The present invention relates to an extrusion molding device and a method for manufacturing a green honeycomb molded body.
Ceramic honeycomb fired bodies have been widely known as diesel particulate filters or the like. The ceramic honeycomb fired body has a structure in which one end sides of some through holes of a honeycomb structure, which includes a large number of through holes, are sealed with a sealing material, and the other end sides of the remaining through holes are sealed with a sealing material. In Patent Literature 1, an extrusion molding device used for manufacturing a green honeycomb honeycomb molded body is disclosed. The device includes a first pipe having a screw, a filtration net, a taper tube, and a die, in this order.
[Patent Literature 1] Japanese Unexamined Patent Publication No. 2000-301517
Now, in an extrusion molding device such as Patent Literature 1, in order to extrude a green honeycomb molded body in a desired honeycomb geometry, there is a case where it is preferable to provide extension tube portions, the inner diameter of which is constant, at the front and rear of the taper tube.
Then, in the extrusion molding device of such a configuration, in the case of, for example, changing an exterior shape of a green honeycomb molded body to be molded, it is cumbersome to remove the die, the extension tube portion, the resistance tube, and the extension tube portion, from the extrusion molding device, and to fasten thereafter the other extension tube portion, the resistance tube, the extension tube portion, and the die, to the extrusion molding device.
The present invention is made in view of the above problem and has an objective to provide an extrusion molding device that is easy to perform changing operation and a method for manufacturing a green honeycomb molded body using the extrusion molding device.
An extruding device according to the present invention comprises a first pipe, a screw that is provided in the first pipe, a second pipe that is connected to the outlet of the first pipe, a flow adjustment plate that is provided between the first pipe and the second pipe, and a die that is connected to the outlet of the second pipe. The second pipe includes, in order from the side of the first pipe, a first portion having a constant inner diameter, a second portion having an inner diameter that decreases as the second portion extends from the first portion, and a third portion having a constant inner diameter. The second portion is undetachably integrated with the first portion, and the third portion is undetachably integrated with the second portion.
According to the present invention, since the first portion, the second portion, and the third portion are integrated, a detachable mechanism between the first portion and the second portion, and a detachable mechanism between the second portion and the third portion, are dispensed with, the reduction in weight and costs of the second pipe is achieved, and moreover the change of the first portion to the third portion can be quickly performed when the external shape of an extrusion-molded body (e.g., a diameter) is changed.
The inner surface of the second portion may include a slope inclining such that the inner diameter gradually decreases as the second portion extends from an upstream side to a downstream side, and an inclination angle of the inner surface of the second portion with respect to a central axis of the second portion may decrease stepwise as the second portion extends from the upstream side to the downstream side. In this case, composite material can be smoothly led toward the die.
The above extrusion molding device may further comprise a hydraulic clamp or magnet clamp that fastens the second pipe and the first pipe in a detachable manner. In this case, the change of the first portion to the third portion becomes further easier.
In the flow adjustment plate, an inclining through hole may be formed, the inclining through hole inclining with respect to the central axis of a channel that runs from the first pipe toward the second pipe. In this case, at least some of composite material on the upstream side of the flow adjustment plate passes through the inclining through hole of the flow adjustment plate and flows in a direction that inclines with respect to the central axis of the channel, in the downstream side of the flow adjustment plate. By a flow inclining with respect to the central axis of the channel being formed, composite material fluxes are merged with one another in a direction orthogonal to the central axis of the channel. For this reason, it is possible to reduce the variations of the composite material in fluidity in the direction orthogonal to the central axis of the channel.
The inclining through hole may be formed close to a center of the flow adjustment plate. In this case, since the flow inclining with respect to the central axis of the channel occurs in the central portion of the channel, composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion are merged with one another. In an extrusion molding device, the fluidity of a composite material flux flowing through the central portion of the channel tends to be high as compared with the fluidity of a composite material flux flowing through the periphery of the central portion. Therefore, by mixing the composite material flux flowing through the central portion of the channel and the composite material flux flowing through the periphery of the central portion, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The inclining through hole may be formed so as to approach the central axis as extending from one end side toward another end side. In this case, by composite material passing through the inclining through hole, a flow from the central portion of the channel toward the outside or a flow from the outside toward the central portion of the channel is formed. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of central portion to be further better mixed with one another, and thus it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
In the flow adjustment plate, a plurality of inclining through holes including the inclining through hole may be formed, some of the inclining through holes may be formed so as to approach the central axis as extending from an upstream side toward a downstream side, and others of the inclining through holes may be formed so as to approach the central axis as extending from the downstream side toward the upstream side. In this case, by the composite material fluxes flowing through the inclining through holes, both of the flows from the central portion of the channel toward the outside and flows from the outside toward the central portion of the channel are formed. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of central portion to be further better mixed with one another, and thus it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The flow adjustment plate may include a main member that has an opening at a center, and a core member that is disposed in the opening, and the inclining through hole may be formed in the core member. In this case, for example, a plurality of core members can be prepared that differ in inner diameter, number, disposition, or inclining direction of inclining through holes, and can be changed as appropriate in conformity with the composition or the like of composite material. For this reason, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The flow adjustment plate may include a plurality of stacked plates that are stacked along a central axis of a channel running from the first pipe toward the second pipe, in each of the stacked plates, a plurality of through holes may be formed, and the through holes in each of the stacked plates may be connected to a plurality of the through holes that are formed in the stacked plate adjacent to the each of the stacked plates. In this case, at least some of composite material on the upstream side of the flow adjustment plate passes through the through holes of the stacked plates. The through holes of each stacked plate are connected to a plurality of through holes of an adjacent stacked plate. At locations where a through hole on the upstream side is connected to a plurality of through holes on the downstream side, a composite material flux flowing out from the one through hole is separated and flows into the plurality of through holes. At locations where a through hole on the downstream side is connected to a plurality of through holes on the upstream side, composite material fluxes flowing out from the plurality of through holes flow into the one through hole and are merged with one another. In such a manner, the separation and merging of composite material occur in the course of passing through the plurality of stacked plates, which causes composite material fluxes to be mixed with one another in directions orthogonal to the central axis of the channel. For this reason, it is possible to reduce the variations of composite material in fluidity in the directions orthogonal to the central axis of the channel.
Each of the stacked plates may be disposed at a center of the flow adjustment plate. In this case, the separation and merging of the composite material occur in the central portion of the channel, and thus composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion are merged with one another. In an extrusion molding device, the fluidity of a composite material flux flowing through the central portion of the channel tends to be high as compared with the fluidity of a composite material flux flowing through the periphery of the central portion. Therefore, by mixing the composite material flux flowing through the central portion of the channel and the composite material flux flowing through the periphery of the central portion, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The plurality of stacked plates may include a stacked plate on an upstream side, a stacked plate on a downstream side, and a middle stacked plate that is disposed between the stacked plates on the upstream side and the downstream side, the through holes formed in the stacked plate on the downstream side may be connected to a plurality of the through holes that are formed closest to a center side and closest to an outer edge side of the stacked plate on the upstream side, via the through holes formed in the middle stacked plate. In this case, composite material fluxes flowing into the through hole that are formed closest to the center side of the stacked plate on the upstream side and composite material fluxes flowing into the through holes that are formed closest to the outer edge side of the stacked plate on the upstream side flow into one through hole of the stacked plate on the downstream side and are merged with one another. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion to be further better mixed with one another. Therefore, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The flow adjustment plate may include a main member that has an opening at a center, and a core member that is disposed in the opening, and the plurality of stacked plates may form the core member. In this case, for example, a plurality of core members can be prepared that differ in number of stacked plates, or in inner diameter, number, or disposition of the through holes of each stacked plate, and can be changed as appropriate in conformity with the composition or the like of composite material. For this reason, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The plurality of stacked plates may include a stacked plate on an upstream side, a stacked plate on a downstream side, and a middle stacked plate that is disposed between the stacked plates on the upstream side and the downstream side, and in the middle stacked plate, the through holes may be formed that are smaller in inner diameter and larger in number as compared with the through holes of the stacked plates on the upstream side and the downstream side. In this case, the separation and merging of the composite material occur at more spots, which causes composite material fluxes to be further better mixed with one another in the directions orthogonal to the central axis of the channel. Therefore, it is possible to further reduce the variations of the composite material in fluidity in a direction orthogonal to the central axis of the channel.
The second pipe may further include a fourth portion that is positioned. on a downstream side of the third portion, and in the fourth portion, a rod that projects from an inner surface of the fourth portion toward a center side, and an actuator that adjusts a projecting length of the rod from the inner surface of the fourth portion, may be provided. In this case, by adjusting the projecting lengths of the rods 74, it is possible to adjust the distribution of flow rate in the channel of the fourth portion so as to suppress the flexure of a molded body extruded from the die.
A method for manufacturing a green honeycomb molded body according to the present invention includes a step of extruding a ceramic material using an extrusion molding device, to obtain the green honeycomb molded body. The extrusion molding device is the above-described extrusion molding device.
According to the present invention, an extrusion molding device that is easy to perform changing operation and a method for manufacturing a green honeycomb molded body using the extrusion molding device are provided.
Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. First, a green honeycomb molded body will be described prior to the description of an extrusion molding device according to the present invention.
A green honeycomb molded body 70 illustrated in
The length of the green honeycomb molded body 70 in a direction in which the through holes 71a and 71b extend is not specially limited, and can be, for example, 40 to 350 mm. In addition, the outer diameter of the green honeycomb molded body 70 is not specially limited, either, and can be, for example, 100 to 320 mm.
The composite material that makes up the green honeycomb molded body 70 is not specially limited and contains an inorganic compound source powder being a ceramic material, an organic binder such as a methyl cellulose, and an additive that is added as needed. From the viewpoint of high-temperature tolerance of a honeycomb fired body, preferred ceramic materials include an oxide such as an alumina, silica, mullite, cordierite, glass, and aluminum titanate, a silicon carbide, a silicon nitride, and the like. Note that the aluminum titanate can further contain a magnesium and/or a silicon.
For example, in the case of producing a green honeycomb molded body made of an aluminum titanate, the inorganic compound source powder contains an aluminum source powder such as an α alumina powder, and an titanium source powder such as an anatase-type or rutile-type titania powder, and can further contain, as needed, a magnesium source powder such as a magnesia powder and magnesia spinel powder, and/or a silicon source powder such as a silicon oxide powder and glass frit.
Organic binders include celluloses including a methyl cellulose, carboxymethyl cellulose, hydroxyalkyl methyl cellulose, carboxymethyl cellulose sodium, and the like; alcohols including a polyvinyl alcohol and the like; and a lignin sulfonate.
Additives include, for example, a pore forming agent, lubricant and plasticizer, dispersant, and solvent.
Pore forming agents include a carbon material such as a graphite; resins including a polyethylene, polypropylene, polymethyl methacrylate; a vegetable material such as a starch, nut shell, walnut shell, and corn; an ice; a dry ice, and the like.
Lubricants and plasticizers include alcohols including a glycerin; a higher fatty acid such as a caprylic acid, lauric acid, palmitic acid, arachidic acid, oleic acid, and stearic acid; a metal stearate such as an aluminum stearate, a polyoxyalkylene alkyl ether (POAAE), and the like.
Dispersants include, for example, an inorganic acid such as a nitric acid, hydrochloric acid, and sulfuric acid; an organic acid such as an oxalic acid, citric acid, acetic acid, malic acid, and lactic acid; alcohols including a methanol, ethanol, propanol, and the like; a surfactant such as an ammonium polycarboxylate, polyoxyalkylene alkyl ether, and the like.
As a solvent, for example, alcohols including a methanol, ethanol, butanol, propanol, and the like; glycols including a propylene glycol, polypropylene glycol, ethylene glycol, and the like; a water, and the like can be used.
An example of an extrusion molding device according to a first embodiment will be described with reference to
The extrusion molding device 1 mainly includes a first pipe 10, a second pipe 50 that is connected to the outlet of the first pipe 10, a flow adjustment plate 20 that is provided between the first pipe 10 and the second pipe 50, a die 90 that is connected on the downstream side of the second pipe 50, and screws 2A and 2B that are provided in the first pipe 10.
The first pipe 10 includes, in the order from the upstream side thereof, a barrel portion 12, an extended portion 14, a tapered portion 16, and an adjustment plate fixing section 18.
The screw 2A is provided in the upper tier of the barrel portion 12, and the screw 2B is provided in the lower tier of the barrel portion 12. The screws 2A and 2B knead composite material that is supplied from an inlet 12a of the barrel portion 12 and transfer the composite material to an outlet 12e of the barrel portion 12 through a channel 12b.
As illustrated in
In the tapered portion 16, a channel 16a is formed that runs to the channel 14a. The inner diameter of the channel 16a increases as the channel 16a extending from the barrel portion 12. The inner diameter of the tapered portion 16 on the upstream side thereof is, for example, the same as the inner diameter of the channel 14a.
In the adjustment plate fixing section 18, a channel 18b is formed that runs to the channel 16a. On the downstream side of the adjustment plate fixing section 18, in the circumferential portion of the channel 18b, a recessed portion 18c is formed that houses the circumferential portion of the flow adjustment plate 20. On the outer circumference of the adjustment plate fixing section 18, a flange portion 18d is formed.
The extended portion 14 and the tapered portion 16 are fastened to each other by bolts 13, and the tapered portion 16 and the adjustment plate fixing section 18 are fastened to each other by welding. Although not illustrated, the barrel portion 12 and the extended portion 14 are fastened to each other by a bolt.
The second pipe 50 includes, in the order from the upstream side thereof (a first pipe 10 side), as first portion 32, a second portion 34, a third portion 36, a fourth portion 38, and a fifth portion 40.
In the first portion 32, a channel 32b is formed that runs to the channel 18b. The inner diameter of the channel 32b is, for example, the same as the inner diameter of the channel 18b. The length of the channel 32b can be, for example, 50 to 100 mm. The first portion 32 has a function of the connection with an upstream portion. On the outer circumference of the first portion 32, a flange portion 32c is formed that overlaps with the flange portion 18d of the first pipe 10.
A channel 34a of the second portion 34 has an inner diameter that decreases as the channel 34a extends from an upstream side to a downstream side. Specifically, the inner surface of the channel 34a includes a slope inclining such that the inner diameter gradually decreases as the channel 34a extends from the upstream side to the downstream side. The inclination angle of the inner surface of the channel 34a with respect to a central axis CL1 of the channel 34a decreases stepwise as the channel 34a extends from the upstream side to the downstream side. For example, the inner surface of the channel 34a is divided into three regions 35a, 35b, and 35c that are arranged from the upstream side to the downstream side. The inclination angle of the region 35a with respect to the central axis CL1 is larger than the inclination angle of the region 35b with respect to the central axis CL1. The inclination angle of the region 35b with respect to the central axis CL1 is larger than the inclination angle of the region 35c with respect to central axis CL1. The inclination angle of the region 35c with respect to the central axis CL1 is substantially 0°. That is, the region 35c does not incline with respect to the central axis CL1.
The channel 34a runs to the channel 32b, and the inner diameter of the channel 34a on the upstream side thereof is, for example, the same as the inner diameter of the channel 32b. It is preferable that the inner diameter of the channel 34a on the downstream side thereof is smaller than the inner diameter of the channel 12b of the barrel portion 12. It is preferable that the inner diameter of the channel 34a on the downstream side thereof is 60 to 100% of the inner diameter of the channel 12b. It is preferable that the length of the channel 34a is, for example, 100 to 200 mm, It is preferable that the inclination angle of the inner surface of the channel 34a with respect to the central axis CL1 is 0 to 40°. The channel 34a has a function of flow amount adjustment of the composite material in a paste form.
In the third portion 36, a channel 36a is formed that runs to the channel 34a. The inner diameter of the channel 36a is constant and, for example, the same as the inner diameter of the channel 34a on the downstream side thereof. The length of the channel 36a is, for example, 50 to 150 mm. The channel 36a has a function of flow amount adjustment of the composite material in a paste form.
The first portion 32 is welded to the second portion 34, and the third portion 36 is welded to the second portion 34. The welding method is not specially limited, and brazing, arc welding, or the like can be employed. Spots to be welded are not specially limited, either. Furthermore, the fastening method for the first portion 32 and the second portion 34, and the fastening method for the second portion 34 and the third portion 36 are not limited to welding. The first portion 32 and the second portion 34, and the second portion 34 and the third portion 36 may be undetachably integrated. Being undetachably integrated means that the integrated thing cannot be separated unless a fastened section is broken. The other examples of being detachably integrated include a manner in which the first portion 32 and the second portion 34, and the second portion 34 and the third portion 36 are integrally formed from the same material.
On the outer circumference of the second portion 34, a jacket structure 34J is formed, and cooling medium such as cooling water can be supplied to the jacket structure 34J.
Between the adjustment plate fixing section 18 of the first pipe 10 and the first portion 32 of the second pipe 50, the flow adjustment plate 20 is disposed so as to partition off the channel 18b and the channel 32b. The flow adjustment plate 20 is sandwiched by the adjustment plate fixing section 18 and the first portion 32, and the circumferential portion of the flow adjustment plate 20 is housed in the recessed portion 18c. The flow adjustment plate 20 is also referred to as a current plate, including a large number of through holes that penetrate therethrough in a flowing direction. By adjusting the positions and the size of the through holes, it is possible to control the flow behavior of the composite material in the second pipe 50. In addition, foreign objects can be removed by the flow adjustment plate 20. The diameter of the through holes is, for example, 1 to 10 mm.
The flow adjustment plate 20 has an outer diameter that is larger than the inner diameter of the channels 18b and 32b of the adjustment plate fixing section 18 and the first portion 32, and a central portion of the flow adjustment plate 20 partitions off the channel 18b and the channel 32b. The flow adjustment plate 20 is sandwiched by the adjustment plate fixing section 18 and the first portion 32 so as to be attached to the first pipe 10 and the second pipe 50 in a detachable manner.
It is preferable that the flow adjustment plate 20 is a structure that hardly deforms even when pressure is applied thereto from the upstream side thereof. From such a viewpoint, it is preferable that the material of the flow adjustment plate 20 is, for example, a carbon steel or the like. Examples of a preferable material other than the carbon steel include a special steel that contains a nickel, chromium, tungsten, or the like. It is preferable from the viewpoint of securing a sufficient strength that the thickness of the flow adjustment plate 20 is 10 to 100 mm.
The first pipe 10 and the second pipe 50 are detachably coupled to each other by, for example, hydraulic clamps 60. As illustrated in
To couple the first pipe 10 and the second pipe 50 to each other, the locking section 66 is inserted into the through holes 18a and 32a. Causing the locking section 66 to rotate using the cylinder actuator 62 brings about the state that, as illustrated in
To separate the first pipe 10 from the second pipe 50, the locking section 66 is moved away from the cylinder actuator 62. Causing the locking section 66 to rotate using the cylinder actuator 62 brings about the state that, as illustrated in
Referring hack to
In the fifth portion 40, a channel 40a is formed that runs to the channel 38b. The inner diameter of the channel 40a is constant and, for example, the same as the inner diameter of the channel 38b. The length of the channel of the fifth portion 40 is, for example, 20 to 300 mm. On the downstream side of the channel 40a, the die 90 is provided. The die 90 is for shaping the composite material to obtain the molded body 70 in the shape illustrated in
The material of the second pipe 50 is not specially limited, and a metallic material such as an iron, and stainless can be used. It is preferable that the inner surface of the channel of the second pipe 50 includes a tungsten carbide layer so as to suppress abrasion. The tungsten carbide layer can be formed by a thermal spraying method.
Next, a method for manufacturing the green honeycomb molded body 70 using the extrusion molding device 1 will be described. First, a composite material is fed from the inlet 12a into the channel 12b. By operating the screws 2A and 2B, the composite material is kneaded and transferred to the outlet 12e on the downstream side of the first pipe 10. The kneaded material is caused to pass through the plurality of through holes of the flow adjustment plate 20 for the adjustment of flow rate distribution such as the unification of flow rate distribution, and thereafter fed to the die 90 through the second pipe 50. The linear velocity of the composite material on the downstream side of the die 90 can be 10 to 150 cm/min.
The composite material is extruded from the die 90, and the molded body 70A is collected on a support table 95. By cutting the molded body 70A into pieces of a predetermined length, green honeycomb molded bodies 70 are obtained. As seen from the above, this method includes the process of extruding ceramic material using the extrusion molding device 1 to obtain the green honeycomb molded body 70. By sealing one or the other end of the through holes of the green honeycomb molded body 70 and thereafter firing the green honeycomb molded body 70, a honeycomb structure (a honeycomb filter) is obtained.
In order to obtain a green honeycomb molded body 70 in a different external shape, as illustrated in
According to the present embodiment, since the first portion 32, the second portion 34, and the third portion 36 of the second pipe 50 are fastened to each other by welding, the attachment/detachment of the second pipe 50 to/from the first pipe 10 is easy, and furthermore weight reduction is possible.
Subsequently, an extrusion molding device according to a second embodiment will be described with reference to
The magnet clamp 80 includes a back core 85, a plurality of hard magnetic bodies 81, a plurality of hard magnetic bodies 83, and a plurality of soft magnetic bodies 82. The hack core 85 is formed by a bottom portion 85a along the flange portion 18d, and wall portions 85b and 85c that project from the bottom portion 85a toward a flange portion 32c side, on an inner circumference side and an outer circumference side of the flange portion 18d, respectively. The back core 85 has soft magnetism. The plurality of hard magnetic bodies 81 and the soft magnetic bodies 82 are disposed between the wall portions 85b and 85c and alternately arranged along a surface opposite the bottom portion 85a. The hard magnetic bodies 81 form permanent magnets. The hard magnetic bodies 81 sandwiching the soft magnetic bodies 82 are disposed in such a manner that the same poles of the hard magnetic bodies 81 face each other across a soft magnetic body 82. The hard magnetic bodies 83 are put between the bottom portion 85a of the back core 85 and the soft magnetic bodies 82. In the hard magnetic bodies 83, coils 84 are provided that inverse the poles of the hard magnetic bodies 83. Note that examples of the hard magnetic body 81 include a neodymium magnet. Examples of the hard magnetic body 83 include an Alnico magnet. Examples of the soft magnetic body 82 include an iron. The flange portion 32c of the second pipe 50 is formed of a soft magnetic material, such as an iron, a martensitic stainless, and a ferritic stainless, which are attractable by a magnet.
When current is caused to flow through the coils 84, and by magnetic flux generated from the coils 84, the orientations of the poles of the hard magnetic bodies 83 are made as illustrated in
In contrast, when current in the reverse direction is caused to flow through the coils 84 and by magnetic flux generated from the coils 84, the orientations of the poles of the hard magnetic bodies 83 are made as illustrated in
Subsequently, an extrusion molding device according to a third embodiment will be described. As illustrated in
As illustrated in
By the fitted portion 204c being fitted to the hole portion 203b, the position of the core member 204 in a direction orthogonal to the central axis CL1 is determined. By the large-diameter portion 204d being caught on the boundary portions of the hole portions 203a and 203b of the opening 203, the movement of the core member 204 toward the downstream side is restricted. In contrast, by the sheet member 202, the movement of the core member 204 toward the upstream side is restricted. The core member 204 is thereby retained in the opening 203.
As illustrated in
As illustrated in
As illustrated in
The end portions on the upstream side of the inclining through holes 207 are positioned on the outer circumference side of the core member 204 as compared with the end portions on the upstream side of the inclining through holes 206, surrounding the end portions on the upstream side of the inclining through holes 206 in the recessed portion 210. The end portions on the downstream side of the inclining through holes 207 are positioned on the outer circumference side of the core member 204 as compared with the end portions on the downstream side. of the inclining through holes 206.
As illustrated in
As illustrated in
The end portions on the upstream side of the inclining through. holes 209 are positioned on the outer circumference side of the core member 204 as compared with the end portions on the upstream side of the inclining through holes 208. The end portions on the downstream side of the inclining through holes 209 are positioned close to the central axis CL1 as compared with the end portions on the downstream side of the inclining through holes 206 and 207.
According to the present embodiment, the composite material in the channel 18b passes through the through holes 205 or the inclining through holes 206, 207, 208, and 209. Material composition fluxes having passed through the inclining through holes 206, 207, 208, and 209 flow in the channel 32b in directions that incline with respect to the central axis CL1. By forming the flows inclining with respect to the central axis CL1, the composite material fluxes are mixed with one another in directions orthogonal to the central axis CL1. For this reason, it is possible to reduce the variations of the composite material in fluidity in the directions orthogonal to the central axis CL1.
Since the inclining through holes 206, 207, 208, and 209 are positioned close to the center of the flow adjustment plate 20A, flows inclining with respect to the central axis CL1 are generated in the central portion of the channel extending from the first pipe 10 toward the second pipe 50. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion to be mixed with one another. In an extrusion molding device, the fluidity of a composite material flux flowing through the central portion of the channel tends to be high as compared with the fluidity of a composite material flux flowing through the periphery of the central portion. Therefore, by mixing the composite material flux flowing through the central portion of the channel and the composite material flux flowing through the periphery of the central portion, it is possible to further reduce the variations of the composite material in fluidity in the directions orthogonal to the central axis CL1.
The inclining through holes 206, 207, 208, and 209 are formed so as to approach the central axis CL1 as extending from one end side (the upstream side or the downstream side) to the other end side. For this reason, by composite material fluxes passing through the inclining through holes 206, 207, 208, and 209, flows from the central portion toward the outside of the channel or flows from the outside toward the central portion of the channel are formed. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion to be further better mixed with one another. Therefore, it is possible to further reduce the variations of the composite material in fluidity in the directions orthogonal to the central axis CL1.
In particular, the inclining through holes 206 and 207 are formed so as to approach the central axis CL1 as extending from the downstream side toward the upstream side. The inclining through holes 208 and 209 are formed so as to approach the central axis CL1 as extending from the upstream side toward the downstream side. For this reason, by the composite material fluxes flowing through the inclining through holes 206, 207, 208, and 209, both of the flows from the central portion of the channel toward the outside and flows from the outside toward the central portion of the channel are formed. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion to be further better mixed with one another. Therefore, it is possible to further reduce the variations of the composite material in fluidity in the directions orthogonal to the central axis CL1.
Note that a plurality of core members 204 can be prepared that differ in inner diameter, number, disposition, or inclining direction of inclining through holes, and can be changed as appropriate in conformity with the composition or the like of composite material. For this reason, it is possible to further reduce the variations of paste in fluidity in the directions orthogonal to the central axis CL1.
The inclining through holes are not necessarily formed close to the center of the flow adjustment plate 20A and can be formed in the main member 201. In addition, a through. hole parallel to the central axis CL1 may be formed in the core member 204. The main member 201 and the core member 204 may be undetachably integrated.
Subsequently, an extrusion molding device according to a fourth embodiment will be described. The extrusion molding device according to the present embodiment is one in which the core member 204 in the third embodiment is replaced with a core member 212. The core member 212 is also for achieving the uniformity of flow rate between the central portion and the periphery of the channel.
As illustrated in
By the fitted portion 212c being fitted to the hole portion 203b, the position of core member 212 in a direction orthogonal to the central axis CL1 is determined. By the large-diameter portion 212d being caught on the boundary portions of the hole portions 203a and 203b of the opening 203, the movement of the core member 212 toward the downstream side is restricted. In contrast, by the sheet member 202, the movement of the core member 212 toward the upstream side is restricted. The core member 212 is thereby retained in the opening 203.
The core member 212 is formed by round-shaped stacked plates 213, 214, 215, 216, and 217 that are stacked from the downstream side to the upstream side along the central axis CL1. The large-diameter portion 212d is provided in the stacked plate 217 on the upstream side. The small-diameter portion 212e is provided, in the stacked plate 213 on the downstream side. At the outer edge portions on the downstream side faces of the stacked plates 214, 215, 216, and 217, but not of the stacked plate 213 on the downstream side, projections 214a, 215a, 216a, and 217a are formed that project on the downstream side. At the outer edge portions on the upstream side face of the stacked plates 213, 214, 215, and 216, but not of the stacked plate 217 on the upstream side, recessed portions 213b, 214b, 215b, and 216b are formed that correspond to the projections 214a, 215a, 216a, and 217a, respectively.
By the projections 214a, 215a, 216a, and 217a being fitted to the recessed portions 213b, 214b, 215b, and 216b, respectively, the relatively rotational movements between the stacked plates 213, 214, 215, 216, and 217 are prevented. This determines the relative positions between through holes 218, 219, 220, 221, and 222 to be described later. The stacked plates 213, 214, 215, 216, and 217 are fastened to each other by a bolt or the like.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
According to the present embodiment, composite material in the channel 18b flows into the through holes 205 or the through holes 222. Composite material fluxes flowing into the through holes 222 flow into the through holes 221 connected to the through holes 222. Since each through hole 222 is connected to a plurality of through holes 221, a composite material flux having passed through each through hole 222 is separated and flows into a plurality of through holes 221. Since there are some through holes 221 each of which is connected to a plurality of through holes 222, the composite material fluxes flow from a plurality of through holes 222 into the through hole 221 and merge with one another.
The composite material flowing into the through holes 221 flows into the through holes 220 connected to the through holes 221. Since there are some through holes 221 each of which is connected to a plurality of through holes 220, a composite material flux having passed through the through hole 221 is separated and flows into a plurality of through holes 220. Since each through hole 220 is connected to a plurality of through holes 221, composite material fluxes flow from a plurality of through holes 221 into each through hole 220 and merge with one another.
The composite material flowing into the through hole 220 flows into the through holes 219 connected to the through holes 220. Since each through hole 220 is connected to a plurality of through holes 219, a composite material flux having passed through each through hole 220 is separated and flows into a plurality of through holes 219. Since there are some through holes 219 each of which is connected to a plurality of through holes 220, composite material fluxes flow from a plurality of through holes 220 into the through hole 219 and merge with one another.
The composite material flowing into the through holes 219 flows into the through holes 218 connected to the through holes 219. Since there are some through holes 219 each of which is connected to a plurality of through holes 218, a composite material flux having passed through the through hole 219 is separated and flow into a plurality of through holes 218. Since each through hole 218 is connected to a plurality of through holes 219, composite material fluxes flow from a plurality of through holes 219 into each through hole 218 and merge with one another.
In such a manner, the separation and merging of composite material occur in the course of passing through the five stacked plates 217, 216, 215, 214, and 213, which causes composite material fluxes to be mixed with one another in directions orthogonal to the central axis CL1. For this reason, it is possible to reduce the variations of composite material in fluidity in the directions orthogonal to the central axis CL1.
Each of the stacked plates 213, 214, 215, 216, and 217 is disposed at the center of the flow adjustment plate 20A. This causes the separation and merging of the composite material in the central portion of the channel, and composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion are mixed with one another. As described above, the fluidity of a composite material flux flowing through the central portion of the channel tends to be high as compared with the fluidity of a composite material flux flowing through the periphery of the central portion. Therefore, by mixing the composite material flux flowing through the central portion of the channel and the composite material flux flowing through the periphery of the central portion, it is possible to further reduce the variation of the composite material in fluidity in the directions orthogonal to the central axis CL1.
The through holes 218B formed in the stacked plate 213 on the downstream side are connected to the plurality of through holes 222A and 222B that are formed closest to the center C5 side and closest to the outer edge side, respectively, of the stacked plate 217 on the upstream side, via the through holes 219, 220, and 221 formed in the stacked plates 214, 215, and 216 in the middle. For this reason, composite material fluxes flowing into the through holes 222A formed closest to the center C5 side in the stacked plate 217 on the upstream side and composite material fluxes flowing into the through holes 222B formed closest to the outer edge side in the stacked plate on the upstream side flow one of the through holes 218 of the stacked plate 213 on the downstream side and merge with one another. This causes composite material fluxes flowing through the central portion of the channel and composite material fluxes flowing through the periphery of the central portion to be further better mixed with one another. Therefore, it is possible to further reduce the variations of the composite material in fluidity in the directions orthogonal to the central axis CL1.
In the stacked plates 214 and 216 in the middle, the through holes 219 and 221 are formed that are smaller in inner diameter and larger in number as compared to the through holes 218 and 222 of the stacked plates 213 and 217 on the upstream side and the downstream side. For this reason, the separation and merging of the composite material occur at more spots, which causes composite material fluxes to be further better mixed with one another in the directions orthogonal to the central axis CL1. Therefore, it is possible to further reduce the variations of composite material in fluidity in the directions orthogonal to the central axis CL1.
Note that a plurality of core members 212 can be prepared that differ in number of stacked plates, or in inner diameter, number, or disposition of the through holes of each stacked plate, and can be changed as appropriate in conformity with the composition or the like of composite material. For this reason, it is possible to further reduce the variations of composite material in fluidity in the directions orthogonal to the central axis CL1.
The stacked plates are not necessarily disposed at the center of the flow adjustment plate 20A and may be disposed at a decentered position. In addition, the flow adjustment plate 20A is not necessarily divided into the main member 201 and the core member 212, and the entire flow adjustment plate 20A may be formed by stacked plates.
The embodiments have been described above in detail, but the present invention is not limited to the above embodiments. For example, in the above embodiments, the description has been made about, by way of example, the aspect in which the first pipe 10 includes the extended portion 14, the tapered portion 16, and the adjustment plate fixing section 18, but the embodiments can be practiced even if the flow adjustment plate 20 or 20A is provided in the outlet of the barrel portion 12. That is, the form of the first pipe 10 is not specially limited, and one or more screws may be disposed on an upstream side and the flow adjustment plate 20 or 20A may be disposed on the upstream side of the second pipe 50. Note that, when the first pipe 10 includes the tapered portion 16 the inner diameter of which is expanded as compared with the barrel portion 12, there is an advantage that a molded body having a diameter larger than the inner diameter of the channel 12b can be manufactured.
In addition, in the above embodiments, the second pipe 50 includes the fourth portion 38 and the fifth portion 40 but may not include the fourth portion 38 and the fifth portion 40, and the die 90 may be directly fastened in the outlet of the third portion 36. In addition, the second pipe 50 may include another tubular portion, other than the fourth portion 38 and the fifth portion 40, on the downstream side of the third portion 36.
In addition, the form of the flow adjustment plate 20, and the structure for fastening the flow adjustment plate 20 or 20A between the first pipe 10 and the second pipe 50 are not specially limited.
In addition, the structures of the hydraulic clamp 60 and the magnet clamp 80 according to the above embodiments, the structures for attaching the hydraulic clamp 60 or the magnet clamp 80 to the first pipe 10, and the clamp structure between them and the second pipe 50 are not limited to the above embodiments.
In addition, in the above embodiments, the hydraulic clamp 60 and the magnet clamp 80 are described by way of example, but the above embodiments can be practiced also by fastening the first pipe 10 and the first portion 32 of the second pipe 50 by the other fastening methods such as using a screw.
Also the cross-sectional shape of the channel of the first pipe 10 and the second pipe 50 is not limited to a circle, and may be an ellipse or a polygon. In this case, the inner diameter of the channel can be expressed as a circle equivalent diameter.
In addition, in the above embodiments, the cylindrical green honeycomb molded body 70 is described by way of example, but the shape and the structure of a molded body molded by the die 90 are not limited to this. The exterior shape of the green honeycomb molded body 70 may be, for example, a prism such as a quadrangular prism, or an elliptic cylinder. In addition, the disposition of the through holes 71a and 71b are not specially limited. For example, the disposition may not be an equilateral triangular disposition and may be, for example, a square disposition, a hexagonal disposition, or the like. Furthermore, also the shapes of the through holes 71a and 71b may not be hexagons, and may be, for example, triangles, quadrilaterals, octagons, round shapes, and the combinations thereof.
The present invention is applicable to the manufacture of a green honeycomb molded body.
1 extrusion molding device
2A, 2B screw
10 first pipe
20, 20A flow adjustment plate
32 first portion
34 second portion
35a, 35b, 35c region
36 third portion
50 second pipe
60 hydraulic clamp
70 green honeycomb molded body
80 magnet clamp
90 die
201 main member
203 opening
204, 212 core member
206, 207, 208, 209 inclining through hole
212 core member
213, 214, 215, 216, 217 stacked plate
218, 219, 220, 221, 222 through hole
CL1 central axis
Number | Date | Country | Kind |
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2013-209377 | Oct 2013 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2014/076426 | 10/2/2014 | WO | 00 |