Manufacturing method of honeycomb structure

Patent metadata

Field	Value
Publication number	US-9099228-B2
Application number	US-201313851397-A
Country	US
Kind code	B2
Filing date	Mar 27, 2013
Priority date	Mar 29, 2012
Publication date	Aug 4, 2015
Grant date	Aug 4, 2015

Abstract

The manufacturing method of the honeycomb structure includes a step of coating a surface of each of releasing sheets with a paste for an electrode, to prepare electrode forming sheets in which the releasing sheets are provided with electrode paste films; a formed honeycomb body with the electrode forming sheets forming step of attaching the electrode forming sheets to a side surface of a tubular formed ceramic honeycomb body which is the curved surface to prepare a formed honeycomb body with the electrode forming sheets; and a honeycomb structure forming step of firing the formed honeycomb body, or removing releasing sheets from the formed honeycomb body to form the formed honeycomb body with the pastes for the electrodes, and then firing the formed honeycomb body with the pastes for the electrodes, to obtain a honeycomb structure having a side surface provided with the electrodes.

First claim

What is claimed is:

1. A manufacturing method of a honeycomb structure, comprising:
a step of coating a surface of each of a plurality of releasing sheets with a paste for an electrode, to prepare electrode forming sheets in which the surface of each of the releasing sheets is provided with an electrode paste film,
wherein a thickness of the releasing sheets is from 38 to 300 μm;
a formed honeycomb body with the electrode forming sheets forming step of attaching the electrode forming sheets to a side surface of a tubular formed ceramic honeycomb body which is a curved surface, the formed ceramic honeycomb body having partition walls with which a plurality of cells extending from one end surface to another end surface are formed to become through channels of a fluid, and an outer peripheral wall positioned at the outermost periphery, so that the electrode paste films adhere on the side surface of the formed ceramic honeycomb body, to prepare a formed honeycomb body with the electrode forming sheets which is the formed ceramic honeycomb body having the side surface provided with the electrode forming sheets; and
a honeycomb structure forming step of firing the formed honeycomb body with the electrode forming sheets, or removing the releasing sheets from the formed honeycomb body with the electrode forming sheets to form the formed honeycomb body with the pastes for the electrodes, and then firing the formed honeycomb body with the pastes for the electrodes, to obtain a honeycomb structure having the side surface provided with the electrodes of uniform thickness.

2. The manufacturing method of the honeycomb structure according to claim 1 ,
wherein the surface of each of the releasing sheets is coated with the paste for the electrode, to prepare the electrode forming sheets in which the surface of each of the releasing sheets is provided with the electrode paste film constituted of a plurality of electrode paste layers.

3. The manufacturing method of the honeycomb structure according to claim 1 , wherein a surface roughness Ra of the releasing sheet is from 0.05 to 10 μm.

4. The manufacturing method of the honeycomb structure according to claim 1 , wherein the surface roughness Ra of the releasing sheet is smaller than a surface roughness Ra of the formed ceramic honeycomb body.

5. The manufacturing method of the honeycomb structure according to claim 1 , wherein a water absorption of the releasing sheet is from 0.003 to 0.12 g/minute.

6. The manufacturing method of the honeycomb structure according to claim 1 , wherein a thickness of each of the electrode paste films which adhere on the side surface of the formed honeycomb body with the pastes for the electrodes is from 10 to 5000 μm.

7. The manufacturing method of the honeycomb structure according to claim 2 , wherein a thickness of each of the electrode paste films which adhere on the side surface of the formed honeycomb body with the pastes for the electrodes is from 10 to 5000 μm.

8. The manufacturing method of the honeycomb structure according to claim 3 , wherein a thickness of each of the electrode paste films which adhere on the side surface of the formed honeycomb body with the pastes for the electrodes is from 10 to 5000 μm.

9. The manufacturing method of the honeycomb structure according to claim 4 , wherein a thickness of each of the electrode paste films which adhere on the side surface of the formed honeycomb body with the pastes for the electrodes is from 10 to 5000 μm.

10. The manufacturing method of the honeycomb structure according to claim 5 , wherein a thickness of each of the electrode paste films which adhere on the side surface of the formed honeycomb body with the pastes for the electrodes is from 10 to 5000 μm.

11. The manufacturing method of the honeycomb structure according to claim 1 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

12. The manufacturing method of the honeycomb structure according to claim 2 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

13. The manufacturing method of the honeycomb structure according to claim 3 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

14. The manufacturing method of the honeycomb structure according to claim 4 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

15. The manufacturing method of the honeycomb structure according to claim 5 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

16. The manufacturing method of the honeycomb structure according to claim 6 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

17. The manufacturing method of the honeycomb structure according to claim 7 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

18. The manufacturing method of the honeycomb structure according to claim 8 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

19. The manufacturing method of the honeycomb structure according to claim 9 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times a center angle of each of the electrodes is from 15° to 65°, which is the angle measured from the center of the cross section of the honeycomb body to edges of the electrodes on the side surface.

20. The manufacturing method of the honeycomb structure according to claim 10 ,
wherein in a cross section of the honeycomb structure which is orthogonal to an extending direction of the cells, 0.5 times

Assignees

• Ngk Insulators Ltd

Inventors

• Ogawa Toru
• Fujita Shuhei
• Yoshida Shinya

Classifications

• C04B41/5059

  Silicon carbide · CPC title

• H01B13/0016 Primary

  for heat treatment · CPC title

• B28B11/041

  for moulded articles undergoing a thermal treatment at high temperatures, such as burning, after coating · CPC title

• F01N3/022

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01D46/2418

  Honeycomb filters (used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006) · CPC title