Ngk Insulators, Inc.

Seiichiro Hayashi

Masanari Iwade

Tomoki Nagae

Hirofumi Hosokawa

Kensuke Okumura

Takao Saito

Hironori Takahashi

Yuichi Tajima

Masayuki Hironaga

Takehiko Watanabe

Kazuhiko Hamatsuka

Norihiro Asakura

Takashi Matsukubo

Keisuke Toba

Masanari Iwada

A manufacturing method includes: a dry mixing step of dry mixing a raw material by batch processing; a wet mixing step of adding liquid to a dry mixture obtained at the dry mixing step, the liquid including at least one type of water, surfactant, lubricant and plasticizer, while wet mixing; a kneading step of kneading a wet mixture obtained at the wet mixing step; and a forming step of extruding a kneaded mixture (forming raw material) obtained at the kneading step to make a ceramic formed body. In the kneading step, the liquid is further added during kneading of the wet mixture.

Method for manufacturing ceramic formed body, and apparatus for manufacturing ceramic formed body

A microwave drying method of a honeycomb formed body includes: an introduction step of disposing the honeycomb formed body while keeping an axis direction of cells of the honeycomb formed body vertically and introducing the honeycomb formed body into a drying furnace capable of irradiating with microwaves; a reflector placing step of placing a microwave reflector above the honeycomb formed body, the microwave reflector including a reflecting face having a coverage factor to an area of an end face of the honeycomb formed body that is 15% to 30%; and a microwave drying step of irradiating the honeycomb formed body with the microwaves of 915 MHz in frequency from above to dry the honeycomb formed body.

Microwave drying method of honeycomb formed body

A die has two surfaces, in a forming material supplying surface which is one surface, a plurality of back holes to introduce a forming material of a honeycomb formed body into the die are formed, and in a honeycomb formed body extruding surface which is the other surface, lattice-shaped slits corresponding to cell partition walls are formed, the back holes communicate with the slits in slit intersecting portions of the slits, polygonal cell blocks defined by the slits include chamfered portions in which parts of corner portions and the like are chamfered at a chamfering angle &#x3b8; of 1.0 to 8.0&#xb0; to the extruding direction, from the honeycomb formed body extruding surface toward a slit depth direction, and straight portions which are not chamfered, and a ratio of a length L of the straight portion to a slit depth D is from 20 to 60%.

Honeycomb formed body extruding die

A cutting method of a honeycomb formed body is provided. This is a cutting method of a honeycomb formed body in which, while a kneaded material containing a ceramic raw material is extruded to form a honeycomb formed body with a honeycomb shape having partition walls defining and forming a plurality of cells, the extruded honeycomb formed body is cut before drying by a cutting blade vibrated at a frequency of 0.3 kHz or more in a direction perpendicular to a direction in which this honeycomb formed body moves. It is preferably a cutting method of a honeycomb formed body in which the cutting blade is vibrated at a high frequency of 10 kHz or more.

Cutting method of honeycomb formed body

By providing a manufacturing method of an electrode for a honeycomb structure forming die including: arranging a plurality of processing electrodeshaving a shape which is complementary to that of the flow-through cells, at positions corresponding to the plurality of flow-through cells in the one surfaceB of the electrode base bodyB; discharging electricity from the plurality of processing electrodestoward the one surfaceB of the electrode base bodyB to carve the electrode base bodyB, so that a plurality of electrode cells having a shape which is analogous to that of the flow-through cells are formed in the electrode base bodyB; whereby obtaining a honeycomb electrode where a plurality of electrode cells partitioned by electrode partition walls appear on the one surface.

Manufacturing method of electrode for honeycomb structure forming die

By providing a honeycomb electrode, i.e., an electrode for a honeycomb structure forming die including a thick plate-like electrode base body made of an electricity discharging material and having two main surfaces, only one surface of two main surfaces of the electrode base body is provided with a plurality of electrode cells partitioned by electrode partition walls, and a shape of the electrode cells in the one surface is analogous to that of flow-through cells of the honeycomb structure.

Electrode for honeycomb structure forming die

By providing a manufacturing method of an electrode for a honeycomb structure forming die including: preparing a thick plate-like electrode base body made of an electricity discharging material and having two surfaces; making a plurality of holes in the electrode base body at positions corresponding to flow-through cells; inserting processing electrodes into the holes, and discharging electricity from the insides of the holes toward side surfaces of the holes of the electrode base body to process the side surfaces of the holes of the electrode base body into shapes corresponding to the porous partition walls; whereby obtaining an electrode where a plurality of electrode cells partitioned by electrode partition walls appear on at least one of the surfaces thereof.

A method for manufacturing a honeycomb structure forming die including a liquid groove forming step for forming linear processing liquid grooves whose width is smaller than that of the slit, in positions for forming the slits that form the partition walls of the honeycomb structure by subjecting the kneaded clay to extrusion in one side end face as a kneaded clay forming face of a plate-shaped die substrate. An introduction hole forming step for forming introduction holes for introducing the kneaded clay is performed before or after the liquid groove forming step. Slits communicating with the introduction holes are formed by performing comb-like electro-discharge machining by a comb-like electrode where plate-shaped protrusion electrodes, each corresponding to the width of the slit, are disposed in positions including the processing liquid grooves.

Method for manufacturing honeycomb structure forming die

There is provided a method for manufacturing a honeycomb structure forming die, the method includes: an introduction hole forming step for forming, in plate-shaped die substrate having one side end face and the other side end face, a plurality of introduction holes for introducing kneaded clay on the other side end face to function as a kneaded clay introduction face, and a slit forming step for forming slits communicating with the introduction holes in order to form the partition walls of the honeycomb structure by extruding the kneaded clay by performing a comb-like electro-discharge machining by a comb-like electrodewhere a plurality of plate-shaped protrusion electrodescorresponding with width of the slits are disposed on the one side end face to function as a kneaded clay formation face of the die substrate.

A die for forming a honeycomb structure, comprising a platy die base member having a clay supply face on back surface thereof and including a plurality of introduction holes for introducing a mixed raw material for forming; and a clay forming face on upper surface including a plurality of slits for extrusion of the material being connected to the introduction holes and formed lattice-like partition regions; at least a part of lattice-like partition regions being provided in such a position that the extended line of at least part of a plurality of lattice-like regions overlap with the slits at edges thereof as top view, slits including inner peripheral slits formed in the inner peripheral region, and outer peripheral slits formed in the outer peripheral region surrounding the inner peripheral region and having a width-enlarged portion having a width larger than that of the inner peripheral slit, and production method thereof.

Die for forming honeycomb structure and manufacturing method of the same

A die for forming the honeycomb structure includes: a plate-like die main body including an introducing portion provided on the side of one surface thereof and having a plurality of back holes and a forming portion provided on the side of the other surface thereof and having slits; and a back plate detachably attached to the surface of the introducing portion and having a plurality of through holes connected to the back holes of the introducing portion. Through hole opening portions of the through holes formed in the back plate in the one surface of the die main body have such an enlarging shape as to enlarge toward the one surface of the die main body. The die for forming the honeycomb structure can decrease the resistance of a forming material during extrusion.

Die for forming honeycomb structure

A plate-like shape diefor forming a honeycomb structure provided with an introduction portionhaving plural back holes on one side face (an introduction side) thereof and a formation portion provided with siltscommunicating with plural back holeson other side face thereof; using for forming a honeycomb shape with passing raw materials being introduced from back holesof an introduction portionthrough siltsbeing provided on the forming portion, wherein the introduction portionis composed of two layers of a plate-like abrasion portionconstituting an introduction face, and an introduction portion main bodylocated between the abrasion portionand the forming portion, and the abrasion portionis detachably disposed on the introduction portion main body

A process for producing a die for forming a honeycomb structure having slits having hexagonal honeycomb cell shapeat one of surfacesof a plate-like base material for die, and backside holeseach communicating with respective slitsat the other surface, which comprises the steps of forming holesfor dielectric fluid each having an opening diameter smaller than the width of the slitin a predetermined depth at the one of surfacesthereof, and holescommunicating with holesat the rest surface; and then passing a dielectric fluidfor electrical discharge machining from the surfaceto the surfacevia holesanduntil the machining proceeds to a position communicating with each hole; thereby, the slitsare formed at the surfaceof the base material

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Nagoya, Japan

Seiichiro Hayashi