Honeycomb structural sheet, laminate, and method for producing same

Abstract

The purpose of the present invention is to provide: a honeycomb-structured sheet having little clogging; a laminate obtained by laminating the honeycomb-structured sheet; and a method for producing the honeycomb-structured sheet and the laminate. Provided is a method for manufacturing a honeycomb structural sheet (2) in which a honeycomb structural body (10) obtained by bonding a plurality of sheet base materials (4) to each other is sliced on a surface orthogonal to one direction and a honeycomb structural sheet (2) in which the one direction is the thickness direction is manufactured, the honeycomb structural body (10) being formed by bonding a plurality of sheet base materials (4) to each other. And a plurality of cell holes (3) which are partitioned by the plurality of sheet substrates (4) and penetrate in the one direction are formed in the honeycomb structure sheet (2), and the method for manufacturing the honeycomb structure sheet (2) is characterized in that the honeycomb structure (10) is sliced in a face along the horizontal direction in a state that the honeycomb structure (10) is arranged in a manner that the one direction is the vertical direction.

Description

Technical Field

[0001] The present invention relates to a honeycomb structure sheet and a laminate, and methods for producing the same.

[0002] This application claims priority based on Japanese Patent Application No. 2022-085774 filed in Japan on May 26, 2022, the contents of which are incorporated herein by reference. Background Art

[0003] In recent years, due to changes in living environments and increased health awareness, air conditioning equipment such as air conditioners, air purifiers, humidifiers, and dehumidifiers have been widely used in various living spaces such as homes, offices, factories, and cars. In these air conditioning equipment, various deodorizing materials are used to obtain purified air.

[0004] As a deodorizing material, a material is known in which a plurality of lining members and a plurality of corrugated members are bonded to each other to form a honeycomb structure having a plurality of small cells extending in one direction. If a deodorizing component is carried on the lining member or the corrugated member having the honeycomb structure, the air to be treated contacts the deodorizing component and is purified while passing through the small cells forming a flow path.

[0005] The thickness of the deodorant material (the length of the cell hole) is generally about 10 mm to 30 mm. In order to efficiently manufacture the deodorant material, a liner member or a corrugated member having a length of about 30 cm to 200 cm in the cell hole direction is usually used to manufacture a honeycomb structure, and the honeycomb structure is cut at a surface orthogonal to the cell hole direction, and a honeycomb structure sheet of a desired thickness is used as the deodorant material.

[0006] When the honeycomb structure is cut, the honeycomb structure arranged so that the surface direction of the lining member becomes the horizontal direction is conventionally cut along the surface along the vertical direction (for example, Patent Document 1).

[0007] Prior art literature

[0008] Patent Literature

[0009] Patent Document 1: Japanese Utility Model Application Laid-Open No. 4-81615 Summary of the invention

[0010] Problem that the invention aims to solve

[0011] However, the conventional honeycomb structure sheet has a problem that the cells are easily clogged.

[0012] Furthermore, when the honeycomb structure sheet is immersed in a liquid containing a functional agent such as a deodorizing component and dried to carry these components, there is a problem that the functional agent adheres to foreign matter clogging the cell pores, causing further clogging.

[0013] Furthermore, when a deodorant material is manufactured by stacking a plurality of relatively thin honeycomb structure sheets, if any of the cell holes in the stacking direction are clogged, the flow of air is blocked. Therefore, the influence of the clogging is even more difficult to ignore.

[0014] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a honeycomb structure sheet with less clogging, a laminated body formed by laminating the honeycomb structure sheets, and a method for producing the same.

[0015] Solutions for solving problems

[0016] The present invention adopts the following structure.

[0017] [1] A method for manufacturing a honeycomb structure sheet, wherein a honeycomb structure is sliced ​​along a surface perpendicular to a direction to manufacture a honeycomb structure sheet in which the one direction is a thickness direction, wherein the honeycomb structure is formed by bonding a plurality of sheet substrates to each other, and a plurality of cells are formed which are divided by the plurality of sheet substrates and penetrate along the one direction, wherein the method for manufacturing the honeycomb structure sheet is characterized in that:

[0018] In a state where the honeycomb structure is arranged so that the one direction becomes a vertical direction, the honeycomb structure is sliced ​​along a surface along a horizontal direction.

[0019] [2] The method for producing a honeycomb structure sheet according to [1], further comprising applying or impregnating a liquid containing a functional agent on the honeycomb structure sheet.

[0020] [3] A method for producing a laminate, wherein:

[0021] A plurality of honeycomb structure sheets obtained by the method for producing a honeycomb structure sheet according to [1] or [2] are stacked.

[0022] [4] A honeycomb structure sheet, which is formed by bonding a plurality of sheet substrates to each other, and has a plurality of cells divided by the plurality of sheet substrates and penetrating in the thickness direction, wherein:

[0023] The plurality of small chamber holes are formed in an area of ​​254 mm square, with 2,000 to 15,000 holes.

[0024] The thickness of the honeycomb structure sheet is 1 mm to 20 mm.

[0025] The proportion of the small cells whose area is blocked is 1 / 3 or more among the plurality of small cells is 0.1% or less.

[0026] [5] The honeycomb structure sheet according to [4], wherein a functional agent is supported on the sheet base material.

[0027] [6] A laminated body, wherein the laminated body is formed by laminating a plurality of honeycomb structure sheets according to [4] or [5].

[0028] Effects of the Invention

[0029] The honeycomb structure sheet of the present invention has less clogging, and the laminated body using the honeycomb structure sheet does not cause excessive pressure loss, and can efficiently perform functions such as deodorization. In addition, according to the method for manufacturing the honeycomb structure sheet of the present invention, a honeycomb structure sheet with less clogging can be efficiently manufactured. In addition, according to the method for manufacturing the laminated body of the present invention, the pressure loss is not excessive, and a laminated body that efficiently performs functions such as deodorization can be manufactured. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is an exploded perspective view of a laminated body according to one embodiment of the present invention.

[0031] Figure 2 It is a perspective view of the honeycomb structure used in the present invention.

[0032] Figure 3 This is a schematic perspective view of a slicer for slicing a honeycomb structure.

[0033] Figure 4 This is a schematic front view of a slicer for slicing a honeycomb structure.

[0034] Figure 5 This is an explanatory diagram of a knife unit in a slicer.

[0035] Figure 6 It is a cross-sectional view of the belt knife in the knife unit.

[0036] Figure 7 It is an explanatory diagram showing a state in the middle of slicing a honeycomb structure by a slicer.

[0037] Figure 8 It is an explanatory diagram showing a state in which a honeycomb structure body is sliced ​​by a slicer to obtain a honeycomb structure sheet.

[0038] Fig. 9 This is a diagram for explaining the mechanism of action of the present invention. DETAILED DESCRIPTION

[0039] In the present specification, a numerical range expressed using "to" means a range including the numerical values ​​described before and after "to" as the lower limit and the upper limit.

[0040] <Honeycomb structure sheet>

[0041] Figure 1 Each of the honeycomb structure sheets 2 is a honeycomb structure sheet according to one embodiment of the present invention.

[0042] The honeycomb structure sheet 2 can be used alone for deodorization or the like, or it can be used as a Figure 1 A plurality of layers are stacked as shown to form a stacked body 1 .

[0043] The honeycomb structure sheet 2 is formed into a thin flat shape extending in a planar manner. Figure 1 The length in the Z direction) is 1mm to 20mm.

[0044] When the thickness of the honeycomb structure sheet 2 is 1 mm or more, it is easy to ensure processing accuracy during manufacturing. When the thickness of the honeycomb structure sheet 2 is 20 mm or less, the advantage of using the manufacturing method of the deodorant sheet of the present invention described later is large.

[0045] The thickness of the honeycomb structure sheet 2 in the case where a plurality of honeycomb structure sheets 2 are stacked to form the stacked body 1 ( Figure 1 The length in the Z direction) is preferably 1 mm to 20 mm, more preferably 1 mm to 15 mm, further preferably 1 mm to 10 mm, and particularly preferably 2.5 mm to 10 mm.

[0046] If the thickness of the honeycomb structure sheet 2 is above the lower limit value in the above preferred range, it is easy to ensure the processing accuracy during manufacturing. If the thickness of the honeycomb structure sheet 2 is below the upper limit value in the above preferred range, even if a plurality of honeycomb structure sheets 2 are stacked, the thickness of the entire laminate 1 will not become too large.

[0047] When the honeycomb structure sheet 2 is used for deodorization without being stacked, the thickness of the honeycomb structure sheet 2 ( Figure 1 The length in the Z direction) is preferably 1 mm to 50 mm, more preferably 2.5 mm to 30 mm, further preferably 5 mm to 20 mm, and particularly preferably 5 mm to 10 mm.

[0048] When the thickness of the honeycomb structure sheet 2 is equal to or greater than the lower limit value in the above-mentioned preferred range, it is easy to ensure the required strength when the honeycomb structure sheet 2 is used for deodorization or the like.

[0049] When the thickness of the honeycomb structure sheet 2 is equal to or less than the upper limit value in the above-mentioned preferred range, the advantage of adopting the method for producing a deodorant sheet of the present invention described later is large.

[0050] like Figure 1 As shown, the honeycomb structure sheet 2 is formed by bonding a plurality of sheet base materials 4. The plurality of sheet base materials 4 are arranged so that their surface directions are along the thickness direction (Z direction).

[0051] A large number of small cells 3 are formed between the plurality of sheet substrates 4. The small cells 3 are opened at both upper and lower ends in the thickness direction and penetrate in the thickness direction (Z direction). The small cells 3 serve as flow paths for gases such as air to be processed to pass through.

[0052] The shape of the cell hole 3 when viewed from above is not particularly limited, and in the example shown in the figure, it is a mountain shape (roughly a triangle shape), but it may also be a quadrilateral shape, a rhombus shape, a hexagonal shape, a circular shape, etc. A plurality of cell holes 3 are regularly or irregularly arranged and connected at relatively narrow intervals in the vertical, horizontal, oblique, etc. directions in the XY plane.

[0053] In this embodiment, 2000 to 15000 cells 3 are formed per 254 mm square (10 inches square) area. The number of cells 3 per 10 inches square area is preferably 2000 to 15000, and more preferably 4000 to 12000.

[0054] If the number of the cell holes 3 per 10-inch square area is 2,000 or more, deodorization can be performed efficiently. If the number of the cell holes 3 per 10-inch square area is 15,000 or less, the flow of the passing air is not hindered.

[0055] The specific structure of the plurality of sheet base materials 4 is not particularly limited, but is preferably composed of a combination of a plurality of lining members 5 extending linearly in a plan view and a plurality of corrugated members 6 in a corrugated shape in a plan view from the viewpoint of efficient production.

[0056] exist Figure 1 , an example is shown in which the lining members 5 and the corrugated members 6 are alternately stacked along the X direction.

[0057] The sheet base material 4 is not limited to the form where the lining members 5 and the corrugated members 6 are alternately stacked, and for example, the corrugated members 6 may be bonded to each other adjacently. In addition, the lining members 5 may be bonded to each other adjacently.

[0058] The pitch of the corrugated member 6 constituting the sheet base 4 is preferably 2 mm to 8 mm, more preferably 4 mm to 6 mm. The height of the corrugated member 6 is preferably 1 mm to 5 mm, more preferably 2 mm to 4 mm.

[0059] The pitch and height of the corrugated member 6 do not need to be uniform, and for example, corrugated members 6 stacked in the X direction and having different heights and pitches in each layer may be used. In addition, when using corrugated members 6 having the same height and pitch in each layer, their phases may be the same or different.

[0060] The material constituting the sheet substrate 4 is not particularly limited as long as it can maintain its shape, and examples thereof include inorganic materials, organic materials, or paper, nonwoven fabrics, woven fabrics, plastic films, etc. The material constituting the sheet substrate 4 is preferably capable of carrying a functional agent, etc. In addition, the functional agent, etc. may be filled inside or outside.

[0061] In particular, paper and nonwoven fabrics made of inorganic fibers or organic fibers are preferred because they can easily retain chemical solutions such as functional agents by absorbing liquids through capillary phenomena. Paper and nonwoven fabrics can be easily formed by wet papermaking using inorganic fibers or organic fibers.

[0062] Examples of inorganic fibers include glass fibers, ceramic fibers, and carbon fibers. Among them, glass fibers are preferred in terms of safety to the human body and cost. Examples of organic fibers include pulp and resin fibers.

[0063] The sheet substrate 4 preferably contains 30% by mass or more of inorganic fibers, more preferably 40% by mass or more of inorganic fibers, and further preferably 50% by mass or more of inorganic fibers. The inclusion of inorganic fibers can provide high heat resistance, high thermal insulation, non-flammability, and the like.

[0064] The material that occupies the largest mass percentage among the materials constituting the sheet base material 4 is preferably an inorganic fiber.

[0065] It is also preferable to use both inorganic fibers and organic fibers to constitute the sheet base material 4. By including organic fibers in addition to inorganic fibers, formability is improved.

[0066] The mass per unit area of ​​the sheet substrate 4 is not particularly limited, but when it is made of paper or nonwoven fabric, it is preferably 10 g / m 2 ~100g / m 2 , more preferably 15g / m 2 ~60g / m 2 If the mass per unit area is above the lower limit in the preferred range, the strength of the sheet base material 4 formed in a corrugated shape or the like can be sufficiently obtained. If the mass per unit area is below the upper limit in the preferred range, the thickness is suppressed and the cell pores 3 with a sufficient cross-sectional area are easily formed, so that the pressure loss can also be suppressed.

[0067] The honeycomb structure sheet 2 preferably has a functional agent carried on the sheet substrate 4 in addition to the sheet substrate 4. Examples of the functional agent include an adsorbent having a function of adsorbing malodorous components and performing deodorization, an antibacterial agent having antibacterial and antifungal functions, an antifungal agent, an ozone decomposition agent having an ozone decomposition function, and a flame retardant. These may be used alone or in combination of two or more.

[0068] The adsorbent is not particularly limited, but examples thereof include activated carbon; zeolites such as mordenite, ferrierite, and molecular sieves; silica gel; alumina gel; hydrazides, pyrrole compounds, organic acids, and other known materials.

[0069] The antibacterial agent and the antifungal agent are not particularly limited, but examples thereof include known materials such as silver-containing antibacterial agents.

[0070] The ozone decomposer is not particularly limited, but examples thereof include known materials such as manganese catalyst-based ozone decomposers, copper·manganese catalyst-based ozone decomposers, and activated carbon-based ozone decomposers.

[0071] The functional agent is not limited thereto, and various known functional agents can also be used. The functional agent can be in various forms such as powder, granular, and fibrous. In addition, the method for carrying the functional agent on the sheet substrate 4 is also not limited, and the functional agent can be kept inside the sheet substrate 4, or the functional agent can be attached to the surface of the sheet substrate 4, or an impregnation liquid containing the functional agent can be applied to the sheet substrate 4, or the sheet substrate 4 can be immersed in the impregnation liquid. By carrying the functional agent on the sheet substrate 4, the air purification effect such as deodorization can be efficiently achieved.

[0072] In the honeycomb structure sheet 2 of the present embodiment, the ratio of the cells 3 in which 1 / 3 or more of the area of ​​the entire cells 3 is blocked (hereinafter referred to as "blocking rate") is 0.1% or less.

[0073] The honeycomb structure sheet 2 has a clogging rate of 0.1% or less, and thus the pressure loss does not become excessive, and the deodorizing function can be efficiently exhibited.

[0074] In the honeycomb structure sheet 2 of the present embodiment, the standard deviation σ of the thickness is preferably 0.2 mm or less, more preferably 0.15 mm or less, and further preferably 0.1 mm or less.

[0075] Since the standard deviation σ of the thickness of the honeycomb structure sheet 2 is equal to or smaller than a preferred value, the processing accuracy in the case of a laminated body is improved.

[0076] <Laminated body>

[0077] Figure 1 This is an exploded perspective view of a laminate 1 according to one embodiment of the present invention. The laminate 1 is used, for example, when removing a component to be removed from a gas such as air, and is used, for example, in an air purifier for purposes such as deodorization and removal of foreign matter. The laminate 1 includes a plurality of honeycomb structure sheets 2. The number of stacked honeycomb structure sheets 2 constituting the laminate 1 is not particularly limited, but can be, for example, 2 to 10 layers.

[0078] The laminate 1 is formed by arranging a plurality of honeycomb structure sheets 2 in the thickness direction ( Figure 1The honeycomb structure sheets 2 are stacked in the Z direction and are bonded to each other on one side by an adhesive or the like in the thickness direction, so that a plurality of honeycomb structure sheets 2 are integrated.

[0079] The plurality of honeycomb structure sheets 2 constituting the stack 1 may be stacked so that the cells 3 overlap and are linearly connected, or may be stacked so that the cells 3 are staggered and are connected via complex paths.

[0080] Methods for staggering the positions of the individual cell holes 3 include a method of stacking the lining members 5 of the individual honeycomb structure sheets 2 in a cross manner, a method of staggering the phases of the corrugated members 6 constituting the individual honeycomb structure sheets 2, a method of combining members with different pitches and heights as the corrugated members 6 constituting the individual honeycomb structure sheets 2, etc.

[0081] The more the cell holes 3 of each honeycomb structure sheet 2 are connected in a straight line or a shape close to a straight line, the more the pressure loss can be reduced. On the other hand, if the positions of the cell holes 3 of each honeycomb structure sheet 2 are staggered and the cell holes 3 are connected through a complex path, the contact efficiency between the sheet substrate 4 and the air etc. is improved.

[0082] The laminate 1 may be a laminate of a plurality of honeycomb structure sheets 2 carrying different kinds of functional agents. In this way, a single laminate 1 can exhibit a plurality of functions.

[0083] In particular, it is preferable that the functional agents, which impair the function of one system if they coexist in one system, are supported on the sheet base material 4 of the other honeycomb structure sheet 2 .

[0084] For example, it is known that when activated carbon, which is effective against a large number of odorous gas components but has difficulty in adsorbing aldehydes, and hydrazide, which is effective in removing aldehydes, are used simultaneously, the activated carbon becomes a catalyst and the functional group (amino group) of the hydrazide is oxidized, resulting in a decrease in performance against aldehydes.

[0085] Therefore, if the honeycomb structure sheet 2 carrying activated carbon and the honeycomb structure sheet 2 carrying hydrazide are prepared separately and these sheets are stacked, the effects of activated carbon and hydrazide can be exerted simultaneously.

[0086] The laminated body 1 can reduce the pressure loss by laminating the honeycomb structure sheets 2 having a low plugging rate.

[0087] Furthermore, by laminating the honeycomb structure sheets 2 having a small standard deviation σ of the thickness, leakage of air and the like from the joints between the honeycomb structure sheets 2 is suppressed. Therefore, a function such as deodorization can be efficiently exhibited.

[0088] <Honeycomb structure>

[0089] The honeycomb structure sheet 2 of the above embodiment can be formed by facing the surface perpendicular to the direction in which the cell holes 3 penetrate. Figure 2 The honeycomb structure 10 shown is manufactured by slicing.

[0090] like Figure 2 As shown, the honeycomb structure 10 is formed by bonding a plurality of sheet base materials 4 to each other. The plurality of sheet base materials 4 are arranged so that the surface direction thereof is along the thickness direction (Z direction).

[0091] A large number of small cell holes 3 are formed between the plurality of sheet base materials 4. The small cell holes 3 are opened at upper and lower ends in the thickness direction and penetrate in the thickness direction (Z direction).

[0092] The honeycomb structure 10 is configured similarly to the honeycomb structure sheet 2 except that the thickness is different, and the preferred form is also the same.

[0093] The thickness of the honeycomb structure 10 ( Figure 2 The length in the Z direction) is preferably 50 mm to 2000 mm, more preferably 100 mm to 1000 mm, further preferably 100 mm to 500 mm, and particularly preferably 150 mm to 300 mm.

[0094] When the thickness of the honeycomb structure 10 is equal to or greater than the lower limit value in the above-described preferred range, a plurality of honeycomb structure sheets 2 can be manufactured from one honeycomb structure 10 , which is efficient.

[0095] When the thickness of the honeycomb structure 10 is equal to or less than the upper limit value within the above-mentioned preferred range, it is easy to avoid an increase in the size of an apparatus for slicing the honeycomb structure 10 .

[0096] The size of the honeycomb structure 10 in a plan view in each of the X direction and the Y direction is preferably 10 mm to 2000 mm, more preferably 10 mm to 1000 mm, further preferably 20 mm to 500 mm, particularly preferably 100 mm to 500 mm.

[0097] When the size of the honeycomb structure 10 in a plan view is equal to or larger than the lower limit value in the above preferred range, a large-area honeycomb structure sheet 2 can be manufactured. In addition, a plurality of honeycomb structure sheets 2 can be manufactured from one honeycomb structure 10, which is efficient.

[0098] When the size of the honeycomb structure 10 in a plan view is equal to or smaller than the upper limit value in the above-mentioned preferred range, it is easy to avoid an increase in the size of an apparatus for slicing the honeycomb structure 10 .

[0099] <Manufacturing of Honeycomb Structure>

[0100] The method for manufacturing the honeycomb structure 10 is not particularly limited, but it is preferred that the sheet base 4 is composed of a liner member 5 and a corrugated member 6. The liner member 5 and the corrugated member 6 may be made of the same material or different materials.

[0101] As an example of manufacturing, a corrugated sheet is processed in a corrugated sheet mill, and a continuous corrugated member 6 and a continuous liner member 5 having a corrugated shape (convex and concave) are bonded to produce a single-wave formed body. Then, the single-wave formed body is cut into a predetermined area to obtain a plurality of single-wave formed bodies. The surface of the liner member 5 of the single-wave formed body is bonded to the surface of the corrugated member 6 of another single-wave formed body and stacked, thereby obtaining a honeycomb structure 10.

[0102] As the adhesive used for bonding the lining member 5 and the corrugated member 6, an organic paste such as ethylene vinyl acetate copolymer and polyvinyl alcohol, or an inorganic paste such as colloidal silica, water glass, sepiolite, and alumina sol can be used as appropriate.

[0103] <Slicer>

[0104] Reference Figure 3 , Figure 4 , one form of a slicer used in the method for manufacturing the honeycomb structure sheet of this form is described.

[0105] like Figure 4 As shown, the present slicing machine 100 is composed of the following components: a knife unit 20 having a belt knife 21; a moving table 30 that carries the honeycomb structure 10 and moves the honeycomb structure 10 toward the belt knife 21; a roller 40 that presses the honeycomb structure 10 in front of the belt knife 21; a fixed table 50 that carries the honeycomb structure slice obtained by slicing with the belt knife 21; and a guide plate 60 that guides the obtained honeycomb structure slice onto the fixed table 50. In addition, Figure 3 In the figure, for convenience, the illustration of the fixing table 50 is omitted.

[0106] like Figure 5 As shown, the knife unit 20 is basically composed of an endless belt knife 21 and a pair of pulleys 25 and 26.

[0107] A belt knife 21 is wound around a pair of pulleys 25, 26, and one (lower) belt knife 21 (hereinafter referred to as "lower belt knife 21") and the other (upper) belt knife 21 (hereinafter referred to as "upper belt knife 21") are held between the pair of pulleys 25, 26 and maintained in a tensioned state by the pair of pulleys 25, 26.

[0108] The rotating axes of the pair of pulleys 25 and 26 are set to be rotatable substantially parallel to the horizontal direction. Moreover, by rotating one or both of the pair of pulleys 25 and 26, the belt knife 21 is rotated, and the lower belt knife 21 and the upper belt knife 21 are each rotated along the horizontal plane ( Figure 5 The XY plane) of the vehicle.

[0109] The pair of pulleys 25 and 26 can be moved in the vertical direction (Z direction) by a driving mechanism (not shown). As the pair of pulleys 25 and 26 move up and down, the horizontal planes on which the lower and upper belt knives 21 and 21 respectively run also move up and down.

[0110] The travel direction of the lower belt knife 21 is Figure 5 The approximate Y direction, but if Figure 3 Shown slightly tilted.

[0111] In addition, the X direction is a moving direction of the honeycomb structure 10 in the slicer 100 , and the Y direction is a direction orthogonal to the X direction in a horizontal plane.

[0112] The belt knife 21 is not particularly limited, but Figure 6 As shown, it can also be basically composed of a knife portion 22, an upper knife pressing portion 23 and a lower knife pressing portion 24. One end of the knife portion 22 exposed from the upper knife pressing portion 23 and the lower knife pressing portion 24 is set as a knife tip, and the other end is clamped by the upper knife pressing portion 23 and the lower knife pressing portion 24.

[0113] The moving stage 30 includes a fixed base 31 and a sliding portion 32 slidably disposed along the upper surface of the fixed base 31 .

[0114] The slide portion 32 moves in a horizontally placed state with the honeycomb structure 10. Figure 3 , Figure 4 The slide portion 32 has a fixing mechanism for fixing the honeycomb structure 10 to the upper surface.

[0115] The pressing roller 40 is arranged in front of (near the opposite X direction) the lower belt knife 21 travels, and prevents the honeycomb structure 10 from floating from the movable table of the moving table 30 in the moving direction (top end in the X direction).

[0116] The fixing table 50 is arranged on the X direction side of the knife unit 20. The lower surface of the fixing table 50 is provided at a position slightly above the position of the blade tip of the knife portion 22 of the tape knife 21.

[0117] The guide plate 60 is installed between the tape knife 21 and the fixing table 50 in such a manner that the fixing table 50 side is elevated.

[0118] <Method for producing honeycomb structure sheet>

[0119] Next, the slicer 100 is used to Figure 2 A method for manufacturing a honeycomb structure sheet according to one embodiment of the present invention will be described by taking the case where the honeycomb structure 10 is sliced ​​as an example.

[0120] First, the slide portion 32 of the moving stage 30 is arranged at a position (initial position) that does not overlap with the knife unit 20 in the X direction.

[0121] Next, the upper and lower positions of the pair of pulleys 25 and 26 are adjusted. Specifically, the positions are adjusted so that when the slide portion 32 is moved in the X direction, the blade tip of the blade portion 22 of the lower belt blade 21 (hereinafter sometimes referred to as "the blade tip of the belt blade 21") contacts a position of the mounted honeycomb structure 10 that is lowered from the upper surface by an amount corresponding to the thickness of the obtained honeycomb structure sheet 2.

[0122] Then, the honeycomb structure 10 is placed on the slide portion 32. At this time, the plurality of cell holes 3 of the honeycomb structure 10 are connected in a vertical direction ( Figure 3 , 4 Next, in this state, the sliding portion 32 is moved in the X direction.

[0123] So, first of all, Figure 4 As shown, the blade tip of the belt knife 21 contacts the honeycomb structure 10. Since the upper and lower positions of the pair of pulleys 25 and 26 are adjusted in advance, the upper and lower positions where the blade tip of the belt knife 21 contacts are the positions of the honeycomb structure 10 that are lowered from the upper surface by an amount corresponding to the thickness of the obtained honeycomb structure sheet 2.

[0124] In addition, since the running direction of the lower belt knife 21 is slightly inclined in the opposite direction to the X direction, the portion where the blade tip of the belt knife 21 first contacts becomes the corner portion ( Figure 3 As a result, by moving the moving stage 30 further in the X direction, the blade tip of the belt knife 21 easily enters the honeycomb structure 10 starting from the corner.

[0125] When the sliding portion 32 is further moved in the X direction, Figure 7 As shown, the blade tip of the belt knife 21 moves horizontally while slicing the honeycomb structure 10, and the sliced ​​portion gradually separates upward along the guide plate 60. In addition, the remaining portion after slicing moves in the X direction under the fixing table 50 without contacting the fixing table 50.

[0126] When the sliding portion 32 is further moved in the X direction, Figure 8 As shown, the honeycomb structure sheet 2 is completely separated by the belt knife 21 and transferred from the guide plate 60 to the fixing table 50 .

[0127] In addition, the remaining portion (remaining structure 11 ) after the separation of the honeycomb structure sheet 2 remains below the fixing table 50 , and the production of the first honeycomb structure sheet 2 is completed.

[0128] Next, the slide portion 32 is moved in the reverse X direction to return to the initial position, and the remaining structure 11 is converted into a new honeycomb structure 10 .

[0129] Then, the vertical positions of the pair of pulleys 25 and 26 are lowered by an amount corresponding to the thickness of the honeycomb structure sheet 2. That is, the vertical positions of the pair of pulleys 25 and 26 are adjusted to a position where the blade tip of the belt knife 21 contacts a position of the new honeycomb structure 10 that is lowered from the upper surface by an amount corresponding to the thickness of the obtained honeycomb structure sheet 2.

[0130] Then, by moving the slide portion 32 in the X direction, the Figure 4 , Figure 7 , Figure 8 The second honeycomb structure sheet 2 can be obtained in the same manner as described above with respect to the method for producing the first honeycomb structure sheet 2 .

[0131] Then, the operation of returning the slide part 32 to the initial position, lowering the vertical positions of the pair of pulleys 25 and 26 by an amount corresponding to the thickness of the honeycomb structure sheet 2, and then moving the slide part 32 in the X direction is repeated again, thereby obtaining a plurality of honeycomb structure sheets 2.

[0132] Furthermore, since the uppermost surface of the honeycomb structure 10 is slightly lacking in flatness, the first honeycomb structure sheet 2 may be discarded and the second and subsequent honeycomb structure sheets 2 may be used.

[0133] According to the manufacturing method of the honeycomb structure sheet of the above embodiment, a honeycomb structure sheet 2 with a low clogging rate is obtained. In addition, the uniformity of thickness is also improved. This is presumably because the adhesive or the like can be prevented from becoming a cause of clogging due to sliding in the horizontal direction.

[0134] use Fig. 9 , explaining the situation when slicing is performed along a plane in the vertical direction in a state where a large number of cell holes 3 are arranged in a manner such that one direction through them is in the horizontal direction.

[0135] like Fig. 9 As shown, the sheet base material 4 including the liner member 5 and the corrugated member 6 are bonded to each other by an adhesive 7. The following is presumed to be the cause of the clogging: when the honeycomb structure 10 is sliced ​​along the vertical direction, the adhesive 7 melts due to the friction heat of the knife and drips in the vertical direction.

[0136] On the other hand, when the honeycomb structure 10 is sliced ​​along the horizontal direction, even if the adhesive 7 is melted due to the friction heat of the knife, the melted adhesive 7 is cut along the sheet base material 4 ( Fig. 9 Therefore, it is estimated that it is not easy to clog the space between the sheet substrates 4, that is, the small cell pores 3.

[0137] In addition, when slicing along the plane in the vertical direction, it is difficult to separate the sliced ​​honeycomb structure sheet 2 from the remaining structure 11. Therefore, when returning the positional relationship between the knife and the honeycomb structure 10 (remaining structure 11) to the initial position, the knife must be returned in a state of being sandwiched between the honeycomb structure sheet 2 and the honeycomb structure 10 (remaining structure 11). At this time, friction is generated, and friction heat is generated again.

[0138] In contrast, when slicing is performed along a horizontal surface, it is easy to separate the sliced ​​honeycomb structure sheet 2 from the remaining structure 11 up and down. Therefore, when the positional relationship between the knife and the honeycomb structure 10 (remaining structure 11) is returned to the initial position, the knife and the honeycomb structure sheet 2 or the knife and the honeycomb structure 10 (remaining structure 11) will not contact and rub.

[0139] In particular, when the blade is a belt blade 21 that moves in one direction, it is considered that the generation of frictional heat can be further reduced.

[0140] Therefore, according to the manufacturing method of the honeycomb structure sheet of the above embodiment, the melting out of the adhesive 7 caused by the friction and frictional heat can be suppressed, and therefore, it is estimated that the honeycomb structure sheet 2 having a low clogging rate and improved thickness uniformity can be obtained.

[0141] <Coating and impregnation of liquid containing functional agent>

[0142] The obtained honeycomb structure sheet 2 can be used as a deodorant material or the like by coating or impregnating a liquid containing a functional agent such as an adsorbent (hereinafter referred to as “liquid containing a functional agent”).

[0143] The liquid containing the functional agent may include a binder and a thickener in addition to the above-mentioned functional agent. When the liquid containing the functional agent is applied to or impregnated on the honeycomb structure sheet 2, it is particularly preferred to use a thickener in the case where it is difficult to stir the coating liquid all the time, or when the coating liquid is separated into an emulsion containing water and a binder component and a porous functional agent such as activated carbon.

[0144] The functional agent-containing liquid may contain a colorant, a wetting agent, a paper strength enhancer, a waterproofing agent, a pH adjuster, a defoaming agent, a preservative, and the like as necessary.

[0145] The medium of the liquid containing the functional agent is not particularly limited, but water, ethanol, etc. can be used.

[0146] After coating and impregnation with the liquid containing the functional agent, drying is performed.

[0147] Furthermore, when the sheet base material 4 constituting the honeycomb structure 10 itself includes a functional agent such as an adsorbent, the honeycomb structure sheet 2 obtained by slicing the honeycomb structure 10 can also be used directly as a deodorant material or the like.

[0148] <Layering>

[0149] When the laminate 1 is produced by laminating honeycomb structure sheets 2 , preferably honeycomb structure sheets 2 coated or impregnated with a liquid containing a functional agent, the same adhesive as that listed as the adhesive for bonding the liner member 5 and the corrugated member 6 can be used.

[0150] Before stacking and bonding the honeycomb structure sheets 2, each honeycomb structure sheet 2 is preferably preliminarily Figure 1 The outer edge of the XY plane is roughly cut so that it is slightly larger than the outer edge of the final laminated body 1. In addition, it is preferable to perform precision cutting on the outer edge of the final laminated body 1 so that it has an appropriate size after lamination and bonding.

[0151] Example

[0152] Hereinafter, the present invention will be described in detail with reference to Examples, but the present invention is not limited to the following description.

[0153] <Measurement method>

[0154] [Thickness of honeycomb structure sheet]

[0155] The thickness of the honeycomb structure sheet of each example was measured at 20 locations using a coolant-proof micrometer (manufactured by Mitutoyo), and the average value and standard deviation thereof were determined.

[0156] In addition, the 20 measurement sites were selected evenly and randomly without partiality.

[0157] [Clogging rate of honeycomb structure sheet]

[0158] The honeycomb structure sheet of each example was visually observed, and the number of cells in which 1 / 3 or more of the area of ​​the cell holes was blocked was counted.

[0159] The ratio of this number to 12,000 (the approximate number of all cell holes) was defined as the clogging rate.

[0160] [Pressure loss of laminated body]

[0161] The pressure loss of the laminated body of each example was determined at a wind speed of 1.74 m / s using a measuring device in accordance with Japanese Industrial Standard JIS B8330.

[0162] <Honeycomb structure>

[0163] The honeycomb structure used in each example was made of Oji F-Tex glass paper PHN-50G (glass nonwoven fabric using glass fiber and pulp, with a unit area mass of 50 g / m 2 ) and a corrugated member (pitch 5mm, height 2mm) that has been corrugated are alternately stacked to obtain a honeycomb structure with a height of 300mm, a size of 254mm (1 inch) square and approximately 12,000 cells.

[0164] <Examples 1 to 5>

[0165] The honeycomb structure sheets of each example were obtained by slicing the honeycomb structure body using the slicer 100 described in the above embodiment and the method described in the above embodiment, with the set thickness set to the set thickness described in Table 1. The slicing surface is a surface perpendicular to a direction in which many small cell holes penetrate, and is a surface along the horizontal direction.

[0166] Table 1 shows the average thickness, standard deviation of thickness, number of clogged cells (after cutting), and clogged ratio (after cutting) of the honeycomb structure sheets of each example obtained.

[0167] In addition, the honeycomb structure sheets of each example were immersed in a functional material-containing liquid containing activated carbon, silica, organic acid and acrylic resin in water, with a viscosity of 12 seconds (Zion cup #2) and a solid content concentration of 35% by mass. 3 ) was impregnated so that the coating amount became 0.45 g (the dry coating amount was about 0.16 g), and then dried using an air-blowing dryer at 150° C. for 30 minutes.

[0168] Table 1 shows the number of blocked cells (after immersion) and the blocking ratio (after immersion) of the honeycomb structure sheet of each example after immersion.

[0169] [Table 1]

[0170]

[0171] <Comparative Examples 1 to 4>

[0172] The honeycomb structure sheets of each example were obtained by slicing the above honeycomb structure using a vertical cutter (manufactured by Sakura Machinery) with a set thickness as described in Table 2. The sliced ​​surface is a surface perpendicular to a direction in which many small cells penetrate and is a surface along the vertical direction.

[0173] Table 2 shows the average thickness, standard deviation of thickness, number of clogged cells (after cutting), and clogged ratio (after cutting) of the honeycomb structure sheets of each example obtained.

[0174] In addition, the honeycomb structure sheets of each example were immersed in a functional material-containing liquid containing activated carbon, silica, organic acid and acrylic resin in water, with a viscosity of 12 seconds (Zion cup #2) and a solid content concentration of 35% by mass. 3 ) was impregnated so that the coating amount became 0.45 g (the dry coating amount was about 0.16 g), and then dried using an air-blowing dryer at 150° C. for 30 minutes.

[0175] Table 2 shows the number of blocked cells (after immersion) and the blocking ratio (after immersion) of the honeycomb structure sheet of each example after immersion.

[0176] In addition, in Comparative Example 4, the sheet shook during cutting, and the honeycomb structure sheet could not be produced.

[0177] [Table 2]

[0178]

[0179] As shown in Table 1, the honeycomb structure sheets of the embodiments are all sliced ​​with a small standard deviation of thickness and with a high processing accuracy. In addition, the blockage rate is low after cutting and after impregnation. In addition, the pressure loss of the laminated body of the embodiment is small. In addition, as shown in Example 5, it can also be known that even a very thin honeycomb structure sheet with a thickness of 1 mm can be manufactured without problems.

[0180] In contrast, the honeycomb structure sheets of the comparative examples all had large standard deviations in thickness and low processing accuracy. In addition, the clogging rate after cutting was high, and the clogging rate after immersion was even higher. In addition, the pressure loss of the laminated body of the comparative example was large.

[0181] In addition, it is found that, when the sliced ​​surface is set in the vertical direction, it is difficult to produce a honeycomb structure sheet thinner than 3 mm in thickness.

[0182] Description of Reference Numerals

[0183] 1. Laminated body; 2. Honeycomb structure sheet; 3. Cell hole; 4. Sheet substrate; 5. Lining member; 6. Corrugated member; 7. Adhesive; 10. Honeycomb structure; 11. Remaining structure; 20. Knife unit; 21. Belt knife; 30. Moving table; 40. Pressing roller; 50. Fixed table; 60. Guide plate; 100. Slicer.

Claims

1. A method for manufacturing a honeycomb structure sheet, wherein a honeycomb structure is sliced ​​on a surface perpendicular to a direction to manufacture a honeycomb structure sheet in which the one direction is a thickness direction, the honeycomb structure is formed by bonding a plurality of sheet substrates to each other, and a plurality of small cells are formed which are divided by the plurality of sheet substrates and penetrate along the one direction, the method for manufacturing the honeycomb structure sheet being characterized in that: In a state where the honeycomb structure is arranged so that the one direction becomes a vertical direction, the honeycomb structure is sliced ​​along a surface along a horizontal direction.

2. The method for producing a honeycomb structure sheet according to claim 1, wherein: Furthermore, a liquid containing a functional agent is applied to and impregnated on the honeycomb structure sheet.

3. A method for producing a laminate, wherein: A plurality of honeycomb structure sheets obtained by the method for producing a honeycomb structure sheet according to claim 1 or 2 are stacked.

4. A honeycomb structure sheet, which is formed by bonding a plurality of sheet substrates to each other, and has a plurality of cells divided by the plurality of sheet substrates and penetrating in the thickness direction, wherein: The plurality of small chamber holes are formed in an area of ​​254 mm square, with 2,000 to 15,000 holes. The thickness of the honeycomb structure sheet is 1 mm to 20 mm. The proportion of the small cells whose area is blocked is 1 / 3 or more among the plurality of small cells is 0.1% or less.

5. The honeycomb structure sheet according to claim 4, wherein: The sheet substrate carries a functional agent.

6. A laminate, wherein: The laminate is formed by laminating a plurality of honeycomb structure sheets according to claim 4 or 5.

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