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 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 partitions formed between the through-holes, immersing each of end portions of the body in the longitudinal direction into a sealant slurry heated at a temperature in the range of from 50° C. to 100° C. such that the sealant slurry infiltrates into the through-holes at one of the end portions of the body and seals either end of each of the through-holes of the body, and sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.

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;   immersing each of end portions of the body in the longitudinal direction into a sealant slurry heated at a temperature in a range of from 50° C. to 100° C. such that the sealant slurry infiltrates into the through-holes at one of the end portions of the body and seals one end of each of the through-holes of the body; and   sintering the body having the honeycomb structure such that a ceramic body having the honeycomb structure is formed.   
     
     
         2 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the immersing of the end portions of the body includes oscillating the sealant slurry while each of the end portions of the body is being immersed into the sealant slurry. 
     
     
         3 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein each of the end portions of the body is immersed into the sealant slurry under atmospheric open air. 
     
     
         4 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein each of the end portions of the body is immersed into the sealant slurry under atmospheric open air. 
     
     
         5 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the sealant slurry includes ceramic particles, a thermoplastic binder ingredient and a solvent. 
     
     
         6 . 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. 
     
     
         7 . 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. 
     
     
         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 1 , further comprising placing a masking film having a checkered pattern onto an end surface of the body such that each of the end portions of the body is covered in the checkered pattern, wherein the sealant slurry infiltrates into the one end of the through-holes and seals the one end of each of the through-holes of the body in the checkered pattern. 
     
     
         10 . The method for manufacturing a ceramic honeycomb structure according to  claim 1 , wherein the applying of the sealant slurry comprises forming an end surface of the body having a checkered pattern such that the one end of each of the through-holes of the body is sealed in the checkered pattern. 
     
     
         11 . A ceramic honeycomb structural body produced by the method for manufacturing a ceramic honeycomb structure according to  claim 1 . 
     
     
         12 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the sealant slurry includes ceramic particles, a thermoplastic binder ingredient and a solvent. 
     
     
         13 . The method for manufacturing a ceramic honeycomb structure according to  claim 3 , wherein the sealant slurry includes ceramic particles, a thermoplastic binder ingredient and a solvent. 
     
     
         14 . The method for manufacturing a ceramic honeycomb structure according to  claim 4 , wherein the sealant slurry includes ceramic particles, a thermoplastic binder ingredient and a solvent. 
     
     
         15 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , 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. 
     
     
         16 . The method for manufacturing a ceramic honeycomb structure according to  claim 3 , 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. 
     
     
         17 . The method for manufacturing a ceramic honeycomb structure according to  claim 4 , 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. 
     
     
         18 . The method for manufacturing a ceramic honeycomb structure according to  claim 5 , 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 2 , further comprising placing a masking film having a checkered pattern onto an end surface of the body such that each of the end portions of the body is covered in the checkered pattern, wherein the sealant slurry infiltrates into the one end of the through-holes and seals the one end of each of the through-holes of the body in the checkered pattern. 
     
     
         20 . The method for manufacturing a ceramic honeycomb structure according to  claim 2 , wherein the applying of the sealant slurry comprises forming an end surface of the body having a checkered pattern such that the one end of each of the through-holes of the body is sealed in the checkered pattern.