JP6448394B2 - Manufacturing method of honeycomb structure - Google Patents

Description

The present invention relates to the production how the honeycomb structure. More specifically, in a segment type honeycomb structure, there is no restriction on the position of a sensor such as a thermocouple for measuring the temperature of the joint, and any shape of the joint surface of the honeycomb segment can be used. installation of the sensor is possible, relates to the production how the honeycomb structure.

  Exhaust gas emitted from engines such as automobiles contains harmful particulate matter (also called “particulate matter” or “PM”). Is required to be collected. As a filter for collecting the particulate matter (“diesel particulate filter” or “DPF”), a ceramic honeycomb structure is incorporated in an exhaust gas system of a diesel engine.

  Such a honeycomb structure includes a segment type honeycomb structure in which a plurality of honeycomb segments are bonded with a bonding material. To design the honeycomb structure, set usage standards, and calculate the thermal stress of each part of the honeycomb structure, the temperature inside the honeycomb structure, especially the temperature at the joint, is determined by the thermocouple. There is a need to. In the fluid flow path of the honeycomb structure, the arrangement of the sensor is relatively easy, but the arrangement at the joint is difficult. Therefore, it was only possible to indirectly estimate the temperature of the joint from the temperature in the vicinity of the joint. Accordingly, there has been a strong demand for the development of a technology that can measure the temperature of the joint with high accuracy.

  Conventionally, in the measurement of the joint temperature of a segment type honeycomb structure, a long hole having a length of about 1 mm is formed in the joint by using a tool such as a drill in order to place a thermocouple at the joint of a plurality of honeycomb segments. And a thermocouple was inserted into the hole. In drilling with such a drill, it is necessary to form a straight hole, so that there are restrictions on the measurement position and it is difficult to confirm whether the actual drilling position is a desired position. In addition, when drilling, only a large hole having a diameter of 1 mm or more could be drilled. For example, when using a thin thermocouple such as 0.3 mm or 0.5 mm, the gap between the thermocouple and the hole There was a disadvantage that became larger. If the gap is large as described above, accurate temperature measurement cannot be performed. Conventionally, it has been necessary to fill the gap with a ceramic material or the like.

  In addition, it is difficult to make a long and narrow hole in a thin joint portion because there is a high possibility of damage to the joint portion or a tool for processing the joint portion. In particular, segment type honeycomb structures use hard ceramics such as silicon carbide, silicon nitride, cordierite, alumina, and mullite as joints, so that the drill blade is easily broken during processing, and there is a problem in terms of cost. there were. Further, the depth of the hole that can be opened is limited to about 40 mm. Furthermore, it was necessary to prepare an extra honeycomb segment in consideration of failure of drilling and damage to the honeycomb structure.

  Further, as described in Patent Document 1, when the joint surfaces of adjacent honeycomb segments have a curvature, or when the segments are shifted up and down, left and right, further described in Patent Document 2 As shown in the figure, when adjacent honeycomb segments have warpage, it is necessary to make a curved hole, which is substantially impossible by a method using a conventional drill.

JP 2007-260530 A International Publication No. 2005/047210 JP 2004-262670 A

The present invention has been made to solve such problems of the prior art. The problem is that in a segment type honeycomb structure, the honeycomb segment can be set easily and accurately without any restriction on the setting position of the sensor joint, regardless of the shape of the honeycomb segment. It is to provide a manufacturing how the structure.

According to the present invention, described below, producing how honeycomb structure is provided.

[1] A step of preparing a plurality of honeycomb segments for partitioning a plurality of cells extending from an inflow end surface to an outflow end surface serving as a fluid flow path, and a step of preparing an elongated core having a larger diameter than a sensor to be inserted And applying a bonding material to the bonding surfaces of the plurality of honeycomb segments to form a bonded portion, one end of the core is at a desired position, and the other end of the core is a honeycomb segment. A honeycomb structure including: a step of installing at least one of the cores so as to communicate with the outside; and a step of forming an elongated hole for inserting a sensor by removing the core from the joint portion. Manufacturing method.

[2] The method for manufacturing a honeycomb structured body according to [1], wherein the core has a linear shape.

[3] The method for manufacturing a honeycomb structure according to [1], wherein the core has a curved shape including at least one curved portion.

[4] The method for manufacturing a honeycomb structured body according to [3], wherein a curvature radius of the curved portion is 2 mm or more and 5 times or more of a sensor outer diameter.

[5] The method for manufacturing a honeycomb structured body according to any one of [1] to [4], wherein the core is formed of a thermoplastic material, a combustible material, or a metal material.

[6] In the step of forming the elongated hole for inserting the sensor, the core is removed by melting and / or burning by heating the core. The manufacturing method of the honeycomb structure in any one.

[7] The method according to any one of [1] to [5], wherein in the step of forming the elongated hole for inserting the sensor, the core is removed by pulling out the joint before or after heating and drying. Method for manufacturing the honeycomb structure.

[8] One end of the core is disposed so as to be concentrated from at least one of the outflow end surface and the side surface of the honeycomb structure obtained by joining the honeycomb segments and communicate with the outside of the honeycomb segment. The method for manufacturing a honeycomb structure according to any one of [1] to [7].

[9] The manufacturing of the honeycomb structure according to any one of [1] to [8], wherein the hole portion having a linear distance from the opening of the hole portion to the stop position of the hole portion is at least 50 mm. Method.

[10] The method for manufacturing a honeycomb structured body according to any one of [1] to [9], further including a step of inserting the sensor into the hole.

[11] The method for manufacturing a honeycomb structure according to any one of [1] to [10], wherein a difference between a diameter of the hole and an outer diameter of the sensor is 0.02 mm to 1.5 mm.

[12] The method for manufacturing a honeycomb structured body according to any one of [1] to [11], wherein the sensor is a temperature measurement sensor.

  In the manufacturing method of the honeycomb structure of the present invention, a hole for inserting a sensor is formed in a joined portion of the honeycomb segment by using a removable core during joining of the plurality of honeycomb segments or after joining. There is no restriction | limiting in the formation position of a hole part. Therefore, the sensor can be easily installed even at a location separated from the outflow end face of the honeycomb structure by, for example, 50 mm or more, which was impossible in the past. In addition, the measurement position by the sensor (the tip position of the sensor) and the sensor drawing position from the honeycomb structure can be freely set in both the axial direction and the radial direction of the honeycomb structure. In addition, since the position of the hole can be set accurately, the measurement position by the sensor (for example, in the case of temperature measurement, the tip position of the thermocouple which is a temperature sensor) can be accurately grasped.

  In addition, by using a curved core, it is possible to form a curved hole, which has been impossible in the past, so when the joint surfaces of adjacent honeycomb segments have a curvature, The sensor can be easily installed even when the segments are displaced in the vertical and horizontal directions, and even when the adjacent honeycomb segments have warpage. That is, according to the present invention, the sensor can be installed regardless of the shape of the joint surface of the honeycomb segment. Moreover, even when the bonding surfaces of adjacent honeycomb segments have no curvature, it is possible to prevent the sensor from coming off by adopting a curved hole.

  In addition, by using a core with a small diameter, accurate temperature measurement is possible even when a thin sensor having a diameter of 0.3 to 0.5 mm, for example, which has been impossible in the past is used. It was.

FIG. 3 is a perspective view of the honeycomb structure manufactured according to the first embodiment of the manufacturing method of the present invention from the inflow end surface side, and schematically shows the position of the sensor installed in the joint from the inflow end surface side. It is a schematic diagram. It is sectional drawing along the A-A 'line | wire of the honeycomb structure of FIG. 1A. It is the figure which saw through the honeycomb structure manufactured according to 2nd embodiment of the manufacturing method of this invention from the inflow end surface side, Comprising: The position of the sensor installed in the junction part was shown typically from the said inflow end surface side It is a schematic diagram. It is the figure which saw through the honeycomb structure of Drawing 2A from the side, and is the mimetic diagram showing typically the position of the sensor installed in the joined part from the side. It is the figure which saw through the honeycomb structure manufactured according to 3rd embodiment of the manufacturing method of the present invention from the inflow end face side, and showed the position of the sensor installed in the joined part from the inflow end face side typically It is a schematic diagram. It is the figure which saw through the honeycomb structure of Drawing 3A from the side, and is the mimetic diagram showing typically the position of the sensor installed in the joined part from the side. FIG. 7 is a perspective view of a honeycomb structure manufactured according to the fourth embodiment of the manufacturing method of the present invention from the inflow end surface side, and schematically shows the position of the sensor installed in the joint from the inflow end surface side. It is a schematic diagram. It is the figure which saw through the honeycomb structure of Drawing 4A from the side, and is the mimetic diagram showing typically the position of the sensor installed in the joined part from the side. It is the perspective view which showed typically the process A of the manufacturing method of this invention. It is the perspective view which showed typically the process C of the manufacturing method of this invention. It is the perspective view which showed typically the process C of the manufacturing method of this invention. It is the figure which showed typically the process D of the manufacturing method of this invention, and is the perspective view which showed typically the honeycomb structure after removing a core. It is the figure which saw through the enlarged part of the outflow end surface of the honeycomb structure manufactured according to 1st embodiment from the said outflow end surface, Comprising: It is the schematic diagram of the hole part for sensor insertion formed after the core was removed.

  Embodiments of the present invention will be described below. The present invention is not limited to the following embodiments, and appropriate modifications, improvements, etc., to the following embodiments are made based on the ordinary knowledge of those skilled in the art without departing from the spirit of the present invention. It should be understood that the addition of is also within the scope of the present invention.

(1) First Embodiment of Honeycomb Structure Manufacturing Method FIG. 1A shows a honeycomb structure 100 manufactured according to the first embodiment of the honeycomb structure manufacturing method of the present invention from the inflow end face side. It is the figure seen through, Comprising: The schematic diagram which showed typically the position of the sensor 16 installed in junction part 13 'from the said inflow end surface side is shown. FIG. 1B shows a cross-sectional view along AA ′ of FIG. 1A. Hereinafter, the first embodiment of the manufacturing method of the honeycomb structure may be simply referred to as “the manufacturing method of the first embodiment”. The honeycomb structure 100 is obtained by bonding a plurality of honeycomb segments 10 with a bonding material 13.

  The manufacturing method according to the first embodiment includes the following steps A to D. Step A is a step of preparing a plurality of honeycomb segments that partition and form a plurality of cells extending from the inflow end surface to the outflow end surface serving as a fluid flow path. Step B is a step of preparing an elongated core 11 having a larger diameter than the sensor 16 to be inserted. In the step C, when the bonding material 13 is applied to the bonding surfaces 12 of the plurality of honeycomb segments to form the bonding portion 13 ′, one end of the core 11 is placed at a desired position, and the core 11 This is a step of installing at least one core 11 such that one end communicates with the outside of the honeycomb segment. Step D is a step of forming the elongated hole portion 14 for inserting a sensor by removing the core 11 from the joint portion 13 ′. In addition, a conventionally well-known method can be used about the joining method of the honeycomb segment other than the said process AD based on this invention. Below, the said process AD is demonstrated in detail, referring FIG. 5A-FIG. 5E. Here, FIG. 5A is a perspective view schematically showing step A of the manufacturing method of the present invention. FIG. 5B is a perspective view schematically showing Step C of the manufacturing method of the present invention. FIG. 5C is a perspective view schematically showing step C of the manufacturing method of the present invention. FIG. 5D is a diagram schematically showing step D of the manufacturing method of the present invention, and is a perspective view schematically showing the honeycomb structure after the core is removed.

(Process A)
Step A is a step of preparing a plurality of honeycomb segments 10 for partitioning and forming a plurality of cells 17 (see FIG. 5A) extending from the inflow end surface to the outflow end surface serving as a fluid flow path. There is no restriction | limiting in particular about the method of producing the honeycomb segment 10, A conventionally well-known method can be used. In this embodiment, as shown in FIG. 1A and FIG. 1B, the rectangular pillar honeycomb segment 10 is used. However, in the present invention, the shape of the honeycomb segment 10 used is not limited. For example, the bonding surface 12 of the adjacent honeycomb segment 10 at the time of bonding may have a curvature or a warp. Further, the present invention is not limited to a rectangular honeycomb segment, and may be a triangular prism, a hexagonal prism, other polygons, a cylinder, or a combination of a triangular prism and a hexagonal prism.

  Moreover, there is no restriction | limiting in particular also about the material of the honeycomb segment 10, A conventionally well-known material can be used. As the material of the honeycomb segment 10, from the viewpoint of strength and heat resistance, silicon carbide, silicon-silicon carbide based composite material, silicon nitride, cordierite, mullite, alumina, spinel, silicon carbide cordierite based composite material, silicon- It is preferable to use at least one selected from the group consisting of a silicon carbide composite material, lithium aluminum silicate, aluminum titanate, zeolite, and Fe—Cr—Al-based metal.

  The honeycomb segment 10 is prepared by, for example, adding a binder such as methyl cellulose, hydroxypropoxyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and polyvinyl alcohol, a surfactant, water as a solvent, and the like to those appropriately selected from the above materials. Then, a plastic clay is formed, and the clay is extruded so as to have the shape described above. Subsequently, after drying by a microwave, a hot air, etc., it can carry out by baking. The honeycomb segment 10 may be a fired body obtained by drying and firing the shaped body obtained by extruding the kneaded clay, a dried body before firing, or a shaped body before drying.

(Process B)
Step B is a step of preparing an elongated core 11 having a larger diameter than the sensor 16 to be inserted. The core 11 is given the reference numeral 11 in FIG. 5C. The diameter of the core 11 may be slightly larger than the diameter of the sensor 16, but if the gap between the diameter of the hole formed after the core 11 is removed and the diameter of the sensor 16 is too small, the sensor 16 is inserted. Unfortunately, if the gap is too large, it is necessary to fill the gap with a large amount of ceramic material or the like. Therefore, the gap is preferably about 0.02 mm to 1.5 mm. Depending on the material of the core 11 to be used, when it expands or contracts at the time of heating and drying, the gap finally obtained is about 0.02 mm to 1.5 mm. The diameter of the core 11 may be adjusted. Further, the length of the core 11 is not particularly limited, but is longer than the distance from the measurement position 18 (stop position of the hole) of the sensor to the insertion opening (opening of the hole) of the sensor 16. Is preferred. When the core is curved, the length of the core can be appropriately set according to the curvature of the core. In the present invention, by using a core having a length such that the linear distance from the opening of the hole portion to the stop position of the hole portion is 50 mm or more, a long hole portion that is difficult to form by the conventional manufacturing method is used. Can be formed.

  Examples of the material of the core 11 to be used include, but are not limited to, a thermoplastic material such as a wax material and a resin, a combustible material such as a cotton thread, or a metal. Any material that can be removed from the joint 13 'during or after joining the honeycomb segments can be used in the present invention. Further, these various materials may be used alone or in combination.

  When a wax material is used as the core 11, the wax material may be processed into a rod shape and used as a linear core, or may be curved according to the installation position of the sensor 16 or the like.

  When resin is used as the core 11, for example, a straw, a straw with bellows, a vinyl pipe, a resin-coated electric wire, and an elongated rubber balloon are preferable. The resin-coated electric wire may have a metal in its core.

  When a metal is used as the core 11, a rod or pipe made of iron, aluminum, copper, stainless steel or the like is preferable. Moreover, you may use the solder which has tin as a main component.

  The cross-sectional shape of the core 11 is not particularly limited as long as the sensor 16 can be inserted, and examples thereof include a polygon such as a quadrangle, a circle, and an ellipse. In the process D described later, when the hole 14 is formed in the bonding material 13 by pulling out the core 11 from the relatively soft bonding material 13 before drying, the cross-sectional shape of the core 11 is circular. Preferably there is. Further, in Step D described later, when the core 11 is removed from the bonding material 13 by melting or burning, the size of the cross section of the core 11 changes in the longitudinal direction of the core 11. May be. For example, the core 11 may be configured such that the size of the cross section increases or decreases between the stop position of the hole and the opening of the hole. Further, the core 11 may be such that its cross section increases at the measurement position 18 (the stop position of the hole). The hole formed from the core 11 having such a shape is difficult to form by processing with a conventional tool such as a drill.

  As the sensor 16 to be inserted, a sheathed thermocouple can be considered in the manufacturing method of the first embodiment, but various types of conventionally known thermocouples can be used depending on the application. Although the diameter of the sensor 16 should just be smaller than the thickness of joining part 13 ', Preferably it is 0.1 mm-1.5 mm. The sensors to be inserted include, in addition to thermocouples, acceleration sensors, strain gauges, gas velocimeters, and gas analyzer sampling tubes.

(Process C)
In the step C, when the bonding material 13 is applied to the bonding surfaces 12 of the plurality of honeycomb segments 10 to form the bonding portion 13 ′, one end of the core 11 is placed at a desired position, and the core 11 This is a step of installing at least one core 11 so that the other end communicates with the outside of the honeycomb segment 10. As the bonding material 13, a ceramic material kneaded with a solvent such as water can be used. Examples of the ceramic material include cordierite, silicon carbide, silicon-silicon carbide based composite material, mullite, alumina, aluminum titanate, zeolite, silicon nitride, and silicon carbide-cordierite based composite material. The desired position may be the measurement position 18 by the sensor 16.

  The core 11 is preferably embedded in the bonding material 13 when the bonding material 13 is applied to the bonding surface 12 of the honeycomb segment 10 to form the bonding portion 13 ′. An example of the method for embedding the core 11 in the bonding material 13 is shown in FIGS. 5B to 5C. For example, as shown in FIG. 5B, first, the bonding material 13 is applied to the bonding surface 12. Next, as shown in FIG. 5C, the core 11 is installed, the bonding material 13 is again applied thereon, another honeycomb segment 10 is assembled, and a similar process is performed until a desired honeycomb structure 100 is obtained. repeat. However, this is only an example, and there is no particular limitation as long as the core 11 can be installed at a desired position in the joint portion 13 ′. For example, in this embodiment, the bonding material 13 is applied again from above the installed core 11, but the honeycomb segment 10 to which the bonding material 13 has already been applied may be assembled on the core 11. Alternatively, the core 11 may be installed on the bonding surface 12, the bonding material 13 may be applied thereon, and another honeycomb segment 10 may be assembled.

  In the manufacturing method of the first embodiment, as shown in FIGS. 1A and 1B, the positions (1, 2, 3, 4) in the joint portion 13 ′ where the corners of the honeycomb segments 10 face each other, and the honeycomb The purpose is to arrange the sensor 16 at the position (5) in the joint portion 13 'facing the side portions of the segments 10. For this reason, five curved cores 11 are prepared, and one end of each core 11 is installed at the positions 1 to 5, and the other end of the core 11 joins the honeycomb segment 10. The honeycomb structure 100 is installed so as to communicate with the outside of the honeycomb structure 100 at approximately one position α1 in the outflow end face of the honeycomb structure 100 obtained in this manner. Thus, on the outflow end face, the position where the core 11 communicates with the outside of the honeycomb segment 10 is the insertion port (1 ′, 1 ′, sensor 16) corresponding to the sensor 16 (1, 2, 3, 4, 5). 2 ′, 3 ′, 4 ′, 5 ′). Here, the insertion openings (1 ', 2', 3 ', 4', 5 ') of the sensor 16 are intensively formed at the one location α1, as shown in FIG. 5E. Such a configuration has an advantage of facilitating the handling of the wiring after the sensor 16 is finally inserted, the replacement of the sensor 16, and the like.

(Process D)
Step D is a step of forming the elongated hole portion 14 for sensor insertion by removing the core 11 from the joint portion 13 ′. The bonding portion 13 ′ may be formed by removing moisture from the bonding material 13 or by heating and drying. The method for removing the core 11 differs depending on the material of the core 11 used.

  When a wax material is used as the core 11, the wax material dissolves and flows out of the honeycomb structure 100 when the joint 13 'is heated and dried (about 100 ° C.), and therefore can be easily removed. In addition, it is also possible to remove the said core 11 by pulling out before heat drying.

  When the resin is used as the core 11, the temperature is raised after drying by heating, so that the resin is dissolved and discharged, or the temperature is further increased to burn the core 11, or the resin is drawn before or after the heating and drying. Therefore, it can be easily removed.

When a high melting point metal such as iron, aluminum, copper, or stainless steel is used as the core 11, it can be pulled out before the joint 13 ′ (joining material 13) is heat-dried, but the joint material 13 is pulled out after the heat-drying. It is preferable. Pulling out the metal core 11 after heating and drying has the advantage that the hole 14 is less likely to be damaged by the metal core 11 when being pulled out. The refractory metal means a metal that does not melt at the heating and drying temperature of the bonding material 13, that is, has a melting point higher than the heating and drying temperature.

On the other hand, when a low-melting-point metal such as solder is used as the core 11, it can be easily removed by dissolving and flowing out at the time of heating and drying like other thermoplastic materials (for example, wax). . In addition to melting by heating, the core 11 can be removed by pulling out before heating and drying. The low melting point metal means a metal that melts at the heating and drying temperature of the bonding material 13, that is, has a melting point equal to or lower than the heating and drying temperature.

  FIG. 5E is a schematic view of an enlarged portion of the outflow end surface of the honeycomb structure 100 manufactured according to the manufacturing method of the first embodiment as seen through from the outflow end surface. FIG. 5E schematically shows a sensor insertion hole 14 formed after the core 11 is removed. As already described, the hole 14 is formed in the shape of a blind hole in the portion from which the core 11 is removed, and the opening of the hole 14 corresponds to the insertion port (1 ′, 2 ′, 3) of the sensor 16, respectively. '4', 5 ').

  A sensor 16 such as a temperature sensor such as a desired thermocouple or a strain sensor such as a strain gauge is inserted into the insertion port (1 ′, 2 ′, 3 ′, 4 ′, 5 ′) of the sensor 16 of FIG. 5E. Is possible. In order to improve measurement accuracy, the gap is preferably filled with the same material as the bonding material 13. In this case, before the sensor 16 is inserted, water or the like may be added to the bonding material 13 to reduce the viscosity, and the sensor 16 may be inserted after that.

  In addition to these steps, various processes such as firing are actually performed in the manufacture of the honeycomb structure 100, but these can be omitted here because conventionally known methods can be used.

(2) Second Embodiment of Manufacturing Method of Honeycomb Structure FIG. 2A is a schematic view of the honeycomb structure manufactured according to the second embodiment of the manufacturing method of the honeycomb structure according to the present invention as seen through from the inflow end face side. FIG. FIG. 2A schematically shows the position of the sensor 16 installed in the joint 13 ′ from the inflow end face side. FIG. 2B is a schematic view of the honeycomb structure of FIG. 2A seen through from the side. In FIG. 2B, the position of the sensor 16 installed in the joint 13 ′ is schematically shown from the side. Hereinafter, the second embodiment of the manufacturing method of the honeycomb structure may be simply referred to as “the manufacturing method of the second embodiment”.

  The manufacturing method of the second embodiment includes substantially the same steps as the manufacturing method of the first embodiment. However, the arrangement of the core 11 in the process C is different from the manufacturing method of the first embodiment.

  As shown in FIG. 2A, in the manufacturing method of the second embodiment, the sensor insertion hole 14 is formed on each of the A surface, the B surface, and the C surface. The core 11 is installed. In this way, the measurement position (for example, in the case of temperature measurement, the tip position of the thermocouple that is a temperature sensor or the temperature measurement position) can be freely set. In this case, the curved core 11 is used for the installation position (1 to 7) of the sensor 16, and the linear core 11 is used for the installation position (8, 9) of the sensor 16. In this way, the cores 11 having various shapes can be used in combination.

  Further, in the manufacturing method of the second embodiment, the insertion ports for the sensor 16 are formed almost intensively at approximately two locations α2 and β2 on the outflow end surface of the honeycomb structure 200 obtained by joining the honeycomb segments 10. . At this time, with respect to the installation position (1 to 3) of the sensor 16 close to the first location α2, an insertion port for the sensor 16 is provided at the first location α2. About the installation position (4-9) of the sensor 16 close to the 2nd location (beta) 2, the insertion port of the sensor 16 is provided in said 2nd location (beta) 2. When the sensor insertion hole 14 is formed in such a configuration, there is an advantage that the insertion length of the sensor 16 into the honeycomb structure 200 can be shortened.

(3) Third Embodiment of Honeycomb Structure Manufacturing Method FIG. 3A is a schematic view of a honeycomb structure 300 manufactured according to the third embodiment of the manufacturing method of the present invention as seen through from the inflow end face side. FIG. 3A schematically shows the position of the sensor 16 installed in the joint 13 ′ from the inflow end face side. FIG. 3B is a schematic view of the honeycomb structure 300 of FIG. 3A seen through from the side. In FIG. 3B, the position of the sensor 16 installed in the joint portion 13 ′ is schematically shown from the side. Hereinafter, the third embodiment of the method for manufacturing the honeycomb structure 300 may be simply referred to as “the manufacturing method of the third embodiment”.

  The manufacturing method of the third embodiment includes substantially the same steps as the manufacturing method of the first embodiment and the manufacturing method of the second embodiment. However, the arrangement of the core 11 in the process C is different from any of the embodiments.

  As shown in FIG. 3A, in the manufacturing method of the third embodiment, the insertion opening of the sensor 16 is not limited to the location (δ3) of the outflow end surface of the honeycomb structure 300, but the location of the side surface (α3, β3, γ3). Also provided. In this manufacturing method, either a curved or linear core 11 may be used. Such a configuration has an advantage that the insertion length of the sensor 16 into the honeycomb structure 300 can be shortened, and is suitable for manufacturing a honeycomb structure in which the wiring of the sensor 16 is desired to be taken out from the side surface.

(4) Fourth Embodiment of Manufacturing Method of Honeycomb Structure FIG. 4A is a schematic view of a honeycomb structure 400 manufactured according to the fourth embodiment of the manufacturing method of the present invention as seen through from the inflow end face side. FIG. 4A schematically shows the position of the sensor 16 installed in the joint portion 13 ′ from the inflow end face side. FIG. 4B is a schematic view of the honeycomb structure 400 of FIG. 4A seen through from the side. FIG. 4B schematically shows the position of the sensor 16 installed in the joint 13 ′ from the side. Hereinafter, the fourth embodiment of the manufacturing method of the honeycomb structure 400 may be simply referred to as “the manufacturing method of the fourth embodiment”.

  The manufacturing method of the fourth embodiment is characterized by the shape of the curved core 11. Therefore, the manufacturing method of the fourth embodiment can be combined with any of the first to third embodiments.

  In the manufacturing method of the fourth embodiment, the sensor insertion hole 14 is formed using the curved core 11. It is considered that the sensor 16 is less likely to come off when the sensor insertion hole 14 is curved than when the sensor insertion hole 14 is linear, but the sensor 16 may still fall out. In such a case, preferably, as shown in FIG. 4B, the sensor 16 is not easily removed by forming two or more curved portions 15.

  Similarly, as shown in FIG. 4B, when the radius of curvature of the bending portion 15 is 2 mm or more and 5 times or more of the sensor outer diameter, the sensor 16 can be easily inserted and the sensor 16 is not easily broken. This is preferable because of the advantageous effect.

  In the present embodiment, the honeycomb structure having a rectangular outer peripheral shape is exemplified, but the present invention is not limited to this. The present invention can be applied to a method for manufacturing a honeycomb structure having any outer peripheral shape, which is known for segment-type honeycomb structures. For example, a joined body may be manufactured by joining a plurality of honeycomb segments, and the outer peripheral portion of the obtained joined body may be ground into a predetermined shape such as a polygon such as a circle, an ellipse, or a triangle. Moreover, when forming an outer peripheral wall in the outer peripheral part of the joined body, an outer peripheral coating material is applied to the outer peripheral surface of the obtained joined body or the ground joined body, for example, with an arbitrary thickness of 0.1 mm to 10 mm May be applied to form an outer peripheral wall.

  Constituent elements having the same meaning with respect to the reference numerals in the drawings are given the same reference numerals.

Example 1
As shown in FIG. 5A, 24 square pillar-shaped honeycomb segments with a = 50 mm, b = 50 mm, and c = 300 mm were prepared. For the honeycomb segment, a pore forming material, a binder, a surfactant, and water are added to a ceramic raw material in which 80 parts by mass of SiC powder and 20 parts by mass of metal Si powder are mixed to produce a forming raw material and kneaded. The clay thus obtained was extruded by using a die for forming a honeycomb molded body, dried by heating, and sintered. The partition wall thickness was 100 μm, and the number of cells (cell density) was 65 / cm ² .

  Five cylindrical cores having a length of 400 mm and a diameter of 0.17 mm were made of wax.

  A silica fiber, an organic binder and water were added to the alumina powder and kneaded to prepare a paste-like bonding material. Next, the obtained bonding material was applied to the side surfaces of the honeycomb segments so as to have a thickness of 1 mm, and the six honeycomb segments were bonded in a horizontal row. Next, the bonding material was further applied to the surface on which the cores of the bonded honeycomb segments were installed so that the thickness was 0.5 mm.

  Next, the previously prepared five cores were placed on the bonding material applied to the surface on which the cores were installed. Specifically, after one end of the core was installed at each of the sensor installation positions 1 to 5 corresponding to the temperature measurement position, the other end of the core was joined in the horizontal row. Of the six honeycomb segments, the other end of the core protruded by 1 mm or more from the outflow end of the outermost honeycomb segment. If the protruding length is too long, it may be removed by cutting or the like. The linear distance from the temperature measurement position to the core drawing position was 295 mm for installation position 1, 250 mm for installation position 2, 200 mm for installation position 3, 80 mm for installation position 4, and 50 mm for installation position 5. . The actual distance from the temperature measurement position to the core drawing position was 395 mm for installation position 1, 370 mm for installation position 2, 300 mm for installation position 3, 150 mm for installation position 4, and 100 mm for installation position 5.

  After the core was installed in the bonding material, the bonding material was again applied with a thickness of 0.5 mm, and the honeycomb segments were arranged from above to obtain a bonded honeycomb segment assembly. Furthermore, six honeycomb segments were stacked in two layers with the bonding material interposed therebetween to obtain a 6 × 4 honeycomb segment bonded body.

  The obtained honeycomb segment bonded body was heated and dried at 120 ° C. for 1 hour so that the core drawing position was down, and a honeycomb structure in which 24 honeycomb segments were bonded via the bonded portion was obtained. Obtained. At the same time, the core melted and flowed out of the bonding material and removed. Needless to say, the core may be burned and removed at a higher temperature. In the obtained honeycomb structure, a hole was formed in a portion where the core flowed out and removed. A sheath thermocouple (K thermocouple) of a stainless steel (SUS316) protective tube having an outer diameter of 0.15 mm was inserted into the hole. Before inserting the thermocouple, the bonding material diluted 1.5 times with water and made into a slurry was poured into the hole.

  A propane combustion gas at 400 ° C. was passed through the honeycomb structure in which the thermocouple was inserted, and the temperature at the position where each thermocouple was installed was measured using the thermocouple. As a result, it was possible to measure the temperature of the joint part 50 mm or more away from the thermocouple insertion port, which could not be measured by the conventional method.

(Example 2)
A honeycomb segment was prepared in the same manner as in Example 1. As the core, a wire rod made of stainless steel (SUS304) having a diameter of 0.55 mm was used. The bonding material was applied with a thickness of 1 mm, and the core was pushed into the bonding material and installed. After drying the 6 × 4-stage joined honeycomb segment assembly, the core was pulled out from the obtained honeycomb structure to obtain a hole. When the core is pulled out, it can be easily pulled out by pulling, pushing, rotating, or applying vibration to the core. When the core is installed, it is easy to pull out the core by applying edible oil such as olive oil, fat or butter to the surface of the core. A sheath thermocouple (K thermocouple) of an outer diameter 0.5 mm, stainless steel (SUS316) protective tube was inserted into the hole.

  A propane combustion gas at 600 ° C. was passed through the honeycomb structure in which the thermocouple was inserted, and the temperature at the position where each thermocouple was installed was measured using the thermocouple. As a result, it was possible to measure the temperature of the joint part 50 mm or more away from the thermocouple insertion port, which could not be measured by the conventional method.

  The production method of the present invention is a method of producing a honeycomb structure that can be used as a filter or catalyst carrier for purifying exhaust gas discharged from an automobile or the like.

1-9: Sensor installation position (hole stop position), 1′-9 ′: Sensor insertion port (hole opening), 10: Honeycomb segment, 11: Core, 12: Joining surface, 13: Joining Material: 13 ': Joint part, 14: Hole part, 15: Curved part, 16: Sensor, 17: Cell, 18: Measurement position by sensor, α1, α2, β2, α3, β3, γ3, δ3: Sensor insertion port Location, 100, 200, 300, 400: honeycomb structure.

Claims (12)

Preparing a plurality of honeycomb segments for partitioning a plurality of cells extending from an inflow end surface to an outflow end surface to be a fluid flow path;
Providing an elongated core having a larger diameter than the sensor to be inserted;
When a bonding material is applied to the bonding surfaces of the plurality of honeycomb segments to form a bonded portion, one end of the core is placed at a desired position, and the other end of the core is placed outside the honeycomb segment. Installing at least one of the cores so as to communicate;
Forming an elongated hole for sensor insertion by removing the core from the joint; and
A method for manufacturing a honeycomb structure, comprising:   The method for manufacturing a honeycomb structured body according to claim 1, wherein the core has a linear shape.   The method for manufacturing a honeycomb structured body according to claim 1, wherein the core has a curved shape including at least one curved portion.   The manufacturing method of the honeycomb structure according to claim 3, wherein a curvature radius of the curved portion is 2 mm or more and 5 times or more of a sensor outer diameter.   The method for manufacturing a honeycomb structured body according to any one of claims 1 to 4, wherein the core is formed of a thermoplastic material, a combustible material, or a metal material.   6. The method according to claim 1, wherein in the step of forming the elongated hole for inserting the sensor, the core is removed by melting and / or burning by heating the core. The manufacturing method of the honeycomb structure as described.   The honeycomb structure according to any one of claims 1 to 5, wherein in the step of forming the elongated hole portion for inserting the sensor, the core is removed by pulling out the joint portion before or after heat drying. Body manufacturing method.   The one end of the core is disposed so as to be concentrated from at least one of the outflow end surface and the side surface of the honeycomb structure obtained by joining the honeycomb segments and communicate with the outside of the honeycomb segment. The manufacturing method of the honeycomb structure as described in any one of -7.   The method for manufacturing a honeycomb structured body according to any one of claims 1 to 8, wherein the hole portion having a linear distance from an opening of the hole portion to a stop position of the hole portion is at least 50 mm.   The method for manufacturing a honeycomb structured body according to any one of claims 1 to 9, further comprising a step of inserting the sensor into the hole.   The method for manufacturing a honeycomb structured body according to any one of claims 1 to 10, wherein a difference between a diameter of the hole and an outer diameter of the sensor is 0.02 mm to 1.5 mm.   The method for manufacturing a honeycomb structured body according to any one of claims 1 to 11, wherein the sensor is a temperature measuring sensor.

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