Ibiden Company Limited

Kazunori Yamayose

Kazushige Ohno

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the paste and having a honeycomb structure such that the body has the honeycomb structure having through-holes extending in the longitudinal direction of the body and partitions formed between the through-holes, sintering the body made of the paste such that a ceramic body having the honeycomb structure is formed, applying sealant to either end of each through-hole of the ceramic body such that each through-hole of the ceramic body is sealed at one end, and heating the sealant sealing one end of each through-hole such that the ceramic body having cured sealant at one end of each through-hole in the honeycomb structure is formed.

Method for manufacturing aluminum-titanate-based ceramic honeycomb structure

A method for manufacturing a ceramic honeycomb structure includes kneading inorganic particles and binder ingredient such that raw material paste including the inorganic particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having multiple through-holes extending in the longitudinal direction of the body and multiple partitions formed between the through-holes, degreasing of the body including heating the body in atmosphere maintaining oxygen concentration of 0.2% or less in the first heating and heating the body in atmosphere having oxygen concentration which is higher than the oxygen concentration of the first heating in the second heating such that a degreased body having the honeycomb structure is formed, and sintering the degreased body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.

Method for manufacturing ceramic honeycomb structure

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having multiple through-holes extending in the longitudinal direction of the body and multiple partition portions formed between the through-holes, drying the body made of the raw material paste and having the honeycomb structure such that the body maintains temperature difference of 20&#xb0; C. or lower between surface temperature at an outer surface of the body and temperature at a central portion of the body and a dried body having the honeycomb structure is formed, and sintering the dried body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.

A method for manufacturing a ceramic body having a honeycomb structure includes bringing titania particles and alumina particles into contact with each other such that the titania particles and the alumina particles are adhered to each other and form a precursor including particles having the titania particles and the alumina particles, combining the precursor with a binder material such that a raw material paste including the precursor and the binder material is prepared, forming a body including the raw material and having a honeycomb structure, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having multiple through-holes extending in the longitudinal direction of the body and multiple partition portions formed between the through-holes, applying sealant composition including aluminum hydroxide particles, talc particles, kaolin particles, water and organic binder to either end of each through-hole of the body in the longitudinal direction such that the honeycomb structure of the body has each through-hole sealed at one end, and sintering the body made of the raw material paste and having the honeycomb structure sealed by the sealant composition such that a ceramic body having the honeycomb structure is formed.

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and a binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having through-holes extending in the longitudinal direction of the body and partitions formed between the through-holes, immersing each of end portions of the body in the longitudinal direction into a sealant slurry heated at a temperature in the range of from 50&#xb0; C. to 100&#xb0; C. such that the sealant slurry infiltrates into the through-holes at one of the end portions of the body and seals either end of each of the through-holes of the body, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder such that raw material paste including the titania particles, the alumina particles and the binder is prepared, extruding the raw material paste through a die for forming a honeycomb structure such that a body made of the raw material paste and having the honeycomb structure is formed, supporting the body extruded from the die on a holder while moving the holder along extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that the diameter of the body held by the holder changes to the target diameter size, and sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed.

A method for manufacturing a ceramic honeycomb structure includes kneading titania particles, alumina particles and binder ingredient such that raw material paste including the titania particles, alumina particles and binder ingredient is prepared, forming a body made of the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having multiple through-holes extending in the longitudinal direction of the body and multiple partition portions formed between the through-holes, positioning on a base having granules the body made of the raw material paste and having the honeycomb structure such that the granules are interposed between the body and the base, and sintering the body made of the raw material paste and having the honeycomb structure on the base with the granules interposed between the body and the base such that a ceramic body having the honeycomb structure is formed on the base with the granules.

A honeycomb structure includes aluminum titanate, cell walls, and pore portions. The cell walls extend along a longitudinal direction of the honeycomb structure to define cells between the cell walls. The pore portions have an average pore diameter of about 10 &#x3bc;m to about 20 &#x3bc;m. A length of a longest pore portion among the pore portions in a binary image including substrate portions and the pore portions is about 8 times or less of the average pore diameter. The binary image is converted from a microscopic image of a cross section of the cell walls in parallel with the longitudinal direction. The length is measured along a line drawn in a direction perpendicular to a thickness direction of the cell walls.

Honeycomb structure

A honeycomb structure includes aluminum titanate and cell walls. The cell walls extend along a longitudinal direction of the honeycomb structure to form a plurality of cells between the cell walls. A porosity of the honeycomb structure is from about 40% to about 60%. In a binary image of substrate portions and pore portions of each of the cell walls, an area ratio (%) of the pore portions to a whole area in a rectangularly-divided image is in a range from (the porosity&#x2212;about 25%) to (the porosity+about 25%). The binary image is converted from a microscopic image of a cross section of each of the cell walls in parallel with the longitudinal direction. The rectangularly-divided image is formed by dividing the binary image in a direction parallel to a thickness direction of each of the cell walls at a predetermined width.

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Stuttgart, Germany

Kazunori Yamayose