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 a binder such that a raw material paste containing the titania particles, the alumina particles and the binder is prepared, forming a body made of the raw material paste and having the honeycomb structure, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure and made of aluminum titanate is formed. The kneading includes combining the binder, a titania powder containing the titania particles and an alumina powder containing the alumina particles, and the titania powder includes potassium in an amount of from 100 ppm to 600 ppm with respect to the titania powder in a weight ratio based on conversion from K 2 O.

What is claimed is: 
     
         1 . A method for manufacturing a ceramic honeycomb structure, comprising:
 kneading titania particles, alumina particles and a binder such that a raw material paste comprising the titania particles, the alumina particles and the binder is prepared;   forming a body comprising the raw material paste and having the honeycomb structure; and   sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure and comprising aluminum titanate is formed,   wherein the kneading includes combining the binder, a titania powder comprising the titania particles and an alumina powder comprising the alumina particles, and the titania powder includes potassium in an amount of from 100 ppm to 600 ppm with respect to the titania powder in a weight ratio based on conversion from K 2 O.   
     
     
         2 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising forming a precursor comprising particles comprising the titania particles and the alumina particles, wherein the forming of the precursor comprises bringing the titania particles and the alumina particles into contact with each other such that the titania particles and the alumina particles are adhered to each other and form the precursor comprising the particles comprising the titania particles and the alumina particles, and the kneading comprises kneading the binder ingredient and the particles of the precursor comprising the titania particles and the alumina particles. 
     
     
         3 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the forming of the precursor includes spray-drying the alumina particles onto the titania particles. 
     
     
         4 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the kneading includes combining mullite particles, the binder, the titania particles and the alumina particles such that a raw material paste comprising the mullite particles, the titania particles, the alumina particles and the binder is prepared. 
     
     
         5 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the kneading includes combining a pore-forming agent, the binder, the titania particles and the alumina particles such that a raw material paste comprising the pore-forming agent, the titania particles, the alumina particles and the binder is prepared. 
     
     
         6 . The method for manufacturing a ceramic honeycomb structure according to  claim 5 , wherein the pore-forming agent is at least one material selected from the group consisting of a graphite material, a polyethylene material, a polypropylene material, a polymethylmethacrylate material, a starch material, a nut shell material, a walnut shell material, a corn material, an ice material, and a dry ice material. 
     
     
         7 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the kneading includes combining a sintering additive, the binder, the titania particles and the alumina particles such that a raw material paste comprising the sintering additive, the titania particles, the alumina particles and the binder is prepared. 
     
     
         8 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the kneading includes combining a sintering additive comprising mullite particles, the binder, the titania particles and the alumina particles such that a raw material paste comprising the sintering additive, the titania particles, the alumina particles and the binder is prepared. 
     
     
         9 . The method for manufacturing a ceramic honeycomb structure according to  claim 5 , wherein the pore-forming agent is added in an amount in a range of 0.1% to 30% by mass based on 100% by mass of the precursor. 
     
     
         10 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the titania particles and the alumina particles have a ratio of a particle diameter of the titania particles to a particle diameter of the alumina particles in a range of from 10:1 to 10:3. 
     
     
         11 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the binder material includes at least one binder selected from the group consisting of a cellulose, an alcohol, a salt, a wax and a thermoplastic resin. 
     
     
         12 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the kneading includes combining mullite particles, the binder and the precursor such that a raw material paste comprising the mullite particles, the precursor and the binder is prepared. 
     
     
         13 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the kneading includes combining a pore-forming agent, the binder and the precursor such that a raw material paste comprising the pore-forming agent, the precursor and the binder is prepared. 
     
     
         14 . The method for manufacturing a ceramic honeycomb structure according to  claim 13 , wherein the pore-forming agent is at least one material selected from the group consisting of a graphite material, a polyethylene material, a polypropylene material, a polymethylmethacrylate material, a starch material, a nut shell material, a walnut shell material, a corn material, an ice material, and a dry ice material. 
     
     
         15 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the kneading includes combining a sintering additive, the binder and the precursor such that a raw material paste comprising the sintering additive, the precursor and the binder is prepared. 
     
     
         16 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the kneading includes combining a sintering additive comprising mullite particles, the binder and the precursor such that a raw material paste comprising the sintering additive, the precursor and the binder is prepared. 
     
     
         17 . The method for manufacturing a ceramic honeycomb structure according to  claim 13 , wherein the pore-forming agent is added in an amount in a range of 0.1% to 30% by mass based on 100% by mass of the precursor. 
     
     
         18 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the titania particles and the alumina particles have a ratio of a particle diameter of the titania particles to a particle diameter of the alumina particles in a range of from 10:1 to 10:3. 
     
     
         19 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the binder material includes at least one binder selected from the group consisting of a cellulose, an alcohol, a salt, a wax and a thermoplastic resin. 
     
     
         20 . A ceramic honeycomb structural body produced by the method for manufacturing a ceramic honeycomb structure according to  claim 1 .