Production method of ceramic honeycomb filter
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example 1
[0037]Powders comprising kaolin, talc, silica, aluminum hydroxide and alumina were formulated to prepare cordierite-forming powder comprising 47-53% of SiO2 and 32-38% of Al2O3 by mass. The cordierite-forming powder was fully blended with a methylcellulose binder, a pore-forming agent, and a predetermined amount of water to form a plastic moldable material.
[0038]The moldable material was extrusion-molded, dried, and sintered at 1400° C., to produce a cordierite ceramic honeycomb structure 1 (outer diameter: 267 mm, length: 314 mm, cell wall pitch: 1.55 mm, cell wall thickness: 0.32 mm, and cell wall porosity: 63%) having large numbers of flow paths with tetragonal cross sections.
[0039]As shown in FIG. 2, a resin mask film 6 was attached to an end surface of the ceramic honeycomb structure 1 [step (a)], and provided with holes 7 in a checkerboard pattern by laser [step (b)]. An end portion of the ceramic honeycomb structure 1 on the side of the end surface 12 was immersed in a pluggi...
example 2
[0041]After forming a cordierite ceramic honeycomb structure 1 (outer diameter: 267 mm, length: 304 mm, cell wall pitch: 1.55 mm, cell wall thickness: 0.32 mm, and cell wall porosity: 63%) having large numbers of flow paths 3, 4 with substantially tetragonal cross sections in the same manner as in Example 1, a plugging material slurry 8 was charged into both end portions of the flow paths 3, 4 alternately in a checkerboard pattern, such that the resultant plugs 5 became as long as about 10 mm. The plugs 5 were sintered at 1400° C. to produce the cordierite ceramic honeycomb filter 11 shown in FIG. 5(a). Plugging material protrusions 51 were formed in the flow paths of the filter that should not be plugged near each end surface. As a result of blowing a high-pressure air of 1 MPa to the flow paths 3, 4 on both ends of the filter 11, substantially all plugging material protrusions 51 were removed.
example 3
[0042]After forming a cordierite ceramic honeycomb structure 1 (outer diameter: 267 mm, length: 304 mm, cell wall pitch: 1.55 mm, cell wall thickness: 0.32 mm, and cell wall porosity: 63%) having large numbers of flow paths 3, 4 with substantially tetragonal cross sections in the same manner as in Example 1, plugs 5 of about 10 mm in length were formed in the end portions of the flow paths 3 on one side. There were plugging material protrusions 51 partially formed in the flow paths 4 near the end surface 12. A drill of 1.0 mm in diameter was inserted into a flow path 4 having a plugging material protrusion 51, and moved along the flow path while rotating to remove the plugging material protrusions 51. Plugs 5 of about 10 mm in length were then formed in the other end portions of the flow paths 4, and plugging material protrusions 51 were removed by the drill. The plugs 5 were finally sintered at 1400° C.
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Abstract
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