Honeycomb structure sheet and laminate and method for manufacturing the same

Abstract

Provided is a honeycomb structure sheet with less clogging, a laminate of the honeycomb structure sheet, and a method for manufacturing the same. A method for manufacturing a honeycomb structure sheet (2) in which a honeycomb structure (10) formed by a plurality of sheet base materials (4) adhered to each other and formed with a plurality of cell holes (3) divided by the plurality of sheet base materials (4) and penetrating in one direction is sliced in a direction orthogonal to the one direction to manufacture the honeycomb structure sheet (2) in which the one direction becomes a thickness direction, the method being characterized in that the honeycomb structure (10) is disposed in a state in which the one direction becomes a vertical direction, and the honeycomb structure (10) is sliced in a horizontal direction.

Description

Technical Field

[0001] This invention relates to honeycomb structure sheets and laminates, as well as methods for manufacturing them.

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

[0003] In recent years, due to changes in living environment and increased health awareness, air conditioning equipment such as air conditioners, air purifiers, humidifiers, and dehumidifiers have been widely used in various living spaces, including homes, offices, factories, and cars. These air conditioning devices utilize various deodorizing materials to achieve purified air.

[0004] As a deodorizing material, it is known to be a honeycomb structure in which multiple liner components and multiple corrugated components are bonded together to form a plurality of small chambers extending in one direction. If the liner components and corrugated components forming the honeycomb structure carry deodorizing components, the air to be treated is purified by contacting the deodorizing components as it passes through the small chambers that form the flow path.

[0005] The thickness (length of the small chambers) of deodorizing materials is generally around 10mm to 30mm. In order to manufacture deodorizing materials efficiently, lining components or corrugated components with a length of about 30cm to 200cm in the direction of the small chambers are usually used to manufacture honeycomb structures. The honeycomb structure is cut at a surface orthogonal to the direction of the small chambers, and the honeycomb structure sheet of the desired thickness is used as the deodorizing material.

[0006] In the past, when cutting a honeycomb structure, the honeycomb structure was arranged in such a way that the face direction of the liner member was horizontal when it was cut along the vertical direction (for example, Patent Document 1).

[0007] Existing technical documents

[0008] Patent documents

[0009] Patent Document 1: Japanese Utility Model Application Publication No. 4-81615 Summary of the Invention

[0010] The problem the invention aims to solve

[0011] However, traditional honeycomb structure sheets have the problem of small pores being easily clogged.

[0012] In addition, when the honeycomb structure sheet is immersed in a liquid containing functional agents such as deodorizing ingredients and dried to carry these ingredients, there is a problem that the blockage may further progress because the functional agents adhere to foreign objects that block the pores of the cells.

[0013] Furthermore, when deodorizing materials are manufactured by overlapping multiple thin honeycomb structure sheets, if any small pore in the stacking direction becomes blocked, airflow will be impeded. Therefore, the impact of blockage is even more difficult to ignore.

[0014] The present invention was made in view of the above circumstances, and its objective is to provide a honeycomb structure sheet with less clogging, a laminate formed by stacking the honeycomb structure sheet, and a method for manufacturing the same.

[0015] Solution for solving the problem

[0016] The present invention employs the following structure.

[0017] [1] A method for manufacturing a honeycomb structure sheet, wherein a honeycomb structure is sliced ​​on a surface orthogonal to a certain direction to manufacture a honeycomb structure sheet in which the certain direction is the thickness direction, the honeycomb structure being formed by bonding multiple sheet substrates together, and having a plurality of small cells divided by the multiple sheet substrates and extending along the certain direction, the method for manufacturing the honeycomb structure sheet is characterized in that...

[0018] With the honeycomb structure configured in a vertical orientation, slices are made from the face along the horizontal direction.

[0019] [2] According to the method for manufacturing the honeycomb structure sheet described in [1], a liquid containing a functional agent is further coated or impregnated onto the honeycomb structure sheet.

[0020] [3] A method for manufacturing a laminated body, wherein...

[0021] Multiple honeycomb structure sheets are stacked using the manufacturing method of the honeycomb structure sheet described in [1] or [2].

[0022] [4] A honeycomb structure sheet, which is formed by bonding multiple sheet substrates together, forming a plurality of small cells that are divided by the multiple sheet substrates and penetrate along the thickness direction, wherein,

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

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

[0025] The proportion of the numerous small chambers whose area is more than 1 / 3 blocked is less than 0.1%.

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

[0027] [6] A laminate, wherein the laminate is formed by stacking a plurality of honeycomb structure sheets as described in [4] or [5].

[0028] The effects of the invention

[0029] The honeycomb structure sheet of the present invention exhibits less clogging, and the laminate using this honeycomb structure sheet does not result in excessive pressure loss, thus achieving efficient deodorization and other functions. Furthermore, the manufacturing method of the honeycomb structure sheet according to the present invention enables the efficient production of honeycomb structure sheets with less clogging. Additionally, the manufacturing method of the laminate according to the present invention prevents excessive pressure loss and enables the production of laminates that efficiently perform deodorization and other functions. Attached Figure Description

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

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

[0032] Figure 3 This is a schematic three-dimensional diagram of a slicer used to slice honeycomb structures.

[0033] Figure 4 This is a schematic front view of a slicer used to slice a honeycomb structure.

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

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

[0036] Figure 7 This is an explanatory diagram showing the intermediate state of slicing a honeycomb structure using a slicer.

[0037] Figure 8 This is an explanatory diagram showing the process of slicing a honeycomb structure using a slicer to obtain honeycomb structure pieces.

[0038] Figure 9 This is an explanatory diagram illustrating the mechanism of action of the present invention. Detailed Implementation

[0039] In this specification, the numerical range indicated by “~” refers to the range including the values ​​recorded before and after “~” as the lower and upper limits.

[0040] <Honeycomb Structure Panel>

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

[0042] The honeycomb structure sheet 2 can be used individually for purposes such as deodorization, or as... Figure 1 The multiple layers shown are stacked as a stack body 1.

[0043] The honeycomb structure sheet 2 is configured as a thin, flat shape that extends in a planar pattern. In this configuration, the thickness of the honeycomb structure sheet 2 ( Figure 1 The length in the Z direction is 1mm to 20mm.

[0044] If the thickness of the honeycomb structure sheet 2 is 1 mm or more, it is easy to ensure the processing accuracy during manufacturing. If the thickness of the honeycomb structure sheet 2 is 20 mm or less, the manufacturing method of the deodorizing sheet of the present invention, described later, has greater advantages.

[0045] The thickness of the honeycomb structure 2 when multiple honeycomb structure pieces 2 are stacked to form a laminate 1. Figure 1 The length in the Z direction is preferably 1 mm to 20 mm, more preferably 1 mm to 15 mm, even more preferably 1 mm to 10 mm, and particularly preferably 2.5 mm to 10 mm.

[0046] If the thickness of the honeycomb structure piece 2 is above the lower limit of the above-mentioned preferred range, it is easy to ensure the processing accuracy during manufacturing. If the thickness of the honeycomb structure piece 2 is below the upper limit of the above-mentioned preferred range, even if multiple honeycomb structure pieces 2 are overlapped, the overall thickness of the laminate 1 will not become too large.

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

[0048] If the thickness of the honeycomb structure sheet 2 is above the lower limit of the above-mentioned preferred range, the required strength can be easily ensured when used for purposes such as deodorization.

[0049] If the thickness of the honeycomb structure sheet 2 is below the upper limit of the above-mentioned preferred range, then the deodorizing sheet manufacturing method of the present invention described later has a greater advantage.

[0050] like Figure 1 As shown, the honeycomb structure 2 is formed by bonding multiple substrate sheets 4 together. The multiple substrate sheets 4 are all arranged such that their surface direction is along the thickness direction (Z direction).

[0051] A plurality of small chambers 3 are formed between multiple sheet substrates 4, which are divided by the sheet substrates 4. The small chambers 3 are open at both ends in the thickness direction and extend through the thickness direction (Z direction). The small chambers 3 serve as flow paths for gases such as air, which are the objects to be processed, to pass through.

[0052] The shape of the small chamber 3 when viewed from above is not particularly limited. In the example shown, it is a mountain-shaped shape (roughly triangular), but it can also be, for example, a quadrilateral shape, a rhombus shape, a hexagonal shape, a circular shape, etc. Multiple small chambers 3 are arranged and connected regularly or irregularly in the longitudinal, transverse, and diagonal directions in the XY plane with narrow intervals.

[0053] In this configuration, the number of small chamber holes 3 is 2,000 to 15,000 per 254 mm square (10 inch square) area. The number of small chamber holes 3 per 10 inch square area is preferably 2,000 to 15,000, more preferably 4,000 to 12,000.

[0054] If the number of small pores 3 per 10-inch square area is more than 2000, it can effectively deodorize. If the number of small pores 3 per 10-inch square area is less than 15000, it will not hinder the flow of air.

[0055] The specific structure of the multiple sheet substrates 4 is not particularly limited, but from the perspective of efficient production, it is preferable to consist of a combination of multiple liner members 5 that extend in a straight line when viewed from above and multiple corrugated members 6 that are wavy when viewed from above.

[0056] exist Figure 1 The image shows an example of liner member 5 and corrugated member 6 being stacked alternately along the X direction.

[0057] The sheet substrate 4 is not limited to a configuration where the liner members 5 and corrugated members 6 are alternately stacked; for example, it can also be a portion where the corrugated members 6 are bonded to each other adjacent to each other. Alternatively, it can also be a portion where the liner members 5 are bonded to each other adjacent to each other.

[0058] The pitch of the corrugated members 6 constituting the substrate 4 is preferably 2 mm to 8 mm, more preferably 4 mm to 6 mm. Furthermore, the height of the corrugated members 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. For example, corrugated members 6 stacked along the X direction with different heights and pitches for each layer can also be used. In addition, when using corrugated members 6 with the same height and pitch for each layer, their phases can be the same or different.

[0060] The material constituting the substrate 4 is not particularly limited as long as it can maintain its shape, and examples include inorganic materials, organic materials, or combinations thereof, such as paper, non-woven fabric, woven fabric, and plastic film. Preferably, the material constituting the substrate 4 can support functional agents, etc. Furthermore, the functional agents, etc., can be either internally or externally filled.

[0061] In particular, paper and nonwoven fabrics using inorganic or organic fibers are preferred because they readily retain chemical solutions containing functional agents by utilizing capillary action to absorb liquids. Paper and nonwoven fabrics can be easily formed using inorganic or organic fibers through wet papermaking.

[0062] Examples of inorganic fibers include glass fiber, ceramic fiber, and carbon fiber. Among these, glass fiber is preferred due to its safety for human health and cost-effectiveness. Examples of organic fibers include pulp and resin fiber.

[0063] The substrate 4 preferably contains 30% or more inorganic fibers by mass, more preferably 40% or more inorganic fibers by mass, and even more preferably 50% or more inorganic fibers by mass. By containing inorganic fibers, it can possess high heat resistance, high heat insulation, and non-flammability.

[0064] The material that occupies the largest mass percentage within the material constituting the substrate 4 is preferably inorganic fiber.

[0065] Furthermore, it is preferable to use both inorganic and organic fibers to form the sheet substrate 4. By incorporating organic fibers into the inorganic fiber base, the formability is improved.

[0066] The mass per unit area of ​​the substrate 4 is not particularly limited, but when it is paper or nonwoven fabric, it is preferably set to 10 g / m². 2 ~100g / m 2 More preferably, it is set to 15g / m 2 ~60g / m 2 If the mass per unit area is above the lower limit of the preferred range, sufficient strength of the sheet substrate 4 formed in a corrugated shape or the like can be obtained. If the mass per unit area is below the upper limit of the preferred range, the thickness is suppressed, and small chambers 3 with sufficient cross-sectional area can be easily formed, thus also suppressing pressure loss.

[0067] In addition to the substrate 4, the honeycomb structure sheet 2 preferably also includes a functional agent supported on the substrate 4. Examples of functional agents include adsorbents that adsorb malodorous components and deodorize, antibacterial agents and antifungal agents, ozone decomposition agents, and flame retardants. Only one type of these agents may be used, or two or more may be used simultaneously.

[0068] There are no particular limitations on adsorbents, but known materials such as activated carbon, mordenite, magnesium alkali zeolite, molecular sieves, silica gel, alumina gel, acyl hydrazides, pyrrole compounds, and organic acids can be listed.

[0069] As an antibacterial agent and antifungal agent, there are no particular limitations, but well-known materials such as silver-containing antibacterial agents can be listed.

[0070] There are no particular limitations on ozone decomposition agents, but well-known materials such as manganese catalyst-based ozone decomposition agents, copper-manganese catalyst-based ozone decomposition agents, and activated carbon-based ozone decomposition agents can be listed.

[0071] The functional agent is not limited to this; various known functional agents can also be used. The functional agent can be in various forms, such as powder, granules, or fibers. Furthermore, the method of carrying the functional agent onto the substrate 4 is not limited; the functional agent can be retained inside the substrate 4, or it can be adhered to the surface of the substrate 4. Alternatively, an impregnation solution containing the functional agent can be coated onto the substrate 4, or the substrate 4 can be impregnated with the impregnation solution. By carrying the functional agent onto the substrate 4, air purification effects such as deodorization can be achieved efficiently.

[0072] In the honeycomb structure 2 of this form, the proportion of small chambers 3 with more than 1 / 3 of their area blocked (hereinafter referred to as the "blockage rate") is less than 0.1%.

[0073] For the honeycomb structure sheet 2, since the clogging rate is less than 0.1%, it can effectively perform functions such as deodorization without causing excessive pressure loss.

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

[0075] For the honeycomb structure sheet 2, since the standard deviation of the thickness σ is below the preferred value, the processing accuracy is improved when it is used as a laminate.

[0076] <Layered Body>

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

[0078] The laminate 1 is constructed by placing multiple honeycomb structure pieces 2 in the thickness direction ( Figure 1In the Z direction, the honeycomb structure pieces 2 are stacked on one side and joined together on the other side using adhesives or the like in the thickness direction, so that multiple honeycomb structure pieces 2 are integrated into one.

[0079] The multiple honeycomb structure pieces 2 constituting the laminate 1 can be stacked either in a way that the positions of each small cell 3 overlap and the small cell 3 are connected in a straight line, or in a way that the positions of each small cell 3 are staggered and the small cell 3 are connected through a complex path.

[0080] As a method to stagger the positions of each small cell 3, methods such as stacking the liner members 5 of each honeycomb structure piece 2 in an intersecting manner, staggering the phases of the corrugated members 6 constituting each honeycomb structure piece 2, and combining members with different pitches and heights as the corrugated members 6 constituting each honeycomb structure piece 2 are examples.

[0081] The more the small cells 3 of each honeycomb structure sheet 2 are connected in a straight or nearly straight shape, the less pressure loss can be achieved. On the other hand, if the positions of the small cells 3 of each honeycomb structure sheet 2 are staggered and the small cells 3 are connected by complex paths, the contact efficiency between the sheet substrate 4 and air, etc., is increased.

[0082] The laminate 1 can also be stacked with various honeycomb structure sheets 2 carrying different types of functional agents. Thus, a single laminate 1 can perform multiple functions.

[0083] In particular, preferably, the functional agent, which would impair the function of one if coexisting in a system, is carried on the substrate 4 of another honeycomb structure sheet 2.

[0084] For example, it is known that when activated carbon, which is effective for adsorbing large amounts of odorous gas components but is difficult to adsorb aldehydes, is used at the same time as hydrazide, which is effective for removing aldehydes, the activated carbon becomes a catalyst, and the functional group (amino group) of the hydrazide is oxidized, resulting in a decrease in its performance against aldehydes.

[0085] Therefore, if a honeycomb structure sheet 2 carrying activated carbon and a 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 laminate 1 reduces pressure loss by stacking honeycomb structure sheets 2 with a low blockage rate.

[0087] Furthermore, by using honeycomb structure sheets 2 with a small standard deviation σ in their stacked thickness, leakage of air and other substances from the joints between the honeycomb structure sheets 2 is suppressed. Therefore, it can efficiently perform functions such as deodorization.

[0088] <Honeycomb Structure>

[0089] The honeycomb structure 2 of the above embodiment can be perpendicular to the direction through which the small cell 3 penetrates. 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 multiple sheet substrates 4 together. The multiple sheet substrates 4 are all arranged such that their surface direction is along the thickness direction (Z direction).

[0091] A plurality of small chambers 3 are formed between multiple sheet substrates 4, which are divided by the sheet substrates 4. The small chambers 3 are open at the upper and lower ends in the thickness direction and extend through the thickness direction (Z direction).

[0092] The honeycomb structure 10 is constructed in the same way as the honeycomb structure sheet 2, except for the difference in thickness, and the preferred shape is also the same.

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

[0094] If the thickness of the honeycomb structure 10 is above the lower limit of the above-mentioned preferred range, multiple honeycomb structure pieces 2 can be manufactured from one honeycomb structure 10, thus making it more efficient.

[0095] If the thickness of the honeycomb structure 10 is below the upper limit of the above-mentioned preferred range, it is easy to avoid the need for large-scale devices for slicing the honeycomb structure 10.

[0096] The size of the honeycomb structure 10 when viewed from above is preferably 10mm to 2000mm in each of the X and Y directions, more preferably 10mm to 1000mm, even more preferably 20mm to 500mm, and particularly preferably 100mm to 500mm.

[0097] If the size of the honeycomb structure 10 when viewed from above is above the lower limit of the aforementioned preferred range, then large-area honeycomb structure pieces 2 can be manufactured. Furthermore, multiple honeycomb structure pieces 2 can be manufactured from a single honeycomb structure 10, thus increasing efficiency.

[0098] If the size of the honeycomb structure 10 when viewed from above is below the upper limit of the above-mentioned preferred range, it is easy to avoid the need for large-scale devices for slicing the honeycomb structure 10.

[0099] <Manufacturing of honeycomb structures>

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

[0101] In one example of manufacturing, corrugation is performed in a corrugated sheet rolling mill, bonding continuous corrugated members 6 and continuous liner members 5 with a wave pattern (convex and concave) to create a single-wave molded body. Then, the single-wave molded body is cut to a predetermined area to obtain multiple single-wave molded bodies. By bonding and stacking the surface of the liner member 5 of one single-wave molded body to the surface of the corrugated member 6 of another single-wave molded body, a honeycomb structure 10 is obtained.

[0102] The adhesive used for bonding the liner component 5 and the corrugated component 6 can appropriately include organic pastes such as ethylene vinyl acetate copolymer and polyvinyl alcohol, and inorganic pastes such as colloidal silica, water glass, sepiolite, and aluminum sol.

[0103] <Slicer>

[0104] Reference Figure 3 , Figure 4 This describes a type of slicing machine used in the manufacturing method of the honeycomb structure sheet of this type.

[0105] like Figure 4 As shown, the slicer 100 of this type comprises the following components: a blade unit 20 having a belt blade 21; a moving stage 30 that carries the honeycomb structure 10 and moves the honeycomb structure 10 toward the belt blade 21; a roller 40 that presses the honeycomb structure 10 in front of the belt blade 21; a fixed stage 50 that holds the honeycomb structure sheet obtained by slicing using the belt blade 21; and a guide plate 60 that guides the obtained honeycomb structure sheet onto the fixed stage 50. Furthermore, in Figure 3 For convenience, the illustration of the fixed platform 50 has been omitted.

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

[0107] A belt cutter 21 is wound around a pair of pulleys 25 and 26. The belt cutter 21 on one side (below) and the belt cutter 21 on the other side (above) between the pair of pulleys 25 and 26 are kept taut by the pair of pulleys 25 and 26.

[0108] The rotation axes of the pair of pulleys 25 and 26 are configured to rotate approximately parallel to the horizontal direction. Furthermore, by rotating either or both of the pulleys 25 and 26, the belt cutter 21 is rotated, with the lower and upper belt cutters 21 each rotating along the horizontal plane. Figure 5 (Travels on the XY plane).

[0109] A pair of pulleys 25 and 26 can move vertically (Z-direction) using a drive mechanism (not shown). As the pulleys 25 and 26 move vertically, the horizontal planes on which the lower and upper belt cutters 21 travel also move vertically.

[0110] The direction of travel of the belt-type blade 21 below is Figure 5 The approximate Y-direction, but as Figure 3 It is slightly tilted as shown.

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

[0112] There are no specific limitations on the type of belt-type knife 21, but as... Figure 6 As shown, it can also be basically composed of a blade part 22, an upper blade pressing part 23, and a lower blade pressing part 24. The end of the blade part 22 exposed from the upper blade pressing part 23 and the lower blade pressing part 24 is set as the blade tip, and the other end is clamped by the upper blade pressing part 23 and the lower blade pressing part 24.

[0113] The moving stage 30 has a fixed base 31 and a sliding part 32 that is capable of sliding along the upper surface of the fixed base 31.

[0114] The sliding part 32 moves towards the honeycomb structure 10 in a horizontally mounted state. Figure 3 , Figure 4 It can move in the X direction or the opposite X direction. The sliding part 32 has a fixing mechanism for fixing the honeycomb structure 10 to the upper surface.

[0115] The pressing roller 40 is positioned in front of the belt cutter 21 below (near the opposite X direction) to prevent the honeycomb structure 10 from floating off the movable table of the moving table 30 in the direction of movement (X-direction top).

[0116] The fixed stage 50 is positioned on the X-direction side of the tool unit 20. The lower surface of the fixed stage 50 is located slightly above the tip of the tool section 22 of the belt cutter 21.

[0117] The guide plate 60 is mounted between the belt cutter 21 and the fixed platform 50 by raising it to the side of the fixed platform 50.

[0118] <Manufacturing Method of Honeycomb Structure Panels>

[0119] The slicer 100 described above will be used to process... Figure 2 Taking the case of slicing a honeycomb structure 10 as an example, a method for manufacturing a honeycomb structure sheet of one aspect of the present invention will be described.

[0120] First, the sliding part 32 of the moving stage 30 is positioned in the X direction without overlapping with the knife unit 20 (initial position).

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

[0122] Then, the honeycomb structure 10 is placed on the sliding part 32. At this time, the many small cells 3 of the honeycomb structure 10 are vertically oriented in a through-flow direction. Figure 3 , 4 The slider 32 is configured in the Z direction. Then, in this state, the slider 32 is moved in the X direction.

[0123] Therefore, firstly, as Figure 4 As shown, the tip of the belt cutter 21 contacts the honeycomb structure 10. Since the vertical positions of the pair of pulleys 25 and 26 were adjusted first, the vertical position of the tip of the belt cutter 21 is the position where the honeycomb structure 10 has descended from its upper surface by an amount corresponding to the thickness of the resulting honeycomb structure sheet 2.

[0124] Furthermore, since the travel direction of the lower belt blade 21 is slightly tilted in the opposite X direction, the part where the blade tip of the belt blade 21 initially contacts becomes the corner of the honeycomb structure 10. Figure 3 (The lower corner of the diagram). As a result, by moving the stage 30 further in the X direction, the tip of the belt cutter 21 easily enters the honeycomb structure 10, starting from the corner.

[0125] When the sliding part 32 is further moved in the X direction, such as Figure 7 As shown, the blade tip of the belt cutter 21 moves horizontally while slicing the honeycomb structure 10, and the sliced ​​portion gradually separates upward along the guide plate 60. Furthermore, the remaining sliced ​​portion travels downward in the X direction of the fixed stage 50 without contacting the fixed stage 50.

[0126] When the sliding part 32 is further moved in the X direction, such as Figure 8 As shown, the honeycomb structure piece 2 is completely separated using the belt cutter 21 and transferred from the guide plate 60 to the fixed stage 50.

[0127] In addition, the remaining part (remaining structure 11) after the honeycomb structure piece 2 is separated remains below the fixing platform 50, and the manufacturing of the first honeycomb structure piece 2 is completed.

[0128] Next, the sliding part 32 is moved in the opposite X direction to return to the initial position, and the remaining structure 11 is set as the 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 piece 2. That is, the vertical positions of the pair of pulleys 25 and 26 are adjusted so that the tip of the belt cutter 21 contacts the position of the new honeycomb structure 10 after it has been lowered from its upper surface by an amount corresponding to the thickness of the resulting honeycomb structure piece 2.

[0130] Then, by moving the sliding part 32 in the X direction, it interacts with the user. Figure 4 , Figure 7 , Figure 8 Similarly, when describing the manufacturing method of the first honeycomb structure piece 2, the second honeycomb structure piece 2 can be obtained.

[0131] Then, by repeating the operation of returning the sliding part 32 to its initial position and lowering the vertical position 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 sliding part 32 in the X direction, multiple honeycomb structure sheets 2 can be obtained.

[0132] In addition, the uppermost surface of the honeycomb structure 10 is slightly lacking in flatness, so the first honeycomb structure piece 2 can be discarded and the second and subsequent honeycomb structure pieces 2 can be used instead.

[0133] According to the manufacturing method of the honeycomb structure sheet with the above-described morphology, a honeycomb structure sheet 2 with a low clogging rate was obtained. Furthermore, the uniformity of thickness was also improved. This is presumably because, since it slides along the horizontal direction, it avoids the formation of clogging agents such as adhesives.

[0134] use Figure 9 This describes the situation when slicing a plane along the vertical direction, with many small chambers 3 arranged in a horizontally oriented manner.

[0135] like Figure 9 As shown, the sheet substrate 4, including the liner member 5 and the corrugated member 6, is bonded to each other using adhesive 7. It is speculated that the following is the cause of the blockage: when the honeycomb structure 10 is sliced ​​along the vertical direction, the adhesive 7 melts due to the frictional heat of the blade and drips along the vertical direction.

[0136] On the other hand, when slicing the honeycomb structure 10 along the horizontal direction, even if the adhesive 7 melts due to the frictional heat of the blade, the molten adhesive 7 will spread along the substrate 4 ( Figure 9 The paper drips down in the thickness direction of the paper surface, therefore, it is speculated that it is not easy to block the gap between the sheet substrate 4 and the sheet substrate 4, that is, the small chamber 3.

[0137] Furthermore, when slicing along a vertical plane, it is difficult to separate the sliced ​​honeycomb structure 2 from the remaining structure 11. Therefore, when returning the positional relationship between the blade and the honeycomb structure 10 (remaining structure 11) to the initial position, the blade must return while being clamped between the honeycomb structure 2 and the honeycomb structure 10 (remaining structure 11). At this time, friction is generated, and frictional heat is generated again.

[0138] In contrast, when slicing along a horizontal plane, the sliced ​​honeycomb structure 2 is easily separated from the remaining structure 11. Therefore, when the positional relationship between the blade and the honeycomb structure 10 (remaining structure 11) is returned to the initial position, the blade will not come into contact with or rub against the honeycomb structure 2 or the honeycomb structure 10 (remaining structure 11).

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

[0140] Therefore, according to the manufacturing method of the honeycomb structure sheet with the above-described form, it is also possible to suppress the melting of the adhesive 7 that is generated by friction and frictional heat. Therefore, it is speculated that a honeycomb structure sheet 2 with a lower blockage rate and improved thickness uniformity can be obtained.

[0141] <Coating and impregnation of liquids containing functional agents>

[0142] The resulting honeycomb structure sheet 2 can be used as a deodorizing material by coating or impregnating it with a liquid containing functional agents such as adsorbents (hereinafter referred to as "liquid containing functional agents").

[0143] In addition to the functional agents mentioned above, the liquid containing functional agents may also include binders and thickeners. When coating or impregnating the honeycomb structure sheet 2 with the liquid containing functional agents, thickeners are particularly preferred in cases where it is difficult to continuously stir the coating liquid, or in cases where the coating liquid separates into an emulsion containing water, binder components, and porous functional agents such as activated carbon.

[0144] Liquids containing functional agents may also contain colorants, wetting agents, paper strength enhancers, waterproofing agents, pH adjusters, defoamers, preservatives, etc., as needed.

[0145] There are no particular restrictions on the medium for liquids containing functional agents, but water, ethanol, etc. can be used.

[0146] After coating and impregnating with a liquid containing functional agents, the product is dried.

[0147] Furthermore, if the substrate 4 constituting the honeycomb structure 10 itself includes functional agents such as adsorbents, the honeycomb structure sheet 2 obtained by slicing the honeycomb structure 10 can also be used directly as a deodorizing material.

[0148] <Layering>

[0149] When a laminate 1 is manufactured by laminating honeycomb structure sheets 2, preferably by coating or impregnating honeycomb structure sheets 2 with a liquid containing a functional agent, the same adhesive as those listed as adhesives for bonding backing member 5 and corrugated member 6 can be used as the adhesive.

[0150] Before stacking and bonding each honeycomb structure piece 2, each honeycomb structure piece 2 is preferably pre-treated with... Figure 1 The outer edge of the XY plane is coarsely cut such that it is slightly larger than the outer edge of the final laminate 1. Alternatively, it is preferable to precisely cut the outer edge of the laminate 1 after lamination and bonding so that the final laminate 1 is the appropriate size.

[0151] Example

[0152] The present invention will be described in detail below with examples, but the present invention is not limited to the following description.

[0153] <Measurement Methods>

[0154] [Thickness of the honeycomb structure sheet]

[0155] Using a coolant-resistant micrometer (Mitutoyo), the thickness of the honeycomb structure sheets at 20 different locations was measured, and the average value and standard deviation were calculated.

[0156] In addition, the 20 measurement sites were selected equally in a random and non-local manner.

[0157] [Clogging rate of cellular structured panels]

[0158] Visually observe the honeycomb structure sheets of each example and count the number of cells whose area is blocked by more than 1 / 3 of the cell opening.

[0159] The blockage rate is defined as the ratio of this number to 12,000 (an approximate number of all small chambers).

[0160] [Pressure loss of laminated structures]

[0161] The pressure loss of each example laminate was determined using a measuring device based on Japanese Industrial Standard JIS B8330, with a wind speed of 1.74 m / s.

[0162] <Honeycomb Structure>

[0163] For the honeycomb structures used in each example, the cellophane used will be made by Prince F-Tex PHN-50G (a glass nonwoven fabric made of glass fiber and pulp, with a unit area mass of 50g / m²). 2 Alternating layers of liner components (5mm pitch, 2mm height) and corrugated components (5mm pitch, 2mm height) were used to create a honeycomb structure with approximately 12,000 small cells, each 300mm high and 254mm (1 inch) square.

[0164] <Examples 1-5>

[0165] By using the slicer 100 described in the above embodiments and employing the method described in the above embodiments, the honeycomb structure described above is sliced ​​with the set thickness set as recorded in Table 1, thereby obtaining honeycomb structure sheets of each example. The slicing surface is a surface orthogonal to a direction through which a plurality of small cells penetrate, and is a surface along the horizontal direction.

[0166] The average thickness, standard deviation of thickness, number of blocked cells (after cutting), and blockage rate (after cutting) of the honeycomb structure sheets obtained for each example are shown in Table 1.

[0167] In addition, the honeycomb structure sheets obtained in each example were immersed in a liquid containing activated carbon, silica, organic acid, and acrylic resin with a viscosity of 12 seconds (Zeig Cup #2) and a solid content concentration of 35% by mass, containing functional materials. 3 After impregnation with a coating amount of 0.45g (dry coating amount is approximately 0.16g), it is dried using a blower dryer at 150°C for 30 minutes.

[0168] The number of blocked cells (after impregnation) and the blockage rate (after impregnation) of the honeycomb structure sheets of each example after impregnation are shown in Table 1.

[0169] [Table 1]

[0170]

[0171] <Comparative Examples 1-4>

[0172] Using a vertical cutting machine (Sakura Machinery Manufacturing), the honeycomb structure described above was sliced ​​with the set thickness set as described in Table 2, thereby obtaining honeycomb structure sheets for each example. The sliced ​​surface is a surface orthogonal to a direction through which many small cells penetrate, and is a surface along the vertical direction.

[0173] The average thickness, standard deviation of thickness, number of blocked cells (after cutting), and blockage rate (after cutting) of the honeycomb structure sheets obtained for each example are shown in Table 2.

[0174] In addition, the honeycomb structure sheets obtained in each example were immersed in a liquid containing activated carbon, silica, organic acid, and acrylic resin with a viscosity of 12 seconds (Zeig Cup #2) and a solid content concentration of 35% by mass, containing functional materials. 3 After impregnation with a coating amount of 0.45g (dry coating amount is approximately 0.16g), it is dried using a blower dryer at 150°C for 30 minutes.

[0175] The number of blocked cells (after impregnation) and the blockage rate (after impregnation) of the honeycomb structure sheets obtained after impregnation are shown in Table 2.

[0176] Furthermore, in Comparative Example 4, the sheet wobbled during cutting, making it impossible to manufacture the honeycomb structure sheet.

[0177] [Table 2]

[0178]

[0179] As shown in Table 1, the honeycomb structure sheets in the embodiments were all sliced ​​with a small standard deviation in thickness and with high processing precision. Furthermore, the clogging rate was low after cutting and impregnation. Additionally, the pressure loss of the laminates in the embodiments was low. Furthermore, as shown in Embodiment 5, it can be seen that even very thin honeycomb structure sheets with a thickness of 1 mm can be manufactured without problems.

[0180] In contrast, the honeycomb structure sheets in the comparative examples all exhibited larger standard deviations in thickness and lower processing precision. Furthermore, the clogging rate was higher after cutting, and further increased after impregnation. Additionally, the laminates in the comparative examples experienced greater pressure loss.

[0181] In addition, it is known that when the slice surface is set to the vertical direction, it is difficult to manufacture honeycomb structure sheets thinner than 3mm.

[0182] Explanation of reference numerals in the attached figures

[0183] 1. Laminated body; 2. Honeycomb structure sheet; 3. Cellular hole; 4. Sheet substrate; 5. Liner component; 6. Corrugated component; 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 ​​with a surface orthogonal to a certain direction to manufacture a honeycomb structure sheet in which the certain direction is the thickness direction, the honeycomb structure being formed by bonding multiple sheet substrates together, forming a plurality of small cells divided by the multiple sheet substrates and extending along the certain direction, the method for manufacturing the honeycomb structure sheet being characterized in that… With the honeycomb structure configured in a vertical orientation, the honeycomb structure is lowered from its top surface by an amount corresponding to the thickness of the honeycomb sheet, and the honeycomb structure is sliced ​​along a horizontal direction, thereby separating the honeycomb sheet from the remaining portion of the honeycomb structure.

2. The method for manufacturing a honeycomb structure sheet according to claim 1, wherein, The liquid containing the functional agent is also coated or impregnated onto the honeycomb structure sheet.

3. A method for manufacturing a laminated body, wherein, Multiple honeycomb structural sheets obtained by the manufacturing method of the honeycomb structural sheet according to claim 1 or 2 are stacked.

4. A honeycomb structure sheet, which is formed by bonding multiple sheet substrates together, creating a plurality of small cells that are divided by the multiple sheet substrates and extend along the thickness direction, wherein... The honeycomb structure sheet is obtained using the manufacturing method of the honeycomb structure sheet according to claim 1. The plurality of small chambers are formed in an area of ​​2,000 to 15,000 per 254 mm square. The thickness of the honeycomb structure sheet is 1mm to 20mm. The proportion of the numerous small chambers whose area is more than 1 / 3 blocked is less than 0.1%.

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

6. A layered body, wherein, The laminate is formed by stacking multiple honeycomb structure sheets as described in claim 4 or 5.

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