Method of manufacturing ceramic structure

Patent metadata

Field	Value
Publication number	US-10556365-B2
Application number	US-201715438805-A
Country	US
Kind code	B2
Filing date	Feb 22, 2017
Priority date	Mar 25, 2016
Publication date	Feb 11, 2020
Grant date	Feb 11, 2020

Abstract

A manufacturing method includes a mixing step, a kneading step of kneading a wet mixture, a liquid adding step of further adding a liquid to a kneaded material, a forming step of extruding a forming material of which viscosity is adjusted into a honeycomb formed body, a drying step of drying the honeycomb formed body, and a dimension measuring step of measuring a dry dimension of a honeycomb dried body that has been dried, where in the liquid adding step, the amount of the liquid to be added is adjusted based on the result of measuring the dry dimension of the honeycomb dried body.

First claim

What is claimed is:

1. A method of manufacturing a ceramic structure comprising:
a dry-mixing step of dry-mixing by a batch process a raw material for forming a ceramic formed body;
a wet-mixing step of adding a liquid including at least one of water, surfactant, lubricant, and plasticizer to a dry mixture obtained by the dry-mixing step and performing wet-mixing;
a kneading step of kneading a wet mixture obtained by the wet-mixing step;
a liquid adding step, performed in the kneading step, of further adding the liquid to a kneaded material formed by kneading the wet mixture;
a forming step of extruding a forming material of which viscosity is adjusted by the kneading step and the liquid adding step into a ceramic formed body;
a drying step of drying the ceramic formed body; and
a dimension measuring step of measuring a dry dimension of a ceramic dried body obtained by the drying step, wherein
in the liquid adding step,
an amount of the liquid to be added to the kneaded material is adjusted based on a result of measuring the dry dimension of the ceramic dried body in the dimension measuring step.

2. The method of manufacturing a ceramic structure according to claim 1 , wherein
the amount of the liquid added in the liquid adding step is
1.5% by mass to 4.5% by mass of a total amount of the liquid added in the wet-mixing step and the liquid adding step.

3. The method of manufacturing a ceramic structure according to claim 1 , wherein
the dimension measuring step includes
an image capturing step of capturing an image of either one of dried body end faces of the ceramic dried body, and
an image analyzing step of comparing an end face image of the dried body end face captured in the image capturing step with a standard image of a previously specified standard dried body end face to detect a deviation of the end face image from the standard image and performing imagery-analysis, and
in the liquid adding step,
an amount of the liquid to be added to the kneaded material is determined based on a result of the imagery-analysis performed in the image analyzing step.

4. The method of manufacturing a ceramic structure according to claim 1 , wherein
the dimension measuring step includes
a dimensional data obtaining step of emitting a laser to a dried body surface of the ceramic dried body to obtain a total dimensional data related to a total dimension of the ceramic dried body, and
a dimension analyzing step of comparing the total dimensional data obtained by the dimensional data obtaining step with a previously specified standard total dimensional data to detect a deviation of the total dimensional data from the standard total dimensional data and performing analysis, and
in the liquid adding step,
an amount of the liquid added to the kneaded material is determined based on a result of analysis on a total dimension in the dimension analyzing step.

5. The method of manufacturing a ceramic structure according to claim 1 , wherein the kneading step and the forming step are integrally and continuously performed.

Assignees

• Ngk Insulators Ltd

Inventors

• Yamada Takuya
• Nakamura Hirotada
• Umetsu Nobuyuki

Classifications

• B28B11/243

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• B28B17/0072

  Product control or inspection · CPC title

• B28B17/0081 Primary

  Process control · CPC title

• B28B3/20

  wherein the material is extruded {(extrusion moulding of plastics B29C48/00)} · CPC title

• B28B2003/203

  for multi-channelled structures, e.g. honeycomb structures · CPC title