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 such that raw material paste including the titania particles, the alumina particles and the binder is prepared, extruding the raw material paste through a die for forming a honeycomb structure such that a body made of the raw material paste and having the honeycomb structure is formed, supporting the body extruded from the die on a holder while moving the holder along extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that the diameter of the body held by the holder changes to the target diameter size, and sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed.

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;   extruding the raw material paste through a die for forming a honeycomb structure such that a body comprising the raw material paste and having the honeycomb structure is formed;   supporting the body extruded from the die on a holder while moving the holder along an extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that a diameter of the body held by the holder changes to the target diameter size; and   sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed,   wherein the moving speed is less than the extruding speed such that the body extruded from the die is reduced in length with respect to a longitudinal direction of the honeycomb structure due to compression exerted by the holder, that the diameter of the body extruded from the die is increased to the target diameter size and that a thickness of a partition wall portion of the honeycomb structure is increased.   
     
     
         2 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the extruding of the raw material paste comprises extruding the raw material paste in a horizontal direction through the die. 
     
     
         3 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the extruding of the raw material paste comprises extruding the raw material paste in a horizontal direction through the die, and the holder for supporting the body extruded from the die is a belt conveyor. 
     
     
         4 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the extruding of the raw material paste comprises extruding the raw material paste downward in a vertical direction through the die. 
     
     
         5 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the extruding of the raw material paste comprises extruding the raw material paste downward in a vertical direction through the die, and the supporting of the body comprises supporting a lower-end surface of the body on the holder moving in the extrusion direction. 
     
     
         6 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising drying the body having the honeycomb structure with the target diameter size prior to the sintering. 
     
     
         7 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , further comprising applying a sealant material to one end of each of through-holes in the honeycomb structure of the body such that each of the through-holes in the honeycomb structure of the body is sealed at the one end. 
     
     
         8 . 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. 
     
     
         9 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the forming of the precursor includes 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. 
     
     
         10 . A ceramic honeycomb structural body produced by the method for manufacturing a ceramic honeycomb structure according to  claim 1 . 
     
     
         11 . 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;   extruding the raw material paste through a die for forming a honeycomb structure such that a body comprising the raw material paste and having the honeycomb structure is formed;   supporting the body extruded from the die on a holder while moving the holder along an extrusion direction at a moving speed relative to an extruding speed of the raw material based on a target diameter size set for the body such that a diameter of the body held by the holder changes to the target diameter size; and   sintering the body having the honeycomb structure with the target diameter size such that a ceramic body having the honeycomb structure with the target diameter size is formed,   wherein the moving speed is greater than the extruding speed such that the body extruded from the die is increased in length with respect to a longitudinal direction of the honeycomb structure due to pulling exerted by the holder, the diameter of the body extruded from the die is reduced to the target diameter size and that a thickness of a partition wall portion of the honeycomb structure is reduced.   
     
     
         12 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the extruding of the raw material paste comprises extruding the raw material paste in a horizontal direction through the die. 
     
     
         13 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the extruding of the raw material paste comprises extruding the raw material paste in a horizontal direction through the die, and the holder for supporting the body extruded from the die is a belt conveyor. 
     
     
         14 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the extruding of the raw material paste comprises extruding the raw material paste downward in a vertical direction through the die. 
     
     
         15 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the extruding of the raw material paste comprises extruding the raw material paste downward in a vertical direction through the die, and the supporting of the body comprises supporting a lower-end surface of the body on the holder moving in the extrusion direction. 
     
     
         16 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , further comprising drying the body having the honeycomb structure with the target diameter size prior to the sintering. 
     
     
         17 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , further comprising applying a sealant material to one end of each of through-holes in the honeycomb structure of the body such that each of the through-holes in the honeycomb structure of the body is sealed at the one end. 
     
     
         18 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , 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. 
     
     
         19 . The method for manufacturing a ceramic honeycomb structure according to  claim 11 , wherein the forming of the precursor includes 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. 
     
     
         20 . A ceramic honeycomb structural body produced by the method for manufacturing a ceramic honeycomb structure according to  claim 11 .