JP4357110B2 - Manufacturing method of honeycomb filter - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a honeycomb filter used as a filter for removing particulates and the like in exhaust gas discharged from an internal combustion engine.
[0002]
[Prior art]
Recently, it has become a problem that particulates contained in exhaust gas discharged from internal combustion engines such as automobiles, buses, trucks and the like and construction machines cause harm to the environment and the human body.
Various honeycomb filters that purify exhaust gas by collecting particulates in exhaust gas by passing the exhaust gas through a porous ceramic have been proposed.
[0003]
Such a honeycomb filter usually has a ceramic block 15 formed by binding a plurality of porous ceramic members 30 made of silicon carbide or the like, like the honeycomb filter 10 shown in FIG. A sealing material layer 12 is formed on the surface. Further, as shown in FIG. 2, the porous ceramic member 30 has a large number of through holes 31 arranged in parallel in the longitudinal direction, and a partition wall 33 separating the through holes 31 functions as a filter.
[0004]
That is, in the through hole 31 formed in the porous ceramic member 30, as shown in FIG. 2B, either the inlet side or the outlet side end of the exhaust gas is sealed with the filler 32, The exhaust gas that has flowed into one through-hole 31 always passes through the partition wall 33 separating the through-holes 31 and then flows out from the other through-holes 31.
[0005]
In the exhaust gas purification apparatus, the honeycomb filter 10 having such a configuration is installed in the exhaust passage of the internal combustion engine, and particulates in the exhaust gas discharged from the internal combustion engine are separated by the partition wall 33 when passing through the honeycomb filter 10. It is captured and the exhaust gas is purified.
[0006]
When manufacturing such a honeycomb filter 10, first, a mixed composition containing a solvent, a binder and the like in addition to the ceramic particles as a raw material is prepared, and extrusion molding or the like is performed using this mixed composition to form a ceramic. Create a body. And the porous ceramic member 30 is manufactured by giving each process of drying, degreasing, and baking to this ceramic molded object.
[0007]
Next, the ceramic laminate 15 is assembled by laminating the porous ceramic member 30 via an adhesive paste that becomes the adhesive layer 14, dried, and then cut into a predetermined shape to produce the ceramic block 15. The honeycomb filter 10 is manufactured by forming the sealing material layer 13 on the outer peripheral portion of the ceramic block 15.
[0008]
However, when the honeycomb filter 10 is manufactured by such a method, the adhesive paste applied to the side surface of the porous ceramic member 30 protrudes from the end surface portion of the porous ceramic member 30 in the assembly process of the ceramic laminate. In some cases, the through hole 31 adheres to the portion where the through hole 31 is formed and blocks the through hole 31.
[0009]
In addition, the same problem may occur in the process of forming the sealing material layer 13. That is, when the sealing material paste that becomes the sealing material layer 13 is applied to the outer peripheral portion of the ceramic block 15 to form the sealing material paste layer, the sealing material paste protrudes from the end face of the ceramic block 15 to form the through holes 31. In some cases, the through-hole 31 may be blocked by adhering to the existing portion.
As described above, when the adhesive paste or the sealing material paste blocks the through hole 31, the through hole 31 is clogged and the function of the honeycomb filter as a filter is deteriorated.
[0010]
Then, the adhesive tape was stuck on the both end surfaces of the porous ceramic member 30 to prevent such clogging of the through-holes. However, the adhesive tape and the vinyl tape have such heat resistance and durability. Therefore, in the process of manufacturing the honeycomb filter 10, damage, decomposition, peeling, and the like may occur.
[0011]
[Problems to be solved by the invention]
The present invention was made to solve these problems, and the masking material attached to both end faces of the porous ceramic member may be easily damaged, decomposed, or peeled off during the manufacture of the honeycomb filter. Therefore, an object of the present invention is to provide a manufacturing method for manufacturing a honeycomb filter having good characteristics without a sealing material or the like entering a through hole of the honeycomb filter.
[0012]
[Means for Solving the Problems]
In the present invention, a plurality of prismatic porous ceramic members each having a large number of through holes arranged in parallel in the longitudinal direction with a partition wall therebetween are bound together via an adhesive layer to constitute a ceramic block, and the outer periphery thereof is sealed. A method for manufacturing a honeycomb filter coated with a material layer and configured so that a partition wall separating the through holes functions as a particle collecting filter,
After producing the porous ceramic member, a masking material having an adhesive layer formed on a base film having a hardness of 50 to 150 ° and a heat-resistant temperature of 120 ° C. or more, and an adhesive force of 500 to 2000 gf / 19 mm width. A masking material affixing step for adhering to both end faces of the porous ceramic member, and applying an adhesive paste to the side surface of the porous ceramic member affixing the masking material, Assembling the ceramic laminate by repeating the process of laminating porous ceramic members The ceramic laminate is heated to dry and cure the adhesive paste. Ceramic laminate manufacturing process and cutting part of the ceramic laminate And cutting the masking material bonded to the end face of the ceramic laminate into the shape of the cut portion of the ceramic laminate. A ceramic block manufacturing process for manufacturing the ceramic block and a sealing material layer formed on the outer periphery of the ceramic block A sealing material layer forming step to form a honeycomb filter, and a release sheet having an adhesive strength stronger than the adhesive strength of the masking material is pressed against the end face of the honeycomb filter, and the masking material is adhered to the release sheet. Then, the masking material is peeled off from the end face of the honeycomb filter by pulling off the peeling sheet. It is a manufacturing method of the honey-comb filter characterized by including a masking material peeling process.
Hereinafter, the manufacturing method of the honeycomb filter of the present invention will be described.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
The method for manufacturing a honeycomb filter according to the present invention includes a plurality of prismatic porous ceramic members each having a plurality of through-holes arranged in parallel in the longitudinal direction with a partition wall interposed therebetween to form a ceramic block through an adhesive layer. A honeycomb filter manufacturing method in which the outer peripheral portion is coated with a sealing material layer, and the partition walls separating the through holes function as a filter for collecting particles,
After producing the porous ceramic member, a masking material having an adhesive layer formed on a base film having a hardness of 50 to 150 ° and a heat-resistant temperature of 120 ° C. or more, and an adhesive force of 500 to 2000 gf / 19 mm width. A masking material affixing step for adhering to both end faces of the porous ceramic member, and applying an adhesive paste to the side surface of the porous ceramic member affixing the masking material, Assembling the ceramic laminate by repeating the process of laminating porous ceramic members The ceramic laminate is heated to dry and cure the adhesive paste. Ceramic laminate manufacturing process and cutting part of the ceramic laminate And cutting the masking material bonded to the end face of the ceramic laminate into the shape of the cut portion of the ceramic laminate. A ceramic block manufacturing process for manufacturing the ceramic block and a sealing material layer formed on the outer periphery of the ceramic block A sealing material layer forming step to form a honeycomb filter, and a release sheet having an adhesive strength stronger than the adhesive strength of the masking material is pressed against the end face of the honeycomb filter, and the masking material is adhered to the release sheet. Then, the masking material is peeled off from the end face of the honeycomb filter by pulling off the peeling sheet. And a masking material peeling step.
[0014]
In the method for manufacturing a honeycomb filter of the present invention, first, a porous ceramic member is manufactured. Since the manufacturing method is as described in the prior art, a detailed description thereof is omitted here.
In addition, the ceramic that is a raw material of the porous ceramic member is not particularly limited and includes various ceramics. Among these, silicon carbide having high heat resistance, excellent mechanical properties, and high thermal conductivity. Is preferred.
[0015]
The porous ceramic member is preferably made of ceramic crystals having an average particle diameter of 2 to 150 μm, more preferably 10 to 70 μm. When the average particle size of the ceramic crystal is less than 2 μm, the pore diameter of the pores present in the porous ceramic member becomes too small and immediately clogs, making it difficult to function as a filter. On the other hand, if the average particle diameter of the ceramic crystal exceeds 150 μm, the pore diameter of the pores present in the ceramic crystal becomes too large, and the strength of the porous ceramic member may be reduced. Moreover, it is not so easy to manufacture a porous ceramic member having ceramic crystals having a predetermined ratio of open pores and an average particle size exceeding 150 μm.
[0016]
Next, the masking material in which the adhesive layer was formed on the base film is affixed on the both end surfaces of the produced porous ceramic member.
[0017]
Since the hardness of the base film is 50 to 150 °, it is masked to the shape of the cut portion without being torn off, peeled off or stretched excessively in the step of cutting the ceramic laminate described later. The material is also cut.
When the hardness is less than 50 °, the base film is too soft, so when the ceramic laminate is cut, it is not cut into the same shape as the cut portion, the masking material is stretched, and a seal described later Inconveniences such as obstructing the material layer forming process and the masking material at the portion to be sealed being cut off are lost. On the other hand, when the hardness exceeds 150 °, it becomes too hard, so that it cannot be firmly attached to the end face on which some unevenness is formed, and is easily peeled off.
[0018]
Moreover, since the heat-resistant temperature of the said base film is 120 degreeC or more, it does not deteriorate or decompose | disassemble by the drying process of the sealing material layer mentioned later.
There exists a possibility that the said base film may decompose | disassemble in the subsequent drying process etc. as the said heat-resistant temperature is less than 120 degreeC. The heat-resistant temperature is desirably 150 ° C. or higher.
[0019]
The pressure-sensitive adhesive is not particularly limited, and examples thereof include rubber pressure-sensitive adhesives such as polyisobutylene, SBR, butyl rubber, and chloroprene rubber, and other acrylic pressure-sensitive adhesives.
[0020]
Since the adhesive strength of the masking material coated with such an adhesive is 500 to 2000 gf / 19 mm width, it can be easily peeled off in the step of peeling the masking material using a release sheet described later, and No peeling occurs during the manufacture of the honeycomb filter. If the adhesive strength is less than 500 gf / 19 mm width, the adhesive strength is insufficient, and the masking material may peel off during the manufacture of the honeycomb filter. On the other hand, when the adhesive strength exceeds 2000 gf / 19 mm width, it is difficult to completely remove the masking material in a subsequent masking material peeling step. The adhesive strength is desirably 1000 to 1500 gf / 19 mm width.
[0021]
The base film is preferably a resin film. It is because it is excellent in heat resistance and durability and can substantially satisfy each of the above characteristics.
Among such resin-based films, a polyester film is desirable, and a PET film is particularly desirable. This is because the above-described characteristics can be satisfied, and in particular, heat resistance and durability are excellent.
[0022]
As for the thickness of the masking material which consists of such a base film and an adhesive layer, it is desirable that it is 10-500 micrometers. If the thickness is less than 10 μm, the strength is reduced and the film is easily damaged. On the other hand, when the thickness exceeds 500 μm, the hardness becomes high and the handleability is inferior. Further, as described above, it becomes difficult to follow the shape of the end face, so that it is easy to peel off. The thickness of the masking material is more preferably 10 to 100 μm.
[0023]
The method for attaching the masking material to both end faces of the porous ceramic member is not particularly limited. For example, the masking material is cut in the same shape as the end face of the porous ceramic member in advance, and a mechanical arm or the like is used. You can paste it automatically or you can stick it by hand. In view of productivity, a method of automatically attaching using a mechanical arm or the like is desirable.
[0024]
Next, an adhesive paste is applied to the side surface of the porous ceramic member to which the masking material is pasted, and the process of laminating another porous ceramic member on the adhesive paste is repeated to obtain a ceramic laminate. The ceramic laminated body production process to assemble is performed.
[0025]
In this ceramic laminate manufacturing process, as shown in FIG. 3, the upper side of the porous ceramic member 30 placed in an obliquely inclined state on the table 60 having a V-shaped cross section is directed. The adhesive paste is printed on the two side surfaces 30a and 30b using, for example, a brush, a squeegee, a roll, etc., to form an adhesive paste layer 61 having a predetermined thickness.
[0026]
Next, another porous ceramic member 30 is laminated on the adhesive paste layer 61. Then, after the adhesive paste layer 61 is formed on the side surface of the porous ceramic member 30, the process of laminating the other porous ceramic member 30 is repeated, and a prismatic ceramic laminate having a predetermined size is performed. Create a body.
[0027]
The adhesive paste is not particularly limited as long as it has heat resistance, and examples thereof include an organic binder, an inorganic binder, inorganic fibers, and inorganic particles. The adhesive paste having such a composition is well-familiar with the porous ceramic member and excellent in adhesive strength, and also excellent in thermal conductivity.
[0028]
Examples of the organic binder include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxy cellulose, and the like. These may be used alone or in combination of two or more. Among the organic binders, carboxycellulose is preferable.
[0029]
Examples of the inorganic binder include silica sol and alumina sol. These may be used alone or in combination of two or more. Among the inorganic binders, silica sol is preferable.
[0030]
Examples of the inorganic fibers include ceramic fibers such as silica-alumina, mullite, alumina, and silica. These may be used alone or in combination of two or more. Of the inorganic fibers, silica-alumina fibers are preferred.
[0031]
Examples of the inorganic particles include carbides and nitrides, and specific examples include inorganic powders or whiskers made of silicon carbide, silicon nitride, boron nitride, or the like. These may be used alone or in combination of two or more. Of the inorganic particles, silicon carbide having excellent thermal conductivity is preferable.
[0032]
In this adhesive paste, in order to soften the adhesive paste layer and impart fluidity to facilitate application, in addition to the organic binder, inorganic binder, inorganic fiber and inorganic particles described above, approximately 35% of the total weight. About 65% by weight of water and other solvents such as acetone and alcohol are contained. The viscosity of the adhesive paste is preferably 15 to 25 Pa · s (10,000 to 20,000 cps (cP)).
[0033]
The adhesive paste is not particularly limited as a method for adhering to the side surface of the porous ceramic member, for example, the adhesive paste is transported using a tube or the like, the lump of the adhesive paste is allowed to flow out of the tube, Examples include a method of adhering to the side surface of the porous ceramic member.
[0034]
Next, the ceramic laminate thus produced is heated, for example, at 50 to 150 ° C. for 1 hour to dry and cure the adhesive paste layer to obtain an adhesive layer, and then the ceramic laminate. The ceramic block preparation process which cuts one part and produces the said ceramic block is performed.
[0035]
The method for cutting a part of the ceramic laminate is not particularly limited, and examples thereof include a method for cutting the outer peripheral portion of the ceramic laminate using a diamond cutter or the like.
At this time, the ceramic laminate End face Since the masking material adhered to has the above-described characteristics, the masking material at the cutting portion is cut into the same shape as the cutting portion without stretching, breaking or peeling off. Therefore, it is possible to prevent the sealing material paste from entering the through-holes of the porous ceramic member in the sealing material layer forming step described later.
[0036]
Next, a sealing material paste is applied to the outer peripheral portion of the ceramic block thus manufactured and dried to form a sealing material layer, thereby manufacturing a honeycomb filter.
[0037]
It does not specifically limit as said sealing material paste, For example, the paste which consists of a composition similar to the said adhesive paste can be mentioned.
[0038]
Further, the method for forming the sealing material layer is not particularly limited. For example, the ceramic block is pivotally supported and rotated in the direction of the rotation axis, and a tube or the like is used similarly to the case where the adhesive layer is formed. The lump of the sealing material paste is attached to the outer peripheral portion of the rotating ceramic block. And the method of extending a sealing material paste using a plate-shaped member etc. and forming a sealing material paste layer can be mentioned.
At this time, the sealing material paste may adhere to the end face, but in the present invention, since the masking material is attached to the end face, the sealing material paste does not enter the through hole of the porous ceramic member.
Thereafter, for example, by drying at a temperature of 120 ° C. or higher, moisture is evaporated to form a sealing material layer. However, the masking material used in the present invention has a heat resistance of 120 ° C. or higher, so this drying step It will be too soft and will not shrink or decompose.
[0039]
Next, the manufacturing method of the honeycomb filter of the present invention is completed by performing a masking material peeling step for peeling off the masking material attached to both end faces of the honeycomb filter thus manufactured.
[0040]
The method for peeling the masking material is not particularly limited. For example, a peeling sheet coated with an adhesive having an adhesive strength stronger than the adhesive strength of the masking material is pressed against the end face of the honeycomb filter, and the peeling is performed. The above masking material is adhered to the sheet for use, and then the peeling sheet is pulled away so that the plurality of masking materials are peeled off from the end face of the honeycomb filter, or manually peeled off using a spatula or a cutter. Although a method etc. can be mentioned, The method using a peeling sheet is preferable.
[0041]
As a peeling sheet which apply | coated the adhesive which has an adhesive strength stronger than the adhesive force of the said masking material, what apply | coated the rubber-type adhesive to the polyester film etc. can be mentioned, for example.
[0042]
The adhesive strength of the release sheet is desirably 3000 to 8000 g / 25 mm width. When the adhesive strength is less than 3000 g / 25 mm width, the adhesive strength is insufficient, and the masking material may not be completely peeled from the end face of the honeycomb filter. On the other hand, when the adhesive strength exceeds 8000 g / 25 mm width, the adhesive strength is too strong, so that the handleability is inferior, and the adhesive strength is sufficient to peel off the masking material. The peeling sheet that is included causes an increase in manufacturing costs. Note that the above-mentioned masking material having the above-mentioned adhesive strength is not easily peeled off due to heat or external factors during the manufacture of the honeycomb filter, but is easier to use with the above-mentioned peeling sheet having a stronger adhesive strength than the above-mentioned masking material. Further, it can be peeled from the end face of the honeycomb filter.
[0043]
In addition, the shape of the release sheet may include any shape such as substantially the same shape as the end face of the honeycomb filter, a rectangular shape, and the size of the release sheet can completely cover the end face of the honeycomb filter. It is desirable to be a thing. This is because the masking material affixed to substantially the entire end face of the honeycomb filter can be completely bonded.
[0044]
The method for pressing such a release sheet against the end face of the honeycomb filter is not particularly limited, and can be pressed by any method, but a method of rolling a roller along the end face of the honeycomb filter is desirable. This is because the angle formed between the roller and the end face of the honeycomb filter is always constant, so that the release sheet can be pressed against the end face of the honeycomb filter with a uniform pressing force.
[0045]
The diameter of the roller is appropriately adjusted according to the diameter of the end face of the honeycomb filter to be pressed, and is preferably about 50 to 200 mm. If the diameter is less than 50 mm, it takes time to roll the roller from one end portion of the end face of the honeycomb filter to the other end portion with the center interposed therebetween, resulting in a decrease in productivity. On the other hand, when the diameter exceeds 200 mm, it becomes difficult to press the release sheet against the end face of the honeycomb filter with uniform pressing.
[0046]
The width of the roller is not particularly limited, and is preferably adjusted to be slightly larger than the diameter of the end face of the honeycomb filter. This is because the roller can be rolled only once along the end face of the honeycomb filter.
[0047]
Further, it is desirable that at least the surface of the roller is an elastic body having a hardness of 40 to 90 °. This is because when the release sheet is pressed against the end face of the honeycomb filter using the roller, damage to the end face of the release sheet, the masking material, and the honeycomb filter is prevented.
[0048]
The elastic body is preferably formed with a thickness of at least 5 mm from the surface of the roller. When the elastic body has a thickness of less than 5 mm, when the roller is pressed against the end face of the honeycomb filter, the elastic body is deformed and the elastic body non-forming portion of the roller is pressed, and the release sheet and the masking material In addition, the end face of the honeycomb filter may be damaged.
In addition, since it is “at least”, the entire roller may be made of the elastic body.
[0049]
The elastic body is preferably urethane foam rubber or chloroprene sponge rubber. It has an appropriate hardness, and when the release sheet is pressed against the end face of the honeycomb filter, the portion in contact with the end face of the honeycomb filter is deformed appropriately, and the release sheet and the adhesive sheet are securely attached. Because it can be attached.
[0050]
The elastic body is most preferably neoprene sponge rubber. The neoprene sponge rubber which has a suitable hardness of 50 ° and does not damage the peeling sheet, the masking material and the end face of the honeycomb filter when pressed against the end face of the honeycomb filter, and is in contact with the end face of the honeycomb filter This is because the material can be appropriately deformed and the entire masking material can be reliably attached to the release sheet. Moreover, the processability is also excellent.
[0051]
Examples of other elastic bodies include, for example, synthetic rubbers such as styrene / butadiene rubber, butadiene rubber, isoprene rubber, chloroprene rubber, urethane rubber and silicone rubber, elastomers such as polyisobutylene and polyethylene, polyurethane foam, polystyrene foam, and foam. Examples thereof include plastic foams such as polyethylene and expanded polypropylene, natural rubber, sponge rubber and the like.
[0052]
As explained above, since the manufacturing method of the honeycomb filter of the present invention has a masking material excellent in heat resistance and durability attached to both end faces of the manufactured porous ceramic member, the attached masking material is A honeycomb filter having good characteristics can be manufactured without being easily broken, disassembled, or peeled off during the manufacture of the honeycomb filter, and as a result, a sealing material or the like does not enter the through hole of the honeycomb filter. it can.
[0053]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.
[0054]
Example 1
After adding and kneading an organic binder, water, etc. to silicon carbide powder, extrusion molding is performed to produce a honeycomb-shaped product, followed by drying, degreasing and firing, as shown in FIG. The average pore size is 1-40 μm, and the number of cells is 31 / cm ² Thus, a porous ceramic member having a partition wall thickness of 0.3 mm was manufactured.
[0055]
Next, a masking material (manufactured by Nitto Denko Corporation: No. 315) made of a PET film coated with a thermosetting rubber adhesive as an adhesive was attached to both end faces of the porous ceramic member.
The masking material had a hardness of 110 °, a heat resistant temperature of 150 ° C., and an adhesive strength of 1200 g / 19 mm width.
[0056]
Next, a ceramic laminate is produced by binding a number of the porous ceramic members using a heat-resistant adhesive containing inorganic fibers, inorganic particles, etc., and then cutting with a diamond cutter to make a ceramic block Then, a sealing material made of the same component as the above adhesive was formed on the outer periphery thereof, and dried at 130 ° C. to produce a cylindrical honeycomb filter as shown in FIG.
[0057]
Then, as a release sheet, a polyester film coated with a rubber adhesive (manufactured by Scotch: No. 859) is pressed against the end face of the honeycomb filter, the masking material is adhered to the release sheet, and the release sheet is removed. The masking material was peeled off from the end face of the honeycomb filter by pulling the sheet for use away from the end face of the honeycomb filter.
The adhesive strength of the release sheet was 5000 gf / 25 mm width, and when the release sheet was pressed against the end face of the honeycomb filter, a roller having neoprene rubber formed on the surface thereof was used.
[0058]
In this Example 1, the masking material affixed to the porous ceramic member was cut into the same shape as the cut shape without being torn, stretched, or peeled even in the ceramic block manufacturing process. . In the drying process, neither alteration nor decomposition occurred. Furthermore, it was easily peeled off by the release sheet even in the peeling step. A honeycomb filter having good characteristics could be manufactured. Further, when the state of the end face of the manufactured honeycomb filter was visually observed, there was no through-hole in which clogging occurred in particular.
[0059]
Comparative Example 1
A honeycomb filter was produced in the same manner as in Example 1 except that a commercially available gum tape was used as the masking material to be attached to both end faces of the porous ceramic member.
[0060]
In this Comparative Example 1, the gummed tape affixed to both end faces of the porous ceramic member as the masking material was partially damaged and peeled off during the manufacture of the honeycomb filter, and the end face of the porous ceramic member was Could not be completely covered. In addition, when the state of the end face of the manufactured honeycomb filter was visually observed, the adhesive paste and the sealant paste penetrated into a part of the through hole of the honeycomb filter, and there was a clogged portion. The honeycomb filter according to Example 1 was inferior in function as a filter.
[0061]
【The invention's effect】
The manufacturing method of the honeycomb filter of the present invention is as described above, and the masking material is excellent in heat resistance and has appropriate hardness and adhesiveness. Therefore, the masking material attached to the end face portion of the honeycomb filter is, During the manufacture of the honeycomb filter, a part of the honeycomb filter is not peeled off or damaged, and no decomposition or alteration occurs. Therefore, the through hole of the honeycomb filter is not clogged, and the honeycomb filter can be manufactured satisfactorily.
[Brief description of the drawings]
FIG. 1 is a perspective view schematically showing an embodiment of a honeycomb filter.
FIG. 2 (a) is a perspective view schematically showing a porous ceramic member constituting a honeycomb filter, and FIG. 2 (b) is a cross-sectional view taken along line AA.
FIG. 3 is an explanatory view schematically showing how a ceramic block is manufactured.
[Explanation of symbols]
10 Honeycomb filter
13 Sealing material layer
14 Adhesive layer
15 Ceramic block
30 Porous ceramic member
30a, 30b side
31 Through hole
32 Filler
33 Bulkhead
60 units
61 Adhesive paste layer

Claims (12)

A plurality of prismatic porous ceramic members with a number of through-holes arranged in parallel in the longitudinal direction across the partition walls are bound together via an adhesive layer to form a ceramic block, and the outer periphery is coated with a sealing material layer A method for manufacturing a honeycomb filter configured such that a partition wall separating the through holes functions as a filter for collecting particles, and after manufacturing the porous ceramic member, its hardness is 50 to 150 °, heat resistance A masking material pasting step in which a pressure-sensitive adhesive layer is formed on a base film having a temperature of 120 ° C. or higher, and a masking material having an adhesive strength of 500 to 2000 gf / 19 mm width is pasted to both end faces of the porous ceramic member; The adhesive paste is applied to the side surface of the porous ceramic member to which the masking material is pasted, and the other is placed on the adhesive paste. Repeat laminating a porous ceramic member, assembled ceramic laminate, drying the adhesive paste by heating the ceramic laminate, the ceramic laminate manufacturing step of curing, a portion of said ceramic laminate A ceramic block manufacturing step of cutting and manufacturing the ceramic block by cutting the masking material bonded to the end face of the ceramic laminate into the shape of the cut portion of the ceramic laminate, and an outer peripheral portion of the ceramic block A sealing material layer forming step of forming a sealing material layer on the honeycomb filter and pressing a release sheet having an adhesive strength stronger than the adhesive strength of the masking material against an end face of the honeycomb filter; By adhering the masking material and then pulling off the release sheet. And a masking material peeling step for peeling the masking material from the end face of the honeycomb filter.   The method for manufacturing a honeycomb filter according to claim 1, wherein the base film is made of a PET film.   The method for manufacturing a honeycomb filter according to claim 1 or 2, wherein the masking material has a thickness of 10 to 500 µm. The manufacturing of the honeycomb filter according to any one of 1 to 3, wherein in the masking material attaching step, the masking material is previously cut into the same shape as the end face of the porous ceramic member and automatically attached using a mechanical arm. Method. The said sealing material layer formation process WHEREIN: The said sealing material paste is made to adhere to the outer peripheral part of the said ceramic block, a sealing material paste layer is formed, and it is made to dry at the temperature of 120 degreeC or more. Manufacturing method of honeycomb filter. The honeycomb filter according to claim 5, wherein, in the sealing material layer forming step, the ceramic block is pivotally supported and rotated in a rotation axis direction, and the sealing material paste is stretched using a plate-like member to form a sealing material paste layer. Manufacturing method. The method for manufacturing a honeycomb filter according to any one of claims 1 to 6, wherein the peeling sheet has an adhesive strength of 3000 to 8000 gf / 25 mm width. The method for manufacturing a honeycomb filter according to any one of claims 1 to 7, wherein, in the masking material peeling step, the peeling sheet is pressed against the end face of the honeycomb filter by rolling a roller along the end face of the honeycomb filter. The method for manufacturing a honeycomb filter according to claim 8, wherein at least a surface of the roller is an elastic body having a hardness of 40 to 90 °. The method for manufacturing a honeycomb filter according to claim 9, wherein the elastic body is formed with a thickness of at least 5 mm from a surface of the roller. The method for manufacturing a honeycomb filter according to claim 9 or 10, wherein the elastic body is urethane foam rubber or chloroprene sponge rubber. The method for manufacturing a honeycomb filter according to claim 11, wherein the elastic body is neoprene sponge rubber.

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