Method for producing honeycomb structure

Patent metadata

Field	Value
Publication number	US-11866378-B2
Application number	US-201916979172-A
Country	US
Kind code	B2
Filing date	Mar 12, 2019
Priority date	Mar 13, 2018
Publication date	Jan 9, 2024
Grant date	Jan 9, 2024

Abstract

Disclosed is a method for manufacturing a honeycomb structure. The method includes molding a molded body from a mixture containing silicon carbide particles, an organic component, and a dispersion medium, removing the organic component included in the molded body to obtain a porous honeycomb body, and impregnating an inner portion of partition walls of the porous honeycomb body with metal silicon. In a state in which the porous honeycomb body is placed on a support inside a container containing solid metal silicon, the impregnating an inner portion of the partition walls is performed by heating the inside of the container to a temperature higher than or equal to a melting point of the metal silicon so that the porous honeycomb body is impregnated with molten metal silicon through the support that is porous.

First claim

The invention claimed is:

1. A method for manufacturing a honeycomb structure that includes partition walls partitioning a plurality of cells, the method comprising:
molding a molded body from a mixture containing silicon carbide particles, an organic component, and a dispersion medium;
removing the organic component included in the molded body to obtain a porous honeycomb body; and
impregnating an inner portion of the partition walls of the porous honeycomb body with metal silicon,
wherein in a state in which the porous honeycomb body is placed on a support inside a container containing solid metal silicon, said impregnating is performed by heating the inside of the container to a temperature higher than or equal to a melting point of the metal silicon so that the porous honeycomb body is impregnated with molten metal silicon through the support that is porous, and
further comprising heating the porous honeycomb body at a temperature higher than or equal to 1800° C. between said removing and said impregnating.

2. The method for manufacturing a honeycomb structure according to claim 1 , wherein the metal silicon is placed on a bottom surface of the container.

3. The method for manufacturing a honeycomb structure according to claim 1 , wherein
the molded body is placed on the support inside the container, and
said removing is performed by setting a temperature inside the container to a first temperature that is a temperature at which the organic component is burned and removed and is lower than the melting point of the metal silicon, and then said impregnating is performed by increasing the temperature to a second temperature that is higher than or equal to the melting point of the metal silicon.

4. The method for manufacturing a honeycomb structure according to claim 3 , wherein the first temperature is higher than or equal to 400° C. and lower than or equal to 1400° C.

5. The method for manufacturing a honeycomb structure according to claim 3 , wherein the second temperature is higher than or equal to 1420° C. and lower than or equal to 2000° C.

6. The method for manufacturing a honeycomb structure according to claim 1 , wherein the porous honeycomb body placed inside the container is an assembly of a plurality of porous honeycomb bodies, from which an organic component included therein has been removed.

Assignees

• Ibiden Co Ltd

Inventors

• ISHIGURO Sonosuke
• Koga Yoshihiro

Classifications

• C04B38/0006 Primary

  Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083) · CPC title

• C04B35/565

  based on silicon carbide · CPC title

• C04B38/0655

  Porous materials (C04B38/0625 takes precedence) · CPC title

• C04B41/4523

  applied from the molten state (vitreous materials C04B41/5022); Thermal spraying, e.g. plasma spraying · CPC title

• C04B41/87

  Ceramics · CPC title