Method for manufacturing honeycomb structure

Patent metadata

Field	Value
Publication number	US-11573052-B2
Application number	US-201815921913-A
Country	US
Kind code	B2
Filing date	Mar 15, 2018
Priority date	Mar 28, 2017
Publication date	Feb 7, 2023
Grant date	Feb 7, 2023

Abstract

A method for manufacturing a honeycomb structure, includes: a step of manufacturing a honeycomb formed body to manufacture a non-fired honeycomb formed body having volume of 7 L or more; a drying step of drying the manufactured non-fired honeycomb formed body to obtain a honeycomb dried body; and a firing step of firing the obtained honeycomb dried body to obtain a honeycomb structure. The drying step includes: an induction drying step to obtain a first dried honeycomb formed body by removing 20 to 80% of the entire water that the non-fired honeycomb formed body contained before drying, and a microwave drying step to obtain a honeycomb dried body by removing the residual water. The honeycomb dried body subjected to this microwave drying step is obtained by removing 90% or more of the entire water that the non-fired honeycomb formed body contained before drying.

First claim

What is claimed is:

1. A method for manufacturing a honeycomb structure, comprising:
a step of manufacturing a honeycomb formed body to manufacture a non-fired honeycomb formed body having volume of 7 L or more and including a cell wall that defines a plurality of cells extending from a first end face as one end face to a second end face as the other end face, the non-fired honeycomb formed body including a raw material composition containing a ceramic raw material and water;
a drying step of drying the manufactured non-fired honeycomb formed body to obtain a honeycomb dried body; and
a firing step of firing the obtained honeycomb dried body to obtain a honeycomb structure, wherein
the drying step includes:
a first drying step comprising an induction drying step of induction-drying the non-fired honeycomb formed body so as to obtain a first dried honeycomb formed body by removing 20 to 80% of the entire water that the non-fired honeycomb formed body contained before drying, and
a second drying step comprising a microwave drying step of microwave-drying the first dried honeycomb formed body subjected to the induction drying step so as to obtain a honeycomb dried body by removing the residual water,
wherein the honeycomb dried body subjected to the microwave drying step is obtained by removing 90% or more of the entire water that the non-fired honeycomb formed body contained before drying,
wherein the percentage of water removed after induction-drying is determined by the expression: (1−(water content after induction-drying/entire water content before drying))×100,
wherein the percentage of water removed after microwave-drying is determined by the expression: (1−(water content after microwave-drying/entire water content before drying))×100, and
wherein the first drying step excludes microwave-drying and the second drying step excludes induction-drying.

2. The method for manufacturing a honeycomb structure according to claim 1 , wherein the non-fired honeycomb formed body to be supplied to the induction drying step in the drying step has water content before drying of 20 to 60%.

3. The method for manufacturing a honeycomb structure according to claim 1 , wherein the raw material composition includes water absorbable resin as pore former.

4. The method for manufacturing a honeycomb structure according to claim 1 , wherein the non-fired honeycomb formed body to be supplied to the induction drying step in the drying step has a round pillar shape,
the non-fired honeycomb formed body has a diameter of an end face of 220 to 400 mm, and has a length in the cell-extending direction of 200 to 400 mm, and
the non-fired honeycomb formed body has a thickness of the cell wall of 30 to 350 μm.

Assignees

• Ngk Insulators Ltd

Inventors

• Okumura Kensuke

Classifications

• C04B35/195

  Alkaline earth aluminosilicates, e.g. cordierite {or anorthite} · CPC title

• C04B2111/0081

  as catalysts or catalyst carriers · CPC title

• C04B2235/6021

  Extrusion moulding · CPC title

• C04B2235/94

  Products characterised by their shape · CPC title

• C04B2235/606

  Drying · CPC title