Manufacturing method of plugged honeycomb structure and plugged honeycomb structure

Abstract

There is disclosed a manufacturing method of a plugged honeycomb structure, capable of inexpensively manufacturing the plugged honeycomb structure which does not have any defect in a short time without any restriction on an operation environment and capable of reducing an amount of industrial wastes. A mask 30 for forming plugging portions is prepared based on image data of an end surface of a honeycomb structure 2 by an optical forming process, the mask having pores 33 capable of communicating with cells 19a to be plugged and convex portions 35 capable of fitting into cells 19b which are not to be plugged. After fixing the mask to the end surface of the honeycomb structure 2, the honeycomb structure 2 to which the plugging portion forming mask 30 is fixed is set in a vessel 20 having, in an upper portion, an opening into which the plugging portion forming mask 30 can fit and containing a slurry 50 for plugging, and opening ends of the cells 19a to be plugged are filled with the slurry 50 for plugging through the pores 33 of the plugging portion forming mask 30 to thereby form the plugging portions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing one example of an embodiment of a manufacturing method according to the present invention;

FIG. 2 is a schematic diagram showing one example of the embodiment of the manufacturing method according to the present invention;

FIG. 3 is a schematic diagram showing one example of the embodiment of the manufacturing method according to the present invention;

FIG. 4 is a schematic diagram showing one example of the embodiment of the manufacturing method according to the present invention;

FIG. 5 is a schematic diagram showing one example of the embodiment of the manufacturing method according to the present invention;

FIG. 6 is a schematic diagram showing another example of the embodiment of the manufacturing method according to the present invention;

FIG. 7 is a schematic diagram showing still another example of the embodiment of the manufacturing method according to the present invention;

FIG. 8 is a schematic diagram showing an embodiment of a mask for forming plugging portions for use in the manufacturing method of the present invention;

FIG. 9 is a schematic diagram showing the embodiment of the mask for forming the plugging portions for use in the manufacturing method of the present invention;

FIG. 10( a)(b) are schematic diagrams showing a structure of a mask support member, FIG. 10(a) is a plan view, and FIG. 10(b) is a sectional view;

FIG. 11 is a schematic diagram showing an example in which the mask for forming the plugging portions is fixed beforehand to the mask support member, and then fixed to an end surface of a honeycomb structure;

FIG. 12 is a schematic diagram showing an example in which the mask for forming the plugging portions is fixed beforehand to the mask support member, and then set in a vessel;

FIG. 13 is a schematic diagram showing a part of a plugged honeycomb structure according to the present invention;

FIG. 14 is a schematic diagram showing a part of a conventional plugged honeycomb structure;

FIG. 15 is a schematic diagram showing one example of an embodiment of the plugged honeycomb structure according to the present invention; and

FIGS. 16( a)(b) are schematic diagrams showing a basic structure of the plugged honeycomb structure, FIG. 16(a) is a plan view viewed from one end surface side, and FIG. 16(b) is a sectional view.

Claims

1. A manufacturing method of a plugged honeycomb structure comprising: a honeycomb structure where a plurality of cells which communicate between two end surfaces of the honeycomb structure are divided by porous partition walls; and plugging portions arranged so as to plug one of two opening ends of each cell, the method comprising:photographing the end surface of the honeycomb structure to acquire image data which specifies shapes and positions of the cells to be plugged and the cells which are not to be plugged, preparing a mask for forming the plugging portions based on the image data by an optical forming process, the mask having pores which communicate with the cells to be plugged and convex portions which fit into the cells which are not to be plugged;fitting the convex portions into the cells which are not to be plugged to thereby fix the mask for forming the plugging portions to the end surface of the honeycomb structure;then fitting the mask for forming the plugging portions into an opening of a vessel to thereby set the honeycomb structure to which the mask for forming the plugging portions is fixed in the vessel having, in an upper portion, the opening into which the mask for forming the plugging portions fits and containing a plugging slurry obtained by forming a material of the plugging portions into a slurry; andfilling opening ends of the cells to be plugged with the slurry for plugging contained in the vessel through the pores of the mask for forming the plugging portions to thereby form the plugging portions.

2. A manufacturing method of a plugged honeycomb structure comprising: a honeycomb structure where a plurality of cells which communicate between two end surfaces of the honeycomb structure are divided by porous partition walls; and plugging portions arranged so as to plug one of two opening ends of each cell, the method comprising:photographing the end surface of the honeycomb structure to acquire image data which specify shapes and positions of the cells to be plugged and the cells which are not to be plugged, preparing a mask for forming the plugging portions based on the image data by an optical forming process, the mask having pores which communicate with the cells to be plugged and convex portions which fit into the cells which are not to be plugged;fitting the mask for forming the plugging portions into an opening of a vessel to thereby set the mask in the vessel having, in an upper portion, the opening into which the mask for forming the plugging portions fits and containing a plugging slurry obtained by forming a material of the plugging portions into a slurry;then fixing the end surface of the honeycomb structure to the mask for forming the plugging portions so that the convex portions of the mask for forming the plugging portions fit into the cells which are not to be plugged; andfilling opening ends of the cells to be plugged with the slurry for plugging contained in the vessel through the pores of the mask for forming the plugging portions to thereby form the plugging portions.

3. A manufacturing method of a plugged honeycomb structure comprising: a honeycomb structure where a plurality of cells which communicate between two end surfaces of the honeycomb structure are divided by porous partition walls; and plugging portions arranged so as to plug one of two opening ends of each cell, the method comprising:photographing the end surface of the honeycomb structure to acquire image data which specifies shapes and positions of the cells to be plugged and the cells which are not to be plugged, preparing a mask for forming the plugging portions based on the image data by an optical forming process, the mask having pores which communicate with the cells to be plugged and convex portions which fit into the cells which are not to be plugged;fitting the convex portions into the cells which are not to be plugged to thereby fix the mask for forming the plugging portions to the end surface of the honeycomb structure;immersing the end surface of the honeycomb structure to which the mask for forming the plugging portions is fixed into a plugging slurry obtained by forming a material of the plugging portions into a slurry and contained in a vessel; andfilling opening ends of the cells to be plugged with the slurry for plugging through the pores of the mask for forming the plugging portions to thereby form the plugging portions.

4. The manufacturing method of the plugged honeycomb structure according to claim 1, wherein the mask for forming the plugging portions is fixed beforehand to a mask support member having a structure including a large number of pores, and then fixed to the end surface of the honeycomb structure.

5. The manufacturing method of the plugged honeycomb structure according to claim 2, wherein the mask for forming the plugging portions is fixed beforehand to a mask support member having a structure including a large number of pores, and then set in the vessel.

6. The manufacturing method of the plugged honeycomb structure according to claim 1, wherein the convex portions have a shape tapered toward a tip end.

7. The manufacturing method of the plugged honeycomb structure according to claim 6, wherein an outer diameter of a maximum outer diameter portion of the convex portion as a part of the convex portions is larger than an inner dimension of the cell into which the convex portion fits.

8. The manufacturing method of the plugged honeycomb structure according to claim 1, wherein among the convex portions, an outer diameter of the convex portion fitted into the cell positioned at an outermost periphery of the honeycomb structure and having a shape different from that of the cell disposed inwardly from the cell is smaller than that of the other convex portion.

9. A plugged honeycomb structure comprising: a honeycomb structure where a plurality of cells which communicate between two end surfaces of the honeycomb structure are divided by porous partition walls; and plugging portions arranged so as to plug one of two opening ends of each cell, wherein the cells to be plugged among the cells positioned at an outermost periphery of the honeycomb structure are securely plugged with the plugging portions.

10. The plugged honeycomb structure, which is manufactured by the manufacturing method according to claim 1.

11. The plugged honeycomb structure according to claim 10, wherein an outer peripheral portion is provided with a protrusion or a groove as a reference of positioning during the fixing of the mask for forming the plugging portions to the end surface of the honeycomb structure.

12. The plugged honeycomb structure according to claim 9, wherein the cells are plugged with the plugging portions at only one end surface of the honeycomb structure.