JP6810083B2 - A method for manufacturing a base for forming a honeycomb structure and a method for manufacturing a honeycomb structure. - Google Patents

Description

The present invention relates to a method for manufacturing a honeycomb structure molding base, a honeycomb structure molding base, and a method for manufacturing a honeycomb structure. In particular, the present invention relates to a method for producing a honeycomb structure molding base, a honeycomb structure molding base, and a honeycomb structure manufacturing method suitable for an additive manufacturing method.

Conventionally, as a method for manufacturing a ceramic honeycomb structure, a honeycomb having a back hole into which a molding material (powder) is introduced and a base having a base having a grid-like slit communicating with the back hole is formed. A method of extrusion molding using a structure molding base is widely used.
In forming the slits of the honeycomb structure molding base, for example, when they are arranged in a square shape, they are not arranged on the same line such as grinding with a grindstone, a combination of hexagonal shape and square-octagonal shape, etc. In this case, die-sinking electric discharge machining using electrodes is used.
For forming the back hole of the honeycomb structure forming base, for example, cutting using a drill or a reamer tool, electric discharge machining using electrodes, or the like is used.

In Patent Document 1, when a groove is formed in a plate-shaped member for forming a back hole, the minimum width of the columnar portion partitioned by the groove and the height of the columnar portion are defined in a specific range. By doing so, it has been proposed to provide a base for forming a honeycomb structure in which two plate-shaped members constituting a base base are hard to be peeled off, and a method for manufacturing the same, while realizing high moldability.

Further, there is also known a method in which slits are formed as gaps between assembled members (Patent Document 2). In such a honeycomb structure molding base, a plurality of elongated wire rods are bundled and joined to form an introduction layer having an introduction hole into which a material is introduced on one end side, and the molded body is extruded on the other end side. A molding layer having a molding groove to be formed is formed.

Japanese Patent No. 5361224 Japanese Patent No. 3585815

Depending on the processing method described in Patent Document 1, there may be restrictions on the design shape. Further, since the method using a rotary tool is used in the grinding process required for forming the slit and the back opening, the cross-sectional shape of the hole is restricted to a round shape. Further, in such a processing method, the material yield is generally poor by performing the processing from the plate-shaped material and removing most of it. Further, in the production of the base for forming the honeycomb structure, since a plurality of different facilities are used, the total production lead time becomes long, which is not preferable in terms of productivity.

In the method described in Patent Document 2, the structure of bundling and joining a plurality of elongated wire rods is complicated, the production cost increases, and the cumulative error tends to increase, so that the required accuracy is ensured. Becomes difficult.

In view of the problems of the invention described in the prior art document, the present invention has a high degree of freedom in designing the shape and the like, a high material yield, and a high productivity, and a method for manufacturing a honeycomb structure molding base, and a honeycomb. One of the problems is to provide a base for forming a structure and a method for manufacturing a honeycomb structure.

The present inventors have found that the above problems can be solved by molding a base for forming a honeycomb structure by an additional manufacturing method using a so-called 3D printer and further providing a predetermined plating layer. The invention was completed. Specifically, the present invention is specified as follows.

(1) A method for manufacturing a honeycomb structure molding base having a back hole into which a molding raw material is introduced and a slit for extruding the molding raw material into the honeycomb structure in communication with the back hole.
The process of molding the honeycomb structure molding base by the additional manufacturing method, and
A method for manufacturing a honeycomb structure molding base, which comprises a step of providing a plating layer having a thickness of 10 to 300 μm so as to cover at least a part of the back hole and a portion constituting the slit of the honeycomb structure molding base.
(2) The method for manufacturing a honeycomb structure molding base according to (1), wherein the thickness of the plating layer is 20 to 200 μm.
(3) The honeycomb structure molding base according to (1) or (2), wherein the surface roughness (Ra) of the portion of the honeycomb structure molding base where the plating layer is provided is 0.3 to 7 μm. How to manufacture the base.
(4) The method for manufacturing a honeycomb structure molding base according to (3), wherein the surface roughness (Ra) of the portion of the honeycomb structure molding base on which the plating layer is provided is 0.3 to 3 μm. ..
(5) Further, (1) to (4) include a fluid polishing step of polishing the honeycomb structure molding base by flowing an abrasive grain fluid through the back hole and the slit before providing the plating layer. The method for manufacturing a base for forming a honeycomb structure according to any one of.
(6) The surface roughness (Ra) of the back hole and the portion constituting the slit of the honeycomb structure molding base before the fluid polishing step is 5 to 20 μm, and the back surface is obtained by the fluid polishing step. The method for manufacturing a honeycomb structure molding base according to (5), wherein the surface roughness (Ra) of the hole and the portion constituting the slit is 1 to 10 μm.
(7) The method for manufacturing a honeycomb structure molding base according to (6), wherein the surface roughness (Ra) of the back hole and the portion constituting the slit is set to 1 to 5 μm by the fluid polishing step.
(8) The method for manufacturing a honeycomb structure molding base according to any one of (1) to (7), wherein the plating layer is an electroless Ni plating layer.
(9) A honeycomb structure molding base having a back hole into which a molding raw material is introduced and a slit for extruding the molding raw material into the honeycomb structure in communication with the back hole, and the back hole and the slit. A honeycomb structure molding base having a surface roughness (Ra) of 0.3 to 7 μm in a portion covered with a plating layer having a thickness of 10 to 300 μm at least a part of the portion constituting the above.
(10) The base for forming a honeycomb structure according to (9), which is a sintered body.
(11) The base for forming a honeycomb structure according to (10), which is a sintered body formed by an additional manufacturing method.
(12) The base for forming a honeycomb structure according to any one of (9) to (11), wherein the thickness of the plating layer is 20 to 200 μm.
(13) The honeycomb structure molding base according to any one of (9) to (12), wherein the surface roughness (Ra) at the portion covered with the plating layer is 0.3 to 5 μm.
(14) The base for forming a honeycomb structure according to any one of (9) to (13), wherein the plating layer is an electroless Ni plating layer.
(15) The base for forming a honeycomb structure according to (9) to (14), wherein the plating layer is on the outermost surface.
(16) The honeycomb structure molding base is manufactured by the method for manufacturing the honeycomb structure molding base according to any one of (1) to (8), and the honeycomb structure molding base is further used to manufacture the honeycomb structure. A method for manufacturing a honeycomb structure, which comprises a step of extruding a body.
(17) A method for manufacturing a honeycomb structure, which comprises a step of extruding the honeycomb structure using the honeycomb structure molding base according to any one of (9) to (15).

According to the present invention, it is possible to design a base with a high degree of freedom, the material yield is good because of additional processing, and the basic structure can be formed with a single facility, so that the manufacturing lead time is significantly suppressed as compared with the conventional method. It is possible.

It is a perspective view which shows typically the mouthpiece for forming a honeycomb structure manufactured by one Embodiment of this invention. It is a perspective view which shows the honeycomb structure extruded by the honeycomb structure molding base shown in FIG. It is one of the design drawings of the base for forming a honeycomb structure used in the addition manufacturing method in Examples and Comparative Examples.

Hereinafter, with reference to the drawings, a method for manufacturing a honeycomb structure molding base (hereinafter, may be simply referred to as a “base”) of the present invention, a honeycomb structure molding base, and a method for manufacturing a honeycomb structure. The present invention will be described in detail, but the present invention is not construed as being limited thereto, and various changes, modifications, and improvements are made based on the knowledge of those skilled in the art without departing from the scope of the present invention. Can be added.

(1. Honeycomb structure molding base)
In the present invention, the base for forming a honeycomb structure to be manufactured has a basic structure of a back hole into which a molding raw material is introduced and a slit for extruding the molding raw material into the honeycomb structure in communication with the back hole. It suffices if it exists, and its specific shape is not restricted.
Typically, in one embodiment of the present invention, the honeycomb structure molding base has at least two surfaces 5, 6 as shown in FIG. 1, and a molding material is introduced into one surface 5. A plate-shaped base base 2 having a back hole 3 formed and a slit 4 communicating with the back hole 3 formed on the other surface 6 is provided, and a molding material introduced into the back hole 3 is extruded from the slit 4 to form a honeycomb. This is a honeycomb structure molding base 1 for molding the structure 10 (see FIG. 2).

As will be described later, according to the present invention, it is possible to design a base with a high degree of freedom. Therefore, even if the base for forming a honeycomb structure to be manufactured is more complicated than the structure shown in FIG. Good.

As will be described later, when the honeycomb structure molding base is manufactured by the addition manufacturing method, the molding raw material and the honeycomb structure molding base come into contact with each other when the honeycomb structure is extruded due to the technical restrictions of the addition manufacturing method. The unevenness of the surface of the portion to be formed, that is, the back hole of the honeycomb structure molding base and the portion forming the slit may be higher than that of the conventional manufacturing method. In this case, there is a problem that the molding raw material does not flow or does not flow as intended, and it becomes difficult to accurately and uniformly adjust the flow rate.

As a result of further diligent studies on this problem, the present inventor has provided a plating layer having a thickness of 10 to 300 μm on at least a part of the surface of the back hole and the portion forming the slit of the honeycomb structure molding base. It has been found to reduce the surface roughness (Ra) at the site. That is, by providing the plating layer having a thickness of 10 to 300 μm, it is possible to accurately and uniformly adjust the flow rate while enjoying the advantage of the completely new manufacturing method of the addition manufacturing method. Therefore, a high-density and high-precision partition wall is provided. The honeycomb structure having the above can be extruded. From this point of view, the plating layer is a portion where the molding raw material and the honeycomb structure molding base come into contact with each other when the honeycomb structure is extruded, that is, a portion forming a back hole and a slit of the honeycomb structure molding base. It is preferable to provide it on the entire surface.

If the thickness of the plating layer is thinner than 10 μm, the effect of reducing the surface roughness (Ra) at the site is not sufficient. From this viewpoint, the thickness of the plating layer is more preferably 20 μm or more, and more preferably 30 μm or more. Further, when the thickness of the plating layer is thicker than 300 μm, the man-hours required for the plating process are lengthened and the back holes are reduced, so that the pressure at the time of extruding the honeycomb structure is increased. From this viewpoint, the thickness of the plating layer is more preferably 250 μm or less, and more preferably 200 μm or less.

Further, from the viewpoint of facilitating the extrusion of the honeycomb structure, it is preferable that the surface roughness (Ra) at the portion where the plating layer is provided is 0.3 to 7 μm at the portion where the plating layer is provided. Even if the surface roughness (Ra) is made smaller than 0.3 μm, the effect is small and the manufacturing difficulty increases. Therefore, the lower limit is 0.3 μm. From this viewpoint, the surface roughness (Ra) is more preferably 0.5 μm or more, and more preferably 0.7 μm or more. On the other hand, if the surface roughness (Ra) exceeds 7 μm, it becomes difficult to accurately and uniformly adjust the flow rate. From this point of view, the surface roughness (Ra) at the site where the plating layer is provided is more preferably 5 μm or less, and more preferably 3 μm or less.

In the present invention, the thickness of the plating layer is shown as the thickness of the plating layer by measuring the back hole or slit width before and after plating with an image measuring microscope and calculating the difference. Specifically, the back hole diameter and the slit gap amount are measured at five locations where each of the back hole and the slit has a plating layer arbitrarily, and the average value is taken.

The term "surface roughness (Ra)" as used in the present invention refers to JIS B0601 (2013) "Product Geometric Characteristic Specifications (GPS) -Surface Material: Contour Curve Method-Terms, Definitions and Surface Material Parameters Surface Roughness-" It means the surface roughness measured in accordance with "4.2.1 Arithmetic mean height of contour curve" and "Arithmetic mean roughness Ra" of "Definition and display". In the present invention, the reference length L = 4 mm.

As will be described later, since the present invention also assumes that the honeycomb structure molding base is manufactured by the additional manufacturing method, the honeycomb structure molding base in this case is a sintered body, and specifically. Is a sintered body formed by an additional manufacturing method.

The type of the plating layer is not particularly limited, and for example, electric Ni plating or the like can be adopted. Above all, it is preferable to use an electroless Ni plating layer for the reason of plating uniformity. The method of providing the electroless Ni plating layer is not limited, and various known methods can be used.

Further, the honeycomb structure molding base may be coated with an abrasion resistant material from the viewpoint of extending the life and abrasion resistance, but in the present invention, the honeycomb structure forming is formed by providing the plating layer. It is not always necessary to use such a coating, as it is possible to obtain the wear resistance required for the mouthpiece. That is, in the present invention, the plating layer can be provided on the outermost surface of the honeycomb structure molding base.

(2. Manufacturing method of honeycomb structure molding base)
The method for manufacturing the honeycomb structure molding base of the present invention includes a step of molding the honeycomb structure molding base by an additional manufacturing method, and a portion of the honeycomb structure molding base that constitutes the back hole and the slit. A step of providing a plating layer having a thickness of 10 to 300 μm so as to cover at least a part of the honeycomb is included.

Typically, a thin layer of metal or alloy powder constituting a honeycomb structure molding base is formed, and the powder in this thin layer is solidified by sintering or melt bonding with an electron beam or a laser to form a molded product layer. Is formed, and the laminated molded product can be manufactured by laminating the molded product layer.
Preferably, a thin layer is formed by laying powder of a metal or alloy constituting a honeycomb structure molding base on a molding stage, and then the thin layer is irradiated with an electron beam at a portion to be molded. A honeycomb structure molding base can be manufactured by repeating the steps of melting the powder and then solidifying it by natural cooling a plurality of times.

According to the addition manufacturing method, the material yield is remarkably high as compared with the prior art because the processing for removing the excess material is not necessary or can be suppressed to a very small amount. In addition, since the basic structure can be formed with a single facility, the manufacturing lead time can be significantly reduced as compared with the conventional method.

The material of the metal or alloy constituting the base for forming the honeycomb structure is not limited, and various materials can be selected as needed. For example, stainless alloys and cemented carbides can be used. Stainless alloy, for example, SUS630 (C: 0.07 or less, Si: 1.00 or less, Mn: 1.00 or less, P: 0.040 or less, S: 0.030 or less, Ni: 3.00 to 5. 00, Cr: 15.50 to 17.50, Cu: 3.00 to 5.00, Nb + Ta: 0.15 to 0.45, Fe: balance (unit: mass%)) can be mentioned as a preferable example. ..
As the cemented carbide, for example, tungsten carbide is calcined with at least one metal selected from the group consisting of iron (Fe), cobalt (Co), nickel (Ni), titanium (Ti), and chromium (Cr). A bonded tungsten carbide-based cemented carbide can be mentioned as a suitable example.
Any material can be used in the present invention as long as it is available in the additive manufacturing process.

Further, for the above-mentioned reason, after the honeycomb structure molding base is formed by the additional manufacturing method, the thickness 10 to 10 so as to cover at least a part of the back hole and the portion constituting the slit of the honeycomb structure molding base. It is necessary to provide a plating layer of 300 μm. From this point of view, the plating layer is a portion where the molding raw material and the honeycomb structure molding base come into contact with each other when the honeycomb structure is extruded, that is, a portion forming a back hole and a slit of the honeycomb structure molding base. It is preferable to provide it on the entire surface.

Further, the preferable ranges of the thickness of the plating layer and the surface roughness (Rz) at the portion where the plating layer is provided are as described above.

Further, in order to facilitate the surface roughness (Ra) of the surface of the portion forming the back hole or slit of the honeycomb structure molding base after the plating layer is provided, the plating layer is provided. It is preferable to include a fluid polishing step of polishing the base for forming the honeycomb structure by flowing the abrasive grain fluid into the back hole and the slit of the base before providing the base.
Typically, it can be polished by repeatedly passing a fluid (oil or the like) containing abrasive grains such as diamond or silicon carbide through the honeycomb structure forming base. The composition of the abrasive grain fluid and the conditions of the polishing process are not limited, and can be appropriately selected and changed as necessary.

Further, from the viewpoint of facilitating the surface roughness (Ra) of the surface of the portion forming the back hole or slit of the honeycomb structure molding base after the plating layer is provided, the above fluid The surface roughness (Ra) of the part forming the back hole and the slit of the honeycomb structure molding base before the polishing step is 5 to 20 μm, and the part forming the back hole and the slit of the mouthpiece by the above-mentioned fluid polishing step. The surface roughness (Ra) is preferably 1 to 10 μm. In particular, if the surface roughness (Ra) of the portion forming the back hole and the slit of the mouthpiece is set to 1 to 5 μm by the above fluid polishing step, the thickness of the plating layer can be reduced, which is preferable.

As described above, the plating layer is preferably an electroless Ni plating layer. The method of providing the electroless Ni plating layer is not particularly limited, and various known methods can be used. In electroless Ni plating, a plating solution containing nickel and a reducing agent such as sodium hypophosphate and sodium borohydroxide is heated to about 80 to 100 ° C. to plate a base for forming a honeycomb structure. It can be carried out by immersing it in a liquid for a predetermined time.

(3. Manufacturing method of honeycomb structure)
In one aspect, the method for manufacturing a honeycomb structure of the present invention manufactures a honeycomb structure molding base by the method for manufacturing a honeycomb structure molding base of the present invention, and further uses the honeycomb structure molding base. This is a method for manufacturing a honeycomb structure, which includes a step of extrusion-molding the honeycomb structure.

Further, the method for manufacturing a honeycomb structure of the present invention is a method for manufacturing a honeycomb structure including a step of extruding the honeycomb structure using the base for forming the honeycomb structure of the present invention on one side.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limited to the following Examples.

[composition]
Stainless metal powder (Mn: 1.00 or less, Mo: 0.3 or less, Ni: 3.00 to 5.00, Cr: 15.50 to 17.50) as a powder that is a raw material for the base for forming a honeycomb structure. , Cu: 3.00 to 5.00, Fe: 70 to 80 (unit: mass%)) were prepared.

[Additional manufacturing]
As the base for forming the honeycomb structure of each example and the comparative example, a 3D printer ProX300 manufactured by 3Dsystems was used to form the stainless metal powder in a thin layer on the stage, and an electron beam was irradiated to the thin layer to form the stainless metal. The powder was solidified to form a molded product layer, and the molded product layer was repeatedly laminated to prepare a product having the basic structure shown in FIG. The design drawing of the base used in the modeling is shown in FIG.

[Plating layer]
For each embodiment, regarding the honeycomb structure molding base formed by the above-mentioned additional manufacturing.
Fluid polishing is performed using the EX-4350 fluid polishing machine manufactured by Extrude Horn, and after degreasing, it is immersed in a 35% hydrochloric acid bath for 1 minute, electroplated in a nickel chloride acidic bath, and immediately after that, phosphorus Electroless plating was performed in a nickel acid bath by one continuous plating step, and an electroless Ni plating layer having the thickness shown in Table 1 was provided on the back hole and the surface of the slit of the mouthpiece. The method for measuring the thickness of the electroless Ni plating layer is as described above.
The surface roughness (Ra) of the back hole and slit of the base for forming the honeycomb structure before the fluid polishing, and the honeycomb structure after the fluid polishing and before the electroless Ni plating layer is provided. The surface roughness (Ra) of the back hole and the slit of the body molding base is shown in Table 1. The method for measuring the surface roughness (Ra) is as described above.

When the honeycomb structure can be manufactured by extruding the clay using the honeycomb structure molding caps of the manufactured Examples and Comparative Examples to produce the honeycomb structure having the expected properties. Is "◯", and when a honeycomb structure having the expected properties could not be produced, it was marked with "x", and is shown as moldability in Table 1.

1 ... Honeycomb structure molding base 2 ... Base base 3 ... Back hole 4 ... Slits 5, 6 ... Both sides of honeycomb structure molding base 10 ... Honeycomb structure 11 ... Partition 12 ... Cell

Claims (9)

A method for manufacturing a honeycomb structure molding base, which has a back hole into which a molding raw material is introduced and a slit for extruding the molding raw material into the honeycomb structure in communication with the back hole.
The process of molding the honeycomb structure molding base by the additional manufacturing method, and
A method for manufacturing a honeycomb structure molding base, which comprises a step of providing a plating layer having a thickness of 10 to 300 μm so as to cover at least a part of the back hole and a portion constituting the slit of the honeycomb structure molding base. The method for manufacturing a honeycomb structure molding base according to claim 1, wherein the thickness of the plating layer is 20 to 200 μm. The method for manufacturing a honeycomb structure molding base according to claim 1 or 2, wherein the surface roughness (Ra) of the portion of the honeycomb structure molding base provided with the plating layer is 0.3 to 7 μm. The method for manufacturing a honeycomb structure molding base according to claim 3, wherein the surface roughness (Ra) of the portion of the honeycomb structure molding base provided with the plating layer is 0.3 to 3 μm. Further, according to any one of claims 1 to 4, further comprising a fluid polishing step of polishing the honeycomb structure molding base by flowing an abrasive grain fluid through the back hole and the slit before providing the plating layer. Method for manufacturing a base for forming a honeycomb structure. The surface roughness (Ra) of the back hole and the portion constituting the slit of the honeycomb structure molding base before the fluid polishing step is 5 to 20 μm, and the back hole and the back hole and the said portion are subjected to the fluid polishing step. The method for manufacturing a honeycomb structure molding base according to claim 5, wherein the surface roughness (Ra) of the portion constituting the slit is 1 to 10 μm. The method for manufacturing a honeycomb structure molding base according to claim 6, wherein the surface roughness (Ra) of the back hole and the portion constituting the slit is set to 1 to 5 μm by the fluid polishing step. The method for manufacturing a honeycomb structure molding base according to any one of claims 1 to 7, wherein the plating layer is an electroless Ni plating layer. The honeycomb structure molding base is manufactured by the method for manufacturing the honeycomb structure molding base according to any one of claims 1 to 8, and the honeycomb structure is extruded using the honeycomb structure molding base. A method for manufacturing a honeycomb structure including a step.