Method for Producing Ceramic Honeycomb Filter

• US 20090008830A1
• Filed: 01/29/2007
• Published: 01/08/2009
• Est. Priority Date: 01/27/2006
• Status: Active Grant

• Current Assignee: Hitachi Metals (Thailand) Ltd.
• Original Assignee: Hitachi Metals (Thailand) Ltd.
• Inventors: Ohtsubo, Yasuhiko, Okazaki, Shunji
• Granted Patent: US 7,687,008 B2
• Time in Patent Office: Days
• US Class Current: 264/442
• CPC Class Codes: B01D 2279/30 for treatment of exhaust gases from IC Engines
• CPC Class Codes: B01D 46/0001 Making filtering elements
• CPC Class Codes: B01D 46/2418 Honeycomb filters used for filtering exhaust gases of an internal combustion engine F01N3/022; ceramic honeycomb structures per se C04B38/0006
• CPC Class Codes: B28B 11/006 Making hollow articles or partly closed articles
• CPC Class Codes: C04B 35/195 Alkaline earth aluminosilicates, e.g. cordierite or anorthite
• CPC Class Codes: C04B 38/0006 Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 38/0009 characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls
• CPC Class Codes: C04B 38/068 Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons
• CPC Class Codes: F01N 2330/30 Honeycomb supports characterised by their structural details
• CPC Class Codes: F01N 3/0222 the structure being monolithic, e.g. honeycombs
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A method for producing a ceramic honeycomb filter having large numbers of flow paths partitioned by cell walls, the flow paths having plugs at positions separate from an end surface of the honeycomb filter, comprising the steps of introducing a base-forming material into the flow paths on one end surface side, charging a plug-forming material into flow paths to be provided with plugs from the other end surface side, and sintering it.

Claims

1. A method for producing a ceramic honeycomb filter having large numbers of flow paths partitioned by cell walls, said flow paths having plugs at positions separate from an end surface of said honeycomb filter, comprising the steps of introducing a base-forming material into said flow paths on one end surface side, charging a plug-forming material into flow paths to be provided with plugs from the other end surface side, and sintering it.

2. The method for producing a ceramic honeycomb filter according to claim 1, wherein the charging of said plug-forming material is accelerated.

3. The method for producing a ceramic honeycomb filter according to claim 2, wherein the acceleration of the charging of said plug-forming material is conducted by the addition of a filling accelerator, and/or by mechanical or ultrasonic vibration.

4. The method for producing a ceramic honeycomb filter according to claim 1, wherein said plug-forming material is ceramic powder, ceramic granules, or capsules containing a ceramic powder slurry.

5. The method for producing a ceramic honeycomb filter according to claim 4, wherein the outer diameter of said capsules is 90% or less of the inner diameter of said flow paths.

6. The method for producing a ceramic honeycomb filter according to claim 1, wherein said base-forming material has a viscosity of 5-100 Pa·

s.

7. The method for producing a ceramic honeycomb filter according to claim 5, wherein said base-forming material is an aqueous solution of a water-soluble cellulose compound.

8. The method for producing a ceramic honeycomb filter according to claim 7, wherein said water-soluble cellulose compound is at least one selected from the group consisting of methylcellulose, carboxymethylcellulose, hydroxymethylcellulose, hydroxyethylcellulose and hydroxypropylmethylcellulose.