WO2011142292A1 - Mask for sealing honeycomb structure, and sealing method for honeycomb structure using same - Google Patents
Mask for sealing honeycomb structure, and sealing method for honeycomb structure using same Download PDFInfo
- Publication number
- WO2011142292A1 WO2011142292A1 PCT/JP2011/060550 JP2011060550W WO2011142292A1 WO 2011142292 A1 WO2011142292 A1 WO 2011142292A1 JP 2011060550 W JP2011060550 W JP 2011060550W WO 2011142292 A1 WO2011142292 A1 WO 2011142292A1
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- WIPO (PCT)
- Prior art keywords
- mask
- honeycomb structure
- hole
- opening area
- cell
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/003—Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
- B28B11/006—Making hollow articles or partly closed articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/003—Apparatus or processes for treating or working the shaped or preshaped articles the shaping of preshaped articles, e.g. by bending
- B28B11/006—Making hollow articles or partly closed articles
- B28B11/007—Using a mask for plugging
Definitions
- the present invention relates to a mask used for sealing a honeycomb structure and a method for sealing a honeycomb structure using the mask.
- honeycomb filter structures have been widely known for DPF (Diesel particulate filter) and the like.
- This honeycomb filter structure has a structure in which one end side of a part of cells of a cell structure including a large number of through holes is sealed with a sealing material, and the other end side of the remaining cells is sealed with a sealing material.
- a mask is used to seal a predetermined cell among many cells of the honeycomb structure.
- Patent Documents 1 and 2 describe a method for sealing a honeycomb structure using a mask.
- the mask of the type in which the through holes are provided in advance needs to be aligned with the honeycomb structure.
- the honeycomb structure is a sintered body manufactured through a drying process or a firing process, such as DPF, or a green molded body before firing
- the through-holes of the mask are caused by the shrinkage or deformation of the honeycomb structure in the manufacturing process.
- the cell to be sealed become more difficult to align.
- Some DPFs have a narrow cell pitch (for example, about 1.1 to 2.8 mm). Even if the through-holes of the mask can be appropriately arranged on a part of the end face of the honeycomb structure, the other parts are not displaced. It may occur.
- the present invention has been made in view of the above problems, and can be easily aligned with the end face of the honeycomb structure, and uses a mask useful for reliably sealing a predetermined cell.
- the purpose is to provide a sealing method.
- the mask according to the present invention is used for sealing a cell of a honeycomb structure, and has a plurality of first through holes penetrating from one surface of the mask to the other surface, and the first penetration on the other surface.
- the opening area of the hole is smaller than the opening area of the first through hole on one surface.
- the mask of the present invention is used in a state where the other surface of the mask (the surface with the smaller opening area) is in contact with the end surface of the honeycomb structure. According to the mask, by reducing the opening area of the first through hole on the other surface, the sealing material can be passed through the first through hole even if the position of the first through hole and the position of the cell opening are slightly shifted. It can be supplied into a predetermined cell. Further, the mask has an advantage that sufficient rigidity is easily ensured as compared with a mask having a large opening area of the entire first through hole.
- the first through hole may have a tapered portion whose opening area continuously decreases from one surface to the other surface, or the opening area from one surface to the other surface. May have a stepped portion that discontinuously shrinks.
- the first through hole preferably has an opening area of 0.03 mm 2 or more on the other surface and less than 90% of the opening area of the cells of the honeycomb structure to be sealed by the first through hole.
- the mask according to the present invention has a plurality of second through-holes penetrating in the thickness direction of the mask in a portion in contact with the peripheral edge of the end face of the honeycomb structure in a region in contact with the end face of the honeycomb structure in use. May further be included.
- the second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cells to be sealed by the first through holes Is preferably less than 60%.
- the shape of the cell may be different from other parts due to the presence of the outermost layer forming the side surface of the honeycomb structure.
- the shape of the outermost layer is a cylindrical shape and cells having a square cross-sectional shape are provided therein, a complete cell having a square cross-sectional shape and an incomplete cell in the peripheral portion are formed.
- the second through-hole is useful for completely sealing the incomplete cell as described above and, if necessary, the cell adjacent thereto. That is, the opening area of the second through-hole is limited to less than 60% of the opening area of the cell (complete cell) to be sealed by the first through-hole, while the arrangement of the second through-hole is limited to that of the honeycomb structure.
- the sealing material can be appropriately supplied to the cell to be sealed through the second through hole. Further, by setting the opening area of the second through hole to 0.03 mm 2 or more, the sealing material can easily pass through the second through hole, and a predetermined amount of the sealing material can be easily supplied into the cell.
- the present invention provides a method for sealing the opening of a predetermined cell of a honeycomb structure using the mask. That is, the present invention is a method for sealing cells of a honeycomb structure, (A) placing a mask on one end face of the honeycomb structure; (B) supplying a sealing material through the first through hole of the mask to the opening of the cell to be sealed on one end face of the honeycomb structure;
- the mask has a plurality of first through holes penetrating from one side to the other side, and the opening area of the first through hole on the other side is larger than the opening area of the first through hole on the one side
- the sealing method can be configured as follows. That is, the mask further includes a plurality of second through-holes penetrating in the thickness direction of the mask in a portion that contacts the peripheral edge of the end face of the honeycomb structure in a region that contacts one end face of the honeycomb structure. And the second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cell to be sealed by the first through holes It can be less than 60%.
- the sealing material is supplied to the opening of the cell to be sealed at the peripheral edge of the end face of the honeycomb structure through the second through hole of the mask.
- the sealing method may further include a step of sealing the other end surface after the step of sealing one end surface of the honeycomb structure.
- a honeycomb filter structure can be obtained by performing steps such as drying and firing as necessary. That is, the sealing method is (C) placing another mask on the other end face of the honeycomb structure; (D) A step of supplying a sealing material to the opening of the cell to be sealed on the other end face of the honeycomb structure through the third through hole of the other mask may be further provided.
- the other mask has a plurality of third through holes penetrating from one surface to the other surface, and the opening area of the third through hole on the other surface is the opening of the third through hole on the one surface.
- the mask is arranged so that the other side of the mask is in contact with the end face of the honeycomb structure in the step (a).
- the sealing method can be configured as follows. That is, the other mask has a plurality of fourth penetrations penetrating in the thickness direction of the mask in a portion of the region contacting the other end face of the honeycomb structure and contacting the peripheral edge of the end face of the honeycomb structure.
- the fourth through-holes are provided at intervals narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the cells to be sealed by the third through-holes are further provided.
- a sealing material is supplied through the fourth through hole of the mask to the opening of the cell to be sealed at the peripheral edge of the end face of the honeycomb structure.
- alignment with the end face of the honeycomb structure can be easily performed, and a predetermined cell can be more reliably sealed as compared with the conventional case.
- FIG. 1 (a) is a perspective view showing an example of a honeycomb structure
- FIG. 1 (b) is a partially enlarged view of FIG. 1 (a).
- 2A is a perspective view showing an embodiment of a mask according to the present invention
- FIG. 2B is a partially enlarged view of FIG.
- FIG. 3 is a partial cross-sectional view taken along the line III-III in FIG.
- FIGS. 4A and 4B are partial cross-sectional views showing other aspects of the first through hole included in the mask according to the present invention.
- FIG. 5 is a schematic cross-sectional view showing an example of a sealing device.
- FIG. 6 is a view taken along arrow VI-VI of the sealing device of FIG. FIG.
- FIG. 7A is a perspective view showing another embodiment of the mask according to the present invention
- FIG. 7B is a partially enlarged view of FIG.
- FIG. 8A is a partial end view for explaining the operation of the sealing device of FIG. 6,
- FIG. 8B is a partial cross-sectional view subsequent to FIG. 9A is a partial cross-sectional view subsequent to FIG. 8B
- FIG. 9B is a partial cross-sectional view subsequent to FIG. 9A
- FIG. 10A is a partial cross-sectional view subsequent to FIG. 9B
- FIG. 11B is a partial cross-sectional view subsequent to FIG. 11A.
- FIG. 12 is a partial cross-sectional view showing a state in which an elastic plate enters the first through hole of the mask according to the present invention.
- the honeycomb structure 1 is a cylindrical body in which a large number of cells 1a are arranged substantially in parallel.
- the cell 1a penetrates from one end face of the honeycomb structure 1 to the other end face.
- the cross-sectional shape of the cell 1a is a square as shown in FIG.
- the plurality of cells 1a are arranged in a square arrangement in the honeycomb structure 1 so that the central axis of the cells 1a is located at the apexes of the squares as viewed from the end face.
- the size of the square of the cross section of the cell 1a can be, for example, 0.8 to 2.5 mm on a side, and the opening area is about 0.6 to 7.0 mm 2 (more preferably 0.8 to 6.0 mm). 2 ).
- the cell pitch of the honeycomb structure 1 can be set to 1.1 to 2.8 mm. Note that the cell pitch means the distance between the centers of two adjacent cells, and in the honeycomb structure 1, is the length L shown in FIG.
- the shape of the outermost layer 1c forming a side surface is a cylindrical shape, and as described above, the cell 1a having a square cross-sectional shape inside thereof (hereinafter referred to as “complete cell 1a” or simply “cell 1a”). .)
- the honeycomb structure 1 has cells 1b (hereinafter referred to as “incomplete cells 1b” or simply “cells 1b”) whose cross-sectional shape is not square at the peripheral edge thereof. As shown in FIG. 1B, the shape of the incomplete cell 1b is not constant but varies depending on the location.
- the length in the direction in which the through holes constituting the cells 1a and 1b of the honeycomb structure 1 extend is not particularly limited, but may be, for example, 40 to 350 mm.
- the outer diameter of the honeycomb structure 1 is not particularly limited, but may be, for example, 100 to 320 mm.
- the material of the honeycomb structure 1 is not particularly limited, but a ceramic material is preferable from the viewpoint of high temperature resistance.
- the ceramic material include alumina, silica, mullite, cordierite, glass, oxides such as aluminum titanate, silicon carbide, silicon nitride, and metal.
- the aluminum titanate can further contain magnesium and / or silicon.
- Such a honeycomb structure 1 is usually porous.
- the honeycomb structure 1 may be a green molded body (unfired molded body) that becomes a ceramic material as described above by firing later.
- a green molded object contains the inorganic compound source powder which is a ceramic raw material, organic binders, such as methylcellulose, and the additive added as needed.
- the inorganic compound source powder includes an aluminum source powder such as ⁇ -alumina powder, and a titanium source powder such as anatase-type or rutile-type titania powder.
- magnesium source powders such as magnesia powder and magnesia spinel powder and / or silicon source powders such as silicon oxide powder and glass frit can be included.
- organic binder examples include celluloses such as methylcellulose, carboxymethylcellulose, hydroxyalkylmethylcellulose, and sodium carboxymethylcellulose; alcohols such as polyvinyl alcohol; and lignin sulfonate.
- additives include a pore-forming agent, a lubricant, a plasticizer, a dispersant, and a solvent.
- pore-forming agents include carbon materials such as graphite; resins such as polyethylene, polypropylene, and polymethyl methacrylate; plant materials such as starch, nut shells, walnut shells, and corn; ice; and dry ice.
- Lubricants and plasticizers include alcohols such as glycerin; higher fatty acids such as caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid and stearic acid; metal stearates such as Al stearate, polyoxyalkylene alkyl And ether (POAAE).
- alcohols such as glycerin
- higher fatty acids such as caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid and stearic acid
- metal stearates such as Al stearate, polyoxyalkylene alkyl And ether (POAAE).
- dispersant examples include inorganic acids such as nitric acid, hydrochloric acid and sulfuric acid; organic acids such as oxalic acid, citric acid, acetic acid, malic acid and lactic acid; alcohols such as methanol, ethanol and propanol; ammonium polycarboxylate, poly Surfactants such as oxyalkylene alkyl ethers are listed.
- solvent for example, alcohols such as methanol, ethanol, butanol and propanol; glycols such as propylene glycol, polypropylene glycol and ethylene glycol; and water can be used.
- a mask 5 shown in FIG. 2 is used for sealing predetermined cells of the honeycomb structure 1 shown in FIG.
- the mask 5 is a circular plate-like member, and has a first through hole 5a and a second through hole 5b that penetrate in the thickness direction.
- the material of the mask 5 is not specifically limited, For example, a metal and resin are mentioned.
- an orientation flat 5c is formed on the mask 5, and the ring member 25 of the sealing device 100 shown in FIG. Corresponding protrusions 25b may be provided (see FIG. 6).
- the outer diameter of the mask 5 is preferably larger than the inner diameter of the recess 10 d of the main body 10 of the sealing device 100.
- the first through holes 5a are for supplying the sealing material to the complete cells 1a of the honeycomb structure 1.
- the first through-hole 5a is provided in a portion that contacts the central portion (region other than the peripheral portion) of the end face of the honeycomb structure 1 when the mask 5 is used.
- the cross-sectional shape of the first through hole 5a is a square corresponding to the cell 1a of the honeycomb structure 1 as shown in FIG. These first through-holes 5a are arranged in a staggered manner, and each first through-hole 5a is not adjacent to each other among the plurality of squarely arranged cells 1a in FIG. Are arranged to face only the plurality of cells 1a.
- the shape of the first through hole 5a is not limited to a square, but is smaller than the opening of the cell 1a and is similar to the shape from the viewpoint of the filling property of the paste-like sealing material. It is preferable.
- the first through hole 5a is tapered as shown in FIG. 3, and the opening area differs depending on the position of the mask 5 in the thickness direction. That is, the opening area is continuously reduced from one surface F1 of the mask 5 to the other surface F2.
- the mask 5 is used in a state where the face F2 of the mask 5 is in contact with the end face of the honeycomb structure 1.
- the first through hole 5a is not limited to the tapered shape shown in FIG. 3 as long as the opening area on the surface F2 is smaller than the opening area on the surface F1.
- the first through hole 5a includes a tapered portion 6a whose opening area continuously decreases from the surface F1 toward the surface F2, and a surface F2 side of the tapered portion 6a. It may be constituted by a portion 6b which is located and has a constant opening area. Further, as shown in FIG. 4B, the first through hole 5a may have a step portion 6c whose opening area decreases discontinuously from the surface F1 toward the surface F2.
- the taper angle in the first through hole 5a (angle ⁇ in FIGS. 3 and 4A) is 10 to 70 ° from the viewpoint of the rigidity of the mask 5 and the loss of the sealing material.
- the angle is preferably 30 to 60 °.
- the first through hole 5a preferably has an opening area on the surface F2 of 0.03 mm 2 or more and less than 90% of the opening area of the cell 1a to be sealed by the first through hole 5a.
- the opening area of the first through-hole 5a is more preferably 0.05 mm 2 or more, still more preferably 0.07 mm 2 or more, it may be 0.2 mm 2 or more.
- the opening area on the surface F2 of the first through hole 5a is 90% or more of the opening area of the cell 1a, the position of the first through hole 5a and the position of the opening of the cell 1a are slightly shifted. There is a possibility that the sealing material may be supplied to the neighboring cell 1a that should not be sealed.
- the opening area of the first through-hole 5a is preferably less than 80% and more preferably less than 60% of the opening area of the cell 1a.
- the second through hole 5b is for supplying the sealing material to the incomplete cell 1b of the honeycomb structure 1.
- the second through-holes 5b are provided at a portion narrower than the cell pitch of the honeycomb structure 1 (length L in FIG. 1) at a portion that contacts the peripheral edge of the end face of the honeycomb structure 1 when the mask 5 is used. Preferably it is.
- the interval between the second through holes 5b is preferably L / 10 to 3L / 4, more preferably L / 5 to L / 2, from the viewpoint of reliably sealing all the cells 1b.
- the shape of the second through-hole 5b may be any shape that can provide a large number of through-holes in a limited region regardless of the shape of the incomplete cell 1b.
- the shape of the second through-hole 5b is For example, it may be circular or rectangular, but is preferably circular.
- the mask 5 is formed with an annular band composed of a number of second through holes 5b.
- the second through hole 5b preferably has an opening area on the surface F2 of 0.03 mm 2 or more and less than 60% of the opening area of the cell 1a to be sealed by the first through hole 5a.
- the opening area of the second through hole 5b is more preferably 0.04 mm 2 or more, still more preferably 0.05 mm 2 or more, it may be 0.2 mm 2 or more.
- the opening area on the surface F2 of the second through hole 5b is 60% or more of the opening area of the complete cell 1a, the rigidity of the mask 5 tends to be insufficient, and the mask 5 is sealed with a slight shift. There is a possibility that the sealing material is supplied to the cell 1a in the vicinity which should not be, or the sealing material may easily leak to the outside of the outermost layer 1c shown in FIG.
- the opening area of the second through-hole 5b is preferably 50% or less, more preferably 40% or less of the opening area of the complete cell 1a.
- the opening area of the second through-hole 5b may be constant over the entire range in the thickness direction of the mask 5, or, similarly to the first through-hole 5a shown in FIGS. It may be different depending on the position.
- the mask 5 by reducing the opening area of the first through hole 5a on the surface F2 contacting the end face of the honeycomb structure 1, the position of the first through hole 5a and the position of the opening of the cell 1a are somewhat different. Even if it deviates, the sealing material can be supplied into the predetermined cell 1a through the first through hole 5a.
- the mask 5 has an advantage that it is easy to ensure sufficient rigidity as compared with the case where the entire opening area of the first through-hole 5a is increased. Further, by providing a large number of second through holes 5b in the mask 5, it is possible to more reliably seal the incomplete cell 1b.
- a sealing device suitable for sealing the honeycomb structure 1 using the mask 5 will be described.
- a sealing device 100 shown in FIG. 5 mainly includes a main body unit 10, an elastic plate 20, a pump 50, and a holding unit 80.
- the main body 10 is made of a rigid material.
- the rigid material include metals such as stainless steel and polymer materials such as fiber reinforced plastic.
- a recess 10 d is formed on the upper surface 10 a of the main body 10.
- the shape of the recess 10d is a columnar shape as shown in FIGS.
- the side surface 10b of the recess 10d is perpendicular to the upper surface 10a of the main body 10 and the bottom surface 10c is parallel.
- the diameter of the recess 10d can be set to 100 to 320 mm, for example.
- the depth of the recess 10d can be set to 0.2 to 20 mm, for example.
- the main body 10 is preferably provided with a vibrator 140 such as an ultrasonic vibrator.
- the elastic plate 20 is disposed on the upper surface 10a of the main body 10 so as to cover the opening surface of the recess 10d.
- the elastic plate 20 has elasticity and can be easily deformed.
- a rubber plate is preferable.
- the rubber include natural rubber, and synthetic rubber such as styrene butadiene rubber, butadiene rubber, butyl rubber, ethylene propylene rubber, nitrile rubber, chloroprene rubber, fluorine rubber, silicone rubber, and urethane rubber.
- the thickness of the elastic plate 20 is not particularly limited, but can be, for example, 0.3 to 3.0 mm.
- the elastic plate 20 is fixed to the main body 10 by a ring member 25 and a bolt 31.
- the ring member 25 has an opening 25a at a position corresponding to the concave portion 10d of the main body 10 and thereby has an annular shape.
- the ring member 25 is arrange
- Through-holes h are formed in the ring member 25 and the elastic plate 20, and screw holes j corresponding to the through-holes h are formed in the main body portion 10, and bolts 31 pass through these through-holes h.
- the peripheral portion of the elastic plate 20 is fixed in close contact with the portion around the recess 10d on the upper surface 10a of the main body 10 by being screwed into the screw hole j and fixed.
- the inner diameter of the opening 25 a of the ring member 25 is preferably larger than the inner diameter of the recess 10 d of the main body 10.
- the main body 10 further has a communication passage 10e that opens to the bottom surface 10c of the recess 10d.
- the communication path 10e opens to the bottom surface 10c of the recess 10d, but may be open to the inner surface of the recess 10d.
- the communication path 10e may open to the side surface 10b of the recess 10d.
- the shape and number of openings of the communication passage 10e are not particularly limited.
- a pump 50 is connected to the communication path 10e via a connection pipe 14.
- the pump 50 includes a cylinder 51, a piston 53 disposed in the cylinder 51, and a piston rod 54 connected to the piston 53.
- a motor 55 that reciprocates the piston rod 54 in the axial direction is connected to the piston rod 54.
- the piston rod 54 may be moved manually.
- a closed space V formed by the main body 10, the connection pipe 14, and the cylinder 51 is formed between the elastic plate 20 and the piston 53, and a fluid is contained in the closed space V.
- FL is filled.
- the fluid FL is not particularly limited, and may be a gas such as air, but is preferably a liquid, and particularly preferably spindle oil or the like. Then, by moving the piston 53, the fluid FL can be discharged from the recess 10d of the main body 10, and the fluid FL can be supplied into the recess 10d.
- a holding unit 80 is provided on the main body unit 10.
- the holding unit 80 includes a holding tool 81 that holds the honeycomb structure 1 and a pneumatic cylinder 82 to which the holding tool 81 is connected.
- the holder 81 holds the honeycomb structure 1 such that one end face faces the elastic plate 20 and the recess 10d as shown in FIG.
- the pneumatic cylinder 82 has a cylinder 82a extending in the vertical direction and a piston 82b provided in the cylinder 82a. By adjusting the pressure supplied from the outside, the pressure on both the upper and lower sides of the piston 82b can be adjusted. It has become. As a result, the pneumatic cylinder 82 can move the holder 81 in the direction in which the honeycomb structure 1 and the elastic plate 20 approach each other and in the direction in which they move away from each other. Further, the pneumatic cylinder 82 can bring the honeycomb structure 1 into close contact with the mask 5 by pressing the holder 81 downward with a predetermined force according to the gas supply pressure before and after the piston 82b.
- the pneumatic cylinder 82 can also permit the holder 81 to move freely in the vertical direction by releasing the pressure before and after the piston. That is, the holding unit 80 can switch between a state in which the honeycomb structure 1 held by the holder 81 can freely move upward and a state in which the honeycomb structure 1 is fixed to the main body 10. .
- the sealing method according to the present embodiment is for sealing the opening of a predetermined cell of the honeycomb structure 1 using the mask 5. More specifically, this sealing method comprises the following steps: (A) placing the mask 5 on one end face of the honeycomb structure 1 so that the face F2 of the mask 5 is in contact with the end face of the honeycomb structure 1; and (b) one end face of the honeycomb structure 1. Supplying a sealing material through the first through-hole 5a of the mask 5 to the opening of the cell to be sealed.
- the honeycomb structure 1 has incomplete cells 1b at the periphery as shown in FIG. Therefore, in the step (b), the sealing material is supplied to the incomplete opening of the cell 1b through the second through hole 5b of the mask 5.
- the cell sealing process is performed on one end face of the honeycomb structure 1, and then the same sealing process is performed on the other end face. That is, after the step (b), (C) the step of disposing the surface F2 ′ of the mask 5 ′ on the other end face of the honeycomb structure 1; and (d) the mask 5 ′ at the opening of the cell to be sealed on the other end face of the honeycomb structure 1. Supplying a sealing material through the third through-hole 5a '; Are carried out sequentially.
- the mask 5 ′ has third and fourth through holes 5 a ′ and 5 b ′ corresponding to the first and second through holes 5 a and 5 b of the mask 5, respectively.
- Each of the through holes 5a ′ and 5b ′ penetrates from one surface F1 of the mask 5 ′ to the other surface F2.
- the mask 5 ′ has the same configuration as the mask 5 except that the arrangement of the through holes 5a ′ is a staggered arrangement opposite to the arrangement of the through holes 5a of the mask 5 (see FIGS. 3 and 4).
- the sealing material is inserted into the opening of the incomplete cell 1b through the fourth through hole 5b ′ of the mask 5 ′. Supply.
- the pneumatic cylinder 82 is driven in advance and pulled up above the holder 81 that holds the honeycomb structure 1, and the mask 5 is removed from the elastic plate 20.
- the fluid FL is discharged downward from the recess 10 d of the main body 10.
- FIG. 8A the elastic plate 20 is deformed and is brought into close contact with the side surface 10b and the bottom surface 10c of the concave portion 10d, whereby the concave portion 20d of the elastic plate 20 is formed.
- the sealing material 130 is supplied into the recess 20 d of the elastic plate 20.
- the surface of the sealing material 130 is flattened and defoamed by driving the vibrator 140.
- the sealing material 130 is not particularly limited as long as it can close the ends of the cells 1a and 1b of the honeycomb structure 1, but is preferably liquid.
- a slurry containing a ceramic material or a ceramic raw material, a binder, a lubricant, a pore former, and a solvent can be exemplified.
- the ceramic material examples include the constituent materials of the above-described honeycomb structure and the raw materials thereof.
- the amount of the ceramic material used can be, for example, 50 to 85 parts by weight with respect to 100 parts by weight of the slurry.
- binder examples include celluloses such as methylcellulose, carboxymethylcellulose, hydroxyalkylmethylcellulose, and sodium carboxymethylcellulose; alcohols such as polyvinyl alcohol; and organic binders such as lignin sulfonate.
- the amount of binder used can be, for example, 0 to 30 parts by weight with respect to 100 parts by weight of the slurry.
- Lubricants include alcohols such as glycerin; higher fatty acids such as caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid and stearic acid; and stearic acid metal salts such as aluminum stearate.
- the amount of lubricant used can be, for example, 0.5 to 20 parts by weight with respect to 100 parts by weight of the slurry.
- pore-forming agents include carbon materials such as graphite; resins such as polyethylene, polypropylene, and polymethyl methacrylate; plant materials such as starch, nut shells, walnut shells, and corn; ice; and dry ice.
- the amount of pore-forming agent used can be, for example, 0 to 20 parts by weight with respect to 100 parts by weight of the slurry.
- the solvent for example, alcohols such as methanol, ethanol, butanol and propanol; glycols such as propylene glycol, polypropylene glycol and ethylene glycol; and water can be used. Of these, water is preferable, and ion-exchanged water is more preferably used from the viewpoint of few impurities.
- the amount of the solvent used can be, for example, 10 to 40 parts by weight with respect to 100 parts by weight of the slurry.
- the amount of the sealing material used for sealing one end face of the honeycomb structure 1 can be, for example, 3 to 5000 mL.
- the mask 5 is set on the elastic plate 20 so as to cover the recess 10 d of the main body 10.
- the mask 5 is arranged so that the surface F2 faces upward.
- the holder 81 is moved downward by the pneumatic cylinder 82 to bring the honeycomb structure 1 into contact with the mask 5.
- some of the cells 1a of the honeycomb structure 1 communicate with the first through holes 5a of the mask 5, and all the incomplete cells 1b of the honeycomb structure 1 and the second through holes of the mask 5 are communicated. Communicate with 5b.
- the holding member 81 is pressed downward by the pneumatic cylinder 82 to fix the honeycomb structure 1 to the mask 5 and the main body 10 (step (a)).
- the mask 5 may be arranged on the end face of the honeycomb structure 1 in advance so that the position of the cell 1 a to which the sealing material is to be introduced and the first through hole 5 a are aligned, and this may be attached to the sealing device 100.
- the sealing material 130 is supplied into some cells 1a and all the cells 1b of the honeycomb structure 1 through the through holes 5a and 5b of the mask 5, thereby forming the sealing portion 1p (step (b)). ).
- the top and bottom are turned over, and the honeycomb structure 1 is again held by the holder 81.
- the same operation is performed using the mask 5 ′ in which the mask 5 and the first through-hole 5a are arranged in a zigzag arrangement opposite to each other (steps (c) and (d)).
- the mask 5 ′ and the honeycomb structure 1 can be easily separated from the main body 10 and the elastic plate 20 by deforming the elastic plate 20 upward in the same manner as described above.
- the honeycomb filter structure can be manufactured by drying and firing the honeycomb structure 1 that has been sealed at both ends.
- the sealing method using the mask 5 and the mask 5 ' among the many complete cells 1a, only the cells 1a to be sealed can be sealed more reliably, and all the incomplete cells 1b can be sealed more reliably. Can be sealed. Further, when the elastic plate 20 shown in FIGS. 10A and 11A is in contact with and pressed against the mask 5, the elastic plate 20 is the first as shown in FIG. Enters the through hole 5a. For this reason, the loss of the sealing material can be sufficiently reduced. Furthermore, according to the sealing device 100, the elastic plate can be deformed into a convex shape as shown in FIG. 10B and FIG. 11B, so that the honeycomb structure after the sealing material 130 is supplied 1 can be easily pulled away from the main body 10 and the elastic plate 20. Therefore, the production efficiency can be increased, and the sealed honeycomb structure can be manufactured at a low cost.
- the present invention is not limited to the above-mentioned embodiment.
- the mask 5 having the first through-hole 5a and the second through-hole 5b is illustrated.
- the incomplete cell 1b is not present in the honeycomb structure or the cell 1b is formed using the mask.
- a mask having the first through hole 5a but not having the second through hole 5b may be used.
- the shape and structure of the honeycomb structure 1 are not limited to the above.
- the outer shape of the honeycomb structure 1 may not be a cylinder, and may be, for example, a rectangular column such as a quadrangular column or an elliptical column.
- the opening area of the cell is about 0.6 to 7.0 mm 2 (more preferably about 0.8 to 6.0 mm 2 )
- the cross-sectional shape of the cell is not limited to a square. It may be a quadrangle, a substantially hexagon, a substantially octagon, a substantially circle, or a combination thereof.
- the arrangement of the cells may not be the square arrangement of the cells 1a, and may be, for example, a triangular arrangement or a hexagonal arrangement.
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Abstract
Disclosed is a mask which can be use for sealing cells in a honeycomb structure. The mask has a plurality of first through holes which pass through the mask from one end surface to the other end surface, and the area of the openings of the first through holes at one end surface is smaller that the area of the openings of the first through holes at the other end surface.
Description
本発明は、ハニカム構造体の封口に使用されるマスク及びこれを用いたハニカム構造体の封口方法に関する。
The present invention relates to a mask used for sealing a honeycomb structure and a method for sealing a honeycomb structure using the mask.
従来より、ハニカムフィルタ構造体が、DPF(Diesel particulate filter)用等として広く知られている。このハニカムフィルタ構造体は、多数の貫通孔からなるセル構造の一部のセルの一端側を封口材で封じると共に、残りのセルの他端側を封口材で封じた構造を有する。
Conventionally, honeycomb filter structures have been widely known for DPF (Diesel particulate filter) and the like. This honeycomb filter structure has a structure in which one end side of a part of cells of a cell structure including a large number of through holes is sealed with a sealing material, and the other end side of the remaining cells is sealed with a sealing material.
ハニカム構造体の多数のセルのうち、所定のセルを封口するのにマスクが使用される。このような用途のマスクとして2つのタイプがある。一方は封口すべきセルに対応する箇所に予め貫通孔が設けられているタイプである。他方は貫通孔が予め設けられていないタイプであり、ハニカム構造体の端面に貼り付けた後に封口すべきセルに対応する箇所にレーザー等で貫通孔を設けるものである。下記特許文献1,2には、マスクを用いてハニカム構造体を封口する方法が記載されている。
A mask is used to seal a predetermined cell among many cells of the honeycomb structure. There are two types of masks for such applications. One is a type in which a through hole is provided in advance at a location corresponding to a cell to be sealed. The other is a type in which a through hole is not provided in advance, and a through hole is provided by a laser or the like at a location corresponding to a cell to be sealed after being attached to the end face of the honeycomb structure. The following Patent Documents 1 and 2 describe a method for sealing a honeycomb structure using a mask.
ところで、予め貫通孔が設けられているタイプのマスクは、ハニカム構造体との位置合わせが必要である。特に、ハニカム構造体がDPFのように、乾燥工程や焼成工程を経て製造される焼結体又は焼成前のグリーン成形体の場合、製造プロセスにおけるハニカム構造体の収縮や変形により、マスクの貫通孔と封口すべきセルとの位置合わせがより一層困難になる。DPFは、狭いセルピッチ(たとえば1.1~2.8mm程度)を有するものもあり、ハニカム構造体の端面の一部についてはマスクの貫通孔を適切に配置できても、他の部分ではずれが生じる場合もある。
By the way, the mask of the type in which the through holes are provided in advance needs to be aligned with the honeycomb structure. In particular, when the honeycomb structure is a sintered body manufactured through a drying process or a firing process, such as DPF, or a green molded body before firing, the through-holes of the mask are caused by the shrinkage or deformation of the honeycomb structure in the manufacturing process. And the cell to be sealed become more difficult to align. Some DPFs have a narrow cell pitch (for example, about 1.1 to 2.8 mm). Even if the through-holes of the mask can be appropriately arranged on a part of the end face of the honeycomb structure, the other parts are not displaced. It may occur.
本発明は、上記課題に鑑みてなされたものであり、ハニカム構造体の端面との位置合わせを容易に行うことができ、所定のセルを確実に封口するのに有用なマスク及びこれを用いた封口方法を提供することを目的とする。
The present invention has been made in view of the above problems, and can be easily aligned with the end face of the honeycomb structure, and uses a mask useful for reliably sealing a predetermined cell. The purpose is to provide a sealing method.
本発明に係るマスクは、ハニカム構造体のセルの封口に使用されるものであり、マスクの一方面から他方面にかけて貫通する複数の第1の貫通孔を有し、他方面における第1の貫通孔の開口面積が一方面における第1の貫通孔の開口面積よりも小さい。
The mask according to the present invention is used for sealing a cell of a honeycomb structure, and has a plurality of first through holes penetrating from one surface of the mask to the other surface, and the first penetration on the other surface. The opening area of the hole is smaller than the opening area of the first through hole on one surface.
本発明のマスクは、ハニカム構造体の端面に対してマスクの他方面(開口面積が小さい方の面)を当接させた状態で使用される。上記マスクによれば、他方面における第1の貫通孔の開口面積を小さくしたことで、第1の貫通孔の位置とセルの開口の位置が多少ずれても第1の貫通孔を通じて封口材を所定のセル内に供給できる。また、上記マスクは、第1の貫通孔の全体の開口面積が大きいマスクと比較し、十分な剛性を確保しやすいという利点もある。
The mask of the present invention is used in a state where the other surface of the mask (the surface with the smaller opening area) is in contact with the end surface of the honeycomb structure. According to the mask, by reducing the opening area of the first through hole on the other surface, the sealing material can be passed through the first through hole even if the position of the first through hole and the position of the cell opening are slightly shifted. It can be supplied into a predetermined cell. Further, the mask has an advantage that sufficient rigidity is easily ensured as compared with a mask having a large opening area of the entire first through hole.
本発明において、第1の貫通孔は、一方面から他方面に向けて開口面積が連続的に縮小するテーパ部を有するものであってもよく、あるいは、一方面から他方面に向けて開口面積が不連続的に縮小する段差部を有するものであってもよい。
In the present invention, the first through hole may have a tapered portion whose opening area continuously decreases from one surface to the other surface, or the opening area from one surface to the other surface. May have a stepped portion that discontinuously shrinks.
第1の貫通孔は、他方面における開口面積が0.03mm2以上であり且つ当該第1の貫通孔によって封口すべきハニカム構造体のセルの開口面積の90%未満であることが好ましい。第1の貫通孔の開口面積を、封口すべきセルの開口面積の90%未満とすることで、第1の貫通孔の位置とセルの開口の位置が多少ずれても第1の貫通孔を通じて封口材を所定のセル内により確実に供給できる。第1の貫通孔の開口面積を0.03mm2以上とすることにより、封口材が第1の貫通孔を通過しやすく、所定量の封口材をセル内に供給しやすい。
The first through hole preferably has an opening area of 0.03 mm 2 or more on the other surface and less than 90% of the opening area of the cells of the honeycomb structure to be sealed by the first through hole. By setting the opening area of the first through hole to be less than 90% of the opening area of the cell to be sealed, even if the position of the first through hole and the position of the cell opening are slightly shifted, The sealing material can be reliably supplied in a predetermined cell. By setting the opening area of the first through hole to 0.03 mm 2 or more, the sealing material can easily pass through the first through hole, and a predetermined amount of the sealing material can be easily supplied into the cell.
本発明に係るマスクは、使用時においてハニカム構造体の端面と当接する領域のうち、ハニカム構造体の端面周縁部と当接する部分に、マスクの厚さ方向に貫通する複数の第2の貫通孔を更に有してもよい。この場合、第2の貫通孔は、ハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、開口面積が0.03mm2以上であり且つ第1の貫通孔によって封口すべきセルの開口面積の60%未満であることが好ましい。
The mask according to the present invention has a plurality of second through-holes penetrating in the thickness direction of the mask in a portion in contact with the peripheral edge of the end face of the honeycomb structure in a region in contact with the end face of the honeycomb structure in use. May further be included. In this case, the second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cells to be sealed by the first through holes Is preferably less than 60%.
ハニカム構造体の周縁部は、ハニカム構造体の側面をなす最外層の存在により、セルの形状が他の部分と異なる場合がある。たとえば、最外層の形状が円筒状であり、その内部に断面形状が正方形のセルが設けられたハニカム構造体の場合、断面形状が正方形の完全なセルと、周縁部の不完全なセルとが存在する。
In the peripheral part of the honeycomb structure, the shape of the cell may be different from other parts due to the presence of the outermost layer forming the side surface of the honeycomb structure. For example, in the case of a honeycomb structure in which the shape of the outermost layer is a cylindrical shape and cells having a square cross-sectional shape are provided therein, a complete cell having a square cross-sectional shape and an incomplete cell in the peripheral portion are formed. Exists.
上記のような不完全なセル及び必要であればこれに隣接するセルを完全に封口するのに第2の貫通孔が有用である。すなわち、第2の貫通孔の開口面積を第1の貫通孔によって封口すべきセル(完全なセル)の開口面積の60%未満と制限する一方、第2の貫通孔の配置をハニカム構造体のセルピッチよりも狭い間隔にしてその数を十分に多くすることで、第2の貫通孔を通じて封口材を封口すべきセル内に適切に供給できる。また、第2の貫通孔の開口面積を0.03mm2以上としたことにより、封口材が第2の貫通孔を通過しやすく、所定量の封口材をセル内に供給しやすい。
The second through-hole is useful for completely sealing the incomplete cell as described above and, if necessary, the cell adjacent thereto. That is, the opening area of the second through-hole is limited to less than 60% of the opening area of the cell (complete cell) to be sealed by the first through-hole, while the arrangement of the second through-hole is limited to that of the honeycomb structure. By making the interval narrower than the cell pitch and increasing the number sufficiently, the sealing material can be appropriately supplied to the cell to be sealed through the second through hole. Further, by setting the opening area of the second through hole to 0.03 mm 2 or more, the sealing material can easily pass through the second through hole, and a predetermined amount of the sealing material can be easily supplied into the cell.
本発明は上記マスクを用いてハニカム構造体の所定のセルの開口を封じる方法を提供する。すなわち、本発明はハニカム構造体のセルの封口方法であって、
(a)ハニカム構造体の一方の端面上にマスクを配置する工程と、
(b)ハニカム構造体の一方の端面における封口すべきセルの開口にマスクが有する第1の貫通孔を通じて封止材を供給する工程と、
を備え、上記マスクは一方面から他方面にかけて貫通する複数の第1の貫通孔を有し、他方面における第1の貫通孔の開口面積が一方面における第1の貫通孔の開口面積よりも小さく、上記(a)工程において当該マスクの他方面がハニカム構造体の端面に当接するように当該マスクを配置する封口方法を提供する。 The present invention provides a method for sealing the opening of a predetermined cell of a honeycomb structure using the mask. That is, the present invention is a method for sealing cells of a honeycomb structure,
(A) placing a mask on one end face of the honeycomb structure;
(B) supplying a sealing material through the first through hole of the mask to the opening of the cell to be sealed on one end face of the honeycomb structure;
The mask has a plurality of first through holes penetrating from one side to the other side, and the opening area of the first through hole on the other side is larger than the opening area of the first through hole on the one side There is provided a sealing method for arranging the mask so that the other side of the mask is in contact with the end face of the honeycomb structure in the step (a).
(a)ハニカム構造体の一方の端面上にマスクを配置する工程と、
(b)ハニカム構造体の一方の端面における封口すべきセルの開口にマスクが有する第1の貫通孔を通じて封止材を供給する工程と、
を備え、上記マスクは一方面から他方面にかけて貫通する複数の第1の貫通孔を有し、他方面における第1の貫通孔の開口面積が一方面における第1の貫通孔の開口面積よりも小さく、上記(a)工程において当該マスクの他方面がハニカム構造体の端面に当接するように当該マスクを配置する封口方法を提供する。 The present invention provides a method for sealing the opening of a predetermined cell of a honeycomb structure using the mask. That is, the present invention is a method for sealing cells of a honeycomb structure,
(A) placing a mask on one end face of the honeycomb structure;
(B) supplying a sealing material through the first through hole of the mask to the opening of the cell to be sealed on one end face of the honeycomb structure;
The mask has a plurality of first through holes penetrating from one side to the other side, and the opening area of the first through hole on the other side is larger than the opening area of the first through hole on the one side There is provided a sealing method for arranging the mask so that the other side of the mask is in contact with the end face of the honeycomb structure in the step (a).
上記封口方法によれば、ハニカム構造体の端面との位置合わせを容易に行うことができ、従来と比較して所定のセルをより確実に封口できる。
According to the above-described sealing method, alignment with the end face of the honeycomb structure can be easily performed, and a predetermined cell can be sealed more reliably as compared with the conventional method.
ハニカム構造体の周縁部に不完全なセルが存在する場合、上記封口方法は、以下のような構成とすることができる。すなわち、上記マスクはハニカム構造体の一方の端面と当接する領域のうち、ハニカム構造体の端面周縁部と当接する部分に、当該マスクの厚さ方向に貫通する複数の第2の貫通孔を更に有し、第2の貫通孔はハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、開口面積が0.03mm2以上であり且つ第1の貫通孔によって封口すべきセルの開口面積の60%未満のものとすることができる。そして、上記(b)工程において、ハニカム構造体の端面周縁部における封口すべきセルの開口に当該マスクの第2の貫通孔を通じて封止材を供給する。
When incomplete cells exist at the peripheral edge of the honeycomb structure, the sealing method can be configured as follows. That is, the mask further includes a plurality of second through-holes penetrating in the thickness direction of the mask in a portion that contacts the peripheral edge of the end face of the honeycomb structure in a region that contacts one end face of the honeycomb structure. And the second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cell to be sealed by the first through holes It can be less than 60%. In the step (b), the sealing material is supplied to the opening of the cell to be sealed at the peripheral edge of the end face of the honeycomb structure through the second through hole of the mask.
上記封口方法は、ハニカム構造体の一方の端面を封口処理する工程の後、他方の端面についても封口処理する工程を更に備えてもよい。ハニカム構造体の両方の端面を封口処理した後、必要に応じて乾燥や焼成等の工程を経ることで、ハニカムフィルタ構造体を得ることができる。すなわち、上記封口方法は、
(c)ハニカム構造体の他方の端面上に他のマスクを配置する工程と、
(d)ハニカム構造体の他方の端面における封口すべきセルの開口に上記他のマスクが有する第3の貫通孔を通じて封止材を供給する工程とを更に備えてもよい。この場合、上記他のマスクは、一方面から他方面にかけて貫通する複数の第3の貫通孔を有し、他方面における第3の貫通孔の開口面積が一方面における第3の貫通孔の開口面積よりも小さく、上記(a)工程において当該マスクの他方面がハニカム構造体の端面に当接するように当該マスクを配置する。 The sealing method may further include a step of sealing the other end surface after the step of sealing one end surface of the honeycomb structure. After sealing both the end faces of the honeycomb structure, a honeycomb filter structure can be obtained by performing steps such as drying and firing as necessary. That is, the sealing method is
(C) placing another mask on the other end face of the honeycomb structure;
(D) A step of supplying a sealing material to the opening of the cell to be sealed on the other end face of the honeycomb structure through the third through hole of the other mask may be further provided. In this case, the other mask has a plurality of third through holes penetrating from one surface to the other surface, and the opening area of the third through hole on the other surface is the opening of the third through hole on the one surface. The mask is arranged so that the other side of the mask is in contact with the end face of the honeycomb structure in the step (a).
(c)ハニカム構造体の他方の端面上に他のマスクを配置する工程と、
(d)ハニカム構造体の他方の端面における封口すべきセルの開口に上記他のマスクが有する第3の貫通孔を通じて封止材を供給する工程とを更に備えてもよい。この場合、上記他のマスクは、一方面から他方面にかけて貫通する複数の第3の貫通孔を有し、他方面における第3の貫通孔の開口面積が一方面における第3の貫通孔の開口面積よりも小さく、上記(a)工程において当該マスクの他方面がハニカム構造体の端面に当接するように当該マスクを配置する。 The sealing method may further include a step of sealing the other end surface after the step of sealing one end surface of the honeycomb structure. After sealing both the end faces of the honeycomb structure, a honeycomb filter structure can be obtained by performing steps such as drying and firing as necessary. That is, the sealing method is
(C) placing another mask on the other end face of the honeycomb structure;
(D) A step of supplying a sealing material to the opening of the cell to be sealed on the other end face of the honeycomb structure through the third through hole of the other mask may be further provided. In this case, the other mask has a plurality of third through holes penetrating from one surface to the other surface, and the opening area of the third through hole on the other surface is the opening of the third through hole on the one surface. The mask is arranged so that the other side of the mask is in contact with the end face of the honeycomb structure in the step (a).
ハニカム構造体の周縁部に不完全なセルが存在し、他方の端面においても不完全なセルを封口する場合、上記封口方法は、以下のような構成とすることができる。すなわち、上記他のマスクは、ハニカム構造体の他方の端面と当接する領域のうち、ハニカム構造体の端面周縁部と当接する部分に、当該マスクの厚さ方向に貫通する複数の第4の貫通孔を更に有し、第4の貫通孔はハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、開口面積が0.03mm2以上であり且つ第3の貫通孔によって封口すべきセルの開口面積の60%未満であり、上記(d)工程において、ハニカム構造体の端面周縁部における封口すべきセルの開口に当該マスクの第4の貫通孔を通じて封止材を供給する。
When incomplete cells exist at the peripheral edge of the honeycomb structure and the incomplete cells are sealed also on the other end face, the sealing method can be configured as follows. That is, the other mask has a plurality of fourth penetrations penetrating in the thickness direction of the mask in a portion of the region contacting the other end face of the honeycomb structure and contacting the peripheral edge of the end face of the honeycomb structure. The fourth through-holes are provided at intervals narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the cells to be sealed by the third through-holes are further provided. In the step (d), a sealing material is supplied through the fourth through hole of the mask to the opening of the cell to be sealed at the peripheral edge of the end face of the honeycomb structure.
本発明によれば、ハニカム構造体の端面との位置合わせを容易に行うことができ、従来と比較して所定のセルをより確実に封口できる。
According to the present invention, alignment with the end face of the honeycomb structure can be easily performed, and a predetermined cell can be more reliably sealed as compared with the conventional case.
以下、図面を参照しながら、本発明の好適な実施形態について詳細に説明する。まず、本発明に係るマスクの説明に先立ち、ハニカム構造体について説明する。
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. First, prior to the description of the mask according to the present invention, the honeycomb structure will be described.
(ハニカム構造体)
図1の(a)に示すように、ハニカム構造体1は、多数のセル1aが略平行に配置された円柱体である。セル1aはハニカム構造体1の一方の端面から他方の端面にかけて貫通している。セル1aの断面形状は、図1の(b)に示すように正方形である。これらの複数のセル1aは、ハニカム構造体1において、端面から見て、正方形配置、すなわち、セル1aの中心軸が、正方形の頂点にそれぞれ位置するように配置されている。セル1aの断面の正方形のサイズは、たとえば、一辺0.8~2.5mmとすることができ、その開口面積は0.6~7.0mm2程度(より好ましくは0.8~6.0mm2程度)とすることができる。ハニカム構造体1のセルピッチは、1.1~2.8mmとすることができる。なお、セルピッチとは、隣接する2つのセルの中心間の距離を意味し、ハニカム構造体1にあっては図1の(b)に示す長さLである。 (Honeycomb structure)
As shown in FIG. 1A, thehoneycomb structure 1 is a cylindrical body in which a large number of cells 1a are arranged substantially in parallel. The cell 1a penetrates from one end face of the honeycomb structure 1 to the other end face. The cross-sectional shape of the cell 1a is a square as shown in FIG. The plurality of cells 1a are arranged in a square arrangement in the honeycomb structure 1 so that the central axis of the cells 1a is located at the apexes of the squares as viewed from the end face. The size of the square of the cross section of the cell 1a can be, for example, 0.8 to 2.5 mm on a side, and the opening area is about 0.6 to 7.0 mm 2 (more preferably 0.8 to 6.0 mm). 2 ). The cell pitch of the honeycomb structure 1 can be set to 1.1 to 2.8 mm. Note that the cell pitch means the distance between the centers of two adjacent cells, and in the honeycomb structure 1, is the length L shown in FIG.
図1の(a)に示すように、ハニカム構造体1は、多数のセル1aが略平行に配置された円柱体である。セル1aはハニカム構造体1の一方の端面から他方の端面にかけて貫通している。セル1aの断面形状は、図1の(b)に示すように正方形である。これらの複数のセル1aは、ハニカム構造体1において、端面から見て、正方形配置、すなわち、セル1aの中心軸が、正方形の頂点にそれぞれ位置するように配置されている。セル1aの断面の正方形のサイズは、たとえば、一辺0.8~2.5mmとすることができ、その開口面積は0.6~7.0mm2程度(より好ましくは0.8~6.0mm2程度)とすることができる。ハニカム構造体1のセルピッチは、1.1~2.8mmとすることができる。なお、セルピッチとは、隣接する2つのセルの中心間の距離を意味し、ハニカム構造体1にあっては図1の(b)に示す長さLである。 (Honeycomb structure)
As shown in FIG. 1A, the
ハニカム構造体1は、側面をなす最外層1cの形状が円筒状であり、上述の通り、その内部に断面形状が正方形のセル1a(以下、「完全なセル1a」又は単に「セル1a」という。)を有する。これに加え、ハニカム構造体1は、その周縁部に断面形状が正方形でないセル1b(以下、「不完全なセル1b」又は単に「セル1b」という。)を有する。図1の(b)に示す通り、不完全なセル1bの形状は一定ではなく、場所によって異なっている。
In the honeycomb structure 1, the shape of the outermost layer 1c forming a side surface is a cylindrical shape, and as described above, the cell 1a having a square cross-sectional shape inside thereof (hereinafter referred to as “complete cell 1a” or simply “cell 1a”). .) In addition to this, the honeycomb structure 1 has cells 1b (hereinafter referred to as “incomplete cells 1b” or simply “cells 1b”) whose cross-sectional shape is not square at the peripheral edge thereof. As shown in FIG. 1B, the shape of the incomplete cell 1b is not constant but varies depending on the location.
ハニカム構造体1のセル1a,1bを構成する貫通孔が延びる方向の長さは特に限定されないが、たとえば、40~350mmとすることができる。また、ハニカム構造体1の外径も特に限定されないが、たとえば、100~320mmとすることできる。
The length in the direction in which the through holes constituting the cells 1a and 1b of the honeycomb structure 1 extend is not particularly limited, but may be, for example, 40 to 350 mm. Further, the outer diameter of the honeycomb structure 1 is not particularly limited, but may be, for example, 100 to 320 mm.
ハニカム構造体1の材料は特に限定されないが、高温耐性の観点から、セラミクス材料が好ましい。セラミクス材料としては、たとえば、アルミナ、シリカ、ムライト、コーディエライト、ガラス、チタン酸アルミニウム等の酸化物、シリコンカーバイド、窒化珪素、金属等が挙げられる。なお、チタン酸アルミニウムは、さらに、マグネシウム及び/又はケイ素を含むことができる。このような、ハニカム構造体1は通常多孔質である。
The material of the honeycomb structure 1 is not particularly limited, but a ceramic material is preferable from the viewpoint of high temperature resistance. Examples of the ceramic material include alumina, silica, mullite, cordierite, glass, oxides such as aluminum titanate, silicon carbide, silicon nitride, and metal. The aluminum titanate can further contain magnesium and / or silicon. Such a honeycomb structure 1 is usually porous.
また、ハニカム構造体1は、後で焼成することにより上述のようなセラミクス材料となるグリーン成形体(未焼成成形体)であってもよい。グリーン成形体は、セラミクス原料である無機化合物源粉末、及び、メチルセルロース等の有機バインダ、及び、必要に応じて添加される添加剤を含む。
Further, the honeycomb structure 1 may be a green molded body (unfired molded body) that becomes a ceramic material as described above by firing later. A green molded object contains the inorganic compound source powder which is a ceramic raw material, organic binders, such as methylcellulose, and the additive added as needed.
たとえば、チタン酸アルミニウムのグリーン成形体の場合、無機化合物源粉末は、αアルミナ粉等のアルミニウム源粉末、及び、アナターゼ型やルチル型のチタニア粉末等のチタニウム源粉末を含み、必要に応じて、さらに、マグネシア粉末やマグネシアスピネル粉末等のマグネシウム源粉末及び/又は、酸化ケイ素粉末やガラスフリット等のケイ素源粉末を含むことができる。
For example, in the case of a green molded body of aluminum titanate, the inorganic compound source powder includes an aluminum source powder such as α-alumina powder, and a titanium source powder such as anatase-type or rutile-type titania powder. Furthermore, magnesium source powders such as magnesia powder and magnesia spinel powder and / or silicon source powders such as silicon oxide powder and glass frit can be included.
有機バインダとしては、メチルセルロース、カルボキシルメチルセルロース、ヒドロキシアルキルメチルセルロース、ナトリウムカルボキシルメチルセルロースなどのセルロース類;ポリビニルアルコールなどのアルコール類;リグニンスルホン酸塩が挙げられる。
Examples of the organic binder include celluloses such as methylcellulose, carboxymethylcellulose, hydroxyalkylmethylcellulose, and sodium carboxymethylcellulose; alcohols such as polyvinyl alcohol; and lignin sulfonate.
添加物としては、たとえば、造孔剤、潤滑剤、可塑剤、分散剤及び溶媒が挙げられる。
Examples of additives include a pore-forming agent, a lubricant, a plasticizer, a dispersant, and a solvent.
造孔剤としては、グラファイト等の炭素材;ポリエチレン、ポリプロピレン、ポリメタクリル酸メチル等の樹脂類;でんぷん、ナッツ殻、クルミ殻、コーンなどの植物材料;氷;及びドライアイス等などが挙げられる。
Examples of pore-forming agents include carbon materials such as graphite; resins such as polyethylene, polypropylene, and polymethyl methacrylate; plant materials such as starch, nut shells, walnut shells, and corn; ice; and dry ice.
潤滑剤及び可塑剤としては、グリセリンなどのアルコール類;カプリル酸、ラウリン酸、パルミチン酸、アラキジン酸、オレイン酸、ステアリン酸などの高級脂肪酸;ステアリン酸Alなどのステアリン酸金属塩、ポリオキシアルキレンアルキルエーテル(POAAE)などが挙げられる。
Lubricants and plasticizers include alcohols such as glycerin; higher fatty acids such as caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid and stearic acid; metal stearates such as Al stearate, polyoxyalkylene alkyl And ether (POAAE).
分散剤としては、たとえば、硝酸、塩酸、硫酸などの無機酸;シュウ酸、クエン酸、酢酸、リンゴ酸、乳酸などの有機酸;メタノール、エタノール、プロパノールなどのアルコール類;ポリカルボン酸アンモニウム、ポリオキシアルキレンアルキルエーテルなどの界面活性剤などが挙げられる。
Examples of the dispersant include inorganic acids such as nitric acid, hydrochloric acid and sulfuric acid; organic acids such as oxalic acid, citric acid, acetic acid, malic acid and lactic acid; alcohols such as methanol, ethanol and propanol; ammonium polycarboxylate, poly Surfactants such as oxyalkylene alkyl ethers are listed.
溶媒としては、たとえば、メタノール、エタノール、ブタノール、プロパノールなどのアルコール類;プロピレングリコール、ポリプロピレングリコール、エチレングリコールなどのグリコール類;及び水などを用いることができる。
As the solvent, for example, alcohols such as methanol, ethanol, butanol and propanol; glycols such as propylene glycol, polypropylene glycol and ethylene glycol; and water can be used.
(ハニカム構造体封口用マスク)
図2に示すマスク5は、図1に示すハニカム構造体1の所定のセルを封口するのに使用されるものである。マスク5は、円形の板状部材であり、厚さ方向に貫通する第1の貫通孔5a及び第2の貫通孔5bを有する。なお、マスク5の材料は特に限定されず、たとえば、金属や樹脂が挙げられる。また、マスク5の貫通孔5aの位置決めを容易にすべく、マスク5には、オリエンテーションフラット5cが形成され、これに対応して図5に示す封口装置100のリング部材25にもオリエンテーションフラット5cに対応する突起25bを設けてもよい(図6参照)。また、マスク5の外径は、封口装置100の本体部10の凹部10dの内径よりも大きくされていることが好ましい。 (Honeycomb structure mask)
Amask 5 shown in FIG. 2 is used for sealing predetermined cells of the honeycomb structure 1 shown in FIG. The mask 5 is a circular plate-like member, and has a first through hole 5a and a second through hole 5b that penetrate in the thickness direction. In addition, the material of the mask 5 is not specifically limited, For example, a metal and resin are mentioned. Further, in order to facilitate positioning of the through hole 5a of the mask 5, an orientation flat 5c is formed on the mask 5, and the ring member 25 of the sealing device 100 shown in FIG. Corresponding protrusions 25b may be provided (see FIG. 6). The outer diameter of the mask 5 is preferably larger than the inner diameter of the recess 10 d of the main body 10 of the sealing device 100.
図2に示すマスク5は、図1に示すハニカム構造体1の所定のセルを封口するのに使用されるものである。マスク5は、円形の板状部材であり、厚さ方向に貫通する第1の貫通孔5a及び第2の貫通孔5bを有する。なお、マスク5の材料は特に限定されず、たとえば、金属や樹脂が挙げられる。また、マスク5の貫通孔5aの位置決めを容易にすべく、マスク5には、オリエンテーションフラット5cが形成され、これに対応して図5に示す封口装置100のリング部材25にもオリエンテーションフラット5cに対応する突起25bを設けてもよい(図6参照)。また、マスク5の外径は、封口装置100の本体部10の凹部10dの内径よりも大きくされていることが好ましい。 (Honeycomb structure mask)
A
第1の貫通孔5aはハニカム構造体1の完全なセル1aに封止材を供給するためのものである。第1の貫通孔5aは、マスク5の使用時においてハニカム構造体1の端面の中央部(周縁部以外の領域)と当接する部分に設けられている。
The first through holes 5a are for supplying the sealing material to the complete cells 1a of the honeycomb structure 1. The first through-hole 5a is provided in a portion that contacts the central portion (region other than the peripheral portion) of the end face of the honeycomb structure 1 when the mask 5 is used.
第1の貫通孔5aの断面形状は、図2の(b)に示すように、ハニカム構造体1のセル1aに対応する正方形である。これらの第1の貫通孔5aは、千鳥配置されており、各第1の貫通孔5aは、図1の(b)の正方配置された複数のセル1aのうち、互いに上下左右に隣接しない関係にある複数のセル1aのみに対向して配置される。なお、第1の貫通孔5aの形状は、正方形に限定されるものではないが、ペースト状の封口材の充填性の観点から、セル1aの開口よりもひと回り小さく、その形状と相似形であることが好ましい。
The cross-sectional shape of the first through hole 5a is a square corresponding to the cell 1a of the honeycomb structure 1 as shown in FIG. These first through-holes 5a are arranged in a staggered manner, and each first through-hole 5a is not adjacent to each other among the plurality of squarely arranged cells 1a in FIG. Are arranged to face only the plurality of cells 1a. The shape of the first through hole 5a is not limited to a square, but is smaller than the opening of the cell 1a and is similar to the shape from the viewpoint of the filling property of the paste-like sealing material. It is preferable.
第1の貫通孔5aは、図3に示すようにテーパ状になっており、開口面積がマスク5の厚さ方向の位置によって異なっている。すなわち、マスク5の一方の面F1から他方の面F2に向けて開口面積が連続的に縮小している。なお、マスク5は、ハニカム構造体1の端面に対してマスク5の面F2を当接させた状態で使用される。
The first through hole 5a is tapered as shown in FIG. 3, and the opening area differs depending on the position of the mask 5 in the thickness direction. That is, the opening area is continuously reduced from one surface F1 of the mask 5 to the other surface F2. The mask 5 is used in a state where the face F2 of the mask 5 is in contact with the end face of the honeycomb structure 1.
第1の貫通孔5aは、面F2における開口面積が面F1における開口面積よりも小さいものである限り、図3に示すテーパ状に限定されるものではない。たとえば、図4の(a)に示すように、第1の貫通孔5aは、面F1から面F2に向けて開口面積が連続的に縮小するテーパ部6aと、テーパ部6aの面F2側に位置し開口面積が一定の部分6bとによって構成されてもよい。また、図4の(b)に示すように、第1の貫通孔5aは、面F1から面F2に向けて開口面積が不連続的に縮小する段差部6cを有するものであってもよい。
The first through hole 5a is not limited to the tapered shape shown in FIG. 3 as long as the opening area on the surface F2 is smaller than the opening area on the surface F1. For example, as shown in FIG. 4A, the first through hole 5a includes a tapered portion 6a whose opening area continuously decreases from the surface F1 toward the surface F2, and a surface F2 side of the tapered portion 6a. It may be constituted by a portion 6b which is located and has a constant opening area. Further, as shown in FIG. 4B, the first through hole 5a may have a step portion 6c whose opening area decreases discontinuously from the surface F1 toward the surface F2.
第1の貫通孔5aにおけるテーパの角度(図3及び図4の(a)における角度α)は、マスク5の剛性及び封口材のロスの低減等の観点から、10~70°であることが好ましく、30~60°であることがより好ましい。
The taper angle in the first through hole 5a (angle α in FIGS. 3 and 4A) is 10 to 70 ° from the viewpoint of the rigidity of the mask 5 and the loss of the sealing material. The angle is preferably 30 to 60 °.
第1の貫通孔5aは、面F2における開口面積が0.03mm2以上であり且つ第1の貫通孔5aによって封口すべきセル1aの開口面積の90%未満であることが好ましい。第1の貫通孔5aの面F2における開口面積が0.03mm2未満であると、封口材が第1の貫通孔5aを通過しにくくなり、所定量の封口材をセル1a内に供給しにくくなる。第1の貫通孔5aの上記開口面積は、0.05mm2以上であることがより好ましく、0.07mm2以上であることが更に好ましく、0.2mm2以上であってもよい。
The first through hole 5a preferably has an opening area on the surface F2 of 0.03 mm 2 or more and less than 90% of the opening area of the cell 1a to be sealed by the first through hole 5a. When the opening area on the surface F2 of the first through hole 5a is less than 0.03 mm 2 , the sealing material is difficult to pass through the first through hole 5a, and it is difficult to supply a predetermined amount of the sealing material into the cell 1a. Become. The opening area of the first through-hole 5a is more preferably 0.05 mm 2 or more, still more preferably 0.07 mm 2 or more, it may be 0.2 mm 2 or more.
他方、第1の貫通孔5aの面F2における開口面積がセル1aの開口面積の90%以上であると、第1の貫通孔5aの位置とセル1aの開口の位置が少しずれただけで、封口すべきでない近傍のセル1aに封口材を供給するおそれがある。第1の貫通孔5aの上記開口面積は、セル1aの開口面積の80%未満であることが好ましく、60%未満であることがより好ましい。
On the other hand, if the opening area on the surface F2 of the first through hole 5a is 90% or more of the opening area of the cell 1a, the position of the first through hole 5a and the position of the opening of the cell 1a are slightly shifted. There is a possibility that the sealing material may be supplied to the neighboring cell 1a that should not be sealed. The opening area of the first through-hole 5a is preferably less than 80% and more preferably less than 60% of the opening area of the cell 1a.
第2の貫通孔5bはハニカム構造体1の不完全なセル1bに封止材を供給するためのものである。第2の貫通孔5bは、マスク5の使用時においてハニカム構造体1の端面周縁部と当接する部分に、ハニカム構造体1のセルピッチ(図1の長さL)よりも狭い間隔で設けられていることが好ましい。第2の貫通孔5bの間隔は、全てのセル1bを確実に封口する観点から、L/10~3L/4であることが好ましく、L/5~L/2であることがより好ましい。
The second through hole 5b is for supplying the sealing material to the incomplete cell 1b of the honeycomb structure 1. The second through-holes 5b are provided at a portion narrower than the cell pitch of the honeycomb structure 1 (length L in FIG. 1) at a portion that contacts the peripheral edge of the end face of the honeycomb structure 1 when the mask 5 is used. Preferably it is. The interval between the second through holes 5b is preferably L / 10 to 3L / 4, more preferably L / 5 to L / 2, from the viewpoint of reliably sealing all the cells 1b.
第2の貫通孔5bの形状は、不完全なセル1bの形状に関わらず、限られた領域に多数の貫通孔を設けることができる形状であればよく、第2の貫通孔5bの形状はたとえば円形もしくは矩形であってもよいが、好ましくは円形である。図2の(a)に示すように、マスク5には多数の第2の貫通孔5bからなる環状の帯が形成されている。
The shape of the second through-hole 5b may be any shape that can provide a large number of through-holes in a limited region regardless of the shape of the incomplete cell 1b. The shape of the second through-hole 5b is For example, it may be circular or rectangular, but is preferably circular. As shown in FIG. 2A, the mask 5 is formed with an annular band composed of a number of second through holes 5b.
第2の貫通孔5bは、面F2における開口面積が0.03mm2以上であり且つ第1の貫通孔5aによって封口すべきセル1aの開口面積の60%未満であることが好ましい。第2の貫通孔5bの面F2における開口面積が0.03mm2未満であると、封口材が第2の貫通孔5bを通過しにくくなり、所定量の封口材をセル1b内に供給しにくくなる。第2の貫通孔5bの上記開口面積は、0.04mm2以上であることがより好ましく、0.05mm2以上であることが更に好ましく、0.2mm2以上であってもよい。
The second through hole 5b preferably has an opening area on the surface F2 of 0.03 mm 2 or more and less than 60% of the opening area of the cell 1a to be sealed by the first through hole 5a. When the opening area on the surface F2 of the second through-hole 5b is less than 0.03 mm 2 , it becomes difficult for the sealing material to pass through the second through-hole 5b, and it is difficult to supply a predetermined amount of the sealing material into the cell 1b. Become. The opening area of the second through hole 5b is more preferably 0.04 mm 2 or more, still more preferably 0.05 mm 2 or more, it may be 0.2 mm 2 or more.
他方、第2の貫通孔5bの面F2における開口面積が完全なセル1aの開口面積の60%以上であると、マスク5の剛性が不十分となりやすく、またマスク5のわずかなズレで封口すべきでない近傍のセル1aに封口材を供給するおそれ、あるいは、図1の(b)に示す最外層1cの外側に封口材が漏れ出しやすくなるおそれがある。第2の貫通孔5bの上記開口面積は、完全なセル1aの開口面積の50%以下であることが好ましく、40%以下であることがより好ましい。
On the other hand, if the opening area on the surface F2 of the second through hole 5b is 60% or more of the opening area of the complete cell 1a, the rigidity of the mask 5 tends to be insufficient, and the mask 5 is sealed with a slight shift. There is a possibility that the sealing material is supplied to the cell 1a in the vicinity which should not be, or the sealing material may easily leak to the outside of the outermost layer 1c shown in FIG. The opening area of the second through-hole 5b is preferably 50% or less, more preferably 40% or less of the opening area of the complete cell 1a.
第2の貫通孔5bの開口面積は、マスク5の厚さ方向の全範囲にわたって一定であってもよいし、図3,4に示す第1の貫通孔5aと同様、マスク5の厚さ方向の位置によって異なっていてもよい。
The opening area of the second through-hole 5b may be constant over the entire range in the thickness direction of the mask 5, or, similarly to the first through-hole 5a shown in FIGS. It may be different depending on the position.
マスク5によれば、ハニカム構造体1の端面に当接する面F2における第1の貫通孔5aの開口面積を小さくしたことで、第1の貫通孔5aの位置とセル1aの開口の位置が多少ずれても第1の貫通孔5aを通じて封口材を所定のセル1a内に供給できる。また、マスク5は、第1の貫通孔5aの全体の開口面積を大きくした場合と比較し、十分な剛性を確保しやすいという利点もある。更に、マスク5に多数の第2の貫通孔5bを設けたことで、不完全なセル1bをより確実に封口できる。
According to the mask 5, by reducing the opening area of the first through hole 5a on the surface F2 contacting the end face of the honeycomb structure 1, the position of the first through hole 5a and the position of the opening of the cell 1a are somewhat different. Even if it deviates, the sealing material can be supplied into the predetermined cell 1a through the first through hole 5a. In addition, the mask 5 has an advantage that it is easy to ensure sufficient rigidity as compared with the case where the entire opening area of the first through-hole 5a is increased. Further, by providing a large number of second through holes 5b in the mask 5, it is possible to more reliably seal the incomplete cell 1b.
(封口装置)
マスク5を用いてハニカム構造体1の封口を実施するのに好適な封口装置について説明する。図5に示す封口装置100は、主として、本体部10、弾性板20、ポンプ50及び保持部80を備える。 (Sealing device)
A sealing device suitable for sealing thehoneycomb structure 1 using the mask 5 will be described. A sealing device 100 shown in FIG. 5 mainly includes a main body unit 10, an elastic plate 20, a pump 50, and a holding unit 80.
マスク5を用いてハニカム構造体1の封口を実施するのに好適な封口装置について説明する。図5に示す封口装置100は、主として、本体部10、弾性板20、ポンプ50及び保持部80を備える。 (Sealing device)
A sealing device suitable for sealing the
本体部10は、剛性材料から形成されている。剛性材料としては、ステンレス等の金属や、繊維強化プラスチック等のポリマー材料が挙げられる。本体部10の上面10aには、凹部10dが形成されている。本実施形態では、凹部10dの形状は、図5及び図6に示すように、円柱状とされている。そして、本体部10の上面10aに対して、凹部10dの側面10bが垂直、かつ、底面10cが平行とされている。凹部10dの直径は、たとえば、100~320mmとすることができる。凹部10dの深さは、たとえば、0.2~20mmとすることができる。なお、本体部10には、超音波振動器等の加振器140が設けられていることが好ましい。
The main body 10 is made of a rigid material. Examples of the rigid material include metals such as stainless steel and polymer materials such as fiber reinforced plastic. A recess 10 d is formed on the upper surface 10 a of the main body 10. In the present embodiment, the shape of the recess 10d is a columnar shape as shown in FIGS. The side surface 10b of the recess 10d is perpendicular to the upper surface 10a of the main body 10 and the bottom surface 10c is parallel. The diameter of the recess 10d can be set to 100 to 320 mm, for example. The depth of the recess 10d can be set to 0.2 to 20 mm, for example. The main body 10 is preferably provided with a vibrator 140 such as an ultrasonic vibrator.
弾性板20は、凹部10dの開口面を覆うように、本体部10の上面10a上に、配置されている。弾性板20は、弾性を有し、容易に変形しうる。弾性板20としては、ゴム板が好ましい。ゴムとしては、天然ゴムや、スチレンブタジエンゴム、ブタジエンゴム、ブチルゴム、エチレンプロピレンゴム、ニトリルゴム、クロロプレンゴム、ふっ素ゴム、シリコーンゴム、ウレタンゴム等の合成ゴムが挙げられる。弾性板20の厚みは特に限定されないが、たとえば、0.3~3.0mmとすることができる。
The elastic plate 20 is disposed on the upper surface 10a of the main body 10 so as to cover the opening surface of the recess 10d. The elastic plate 20 has elasticity and can be easily deformed. As the elastic plate 20, a rubber plate is preferable. Examples of the rubber include natural rubber, and synthetic rubber such as styrene butadiene rubber, butadiene rubber, butyl rubber, ethylene propylene rubber, nitrile rubber, chloroprene rubber, fluorine rubber, silicone rubber, and urethane rubber. The thickness of the elastic plate 20 is not particularly limited, but can be, for example, 0.3 to 3.0 mm.
弾性板20は、リング部材25、及び、ボルト31により本体部10に固定されている。リング部材25は、本体部10の凹部10dに対応する位置に開口25aを有し、これにより環状形状をなしている。そして、リング部材25は、弾性板20における中央部(凹部10dとの対向部)が露出するように弾性板20上に配置されている。これにより、弾性板20の周辺部が、本体部10とリング部材25とにより挟まれている。リング部材25及び弾性板20には貫通孔hがそれぞれ形成され、本体部10には、これら貫通孔hに対応するねじ孔jが形成されており、ボルト31がこれらの貫通孔hを貫通して配置され、ねじ孔jにねじ込まれて固定されることにより、本体部10の上面10aにおける凹部10dのまわりの部分に、弾性板20の周辺部が密着して固定されている。
The elastic plate 20 is fixed to the main body 10 by a ring member 25 and a bolt 31. The ring member 25 has an opening 25a at a position corresponding to the concave portion 10d of the main body 10 and thereby has an annular shape. And the ring member 25 is arrange | positioned on the elastic board 20 so that the center part (opposite part with the recessed part 10d) in the elastic board 20 may be exposed. Accordingly, the peripheral portion of the elastic plate 20 is sandwiched between the main body portion 10 and the ring member 25. Through-holes h are formed in the ring member 25 and the elastic plate 20, and screw holes j corresponding to the through-holes h are formed in the main body portion 10, and bolts 31 pass through these through-holes h. The peripheral portion of the elastic plate 20 is fixed in close contact with the portion around the recess 10d on the upper surface 10a of the main body 10 by being screwed into the screw hole j and fixed.
図5及び図6に示すように、リング部材25の開口25aの内径は、本体部10の凹部10dの内径よりも大きくされていることが好ましい。
As shown in FIGS. 5 and 6, the inner diameter of the opening 25 a of the ring member 25 is preferably larger than the inner diameter of the recess 10 d of the main body 10.
本体部10は、さらに、凹部10dの底面10cに開口する連通路10eを有している。なお、本実施形態では、連通路10eは凹部10dの底面10cに開口しているが、凹部10dの内面に開口していればよく、たとえば、凹部10dの側面10bに開口していてもよい。また、連通路10eの開口の形状や数も特に限定されない。
The main body 10 further has a communication passage 10e that opens to the bottom surface 10c of the recess 10d. In the present embodiment, the communication path 10e opens to the bottom surface 10c of the recess 10d, but may be open to the inner surface of the recess 10d. For example, the communication path 10e may open to the side surface 10b of the recess 10d. Further, the shape and number of openings of the communication passage 10e are not particularly limited.
連通路10eには、接続パイプ14を介してポンプ50が接続されている。
A pump 50 is connected to the communication path 10e via a connection pipe 14.
ポンプ50は、シリンダ51、シリンダ51内に配置されたピストン53、及び、ピストン53に接続されたピストンロッド54を備える。ピストンロッド54には、ピストンロッド54を軸方向に往復移動させるモータ55が接続されている。なお、ピストンロッド54を手動で動かしてもよい。
The pump 50 includes a cylinder 51, a piston 53 disposed in the cylinder 51, and a piston rod 54 connected to the piston 53. A motor 55 that reciprocates the piston rod 54 in the axial direction is connected to the piston rod 54. The piston rod 54 may be moved manually.
本実施形態では、弾性板20と、ピストン53と、の間には、本体部10、接続パイプ14、及び、シリンダ51により形成される閉鎖空間Vが形成され、閉鎖空間V内には、流体FLが充填されている。流体FLは特に限定されず、空気等の気体でもよいが液体が好ましく、特に、スピンドルオイル等が好ましい。そして、ピストン53を移動させることにより、本体部10の凹部10d内から流体FLを排出することができ、また、凹部10d内に流体FLを供給することができる。
In the present embodiment, a closed space V formed by the main body 10, the connection pipe 14, and the cylinder 51 is formed between the elastic plate 20 and the piston 53, and a fluid is contained in the closed space V. FL is filled. The fluid FL is not particularly limited, and may be a gas such as air, but is preferably a liquid, and particularly preferably spindle oil or the like. Then, by moving the piston 53, the fluid FL can be discharged from the recess 10d of the main body 10, and the fluid FL can be supplied into the recess 10d.
本体部10の上には、保持部80が設けられている。保持部80は、ハニカム構造体1を保持する保持具81、及び保持具81が接続された空気圧シリンダ82を有する。
A holding unit 80 is provided on the main body unit 10. The holding unit 80 includes a holding tool 81 that holds the honeycomb structure 1 and a pneumatic cylinder 82 to which the holding tool 81 is connected.
保持具81は、ハニカム構造体1を、図5に示すように、一方の端面が弾性板20及び凹部10dと対向するように保持する。
The holder 81 holds the honeycomb structure 1 such that one end face faces the elastic plate 20 and the recess 10d as shown in FIG.
空気圧シリンダ82は、上下方向に延びるシリンダ82aと、シリンダ82a内に設けられたピストン82bとを有し、外部からの供給する圧力を調整することによりピストン82bの上下両側での圧力を調節可能となっている。そして、これにより空気圧シリンダ82は、保持具81を、ハニカム構造体1と弾性板20とが近づく方向及びこれらが互いに離れる方向にそれぞれ移動可能である。また、空気圧シリンダ82は、ピストン82bの前後のガスの供給圧力に応じて保持具81を下方に所定の力で押圧することにより、ハニカム構造体1をマスク5に対して密着させることができる。さらに、空気圧シリンダ82は、ピストンの前後の圧力を開放することにより、保持具81が上下方向に自由に移動することを許可することもできる。すなわち、保持部80は、保持具81が保持したハニカム構造体1を上方向に自由に移動可能とする状態と、ハニカム構造体1を本体部10に対して固定する状態とを切替え可能である。
The pneumatic cylinder 82 has a cylinder 82a extending in the vertical direction and a piston 82b provided in the cylinder 82a. By adjusting the pressure supplied from the outside, the pressure on both the upper and lower sides of the piston 82b can be adjusted. It has become. As a result, the pneumatic cylinder 82 can move the holder 81 in the direction in which the honeycomb structure 1 and the elastic plate 20 approach each other and in the direction in which they move away from each other. Further, the pneumatic cylinder 82 can bring the honeycomb structure 1 into close contact with the mask 5 by pressing the holder 81 downward with a predetermined force according to the gas supply pressure before and after the piston 82b. Furthermore, the pneumatic cylinder 82 can also permit the holder 81 to move freely in the vertical direction by releasing the pressure before and after the piston. That is, the holding unit 80 can switch between a state in which the honeycomb structure 1 held by the holder 81 can freely move upward and a state in which the honeycomb structure 1 is fixed to the main body 10. .
(ハニカム構造体の封口方法)
本実施形態に係る封口方法は、マスク5を用いてハニカム構造体1の所定のセルの開口を封止するためのものである。より具体的には、この封口方法は以下の工程を備える:
(a)ハニカム構造体1の一方の端面上に、マスク5の面F2がハニカム構造体1の端面に当接するようにマスク5を配置する工程;及び
(b)ハニカム構造体1の一方の端面における封口すべきセルの開口にマスク5の第1の貫通孔5aを通じて封止材を供給する工程。 (Housing method of honeycomb structure)
The sealing method according to the present embodiment is for sealing the opening of a predetermined cell of thehoneycomb structure 1 using the mask 5. More specifically, this sealing method comprises the following steps:
(A) placing themask 5 on one end face of the honeycomb structure 1 so that the face F2 of the mask 5 is in contact with the end face of the honeycomb structure 1; and (b) one end face of the honeycomb structure 1. Supplying a sealing material through the first through-hole 5a of the mask 5 to the opening of the cell to be sealed.
本実施形態に係る封口方法は、マスク5を用いてハニカム構造体1の所定のセルの開口を封止するためのものである。より具体的には、この封口方法は以下の工程を備える:
(a)ハニカム構造体1の一方の端面上に、マスク5の面F2がハニカム構造体1の端面に当接するようにマスク5を配置する工程;及び
(b)ハニカム構造体1の一方の端面における封口すべきセルの開口にマスク5の第1の貫通孔5aを通じて封止材を供給する工程。 (Housing method of honeycomb structure)
The sealing method according to the present embodiment is for sealing the opening of a predetermined cell of the
(A) placing the
この封口方法によれば、ハニカム構造体5の端面との位置合わせを容易に行うことができ、従来と比較して所定のセルをより確実に封口できる。
According to this sealing method, alignment with the end face of the honeycomb structure 5 can be easily performed, and a predetermined cell can be sealed more reliably than in the past.
ハニカム構造体1は周縁部に図1の(b)に示すように不完全なセル1bが存在する。このため、上記(b)工程において、不完全なセル1bの開口にマスク5の第2の貫通孔5bを通じて封止材を供給する。
The honeycomb structure 1 has incomplete cells 1b at the periphery as shown in FIG. Therefore, in the step (b), the sealing material is supplied to the incomplete opening of the cell 1b through the second through hole 5b of the mask 5.
ハニカムフィルタ構造体を作製するには、ハニカム構造体1の一方の端面についてセルの封口処理を施した後、他方の端面に対しても同様の封口処理を施す。すなわち、上記(b)工程後、
(c)ハニカム構造体1の他方の端面上に、マスク5´の面F2´を配置する工程;及び
(d)ハニカム構造体1の他方の端面における封口すべきセルの開口にマスク5´の第3の貫通孔5a´を通じて封止材を供給する工程;
を順次実施する。 In order to fabricate the honeycomb filter structure, the cell sealing process is performed on one end face of thehoneycomb structure 1, and then the same sealing process is performed on the other end face. That is, after the step (b),
(C) the step of disposing the surface F2 ′ of themask 5 ′ on the other end face of the honeycomb structure 1; and (d) the mask 5 ′ at the opening of the cell to be sealed on the other end face of the honeycomb structure 1. Supplying a sealing material through the third through-hole 5a ';
Are carried out sequentially.
(c)ハニカム構造体1の他方の端面上に、マスク5´の面F2´を配置する工程;及び
(d)ハニカム構造体1の他方の端面における封口すべきセルの開口にマスク5´の第3の貫通孔5a´を通じて封止材を供給する工程;
を順次実施する。 In order to fabricate the honeycomb filter structure, the cell sealing process is performed on one end face of the
(C) the step of disposing the surface F2 ′ of the
Are carried out sequentially.
なお、図7に示すように、マスク5´は、マスク5の第1及び第2の貫通孔5a,5bにそれぞれ相当する第3及び第4の貫通孔5a´,5b´を有する。貫通孔5a´,5b´はいずれもマスク5´一方の面F1から他方の面F2にかけて貫通している。マスク5´は貫通孔5a´の配置がマスク5の貫通孔5aの配置と正反対の千鳥配置であることの他は、マスク5と同様の構成である(図3,4参照)。ハニカム構造体1の他の端面における不完全なセル1bを封口するには、上記(d)工程において、不完全なセル1bの開口にマスク5´の第4の貫通孔5b´を通じて封止材を供給する。
As shown in FIG. 7, the mask 5 ′ has third and fourth through holes 5 a ′ and 5 b ′ corresponding to the first and second through holes 5 a and 5 b of the mask 5, respectively. Each of the through holes 5a ′ and 5b ′ penetrates from one surface F1 of the mask 5 ′ to the other surface F2. The mask 5 ′ has the same configuration as the mask 5 except that the arrangement of the through holes 5a ′ is a staggered arrangement opposite to the arrangement of the through holes 5a of the mask 5 (see FIGS. 3 and 4). In order to seal the incomplete cell 1b on the other end face of the honeycomb structure 1, in the step (d), the sealing material is inserted into the opening of the incomplete cell 1b through the fourth through hole 5b ′ of the mask 5 ′. Supply.
以下、上述の封口装置100及びマスク5を使用してハニカム構造体1を封口する方法について説明する。まず、図5の状態から、予め、空気圧シリンダ82を駆動して、ハニカム構造体1を保持する保持具81上方に引き上げておくと共に、マスク5を弾性板20上から外しておく。次に、ポンプ50のピストン53を下方に引くことにより、本体部10の凹部10dから流体FLを下方に排出させる。これにより、図8の(a)に示すように、弾性板20が変形して凹部10dの側面10b及び底面10cに密着し、これによって、弾性板20の凹部20dが形成する。
Hereinafter, a method for sealing the honeycomb structure 1 using the sealing device 100 and the mask 5 described above will be described. First, from the state of FIG. 5, the pneumatic cylinder 82 is driven in advance and pulled up above the holder 81 that holds the honeycomb structure 1, and the mask 5 is removed from the elastic plate 20. Next, by pulling the piston 53 of the pump 50 downward, the fluid FL is discharged downward from the recess 10 d of the main body 10. As a result, as shown in FIG. 8A, the elastic plate 20 is deformed and is brought into close contact with the side surface 10b and the bottom surface 10c of the concave portion 10d, whereby the concave portion 20d of the elastic plate 20 is formed.
続いて、図8の(b)に示すように、弾性板20の凹部20d内に封口材130を供給する。必要に応じて、加振器140を駆動することにより、封口材130の表面の平坦化、脱泡を促す。
Subsequently, as shown in FIG. 8B, the sealing material 130 is supplied into the recess 20 d of the elastic plate 20. As necessary, the surface of the sealing material 130 is flattened and defoamed by driving the vibrator 140.
封口材130は、ハニカム構造体1のセル1a,1bの端部を閉鎖できるものであれば特に限定されないが、液状であることが好ましい。たとえば、封口材として、セラミクス材料又はセラミクス原料と、バインダと、潤滑剤と、造孔剤と、溶媒とを含むスラリーが例示できる。
The sealing material 130 is not particularly limited as long as it can close the ends of the cells 1a and 1b of the honeycomb structure 1, but is preferably liquid. For example, as the sealing material, a slurry containing a ceramic material or a ceramic raw material, a binder, a lubricant, a pore former, and a solvent can be exemplified.
セラミクス材料としては、上述のハニカム構造体の構成材料や、その原料が挙げられる。セラミクス材料の使用量は、たとえば、スラリー100重量部に対して50~85重量部とすることができる。
Examples of the ceramic material include the constituent materials of the above-described honeycomb structure and the raw materials thereof. The amount of the ceramic material used can be, for example, 50 to 85 parts by weight with respect to 100 parts by weight of the slurry.
バインダとしては、メチルセルロース、カルボキシルメチルセルロース、ヒドロキシアルキルメチルセルロース、ナトリウムカルボキシルメチルセルロースなどのセルロース類;ポリビニルアルコールなどのアルコール類;リグニンスルホン酸塩等の有機バインダが挙げられる。バインダの使用量は、たとえば、スラリー100重量部に対して0~30重量部とすることができる。
Examples of the binder include celluloses such as methylcellulose, carboxymethylcellulose, hydroxyalkylmethylcellulose, and sodium carboxymethylcellulose; alcohols such as polyvinyl alcohol; and organic binders such as lignin sulfonate. The amount of binder used can be, for example, 0 to 30 parts by weight with respect to 100 parts by weight of the slurry.
潤滑剤としては、グリセリンなどのアルコール類;カプリル酸、ラウリン酸、パルミチン酸、アラキジン酸、オレイン酸、ステアリン酸などの高級脂肪酸;ステアリン酸アルミニウムなどのステアリン酸金属塩などが挙げられる。潤滑剤の使用量は、たとえば、スラリー100重量部に対して0.5~20重量部とすることができる。
Lubricants include alcohols such as glycerin; higher fatty acids such as caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid and stearic acid; and stearic acid metal salts such as aluminum stearate. The amount of lubricant used can be, for example, 0.5 to 20 parts by weight with respect to 100 parts by weight of the slurry.
造孔剤としては、グラファイト等の炭素材;ポリエチレン、ポリプロピレン、ポリメタクリル酸メチル等の樹脂類;でんぷん、ナッツ殻、クルミ殻、コーンなどの植物材料;氷;及びドライアイス等などが挙げられる。造孔剤の使用量は、たとえば、スラリー100重量部に対して0~20重量部とすることができる。
Examples of pore-forming agents include carbon materials such as graphite; resins such as polyethylene, polypropylene, and polymethyl methacrylate; plant materials such as starch, nut shells, walnut shells, and corn; ice; and dry ice. The amount of pore-forming agent used can be, for example, 0 to 20 parts by weight with respect to 100 parts by weight of the slurry.
溶媒としては、たとえば、メタノール、エタノール、ブタノール、プロパノールなどのアルコール類;プロピレングリコール、ポリプロピレングリコール、エチレングリコールなどのグリコール類;及び水などを用いることができる。なかでも、水が好ましく、不純物が少ない点で、より好ましくはイオン交換水が用いられる。溶媒の使用量は、たとえば、スラリー100重量部に対して10~40重量部とすることができる。
As the solvent, for example, alcohols such as methanol, ethanol, butanol and propanol; glycols such as propylene glycol, polypropylene glycol and ethylene glycol; and water can be used. Of these, water is preferable, and ion-exchanged water is more preferably used from the viewpoint of few impurities. The amount of the solvent used can be, for example, 10 to 40 parts by weight with respect to 100 parts by weight of the slurry.
ハニカム構造体1の一方の端面の封口に使用する封口材の量は、たとえば、3~5000mLとすることができる。
The amount of the sealing material used for sealing one end face of the honeycomb structure 1 can be, for example, 3 to 5000 mL.
続いて、図9の(a)に示すように、本体部10の凹部10dを覆うように弾性板20上にマスク5をセットする。このとき、マスク5は面F2が上向きになるように配置する。次いで、空気圧シリンダ82により保持具81を下方に移動させてハニカム構造体1をマスク5に接触させる。これにより、ハニカム構造体1の一部のセル1aとマスク5の第1の貫通孔5aとを連通させると共に、ハニカム構造体1のすべての不完全なセル1bとマスク5の第2の貫通孔5bとを連通させる。さらに、空気圧シリンダ82により保持具81を下方に押圧し、ハニカム構造体1をマスク5及び本体部10に対して固定する((a)工程)。あるいは、封口材を導入したいセル1aと第1の貫通孔5aの位置が合うように予めハニカム構造体1の端面にマスク5を配置し、これを封口装置100に装着してもよい。
Subsequently, as shown in FIG. 9A, the mask 5 is set on the elastic plate 20 so as to cover the recess 10 d of the main body 10. At this time, the mask 5 is arranged so that the surface F2 faces upward. Next, the holder 81 is moved downward by the pneumatic cylinder 82 to bring the honeycomb structure 1 into contact with the mask 5. As a result, some of the cells 1a of the honeycomb structure 1 communicate with the first through holes 5a of the mask 5, and all the incomplete cells 1b of the honeycomb structure 1 and the second through holes of the mask 5 are communicated. Communicate with 5b. Further, the holding member 81 is pressed downward by the pneumatic cylinder 82 to fix the honeycomb structure 1 to the mask 5 and the main body 10 (step (a)). Alternatively, the mask 5 may be arranged on the end face of the honeycomb structure 1 in advance so that the position of the cell 1 a to which the sealing material is to be introduced and the first through hole 5 a are aligned, and this may be attached to the sealing device 100.
次いで、ポンプ50のピストンを上方に移動させることにより、凹部10d内に流体FLを供給し、これによって、図9の(b)に示すように、弾性板20がマスク5に向かって移動する。この工程は、図10の(a)に示すように、弾性板20がマスク5に接触し、弾性板20の変形が解消するまで行なう。
Next, by moving the piston of the pump 50 upward, the fluid FL is supplied into the recess 10d, whereby the elastic plate 20 moves toward the mask 5 as shown in FIG. 9B. This step is performed until the elastic plate 20 comes into contact with the mask 5 and the deformation of the elastic plate 20 is eliminated, as shown in FIG.
これにより、封口材130がマスク5の貫通孔5a,5bを介して、ハニカム構造体1の一部のセル1a及びすべてのセル1b内に供給され、封口部1pが形成する((b)工程)。
Thereby, the sealing material 130 is supplied into some cells 1a and all the cells 1b of the honeycomb structure 1 through the through holes 5a and 5b of the mask 5, thereby forming the sealing portion 1p (step (b)). ).
続いて、空気圧シリンダ82によるハニカム構造体1の下方向への押圧を停止してハニカム構造体1が上方に自由に移動できるようした後、ピストン53をさらに上昇させ弾性板20と本体部10との間にさらに流体FLを供給する。これにより、図10の(b)に示すように、弾性板20は、上方向に凸状に変形し、マスク5及びハニカム構造体1が上方に移動する。このとき、凸状に変形する弾性板20の周辺部はマスク5から離れるので、これにより、マスク5及びハニカム構造体1を、本体部10から容易に引き離すことができる。
Subsequently, after the downward pressing of the honeycomb structure 1 by the pneumatic cylinder 82 is stopped so that the honeycomb structure 1 can freely move upward, the piston 53 is further raised, and the elastic plate 20 and the main body 10 Further, fluid FL is supplied. Thereby, as shown in FIG. 10B, the elastic plate 20 is deformed in a convex shape upward, and the mask 5 and the honeycomb structure 1 are moved upward. At this time, the peripheral portion of the elastic plate 20 deformed into a convex shape is separated from the mask 5, so that the mask 5 and the honeycomb structure 1 can be easily separated from the main body portion 10.
続いて、ハニカム構造体1を保持具81から外した後、天地をひっくり返したうえで再びハニカム構造体1を保持具81に保持する。次いで、マスク5と第1の貫通孔5aの配置が正反対の千鳥配置とされたマスク5´を用いて、同様の操作を行なう((c)工程及び(d)工程)。これにより、図11の(a)に示すように、残りのセル1a及びすべての不完全なセル1bの他端側が封口材で封口され、封口部1pが形成する。続いて、上述と同様にして弾性板20を上に凸状に変形させることにより、マスク5´及びハニカム構造体1を容易に本体部10及び弾性板20から引き離すことができる。
Subsequently, after removing the honeycomb structure 1 from the holder 81, the top and bottom are turned over, and the honeycomb structure 1 is again held by the holder 81. Next, the same operation is performed using the mask 5 ′ in which the mask 5 and the first through-hole 5a are arranged in a zigzag arrangement opposite to each other (steps (c) and (d)). As a result, as shown in FIG. 11A, the other ends of the remaining cells 1a and all the incomplete cells 1b are sealed with the sealing material to form the sealing portion 1p. Subsequently, the mask 5 ′ and the honeycomb structure 1 can be easily separated from the main body 10 and the elastic plate 20 by deforming the elastic plate 20 upward in the same manner as described above.
そしてこのようにして、両端に対して封口処理が施されたハニカム構造体1を乾燥、焼成等することにより、ハニカムフィルタ構造体を製造することができる。
In this manner, the honeycomb filter structure can be manufactured by drying and firing the honeycomb structure 1 that has been sealed at both ends.
マスク5及びマスク5´を使用した上記封口方法によれば、多数の完全なセル1aのうち、封口すべきセル1aのみをより確実に封口できると共に、不完全なセル1bの全てをより確実に封口できる。また、図10の(a)及び図11の(a)に示す弾性板20がマスク5に接触して押圧している状態にあっては、図12に示すように、弾性板20が第1の貫通孔5a内に入り込む。このため、封口材のロスを十分に低減することができる。更に、封口装置100によれば、図10の(b)及び図11の(b)に示す通り、弾性板を凸状に変形させることができるので、封口材130を供給した後のハニカム構造体1に接しているマスク5を本体部10や弾性板20から容易に引き離すことができる。したがって、生産効率を高めることができ、封口されたハニカム構造体を低コスト化で製造することができる。
According to the sealing method using the mask 5 and the mask 5 ', among the many complete cells 1a, only the cells 1a to be sealed can be sealed more reliably, and all the incomplete cells 1b can be sealed more reliably. Can be sealed. Further, when the elastic plate 20 shown in FIGS. 10A and 11A is in contact with and pressed against the mask 5, the elastic plate 20 is the first as shown in FIG. Enters the through hole 5a. For this reason, the loss of the sealing material can be sufficiently reduced. Furthermore, according to the sealing device 100, the elastic plate can be deformed into a convex shape as shown in FIG. 10B and FIG. 11B, so that the honeycomb structure after the sealing material 130 is supplied 1 can be easily pulled away from the main body 10 and the elastic plate 20. Therefore, the production efficiency can be increased, and the sealed honeycomb structure can be manufactured at a low cost.
以上、本発明の好適な実施形態について詳細に説明したが、本発明は上記実施形態に限定されるものではない。たとえば、上記実施形態においては、第1の貫通孔5a及び第2の貫通孔5bを有するマスク5を例示したが、ハニカム構造体に不完全なセル1bがない場合やマスクを用いてセル1bを封口する必要がない場合などにあっては、第1の貫通孔5aを有するが、第2の貫通孔5bを有しないマスクを使用してもよい。
As mentioned above, although the suitable embodiment of the present invention was described in detail, the present invention is not limited to the above-mentioned embodiment. For example, in the above-described embodiment, the mask 5 having the first through-hole 5a and the second through-hole 5b is illustrated. However, when the incomplete cell 1b is not present in the honeycomb structure or the cell 1b is formed using the mask. When there is no need to seal, a mask having the first through hole 5a but not having the second through hole 5b may be used.
ハニカム構造体1の形状や構造も上述に限定されない。たとえば、ハニカム構造体1の外形形状も円柱でなくてもよく、たとえば、四角柱等の角柱や楕円柱でもよい。また、セルの開口面積が0.6~7.0mm2程度(より好ましくは0.8~6.0mm2程度)であれば、セルの断面形状は正方形に限られず、たとえば、略三角形、略四角形、略六角形、略八角形、略円形又はこれらの組み合わせであってもよい。更に、セルの配置もセル1a正方形配置でなくてもよく、たとえば、三角配置、六角配置等でも構わない。
The shape and structure of the honeycomb structure 1 are not limited to the above. For example, the outer shape of the honeycomb structure 1 may not be a cylinder, and may be, for example, a rectangular column such as a quadrangular column or an elliptical column. Further, if the opening area of the cell is about 0.6 to 7.0 mm 2 (more preferably about 0.8 to 6.0 mm 2 ), the cross-sectional shape of the cell is not limited to a square. It may be a quadrangle, a substantially hexagon, a substantially octagon, a substantially circle, or a combination thereof. Furthermore, the arrangement of the cells may not be the square arrangement of the cells 1a, and may be, for example, a triangular arrangement or a hexagonal arrangement.
1…ハニカム構造体、1a…完全なセル、1b…不完全なセル、5,5´…マスク、5a…第1の貫通孔、5b…第2の貫通孔、5a´…第3の貫通孔、5b´…第4の貫通孔、6a…テーパ部、6c…段差部、F1…マスクの面(一方面)、F2…マスクの面(他方面)。
DESCRIPTION OF SYMBOLS 1 ... Honeycomb structure, 1a ... Complete cell, 1b ... Incomplete cell, 5, 5 '... Mask, 5a ... 1st through-hole, 5b ... 2nd through-hole, 5a' ... 3rd through-hole 5b '... 4th through-hole, 6a ... tapered portion, 6c ... stepped portion, F1 ... mask surface (one surface), F2 ... mask surface (other surface).
Claims (11)
- ハニカム構造体のセルの封口に使用されるマスクであって、
当該マスクの一方面から他方面にかけて貫通する複数の第1の貫通孔を有し、前記他方面における前記第1の貫通孔の開口面積が前記一方面における前記第1の貫通孔の開口面積よりも小さいマスク。 A mask used for sealing a cell of a honeycomb structure,
The mask has a plurality of first through holes penetrating from one surface of the mask to the other surface, and the opening area of the first through hole on the other surface is larger than the opening area of the first through hole on the one surface. Even a small mask. - 前記第1の貫通孔は、前記一方面から前記他方面に向けて開口面積が連続的に縮小するテーパ部を有する、請求項1に記載のマスク。 2. The mask according to claim 1, wherein the first through-hole has a tapered portion whose opening area continuously decreases from the one surface toward the other surface.
- 前記第1の貫通孔は、前記一方面から前記他方面に向けて開口面積が不連続的に縮小する段差部を有する、請求項1に記載のマスク。 2. The mask according to claim 1, wherein the first through hole has a step portion in which an opening area discontinuously decreases from the one surface toward the other surface.
- 前記第1の貫通孔は、前記他方面における開口面積が0.03mm2以上であり且つ当該第1の貫通孔によって封口すべき前記ハニカム構造体のセルの開口面積の90%未満である、請求項1~3のいずれか一項に記載のマスク。 The first through hole has an opening area of 0.03 mm 2 or more on the other surface and less than 90% of the opening area of the cells of the honeycomb structure to be sealed by the first through hole. Item 4. The mask according to any one of Items 1 to 3.
- 前記第1の貫通孔は、前記他方面における開口面積が0.2mm2以上である、請求項4に記載のマスク。 The mask according to claim 4, wherein the first through hole has an opening area on the other surface of 0.2 mm 2 or more.
- 使用時において前記ハニカム構造体の端面と当接する領域のうち、前記ハニカム構造体の端面周縁部と当接する部分に、当該マスクの厚さ方向に貫通する複数の第2の貫通孔を更に有し、
前記第2の貫通孔は、前記ハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、前記他方面における開口面積が0.03mm2以上であり且つ前記第1の貫通孔によって封口すべきセルの開口面積の60%未満である、請求項1~5のいずれか一項に記載のマスク。 Among the regions in contact with the end face of the honeycomb structure during use, the portion further in contact with the peripheral edge of the end face of the honeycomb structure further includes a plurality of second through holes penetrating in the thickness direction of the mask. ,
The second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, and the opening area on the other surface is 0.03 mm 2 or more and should be sealed by the first through holes. The mask according to any one of claims 1 to 5, wherein the mask is less than 60% of the open area of the cell. - 前記第2の貫通孔は、前記他方面における開口面積が0.2mm2以上である、請求項6に記載のマスク。 The mask according to claim 6, wherein the second through hole has an opening area of 0.2 mm 2 or more on the other surface.
- ハニカム構造体のセルの封口方法であって、
(a)前記ハニカム構造体の一方の端面上にマスクを配置する工程と、
(b)前記ハニカム構造体の前記一方の端面における封口すべきセルの開口に前記マスクが有する第1の貫通孔を通じて封止材を供給する工程と、
を備え、
前記マスクは、当該マスクの一方面から他方面にかけて貫通する複数の前記第1の貫通孔を有し、前記他方面における前記第1の貫通孔の開口面積が前記一方面における前記第1の貫通孔の開口面積よりも小さく、
(a)工程において当該マスクの前記他方面がハニカム構造体の端面に当接するように当該マスクを配置する封口方法。 A method for sealing cells of a honeycomb structure,
(A) placing a mask on one end face of the honeycomb structure;
(B) supplying a sealing material through a first through hole of the mask to an opening of a cell to be sealed on the one end face of the honeycomb structure;
With
The mask has a plurality of first through holes penetrating from one side of the mask to the other side, and an opening area of the first through hole on the other side is the first through hole on the one side. Smaller than the opening area of the hole,
(A) A sealing method in which, in the step (a), the mask is arranged so that the other surface of the mask is in contact with the end surface of the honeycomb structure. - 前記マスクは、前記ハニカム構造体の前記一方の端面と当接する領域のうち、前記ハニカム構造体の端面周縁部と当接する部分に、当該マスクの厚さ方向に貫通する複数の第2の貫通孔を更に有し、
前記第2の貫通孔は、前記ハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、開口面積が0.03mm2以上であり且つ前記第1の貫通孔によって封口すべきセルの開口面積の60%未満であり、
(b)工程において、前記ハニカム構造体の端面周縁部における封口すべきセルの開口に当該マスクの前記第2の貫通孔を通じて封止材を供給する、請求項8に記載の封口方法。 The mask has a plurality of second through-holes penetrating in the thickness direction of the mask in a portion of the region contacting the one end surface of the honeycomb structure and contacting the peripheral edge of the end surface of the honeycomb structure. Further comprising
The second through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cells to be sealed by the first through holes Less than 60% of
The sealing method according to claim 8, wherein, in the step (b), a sealing material is supplied to the opening of the cell to be sealed at the peripheral edge portion of the honeycomb structure through the second through hole of the mask. - (c)前記ハニカム構造体の他方の端面上に他のマスクを配置する工程と、
(d)前記ハニカム構造体の前記他方の端面における封口すべきセルの開口に前記他のマスクが有する第3の貫通孔を通じて封止材を供給する工程と、
を更に備え、
前記他のマスクは、当該マスクの一方面から他方面にかけて貫通する複数の前記第3の貫通孔を有し、前記他方面における前記第3の貫通孔の開口面積が前記一方面における前記第3の貫通孔の開口面積よりも小さく、
(a)工程において当該マスクの前記他方面が前記ハニカム構造体の端面に当接するように当該マスクを配置する、請求項9に記載の封口方法。 (C) disposing another mask on the other end face of the honeycomb structure;
(D) supplying a sealing material through a third through hole of the other mask to an opening of a cell to be sealed on the other end surface of the honeycomb structure;
Further comprising
The other mask has a plurality of the third through holes penetrating from one surface of the mask to the other surface, and an opening area of the third through hole on the other surface is the third surface on the one surface. Smaller than the opening area of the through-hole,
The sealing method according to claim 9, wherein in the step (a), the mask is arranged so that the other surface of the mask is in contact with an end surface of the honeycomb structure. - 前記他のマスクは、前記ハニカム構造体の前記他方の端面と当接する領域のうち、前記ハニカム構造体の端面周縁部と当接する部分に、当該マスクの厚さ方向に貫通する複数の第4の貫通孔を更に有し、
前記第4の貫通孔は、前記ハニカム構造体のセルピッチよりも狭い間隔で設けられていると共に、開口面積が0.03mm2以上であり且つ前記第3の貫通孔によって封口すべきセルの開口面積の60%未満であり、
(d)工程において、前記ハニカム構造体の端面周縁部における封口すべきセルの開口に当該マスクの前記第4の貫通孔を通じて封止材を供給する、請求項10に記載の封口方法。 The other mask includes a plurality of fourth masks penetrating in the thickness direction of the mask in a portion of the region contacting the other end surface of the honeycomb structure that contacts the peripheral edge of the end surface of the honeycomb structure. Further having a through hole,
The fourth through holes are provided at an interval narrower than the cell pitch of the honeycomb structure, the opening area is 0.03 mm 2 or more, and the opening area of the cells to be sealed by the third through holes Less than 60% of
The sealing method according to claim 10, wherein in the step (d), a sealing material is supplied to the opening of the cell to be sealed at the peripheral edge of the end face of the honeycomb structure through the fourth through hole of the mask.
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Cited By (2)
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EP2570244A1 (en) * | 2010-05-11 | 2013-03-20 | Sumitomo Chemical Company, Limited | Mask for sealing honeycomb structure, and sealing method for honeycomb structure using same |
JP2020073263A (en) * | 2013-07-10 | 2020-05-14 | スマート セパレーションズ リミテッド | Inorganic filter, blood filtering device, method for filtering fluid to remove particle from fluid, and mask |
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CN106103024B (en) | 2014-03-27 | 2018-01-30 | 日本碍子株式会社 | The manufacture method of plugged honeycomb structure |
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JP2000280222A (en) * | 1999-03-29 | 2000-10-10 | Ibiden Co Ltd | Method for sealing ceramic molded product |
WO2007097000A1 (en) * | 2006-02-24 | 2007-08-30 | Ibiden Co., Ltd. | End-sealing device for honeycomb formed body, method of placing sealing-material paste, and method of producing honeycomb structure body |
WO2007119408A1 (en) * | 2006-03-17 | 2007-10-25 | Ngk Insulators, Ltd. | Method of manufacturing sealed honeycomb structure |
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2011
- 2011-05-02 JP JP2011103183A patent/JP4852668B2/en not_active Expired - Fee Related
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JP2000280222A (en) * | 1999-03-29 | 2000-10-10 | Ibiden Co Ltd | Method for sealing ceramic molded product |
WO2007097000A1 (en) * | 2006-02-24 | 2007-08-30 | Ibiden Co., Ltd. | End-sealing device for honeycomb formed body, method of placing sealing-material paste, and method of producing honeycomb structure body |
WO2007119408A1 (en) * | 2006-03-17 | 2007-10-25 | Ngk Insulators, Ltd. | Method of manufacturing sealed honeycomb structure |
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EP2570244A1 (en) * | 2010-05-11 | 2013-03-20 | Sumitomo Chemical Company, Limited | Mask for sealing honeycomb structure, and sealing method for honeycomb structure using same |
EP2570244A4 (en) * | 2010-05-11 | 2014-01-08 | Sumitomo Chemical Co | Mask for sealing honeycomb structure, and sealing method for honeycomb structure using same |
JP2020073263A (en) * | 2013-07-10 | 2020-05-14 | スマート セパレーションズ リミテッド | Inorganic filter, blood filtering device, method for filtering fluid to remove particle from fluid, and mask |
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