material for ceramic honeycomb filter |
| EP1428809A3 (en) * | 2002-12-12 | 2005-11-30 | Ngk Insulators, Ltd. | Process for production of formed honeycomb body, and honeycomb structure |
| JP2008136919A (en) * | 2006-11-30 | 2008-06-19 | Hitachi Metals Ltd | Ceramic honeycomb filter and its manufacturing method |
| US7691167B2 (en) | 2003-09-29 | 2010-04-06 | Hitachi Metals, Ltd. | Ceramic honeycomb filter, its production method, and plugging material for ceramic honeycomb filter |
| JP2011206679A (en) * | 2010-03-30 | 2011-10-20 | Ngk Insulators Ltd | Plugged honeycomb structure and method for manufacturing the same |
| KR20170061670A (en) | 2014-09-30 | 2017-06-05 | 히타치 긴조쿠 가부시키가이샤 | Ceramic honeycomb filter and method for manufacturing same |
| JP2019063789A (en) * | 2017-09-29 | 2019-04-25 | 日立金属株式会社 | Manufacturing method of ceramic honeycomb filter and ceramic honeycomb filter |
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| JPH01297114A (en) * | 1988-05-24 | 1989-11-30 | Ibiden Co Ltd | Mesh sealing material for honeycomb filter |
| JPH0253083B2 (en) * | 1980-08-28 | 1990-11-15 | Ngk Insulators Ltd | |
| JPH0631133Y2 (en) * | 1988-10-31 | 1994-08-22 | いすゞ自動車株式会社 | Exhaust gas purification filter |
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| JPH0253083B2 (en) * | 1980-08-28 | 1990-11-15 | Ngk Insulators Ltd | |
| JPS6257624A (en) * | 1985-09-07 | 1987-03-13 | Matsushita Electric Ind Co Ltd | Production of plug for waste gas filter |
| JPS63126514A (en) * | 1986-11-14 | 1988-05-30 | Matsushita Electric Ind Co Ltd | Filter for exhaust gas of diesel engine |
| JPH01297114A (en) * | 1988-05-24 | 1989-11-30 | Ibiden Co Ltd | Mesh sealing material for honeycomb filter |
| JPH0631133Y2 (en) * | 1988-10-31 | 1994-08-22 | いすゞ自動車株式会社 | Exhaust gas purification filter |
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1428809A3 (en) * | 2002-12-12 | 2005-11-30 | Ngk Insulators, Ltd. | Process for production of formed honeycomb body, and honeycomb structure |
| JP2005046764A (en) * | 2003-07-30 | 2005-02-24 | Asahi Glass Co Ltd | Sealing material for silicon nitride-based honeycomb filter and method for sealing silicon nitride-based honeycomb filter by using the same |
| JP2005125318A (en) * | 2003-09-29 | 2005-05-19 | Hitachi Metals Ltd | Ceramic honeycomb filter and production method therefor, and sealing material for ceramic honeycomb filter |
| US7691167B2 (en) | 2003-09-29 | 2010-04-06 | Hitachi Metals, Ltd. | Ceramic honeycomb filter, its production method, and plugging material for ceramic honeycomb filter |
| KR101123173B1 (en) | 2003-09-29 | 2012-03-19 | 히타치 긴조쿠 가부시키가이샤 | Ceramic honeycomb filter and method for production thereof |
| JP2008136919A (en) * | 2006-11-30 | 2008-06-19 | Hitachi Metals Ltd | Ceramic honeycomb filter and its manufacturing method |
| JP2011206679A (en) * | 2010-03-30 | 2011-10-20 | Ngk Insulators Ltd | Plugged honeycomb structure and method for manufacturing the same |
| KR20170061670A (en) | 2014-09-30 | 2017-06-05 | 히타치 긴조쿠 가부시키가이샤 | Ceramic honeycomb filter and method for manufacturing same |
| US9981881B2 (en) | 2014-09-30 | 2018-05-29 | Hitachi Metals, Ltd. | Ceramic honeycomb filter and its production method |
| EP3517195A1 (en) | 2014-09-30 | 2019-07-31 | Hitachi Metals, Ltd. | Method for producing a ceramic honeycomb filter |
| US10556833B2 (en) | 2014-09-30 | 2020-02-11 | Hitachi Metals, Ltd. | Ceramic honeycomb filter and its production method |
| JP2019063789A (en) * | 2017-09-29 | 2019-04-25 | 日立金属株式会社 | Manufacturing method of ceramic honeycomb filter and ceramic honeycomb filter |
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