Manufacturing method for honeycomb structure and honeycomb structure

Patent metadata

Field	Value
Publication number	US-9555355-B2
Application number	US-201414227255-A
Country	US
Kind code	B2
Filing date	Mar 27, 2014
Priority date	Mar 29, 2013
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

Provided is a technique to manufacture a honeycomb structure reducing a width of dimensional difference generated during firing between an end part and a central part and having excellent thermal shock resistance, and the method includes: a honeycomb formed body preparing step of extruding a kneaded material including a cordierite forming raw material A, to prepare a formed body; a plugged honeycomb formed body preparing step of filling cell openings thereof with a plugging material which includes a forming raw material containing a cordierite forming raw material B and resin balloon of 1.0 to 15 mass % and has a difference in firing shrinkage rate of −1.0 to +2.0% from the formed body, to prepare a plugged formed body; and a honeycomb structure preparing step of firing the prepared plugged formed body, to prepare a honeycomb structure provided with porous plugged portions.

First claim

What is claimed is:

1. A method for manufacturing a honeycomb structure, comprising:
a honeycomb formed body preparing step of extruding a kneaded material obtained by kneading a forming raw material containing a cordierite forming raw material A into a honeycomb shape, to prepare a honeycomb formed body having porous partition walls defining a plurality of cells extending from a first end face as one end face to a second end face as another end face;
a plugged honeycomb formed body preparing step of filling cell openings of the prepared honeycomb formed body with a plugging material which includes a forming raw material containing a cordierite forming raw material B and resin balloon of 1.0 to 15 mass % and has a difference in firing shrinkage rate of −1.0 to +2.0% from the honeycomb formed body, to prepare a plugged honeycomb formed body; and
a honeycomb structure preparing step of firing the prepared plugged honeycomb formed body to prepare a honeycomb structure provided with porous plugged portions at an end part on a first end face side of a first cell as a predetermined cell and at an end part on the second end face side of a second cell as a remaining cell, among the plurality of cells,
wherein a porosity of the porous plugged portions is greater than a porosity of the porous partition walls of the honeycomb formed body, and
wherein a composition of raw material A is different from a composition of raw material B.

2. The method for manufacturing a honeycomb structure according to claim 1 ,
wherein the cordierite forming raw material B includes alumina and aluminum hydroxide, and
a percentage ratio of mass of the aluminum hydroxide to sum of mass of the alumina and the mass of the aluminum hydroxide contained in the cordierite forming raw material B is 20 to 100%.

3. The method for manufacturing a honeycomb structure according to claim 1 , wherein the cordierite forming raw material B includes talc having an average particle diameter of 5 to 30 μm.

4. The method for manufacturing a honeycomb structure according to claim 1 , wherein the cordierite forming raw material B includes 5 to 20 mass % of silica.

5. The method for manufacturing a honeycomb structure according to claim 1 , wherein the cordierite forming raw material B includes silica having an average particle diameter of 1 to 5 μm.

6. A honeycomb structure obtained by the method for manufacturing a honeycomb structure according to claim 1 .

7. The method for manufacturing a honeycomb structure according to claim 1 , wherein the content of resin balloon is 5 to 7.5 mass %.

8. The method for manufacturing a honeycomb structure according to claim 2 , wherein the percentage ratio of mass of the aluminum hydroxide to sum of mass of the alumina and the mass of the aluminum hydroxide contained in the cordierite forming raw material B is 45 to 70%.

9. The method for manufacturing a honeycomb structure according to claim 1 , wherein the content of silica in the cordierite forming raw material B is 9 to 13 mass %.

10. The method for manufacturing a honeycomb structure according to claim 1 , wherein the porosity of the porous plugged portions is at least 17% greater than the porosity of the porous partition walls of the honeycomb structure.

11. The method for manufacturing a honeycomb structure according to claim 1 , wherein the content of resin balloon in the plugging material is 5 to 15 mass %.

12. The method for manufacturing a honeycomb structure according to claim 1 , wherein the percentage ratio of mass of the aluminum hydroxide to sum of mass of the alumina and the mass of the aluminum hydroxide contained in the cordierite forming raw material B is 20 to 70%.

13. The method for manufacturing a honeycomb structure according to claim 1 , wherein the content of silica in the cordierite forming raw material B is 11 to 20 mass %.

Assignees

• Ngk Insulators Ltd

Inventors

• Tsuchiya Yusuke
• Suenobu Hiroyuki
• Houra Masaki
• Hamazaki Yuichi

Classifications

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B2235/3218

  Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol · CPC title

• C04B2235/349

  Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite · CPC title

• C04B38/0006

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

• C04B38/0074

  expressed as porosity percentage · CPC title