JP3413668B2 - Method for producing porous ceramic laminate - Google Patents
Method for producing porous ceramic laminateInfo
- Publication number
- JP3413668B2 JP3413668B2 JP26557893A JP26557893A JP3413668B2 JP 3413668 B2 JP3413668 B2 JP 3413668B2 JP 26557893 A JP26557893 A JP 26557893A JP 26557893 A JP26557893 A JP 26557893A JP 3413668 B2 JP3413668 B2 JP 3413668B2
- Authority
- JP
- Japan
- Prior art keywords
- synthetic resin
- ceramic
- sludge
- resin foam
- excess sludge
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000000919 ceramic Substances 0.000 title claims description 137
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 239000006260 foam Substances 0.000 claims description 112
- 229920003002 synthetic resin Polymers 0.000 claims description 104
- 239000000057 synthetic resin Substances 0.000 claims description 104
- 239000010802 sludge Substances 0.000 claims description 84
- 239000002002 slurry Substances 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 23
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 23
- 239000000853 adhesive Substances 0.000 claims description 20
- 230000001070 adhesive effect Effects 0.000 claims description 20
- 239000002734 clay mineral Substances 0.000 claims description 13
- 239000007787 solid Substances 0.000 claims description 13
- 239000004927 clay Substances 0.000 claims description 10
- 238000004891 communication Methods 0.000 claims description 9
- 239000004568 cement Substances 0.000 claims 1
- 238000007664 blowing Methods 0.000 description 16
- 210000004027 cell Anatomy 0.000 description 12
- 238000007906 compression Methods 0.000 description 10
- 230000006835 compression Effects 0.000 description 9
- 239000007788 liquid Substances 0.000 description 9
- 238000010030 laminating Methods 0.000 description 8
- 238000009423 ventilation Methods 0.000 description 8
- 238000010304 firing Methods 0.000 description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 6
- 229920005830 Polyurethane Foam Polymers 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 238000003475 lamination Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 239000011496 polyurethane foam Substances 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 238000001914 filtration Methods 0.000 description 4
- 230000005484 gravity Effects 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 3
- 150000001768 cations Chemical class 0.000 description 3
- 210000000170 cell membrane Anatomy 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 239000000693 micelle Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000001768 carboxy methyl cellulose Substances 0.000 description 2
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 2
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000001747 exhibiting effect Effects 0.000 description 2
- 239000004519 grease Substances 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 238000005273 aeration Methods 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 229910052575 non-oxide ceramic Inorganic materials 0.000 description 1
- 239000011225 non-oxide ceramic Substances 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910052851 sillimanite Inorganic materials 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 230000009974 thixotropic effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/0615—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances the burned-out substance being a monolitic element having approximately the same dimensions as the final article, e.g. a porous polyurethane sheet or a prepreg obtained by bonding together resin particles
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
Description
【０００１】[0001]
【産業上の利用分野】本発明は、溶融金属ろ過材、通気
性断熱材、厨房用グリスフィルター、触媒担体などに好
適に用いられ、通気・通液抵抗の少ない厚みのあるセラ
ミック多孔体積層体を製造する方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is suitable for use as a molten metal filter material, a gas permeable heat insulating material, a grease filter for kitchens, a catalyst carrier, etc. To a method of manufacturing.
【０００２】[0002]
【従来の技術及び発明が解決しようとする課題】従来よ
り、セル膜のない軟質ポリウレタンフォームなどの内部
連通空間を有する三次元網状骨格構造の合成樹脂発泡体
をセラミック泥漿に浸漬してセラミック泥漿を合成樹脂
発泡体に付着させた後、余剰泥漿を除去し、次いで乾
燥、焼成することによってセラミック多孔体を製造する
方法が知られている。このようなセラミック多孔体は、
三次元網状骨格構造を有するため通気抵抗が少なく、溶
融金属ろ過材、通気性断熱材、厨房用グリスフィルタ
ー、触媒担体用などとして広く使用されているが、これ
らの用途に使用されるに当っては、できるかぎり通気・
通液抵抗（圧力損失）が少ないこと、言い換えれば目づ
まりが少ないことが求められる。2. Description of the Related Art Conventionally, a synthetic resin foam having a three-dimensional reticulated skeleton structure having an internal communication space such as a flexible polyurethane foam without a cell membrane is immersed in a ceramic slurry to form a ceramic slurry. A method is known in which a ceramic porous body is manufactured by removing excess sludge after adhering to a synthetic resin foam, and then drying and firing. Such a ceramic porous body,
Since it has a three-dimensional reticulated skeleton structure, it has little ventilation resistance, and it is widely used as a molten metal filter material, a breathable heat insulating material, a grease filter for kitchens, a catalyst carrier, etc. Ventilate as much as possible
Low liquid flow resistance (pressure loss), in other words, low clogging is required.
【０００３】通気・通液抵抗が大きいと、例えば、溶融
金属ろ過においてはろ過時間が長くなり、生産性がおち
ると共に、場合によってはろ過途中で溶融金属の温度が
下がり、金属が凝固してしまうという不都合がある。ま
た、触媒担体として使用する場合、目づまりが多く、空
孔部が少ないと、触媒コート処理時に付着むらが生じた
り、触媒付着が目づまりを助長する結果、触媒担体とし
ての機能が損われるという問題が生じる。If the resistance to aeration and passage is large, for example, in the molten metal filtration, the filtration time becomes long, the productivity drops, and in some cases, the temperature of the molten metal lowers during the filtration and the metal solidifies. There is an inconvenience. In addition, when used as a catalyst carrier, if there are many cloggings and there are few pores, uneven adhesion may occur during the catalyst coating treatment, or as a result of facilitating clogging of the catalysts, the function as a catalyst carrier is impaired. Occurs.
【０００４】このような点に鑑み、本発明者らは、セラ
ミック多孔体の通気・通液抵抗を少なくするためには、
上述したセラミック多孔体製造時における合成樹脂発泡
体に付着した余剰泥漿の除去が重要であると考え、生産
効率の優れているロールを用いて圧縮絞液し、次いで圧
縮空気を吹きつけることにより、目づまりの少ないセラ
ミック多孔体を得る方法について先に提案した（特願平
４−１９９１７８号）。In view of the above points, the present inventors have found that in order to reduce the ventilation / fluid resistance of the ceramic porous body,
Considering that it is important to remove the surplus sludge attached to the synthetic resin foam during the production of the ceramic porous body described above, it is compressed and squeezed using a roll with excellent production efficiency, and then by blowing compressed air, A method for obtaining a ceramic porous body with less clogging was previously proposed (Japanese Patent Application No. 4-199178).
【０００５】この方法によれば、ロールのみを用いて得
られたものに比べ、格段に目づまりが少なく、圧力損失
の少ないセラミック多孔体を得ることができ、しかも圧
縮空気のブロー圧や方法を制御することによって、圧力
損失、骨格の太さを制御できる。According to this method, it is possible to obtain a ceramic porous body with significantly less clogging and less pressure loss than that obtained by using only rolls, and control the blow pressure and method of compressed air. By doing so, the pressure loss and the thickness of the skeleton can be controlled.
【０００６】しかしながら、最近において、ろ過効率の
向上、耐荷重量増大による処理量の向上等のため、厚さ
があり、かつ通気・通液抵抗の少ないセラミック多孔体
の開発が要望されているが、上記方法では、実用上製造
できるセラミック多孔体の厚さは、セル数にもよるが２
０〜５０ｍｍ程度が限度であった。即ち、圧縮空気を用
いているので、原料の合成樹脂発泡体の厚さが厚すぎる
場合、合成樹脂発泡体の三次元構造内に圧縮空気が入る
と拡散し、合成樹脂発泡体の中心部ではブロー圧力が減
退してしまい、十分に余剰泥漿を吹き飛ばすことができ
ず、セラミック泥漿の付着がむらになってしまい、圧力
損失の少ないセラミック多孔体を得ることが困難である
という問題があった。However, recently, in order to improve the filtration efficiency and the treatment amount by increasing the withstand load, it is desired to develop a ceramic porous body having a large thickness and low resistance to ventilation and liquid passage. According to the above method, the thickness of the ceramic porous body that can be practically manufactured depends on the number of cells, but is 2
The limit was about 0 to 50 mm. That is, since compressed air is used, if the raw material synthetic resin foam is too thick, it diffuses when compressed air enters the three-dimensional structure of the synthetic resin foam, and at the center of the synthetic resin foam. There is a problem that the blow pressure is reduced, the excess sludge cannot be blown off sufficiently, the adhesion of the ceramic sludge becomes uneven, and it is difficult to obtain a ceramic porous body with a small pressure loss.
【０００７】これに対し、このような通気・通液抵抗の
少ない厚みのあるセラミック多孔体を得る方法として、
遠心分離機を用いて余剰泥漿を除去する方法（特開昭５
９−３０５９号公報）があるが、この方法では余剰泥漿
の除去量がロールによる圧縮方法に比べ多く、合成樹脂
発泡体に付着するセラミック泥漿が少ないため、含浸−
遠心分離−乾燥の工程を４〜５回繰り返さなければなら
ず、このため生産性が悪く、コストが高くなる問題があ
る。On the other hand, as a method for obtaining such a thick ceramic porous body with little resistance to ventilation and liquid passage,
Method for removing excess sludge using a centrifuge
9-3059), this method has a larger amount of excess sludge removed than a compression method using rolls, and since less ceramic sludge adheres to the synthetic resin foam, impregnation-
The process of centrifugation-drying must be repeated 4 to 5 times, which results in poor productivity and high cost.
【０００８】本発明は、上記事情に鑑みなされたもの
で、厚さがあり、かつ通気・通液抵抗の少ないセラミッ
ク多孔体積層物を容易かつ確実に製造する方法を提供す
ることを目的とする。The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for easily and reliably producing a ceramic porous body laminate having a large thickness and a low resistance to ventilation and liquid passage. .
【０００９】[0009]
【課題を解決するための手段及び作用】本発明者は、上
記目的を達成するため鋭意検討を重ねた結果、
（１）内部連通空間を有する三次元網状骨格構造の複数
の合成樹脂発泡体それぞれをセラミック泥漿に浸漬して
それぞれの合成樹脂発泡体にセラミック泥漿を付着さ
せ、
（２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、
（３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、
（４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体を用い、上記余剰泥漿
の除去を、セラミック泥漿が付着した合成樹脂発泡体を
圧縮して余剰泥漿を絞り出した後、圧縮空気を吹きつけ
て、残存する余剰泥漿を除去すると共に、骨格間に形成
された泥漿膜を吹き払うようにし、上記セラミック泥漿
付着合成樹脂発泡体相互間を接着剤成分として粘土鉱物
をセラミック固形分の５〜３０重量％含有し、かつ水分
量が１５〜２５重量％のセラミック接着剤により接着、
積層すること、又は
（１）内部連通空間を有する三次元網状骨格構造の複数
の合成樹脂発泡体それぞれをセラミック泥漿に浸漬して
それぞれの合成樹脂発泡体にセラミック泥漿を付着さ
せ、
（２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、
（３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、
（４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体、セラミック泥漿とし
て粘土鉱物をセラミック固形分の５〜３０重量％含有す
るものを用い、上記余剰泥漿の除去を、セラミック泥漿
が付着した合成樹脂発泡体を圧縮して余剰泥漿を絞り出
した後、圧縮空気を吹きつけて、残存する余剰泥漿を除
去すると共に、骨格間に形成された泥漿膜を吹き払うよ
うにし、上記セラミック泥漿付着合成樹脂発泡体相互間
の接着、積層を、該発泡体の接着、積層面におけるセラ
ミック泥漿が、接着剤成分として粘土鉱物をセラミック
固形分の５〜３０重量％含有し、かつ１５〜２５重量％
の水分量を含有している状態で行うようにすることによ
り、各セラミック多孔体相互が剥離なく接着一体化する
ことができ、厚みのあるセラミック多孔体構造物が接着
性よく得られると共に、上記接着、積層すべき各合成樹
脂発泡体は５０ｍｍ以下の厚さとすることができ、かか
る厚さの薄い合成樹脂発泡体に対しそれぞれ余剰泥漿の
除去操作を行った後、接着、積層するので、厚い合成樹
脂発泡体に対して余剰泥漿除去を行う場合に比べて通
気、通液性に優れたセラミック多孔体構造物を得ること
ができることを知見した。Means for Solving the Problems and Actions The inventors of the present invention have conducted extensive studies to achieve the above object, and as a result, (1) each of a plurality of synthetic resin foams having a three-dimensional reticulated skeleton structure having an internal communication space. Is immersed in ceramic sludge to adhere the ceramic sludge to each synthetic resin foam, (2) Excess sludge is removed from each synthetic resin foam, and (3) Each ceramic sludge adhering synthesis from which surplus sludge is removed The resin foams are laminated so that their predetermined surfaces are aligned with each other, and (4) this laminate is dried and fired to produce a ceramic porous body laminate having a three-dimensional net-like skeleton structure, and a composite having a thickness of 50 mm or less. Using a resin foam, the excess sludge is removed by compressing the synthetic resin foam with the ceramic sludge to squeeze out the excess sludge, and then blowing compressed air to remove the remaining excess sludge. In addition to the removal, the sludge film formed between the skeletons is blown off, and 5 to 30% by weight of the ceramic solid content of clay mineral is used as an adhesive component between the above-mentioned ceramic sludge-adhering synthetic resin foams, and the moisture content is increased. Bonded with a ceramic adhesive in an amount of 15 to 25% by weight,
Laminating, or (1) dipping each of a plurality of synthetic resin foams having a three-dimensional net-like skeleton structure having an internal communication space into a ceramic slurry to attach the ceramic slurry to each synthetic resin foam, and (2) each. Excess sludge is removed from the synthetic resin foam of (3) and the predetermined surfaces of the respective ceramic sludge-adhering synthetic resin foams from which the excess sludge has been removed are laminated together, and (4) this laminate is dried and fired. Then, in producing a ceramic porous body laminate having a three-dimensional network skeleton structure, a synthetic resin foam having a thickness of 50 mm or less, and a ceramic sludge containing clay mineral in an amount of 5 to 30% by weight of the ceramic solid content are used. To remove the excess sludge, compress the synthetic resin foam adhered with the ceramic sludge to squeeze out the excess sludge, and then blow compressed air to remove the remaining excess sludge. At the same time as the removal, the sludge film formed between the skeletons is blown off, and the adhesion and the lamination between the above-mentioned ceramic sludge-adhering synthetic resin foams are performed. Clay mineral as a solid content of 5 to 30% by weight, and 15 to 25% by weight
By doing so in a state of containing the water content of the above, each ceramic porous body can be bonded and integrated without peeling, and a thick ceramic porous body structure can be obtained with good adhesiveness, and Each synthetic resin foam to be adhered and laminated can have a thickness of 50 mm or less, and after the surplus sludge is removed from each thin synthetic resin foam, the synthetic resin foam is adhered and laminated. It was found that it is possible to obtain a ceramic porous body structure having excellent ventilation and liquid permeability as compared with the case of removing excess sludge from a synthetic resin foam.
【００１０】特に、このように焼成前に積層することに
よって厚さのあるセラミック多孔体を得る方法によれ
ば、合成樹脂発泡体として薄いものが使用できるので、
セラミック泥漿が付着した合成樹脂発泡体に対して上述
したロールによる圧縮と圧縮空気による吹きつけとを併
用した余剰泥漿除去方法が採用できるため、通気・通液
抵抗が更に少なく、かつ厚さのあるセラミック多孔体を
低コストで得ることができ、しかも用途に応じて発泡体
のセル数や余剰泥漿の除去率等で異なる性質を有する合
成樹脂発泡体を積層することによって、例えばセル数の
多いものとセル数の少ないものとを積層した複合型のセ
ラミック多孔体を得ることもできることを見い出し、本
発明をなすに至ったものである。In particular, according to the method for obtaining a ceramic porous body having a large thickness by laminating before firing as described above, since a thin synthetic resin foam can be used,
Since the surplus sludge removal method that uses both the compression by the roll and the blowing by compressed air described above can be adopted for the synthetic resin foam to which the ceramic sludge has adhered, the ventilation and liquid passing resistance is further reduced and the thickness is thick. A ceramic porous body can be obtained at a low cost, and by laminating synthetic resin foams having different properties depending on the number of cells of the foam and the removal rate of excess sludge depending on the application, for example, one with a large number of cells It was found that a composite type ceramic porous body in which the above and a small number of cells are laminated can be obtained, and the present invention has been completed.
【００１１】従って、本発明は、
（１）内部連通空間を有する三次元網状骨格構造の複数
の合成樹脂発泡体それぞれをセラミック泥漿に浸漬して
それぞれの合成樹脂発泡体にセラミック泥漿を付着さ
せ、
（２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、
（３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、
（４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体を用い、上記余剰泥漿
の除去を、セラミック泥漿が付着した合成樹脂発泡体を
圧縮して余剰泥漿を絞り出した後、圧縮空気を吹きつけ
て、残存する余剰泥漿を除去すると共に、骨格間に形成
された泥漿膜を吹き払うようにし、上記セラミック泥漿
付着合成樹脂発泡体相互間を接着剤成分として粘土鉱物
をセラミック固形分の５〜３０重量％含有し、かつ水分
量が１５〜２５重量％のセラミック接着剤により接着、
積層したことを特徴とするセラミック多孔体の製造方
法、及び
（１）内部連通空間を有する三次元網状骨格構造の複数
の合成樹脂発泡体それぞれをセラミック泥漿に浸漬して
それぞれの合成樹脂発泡体にセラミック泥漿を付着さ
せ、
（２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、
（３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、
（４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体、セラミック泥漿とし
て粘土鉱物をセラミック固形分の５〜３０重量％含有す
るものを用い、上記余剰泥漿の除去を、セラミック泥漿
が付着した合成樹脂発泡体を圧縮して余剰泥漿を絞り出
した後、圧縮空気を吹きつけて、残存する余剰泥漿を除
去すると共に、骨格間に形成された泥漿膜を吹き払うよ
うにし、上記セラミック泥漿付着合成樹脂発泡体相互間
の接着、積層を、該発泡体の接着、積層面におけるセラ
ミック泥漿が、接着剤成分として粘土鉱物をセラミック
固形分の５〜３０重量％含有し、かつ１５〜２５重量％
の水分量を含有している状態で行うようにしたことを特
徴とするセラミック多孔体の製造方法を提供する。Therefore, according to the present invention, (1) each of a plurality of synthetic resin foams having a three-dimensional net-like skeleton structure having an internal communication space is immersed in a ceramic slurry to adhere the ceramic slurry to each synthetic resin foam, (2) Excess sludge is removed from each synthetic resin foam, (3) Predetermined surfaces of the respective ceramic sludge-adhering synthetic resin foams from which the excess sludge is removed are laminated together, and (4) this laminate is When the ceramic porous body laminate having a three-dimensional reticulated skeleton structure is manufactured by drying and firing, a synthetic resin foam having a thickness of 50 mm or less is used to remove the excess sludge, and the synthetic resin to which the ceramic sludge is adhered is removed. After compressing the foam to squeeze out the excess sludge, blow compressed air to remove the residual excess sludge and blow off the sludge film formed between the skeletons. Adhesion between ceramic sludge-adhering synthetic resin foams with a ceramic adhesive containing 5 to 30% by weight of a ceramic solid content as an adhesive component and a moisture content of 15 to 25% by weight,
A method for producing a ceramic porous body characterized by being laminated, and (1) immersing each of a plurality of synthetic resin foams having a three-dimensional net-like skeleton structure having an internal communication space into a ceramic slurry to form each synthetic resin foam. Attaching ceramic sludge, (2) removing excess sludge from each synthetic resin foam, (3) laminating the respective predetermined surfaces of the ceramic sludge-adhering synthetic resin foams from which excess sludge has been removed, 4) When this laminate is dried and fired to produce a ceramic porous body laminate having a three-dimensional network skeleton structure, a synthetic resin foam having a thickness of 50 mm or less, a clay mineral as a ceramic sludge as a ceramic sludge. After removing the excess sludge by compressing the synthetic resin foam adhered with the ceramic sludge to squeeze out the excess sludge, Compressed air is blown to remove the remaining excess sludge, and to blow off the sludge film formed between the skeletons. The ceramic slurry on the bonding and laminating surface contains clay mineral as an adhesive component in an amount of 5 to 30% by weight and a ceramic solid content of 15 to 25% by weight.
The present invention provides a method for producing a ceramic porous body, which is characterized in that it is carried out in a state of containing the above water content.
【００１２】以下、本発明について更に詳しく説明する
と、本発明のセラミック多孔体積層物の製造方法は、上
述したように複数の合成樹脂発泡体をセラミック泥漿に
浸漬し、余剰泥漿を除去し、これらの合成樹脂発泡体を
積層し、乾燥、焼成するものである。The present invention will be described in more detail below. In the method for producing a ceramic porous laminate of the present invention, as described above, a plurality of synthetic resin foams are immersed in a ceramic sludge to remove excess sludge. The above synthetic resin foam is laminated, dried and fired.
【００１３】ここで、本発明で用いる合成樹脂発泡体と
しては、内部連通空間を有する三次元網状骨格構造を有
すればいずれのものでも良く、例えば軟質ポリウレタン
フォーム、特にセル膜のない軟質ポリウレタンフォーム
を好適に使用することができる。また、セル数としては
特に制限はないが、１インチ当り５〜３０個の範囲のも
のが好適であり、セル数の異なる軟質ポリウレタンフォ
ームを２種以上用いても良い。なお、セルの粗いものに
ついては、積層前の厚みを比較的大きくでき、例えば５
個／インチのものでは５０ｍｍ程度とすることができる
が、細かいものについては積層前の厚さを薄く、例えば
３０個／インチのものでは２０ｍｍ程度とすることが好
ましく、従って、３０個／インチのもので６０ｍｍ程度
の厚さの製品を得ようとすれば２０ｍｍの厚さのものを
３枚重ねとすることが良い。Here, the synthetic resin foam used in the present invention may be any one as long as it has a three-dimensional network skeleton structure having an internal communication space, for example, a flexible polyurethane foam, particularly a flexible polyurethane foam having no cell membrane. Can be preferably used. The number of cells is not particularly limited, but is preferably in the range of 5 to 30 cells per inch, and two or more kinds of flexible polyurethane foams having different cells may be used. It should be noted that, for a coarse cell, the thickness before lamination can be made relatively large.
It can be set to about 50 mm for the ones / inch, but it is preferable that the thickness before lamination is thin for the fine ones, for example, about 20 mm for the ones of 30 pieces / inch. In order to obtain a product having a thickness of about 60 mm, it is preferable to stack three 20 mm-thick products.
【００１４】なお、合成樹脂発泡体は、その発泡方向が
厚さ方向又は平面方向のいずれでもよいが、積層を効率
よくするには、厚さ方向に切り出したものを用いること
が好ましい。The synthetic resin foam may be foamed in either the thickness direction or the plane direction, but it is preferable to use the one cut out in the thickness direction for efficient lamination.
【００１５】次に、本発明で用いるセラミック泥漿は、
セラミック粉末を水に懸濁した液で、通常セラミック多
孔体の製造に使用されているものを使用することができ
る。泥漿特性としては、弱いチクソトロピックを示すも
のが良く、酸化物、非酸化物の種類を問わない。好適に
使用される酸化物セラミックとしては、例えばアルミ
ナ、コーディライト、ムライト、ジルコニアなどが挙げ
られ、非酸化物セラミックとしては、例えば炭化ケイ
素、窒化ケイ素などが挙げられる。Next, the ceramic slurry used in the present invention is
A liquid obtained by suspending a ceramic powder in water, which is generally used for producing a ceramic porous body, can be used. As the sludge characteristics, those exhibiting a weak thixotropic property are preferable, regardless of the type of oxide or non-oxide. Suitable oxide ceramics include, for example, alumina, cordierite, mullite, zirconia, and the like, and non-oxide ceramics include, for example, silicon carbide and silicon nitride.
【００１６】本発明においては、セラミック泥漿中に接
着剤成分として木節粘土、並磁器土、蛙目粘土、シリマ
ナイト等の粘土鉱物を配合することができる。In the present invention, clay minerals such as kibushi clay, normal porcelain clay, frog clay and sillimanite can be blended in the ceramic slurry as an adhesive component.
【００１７】即ち、本発明は、セラミック泥漿付着合成
樹脂発泡体相互間を接着剤成分として粘土鉱物をセラミ
ック固形分の５〜３０重量％含有し、かつ水分量が１５
〜２５重量％のセラミック接着剤を用いるものであり、
この場合この接着剤は発泡体相互に積層する際にその接
着、積層面に塗布することもできるが、セラミック泥漿
をこの接着剤と同様の組成にしておけば、かかる塗布操
作を省略することができるものである。この粘土鉱物の
配合量は、泥漿中の固形分の５〜３０重量％、好ましく
は１０〜２５重量％の範囲とすることが良い。５重量％
未満の配合量では接着剤としての機能がなくなる場合が
あり、３０重量％を超えると凝集により目づまり発生の
原因となることがある。なお、このように粘土鉱物を使
用した場合、上記セラミック粉末の固形分に占める割合
は７０〜９５重量％、好ましくは７５〜９０重量％であ
る。That is, the present invention contains 5 to 30% by weight of a ceramic solid content of clay mineral as an adhesive component between the ceramic sludge-adhering synthetic resin foams and has a water content of 15%.
~ 25 wt% ceramic adhesive is used,
In this case, this adhesive can be applied to the bonding and laminating surfaces of the foams when they are laminated to each other, but if the ceramic slurry has the same composition as this adhesive, such an application operation can be omitted. It is possible. The amount of the clay mineral compounded is in the range of 5 to 30% by weight, preferably 10 to 25% by weight, of the solid content in the slurry. 5% by weight
If it is less than 30% by weight, the function as an adhesive may be lost. If it exceeds 30% by weight, aggregation may cause clogging. When the clay mineral is used as described above, the proportion of the ceramic powder in the solid content is 70 to 95% by weight, preferably 75 to 90% by weight.
【００１８】本発明で用いるセラミック泥漿には、上記
セラミック粉末、粘土鉱物のほか、必要に応じてポリビ
ニルアルコール、カルボキシメチルセルロースなどの有
機高分子を泥漿調節剤として添加することができる。ま
た、本発明で用いるセラミック泥漿の粘度は、２０℃で
５０〜２００ポイズ、特に１００〜１８０ポイズの範囲
とすることが作業性の点から好ましい。In addition to the above-mentioned ceramic powder and clay mineral, organic polymers such as polyvinyl alcohol and carboxymethyl cellulose can be added to the ceramic slurry used in the present invention as a slurry regulator, if necessary. Further, the viscosity of the ceramic slurry used in the present invention is preferably in the range of 50 to 200 poise at 20 ° C., particularly 100 to 180 poise from the viewpoint of workability.
【００１９】本発明のセラミック多孔体積層物の製造方
法は、このようなセラミック泥漿に合成樹脂発泡体を浸
漬し、合成樹脂発泡体にセラミック泥漿を付着させた
後、余剰泥漿を除去する。In the method for producing a ceramic porous body laminate of the present invention, a synthetic resin foam is immersed in such a ceramic sludge, the ceramic sludge is adhered to the synthetic resin foam, and then the excess sludge is removed.
【００２０】余剰泥漿を除去する方法に特に制限はな
く、例えばロール等による圧縮方法、遠心分離機による
方法等があるが、本発明においては、ロールなどにより
合成樹脂発泡体を圧縮した後、更に圧縮空気を合成樹脂
発泡体に吹きつけ、これら圧縮と空気吹きつけとを併用
する方法を好適に採用することができる。The method for removing the excess sludge is not particularly limited, and for example, there are a compression method using a roll and the like, a method using a centrifuge, and the like. In the present invention, after compressing the synthetic resin foam with a roll or the like, A method in which compressed air is blown to the synthetic resin foam and these compression and air blowing are used together can be suitably adopted.
【００２１】この方法につき更に詳述すると、まず、合
成樹脂発泡体にセラミック泥漿を浸漬により十分付着さ
せた後、焼成後所定のかさ比重になるように合成樹脂発
泡体を圧縮する。この場合、圧縮方法としては、例えば
ロール、圧締などの方法を採用し得、ロールを使用する
時には、上記かさ比重になるようにロール間隙を決める
が、一般的に圧縮率は２０〜６０％の範囲が良く、また
ロール本数（対）は所定のかさ比重が得られれば１本以
上何本でも良い。This method will be described in more detail. First, after the ceramic sludge is sufficiently adhered to the synthetic resin foam by dipping, the synthetic resin foam is compressed after firing to have a predetermined bulk specific gravity. In this case, as a compression method, for example, a method such as roll or compression can be adopted, and when the roll is used, the roll gap is determined so as to have the above-mentioned bulk specific gravity, but the compression ratio is generally 20 to 60%. Is good, and the number of rolls (pair) may be one or more as long as a predetermined bulk specific gravity is obtained.
【００２２】次いで、圧縮により余剰泥漿を除去した
後、圧縮空気を吹きつけて、更に余剰泥漿を除去すると
共に、骨格間に形成された泥漿膜を吹き払う。Then, after the excess sludge is removed by compression, compressed air is blown to further remove the excess sludge and the sludge film formed between the skeletons is blown off.
【００２３】この場合、圧縮工程を経た合成樹脂発泡体
を樹脂ネット、三次元網状骨格構造の合成樹脂発泡体、
穴あきベルトなどの上下に粗の連通空間を有する保持ベ
ルトに載置し、保持ベルトを一方向に移動させつつ保持
ベルトに近接して設置したブローノズルから圧縮空気を
合成樹脂発泡体に吹きつけるようにすることが好まし
い。なお、保持ベルトを移動させる代わりにブローノズ
ルを移動させても良い。ブローノズルは、局部ブローを
避けるため合成樹脂発泡体の幅全体を同時に吹きつけで
きるような長さとすることが好ましく、また、合成樹脂
発泡体の上下に複数本配置し、上下両方向から同時に圧
縮空気を吹きつけるようにすることが好ましい。一方向
からのみ吹込むと、合成樹脂発泡体内部にブローによる
方向性が現れ、焼成後、骨格断面形状が元の合成樹脂発
泡体の骨格断面（三角形）同様鋭角部が存在したり、付
着むらを生じてしまう場合があるが、両側から相対する
エアーブローによりブローしたエアーは、合成樹脂発泡
体内でお互いに干渉しあってランダム方向にブローさ
れ、これによって、泥漿の付着が丸みを帯びるようにす
ることができ、強度が高く、圧力損失の低いセラミック
多孔体を得ることができる。In this case, the synthetic resin foam obtained through the compression process is a resin net, a synthetic resin foam having a three-dimensional network skeleton structure,
Placed on a holding belt such as a perforated belt that has rough communication spaces above and below, and while moving the holding belt in one direction, blow compressed air to the synthetic resin foam from a blow nozzle installed close to the holding belt. It is preferable to do so. The blow nozzle may be moved instead of moving the holding belt. It is preferable that the blow nozzle has a length such that the entire width of the synthetic resin foam can be sprayed at the same time in order to avoid local blowing, and a plurality of blow nozzles are arranged above and below the synthetic resin foam, and compressed air is simultaneously blown from both upper and lower directions. Is preferably blown. If blown from only one direction, the directionality due to blow appears inside the synthetic resin foam, and after firing, the skeleton cross-sectional shape has sharp corners and uneven adhesion like the skeleton cross-section (triangle) of the original synthetic resin foam. However, the air blown by the air blows that oppose each other on both sides interfere with each other in the synthetic resin foam and are blown in random directions, so that the adhesion of sludge is rounded. It is possible to obtain a ceramic porous body having high strength and low pressure loss.
【００２４】このような圧縮空気の吹きつけ方法を採用
する場合、合成樹脂発泡体の厚さは、要求総厚みやセル
サイズによって適宜選択され、特に制限されないが、１
０〜５０ｍｍ程度、特に１５〜３５ｍｍ程度とすること
が好ましい。１０ｍｍより薄いと、積層して厚さのある
セラミック多孔体を得ることが困難になり、またブロー
圧力に対する合成樹脂発泡体の強度が足りず、ブローに
むらが生じてしまう場合があり、一方セルにもよるが、
５０ｍｍより厚いと、合成樹脂発泡体が三次元網状であ
るため、圧縮空気が内部に入ると拡散し、合成樹脂発泡
体の中心部ではブロー圧力が減退し、十分なブロー効果
が生じない場合がある。When such a compressed air blowing method is adopted, the thickness of the synthetic resin foam is appropriately selected according to the required total thickness and the cell size, and is not particularly limited.
It is preferably about 0 to 50 mm, particularly about 15 to 35 mm. If the thickness is less than 10 mm, it becomes difficult to obtain a ceramic porous body having a large thickness by stacking, and the strength of the synthetic resin foam against the blow pressure may be insufficient, which may cause unevenness in the blow. Depending on
If it is thicker than 50 mm, the synthetic resin foam has a three-dimensional mesh shape, so that compressed air diffuses when it enters the interior, and the blow pressure decreases at the center of the synthetic resin foam, which may not produce a sufficient blowing effect. is there.
【００２５】なお、このような中心部でブロー能力が減
退する現象を防ぐために、ブロー圧力を高くすることが
考えられるが、そのためには空気供給圧力を非常に高く
しなければならず、これによって設備コストの上昇を招
くばかりでなく、たとえこれが可能であるとしても表面
ブロー圧が高くなるので、表面骨格に付着した泥漿まで
吹き飛ばされる場合がある。そのため、セルが細かくな
るにつれて、発泡体の厚さは薄くすることが良い。In order to prevent the phenomenon in which the blow capacity is reduced in such a central portion, it is conceivable to increase the blow pressure, but in order to do so, the air supply pressure must be made extremely high. Not only will this lead to an increase in equipment costs, but even if this is possible, the surface blow pressure will be high, so that the sludge adhering to the surface skeleton may be blown off. Therefore, as the cells become finer, the thickness of the foam should be made thinner.
【００２６】上述したような合成樹脂発泡体を保持ベル
ト上に載置し、保持ベルトを移動させながら圧縮空気を
吹きつける場合、あるいはブローノズルを移動させる場
合、ブロー効果は、ブロー速度、ブロー方向、ブロー圧
などの因子により左右される。When the synthetic resin foam as described above is placed on the holding belt and the compressed air is blown while the holding belt is moved, or when the blow nozzle is moved, the blowing effect is the blowing speed and the blowing direction. , Blow pressure and other factors.
【００２７】この場合、ブロー速度（合成樹脂発泡体又
はブローノズルの移動速度）は１〜３ｍ／ｍｉｎ、特に
１．８〜２．５ｍ／ｍｉｎの範囲とすることが好まし
い。ブロー速度が１ｍ／ｍｉｎより小さいと、ブロー圧
にもよるが骨格表面の泥漿が吹き飛ばされてしまう場合
が生じ、一方３ｍ／ｍｉｎより大きいと表面に生じた網
目間の目づまりが十分に除去されないと共に、合成樹脂
発泡体内部まで十分にブローされない場合がある。In this case, the blowing speed (moving speed of the synthetic resin foam or the blowing nozzle) is preferably 1 to 3 m / min, particularly preferably 1.8 to 2.5 m / min. If the blowing speed is less than 1 m / min, the sludge on the skeleton surface may be blown off depending on the blowing pressure. On the other hand, if the blowing speed is more than 3 m / min, the clogging between the meshes formed on the surface may not be sufficiently removed. , The synthetic resin foam may not be sufficiently blown inside.
【００２８】また、ブロー方向（圧縮空気を吹きつける
方向）は、合成樹脂発泡体の表面に対し垂直方向（合成
樹脂発泡体の厚さ方向）でもよく、また垂直方向からや
や傾けても良く、一般には合成樹脂発泡体の表面から４
５〜１３５°、より好ましくは６０〜１２０°、最も好
ましくは７５〜１０５°の角度で圧縮空気を吹き込むこ
とが良い。The blowing direction (the direction in which compressed air is blown) may be perpendicular to the surface of the synthetic resin foam (thickness direction of the synthetic resin foam) or may be slightly inclined from the vertical direction, Generally 4 from the surface of synthetic resin foam
The compressed air may be blown at an angle of 5 to 135 °, more preferably 60 to 120 °, and most preferably 75 to 105 °.
【００２９】ブロー圧（圧縮空気の圧力）は、合成樹脂
発泡体の厚さによって決めることが良く、具体的には合
成樹脂発泡体の厚さ１ｃｍ当り０．３〜４ｋｇ／ｃ
ｍ2、特に０．８〜１．５ｋｇ／ｃｍ2の範囲の圧力の圧
縮空気を使用することが良い。０．３ｋｇ／ｃｍ2未満
であると、ブロー圧が弱く、網目間の泥漿の目づまりが
十分とれず、また内部まで十分に圧縮空気が届かない場
合がある。一方、４ｋｇ／ｃｍ2より圧力が高いと、合
成樹脂発泡体骨格に付着した泥漿まで吹き飛ばし、焼成
後セラミック多孔体を構成する骨格が得られない場合が
ある。The blow pressure (pressure of compressed air) may be determined according to the thickness of the synthetic resin foam, specifically, 0.3 to 4 kg / c per 1 cm of the synthetic resin foam.
It is advisable to use compressed air with a pressure of m 2 , in particular in the range 0.8 to 1.5 kg / cm 2 . If it is less than 0.3 kg / cm 2 , the blow pressure may be weak, the clogging of the sludge between the meshes may not be sufficiently taken, and the compressed air may not reach the inside sufficiently. On the other hand, if the pressure is higher than 4 kg / cm 2 , the skeleton constituting the ceramic porous body may not be obtained after being blown off even the sludge adhered to the synthetic resin foam skeleton.
【００３０】本発明においては、上記余剰泥漿の除去
後、複数のセラミック泥漿付着合成樹脂発泡体を積層す
るものであるが、この場合、これらセラミック泥漿付着
合成樹脂発泡体相互間を接着剤成分として粘土鉱物をセ
ラミック固形分の５〜３０重量％含有し、かつ水分量が
１５〜２５重量％のセラミック接着剤により接着、積層
する。この方法としては、上記セラミック泥漿組成がこ
の接着剤組成と相違する場合は、上記発泡体の接着、積
層面にこの接着剤を塗布するが、セラミック泥漿組成と
接着剤組成とが同じ場合は、上記発泡体をそのまま積層
すればよく、これにより各セラミック多孔体間で組成的
に一致した積層物を得ることができる。なお、この場合
も上記発泡体の接着、積層面に上記接着剤を塗布するこ
とは差し支えない。In the present invention, after removing the above-mentioned excess sludge, a plurality of ceramic sludge-adhering synthetic resin foams are laminated. In this case, these ceramic sludge-adhering synthetic resin foams are used as adhesive components. The clay mineral is contained in an amount of 5 to 30% by weight of the ceramic solid content, and is bonded and laminated with a ceramic adhesive having a water content of 15 to 25% by weight. As this method, when the ceramic slurry composition is different from the adhesive composition, the foam is adhered, and the adhesive is applied to the laminated surface, but when the ceramic slurry composition and the adhesive composition are the same, The above foam may be laminated as it is, whereby a laminate having a compositionally consistent structure among the ceramic porous bodies can be obtained. Also in this case, the foam may be adhered and the adhesive may be applied to the laminated surface.
【００３１】ここで、上記接着、積層面は、上記接着剤
が湿潤状態にあり、上記水分量を保持していることが必
要である。Here, it is necessary that the adhesive is in a wet state on the bonding and laminating surface and holds the water content.
【００３２】このように積層すべき面が濡れていると良
好な接着が得られるのは、合成樹脂発泡体の骨格先端に
おいて、粘土粒子の置換性塩基が水の極性分子（陽イオ
ン）を周りに配置し、更に粘土が吸着している陽イオン
も水の極性分子を周りに配置する状態（ミセル）がで
き、積層により接触した他の骨格表面も同じ状態なので
粘土が吸着している陽イオンを仲立ちとして互いに極性
分子を引き寄せ合い、接着現象を呈し、乾燥により水分
を除去すると引き寄せあったまま固化するためと考えら
れ、一方乾燥状態同士では、合成樹脂発泡体の骨格先端
が乾燥し、接着の仲立ちをする水分が介在しないため、
積層しても接着しない、即ち骨格先端の粘土粒子は水分
がないため、ミセルが形成されずに密になり、可塑性も
示さず固体となってしまうものと考えられる。When the surfaces to be laminated are wet, good adhesion can be obtained because the displacing base of the clay particles surrounds polar molecules (cations) of water at the skeleton tip of the synthetic resin foam. Cations adsorbed by clay can also be placed in a state (micelles) in which polar molecules of water are placed around, and other skeleton surfaces contacted by lamination are in the same state, so cations adsorbed by clay It is considered that polar molecules are attracted to each other as a mediator, exhibiting an adhesion phenomenon, and when water is removed by drying, they solidify while attracting each other.On the other hand, in the dry state, the skeleton tip of the synthetic resin foam dries and adheres. Because there is no intervening water to mediate,
It is considered that they do not adhere even when laminated, that is, the clay particles at the tip of the skeleton do not have water, so that micelles do not form but become dense and do not exhibit plasticity and become solid.
【００３３】従って、セラミック泥漿付着合成樹脂発泡
体が乾燥している場合は、少なくとも一方、好ましくは
双方の接着、積層面を水で濡らしたり、上記セラミック
泥漿やセラミック接着剤を塗布してその水分量を１５〜
２５重量％、より好ましくは１８〜２３重量％とするも
のである。１５重量％未満では、ミセル形成が不十分に
なり、十分な接着が得られない場合があり、一方２５重
量％を超えると格子に対する保持性が低下して積層した
場合に横にはみ出すような現象が生じ、接着はするが目
づまり発生の原因となる場合がある。Therefore, when the synthetic resin foam adhered to the ceramic sludge is dried, at least one, preferably both, of the adhering and laminating surfaces are wetted with water, or the above-mentioned ceramic sludge or ceramic adhesive is applied and the water content thereof is applied. 15 ~
It is 25% by weight, more preferably 18 to 23% by weight. If it is less than 15% by weight, micelle formation becomes insufficient and sufficient adhesion may not be obtained, while if it exceeds 25% by weight, the retention property to the lattice is deteriorated and a phenomenon such that it sticks out laterally when laminated. May occur and cause adhesion, but may cause clogging.
【００３４】このように積層した後、通常と同様に４０
〜８０℃程度で水分が除去するまで乾燥する。これによ
って積層した相互のセラミック泥漿が固化し、積層面が
接着して合成樹脂発泡体の積層体が得られる。After stacking in this manner, 40
Dry at about -80 ° C until water is removed. As a result, the laminated ceramic sludge solidifies and the laminated surfaces adhere to each other to obtain a laminated body of synthetic resin foam.
【００３５】次いで、通常と同様に１２００〜１５００
℃程度で焼成することによって、各セラミック多孔体が
接着よく一体化した三次元網状構造のセラミック多孔体
積層物を得ることができる。Then, 1200 to 1500 as usual.
By firing at about ° C, it is possible to obtain a ceramic porous body laminate having a three-dimensional network structure in which the respective ceramic porous bodies are integrated well with good adhesion.
【００３６】[0036]
【実施例】以下、実施例と比較例を示し、本発明を具体
的に示すが、本発明は下記の実施例に制限されるもので
はない。なお、以下の例において、部はいずれも重量部
である。EXAMPLES Hereinafter, the present invention will be specifically shown by showing Examples and Comparative Examples, but the present invention is not limited to the following Examples. In the following examples, all parts are parts by weight.
【００３７】［実施例１］セラミック成分として、アル
ミナ８０部、木節粘土１５部、炭酸カルシウム５部に水
２９部を加え、更に解こう剤としてカルボキシルメチル
セルロースを１部、泥漿バインダーとしてポリビニルア
ルコールを３部添加し、セラミック泥漿を調製した。Example 1 As a ceramic component, 80 parts of alumina, 15 parts of kibushi clay, 5 parts of calcium carbonate and 29 parts of water were added, 1 part of carboxymethyl cellulose as a peptizer and polyvinyl alcohol as a slurry binder were added. A ceramic slurry was prepared by adding 3 parts.
【００３８】一方、合成樹脂発泡体として、直線上２５
ｍｍ当りに並ぶ気泡の数が１３個で、幅３００ｍｍ、長
さ４００ｍｍ、厚さ３０ｍｍのセル膜のない三次元網状
骨格構造を有する軟質ポリウレタンフォーム（セル長径
方向は厚さ方向）を使用し、この合成樹脂発泡体を上記
セラミック泥漿に浸漬した。On the other hand, as a synthetic resin foam, a straight line 25
The number of cells lined up per mm is 13 and the width is 300 mm, the length is 400 mm, and the thickness is 30 mm. A flexible polyurethane foam (thickness direction in the major axis direction of the cell) having a three-dimensional network skeleton structure without a cell membrane is used. This synthetic resin foam was immersed in the ceramic slurry.
【００３９】次いで、間隙１８ｍｍの一対のロールによ
り余剰泥漿を絞液した。引き続き樹脂ネット上に合成樹
脂発泡体を乗せ、合成樹脂発泡体を移動させながらその
上下両面に配置したブローノズルにより圧縮空気を同時
に吹きつけた。この場合、合成樹脂発泡体とブローノズ
ルとの距離は１ｃｍとし、上側のブロー圧を２．７ｋｇ
／ｃｍ2、下側のブロー圧を４ｋｇ／ｃｍ2、樹脂ネット
の送り速度を３ｍ／分、ノズル角度を合成樹脂発泡体表
面から８０°の角度でエアーブローを行った。Next, the excess sludge was squeezed with a pair of rolls having a gap of 18 mm. Subsequently, the synthetic resin foam was placed on the resin net, and while moving the synthetic resin foam, compressed air was simultaneously blown by the blow nozzles arranged on both upper and lower surfaces thereof. In this case, the distance between the synthetic resin foam and the blow nozzle is 1 cm, and the upper blow pressure is 2.7 kg.
/ Cm 2 , the lower blow pressure was 4 kg / cm 2 , the resin net feed rate was 3 m / min, and the nozzle angle was 80 ° from the surface of the synthetic resin foam.
【００４０】エアーブローを行ったセラミック泥漿付着
合成樹脂発泡体を平滑板状に載置し、一方上記と同様の
合成樹脂発泡体を用い、同様に浸漬、絞り、エアーブロ
ーを行った他のセラミック泥漿付着合成樹脂発泡体の一
端を上記載置した下側の合成樹脂発泡体の一端と合わせ
た後、一端から順次他端に向けて重ね合わせた。なお、
この時の両者の水分率を測定した。Another ceramic foam adhered with air-blown ceramic sludge was placed on a smooth plate, while the same synthetic resin foam as above was used, and the other ceramics were similarly soaked, squeezed and air-blown. One end of the slurry-adhering synthetic resin foam was aligned with one end of the lower synthetic resin foam placed above, and then they were sequentially laminated from one end to the other end. In addition,
At this time, the water content of both was measured.
【００４１】次に、６０℃で乾燥した後、１３５０℃で
焼成して、三次元網状骨格構造を有するセラミック多孔
体積層物を得た。Next, it was dried at 60 ° C. and fired at 1350 ° C. to obtain a ceramic porous body laminate having a three-dimensional network skeleton structure.
【００４２】得られたセラミック多孔体積層物につい
て、かさ比重を測定すると共に、このセラミック多孔体
積層物を切り出し、積層面の観察を行い、接着状態を次
の３段階で評価した。
○：境界面がない。
△：境界面がところどころにある。
×：境界面が全面にある。The bulk specific gravity of the obtained ceramic porous body laminate was measured, the ceramic porous body laminate was cut out, the laminated surface was observed, and the adhesion state was evaluated in the following three stages. ○: There is no boundary surface. Δ: There are boundaries in places. X: The boundary surface is on the entire surface.
【００４３】また、得られたセラミック多孔体積層物を
５０ｍｍ×５０ｍｍ×厚さ６０ｍｍに切り出し、管径４
０ｍｍ、１０ｍ／ｓでの圧力損失を測定した。なお、圧
力損失は、積層面に対して直角方向に空気を通した場合
（表１中Ａ）と、積層面において積層面と平行に空気を
通した場合（表１中Ｂ）の２種類の測定を行った。これ
らの結果を表１に示す。Further, the obtained ceramic porous body laminate was cut into a size of 50 mm × 50 mm × thickness 60 mm, and the tube diameter was 4
The pressure loss at 0 mm and 10 m / s was measured. There are two types of pressure loss: when air is passed in the direction perpendicular to the laminated surface (A in Table 1) and when air is passed in the laminated surface parallel to the laminated surface (B in Table 1). The measurement was performed. The results are shown in Table 1.
【００４４】［実施例２］セラミック成分を表１に示し
たような配合とした以外は実施例１と同様にしてセラミ
ック多孔体積層物を得、同様に試験を行った。結果を表
１に併記する。[Example 2] A ceramic porous body laminate was obtained in the same manner as in Example 1 except that the ceramic components were mixed as shown in Table 1, and the same tests were conducted. The results are also shown in Table 1.
【００４５】［実施例３］実施例２と同様の合成樹脂発
泡体を同様にセラミック泥漿に浸漬し、絞り、圧縮空気
吹きつけを行った後、乾燥し、２枚の乾燥泥漿付着合成
樹脂発泡体を得た。これらの乾燥合成樹脂発泡体の表面
に、浸漬に使用したセラミック泥漿の水分を２２％に調
節した液を刷毛で塗布し、次いで刷毛塗りした表面相互
を積層し、乾燥し、焼結してセラミック多孔体積層物を
得た。[Example 3] A synthetic resin foam similar to that of Example 2 was similarly immersed in a ceramic slurry, squeezed and blown with compressed air, and then dried, and two pieces of the dried synthetic resin adhered to the slurry were foamed. Got the body On the surface of these dry synthetic resin foams, a liquid in which the water content of the ceramic slurry used for dipping was adjusted to 22% was applied with a brush, and then the brushed surfaces were laminated, dried, and sintered to obtain a ceramic. A porous body laminate was obtained.
【００４６】得られたセラミック多孔体積層物について
実施例１と同様に試験を行った。結果を表１に併記す
る。The same test as in Example 1 was conducted on the obtained ceramic porous body laminate. The results are also shown in Table 1.
【００４７】［比較例１］６０ｍｍ厚の合成樹脂発泡体
を１枚用い、積層しない以外は実施例１と同様に含浸、
ロール圧縮、エアブロー、乾燥、焼成を行って、セラミ
ック多孔体を得た。[Comparative Example 1] A synthetic resin foam having a thickness of 60 mm was used and impregnated in the same manner as in Example 1 except that the layers were not laminated.
Roll compression, air blow, drying and firing were performed to obtain a ceramic porous body.
【００４８】得られたセラミック多孔体を５０ｍｍ×５
０ｍｍ×厚さ６０ｍｍに切り出し、同様に圧力損失を測
定すると共に、実施例１と同様の試験を行った。結果を
表１に併記する。The obtained ceramic porous body was set to 50 mm × 5
It was cut into 0 mm × thickness of 60 mm, the pressure loss was measured in the same manner, and the same test as in Example 1 was performed. The results are also shown in Table 1.
【００４９】［比較例２］セラミック泥漿調製時の水分
を３７部に変更した以外は実施例１と同様にセラミック
多孔体積層物を得、試験を行った。結果を表１に併記す
る。Comparative Example 2 A ceramic porous body laminate was obtained and tested in the same manner as in Example 1 except that the water content during the preparation of the ceramic slurry was changed to 37 parts. The results are also shown in Table 1.
【００５０】［比較例３］セラミック泥漿調製時の水分
を２１部に変更した以外は実施例１と同様にセラミック
多孔体積層物を得、試験を行った。結果を表１に併記す
る。[Comparative Example 3] A ceramic porous body laminate was obtained and tested in the same manner as in Example 1 except that the water content during preparation of the ceramic slurry was changed to 21 parts. The results are also shown in Table 1.
【００５１】［比較例４］セラミック泥漿の調製をアル
ミナ９２部、木節粘土３部、炭酸カルシウム５部、水３
３部に変更した以外は実施例１と同様にしてセラミック
多孔体積層物を得、同様に試験を行った。結果を表１に
併記する。[Comparative Example 4] A ceramic slurry was prepared by using 92 parts of alumina, 3 parts of kibushi clay, 5 parts of calcium carbonate and 3 parts of water.
A ceramic porous body laminate was obtained in the same manner as in Example 1 except that the content was changed to 3 parts, and the same test was performed. The results are also shown in Table 1.
【００５２】［比較例５］セラミック泥漿の調製をアル
ミナ５５部、木節粘土４０部、炭酸カルシウム５部、水
２９部に変更した以外は実施例１と同様にしてセラミッ
ク多孔体積層物を得、同様に試験を行った。結果を表１
に併記する。[Comparative Example 5] A ceramic porous body laminate was obtained in the same manner as in Example 1 except that the preparation of the ceramic slurry was changed to 55 parts of alumina, 40 parts of kibushi clay, 5 parts of calcium carbonate and 29 parts of water. The same test was conducted. The results are shown in Table 1.
Also described in.
【００５３】[0053]
【表１】 [Table 1]
【００５４】[0054]
【発明の効果】本発明のセラミック多孔体の製造方法に
よれば、厚さがあり、かつ通気・通液抵抗の少ないセラ
ミック多孔体を生産性良く製造することができる。According to the method for producing a ceramic porous body of the present invention, it is possible to produce a ceramic porous body having a large thickness and a low resistance to ventilation and liquid passage with high productivity.
Claims (2)
骨格構造の複数の合成樹脂発泡体それぞれをセラミック
泥漿に浸漬してそれぞれの合成樹脂発泡体にセラミック
泥漿を付着させ、 （２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、 （３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、 （４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体を用い、上記余剰泥漿
の除去を、セラミック泥漿が付着した合成樹脂発泡体を
圧縮して余剰泥漿を絞り出した後、圧縮空気を吹きつけ
て、残存する余剰泥漿を除去すると共に、骨格間に形成
された泥漿膜を吹き払うようにし、上記セラミック泥漿
付着合成樹脂発泡体相互間を接着剤成分として粘土鉱物
をセラミック固形分の５〜３０重量％含有し、かつ水分
量が１５〜２５重量％のセラミック接着剤により接着、
積層したことを特徴とするセラミック多孔体の製造方
法。(1) Each of a plurality of synthetic resin foams having a three-dimensional net-like skeleton structure having an internal communication space is immersed in a ceramic slurry to adhere the ceramic slurry to each synthetic resin foam, and (2) each. Excess sludge is removed from the synthetic resin foam of (3) and the predetermined surfaces of the respective ceramic sludge-adhering synthetic resin foams from which the excess sludge has been removed are laminated together, and (4) this laminate is dried and fired. Then, when manufacturing a ceramic porous body laminate having a three-dimensional net-like skeleton structure, a synthetic resin foam having a thickness of 50 mm or less is used, and the excess sludge is removed by compressing the synthetic resin foam adhered with the ceramic sludge. After squeezing out the excess sludge, the compressed air is blown to remove the remaining excess sludge and blow off the sludge film formed between the skeletons. Adhesion between the synthetic resin foams with a ceramic adhesive containing 5 to 30% by weight of a clay solid as a cement component and a water content of 15 to 25% by weight,
A method for producing a ceramic porous body, which is characterized by being laminated.
骨格構造の複数の合成樹脂発泡体それぞれをセラミック
泥漿に浸漬してそれぞれの合成樹脂発泡体にセラミック
泥漿を付着させ、 （２）それぞれの合成樹脂発泡体から余剰泥漿を除去
し、 （３）余剰泥漿を除去したそれぞれのセラミック泥漿付
着合成樹脂発泡体相互の所定面を合わせて積層し、 （４）この積層物を乾燥し、焼成して、三次元網状骨格
構造のセラミック多孔体積層物を製造するに際し、厚さ
が５０ｍｍ以下の合成樹脂発泡体、セラミック泥漿とし
て粘土鉱物をセラミック固形分の５〜３０重量％含有す
るものを用い、上記余剰泥漿の除去を、セラミック泥漿
が付着した合成樹脂発泡体を圧縮して余剰泥漿を絞り出
した後、圧縮空気を吹きつけて、残存する余剰泥漿を除
去すると共に、骨格間に形成された泥漿膜を吹き払うよ
うにし、上記セラミック泥漿付着合成樹脂発泡体相互間
の接着、積層を、該発泡体の接着、積層面におけるセラ
ミック泥漿が、接着剤成分として粘土鉱物をセラミック
固形分の５〜３０重量％含有し、かつ１５〜２５重量％
の水分量を含有している状態で行うようにしたことを特
徴とするセラミック多孔体の製造方法。2. (1) Each of a plurality of synthetic resin foams having a three-dimensional net-like skeleton structure having an internal communication space is immersed in a ceramic slurry to adhere the ceramic slurry to each synthetic resin foam, and (2) each. Excess sludge is removed from the synthetic resin foam of (3) and the predetermined surfaces of the respective ceramic sludge-adhering synthetic resin foams from which the excess sludge has been removed are laminated together, and (4) this laminate is dried and fired. Then, in producing a ceramic porous body laminate having a three-dimensional network skeleton structure, a synthetic resin foam having a thickness of 50 mm or less, and a ceramic sludge containing clay mineral in an amount of 5 to 30% by weight of the ceramic solid content are used. , To remove the excess sludge, compress the synthetic resin foam with the ceramic sludge to squeeze out the excess sludge, and then blow compressed air to remove the residual excess sludge. At the same time, the sludge film formed between the skeletons is blown off, and the above-mentioned ceramic sludge-adhering synthetic resin foams are adhered and laminated to each other. Containing 5 to 30% by weight of clay mineral and 15 to 25% by weight of ceramic solid content
The method for producing a ceramic porous body, wherein the method is performed in a state in which the water content of
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26557893A JP3413668B2 (en) | 1993-09-29 | 1993-09-29 | Method for producing porous ceramic laminate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP26557893A JP3413668B2 (en) | 1993-09-29 | 1993-09-29 | Method for producing porous ceramic laminate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0797280A JPH0797280A (en) | 1995-04-11 |
| JP3413668B2 true JP3413668B2 (en) | 2003-06-03 |
Family
ID=17419073
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP26557893A Expired - Fee Related JP3413668B2 (en) | 1993-09-29 | 1993-09-29 | Method for producing porous ceramic laminate |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3413668B2 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL1007105C2 (en) * | 1997-09-24 | 1999-03-25 | Belone | Porous ceramic products used as e.g. filters, horticultural products or construction elements |
| CN114933488B (en) * | 2022-05-30 | 2023-05-23 | 中国华能集团清洁能源技术研究院有限公司 | Porous medium model and preparation method thereof, oil displacement experimental method and experimental system |
-
1993
- 1993-09-29 JP JP26557893A patent/JP3413668B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0797280A (en) | 1995-04-11 |
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