WO2012018021A1 - Opening-sealing mask and opening-sealing method for honey-comb structure using same - Google Patents

Opening-sealing mask and opening-sealing method for honey-comb structure using same Download PDF

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Publication number
WO2012018021A1
WO2012018021A1 PCT/JP2011/067689 JP2011067689W WO2012018021A1 WO 2012018021 A1 WO2012018021 A1 WO 2012018021A1 JP 2011067689 W JP2011067689 W JP 2011067689W WO 2012018021 A1 WO2012018021 A1 WO 2012018021A1
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Prior art keywords
opening
honeycomb structure
sealing
mask
cross
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PCT/JP2011/067689
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French (fr)
Japanese (ja)
Inventor
康輔 魚江
正春 森
大平　智嗣
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住友化学株式会社
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Publication of WO2012018021A1 publication Critical patent/WO2012018021A1/en

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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
    • B28B11/007—Using a mask for plugging
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs

Definitions

  • the present invention relates to a mask used for sealing a honeycomb structure and a sealing method using the mask.
  • honeycomb filters are widely known for DPF (Diesel particulate filter) use.
  • This honeycomb filter is manufactured by sealing a part of through holes from one end face of a honeycomb structure having a large number of through holes with a sealing material and sealing the remaining through holes from the other end face of the honeycomb structure with a sealing material.
  • Patent Documents 1 and 2 describe a method for sealing a honeycomb structure using a mask.
  • the shape of the through holes near the side wall of the honeycomb structure is affected by the side wall of the honeycomb structure. Therefore, the through hole near the side wall of the honeycomb structure may have a smaller opening cross-sectional area than the through hole formed in the central portion of the honeycomb structure.
  • the opening of the opposing mask is made small in accordance with the through hole having such a small cross-sectional area.
  • the present invention has been made in view of the above problems, and provides a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a through-hole having a small cross-sectional area, and a sealing method using the same. With the goal.
  • the sealing mask according to the present invention is a sealing mask for supplying a sealing material to the through holes of the honeycomb structure, A number of first openings each having a first cross-sectional area; A plurality of second openings, which are arranged so as to surround the first openings and each have a cross-sectional area larger than the first cross-sectional area.
  • the second opening having a cross-sectional area larger than the cross-sectional area of the first opening is arranged so as to surround a large number of the first openings. For this reason, a plurality of through holes including the through holes formed by the side walls of the honeycomb structure, which are located in the vicinity of the side walls of the honeycomb structure, can be opposed to the second openings. Thereby, even when the cross-sectional area of the through hole in the vicinity of the side wall is small, it is easy to supply the sealing material.
  • the aspect ratio of the contour of the second opening is preferably larger than the aspect ratio of the contour of the first opening. Thereby, it is easy to oppose a some through-hole by 2nd opening.
  • the present invention provides a method of sealing a predetermined through-hole of a honeycomb structure using the mask. That is, the present invention is a method for sealing a through hole of a honeycomb structure, (A) placing a mask on one end face of the honeycomb structure; (B) providing a sealing material through a plurality of first openings and a plurality of second openings of the mask to through holes to be sealed in the one end face of the honeycomb structure; The mask is arranged so as to surround the plurality of first openings each having a first cross-sectional area, and the plurality of the plurality of first openings each having a cross-sectional area larger than the first cross-sectional area. And a second opening.
  • the sealing material can be sufficiently supplied even to the small through hole.
  • 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.
  • a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a small through hole and a sealing method using the same.
  • FIG. 1A is a perspective view of a honeycomb structure 70 according to an embodiment of the present invention
  • FIG. 1B is an enlarged view of a portion A of the end surface of FIG. 2A is a perspective view of the mask 170 according to the embodiment of the present invention
  • FIG. 2B is an enlarged view of a portion A on the end surface of FIG. 2A
  • FIG. 3A is a perspective view of the honeycomb structure 70 according to the embodiment of the present invention
  • FIG. 1B is an enlarged view of a portion A of the end face of FIG.
  • FIG. 4 is an enlarged view of a portion C in FIG.
  • the honeycomb structure 70 is a cylindrical body in which a large number of through holes 71 extending in the Z direction are arranged substantially in parallel.
  • the shape of the side wall 70c forming the side surface is cylindrical, and as shown in FIG. 1 (b), a large number (for example, 100 or more) having a square cross-sectional shape in the central portion in the radial direction.
  • a plurality of special-shaped through-holes 71b hereinafter, referred to as “perfect cells 71a” or simply “cells 71a”
  • squares a plurality of special-shaped through-holes 71b having a cross-sectional shape that is not square.
  • the complete cell 71a has a square arrangement as viewed from the end face 70e in the Z-axis direction, that is, the central axis of the complete cell 71a is located at the apex of the square and adjacent sides are parallel to each other.
  • a large number of matrix structures 70 are arranged in a matrix at the center of the end face 70e of the honeycomb structure 70.
  • the size of the square of the cross section of the cell 71a can be, for example, 0.8 to 2.5 mm on a side. In this embodiment, the square size and the cross-sectional area of the complete cell 71a are substantially the same.
  • a plurality of incomplete cells 71b are arranged along the side wall 70c of the honeycomb structure, and are arranged so as to surround many complete cells 71a. Since the incomplete cell 71b is partly formed by the side wall 70c, its cross-sectional shape is not a square and is not constant depending on the shape and position of the side wall 70c, and varies depending on the location. Yes. However, usually, any incomplete cell 71b has a smaller cross-sectional area than the complete cell 71a.
  • the thickness of the partition wall 70w between the cells 71a, between the cells 71b, and between the cells 71a and 71b can be set to, for example, 0.05 to 0.5 mm. Further, the thickness of the side wall 70c is preferably larger than the thickness of the partition wall 70w, and can be 0.1 to 3.0 mm.
  • the length in the Z direction in which the through holes 71 of the honeycomb structure 70 extend is not particularly limited, but may be, for example, 40 to 350 mm.
  • the outer diameter of the honeycomb structure 70 is not particularly limited, but may be, for example, 100 to 320 mm.
  • the material of the honeycomb structure 70 is not particularly limited, but a ceramic material is preferable from the viewpoint of high temperature resistance. Examples thereof 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 70 is usually porous.
  • the honeycomb structure 70 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 examples include pore formers, lubricants and plasticizers, dispersants, and solvents.
  • 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; and stearic acid metal salts such as Al stearate.
  • 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 170 shown in FIGS. 2A and 2B is used to seal a desired through hole 71 of the honeycomb structure 70 shown in FIG.
  • the mask 170 is a circular plate-like member, and has a plurality of first openings 171a and a plurality of second openings 171b penetrating in the thickness direction.
  • the material of the mask 170 is not specifically limited, For example, a metal and resin are mentioned.
  • the thickness of the mask is not particularly limited, but is preferably 0.1 to 3.0 mm, for example.
  • the first opening 171a is for supplying a sealing material only to each complete cell 71a of the honeycomb structure 70.
  • the shape of the first opening 171 a is a square corresponding to the cell 71 a of the honeycomb structure 70.
  • These first openings 171a are arranged in a staggered manner, and as shown in FIG. 3, in a state where the mask 170 is positioned and arranged on the end face of the honeycomb structure 70, the plurality of cells 71a arranged in a square are arranged. Of these, only the plurality of cells 71a that are not adjacent to each other in the vertical and horizontal directions are arranged to face each other.
  • the shape of the first opening 171a is not limited to a square, but may be similar to the shape of the cell 71a and smaller than that from the viewpoint of the filling property of the paste-like sealing material. preferable.
  • the first opening 171a preferably has an opening area of 0.03 mm 2 or more and less than 90% of the opening area of the cell 71a to be sealed by the first opening 171a. If the opening area of the first opening 171a is less than 0.03 mm 2 , the sealing material may not easily pass through the first opening 171a, and a predetermined amount of the sealing material may not be supplied into the cell 71a.
  • the opening area of the first opening 171a is preferably 0.05 mm 2 or more, more preferably 0.07 mm 2 or more, and may be 0.2 mm 2 or more or 0.25 mm 2 or more.
  • the sealing material can be removed from the predetermined cell 71a only by slightly shifting the position of the first opening 171a and the opening of the cell 71a. In some cases, it cannot be supplied to the inside of the cell 71a and should not be sealed.
  • the opening area of the first opening 171a is preferably less than 80% and more preferably less than 60% of the opening area of the cell 71a.
  • the opening area means the opening area of the first opening 171 a on the surface of the mask 170 on the side in contact with the end face of the honeycomb structure 70.
  • the aspect ratio of the contour of the first opening 171a is preferably 1.5 or less, and preferably 1.2 or less.
  • the aspect ratio of the contour is defined by the length of the long side / the length of the short side when the contour of the opening is surrounded by a rectangle (including a square) with a minimum area that circumscribes the opening.
  • the second opening 171b in FIG. 2 (b) is for supplying a sealing material to the incomplete cell 71b of the honeycomb structure 70 in FIG. 1 (b).
  • the second opening 171b in FIG. 2B has a larger cross-sectional area (opening area) than the first opening 171a.
  • the opening area of the second opening 171b is preferably 1.2 to 5 times, more preferably 1.5 to 3.5 times the opening area of the first opening 171a.
  • the shape of the 2nd opening 171b has an elongate shape compared with the 1st opening 171a, and the aspect ratio of the outline of the 2nd opening 171b is larger than the aspect ratio of the outline of the 1st opening 171a.
  • the aspect ratio of the contour of the second opening 171b is more preferably 2 or more, and more preferably 3 or more.
  • the upper limit of the aspect ratio of the outline of the second opening 171b can be about 6.
  • the second opening 171 b faces the plurality of through holes 71 of the honeycomb structure 70 in a state where the mask 170 is positioned and arranged on the end face of the honeycomb structure 70. It is like that.
  • one second opening 171b may be opposed to two incomplete cells 71b, or as shown by an arrow B in FIG. 171b may face one incomplete cell 71b and one complete cell 71a.
  • one second opening 171b is arranged opposite to at least one incomplete cell 71b and any other number of complete cells 71a and / or incomplete cells 71b. What is necessary is just to face 3 or more through-holes. Therefore, the partition walls 70w separating the plurality of through holes 71 of the honeycomb structure 70 are exposed from the second opening 171b.
  • the second opening 171b does not have to have an area facing each of the plurality of through holes 71 facing the second opening 171b, and may be at least partially opposed to each other.
  • the second opening 171b1 does not face the plurality of through holes 71b1 and 71b1 facing the second opening 171b1 and the second opening 171b1.
  • the contour is preferably formed at a distance D, for example, 50 to 500 ⁇ m away from the partition wall 70ws that forms the boundary with the through hole 71c.
  • the side wall 70c is several times thicker than the partition wall 70w, so that the sealing material can easily enter the through hole 71b1 facing the second opening 171 and the intention due to unavoidable misalignment. It is possible to suppress erroneous supply of the sealing material to the through hole 71c not to be performed.
  • the opening diameter of the second opening 171b may change in the thickness direction of the mask 170, for example, a taper shape that gradually decreases as the opening diameter approaches the end face of the honeycomb structure 70.
  • the opening area and outline here mean the opening area and outline of the opening 171 b on the surface side of the mask 5 on the side in contact with the end face of the honeycomb structure 70.
  • the method for positioning the mask 170 with respect to the honeycomb structure 70 is not particularly limited.
  • the mask 170 may be visually observed from the opening of the mask 170 while looking at the partition walls, through holes, side walls, and the like.
  • the method of supplying the sealing material to the through hole 71 through the openings 171a and 171b in the state where the positioning is performed in this way is not particularly limited.
  • the sealing agent supplied on the mask may be pushed into the through-hole through the opening using a squeegee, or may be pushed in by a piston.
  • the sealing material is not particularly limited as long as the end of the through hole 71 of the honeycomb structure 70 can be closed, but is preferably liquid.
  • the sealing material can be exemplified by a slurry containing a ceramic material or a ceramic raw material, a binder, a lubricant, and a solvent.
  • the ceramic material include the constituent material of the above-described honeycomb structure and the raw material thereof.
  • 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 the binder used can be, for example, 0.1 to 10% by mass when the sealing material is 100% by mass.
  • Lubricants include alcohols such as glycerin, caprylic acid, lauric acid, palmitic acid, higher fatty acids such as alginate, oleic acid and stearic acid, and stearic acid metal salts such as Al stearate.
  • the addition amount of the lubricant is usually 0 to 10% by mass, preferably 1 to 10% by mass, more preferably 1 to 5% by mass with respect to 100% by mass of the sealing material.
  • 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, 15 to 40% by mass when the sealing material is 100% by mass.
  • the sealing method according to the present embodiment is for sealing an opening of a predetermined through hole (cell) of the honeycomb structure 70 using the mask 170.
  • this sealing method comprises the following steps: (A) a step of disposing a mask 170 on one end face of the honeycomb structure 70; and (b) a first opening 171a of the mask 5 in the cell 71a and the cell 71b to be sealed on the one end face of the honeycomb structure 70. And supplying a sealing material through the second opening 171b.
  • the sealing material can be sufficiently supplied even to the cell 71b having a small opening area.
  • the same sealing process is applied to the other end face.
  • the mask used for the sealing process of the other end face has the same configuration as that of the mask 170 except that the arrangement of the openings is a staggered arrangement opposite to the arrangement of the openings of the mask 170.
  • the second openings 171b having a larger cross-sectional area than the first openings 171a are arranged so as to surround the first openings 171a.
  • a plurality of through holes including incomplete cells 71b formed by the side wall 70c of the honeycomb structure 70 which are located in the vicinity of the side wall 70c of the honeycomb structure 70, are connected to the second openings 171b having a large cross-sectional area.
  • the second opening 171b allows the desired aspect without facing the through hole that is not desired to be sealed. It is preferable that it is easily opposed to a plurality of through holes.
  • the arrangement of the complete cells 71a of the honeycomb structure 70 may not be a square arrangement, and may be a triangular arrangement, a staggered arrangement, or the like.
  • the number and position of the openings 171b and 171b of the mask 170 can be changed according to the arrangement of the complete cell 71a and the incomplete cell 71b surrounding the complete cell 71a.
  • the cross-sectional shape of the complete cell 71a of the honeycomb structure 70 may not be a square, and may be, for example, a rectangle, a triangle, a polygon, a circle, or the like. Moreover, these may be mixed.
  • the cells 71a of the honeycomb structure 70 may be circular and arranged in an equilateral triangle, that is, the centers of the cells 71a may be respectively arranged at the vertices of a virtual equilateral triangle.
  • cells 71a may have different areas.
  • the outer shape of the honeycomb structure 70 may not be a cylinder, and may be a prism such as a quadrangular prism, for example.
  • the outer shape of the mask 170 is not limited to a circle, and any shape is possible.
  • an ellipse, a polygon such as a rectangle, a triangle, or a hexagon can be taken.
  • regular polygons such as a square, a regular triangle, and a regular hexagon are also preferable.
  • the first opening 171b it is not necessary to arrange the second opening 171b for every incomplete cell 71b, and for the incomplete cell 71b having the same cross-sectional area as the complete cell 71a, the first opening 171b. Can be arranged.
  • a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a small through hole and a sealing method using the same.
  • 70 ... honeycomb structure 71 ... through hole, 71a ... standard shape through hole (complete cell), 71b ... special shape through hole (incomplete cell), 70c ... side wall, 70w ... partition wall, 170 ... mask, 171a ... 1st opening, 171b ... 2nd opening.

Abstract

Disclosed is an opening-sealing mask for supplying an opening-sealing material to through holes of a honey-comb structure, wherein the mask is provided with a large number of first openings each having a first cross-sectional area, and a plurality of second openings arranged to surround the large number of first openings and each second opening having a cross-sectional area larger than the first cross-sectional area.

Description

封口用マスク及びこれを用いたハニカム構造体の封口方法Sealing mask and sealing method of honeycomb structure using the same
　本発明は、ハニカム構造体の封口に用いるマスク及びこれを用いた封口方法に関する。 The present invention relates to a mask used for sealing a honeycomb structure and a sealing method using the mask.
　従来より、ハニカムフィルタが、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は、多数の貫通孔を有するハニカム構造体の一端面から一部の貫通孔を封口材で封じると共に、ハニカム構造体の他端面から残りの貫通孔を封口材で封じることにより製造される。 Conventionally, honeycomb filters are widely known for DPF (Diesel particulate filter) use. This honeycomb filter is manufactured by sealing a part of through holes from one end face of a honeycomb structure having a large number of through holes with a sealing material and sealing the remaining through holes from the other end face of the honeycomb structure with a sealing material. The
　ハニカム構造体の端面の所望の貫通孔のみを封口材により封じる際に、封口すべき貫通孔に対応する箇所に開口が設けられたマスクを使用する。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。 When a desired through hole on the end face of the honeycomb structure is sealed with a sealing material, a mask having openings provided at positions corresponding to the through holes to be sealed is used. The following Patent Documents 1 and 2 describe a method for sealing a honeycomb structure using a mask.
特開２００４－２９０７６６号公報JP 2004-290766 A 特開２００８－１３２７４９号公報JP 2008-132749 A
　ところで、ハニカム構造体が有する多数の貫通孔の内、ハニカム構造体の側壁の近傍の貫通孔の形状はハニカム構造体の側壁の影響を受ける。したがって、ハニカム構造体の側壁の近傍の貫通孔は、ハニカム構造体の中央部に形成される貫通孔よりも開口の断面積が小さくなる場合がある。 By the way, among the many through holes of the honeycomb structure, the shape of the through holes near the side wall of the honeycomb structure is affected by the side wall of the honeycomb structure. Therefore, the through hole near the side wall of the honeycomb structure may have a smaller opening cross-sectional area than the through hole formed in the central portion of the honeycomb structure.
　このような小さな断面積の貫通孔を封口する際には、このような小さな断面積の貫通孔に合わせ、対向するマスクの開口を小さくする。しかし、小さな断面積の貫通孔に対して十分に封口材を供給することが困難な場合がある。 When sealing a through hole having such a small cross-sectional area, the opening of the opposing mask is made small in accordance with the through hole having such a small cross-sectional area. However, it may be difficult to sufficiently supply the sealing material to the through hole having a small cross-sectional area.
　本発明は上記課題に鑑みてなされたものであり、小さな断面積の貫通孔に対しても十分に封口材を供給可能なハニカム構造体の封口用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 provides a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a through-hole having a small cross-sectional area, and a sealing method using the same. With the goal.
　本発明に係る封口用マスクは、ハニカム構造体の貫通孔に封口材を供給するための封口用マスクであって、
　第一の断面積をそれぞれ有する多数の第一開口と、
　前記多数の第一開口を取り囲むように配置され、前記第一の断面積よりも大きな断面積をそれぞれ有する複数の第二開口と、を備える。 The sealing mask according to the present invention is a sealing mask for supplying a sealing material to the through holes of the honeycomb structure,
A number of first openings each having a first cross-sectional area;
A plurality of second openings, which are arranged so as to surround the first openings and each have a cross-sectional area larger than the first cross-sectional area.
　本発明によれば、第一開口の断面積よりも大きな断面積を有する第二開口が、多数の第一開口を取り囲むように配置されている。このため、ハニカム構造体の側壁の近傍に位置する、ハニカム構造体の側壁により形成された貫通孔を含む複数の貫通孔を、この第二開口と対向させることができる。これにより、側壁の近傍の貫通孔の断面積が小さい場合でも、封口材を供給しやすい。 According to the present invention, the second opening having a cross-sectional area larger than the cross-sectional area of the first opening is arranged so as to surround a large number of the first openings. For this reason, a plurality of through holes including the through holes formed by the side walls of the honeycomb structure, which are located in the vicinity of the side walls of the honeycomb structure, can be opposed to the second openings. Thereby, even when the cross-sectional area of the through hole in the vicinity of the side wall is small, it is easy to supply the sealing material.
　ここで、前記第二開口の輪郭のアスペクト比は、前記第一開口の輪郭のアスペクト比よりも大きいことが好ましい。これにより、第二開口により、複数の貫通孔と対向し易い。 Here, the aspect ratio of the contour of the second opening is preferably larger than the aspect ratio of the contour of the first opening. Thereby, it is easy to oppose a some through-hole by 2nd opening.
　本発明は上記マスクを用いてハニカム構造体の所定の貫通孔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貫通孔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貫通孔に前記マスクが有する複数の第一開口及び複数の第二開口を通じて封口材を供給する工程とを備え、
　前記マスクは、第一の断面積をそれぞれ有する前記複数の第一開口と、前記複数の第一開口を取り囲むように配置され、前記第一の断面積よりも大きな断面積をそれぞれ有する前記複数の第二開口と、を有する方法を提供する。 The present invention provides a method of sealing a predetermined through-hole of a honeycomb structure using the mask. That is, the present invention is a method for sealing a through hole of a honeycomb structure,
(A) placing a mask on one end face of the honeycomb structure;
(B) providing a sealing material through a plurality of first openings and a plurality of second openings of the mask to through holes to be sealed in the one end face of the honeycomb structure;
The mask is arranged so as to surround the plurality of first openings each having a first cross-sectional area, and the plurality of the plurality of first openings each having a cross-sectional area larger than the first cross-sectional area. And a second opening.
　上記封口方法によれば、小貫通孔に対しても十分に封口材を供給できる。なお、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。 According to the above sealing method, the sealing material can be sufficiently supplied even to the small through hole. Note that 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.
　本発明によれば、小貫通孔に対しても十分に封口材を供給可能なハニカム構造体の封口用マスク及びこれを用いた封口方法を提供できる。 According to the present invention, it is possible to provide a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a small through hole and a sealing method using the same.
図１の（ａ）は、本発明の実施形態にかかるハニカム構造体７０の斜視図、図１の（ｂ）は、図１の（ａ）の端面のＡの部分の拡大図である。FIG. 1A is a perspective view of a honeycomb structure 70 according to an embodiment of the present invention, and FIG. 1B is an enlarged view of a portion A of the end surface of FIG. 図２の（ａ）は、本発明の実施形態にかかるマスク１７０の斜視図、図２の（ｂ）は、図２の（ａ）の端面のＡの部分の拡大図である。2A is a perspective view of the mask 170 according to the embodiment of the present invention, and FIG. 2B is an enlarged view of a portion A on the end surface of FIG. 2A. 図３の（ａ）は、本発明の実施形態にかかるハニカム構造体７０の斜視図、図１の（ｂ）は、図１の（ａ）の端面のＡの部分の拡大図である。FIG. 3A is a perspective view of the honeycomb structure 70 according to the embodiment of the present invention, and FIG. 1B is an enlarged view of a portion A of the end face of FIG. 図４は、図３のＣの部分の拡大図である。FIG. 4 is an enlarged view of a portion C in FIG.
　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、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, the honeycomb structure will be described.
　図１の（ａ）に示すように、ハニカム構造体７０は、Ｚ方向に伸びる多数の貫通孔７１が略平行に配置された円柱体である。ハニカム構造体７０は、側面を形成する側壁７０ｃの形状が円筒状であり、図１の（ｂ）に示すように、径方向中央部には断面形状が正方形の多数の（例えば、１００個以上の）標準形状貫通孔７１ａ（以下、「完全なセル７１ａ」又は単に「セル７１ａ」という。）と、径方向最外周部に、断面形状が正方形ではない複数の特殊形状貫通孔７１ｂ（以下、「不完全なセル７１ｂ」又は単に「セル７１ｂ」という。）とを有する。 1 (a), the honeycomb structure 70 is a cylindrical body in which a large number of through holes 71 extending in the Z direction are arranged substantially in parallel. In the honeycomb structure 70, the shape of the side wall 70c forming the side surface is cylindrical, and as shown in FIG. 1 (b), a large number (for example, 100 or more) having a square cross-sectional shape in the central portion in the radial direction. And a plurality of special-shaped through-holes 71b (hereinafter, referred to as “perfect cells 71a” or simply “cells 71a”) and a plurality of special-shaped through-holes 71b (hereinafter referred to as “squares”) having a cross-sectional shape that is not square. "Incomplete cell 71b" or simply "cell 71b").
　完全なセル７１ａは、ハニカム構造体７０において、Ｚ軸方向の端面７０ｅから見て、正方形配置、すなわち、完全なセル７１ａの中心軸が、正方形の頂点にそれぞれ位置しかつ隣接する辺同士が平行となるようにハニカム構造体７０の端面７０ｅにおける中央部にマトリクス状に多数配置されている。セル７１ａの断面の正方形のサイズは、例えば、一辺０．８～２．５ｍｍとすることができる。本実施形態では、完全なセル７１ａの正方形のサイズ及び断面積は互いに略同一とされている。 In the honeycomb structure 70, the complete cell 71a has a square arrangement as viewed from the end face 70e in the Z-axis direction, that is, the central axis of the complete cell 71a is located at the apex of the square and adjacent sides are parallel to each other. A large number of matrix structures 70 are arranged in a matrix at the center of the end face 70e of the honeycomb structure 70. The size of the square of the cross section of the cell 71a can be, for example, 0.8 to 2.5 mm on a side. In this embodiment, the square size and the cross-sectional area of the complete cell 71a are substantially the same.
　不完全なセル７１ｂは、ハニカム構造体の側壁７０ｃに沿って複数配置されており、多数の完全なセル７１ａを取り囲むように配置されている。不完全なセル７１ｂは、その一部が側壁７０ｃにより形成されているため、その断面形状は、正方形でないことに加え、側壁７０ｃの形状や位置に依存して互いに一定ではなく、場所によって異なっている。しかしながら、通常は、いずれの不完全なセル７１ｂも、その断面積は完全なセル７１ａの断面積よりも小さい。 A plurality of incomplete cells 71b are arranged along the side wall 70c of the honeycomb structure, and are arranged so as to surround many complete cells 71a. Since the incomplete cell 71b is partly formed by the side wall 70c, its cross-sectional shape is not a square and is not constant depending on the shape and position of the side wall 70c, and varies depending on the location. Yes. However, usually, any incomplete cell 71b has a smaller cross-sectional area than the complete cell 71a.
　セル７１ａ間、セル７１ｂ間、及び、セル７１ａとセル７１ｂとの間の隔壁７０ｗの厚みは、例えば、０．０５～０．５ｍｍとすることができる。また、側壁７０ｃの厚みは、隔壁７０ｗの厚みよりも厚いことが好ましく、０．１～３．０ｍｍとすることができる。 The thickness of the partition wall 70w between the cells 71a, between the cells 71b, and between the cells 71a and 71b can be set to, for example, 0.05 to 0.5 mm. Further, the thickness of the side wall 70c is preferably larger than the thickness of the partition wall 70w, and can be 0.1 to 3.0 mm.
　図１の（ａ）において、ハニカム構造体７０の貫通孔７１が延びるＺ方向の長さは特に限定されないが、例えば、４０～３５０ｍｍとすることができる。また、ハニカム構造体７０の外径も特に限定されないが、例えば、１００～３２０ｍｍとすることできる。 In FIG. 1A, the length in the Z direction in which the through holes 71 of the honeycomb structure 70 extend is not particularly limited, but may be, for example, 40 to 350 mm. Further, the outer diameter of the honeycomb structure 70 is not particularly limited, but may be, for example, 100 to 320 mm.
　ハニカム構造体７０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。例えば、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７０は通常多孔質である。 The material of the honeycomb structure 70 is not particularly limited, but a ceramic material is preferable from the viewpoint of high temperature resistance. Examples thereof 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 70 is usually porous.
　また、ハニカム構造体７０は、後で焼成することにより上述のようなセラミック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 70 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.
　例えば、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を例示できる。 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、例えば、造孔剤、潤滑剤及び可塑剤、分散剤、溶媒が挙げられる。 Examples of additives include pore formers, lubricants and plasticizers, dispersants, and solvents.
　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; and stearic acid metal salts such as Al stearate.
　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.
（封口用マスク）
　図２の（ａ）及び（ｂ）に示すマスク１７０は、図１に示すハニカム構造体７０の所望の貫通孔７１を封口するのに使用されるものである。マスク１７０は、円形の板状部材であり、厚さ方向に貫通する第一開口１７１ａ及び第二開口１７１ｂをそれぞれ複数有する。なお、マスク１７０の材料は特に限定されず、例えば、金属や樹脂が挙げられる。マスクの厚みは特に限定されないが、例えば、０．１～３．０ｍｍが好ましい。 (Mask for sealing)
A mask 170 shown in FIGS. 2A and 2B is used to seal a desired through hole 71 of the honeycomb structure 70 shown in FIG. The mask 170 is a circular plate-like member, and has a plurality of first openings 171a and a plurality of second openings 171b penetrating in the thickness direction. In addition, the material of the mask 170 is not specifically limited, For example, a metal and resin are mentioned. The thickness of the mask is not particularly limited, but is preferably 0.1 to 3.0 mm, for example.
　第一開口１７１ａはハニカム構造体７０の各完全なセル７１ａのみに対して封口材を供給するためのものである。第一開口１７１ａの形状は、ハニカム構造体７０のセル７１ａに対応する正方形である。これらの第一開口１７１ａは、千鳥配置されており、図３に示すように、マスク１７０がハニカム構造体７０の端面上に位置決めして配置された状態で、正方形配置された複数のセル７１ａ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７１ａのみに対向して配置される。なお、第一開口１７１ａ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７１ａの形状と相似でかつ、これよりも小さい形状であることが好ましい。 The first opening 171a is for supplying a sealing material only to each complete cell 71a of the honeycomb structure 70. The shape of the first opening 171 a is a square corresponding to the cell 71 a of the honeycomb structure 70. These first openings 171a are arranged in a staggered manner, and as shown in FIG. 3, in a state where the mask 170 is positioned and arranged on the end face of the honeycomb structure 70, the plurality of cells 71a arranged in a square are arranged. Of these, only the plurality of cells 71a that are not adjacent to each other in the vertical and horizontal directions are arranged to face each other. The shape of the first opening 171a is not limited to a square, but may be similar to the shape of the cell 71a and smaller than that from the viewpoint of the filling property of the paste-like sealing material. preferable.
　第一開口１７１ａは、開口面積が０．０３ｍｍ２以上であり且つ第一開口１７１ａによって封口すべきセル７１ａの開口面積の９０％未満であることが好ましい。第一開口１７１ａの開口面積が０．０３ｍｍ２未満であると、封口材が第一開口１７１ａを通過しにくくなり、所定量の封口材をセル７１ａ内に供給できない場合がある。第一開口１７１ａの開口面積は、０．０５ｍｍ２以上であることが好ましく、０．０７ｍｍ２以上であることがより好ましく、０．２ｍｍ２以上又は０．２５ｍｍ２以上であってもよい。 The first opening 171a preferably has an opening area of 0.03 mm 2 or more and less than 90% of the opening area of the cell 71a to be sealed by the first opening 171a. If the opening area of the first opening 171a is less than 0.03 mm 2 , the sealing material may not easily pass through the first opening 171a, and a predetermined amount of the sealing material may not be supplied into the cell 71a. The opening area of the first opening 171a is preferably 0.05 mm 2 or more, more preferably 0.07 mm 2 or more, and may be 0.2 mm 2 or more or 0.25 mm 2 or more.
　他方、第一開口１７１ａの開口面積がセル７１ａの開口面積の９０％以上であると、第一開口１７１ａの位置とセル７１ａの開口の位置が少しずれただけで、封口材を所定のセル７１ａ内に供給できず、封口すべきでない近傍のセル７１ａに供給する場合がある。第一開口１７１ａの開口面積は、セル７１ａ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 of the first opening 171a is 90% or more of the opening area of the cell 71a, the sealing material can be removed from the predetermined cell 71a only by slightly shifting the position of the first opening 171a and the opening of the cell 71a. In some cases, it cannot be supplied to the inside of the cell 71a and should not be sealed. The opening area of the first opening 171a is preferably less than 80% and more preferably less than 60% of the opening area of the cell 71a.
　なお、第一開口１７１ａの開口径がマスク１７０の厚さ方向に変化する場合、例えば、開口径がハニカム構造体７０の端面に近づくほど徐々に小さくなるテーパ形状の場合等には、ここでいう開口面積とはハニカム構造体７０の端面と当接する側のマスク１７０の表面における第一開口１７１ａの開口面積を意味する。 Here, when the opening diameter of the first opening 171a changes in the thickness direction of the mask 170, for example, when the opening diameter gradually decreases as it approaches the end face of the honeycomb structure 70, it is referred to here. The opening area means the opening area of the first opening 171 a on the surface of the mask 170 on the side in contact with the end face of the honeycomb structure 70.
　第一開口１７１ａの輪郭のアスペクト比は１．５以下であることが好ましく、１．２以下であることが好ましい。輪郭のアスペクト比とは、開口の輪郭を、外接する最小面積の長方形（正方形含む）で囲んだ場合の、長辺長さ／短辺長さで定義される。 The aspect ratio of the contour of the first opening 171a is preferably 1.5 or less, and preferably 1.2 or less. The aspect ratio of the contour is defined by the length of the long side / the length of the short side when the contour of the opening is surrounded by a rectangle (including a square) with a minimum area that circumscribes the opening.
　図２の（ｂ）の第二開口１７１ｂは、図１の（ｂ）のハニカム構造体７０の不完全なセル７１ｂに封口材を供給するためのものである。 The second opening 171b in FIG. 2 (b) is for supplying a sealing material to the incomplete cell 71b of the honeycomb structure 70 in FIG. 1 (b).
　本実施形態では、図２の（ｂ）の第二開口１７１ｂは、第一開口１７１ａよりも断面積（開口面積）が大きくされている。第二開口１７１ｂの開口面積は、第一開口１７１ａの開口面積の１．２～５倍であることが好ましく、１．５～３．５倍であることがより好ましい。また、第二開口１７１ｂの形状は、第一開口１７１ａに比べて細長い形状を有し、第二開口１７１ｂの輪郭のアスペクト比は、第一開口１７１ａの輪郭のアスペクト比よりも大きいことが好ましい。第二開口１７１ｂの輪郭のアスペクト比はより好ましくは２以上であり、より好ましくは３以上である。なお、第二開口１７１ｂの輪郭のアスペクト比の上限は６程度とすることができる。 In the present embodiment, the second opening 171b in FIG. 2B has a larger cross-sectional area (opening area) than the first opening 171a. The opening area of the second opening 171b is preferably 1.2 to 5 times, more preferably 1.5 to 3.5 times the opening area of the first opening 171a. Moreover, it is preferable that the shape of the 2nd opening 171b has an elongate shape compared with the 1st opening 171a, and the aspect ratio of the outline of the 2nd opening 171b is larger than the aspect ratio of the outline of the 1st opening 171a. The aspect ratio of the contour of the second opening 171b is more preferably 2 or more, and more preferably 3 or more. The upper limit of the aspect ratio of the outline of the second opening 171b can be about 6.
　より詳しくは、図３に示すように、マスク１７０がハニカム構造体７０の端面上に位置決めして配置された状態で、第二開口１７１ｂは、ハニカム構造体７０の複数の貫通孔７１と対向するようになっている。例えば、図３の矢印Ａに示すように、一つの第二開口１７１ｂは、２つの不完全なセル７１ｂに対向してもよいし、図３の矢印Ｂに示すように、一つの第二開口１７１ｂは、一つの不完全なセル７１ｂ及び一つの完全なセル７１ａに対向してもよい。いずれにしろ、一つの第二開口１７１ｂは、少なくとも一つの不完全なセル７１ｂと、他の任意の数の完全なセル７１ａ及び／又は不完全なセル７１ｂとに対して対向して配置されていればよく、３つ以上の貫通孔に対して対向していてもよい。したがって、第二開口１７１ｂからは、ハニカム構造体７０の複数の貫通孔７１を隔てる隔壁７０ｗが露出する。 More specifically, as shown in FIG. 3, the second opening 171 b faces the plurality of through holes 71 of the honeycomb structure 70 in a state where the mask 170 is positioned and arranged on the end face of the honeycomb structure 70. It is like that. For example, as shown by an arrow A in FIG. 3, one second opening 171b may be opposed to two incomplete cells 71b, or as shown by an arrow B in FIG. 171b may face one incomplete cell 71b and one complete cell 71a. In any case, one second opening 171b is arranged opposite to at least one incomplete cell 71b and any other number of complete cells 71a and / or incomplete cells 71b. What is necessary is just to face 3 or more through-holes. Therefore, the partition walls 70w separating the plurality of through holes 71 of the honeycomb structure 70 are exposed from the second opening 171b.
　第二開口１７１ｂは、この第二開口１７１ｂと対向する複数の貫通孔７１のそれぞれすべてと対向する面積を有する必要はなく、少なくともそれぞれ一部と対向していればよい。 The second opening 171b does not have to have an area facing each of the plurality of through holes 71 facing the second opening 171b, and may be at least partially opposed to each other.
　また、図４に例示するように（図３のＣの拡大図）、第二開口１７１ｂ１は、この第二開口１７１ｂ１と対向する複数の貫通孔７１ｂ１、７１ｂ１と、この第二開口１７１ｂ１と対向しない貫通孔７１ｃとの境界を形成する隔壁７０ｗｓからは距離Ｄ、例えば、５０～５００μｍ離して輪郭が形成されることが好ましい。ただし、側壁７０ｃとの距離はこれよりも短くてもよく（例えば、Ｄ＝０）、図４にＶで示すように、第二開口１７１ｂの輪郭が側壁７０ｃの上に入り込んでいてもよい。通常、側壁７０ｃは、隔壁７０ｗよりも数倍程度厚いので、このようにすることにより、第二開口１７１と対向する貫通孔７１ｂ１に対して封口材が入りやすくしつつ、不可避な位置ずれによる意図しない貫通孔７１ｃへの封口材の誤供給を抑制できる。 Further, as illustrated in FIG. 4 (enlarged view of FIG. 3C), the second opening 171b1 does not face the plurality of through holes 71b1 and 71b1 facing the second opening 171b1 and the second opening 171b1. The contour is preferably formed at a distance D, for example, 50 to 500 μm away from the partition wall 70ws that forms the boundary with the through hole 71c. However, the distance from the side wall 70c may be shorter than this (for example, D = 0), and the outline of the second opening 171b may enter the side wall 70c as indicated by V in FIG. Normally, the side wall 70c is several times thicker than the partition wall 70w, so that the sealing material can easily enter the through hole 71b1 facing the second opening 171 and the intention due to unavoidable misalignment. It is possible to suppress erroneous supply of the sealing material to the through hole 71c not to be performed.
　なお、第二開口１７１ｂの開口径がマスク１７０の厚さ方向に変化する、例えば、開口径がハニカム構造体７０の端面に近づくほど徐々に小さくなるテーパ形状をとってもよい。ここでいう開口面積や輪郭とはハニカム構造体７０の端面と当接する側のマスク５の表面側における開口１７１ｂの開口面積や輪郭を意味する。 Note that the opening diameter of the second opening 171b may change in the thickness direction of the mask 170, for example, a taper shape that gradually decreases as the opening diameter approaches the end face of the honeycomb structure 70. The opening area and outline here mean the opening area and outline of the opening 171 b on the surface side of the mask 5 on the side in contact with the end face of the honeycomb structure 70.
　なお、ハニカム構造体７０に対する、マスク１７０の位置決め方法は特に限定されず、例えば、マスク１７０の開口から目視等によりハニカム構造体７０の隔壁、貫通孔、側壁等を見ながら行えばよい。
　また、このようにして位置決めがなされた状態で、開口１７１ａ，１７１ｂを介して、封口材を貫通孔７１に供給する方法も特に限定されない。例えば、マスク上に供給した封口剤を、スキージを用いて開口を介して貫通孔内に押し込んでもよいし、ピストンにより押し込んでもよい。 The method for positioning the mask 170 with respect to the honeycomb structure 70 is not particularly limited. For example, the mask 170 may be visually observed from the opening of the mask 170 while looking at the partition walls, through holes, side walls, and the like.
In addition, the method of supplying the sealing material to the through hole 71 through the openings 171a and 171b in the state where the positioning is performed in this way is not particularly limited. For example, the sealing agent supplied on the mask may be pushed into the through-hole through the opening using a squeegee, or may be pushed in by a piston.
　封口材は、ハニカム構造体７０の貫通孔７１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。例えば、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、溶媒とを含むスラリーが例示できる。
　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。 The sealing material is not particularly limited as long as the end of the through hole 71 of the honeycomb structure 70 can be closed, but is preferably liquid. For example, the sealing material can be exemplified by a slurry containing a ceramic material or a ceramic raw material, a binder, a lubricant, and a solvent.
Examples of the ceramic material include the constituent material of the above-described honeycomb structure and the raw material thereof.
　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を例示できる。バインダの使用量は、封口材を１００質量％とした時、例えば、０．１～１０質量％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 the binder used can be, for example, 0.1 to 10% by mass when the sealing material is 100% by mass.
　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、アラギン酸、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等のステアリン酸金属塩などが挙げられる。潤滑剤の添加量は、封口材の１００質量％に対して、通常、０～１０質量％であり、好ましくは１～１０質量％、より好ましくは１～５質量％である。 Lubricants include alcohols such as glycerin, caprylic acid, lauric acid, palmitic acid, higher fatty acids such as alginate, oleic acid and stearic acid, and stearic acid metal salts such as Al stearate. The addition amount of the lubricant is usually 0 to 10% by mass, preferably 1 to 10% by mass, more preferably 1 to 5% by mass with respect to 100% by mass of the sealing material.
　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、封口材を１００質量％とした時、例えば、１５～４０質量％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, 15 to 40% by mass when the sealing material is 100% by mass.
（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１７０を用いてハニカム構造体７０の所定の貫通孔（セル）の開口を封口するためのものである。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７０の一方の端面上にマスク１７０を配置する工程；及び
　（ｂ）ハニカム構造体７０の一方の端面における封口すべきセル７１ａ及びセル７１ｂに、マスク５の第一開口１７１ａ及び第二開口１７１ｂを通じて封口材をそれぞれ供給する工程。 (Housing method of honeycomb structure)
The sealing method according to the present embodiment is for sealing an opening of a predetermined through hole (cell) of the honeycomb structure 70 using the mask 170. Specifically, this sealing method comprises the following steps:
(A) a step of disposing a mask 170 on one end face of the honeycomb structure 70; and (b) a first opening 171a of the mask 5 in the cell 71a and the cell 71b to be sealed on the one end face of the honeycomb structure 70. And supplying a sealing material through the second opening 171b.
　この封口方法によれば、開口面積が小さいセル７１ｂに対しても十分に封口材を供給できる。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７０の一方の端面について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。なお、他方の端面の封口処理に使用するマスクは開口の配置がマスク１７０の開口の配置と正反対の千鳥配置であることの他は、マスク１７０と同様の構成である。 According to this sealing method, the sealing material can be sufficiently supplied even to the cell 71b having a small opening area. In order to manufacture the honeycomb filter structure, after sealing one end face of the honeycomb structure 70, the same sealing process is applied to the other end face. The mask used for the sealing process of the other end face has the same configuration as that of the mask 170 except that the arrangement of the openings is a staggered arrangement opposite to the arrangement of the openings of the mask 170.
　本実施形態によれば、第一開口１７１ａの断面積よりも大きな断面積を有する第二開口１７１ｂが、多数の第一開口１７１ａを取り囲むように配置されている。このため、ハニカム構造体７０の側壁７０ｃの近傍に位置する、ハニカム構造体７０の側壁７０ｃにより形成された不完全なセル７１ｂを含む複数の貫通孔を、この断面積の大きな第二開口１７１ｂと対向させることができる。これにより、側壁７０ｃの近傍の不完全なセル７１ｂの断面積が中央部の完全なセル７１ａの断面積よりも小さい場合でも、封口材を供給しやすい。 According to the present embodiment, the second openings 171b having a larger cross-sectional area than the first openings 171a are arranged so as to surround the first openings 171a. For this reason, a plurality of through holes including incomplete cells 71b formed by the side wall 70c of the honeycomb structure 70, which are located in the vicinity of the side wall 70c of the honeycomb structure 70, are connected to the second openings 171b having a large cross-sectional area. Can be opposed. Thereby, even when the cross-sectional area of the incomplete cell 71b in the vicinity of the side wall 70c is smaller than the cross-sectional area of the complete cell 71a in the central portion, it is easy to supply the sealing material.
　特に、第二開口１７１ｂの輪郭のアスペクト比が、第一開口１７１ａの輪郭のアスペクト比よりも大きい場合には、第二開口１７１ｂによって、封口することを望まない貫通孔と対向させることなく所望の複数の貫通孔と対向させやすく好適である。 In particular, when the aspect ratio of the outline of the second opening 171b is larger than the aspect ratio of the outline of the first opening 171a, the second opening 171b allows the desired aspect without facing the through hole that is not desired to be sealed. It is preferable that it is easily opposed to a plurality of through holes.
　本発明は、上記実施形態に限定されず、さまざまな変形態様が可能である。例えば、ハニカム構造体７０の完全なセル７１ａの配置も、正方形配置でなくてもよく、例えば、３角配置、千鳥配置等でも構わない。この場合、完全なセル７１ａ、及び、これを取り囲む不完全なセル７１ｂの配置に合わせて、マスク１７０の開口１７１ｂ、１７１ｂの数や位置も変更することができる。 The present invention is not limited to the above embodiment, and various modifications are possible. For example, the arrangement of the complete cells 71a of the honeycomb structure 70 may not be a square arrangement, and may be a triangular arrangement, a staggered arrangement, or the like. In this case, the number and position of the openings 171b and 171b of the mask 170 can be changed according to the arrangement of the complete cell 71a and the incomplete cell 71b surrounding the complete cell 71a.
　また、ハニカム構造体７０の完全なセル７１ａの断面形状は、正方形でなくてもよく、例えば、長方形、三角形、多角形、円形等でもよい。また、これらが混在していても構わない。例えば、ハニカム構造体７０のセル７１ａが円形であり、これらが正三角形配列されている、すなわち、セル７１ａの中心が仮想的な正三角形の頂点にそれぞれ配置されていてもよい。また、セル７１ａに、面積が異なるものが混在していてもよい。 Moreover, the cross-sectional shape of the complete cell 71a of the honeycomb structure 70 may not be a square, and may be, for example, a rectangle, a triangle, a polygon, a circle, or the like. Moreover, these may be mixed. For example, the cells 71a of the honeycomb structure 70 may be circular and arranged in an equilateral triangle, that is, the centers of the cells 71a may be respectively arranged at the vertices of a virtual equilateral triangle. In addition, cells 71a may have different areas.
　また、ハニカム構造体７０の外形形状も円柱でなくてもよく、例えば、四角柱等の角柱でもよい。 Further, the outer shape of the honeycomb structure 70 may not be a cylinder, and may be a prism such as a quadrangular prism, for example.
　また、マスク１７０の外形形状は、円に限定されず、任意の形状が可能である。例えば、楕円や、矩形、三角形、六角形等の多角形を取ることができる。特に、正方形、正三角形、正六角形等の正多角形も好ましい。 Also, the outer shape of the mask 170 is not limited to a circle, and any shape is possible. For example, an ellipse, a polygon such as a rectangle, a triangle, or a hexagon can be taken. In particular, regular polygons such as a square, a regular triangle, and a regular hexagon are also preferable.
　また、すべての不完全なセル７１ｂに対して、第二開口１７１ｂを配置する必要は無く、完全なセル７１ａと同程度の断面積を有する不完全なセル７１ｂに対しては、第一開口１７１ｂを配置することが可能である。 Further, it is not necessary to arrange the second opening 171b for every incomplete cell 71b, and for the incomplete cell 71b having the same cross-sectional area as the complete cell 71a, the first opening 171b. Can be arranged.
　本発明によれば、小貫通孔に対しても十分に封口材を供給可能なハニカム構造体の封口用マスク及びこれを用いた封口方法を提供できる。 According to the present invention, it is possible to provide a sealing mask for a honeycomb structure capable of sufficiently supplying a sealing material to a small through hole and a sealing method using the same.
　７０…ハニカム構造体、７１…貫通孔、７１ａ…標準形状貫通孔（完全なセル）、７１ｂ…特殊形状貫通孔（不完全なセル）、７０ｃ…側壁、７０ｗ…隔壁、１７０…マスク、１７１ａ…第一開口、１７１ｂ…第二開口。 70 ... honeycomb structure, 71 ... through hole, 71a ... standard shape through hole (complete cell), 71b ... special shape through hole (incomplete cell), 70c ... side wall, 70w ... partition wall, 170 ... mask, 171a ... 1st opening, 171b ... 2nd opening.

Claims (3)

  1. 　ハニカム構造体の貫通孔に封口材を供給するための封口用マスクであって、
    　第一の断面積をそれぞれ有する複数の第一開口と、
    　前記複数の第一開口を取り囲むように配置され、前記第一の断面積よりも大きな断面積をそれぞれ有する複数の第二開口と、を備える封口用マスク。     A sealing mask for supplying a sealing material to the through holes of the honeycomb structure,
    A plurality of first openings each having a first cross-sectional area;
    A sealing mask comprising: a plurality of second openings that are disposed so as to surround the plurality of first openings and each have a cross-sectional area larger than the first cross-sectional area.
  2. 　前記第二開口の輪郭のアスペクト比は、前記第一開口の輪郭のアスペクト比よりも大きい請求項１記載の封口用マスク。 The sealing mask according to claim 1, wherein the aspect ratio of the contour of the second opening is larger than the aspect ratio of the contour of the first opening.
  3. 　ハニカム構造体の貫通孔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貫通孔に前記マスクが有する複数の第一開口及び複数の第二開口を通じて封口材を供給する工程と、を備え、
    　前記マスクは、第一の断面積をそれぞれ有する前記複数の第一開口と、前記複数の第一開口を取り囲むように配置され、前記第一の断面積よりも大きな断面積をそれぞれ有する前記複数の第二開口とを有する封口方法。     A method for sealing a through hole of a honeycomb structure,
    (A) placing a mask on one end face of the honeycomb structure;
    (B) supplying a sealing material through a plurality of first openings and a plurality of second openings of the mask to through holes to be sealed in the one end face of the honeycomb structure,
    The mask is arranged so as to surround the plurality of first openings each having a first cross-sectional area, and the plurality of the plurality of first openings each having a cross-sectional area larger than the first cross-sectional area. A sealing method having a second opening.
PCT/JP2011/067689 2010-08-03 2011-08-02 Opening-sealing mask and opening-sealing method for honey-comb structure using same WO2012018021A1 (en)

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Citations (3)

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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
JP2008018370A (en) * 2006-07-14 2008-01-31 Denso Corp Ceramic catalyst body
JP2009233938A (en) * 2008-03-26 2009-10-15 Ngk Insulators Ltd Method of manufacturing plugged honeycomb structure

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JP2004154768A (en) * 2002-10-15 2004-06-03 Denso Corp Exhaust gas purifying filter and method for manufacturing the same
JP4589085B2 (en) * 2004-11-17 2010-12-01 日本碍子株式会社 Method for manufacturing ceramic honeycomb structure
JP2008104944A (en) * 2006-10-25 2008-05-08 Ngk Insulators Ltd Honeycomb filter

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Publication number Priority date Publication date Assignee Title
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
JP2008018370A (en) * 2006-07-14 2008-01-31 Denso Corp Ceramic catalyst body
JP2009233938A (en) * 2008-03-26 2009-10-15 Ngk Insulators Ltd Method of manufacturing plugged honeycomb structure

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