JP2006281039A - Manufacturing method of ceramic honeycomb structure - Google Patents

Manufacturing method of ceramic honeycomb structure Download PDF

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JP2006281039A
JP2006281039A JP2005101978A JP2005101978A JP2006281039A JP 2006281039 A JP2006281039 A JP 2006281039A JP 2005101978 A JP2005101978 A JP 2005101978A JP 2005101978 A JP2005101978 A JP 2005101978A JP 2006281039 A JP2006281039 A JP 2006281039A
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honeycomb structure
ceramic honeycomb
face
cup
shaped grindstone
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JP4632125B2 (en
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Shunji Okazaki
俊二 岡崎
Yasuhiko Otsubo
靖彦 大坪
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Proterial Ltd
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Hitachi Metals Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
    • B24B19/22—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B7/00—Machines or devices designed for grinding plane surfaces on work, including polishing plane glass surfaces; Accessories therefor
    • B24B7/10—Single-purpose machines or devices
    • B24B7/16—Single-purpose machines or devices for grinding end-faces, e.g. of gauges, rollers, nuts, piston rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B7/00—Machines or devices designed for grinding plane surfaces on work, including polishing plane glass surfaces; Accessories therefor
    • B24B7/20—Machines or devices designed for grinding plane surfaces on work, including polishing plane glass surfaces; Accessories therefor characterised by a special design with respect to properties of the material of non-metallic articles to be ground
    • B24B7/22—Machines or devices designed for grinding plane surfaces on work, including polishing plane glass surfaces; Accessories therefor characterised by a special design with respect to properties of the material of non-metallic articles to be ground for grinding inorganic material, e.g. stone, ceramics, porcelain
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Filtering Materials (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a ceramic honeycomb structure controlling occurrence of breaking of partitions in processing the end face of the ceramic honeycomb structure and requiring less time for processing of the end face. <P>SOLUTION: In the method of manufacturing a ceramic honeycomb structure having a large number of cells formed with porous partitions, the end face of the structure is ground with a cup-like grindstone so that the end face of the grindstone becomes nearly in parallel with that of the structure. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は、セラミックハニカム構造体の製造方法に関する。   The present invention relates to a method for manufacturing a ceramic honeycomb structure.

ディーゼルエンジンなどの排気ガス中には炭素を主体とするＰＭ（微粒子状物質）が多量に含まれており、これが大気中に放出されると、人体や環境に悪影響を与える。このため、ディーゼルエンジンなどの排気系部品には、ＰＭを捕集するためのフィルタが搭載されている。図４は、自動車の排気ガス中のＰＭを捕集、浄化するフィルタに用いられるハニカム構造体の一例を示したものであり、（ａ）は正面模式図、（ｂ）は側断面模式図である。図４（ａ）（ｂ）において、ハニカム構造体３０は、多孔質セラミックからなり、外周壁１と、この外周壁１の内側に各々直交する隔壁２で仕切られた複数のセル３、４を有しており、セル３、４は、排気ガスの流入側端面７と流出側端面８において交互に封止部５、６で封止されている。また、外周壁１は、金属メッシュあるいはセラミックス製のマットなどで形成された把持部材（図示せず）で使用中に動かないように把持され、金属製の収納容器（図示せず）に配置されている。   Exhaust gas from diesel engines and the like contains a large amount of PM (particulate matter) mainly composed of carbon, and if this is released into the atmosphere, it will adversely affect the human body and the environment. For this reason, exhaust system parts, such as a diesel engine, are equipped with a filter for collecting PM. FIG. 4 shows an example of a honeycomb structure used for a filter for collecting and purifying PM in automobile exhaust gas, (a) is a schematic front view, and (b) is a schematic side sectional view. is there. 4 (a) and 4 (b), the honeycomb structure 30 is made of porous ceramic, and includes a plurality of cells 3 and 4 partitioned by an outer peripheral wall 1 and partition walls 2 orthogonal to the inner side of the outer peripheral wall 1, respectively. The cells 3 and 4 are sealed with sealing portions 5 and 6 alternately at the exhaust gas inflow end surface 7 and the outflow side end surface 8. The outer peripheral wall 1 is gripped so as not to move during use by a gripping member (not shown) formed of a metal mesh or a ceramic mat, and is disposed in a metal storage container (not shown). ing.

このようなフィルタに用いられるセラミックハニカム構造体は、セラミック原料を混合、混練して粘土質素材とし、この粘土質素材を押出し成形後、例えば、特許文献１に記載の極細鋼線で切断し、乾燥、焼成して得られる。焼成して得られたセラミックハニカム構造体の端面にフィルムもしくはマスクを貼り付け、封止するセルのフィルムもしくはマスクを開孔し、開孔された流路に目封止用スラリーを充填してセラミックハニカムフィルタが得られる。このセラミックハニカム構造体は、ＰＭの捕集性能と低い圧力損失の実現のために、最近では高気孔率のものが使用されてきている。   The ceramic honeycomb structure used for such a filter is made by mixing and kneading ceramic raw materials into a clay material, and after extruding the clay material, for example, cutting with an ultrafine steel wire described in Patent Document 1, Obtained by drying and firing. A film or mask is attached to the end face of the ceramic honeycomb structure obtained by firing, the film or mask of the cell to be sealed is opened, and a slurry for plugging is filled in the opened flow path to make the ceramic. A honeycomb filter is obtained. This ceramic honeycomb structure has recently been used with a high porosity in order to achieve PM collection performance and low pressure loss.

特公平４−６０４０２号公報Japanese Patent Publication No. 4-60402

特許文献１に記載の極細鋼線で切断して得られたセラミックハニカム構造体は、切断時に端面でのセルの変形や隔壁の欠けが生じていることがあるので、端面の研削を行い、最終的な長さにすることが必要である。端面でのセルが変形していたり、隔壁の欠けが生じていると、目封止部を形成する工程において、セラミックハニカム構造体の端面と、その端面に貼り付けたフィルムもしくはマスクとの間に隙間が生じ、目封止用スラリーを充填する際、その隙間から目封止用スラリーが目封止しないセルに流れ込み、目封止しないセルが塞がれてしまい、フィルタとして使用した場合に、圧力損失が大きくなるという問題を生じるからである。
前記したセラミックハニカム構造体の端面の研削をする場合、図５（ａ）（ｂ）のように研削工具として円盤状の砥石５１を用いると、この円盤状の砥石５１の使用面となる幅Ｔは、通常、セラミックハニカム構造体の端面７の外径と比べて小さいので、１回の送りで端面全面を研削加工することができず、端面全面を研削加工するには、１回の送りが終了する毎に砥石５１の位置を端面７において、送り方向と直角な方向に移動させて数回にわたって加工する必要があり、加工に時間を要するという問題があった。そして、図５（ｃ）に示すように、研削加工が行われる際、切り込み量ｔで研削している砥石５１は１つの隔壁２と接触面Ｓ２で接しているが、セラミックハニカム構造体はハニカム構造であるので、１つの隔壁２は薄く脆いので、接触面Ｓ２の面積が大きい場合は加工に伴う負荷が大きくなり隔壁２に欠けが生じ易くなる。特に、最近では、気孔率が５５％以上である高気孔率のセラミックハニカム構造体が使用されてきており、このような高気孔率である場合、隔壁はさらに脆いのでより一層欠けが生じ易かった。さらに、セルの変形や隔壁の欠けが深い場合、端面からの加工量を大きくすると、セラミックハニカム構造体の端面に生じる加工負荷が大きくなり、隔壁の欠けがさらに生じることがある。この隔壁の欠けが生じると、前記したように、目封止用スラリーを充填する際、その隙間から目封止用スラリーが目封止しないセルに流れ込み、目封止しないセルが塞がれてしまい、フィルタとして使用した場合に、圧力損失が大きくなるという問題を生じる。そのため、切り込み量を大きく多く取ることができず、切り込み量を数段階に変更して研削加工をする必要があり、加工に時間を要していた。 The ceramic honeycomb structure obtained by cutting with the ultrafine steel wire described in Patent Document 1 may have cell deformation or chipping of the partition walls at the time of cutting. It is necessary to make it as long as possible. If the cells at the end face are deformed or the partition wall is chipped, in the step of forming the plugging portion, the gap between the end face of the ceramic honeycomb structure and the film or mask attached to the end face When a gap is generated and the plugging slurry is filled, the slurry for plugging flows into the cells that are not plugged from the gap, and the cells that are not plugged are blocked, and when used as a filter, It is because the problem that a pressure loss becomes large arises.
When grinding the end face of the ceramic honeycomb structure described above, if a disc-shaped grindstone 51 is used as a grinding tool as shown in FIGS. 5 (a) and 5 (b), the width T used as the working surface of the disc-shaped grindstone 51 will be described. Is usually smaller than the outer diameter of the end face 7 of the ceramic honeycomb structure, so that the entire end face cannot be ground by a single feed, and a single feed is required to grind the entire end face. Each time the process is completed, the grindstone 51 needs to be moved several times on the end face 7 in a direction perpendicular to the feed direction, which requires a long time for the machining. As shown in FIG. 5C, when the grinding process is performed, the grindstone 51 ground with the cutting amount t is in contact with one partition wall 2 at the contact surface S2, but the ceramic honeycomb structure is a honeycomb. Because of the structure, one partition wall 2 is thin and fragile. Therefore, when the area of the contact surface S2 is large, a load associated with processing increases and the partition wall 2 is likely to be chipped. In particular, recently, a ceramic honeycomb structure having a high porosity having a porosity of 55% or more has been used. In such a high porosity, the partition walls are more brittle and thus more easily chipped. . Furthermore, when the deformation of the cell or the partition wall is deep, if the amount of processing from the end surface is increased, the processing load generated on the end surface of the ceramic honeycomb structure increases, and the partition wall may be further chipped. When the partition wall is chipped, as described above, when the plugging slurry is filled, the plugging slurry flows into the non-plugged cells from the gap, and the non-plugged cells are blocked. Therefore, when used as a filter, there arises a problem that pressure loss increases. For this reason, it is not possible to take a large amount of cutting, and it is necessary to change the cutting amount to several stages and perform grinding, which takes time.

本発明の課題は、セラミックハニカム構造体の端面を加工する際に、隔壁に欠けが生じ難く、さらに、端面の加工に要する時間がかからない、セラミックハニカム構造体の製造方法を得ることにある。   An object of the present invention is to obtain a method for manufacturing a ceramic honeycomb structure in which the partition wall is hardly chipped when the end face of the ceramic honeycomb structure is processed, and further, the time required for processing the end face is not required.

上記課題を解決する為、具体的に、本発明は、多孔質の隔壁により形成されるセルを多数有するセラミックハニカム構造体の製造方法において、該セラミックハニカム構造体の端面を、カップ形砥石を用いて、該カップ形砥石の端面が前記セラミックハニカム構造体の端面に略平行となるように研削加工を行うことを特徴とする。   In order to solve the above problems, specifically, the present invention relates to a method for manufacturing a ceramic honeycomb structure having a large number of cells formed of porous partition walls, and a cup-shaped grindstone is used for the end face of the ceramic honeycomb structure. Then, the grinding is performed so that the end face of the cup-shaped grindstone is substantially parallel to the end face of the ceramic honeycomb structure.

前記カップ形砥石の外周面と端面に砥粒層が形成されていることを特徴とする。   An abrasive layer is formed on the outer peripheral surface and the end surface of the cup-shaped grindstone.

前記カップ形砥石の外周面と前記セラミックハニカム構造体の端面とのなす角度が９０°未満であることが好ましい。   It is preferable that an angle formed by the outer peripheral surface of the cup-shaped grindstone and the end surface of the ceramic honeycomb structure is less than 90 °.

前記カップ形砥石の砥粒層は、相対的に粒径の大きい砥粒層と相対的に粒径の小さい砥粒層の２つの砥粒層が形成されていることが好ましい。   The abrasive layer of the cup-shaped grindstone is preferably formed with two abrasive layers, an abrasive layer having a relatively large particle size and an abrasive layer having a relatively small particle size.

次に、本発明の作用効果について図１〜３に基き説明する。
図１で、ハニカム構造体の端面７を、カップ形砥石２０を用いて、該カップ形砥石２０の端面２０ａが前記セラミックハニカム構造体の端面７に略平行となるように研削加工を行うことで、１回の送りで研削加工できる面積が大きくなるので、１回の送りが終了する毎にカップ形砥石の位置を端面において送り方向と直角な方向に移動させる回数を減らすことができ、加工に要する時間を短縮することができる。そして、図１（ｂ）に示すように、研削加工が行われる際、切り込み量ｔで研削しているカップ形砥石２０は、１つの隔壁２と接触面Ｓ１で接しているが、この１つの隔壁２と接する接触面Ｓ１の面積は図５（ｃ）に示す従来の砥石５１が１つの隔壁２と接する接触面Ｓ２と比べて小さくすることができるので、加工に伴う負荷を小さくすることができ、隔壁に欠けを生じ難くすることができる。
そして、カップ形砥石の外周面２０ｂと端面２０ａに砥粒層Ａを形成させることで、ハニカム構造体の端面７からの深さ方向に切り込み量ｔを大きくとることができる。これは、カップ形砥石の端面２０ａのみに砥粒層が形成されている場合は、図１に示すように、切り込み量ｔは、砥粒層Ａの厚さＸまでとなるが、カップ形砥石の外周面に砥粒層が形成されていると、図２（ａ）に示すように、外周面２０ｂの砥粒層でも研削加工が可能となるので、切り込み量ｔは、砥粒層Ａの厚さＸよりも大きくできるからである。したがって、ハニカム構造体の端面からの深さ方向に切り込み量を大きくとることができるので、セルの変形や隔壁の欠けが深い場合であっても、切り込み量を大きくして、切り込み量を数段階に変更しなくても、隔壁に欠けが生じ難く加工をすることができる。 Next, the effect of this invention is demonstrated based on FIGS.
In FIG. 1, the end surface 7 of the honeycomb structure is ground using a cup-shaped grindstone 20 so that the end surface 20a of the cup-shaped grindstone 20 is substantially parallel to the end surface 7 of the ceramic honeycomb structure. Since the area that can be ground by one feed increases, the number of times the cup-shaped grindstone is moved in the direction perpendicular to the feed direction on the end face every time one feed is completed can be reduced. The time required can be shortened. And as shown in FIG.1 (b), when grinding is performed, the cup-shaped grindstone 20 ground with the cutting depth t is in contact with one partition wall 2 at the contact surface S1, but this one The area of the contact surface S1 in contact with the partition wall 2 can be made smaller than the contact surface S2 in which the conventional grindstone 51 shown in FIG. 5 (c) is in contact with one partition wall 2, so that the load caused by processing can be reduced. It is possible to make it difficult for the partition wall to be chipped.
Then, by forming the abrasive grain layer A on the outer peripheral surface 20b and the end surface 20a of the cup-shaped grindstone, the cutting amount t can be increased in the depth direction from the end surface 7 of the honeycomb structure. This is because when the abrasive layer is formed only on the end face 20a of the cup-shaped grindstone, the cutting amount t is up to the thickness X of the abrasive grain layer A as shown in FIG. If an abrasive layer is formed on the outer peripheral surface of the outer peripheral surface, as shown in FIG. 2 (a), grinding can be performed even with the abrasive layer on the outer peripheral surface 20b. This is because it can be larger than the thickness X. Therefore, since it is possible to increase the depth of cut in the depth direction from the end face of the honeycomb structure, even when the cell deformation or the crack of the partition wall is deep, the depth of cut is increased and the depth of cut is several steps. Even if it does not change to, it can be processed so that chipping hardly occurs in the partition wall.

ここで、カップ形砥石の外周面２０ｂとハニカム構造体の端面７とのなす角度θが９０°を超えていると、ハニカム構造体の端面７の加工が終了する際、ハニカム構造体の外周部に欠けが生じ易くなるので、カップ形砥石の外周面とハニカム構造体の端面とのなす角度θは９０°未満であることが好ましい。さらに、カップ形砥石の端面２０ａと外周面２０ｂとの交点にＲ或いは面取りが形成されていると、隔壁に欠けがより生じ難く加工をすることができる。   Here, when the angle θ formed between the outer peripheral surface 20b of the cup-shaped grindstone and the end surface 7 of the honeycomb structure exceeds 90 °, the outer peripheral portion of the honeycomb structure is finished when the processing of the end surface 7 of the honeycomb structure is finished. Therefore, the angle θ formed by the outer peripheral surface of the cup-shaped grindstone and the end surface of the honeycomb structure is preferably less than 90 °. Furthermore, when R or chamfering is formed at the intersection between the end surface 20a and the outer peripheral surface 20b of the cup-shaped grindstone, the partition wall can be machined more easily.

さらに、カップ形砥石の砥粒層は、２種類の砥粒を用い、２種類の砥粒のうち相対的に粒径の小さい砥粒層Ａをカップ形砥石の端面側に形成し、２種類の砥粒のうち相対的に粒径の大きい砥粒層Ｂをカップ形砥石の外周側に形成させるとさらに好ましい。
これは、カップ形砥石の外周面とハニカム構造体の端面とのなす角度が９０°未満である場合、カップ形砥石の外周側に形成された砥粒層Ｂが、まず、ハニカム構造体を研削加工する。この場合、砥粒層Ｂで研削された部位は、ハニカム構造体としては不要な部位であるので、粉砕粉として排出できればよいので砥粒層Ｂは２種類の砥粒のうち相対的に粒径の大きい砥粒を用いることができる。次いで、砥粒層Ａがハニカム構造体の端面部を研削するが、この場合、砥粒層Ｂで研削された部位を２種類の砥粒のうち相対的に粒径の小さい砥粒層Ａで研削するので、ハニカム構造体の端面部で隔壁の欠けが生じ難くなり、良好に加工することができる。したがって、切り込み量ｔが大きい場合に、隔壁との接触面が大きくなることで、砥粒層Ｂで加工される際に伴う負荷が大きくなり隔壁に欠けが生じた場合であっても、砥粒層Ａが仕上加工するので、砥粒層Ｂで加工された際に生じた欠けを砥粒層Ａが除去するので欠けを生じ難くすることができる。これは、特に、ハニカム構造体の気孔率が５５％以上と高い気孔率で、隔壁が脆い場合であっても、欠けを生じ難く良好に加工をすることができるのである。 Further, the abrasive layer of the cup-shaped grindstone uses two types of abrasive grains, and the abrasive layer A having a relatively small particle size is formed on the end face side of the cup-shaped grindstone, and the two types More preferably, an abrasive layer B having a relatively large particle size is formed on the outer peripheral side of the cup-shaped grindstone.
This is because when the angle formed between the outer peripheral surface of the cup-shaped grindstone and the end surface of the honeycomb structure is less than 90 °, the abrasive grain layer B formed on the outer peripheral side of the cup-shaped grindstone first grinds the honeycomb structure. Process. In this case, since the part ground by the abrasive grain layer B is an unnecessary part for the honeycomb structure, the abrasive grain layer B has a relative particle size of two kinds of abrasive grains as long as it can be discharged as pulverized powder. Large abrasive grains can be used. Next, the abrasive layer A grinds the end face portion of the honeycomb structure. In this case, the portion ground by the abrasive layer B is the abrasive layer A having a relatively small particle size out of the two types of abrasive grains. Since grinding is performed, the partition wall is less likely to be chipped at the end face portion of the honeycomb structure, and can be processed satisfactorily. Therefore, when the cutting depth t is large, the contact surface with the partition wall becomes large, so that the load accompanying processing with the abrasive grain layer B increases, and even when the partition wall is chipped, the abrasive grains Since the layer A is finished, since the abrasive layer A removes the chips generated when the abrasive layer B is processed, the chips can be made difficult to occur. This is particularly because the honeycomb structure has a high porosity of 55% or more, and even when the partition walls are brittle, chipping is unlikely to occur and processing can be performed satisfactorily.

本発明のセラミックハニカム構造体の製造方法によれば、セラミックハニカム構造体の端面を加工する際に、隔壁に欠けが生じ難く、さらに、端面の加工に要する時間がかからない、セラミックハニカム構造体を得ることができる。   According to the method for manufacturing a ceramic honeycomb structure of the present invention, when processing the end face of the ceramic honeycomb structure, the partition wall is not easily chipped, and further, the time required for processing the end face is not obtained. be able to.

以下、本発明を実施の形態により詳細に説明する。
（実施の形態）
図１〜３は、実施の形態に係るセラミックハニカム構造体の端面を加工する方法を示した図である。
図１において、セラミックハニカム構造体１０は、次のようにして準備される。セラミック原料として、炭化珪素、窒化珪素、コージェライト、アルミナ、ムライト、ジルコニア、チタン酸アルミニウムあるいはこれらの組合せからなる群から選ばれた少なくとも一種のセラミックを用いる。このセラミック原料に、メチルセルロース及びヒドロキシプロポキシルメチルセルロース等のバインダー、界面活性剤、水、及び必要に応じてカーボン等の造孔剤を添加、混練して可塑性の坏土を作成する。この杯土を押出し成形することで、セルを多数有するセラミックハニカム構造の成形体を成形する。この成形体を所定の長さに極細鋼線で切断し、乾燥の後、焼成して多孔質の隔壁により形成されるセルを多数有するセラミックハニカム構造体が得られる。
次に、カップ形砥石２０は、炭素鋼、高速度鋼、ダイス鋼等の鋼材製の基台２１と軸２２で構成され、基台２１の中央部には逃げ部２３を有しており、その端面２０ａには砥粒層Ａが形成されている。この砥粒層Ａに形成される砥粒の材質には、ダイヤモンド、立方晶窒化ほう素等を用いることができ、その粒度は、＃５０〜＃２７０程度のものを用いることができる。また、砥粒層Ａの厚さＸは０．５〜５ｍｍ程度とすることができる。尚、カップ形砥石２０の外径は、セラミックハニカム構造体１０の外径と同じか、それより大きい外径を有していると、セラミックハニカム構造体の端面全面を１回の加工で完了するので好ましい。
そして、このカップ形砥石によりセラミックハニカム構造体の端面は次のように加工される。
セラミックハニカム構造体１０の外周を加工装置の取付具３１で固定する。セラミックハニカム構造体１０の一方の端面７からの切り込み量ｔが０．１〜５ｍｍとなるように、カップ形砥石２０の位置を決める。次いで、カップ形砥石２０を回転させて送り（図中矢印）をかけ、セラミックハニカム構造体１０の端面７を加工する。そして、一方の端面７の加工が完了すると、取付具３１を外して、セラミックハニカム構造体１０を取付直し、他方の端面８を同様にして加工を行う。カップ形砥石によりセラミックハニカム構造体の端面を加工するので、カップ形砥石の位置を端面において送り方向と直角な方向に移動させる回数を減らすことができ、加工に要する時間を短縮することができる。このようにして加工されたセラミックハニカム構造体は、次に、端面７、８にフィルムを貼り付け、封止する所定のセルのフィルムをレーザー光等の熱で開孔し、開孔されたセルに目封止用スラリーを充填し、焼成してセラミックハニカムフィルタとする。 Hereinafter, the present invention will be described in detail by embodiments.
(Embodiment)
1 to 3 are diagrams showing a method of processing an end face of a ceramic honeycomb structure according to an embodiment.
In FIG. 1, the ceramic honeycomb structure 10 is prepared as follows. As the ceramic raw material, at least one ceramic selected from the group consisting of silicon carbide, silicon nitride, cordierite, alumina, mullite, zirconia, aluminum titanate, or a combination thereof is used. To this ceramic raw material, a binder such as methyl cellulose and hydroxypropoxyl methyl cellulose, a surfactant, water and, if necessary, a pore-forming agent such as carbon are added and kneaded to prepare a plastic clay. A ceramic honeycomb structure formed body having a large number of cells is formed by extruding the clay. This formed body is cut to a predetermined length with an ultrafine steel wire, dried and fired to obtain a ceramic honeycomb structure having a large number of cells formed by porous partition walls.
Next, the cup-shaped grindstone 20 is composed of a base 21 made of a steel material such as carbon steel, high speed steel, die steel, and a shaft 22, and has a relief portion 23 in the center of the base 21. An abrasive layer A is formed on the end face 20a. As the material of the abrasive grains formed in the abrasive grain layer A, diamond, cubic boron nitride or the like can be used, and those having a grain size of about # 50 to # 270 can be used. The thickness X of the abrasive layer A can be about 0.5 to 5 mm. Note that if the outer diameter of the cup-shaped grindstone 20 is the same as or larger than the outer diameter of the ceramic honeycomb structure 10, the entire end face of the ceramic honeycomb structure is completed by one processing. Therefore, it is preferable.
Then, the end face of the ceramic honeycomb structure is processed as follows by this cup-shaped grindstone.
The outer periphery of the ceramic honeycomb structure 10 is fixed by the fixture 31 of the processing apparatus. The position of the cup-shaped grindstone 20 is determined so that the cut amount t from one end face 7 of the ceramic honeycomb structure 10 is 0.1 to 5 mm. Next, the cup-shaped grindstone 20 is rotated and fed (arrow in the figure), and the end face 7 of the ceramic honeycomb structure 10 is processed. When the processing of one end face 7 is completed, the fixture 31 is removed, the ceramic honeycomb structure 10 is reattached, and the other end face 8 is processed in the same manner. Since the end face of the ceramic honeycomb structure is processed with the cup-shaped grindstone, the number of times the position of the cup-shaped grindstone is moved in the direction perpendicular to the feed direction on the end face can be reduced, and the time required for processing can be shortened. The ceramic honeycomb structure thus processed is then bonded to the end faces 7 and 8, and a film of a predetermined cell to be sealed is opened by heat such as laser light, thereby opening the cell. Are filled with a slurry for plugging and fired to obtain a ceramic honeycomb filter.

本発明の実施の形態において、図２（ａ）に示すように、カップ形砥石２０の砥粒層Ａがその外周面２０ｂにまで形成されていると、セラミックハニカム構造体１０の一方の端面７からの切り込み量ｔは０．１〜２０ｍｍ程度とすることができ、セルの変形や隔壁の深い欠けがあっても、切り込み量を大きくすることができるので、短時間で加工をすることができる。   In the embodiment of the present invention, as shown in FIG. 2A, when the abrasive grain layer A of the cup-shaped grindstone 20 is formed up to the outer peripheral surface 20b, one end face 7 of the ceramic honeycomb structure 10 is formed. The amount of cut t can be set to about 0.1 to 20 mm, and the amount of cut can be increased even if the cell is deformed or the partition wall is deeply chipped, so that the processing can be performed in a short time. .

また、図２（ａ）〜（ｃ）に示すように、カップ形砥石の外周面２０ｂとセラミックハニカム構造体の端面７とのなす角度θが、θ＝９０°（図２（ａ））、θ＞９０°（図２（ｂ））、θ＜９０°（図２（ｃ））の３通りとすることができる。
また、図３に示すように、カップ形砥石の外周面の砥粒層は、２種類の砥粒を用い、２種類の砥粒のうち相対的に粒径の小さい砥粒層Ａをカップ形砥石の端面側２０ａに形成し、２種類の砥粒のうち相対的に粒径の大きい砥粒層Ｂをカップ形砥石の外周側２０ｂに形成させることができる。したがって、例えば、砥粒層Ａに粒度が＃１００〜＃２７０程度の仕上用のものを、砥粒層Ｂに粒度が＃５０〜＃１２０程度の粗用のものを用いることができる。このようなカップ形砥石を用いて、セラミックハニカム構造体の端面が次のように加工される。カップ形砥石２０の外周側２０ｂに形成された砥粒層Ｂが、まず、ハニカム構造体の隔壁を加工する。この場合、砥粒層Ｂで研削される部位は、ハニカム構造体としては不要な部位であり、砥粒層Ｂの粒度は、砥粒層Ａと比べて相対的に粗いので、容易に粉砕粉として排出される。次いで、砥粒層Ｂにより粗加工されたハニカム構造体の隔壁を、砥粒層Ａが仕上加工していく。この場合、砥粒層Ｂで研削された部位を２種類の砥粒のうち相対的に粒径の小さい砥粒層Ａで加工するので、ハニカム構造体の端面７で隔壁の欠けが生じ難くなり、良好に加工することができる。このことは、特に、ハニカム構造体の気孔率が５５％以上と高い気孔率で隔壁が脆く欠けが生じ易い場合であっても、欠けを生じず良好に加工をすることができるのである。 2A to 2C, the angle θ formed between the outer peripheral surface 20b of the cup-shaped grindstone and the end surface 7 of the ceramic honeycomb structure is θ = 90 ° (FIG. 2A), There are three ways of θ> 90 ° (FIG. 2B) and θ <90 ° (FIG. 2C).
Moreover, as shown in FIG. 3, the abrasive grain layer of the outer peripheral surface of a cup-shaped grindstone uses two types of abrasive grains, and the abrasive grain layer A having a relatively small grain size is cup-shaped among the two types of abrasive grains. It can be formed on the end face side 20a of the grindstone, and an abrasive layer B having a relatively large particle size can be formed on the outer peripheral side 20b of the cup-shaped grindstone among the two types of abrasive grains. Therefore, for example, the abrasive layer A having a grain size of about # 100 to # 270 can be used, and the abrasive grain layer B having a grain size of about # 50 to # 120 can be used. Using such a cup-shaped grindstone, the end face of the ceramic honeycomb structure is processed as follows. The abrasive grain layer B formed on the outer peripheral side 20b of the cup-shaped grindstone 20 first processes the partition walls of the honeycomb structure. In this case, the part ground by the abrasive grain layer B is an unnecessary part as the honeycomb structure, and the grain size of the abrasive grain layer B is relatively coarse compared to the abrasive grain layer A. As discharged. Next, the abrasive grain layer A finishes the partition walls of the honeycomb structure roughly processed by the abrasive grain layer B. In this case, since the portion ground by the abrasive grain layer B is processed by the abrasive grain layer A having a relatively small grain size out of the two kinds of abrasive grains, the partition wall is less likely to be chipped at the end face 7 of the honeycomb structure. Can be processed well. This means that even when the honeycomb structure has a high porosity of 55% or more and the partition walls are brittle and chipping is likely to occur, the honeycomb structure can be satisfactorily processed without chipping.

先ず、次のようにしてセラミックハニカム構造体を準備した。
カオリン、タルク、シリカ、アルミナなどの粉末を調整して、質量比で、ＳｉＯ２：４８〜５２％、Ａｌ２Ｏ３：３３〜３７％、ＭｇＯ：１２〜１５％を含むようなコージェライト生成原料粉末とし、この、コージェライト生成原料粉末に、メチルセルロース、ヒドロキシプロピルメチルセルロース等のバインダー、潤滑剤、造孔材としてグラファイトを添加し、乾式で十分混合した後、規定量の水を添加、十分な混練を行って可塑化したセラミック杯土を作製した。次に、押出し成形用金型を用いて坏土を押出し成形し、切断してハニカム構造を有する成形体とした。そして、この成形体を、乾燥、焼成させ、隔壁厚０．３ｍｍ、気孔率６５％、平均細孔径２０μｍ、ピッチ１．５ｍｍで、外径Ｄ２２７７ｍｍ、全長３２０ｍｍのコージェライト質セラミックハニカム構造体とした。 First, a ceramic honeycomb structure was prepared as follows.
Kaolin, talc, silica, by adjusting the powder such as alumina, in a mass ratio, SiO 2: 48~52%, Al 2 O 3: 33~37%, MgO: cordierite generation such as those containing from 12 to 15% As a raw material powder, to this cordierite-producing raw material powder, a binder such as methylcellulose and hydroxypropylmethylcellulose, a lubricant, and graphite as a pore-forming material are added, and after mixing thoroughly in a dry process, a specified amount of water is added, and sufficient Kneaded to produce a plasticized ceramic clay. Next, the kneaded material was extruded using an extrusion mold and cut to obtain a formed body having a honeycomb structure. Then, the formed body is dried and fired, and a cordierite ceramic honeycomb structure having a partition wall thickness of 0.3 mm, a porosity of 65%, an average pore diameter of 20 μm, a pitch of 1.5 mm, an outer diameter of D 2 277 mm, and an overall length of 320 mm. It was.

次に、このセラミックハニカム構造体を、図３に示すように、取付具３１で固定する。そして、端面の加工に用いるカップ形砥石２０は、その外径Ｄ１が３００ｍｍで、カップ形砥石の外周面とハニカム構造体の端面とのなす角度θと、カップ形砥石の砥粒層Ａ，Ｂの粒度を表１に示すように変更させたものを用い、セラミックハニカム構造体１０の一方の端面７から所定の切り込み量５ｍｍとなるように、カップ形砥石２０の位置を決める。次いで、カップ形砥石２０を４００回転／分で回転させて１ｍ／分の送りをかけ、セラミックハニカム構造体１０の端面７を加工する。そして、取付具３１を外して、セラミックハニカム構造体１０を取付直し、他方の端面８を同様にして加工を行った。一方、比較例として、従来使用されていた円盤状砥石を用いて加工を行った。この円盤状砥石の砥粒の粒度は、表１に括弧で示している。
そして、加工が完了したセラミックハニカム構造体１０の端面に隔壁の欠けの有無と加工に要した時間を評価した。結果を表１に示す。隔壁の欠けの有無の評価は、端面当りに生じた大きさ５ｍｍ以上の欠け発生数（個／端面）を、比較例２で発生した端面当りの欠け発生数（個／端面）を１としてその比率で表した。加工に要した時間は比較例２で使用した円盤状砥石を用いた場合に要した時間を１としてその比率で表した。 Next, this ceramic honeycomb structure is fixed with a fixture 31, as shown in FIG. The cup-shaped grindstone 20 for use in the processing of the end face, with its outer diameter D 1 is 300 mm, the angle θ between the outer peripheral surface and the end face of the honeycomb structure of the cup-shaped grinding wheel, abrasive grain layer A of the cup-shaped grinding wheel, The grain size of B is changed as shown in Table 1, and the position of the cup-shaped grindstone 20 is determined so that a predetermined cut amount is 5 mm from one end face 7 of the ceramic honeycomb structure 10. Next, the end face 7 of the ceramic honeycomb structure 10 is processed by rotating the cup-shaped grindstone 20 at 400 revolutions / minute and feeding 1 m / minute. And the fixture 31 was removed, the ceramic honeycomb structure 10 was reattached, and the other end surface 8 was processed similarly. On the other hand, as a comparative example, processing was performed using a conventionally used disk-shaped grindstone. The grain size of the abrasive grains of the disc-shaped grindstone is shown in parentheses in Table 1.
Then, the presence / absence of partition wall chipping on the end face of the ceramic honeycomb structure 10 which had been processed and the time required for the processing were evaluated. The results are shown in Table 1. The evaluation of the presence or absence of cracks in the partition wall was performed by assuming that the number of chipped occurrences (pieces / end face) of 5 mm or more generated per end face was 1, and the number of chipped pieces per end face (pieces / end face) generated in Comparative Example 2 was 1. Expressed as a ratio. The time required for processing was expressed as a ratio with the time required when the disk-shaped grindstone used in Comparative Example 2 was used as 1.

Figure 2006281039
Figure 2006281039

表１に示す結果から、本発明の実施例１〜１６は、比較例１、２と比べ、セラミックハニカム構造体の端面に生じる欠けが少なく、加工に要する時間も短いことがわかる。   From the results shown in Table 1, it can be seen that Examples 1 to 16 of the present invention have fewer chips on the end face of the ceramic honeycomb structure and shorter processing time than Comparative Examples 1 and 2.

本発明に係るセラミックハニカム構造体の加工を示した図The figure which showed processing of the ceramic honeycomb structure concerning the present invention 本発明に係るセラミックハニカム構造体の加工を示した図The figure which showed processing of the ceramic honeycomb structure concerning the present invention 本発明に係るセラミックハニカム構造体の加工を示した図The figure which showed processing of the ceramic honeycomb structure concerning the present invention 自動車の排気ガス中のＰＭを捕集、浄化するフィルタに用いられるハニカム構造体を示した図The figure which showed the honeycomb structure used for the filter which collects and purifies PM in the exhaust gas of a car セラミックハニカム構造体の端面の加工で従来技術を示した図The figure which showed the prior art in the processing of the end face of the ceramic honeycomb structure

符号の説明Explanation of symbols

１：外周壁
２：隔壁
３、４：セル
５、６：封止部
７、８：セラミックハニカム構造体の端面
１０：セラミックハニカム構造体
２０：カップ形砥石
２０ａ：カップ形砥石の端面
２０ｂ：カップ形砥石の外周面
２１：基台
２２：軸
２３：逃げ部
３１：取付具
５１：円盤状砥石
Ａ：砥粒層Ａ
Ｂ：砥粒層Ｂ
Ｄ１：カップ形砥石の外径
Ｄ２：ハニカム構造体の外径
Ｓ１、Ｓ２：接触面
Ｔ：砥石幅
α：砥石の円周方向と送り方向とが同一となる部位
Ｘ：砥粒層の厚さ
ｔ：切り込み量
θ：カップ形砥石の外周面とセラミックハニカム構造体の端面とのなす角度

1: outer peripheral wall 2: partition wall 3, 4: cell 5, 6: sealing portion 7, 8: end face of ceramic honeycomb structure 10: ceramic honeycomb structure 20: cup-shaped grindstone 20a: end face 20b of cup-shaped grindstone: cup Outer peripheral surface 21 of the shaped grindstone: Base 22: Shaft 23: Relief part 31: Mounting tool 51: Disc-shaped grindstone A: Abrasive layer
B: Abrasive layer B
D 1 : Outer diameter of the cup-shaped grindstone D 2 : Outer diameter of the honeycomb structure S 1 and S 2: Contact surface T: Grinding wheel width α: Part where the circumferential direction and the feeding direction of the grindstone are the same X: Abrasive layer Thickness t: Cutting depth θ: Angle formed by the outer peripheral surface of the cup-shaped grindstone and the end surface of the ceramic honeycomb structure

Claims (4)

多孔質の隔壁により形成されるセルを多数有するセラミックハニカム構造体の製造方法において、該セラミックハニカム構造体の端面を、カップ形砥石を用いて、該カップ形砥石の端面が前記セラミックハニカム構造体の端面に略平行となるように研削加工を行うことを特徴とするセラミックハニカム構造体の製造方法。 In a method for manufacturing a ceramic honeycomb structure having a large number of cells formed by porous partition walls, a cup-shaped grindstone is used as an end face of the ceramic honeycomb structure, and an end face of the cup-shaped grindstone is formed of the ceramic honeycomb structure. A method for manufacturing a ceramic honeycomb structure, wherein grinding is performed so as to be substantially parallel to an end face. 前記カップ形砥石の外周面と端面に砥粒層が形成されていることを特徴とする請求項１に記載のセラミックハニカム構造体の製造方法。 The method for producing a ceramic honeycomb structure according to claim 1, wherein an abrasive grain layer is formed on an outer peripheral surface and an end surface of the cup-shaped grindstone. 前記カップ形砥石の外周面と前記セラミックハニカム構造体の端面とのなす角度が９０°未満であることを特徴とする請求項１に記載のセラミックハニカム構造体の製造方法。 The method for manufacturing a ceramic honeycomb structure according to claim 1, wherein an angle formed between an outer peripheral surface of the cup-shaped grindstone and an end surface of the ceramic honeycomb structure is less than 90 °. 前記カップ形砥石の砥粒層は、相対的に粒径の大きい砥粒層と相対的に粒径の小さい砥粒層の２つの砥粒層が形成されていることを特徴とする請求項２に記載のセラミックハニカム構造体の製造方法。
3. The abrasive layer of the cup-shaped grindstone is formed with two abrasive layers, an abrasive layer having a relatively large particle size and an abrasive layer having a relatively small particle size. A method for producing a ceramic honeycomb structure according to claim 1.
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