Method for manufacturing aluminum-titanate-based ceramic honeycomb structure

Abstract

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

What is claimed is: 
     
         1 . A method for manufacturing a ceramic honeycomb structure, comprising:
 kneading titania particles, alumina particles and a binder ingredient such that a raw material paste comprising the titania particles, the alumina particles and the binder ingredient is prepared;   forming a body comprising the raw material paste and having a honeycomb structure such that the body has the honeycomb structure having a plurality of through-holes extending in a longitudinal direction of the body and a plurality of partition portions formed between the through-holes;   positioning on a base the body comprising the raw material paste and having the honeycomb structure such that one end surface of the body in the longitudinal direction faces the base and a space is formed between the base and the one end surface of the body; and   sintering under an oxygen atmosphere the body comprising the raw material paste and having the honeycomb structure on the base with the space formed between the base and the one end surface of the body such that a ceramic body having the honeycomb structure is formed on the base.   
     
     
         2 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing granules between the base and the one end surface of the body, and the granules have a mean volume particle diameter which is set greater than a mean pore diameter of the ceramic body having the honeycomb structure. 
     
     
         3 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing between the base and the one end surface of the body an organic sheet having granules. 
     
     
         4 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing between the base and the one end surface of the body a paste material comprising granules and a liquid medium. 
     
     
         5 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body includes placing an undegreased ceramic setter on the base and placing granules on the undegreased ceramic setter such that the granules are interposed between the body and the undegreased ceramic setter. 
     
     
         6 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body includes placing an unsintered ceramic setter on the base and placing granules on the unsintered ceramic setter such that the granules are interposed between the body and the unsintered ceramic setter. 
     
     
         7 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising drying the body comprising the raw material paste and having the honeycomb structure. 
     
     
         8 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising applying a sealant to one end of each of the through-holes of the body in the longitudinal direction such that each of the through-holes of the body is sealed at the one end. 
     
     
         9 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising degreasing the body comprising the raw material paste and having the honeycomb structure such that an organic ingredient in the raw material paste of the body is removed. 
     
     
         10 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising degreasing the body comprising the raw material paste and having the honeycomb structure on the base such that the space is formed between the base and the one end surface of the body and an organic ingredient in the raw material paste of the body is removed. 
     
     
         11 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising forming a precursor comprising particles comprising titania particles and alumina particles, wherein the kneading comprises kneading the binder ingredient and the particles of the precursor comprising the titania particles and the alumina particles. 
     
     
         12 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the forming of the precursor comprises spray-drying the alumina particles onto the titania particles. 
     
     
         13 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing granules between the base and the one end surface of the body, and the granules have a mean volume particle diameter in a range of 25 μm˜500 μm. 
     
     
         14 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing granules between the base and the one end surface of the body, and the granules have a mean volume particle diameter in a range of 50 μm˜400 μm. 
     
     
         15 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the positioning of the body comprises placing granules between the base and the one end surface of the body, and the granules have a mean volume particle diameter in a range of 100 μm˜300 μm. 
     
     
         16 . A ceramic honeycomb structural body produced by the method for manufacturing a ceramic honeycomb structure according to  claim 1 .