U.S. patent application number 11/748099 was filed with the patent office on 2008-05-15 for degreasing jig assembling apparatus, degreasing jig disassembling apparatus, degreasing jig circulating apparatus, method for degreasing ceramic molded body, and method for manufacturing honeycomb structured body.
This patent application is currently assigned to IBIDEN CO., LTD.. Invention is credited to Kenichiro Kasai, Tsuyoshi Kawai, Takamitsu Saijo.
Application Number | 20080111274 11/748099 |
Document ID | / |
Family ID | 38426493 |
Filed Date | 2008-05-15 |
United States Patent
Application |
20080111274 |
Kind Code |
A1 |
Kawai; Tsuyoshi ; et
al. |
May 15, 2008 |
DEGREASING JIG ASSEMBLING APPARATUS, DEGREASING JIG DISASSEMBLING
APPARATUS, DEGREASING JIG CIRCULATING APPARATUS, METHOD FOR
DEGREASING CERAMIC MOLDED BODY, AND METHOD FOR MANUFACTURING
HONEYCOMB STRUCTURED BODY
Abstract
A degreasing jig assembling apparatus includes a robot arm and a
table or a conveyor on which a degreasing jig including a bottom
plate and a cover member is placed. A ceramic molded body is
mounted on the degreasing jig upon degreasing the ceramic molded
body. The ceramic molded body is mounted on the degreasing jig on
the table or the conveyor. The degreasing jig assembling apparatus
further includes a molding body mounting mechanism and a cover
member. The molding body mounting mechanism mounts the ceramic
molded body at a predetermined position on the bottom plate placed
on the table or the conveyor by using the robot arm. The cover
member attaching mechanism attaches the cover member to the bottom
plate in a manner so as to cover the ceramic molded body mounted on
the bottom plate.
Inventors: |
Kawai; Tsuyoshi; (Ibi-gun,
JP) ; Saijo; Takamitsu; (Dunavarsany, HU) ;
Kasai; Kenichiro; (Ibi-gun, JP) |
Correspondence
Address: |
DITTHAVONG MORI & STEINER, P.C.
918 Prince St.
Alexandria
VA
22314
US
|
Assignee: |
IBIDEN CO., LTD.
Ogaki-shi
JP
|
Family ID: |
38426493 |
Appl. No.: |
11/748099 |
Filed: |
May 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2006/309116 |
May 1, 2006 |
|
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11748099 |
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Current U.S.
Class: |
264/238 ;
134/151; 134/40 |
Current CPC
Class: |
C04B 35/565 20130101;
C04B 2237/365 20130101; C04B 2235/5228 20130101; F26B 2210/02
20130101; C04B 2235/767 20130101; C04B 2235/77 20130101; B28B
11/243 20130101; C04B 2235/3826 20130101; C04B 2235/5224 20130101;
Y02P 40/69 20151101; C04B 2237/083 20130101; Y02P 40/60 20151101;
C04B 2235/526 20130101; C04B 33/1352 20130101; C04B 2235/5264
20130101; C04B 2235/5436 20130101; C04B 2235/9623 20130101; C04B
35/638 20130101; C04B 2235/3418 20130101; C04B 2235/5445 20130101;
C04B 2235/5472 20130101; F26B 15/14 20130101; C04B 35/806 20130101;
C04B 37/005 20130101; B28B 11/248 20130101; C04B 35/6316 20130101;
C04B 35/6263 20130101; F26B 15/04 20130101; F27D 5/00 20130101 |
Class at
Publication: |
264/238 ; 134/40;
134/151; 134/40 |
International
Class: |
C23G 5/00 20060101
C23G005/00 |
Claims
1. A degreasing jig assembling apparatus comprising a robot arm;
and a table or a conveyor on which a degreasing jig comprising a
bottom plate and a cover member is placed, a ceramic molded body
being mounted on said degreasing jig upon degreasing the ceramic
molded body, said ceramic molded body being mounted on said
degreasing jig on said table or said conveyor, wherein the
degreasing jig assembling apparatus further comprising: a molding
body mounting mechanism that mounts the ceramic molded body at a
predetermined position on said bottom plate placed on said table or
said conveyor by using said robot arm; and a cover member attaching
mechanism that attaches said cover member to said bottom plate in a
manner so as to cover the ceramic molded body mounted on said
bottom plate.
2. The degreasing jig assembling apparatus according to claim 1,
wherein said conveyor moves intermittently, and upon stopping of
said conveyor, said conveyor shifts from a moving state at a moving
speed of about 1.5 m/min or less to a stopped state.
3. The degreasing jig assembling apparatus according to claim 1,
wherein said table is a rotation table.
4. The degreasing jig assembling apparatus according to claim 1,
wherein said robot arm is provided with a suction mechanism.
5. The degreasing jig assembling apparatus according to claim 1,
wherein said robot arm is provided with a cushioning member at a
contact portion with said ceramic molded body.
6. The degreasing jig assembling apparatus according to claim 1,
wherein said conveyor is a belt conveyor, a chain conveyor, a
roller conveyor or a pallet conveyor.
7. A degreasing jig disassembling apparatus comprising: a robot
arm; and a table or a conveyor on which a degreasing jig comprising
a bottom plate and a cover member is placed, a ceramic molded body
being mounted on said degreasing jig upon degreasing the ceramic
molded body, the degreasing jig on which said ceramic molded body
is mounted being disassembled on said table or said conveyor,
wherein the degreasing jig disassembling apparatus further
comprising a cover member detaching mechanism that detaches said
cover member attached in a manner so as to cover said ceramic
molded body mounted on said bottom plate placed on said table or
said conveyor, by using said robot arm.
8. The degreasing jig disassembling apparatus according to claim 7,
wherein said conveyor moves intermittently, and upon stopping of
said conveyor, said conveyor shifts from a moving state at a moving
speed of about 1.5 m/min or less to a stopped state.
9. The degreasing jig disassembling apparatus according to claim 7,
wherein said table is a rotation table.
10. The degreasing jig disassembling apparatus according to claim
7, wherein said robot arm is provided with a suction mechanism.
11. The degreasing jig disassembling apparatus according to claim
7, wherein said robot arm is provided with a cushioning member at a
contact portion with said ceramic molded body.
12. The degreasing jig disassembling apparatus according to claim
7, wherein said conveyor is a belt conveyor, a chain conveyor, a
roller conveyor or a pallet conveyor.
13. A degreasing jig circulating apparatus comprising: a degreasing
jig assembling apparatus comprising a robot arm, and a table or a
conveyor on which a degreasing jig comprising a bottom plate and a
cover member is placed, a ceramic molded body being mounted on said
degreasing jig upon degreasing the ceramic molded body, said
ceramic molded body being mounted on said degreasing jig on said
table or said conveyor; a degreasing furnace that degreases the
ceramic molded body mounted on the degreasing jig; a degreasing jig
disassembling apparatus comprising a robot arm, and a table or a
conveyor on which said degreasing jig is placed, the degreasing jig
on which said ceramic molded body is mounted being disassembled on
said table or said conveyor; a cover member transporting conveyor
that transports the cover member that has been detached by said
degreasing jig disassembling apparatus to said degreasing jig
assembling apparatus; and a bottom plate transporting conveyor that
transports the bottom plate on which said ceramic molded body is
mounted, with said cover member being detached, wherein said
degreasing jig assembling apparatus comprising: a molding body
mounting mechanism that mounts the ceramic molded body at a
predetermined position on said bottom plate placed on said table or
said conveyor by using said robot arm; a cover member attaching
mechanism that attaches said cover member to said bottom plate in a
manner so as to cover the ceramic molded body mounted on said
bottom plate; and a jig delivering mechanism that delivers the
degreasing jig on which said ceramic molded body is mounted to said
degreasing furnace, said degreasing jig disassembling apparatus
comprising: a jig receiving mechanism that receives the degreasing
jig on which said ceramic molded body is mounted from said
degreasing furnace; a cover member detaching mechanism that
detaches said cover member attached in a manner so as to cover said
ceramic molded body mounted on said bottom plate placed on said
table or said conveyor, by using said robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which said
ceramic molded body is mounted, with said cover member being
detached, to said bottom plate transporting conveyor.
14. The degreasing jig circulating apparatus according to claim 13,
wherein said conveyor in said degreasing jig assembling apparatus
and/or said degreasing jig disassembling apparatus moves
intermittently, and upon stopping of said conveyor, said conveyor
shifts from a moving state at a moving speed of about 1.5 m/min or
less to a stopped state.
15. The degreasing jig circulating apparatus according to claim 13,
wherein said table is a rotation table.
16. The degreasing jig circulating apparatus according to claim 13,
wherein said robot arm is provided with a suction mechanism.
17. The degreasing jig circulating apparatus according to claim 13,
wherein said robot arm is provided with a cushioning member at a
contact portion with said ceramic molded body.
18. The degreasing jig circulating apparatus according to claim 13,
wherein the conveyor used in said degreasing jig assembling
apparatus is a belt conveyor, a chain conveyor, a roller conveyor
or a pallet conveyor.
19. The degreasing jig circulating apparatus according to claim 13,
wherein the conveyor used in said degreasing jig disassembling
apparatus is a belt conveyor, a chain conveyor, a roller conveyor
or a pallet conveyor.
20. The degreasing jig circulating apparatus according to claim 13,
wherein said cover member transporting conveyor is a belt conveyor,
a chain conveyor, roller conveyor or a pallet conveyor.
21. The degreasing jig circulating apparatus according to claim 13,
wherein said degreasing furnace is provided with a belt conveyor,
chain conveyor or a roller conveyor.
22. A method for degreasing a ceramic molded body comprising
degreasing the ceramic molded body by passing a degreasing jig on
which the ceramic molded body is mounted through inside of a
degreasing furnace, using a degreasing jig circulating apparatus,
said degreasing jig circulating apparatus comprising: a degreasing
jig assembling apparatus comprising a robot arm, and a table or a
conveyor on which the degreasing jig comprising a bottom plate and
a cover member is placed, the ceramic molded body being mounted on
said degreasing jig upon degreasing the ceramic molded body, said
ceramic molded body being mounted on said degreasing jig on said
table or said conveyor; the degreasing furnace that degreases the
ceramic molded body mounted on the degreasing jig; a degreasing jig
disassembling apparatus comprising a robot arm, and a table or a
conveyor on which said degreasing jig is placed, the degreasing jig
on which said ceramic molded body is mounted being disassembled on
said table or said conveyor; a cover member transporting conveyor
that transports the cover member that has been detached by said
degreasing jig disassembling apparatus to said degreasing jig
assembling apparatus; and a bottom plate transporting conveyor that
transports the bottom plate on which said ceramic molded body is
mounted, with said cover member being detached, wherein said
degreasing jig assembling apparatus comprising: a molding body
mounting mechanism that mounts the ceramic molded body at a
predetermined position on said bottom plate placed on said table or
said conveyor by using said robot arm; a cover member attaching
mechanism that attaches said cover member to said bottom plate in a
manner so as to cover the ceramic molded body mounted on said
bottom plate; and a jig delivering mechanism that delivers the
degreasing jig on which said ceramic molded body is mounted to said
degreasing furnace, said degreasing jig disassembling apparatus
comprising: a jig receiving mechanism that receives the degreasing
jig on which said ceramic molded body is mounted from said
degreasing furnace; a cover member detaching mechanism that
detaches said cover member attached in a manner so as to cover said
ceramic molded body mounted on said bottom plate placed on said
table or said conveyor, by using said robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which said
ceramic molded body is mounted, with said cover member being
detached, to said bottom plate transporting conveyor.
23. The method for degreasing a ceramic molded body according to
claim 22, wherein said conveyor in said degreasing jig assembling
apparatus and/or said degreasing jig disassembling apparatus moves
intermittently, and upon stopping of said conveyor, said conveyor
shifts from a moving state at a moving speed of about 1.5 m/min or
less to a stopped state.
24. The method for degreasing a ceramic molded body according to
claim 22, wherein said bottom plate is also used as a firing
jig.
25. The method for degreasing a ceramic molded body according to
claim 22, wherein said table is a rotation table.
26. The method for degreasing a ceramic molded body according to
claim 22, wherein said robot arm is provided with a suction
mechanism.
27. The method for degreasing a ceramic molded body according to
claim 22, wherein said robot arm is provided with a cushioning
member at a contact portion with said ceramic molded body.
28. The method for degreasing a ceramic molded body according to
claim 22, wherein the conveyor used in said degreasing jig
assembling apparatus is a belt conveyor, a chain conveyor, a roller
conveyor or a pallet conveyor.
29. The method for degreasing a ceramic molded body according to
claim 22, wherein the conveyor used in said degreasing jig
disassembling apparatus is a belt conveyor, a chain conveyor, a
roller conveyor or a pallet conveyor.
30. The method for degreasing a ceramic molded body according to
claim 22, wherein said cover member transporting conveyor is a belt
conveyor, a chain conveyor, a roller conveyor or a pallet
conveyor.
31. The method for degreasing a ceramic molded body according to
claim 22, wherein said degreasing furnace is provided with a belt
conveyor, a chain conveyor or a roller conveyor.
32. The method for degreasing a ceramic molded body according to
claim 22, wherein said cover member comprises a net-shaped member
or a plate-shaped member having a vent.
33. The method for degreasing a ceramic molded body according to
claim 22, wherein said cover member comprises a net-shaped member
formed by a flat net, a knitted net, a sintered metal net or metal
fibers.
34. The method for degreasing a ceramic molded body according to
claim 22, wherein said cover member is provided with a supporting
member, a through hole for fitting said supporting member thereto
is formed at said bottom plate, and said supporting member is
fitted to said through hole so that the cover member is attached to
the bottom plate.
35. A method for manufacturing a honeycomb structured body
comprising a honeycomb fired body, including: producing a
pillar-shaped honeycomb molded body having a large number of cells
longitudinally placed in parallel with one another with a cell wall
therebetween by molding a ceramic material, degreasing the
honeycomb molded body mounted on a degreasing jig; and firing the
degreased honeycomb molded body to manufacture a honeycomb fired
body, wherein said degreasing of the honeycomb molded body is
carried out by using a degreasing jig circulating apparatus, said
degreasing jig circulating apparatus comprising: a degreasing jig
assembling apparatus comprising a robot arm, and a table or a
conveyor on which a degreasing jig comprising a bottom plate and a
cover member is placed, a honeycomb molded body being mounted on
said degreasing jig upon degreasing the honeycomb molded body, said
honeycomb molded body being mounted on said degreasing jig on said
table or said conveyor; a degreasing furnace that degreases the
honeycomb molded body mounted on the degreasing jig; a degreasing
jig disassembling apparatus comprising a robot arm, and a table or
a conveyor on which said degreasing jig is placed, the degreasing
jig on which said honeycomb molded body is mounted being
disassembled on said table or said conveyor; a cover member
transporting conveyor that transports the cover member that has
been detached by said degreasing jig disassembling apparatus to
said degreasing jig assembling apparatus; and a bottom plate
transporting conveyor that transports the bottom plate on which
said honeycomb molded body is mounted, with said cover member being
detached, said degreasing jig assembling apparatus comprising: a
molding body mounting mechanism that mounts the honeycomb molded
body at a predetermined position on said bottom plate placed on
said table or said conveyor by using said robot arm; a cover member
attaching mechanism that attaches said cover member to said bottom
plate in a manner so as to cover the honeycomb molded body mounted
on said bottom plate; and a jig delivering mechanism that delivers
the degreasing jig on which said honeycomb molded body is mounted
to said degreasing furnace, said degreasing jig disassembling
apparatus comprising: a jig receiving mechanism that receives the
degreasing jig on which said honeycomb molded body is mounted from
said degreasing furnace; a cover member detaching mechanism that
detaches said cover member attached in a manner so as to cover said
honeycomb molded body mounted on said bottom plate placed on said
table or said conveyor, by using said robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which said
honeycomb molded body is mounted, with said cover member being
detached, to said bottom plate transporting conveyor.
36. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said conveyor in said degreasing jig
assembling apparatus and/or said degreasing jig disassembling
apparatus moves intermittently, and upon stopping of said conveyor,
the conveyor shifts from a moving state at a moving speed of about
1.5 m/min or less to a stopped state.
37. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said bottom plate is also used as a
firing jig.
38. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said bottom plate transporting
conveyor transports the bottom plate on which said honeycomb molded
body is mounted, with said cover member being detached, to the
firing of the honeycomb molded body.
39. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said table is a rotation table.
40. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said robot arm is provided with a
suction mechanism.
41. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said robot arm is provided with a
cushioning member at a contact portion with said honeycomb molded
body.
42. The method for manufacturing a honeycomb structured body
according to claim 35, wherein the conveyor used in said degreasing
jig assembling apparatus is a belt conveyor, a chain conveyor, a
roller conveyor or a pallet conveyor.
43. The method for manufacturing a honeycomb structured body
according to claim 35, wherein the conveyor used in said degreasing
jig disassembling apparatus is a belt conveyor, a chain conveyor, a
roller conveyor or a pallet conveyor.
44. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said cover member transporting
conveyor is a belt conveyor, a chain conveyor, a roller conveyor or
a pallet conveyor.
45. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said degreasing furnace is provided
with a belt conveyor, a chain conveyor or a roller conveyor.
46. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said cover member comprises a
net-shaped member or a plate-shaped member having a vent.
47. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said cover member comprises a
net-shaped member formed by a flat net, a knitted net, sintered
metal net or metal fibers.
48. The method for manufacturing a honeycomb structured body
according to claim 35, wherein said cover member is provided with a
supporting member, a through hole for fitting said supporting
member thereto is formed at said bottom plate, and said supporting
member is fitted to said through hole so that the cover member is
attached to the bottom plate.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C.
.sctn.120 to PCT Application No. PCT/JP2006/309116, filed May 1,
2006, entitled "DEGREASING JIG ASSEMBLING APPARATUS, DEGREASING JIG
DISASSEMBLING APPARATUS, DEGREASING JIG CIRCULATING APPARATUS,
METHOD FOR DEGREASING CERAMIC MOLDED BODY, AND METHOD FOR
MANUFACTURING HONEYCOMB STRUCTURED BODY." The contents of this
application are incorporated herein by reference in their
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a degreasing jig assembling
apparatus, a degreasing jig disassembling apparatus, a degreasing
jig circulating apparatus, a method for degreasing a ceramic molded
body, and a method for manufacturing a honeycomb structured
body.
[0004] 2. Discussion of the Background
[0005] In recent years, particulates such as soot contained in
exhaust gases that are discharged from internal combustion engines
of vehicles, such as buses and trucks, and construction machines,
have raised serious problems as contaminants harmful to the
environment and the human body.
[0006] Various honeycomb filters using honeycomb structured bodies
made from porous ceramic materials, which serve as filters that
collect particulates in exhaust gases to purify the exhaust gases,
have been proposed.
[0007] Conventionally, upon manufacturing a honeycomb structured
body, first, a wet mixture is prepared by mixing ceramic powder, a
binder and a dispersant solution and the like with one another.
Moreover, the wet mixture is continuously extrusion-molded through
a die, and the extrusion-molded body is cut into a predetermined
length so that a pillar-shaped honeycomb molded body is
manufactured.
[0008] Next, the resulting honeycomb molded body is dried by using
a microwave drying apparatus or a hot-air drying apparatus.
[0009] Thereafter, the end portions of this honeycomb molded body
are plugged by a plug material paste mainly composed of the ceramic
powder into a diced pattern, and then respective degreasing and
firing processes are carried out so that a honeycomb fired body is
manufactured.
[0010] Thereafter, a sealing material paste is applied to the side
faces of the honeycomb fired body, and the honeycomb fired bodies
are mutually bonded to each other through an adhesive so that an
aggregate of the honeycomb fired bodies in which a number of the
honeycomb fired bodies are combined with one another by interposing
the sealing material layers (adhesive layers) is manufactured.
Next, the resulting aggregate of the honeycomb fired bodies is cut
and machined into a predetermined shape, such as a cylindrical
shape and an cylindroid shape, by using a cutting tool or the like
so that a honeycomb block is formed, and lastly, a sealing material
paste is applied onto the periphery of the honeycomb block to form
a sealing material layer (coat layer); thus, the manufacturing of
the honeycomb structured body is completed.
[0011] In such a method for manufacturing a honeycomb structured
body, the degreasing process is normally carried out on a honeycomb
molded body placed on a degreasing jig.
[0012] Moreover, during the degreasing process, a large amount of
organic components, liquids such as organic substances and
moisture, and gases are generated, and these adhere to wall faces
(in particular, wall faces on the upper side) of a degreasing
furnace to form a tar-like matter, which tend to drop onto the
honeycomb molded body; therefore, with respect to the degreasing
jig, a degreasing jig comprised of two plate-shaped bodies and a
supporting member has been proposed. For example, see Japanese
Unexamined Patent Application Publication No. 2001-19560.
[0013] Here, the above-mentioned degreasing jig is normally used
repeatedly.
[0014] For example, WO 2005/024326 A1 discloses a method in which,
in order to repeatedly use a receiving base on which honeycomb
molded bodies are placed, the receiving base is circulated.
[0015] The contents of Japanese Unexamined Patent Application
Publication No. 2001-19560 and WO 2005/024326 A1 are incorporated
herein by reference in their entirety.
SUMMARY OF THE INVENTION
[0016] According to one aspect of the present invention, a
degreasing jig assembling apparatus includes a robot arm; and a
table or a conveyor on which a degreasing jig including a bottom
plate and a cover member is placed, a ceramic molded body being
mounted on the degreasing jig upon degreasing the ceramic molded
body, the ceramic molded body being mounted on the degreasing jig
on the table or the conveyor, wherein the degreasing jig assembling
apparatus further includes a molding body mounting mechanism that
mounts the ceramic molded body at a predetermined position on the
bottom plate placed on the table or the conveyor by using the robot
arm; and a cover member attaching mechanism that attaches the cover
member to the bottom plate in a manner so as to cover the ceramic
molded body mounted on the bottom plate.
[0017] In the above-mentioned degreasing jig assembling apparatus,
the above-mentioned conveyor moves intermittently, and upon
stopping of the above-mentioned conveyor, the above-mentioned
conveyor desirably shifts from a moving state at a moving speed of
about 1.5 m/min or less to a stopped state.
[0018] In the above-mentioned degreasing jig assembling apparatus,
the above-mentioned table is desirably a rotation table, and also
the above-mentioned robot arm is desirably provided with a suction
mechanism.
[0019] In the above-mentioned degreasing jig assembling apparatus,
the above-mentioned robot arm is desirably provided with a
cushioning member at a contact portion with the above-mentioned
ceramic molded body. The above-mentioned conveyor is desirably a
belt conveyor, a chain conveyor, a roller conveyor or a pallet
conveyor.
[0020] According to another aspect of the present invention, a
degreasing jig disassembling apparatus includes a robot arm; and a
table or a conveyor on which a degreasing jig including a bottom
plate and a cover member is placed, a ceramic molded body being
mounted on the degreasing jig upon degreasing the ceramic molded
body, the degreasing jig on which the ceramic molded body is
mounted being disassembled on the table or the conveyor, wherein
the degreasing jig disassembling apparatus further includes a cover
member detaching mechanism that detaches the cover member attached
in a manner so as to cover the ceramic molded body mounted on the
bottom plate placed on the table or the conveyor, by using the
robot arm.
[0021] In the above-mentioned degreasing jig disassembling
apparatus, the above-mentioned conveyor moves intermittently, and
upon stopping of the above-mentioned conveyor, the above-mentioned
conveyor desirably shifts from a moving state at a speed of about
1.5 m/min or less to a stopped state.
[0022] In the above-mentioned degreasing jig disassembling
apparatus, the above-mentioned table is desirably a rotation
table.
[0023] In the above-mentioned degreasing jig disassembling
apparatus, the above-mentioned robot arm is desirably provided with
a suction mechanism, and also, the above-mentioned robot arm is
desirably provided with a cushioning member at a contact portion
with the above-mentioned ceramic molded body.
[0024] In the above-mentioned degreasing jig disassembling
apparatus, the above-mentioned conveyor is desirably a belt
conveyor, a chain conveyor, a roller conveyor or a pallet
conveyor.
[0025] According to further aspect of the present invention, a
degreasing jig circulating apparatus includes a degreasing jig
assembling apparatus including a robot arm, and a table or a
conveyor on which a degreasing jig including a bottom plate and a
cover member is placed, a ceramic molded body being mounted on the
degreasing jig upon degreasing the ceramic molded body, the ceramic
molded body being mounted on the degreasing jig on the table or the
conveyor; a degreasing furnace that degreases the ceramic molded
body mounted on the degreasing jig; a degreasing jig disassembling
apparatus including a robot arm, and a table or a conveyor on which
the degreasing jig is placed, the degreasing jig on which the
ceramic molded body is mounted being disassembled on the table or
the conveyor; a cover member transporting conveyor that transports
the cover member that has been detached by the degreasing jig
disassembling apparatus to the degreasing jig assembling apparatus;
and a bottom plate transporting conveyor that transports the bottom
plate on which the ceramic molded body is mounted, with the cover
member being detached, wherein the degreasing jig assembling
apparatus includes a molding body mounting mechanism that mounts
the ceramic molded body at a predetermined position on the bottom
plate placed on the table or the conveyor by using the robot arm; a
cover member attaching mechanism that attaches the cover member to
the bottom plate in a manner so as to cover the ceramic molded body
mounted on the bottom plate; and a jig delivering mechanism that
delivers the degreasing jig on which the ceramic molded body is
mounted to the degreasing furnace, the degreasing jig disassembling
apparatus including a jig receiving mechanism that receives the
degreasing jig on which the ceramic molded body is mounted from the
degreasing furnace; a cover member detaching mechanism that
detaches the cover member attached in a manner so as to cover the
ceramic molded body mounted on the bottom plate placed on the table
or the conveyor, by using the robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which the
ceramic molded body is mounted, with the cover member being
detached, to the bottom plate transporting conveyor.
[0026] In the above-mentioned degreasing jig circulating apparatus,
the above-mentioned conveyor in the above-mentioned degreasing jig
assembling apparatus and/or the above-mentioned degreasing jig
disassembling apparatus moves intermittently, and upon stopping of
the above-mentioned conveyor, the above-mentioned conveyor
desirably shifts from a moving state at a moving speed of about 1.5
m/min or less a stopped state.
[0027] In the above-mentioned degreasing jig circulating apparatus,
the above-mentioned table is desirably a rotation table.
[0028] In the above-mentioned degreasing jig circulating apparatus,
the above-mentioned robot arm is desirably provided with a suction
mechanism, and also, the above-mentioned robot arm is desirably
provided with a cushioning member at a contact portion with the
above-mentioned ceramic molded body.
[0029] In the above-mentioned degreasing jig circulating apparatus,
the conveyor used in the above-mentioned degreasing jig assembling
apparatus is desirably a belt conveyor, chain conveyor, roller
conveyor or a pallet conveyor.
[0030] In the above-mentioned degreasing jig circulating apparatus,
the conveyor used in the above-mentioned degreasing jig
disassembling apparatus is desirably a belt conveyor, chain
conveyor, roller conveyor or a pallet conveyor.
[0031] In the above-mentioned degreasing jig circulating apparatus,
the above-mentioned cover member transporting conveyor is desirably
a belt conveyor, a chain conveyor, roller conveyor or a pallet
conveyor, and also, the above-mentioned degreasing furnace is
desirably provided with a belt conveyor, chain conveyor or a roller
conveyor.
[0032] According to the other aspect of the present invention, a
method for degreasing a ceramic molded body includes degreasing the
ceramic molded body by passing a degreasing jig on which the
ceramic molded body is mounted through inside of a degreasing
furnace, using a degreasing jig circulating apparatus, the
degreasing jig circulating apparatus including: a degreasing jig
assembling apparatus including a robot arm, and a table or a
conveyor on which the degreasing jig having a bottom plate and a
cover member is placed, the ceramic molded body being mounted on
the degreasing jig upon degreasing the ceramic molded body, the
ceramic molded body being mounted on the degreasing jig on the
table or the conveyor; the degreasing furnace that degreases the
ceramic molded body mounted on the degreasing jig; a degreasing jig
disassembling apparatus including a robot arm, and a table or a
conveyor on which the degreasing jig is placed, the degreasing jig
on which the ceramic molded body is mounted being disassembled on
the table or the conveyor; a cover member transporting conveyor
that transports the cover member that has been detached by the
degreasing jig disassembling apparatus to the degreasing jig
assembling apparatus; and a bottom plate transporting conveyor that
transports the bottom plate on which the ceramic molded body is
mounted, with the cover member being detached, wherein the
degreasing jig assembling apparatus including: a molding body
mounting mechanism that mounts the ceramic molded body at a
predetermined position on the bottom plate placed on the table or
the conveyor by using the robot arm; a cover member attaching
mechanism that attaches the cover member to the bottom plate in a
manner so as to cover the ceramic molded body mounted on the bottom
plate; and a jig delivering mechanism that delivers the degreasing
jig on which the ceramic molded body is mounted to the degreasing
furnace, the degreasing jig disassembling apparatus including a jig
receiving mechanism that receives the degreasing jig on which the
ceramic molded body is mounted from the degreasing furnace; a cover
member detaching mechanism that detaches the cover member attached
in a manner so as to cover the ceramic molded body mounted on the
bottom plate placed on the table or the conveyor, by using the
robot arm; and a bottom plate delivering mechanism that delivers
the bottom plate on which the ceramic molded body is mounted, with
the cover member being detached, to the bottom plate transporting
conveyor.
[0033] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned conveyor in the above-mentioned
degreasing jig assembling apparatus and/or the above-mentioned
degreasing jig disassembling apparatus moves intermittently and
upon stopping of the above-mentioned conveyor, the above-mentioned
conveyor desirably shifts from a moving state at a moving speed of
about 1.5 m/min or less to a stopped state.
[0034] In the above-mentioned method for degreasing a ceramic
molded body, desirably, the above-mentioned bottom plate is also
used as a firing jig.
[0035] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned table is desirably a rotation
table.
[0036] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned robot arm is desirably provided
with a suction mechanism, and also, the above-mentioned robot arm
is desirably provided with a cushioning member at a contact portion
with the above-mentioned ceramic molded body.
[0037] In the above-mentioned method for degreasing a ceramic
molded body, the conveyor used in the above-mentioned degreasing
jig assembling apparatus is desirably a belt conveyor, a chain
conveyor, a roller conveyor or a pallet conveyor.
[0038] In the above-mentioned method for degreasing a ceramic
molded body, the conveyor used in the above-mentioned degreasing
jig disassembling apparatus is desirably a belt conveyor, chain
conveyor, roller conveyor or a pallet conveyor.
[0039] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned cover member transporting conveyor
is desirably a belt conveyor, a chain conveyor, a roller conveyor
or a pallet conveyor, and also, the above-mentioned degreasing
furnace is desirably provided with a belt conveyor, a chain
conveyor or a roller conveyor.
[0040] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned cover member desirably comprises a
net-shaped member or a flat-shaped member having a vent, and also,
the above-mentioned cover member desirably comprises a net-shaped
member formed by a flat net, a knitted net, a sintered metal net or
metal fibers.
[0041] In the above-mentioned method for degreasing a ceramic
molded body, the above-mentioned cover member is desirably provided
with a supporting member, a through hole for fitting the
above-mentioned supporting member thereto is desirably formed at
the above-mentioned bottom plate, and the above-mentioned
supporting member is fitted to the above-mentioned through hole so
that the cover member is desirably attached to the bottom
plate.
[0042] According to further aspect of the present invention, a
method for manufacturing a honeycomb structured body includes a
honeycomb fired body, including: producing a pillar-shaped
honeycomb molded body having a large number of cells longitudinally
placed in parallel with one another with a cell wall therebetween
by molding a ceramic material, degreasing the honeycomb molded body
mounted on a degreasing jig; and firing the degreased honeycomb
molded body to manufacture a honeycomb fired body, wherein the
degreasing of the honeycomb molded body is carried out by using a
degreasing jig circulating apparatus, the degreasing jig
circulating apparatus including: a degreasing jig assembling
apparatus including a robot arm, and a table or a conveyor on which
a degreasing jig having a bottom plate and a cover member is
placed, a honeycomb molded body being mounted on the degreasing jig
upon degreasing the honeycomb molded body, the honeycomb molded
body being mounted on the degreasing jig on the table or the
conveyor; a degreasing furnace that degreases the honeycomb molded
body mounted on the degreasing jig; a degreasing jig disassembling
apparatus comprising a robot arm, and a table or a conveyor on
which the degreasing jig is placed, the degreasing jig on which the
honeycomb molded body is mounted being disassembled on the table or
the conveyor; a cover member transporting conveyor that transports
the cover member that has been detached by the degreasing jig
disassembling apparatus to the degreasing jig assembling apparatus;
and a bottom plate transporting conveyor that transports the bottom
plate on which the honeycomb molded body is mounted, with the cover
member being detached, the degreasing jig assembling apparatus
including a molding body mounting mechanism that mounts the
honeycomb molded body at a predetermined position on the bottom
plate placed on the table or the conveyor by using the robot arm; a
cover member attaching mechanism that attaches the cover member to
the bottom plate in a manner so as to cover the honeycomb molded
body mounted on the bottom plate; and a jig delivering mechanism
that delivers the degreasing jig on which the honeycomb molded body
is mounted to the degreasing furnace, the degreasing jig
disassembling apparatus including: a jig receiving mechanism that
receives the degreasing jig on which the honeycomb molded body is
mounted from the degreasing furnace; a cover member detaching
mechanism that detaches the cover member attached in a manner so as
to cover the honeycomb molded body mounted on the bottom plate
placed on the table or the conveyor, by using the robot arm; and a
bottom plate delivering mechanism that delivers the bottom plate on
which the honeycomb molded body is mounted, with the cover member
being detached, to the bottom plate transporting conveyor.
[0043] In the present specification, the shape indicated by the
word "pillar" refers to any desired shape of a pillar including a
round pillar, an oval pillar, a polygonal pillar and the like.
[0044] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned conveyor in the
above-mentioned degreasing jig assembling apparatus and/or the
above-mentioned degreasing jig disassembling apparatus moves
intermittently, and upon stopping of the above-mentioned conveyor,
the conveyor desirably shifts from a moving state at a moving speed
of about 1.5 m/min or less to a stopped state.
[0045] In the above-mentioned method for manufacturing a honeycomb
structured body, desirably, the bottom plate is also used as a
firing jig.
[0046] Moreover, desirably, the bottom plate transporting conveyor
transports the bottom plate on which the honeycomb molded body is
mounted, with the cover member being detached, to the firing of the
honeycomb molded body.
[0047] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned table is desirably a rotation
table.
[0048] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned robot arm is desirably
provided with a suction mechanism, and also the above-mentioned
robot arm is desirably provided with a cushioning member at a
contact portion with the above-mentioned honeycomb molded body.
[0049] In the above-mentioned method for manufacturing a honeycomb
structured body, the conveyor used in the above-mentioned
degreasing jig assembling apparatus is desirably a belt conveyor, a
chain conveyor, a roller conveyor or a pallet conveyor.
[0050] In the above-mentioned method for manufacturing a honeycomb
structured body, the conveyor used in the above-mentioned
degreasing jig disassembling apparatus is desirably a belt
conveyor, a chain conveyor, a roller conveyor or a pallet
conveyor.
[0051] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned cover member transporting
conveyor is desirably a belt conveyor, a chain conveyor, a roller
conveyor or a pallet conveyor, and also, the above-mentioned
degreasing furnace is desirably provided with a belt conveyor, a
chain conveyor or a roller conveyor.
[0052] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned cover member desirably
comprises a net-shaped member or a plate-shaped member having a
vent, and also, the above-mentioned cover member desirably
comprises a net-shaped member formed by a flat net, a knitted net,
sintered metal net or metal fibers.
[0053] In the above-mentioned method for manufacturing a honeycomb
structured body, the above-mentioned cover member is desirably
provided with a supporting member, a through hole for fitting the
above-mentioned supporting member thereto is desirably formed at
the above-mentioned bottom plate, and the above-mentioned
supporting member is fitted to the above-mentioned through hole so
that the cover member is desirably attached to the bottom
plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] A more complete appreciation of the invention and many of
the attendant advantages thereof will be readily obtained as the
same becomes better understood by reference to the following
detailed description when considered in connection with the
accompanying drawings, wherein:
[0055] FIG. 1 is a conceptual view that schematically shows the
outline of a degreasing jig assembling apparatus according to an
embodiment of the present invention;
[0056] FIG. 2 is an exploded perspective view showing a degreasing
jig;
[0057] FIG. 3 is a perspective view that shows one example of a
robot arm forming a molded body mounting mechanism;
[0058] FIG. 4 is a partial enlarged perspective view of the robot
arm shown in FIG. 3;
[0059] FIG. 5 is a conceptual view that schematically shows the
outline of another example of the degreasing jig assembling
apparatus according to an embodiment of the present invention;
[0060] FIG. 6 is a conceptual view that schematically shows the
outline of still another example of the degreasing jig assembling
apparatus according to an embodiment of the present invention;
[0061] FIG. 7 is a conceptual view that schematically shows the
outline of a degreasing jig disassembling apparatus according to an
embodiment of the present invention;
[0062] FIGS. 8(a) and 8(b) are conceptual views that schematically
show other examples of the degreasing jig disassembling apparatus
according to an embodiment of the present invention;
[0063] FIG. 9 is a conceptual view that schematically shows the
outline of a degreasing jig circulating apparatus according to an
embodiment of the present invention;
[0064] FIG. 10 is a conceptual view that schematically shows the
outline of another example of the degreasing jig circulating
apparatus according to an embodiment of the present invention;
[0065] FIG. 11 is a conceptual view that schematically shows the
outline of still another example of the degreasing jig circulating
apparatus according to an embodiment of the present invention;
[0066] FIG. 12 is an explanatory drawing that schematically shows
one example of a degreasing process and a firing process in a
manufacturing method according to an embodiment of the present
invention; and
[0067] FIG. 13 is a perspective view that schematically shows one
example of a honeycomb structured body.
DESCRIPTION OF THE EMBODIMENTS
[0068] The embodiments will now be described with reference to the
accompanying drawings, wherein like reference numerals designate
corresponding or identical elements throughout the various
drawings.
[0069] First, the following description will discuss a degreasing
jig assembling apparatus according to an embodiment of the present
invention.
[0070] The degreasing jig assembling apparatus according to an
embodiment of the present invention is a degreasing jig assembling
apparatus comprising a robot arm; and a table or a conveyor on
which a degreasing jig comprising a bottom plate and a cover member
is placed, a ceramic molded body being mounted on the degreasing
jig upon degreasing the ceramic molded body, the ceramic molded
body being mounted on the degreasing jig on the table or the
conveyor, wherein the degreasing jig assembling apparatus further
comprising: a molding body mounting mechanism that mounts the
ceramic molded body at a predetermined position on the bottom plate
placed on the table or the conveyor by using the robot arm; and a
cover member attaching mechanism that attaches the cover member to
the bottom plate in a manner so as to cover the ceramic molded body
mounted on the bottom plate.
[0071] In the present specification, the robot arm refers to an arm
that has active joints provided with motors and the like, and also
has inactive joints without motors and the like, if necessary.
[0072] FIG. 1 is a conceptual view that schematically shows the
outline of the degreasing jig assembling apparatus according to an
embodiment of the present invention.
[0073] As shown in FIG. 1, a degreasing jig assembling apparatus
111 is provided with one robot arm 113, two robot arms 114 (114A,
114B) and two robot arms 115 (115A, 115B), and is also provided
with a rotation table 112 serving as a table on which a degreasing
jig 100 for mounting a ceramic molded body 11 thereon is placed.
Here, the degreasing jig 100 is comprised of a bottom plate 101 and
a cover member 102.
[0074] This degreasing jig assembling apparatus 111 automatically
carries out processes in which the ceramic molded body 11 is
mounted on the bottom plate 101 and the cover member 102 is
attached to the bottom plate 101 in a manner so as to cover the
ceramic molded body 11.
[0075] In the degreasing jig assembling apparatus 111, the robot
arm 113 has a suction mechanism, and has a function for
suction-holding and transporting the ceramic molded body 11 by this
mechanism, and each of the robot arms 114, 115 has a grasping
mechanism, and has a function for transporting and assembling the
degreasing jig 100 by this mechanism.
[0076] Therefore, in the degreasing jig assembling apparatus 111,
the robot arm 113 is allowed to function as a molded body mounting
mechanism.
[0077] In the degreasing jig assembling apparatus 111, the robot
arms 113 to 115 have the above-mentioned mechanisms; however, each
of the robot arms 113 to 115 may have both of the suction mechanism
and the grasping mechanism, or may have only either one of the
mechanisms.
[0078] Moreover, the robot arms 113 to 115 are provided with air
cylinders, and thus allowed to move in vertical directions. Here,
portions, extended from the cylinders, are engaged with ball screws
placed in the horizontal direction, and allowed to move in the
horizontal direction by the moving mechanisms utilizing the ball
screws.
[0079] The degreasing jig 100 to be used in the degreasing jig
assembling apparatus 111 is a degreasing jig comprised of a bottom
plate and a cover member. Referring to the drawings, this
degreasing jig will be explained below in detail.
[0080] FIG. 2 is an exploded perspective view showing the
degreasing jig.
[0081] As shown in FIG. 2, the degreasing jig 100 is comprised of a
plate-shaped bottom plate 101 and a cover member 102 which
comprises a flat net 102c with a frame member 102b being formed on
the outer peripheral edge and supporting members 102a secured to
four corners of this frame member 102b.
[0082] Here, through holes 101a for fitting the supporting members
102a provided to the cover member 102 thereto are formed on the
bottom plate 101, and by fitting the supporting members 102a to
these through holes 101a, the cover member 102 is attached to the
bottom plate 101.
[0083] Moreover, although not shown in the bottom plate 101 of FIG.
2, the bottom plate that includes the degreasing jig may have
grooves formed on the bottom face, and in this case, the groove may
have a shape that allows one portion of the grasping unit to be
fitted thereto when the bottom plate is grasped by the robot arm.
This structure allows the robot arm to positively grasp the bottom
plate 101.
[0084] In the degreasing jig 100 having this structure, since the
cover member 102 is attached in a manner so as to cover the ceramic
molded body placed on the bottom plate 101, even in the case where,
upon degreasing the ceramic molded body, a tar-state matter or the
like, derived from the decomposed organic substance, drops thereon
from above, the matter is prevented from coming into contact with
the ceramic molded body, and since the periphery of the ceramic
molded body is kept in an open state, it is possible to desirably
carry out the degreasing process.
[0085] Moreover, on the bottom plate 101 of the degreasing jig 100
shown in FIG. 2, narrow band-shaped carbon fiber mats 103 are
secured at two portions in parallel with each other so that the
ceramic molded body is placed thereon through the carbon fiber mats
103. Here, the carbon fiber mats 103 may be included on demand.
[0086] The carbon fiber mats are provided so as to prevent the
ceramic molded body from directly coming into contact with the
upper face of the bottom plate, and any mat made from fibers other
than the carbon fiber mat may be used as long as it has durability
to the degreasing treatment temperature, and porous members, made
from a ceramic material and the like, may be attached in place of
the carbon fiber mats.
[0087] Here, the flat net forming the cover member is desirably
made to have a mesh size (aperture diameter) in a range from 0.04
to 0.5 mm.
[0088] The mesh size of less than 0.04 mm makes it difficult for
organic gases generated from the ceramic molded body during the
degreasing process to pass through the flat net, with the result
that the gases aggregate and adhere to the lower face of the flat
net at portions having low furnace temperatures to form a tar-state
matter or the like, which tends to drop onto the ceramic molded
body to adhere thereto; in contrast, in the case where the mesh
size exceeds 0.5 mm, upon degreasing the ceramic molded body, the
tar-state matter or the like, derived from the decomposed organic
substance, drops thereon from an upper portion of the degreasing
furnace, the mesh size exceeding 0.5 mm allows the tar-state matter
or the like to pass through the flat net, dropping on the ceramic
molded body to adhere thereto.
[0089] Here, the flat net portion in the cover member 102 may be
formed by a simple plate-shaped member; however, it is desirable to
form this portion by using a net-shaped member such as a flat net,
a knitted net, a sintered metal net and metal fibers (sintered
metal nonwoven fabric). This arrangement is suitable for preventing
the tar-state matter or the like from adhering to the ceramic
molded body, as described above.
[0090] Moreover, the flat net portion may be prepared as a
plate-shaped member having a plurality of vents (passing holes)
having a round shape, a polygonal shape or the like in the plan
view.
[0091] In the degreasing jig assembling apparatus 111, first, the
cover member 102, transported from the outside by a conveyor 124,
is placed on the rotation table 112 by the robot arm 115A, while
the bottom plate 101, transported from the outside by a conveyor
125, is placed on the rotation table 112 by the robot arm 114A.
[0092] The robot arm 115A has a grasping mechanism so that the
frame member 102b of the cover member 102 is grasped by the
grasping unit 115a, and the cover member 102 is moved onto the
rotation table 112.
[0093] Moreover, the robot arm 114A also has a grasping mechanism
so that the bottom plate 101 is grasped by the grasping unit 114a,
and the bottom member 101 is moved onto the rotation table 112.
[0094] Furthermore, in the case where the bottom plate 101 has
grooves on the bottom face as described above, with respect to the
robot arm 114A, a robot arm having convex-shaped claws on the
inside of the tip of the grasping unit 114a is used so that the
bottom plate 101 may be grasped by fitting these claws to the
grooves.
[0095] In the degreasing jig assembling apparatus having the
structure shown in FIG. 1, the number of the robot arms is not
limited to five, and may be set to less than five, and in this
case, one robot arm is configured to exert a plurality of
functions.
[0096] Next, when the rotation table is shifted by about 1/4
rotation, a predetermined number (five in FIG. 1) of ceramic molded
bodies 11 which, after having been transported from the outside by
a molded body carry-in conveyor 119, are placed on a molded body
receiving unit 118, with side faces being mutually made in contact
with each other, are shifted by the robot arm 113 having the
suction unit 113a, and placed on the bottom plate 101 with
predetermined intervals.
[0097] The robot arm 113, which simultaneously suction-holds a
plurality of ceramic molded bodies 11 (five in FIG. 1), arranges
them on the bottom plate 101 with predetermined intervals. The
reason for the arrangement of the ceramic molded bodies 11 with
predetermined intervals is that, when the interval between the
ceramic molded bodies is too narrow or too wide, deviations tend to
occur in the degree of progress of the degreasing process of the
respective ceramic molded bodies.
[0098] For this reason, desirably, the robot arm 113, which
functions as a molded body mounting mechanism, is configured to
place the ceramic molded bodies that have been suction-held on the
bottom plate 101 with predetermined intervals. Specific examples of
such a robot arm will be described later.
[0099] Here, the rotation table 112 repeats rotations and stoppages
intermittently.
[0100] Here, the robot arm 113 simultaneously places a plurality of
ceramic molded bodies 11 on the bottom plate 101; however, the
degreasing jig assembling apparatus 111 may allow the robot arm 113
to place ceramic molded bodies 11 on the bottom plate 101 one by
one.
[0101] Next, when the rotation table 112 rotates, the robot arm
115B is allowed to grasp the cover member 102 and attach it onto
the bottom plate 101 on which the ceramic molded bodies 11 have
been mounted, in a manner so as to cover the ceramic molded bodies
11. Here, the cover member 102 is provided with four rod-shaped
supporting members 102a, and the cover member 102 is provided with
through holes 101a (see FIG. 2) to which the supporting members
102a are fitted on the corner portions of the bottom plate 101;
thus, the supporting members 102a are fitted to the through holes
101a so that the cover member 102 can be attached to the bottom
plate 101.
[0102] Here, the degreasing jig having such a structure has already
been explained by reference to FIG. 2; however, the degreasing jig
is not necessarily required to have through holes formed in the
bottom plate so as to be fitted to the supporting members, and in
this case, the cover member is only placed on the bottom plate.
Moreover, in addition to the through holes, the bottom plate may
have a positional deviation preventive structure for the cover
member.
[0103] Therefore, in the degreasing jig assembling apparatus 111,
the robot arm 115B is allowed to function as a cover member
attaching mechanism. Here, in the same manner as the robot arm
115A, the robot arm 115B is allowed to grasp the frame member 102b
of the cover member 102 by the grasping unit 115b and move the
cover member 102.
[0104] Next, when the rotation table 112 rotates, the ceramic
molded body 11 is placed thereon, and a degreasing jig 100 to which
the cover member 102 has been attached is placed on the conveyor
123 by the robot arm 114B, and transported to an apparatus used in
the next process (for example, a degreasing process).
[0105] Here, in the same manner as the robot arm 114A, the robot
arm 114B is also provided with a grasping mechanism so that, by
grasping the bottom face with the grasping unit 114b, the
degreasing jig 100 is transported onto the conveyor 123.
[0106] With respect to specific examples of a molded body carry-in
conveyor 119 and conveyors 123 to 125 that are installed in the
degreasing jig assembling apparatus 111, a belt conveyor, a chain
conveyor, a roller conveyor, a pallet conveyor and the like are
listed.
[0107] Next, referring to the drawings, the following description
will discuss a specific example of the robot arm 113 that serves as
a molded body mounting mechanism, which is installed in the
degreasing jig assembling apparatus 111.
[0108] FIG. 3 is a perspective view that shows one example of a
robot arm that serves as the molded body mounting mechanism, and
FIGS. 4(a) and 4(b) are a partial enlarged perspective view of the
robot arm shown in FIG. 3.
[0109] As shown in FIG. 3, the robot arm 113 is provided with a
suction mechanism 60, and this suction mechanism 60 has a structure
in which seven suction members 61a and suction plates 61b are
respectively placed side by side in the horizontal direction so as
to be aligned face to face with each other. Each of the suction
plates 61b on the lower side has a suction hole (not shown) formed
so as to exert a suction force onto the ceramic molded body 11. On
the other hand, tube connecting holes are formed at two positions
of the upper portion of each of the suction members 61a on the
upper side, and tubes 62 are connected thereto through these tube
connecting holes. These tubes 62 are gathered to a tube
distribution member 64 having a rectangular pillar shape with a
cavity formed therein. Moreover, an air suction duct 63 is
connected to the tube distribution member 64, and this air suction
duct 63 is connected to a suction device (not shown).
[0110] Therefore, with respect to the flow of the suction force
(air suction force) in the suction mechanism 60, a suction force,
generated in the suction device, is transmitted to the tube
distribution member 64 through the air suction duct 63, and further
transmitted to the respective suction members 61a through the tubes
62 gathered to the tube distribution member 64. In this manner, the
suction force, generated by the suction device, is not directly
transmitted to the respective suction members 61a, but once
transmitted to the tube distribution member 64, and then
transmitted thereto so that the same suction force is equally
transmitted to all the suction members 61a.
[0111] Moreover, a spring and a tube are sandwiched between the
suction member 61a and the suction plate 61b so that the suction
member 61a and the suction plate 61b are coupled to each other. In
this manner, the suction force from the tube 62 is transmitted to
the suction member 61a, and then directed to the suction holes
formed in the suction plate 61b through the tube sandwiched between
the suction member 61a and the suction plate 61b. The suction
mechanism 60 suction-holds the ceramic molded body 11 by utilizing
the suction force transmitted to the suction holes.
[0112] Here, in the present specification, the suction force refers
to a pressure difference between the inside of the suction system
in the suction mechanism and the outside.
[0113] Furthermore, a supporting plate 65 that supports the suction
mechanism 60 is coupled to the side face of the tube distribution
member 64, and an elevating mechanism 67, such as a cylinder, is
vertically attached to the supporting plate 65 so that by driving
this elevating mechanism 67, the suction mechanism 60 can be raised
and lowered.
[0114] Here, a member, which supports the robot arm 113 and is
placed in the horizontal direction from the upper portion of the
elevating mechanism 67, is engaged with a ball screw, not shown, so
that by rotating the ball screw, and the like, the robot arm 113 is
shifted in the horizontal direction. Moreover, a pivot mechanism 68
is coupled to the further upper portion of the member supporting
the robot arm 113 so that the suction mechanism 60 is allowed to
rotate.
[0115] Next, referring to FIGS. 4(a) and 4(b), the following
description will discuss a mechanism used for adjusting the
intervals of the suction members 61a.
[0116] As shown in FIGS. 4(a) and 4(b), through holes 75 that
penetrate the suction member 61a in the horizontal direction are
formed at two positions of each of the seven suction members 61a.
Moreover, two supporting shafts 71 are inserted through all the
through holes 75 at the respective two positions in a manner so as
to penetrate the seven suction members 61a. Furthermore, the two
ends of each of the two supporting shafts 71 are secured by two
plate-like supporting shaft connecting plates 72 so that the seven
suction members 61a form one unit and are allowed to serve as one
large plate with its width being variably changed within a fixed
range.
[0117] Moreover, nail-shaped hooking portions 73 are formed on the
two ends of each suction member 61a, and with adjacent two of the
hooking portions 73 being formed into one set, a combining ring 74
is passed over them for each set. By the combining ring 74 that has
been passed over each of the sets, all the adjacent suction members
61a are determined in their movable range.
[0118] The two end portions of a driving means 66 to be used for
adjusting the intervals are secured to the upper faces of the
suction members 61a located on the two ends of the seven suction
members 61a placed side by side so that the intervals of the
suction members 61a can be adjusted by this driving means 66.
[0119] In other words, when the length of the driving means 66 is
most shortened, the suction members 61a are mutually made in
contact with one another completely; in contrast, when the length
of the driving means 66 is most lengthened, the interval between
the mutual suction members 61a is made longest within the
expandable range of the combining ring 74. Thus, the mutual
interval between the suction members 61a is determined in two
states, that is, the longest length and the shortest length
adjusted by the driving means 66. In this case, by adjusting the
expandable range of the combining ring 74, the interval between the
mutual suction members 61a can be adjusted.
[0120] In the case where the combining ring 74 is formed by an
elastic member such as rubber, the suction members 61a can be
expanded with equal intervals within a range in which the combining
ring 74 can be extended, regardless of the length of the driving
means 66.
[0121] In other words, in the case where the combining ring 74 is
made from an elastic member also, the intervals between the mutual
suction members 61a are extended and contracted by the extending
and contracting operations of the driving means 66. At this time,
since the combining ring 74 is hooked on the hooking portions 73 of
the adjacent suction members 61a, and since the adjacent suction
members 61a are urged by the same force in the mutually approaching
directions by the elastic force of the combining ring 74, the
suction members 61a are expanded in a manner so as to have mutually
equal intervals. Therefore, within the expandable range of the
combining ring 74, the suction members 61a can be mutually extended
with equal intervals in a desired state between the shortest length
and the longest length of the driving means 66.
[0122] With respect to the material for the combining ring,
examples thereof include: metals such as aluminum, stainless steel,
copper, iron and nickel; rubbers such as silicone rubber, natural
rubber, synthetic rubber and fluororubber; and resins such as PS
resin, ABS resin, POM resin, PC resin, PP resin, PE resin, PPE
resin and PBT resin.
[0123] Moreover, the material used for adjusting the intervals of
the suction members, not limited to the combining ring, another
material such as a spring may be used, and any desired member may
be used as long as it can adjust the intervals of the suction
members.
[0124] Here, the interval between the ceramic molded bodies is not
particularly determined since it depends on the size, degreasing
temperature, degreasing time and the like of the ceramic molded
body. When the interval is too wide, the degreasing process
advances to excess, and, in contrast, when the interval is too
short, the degreasing process becomes insufficient. When the
degreasing process advances to excess or when the degreasing
process becomes insufficient, deviations tend to occur in the
strength of the degreased body.
[0125] The following description will discuss a sequence of
processes in which ceramic molded bodies 11 are placed on the
bottom plate 101 by using the robot arm 113.
[0126] First, the ceramic molded bodies 11, transported by the
molded body carry-in conveyor 119, are collected in a molded body
receiving unit 118. As shown in FIG. 1, in the molded body
receiving unit 118, the ceramic molded bodies 11 are arranged so as
to be made in contact with each other.
[0127] Next, the suction mechanism 60 is lowered so that the side
faces (upper faces in the figure) of the ceramic molded bodies 11
are made in contact with the suction plates 61b. Here, since a
spring is interposed between each suction member 61a and each
suction plate 61b, an impact, exerted upon contacting, can be
alleviated. In this case, the driving means 66, which adjusts the
intervals of the suction members 61a, is set in the shortest state
so as to allow one suction plate 61b to contact to the side face of
one ceramic molded body 11. Then, by activating the suction device,
not shown, to carry out an air suction process, the ceramic molded
body 11 is sucked through the suction holes formed in the suction
plate 61b to be suction-held to the suction plate 61b.
[0128] Thereafter, the suction mechanism 60 is raised to a
predetermined position by the elevating mechanism 67, and the robot
arm 113 is shifted horizontally above the bottom plate 101 of the
degreasing jig by an arm shifting mechanism.
[0129] Next, the driving means 66 is driven so that the intervals
between the seven suction members 61a are adjusted to predetermined
intervals that are suitable for the degreasing process for the
ceramic molded bodies 11. Thus, the intervals between the ceramic
molded bodies 11 are set to equal intervals. The predetermined
intervals suitable for the degreasing process are properly changed
depending on the kind and number of the ceramic molded bodies
11.
[0130] Thereafter, the elevating mechanism 67 is activated to lower
the suction mechanism 60 so as to place the ceramic molded bodies
11 on the bottom plate 101 placed on the rotation table 112. At the
time when the ceramic molded bodies 11 are made in contact with the
carbon fiber mats 103, the lowering process of the suction
mechanism 60 is stopped, and the suction process by the suction
device is then stopped so that they are placed on the bottom plate
101 simultaneously.
[0131] Through the above-mentioned procedures, the plurality of
ceramic molded bodies 11 are placed with intervals suitable for the
degreasing process.
[0132] Here, the suction force used for suction-holding the ceramic
molded body may be appropriately changed depending on the weight
and shape of the ceramic molded bodies to be suction-held, and, for
example, when the suction face of the ceramic molded body is a flat
face and its weight is 210 g, the suction force is set in a range
from 0.7 to 2.0 kPa.
[0133] The robot arm 113 may have a cushioning member attached to
the contact portion to the ceramic molded body.
[0134] The cushioning member is not particularly limited, as long
as it is made from a material having a cushioning function, and
examples of the material include urethane resin, polyethylene,
polypropylene, polystyrene, rubber, epoxy resin and the like.
Moreover, the cushioning member, made from each of these materials,
may be prepared as a solid body or a foamed body.
[0135] The entire cushioning member may be composed of the
above-mentioned material, or the cushioning member may have a
structure in which a sheet-shaped member, made from the
above-mentioned material, is affixed onto a base member made from
metal, resin or a ceramic material.
[0136] Here, not limited to the structure having a rotation table
as shown in FIG. 1, the degreasing jig assembling apparatus may
have a structure provided with a conveyor, for example, as shown in
FIGS. 5 and 6.
[0137] FIGS. 5 and 6 are conceptual views that schematically show
the outlines of other examples of the degreasing jig assembling
apparatus according to an embodiment of the present invention
respectively.
[0138] A degreasing jig assembling apparatus 211 shown in FIG. 5 is
provided with three robot arms 213 to 215 and a jig assembling belt
conveyor 212 that functions as a conveyor carrying thereon the
degreasing jig 100 on which ceramic molded bodies 11 are
mounted.
[0139] This degreasing jig assembling apparatus 211 also
automatically carries out the processes in which: the ceramic
molded bodies 11 are placed on the bottom plate 101 and the cover
member 102 is attached to the bottom plate 101 in a manner so as to
cover the ceramic molded bodies 11. Here, the structure of the
degreasing jig is the same as described earlier.
[0140] Moreover, in the degreasing jig assembling apparatus 211,
the robot arm 213 has the same structure as the robot arm 113 shown
in FIG. 1, the robot arm 214 has the same structure as the robot
arm 114 shown in FIG. 1, and the robot arm 215 has the same
structure as the robot arm 115 shown in FIG. 1.
[0141] In the degreasing jig assembling apparatus 211, first, the
bottom plate 101, transported from outside by a conveyor 225, is
placed by the robot arm 214 on the jig assembling belt conveyer 212
that is intermittently moved.
[0142] At this time, the jig assembling belt conveyor 212 is
stopped.
[0143] Next, when, after having been moved by a predetermined
distance, the jig assembling belt conveyor 212 is again stopped, a
predetermined number of ceramic molded bodies 11 that have been
transported from the outside by a molded body carry-in conveyor 219
and then placed on the molded body receiving unit 218, with the
side faces thereof being made in contact with one another, are
shifted by the robot arm 213 having a suction unit 213a, and placed
on the bottom plate 101 with intervals between them.
[0144] Therefore, in the degreasing jig assembling apparatus 211,
the robot arm 213 functions as a molded body mounting
mechanism.
[0145] Next, when, after having been moved by a predetermined
distance, the jig assembling belt conveyor 212 is stopped, the
cover member 102, transported from the outside by a conveyor 224,
is grasped by the robot arm 215, and attached to the bottom plate
101 on which the ceramic molded bodies 11 have been placed, in a
manner so as to cover the ceramic molded bodies 11.
[0146] Therefore, in the degreasing jig assembling apparatus 211,
the robot arm 215 functions as a cover member attaching
mechanism.
[0147] Thereafter, the degreasing jig 100 on which the ceramic
molded bodies 11 have been placed, with the cover member 102 being
attached thereto, is carried out to an apparatus used in the next
process (for example, the degreasing process) by the jig assembling
belt conveyor 212.
[0148] Here, after the assembling operations on the jig assembling
belt conveyor 212 have been completed, the degreasing jig 100 may
be switched to and placed on another conveyor, and transported to
an apparatus used in the next process.
[0149] Moreover, in the degreasing jig assembling apparatus 211,
the jig assembling belt conveyor 212 is a conveyor that moves
intermittently, and upon stopping of the jig assembling belt
conveyor 212, it is desirable to shift from a moving state with a
moving speed of about 1.5 m/min or less to the stopped state.
[0150] In the case where the moving speed immediately before the
shift to the stopped state is more than about 1.5 m/min, upon
stopping, the ceramic molded body 11 might be moved on the bottom
plate 101 due to force of inertia.
[0151] If the ceramic molded body 11 is moved on the bottom plate
101, the ceramic molded bodies 11 might be made in contact with
each other when moved, or the ceramic molded body 11 might be made
in contact with the cover member 102 to cause damages to the
ceramic molded body.
[0152] Moreover, upon shifting from the moving state of a moving
speed of about 1.5/min or less to the stopped state, the conveyor
shifts from the moving state may be shifted to the stopped state
instantaneously, or the moving speed may be gradually reduced from
the moving state to the stopped state.
[0153] Therefore, when the ceramic molded bodies placed on the
bottom plate 101 are transported at a speed of more than about 1.5
m/min, the moving speed is desirably reduced to a speed of about
1.5 m/min or less prior to the stoppage, and then directed to the
stopped state.
[0154] In the degreasing jig assembling apparatus 211 in the
embodiment shown in FIG. 5, the conveyor forming the degreasing jig
assembling apparatus for placing the degreasing jig 100 thereon may
be a chain conveyor, a roller conveyor or a pallet conveyor aside
from the belt conveyor.
[0155] Moreover, in the degreasing jig assembling apparatus shown
in FIG. 5, the number of robot arms is not particularly limited to
three, and may be less than three or more than three, and in a case
where the number of robot arms is less than three, one robot arm is
allowed to have a plurality of functions.
[0156] More specifically, for example, the robot arm used for
moving the bottom plate and the robot arm used for attaching the
cover member may comprise a single robot arm.
[0157] The degreasing jig assembling apparatus according to an
embodiment of the present invention may have a structure as shown
in FIG. 6.
[0158] A degreasing jig assembling apparatus 311, shown in FIG. 6,
is provided with a robot arm 313, two robot arms 314 (314A, 314B),
a robot arm 315 and a jig assembling pallet conveyor 312 that
functions as a conveyor used for carrying the degreasing jig 100 on
which ceramic molded bodies 11 are mounted.
[0159] This degreasing jig assembling apparatus 311 also
automatically carries out the processes in which: the ceramic
molded bodies 11 are placed on the bottom plate 101 and the cover
member 102 is attached to the bottom plate 101 in a manner so as to
cover the ceramic molded bodies. Here, the structure of the
degreasing jig is the same as described earlier.
[0160] Moreover, in the degreasing jig assembling apparatus 311,
the robot arm 313 has the same structure as the robot arm 113 shown
in FIG. 1, the robot arm 314 has the same structure as the robot
arm 114 shown in FIG. 1, and the robot arm 315 has the same
structure as the robot arm 115 shown in FIG. 1.
[0161] In the degreasing jig assembling apparatus 311, first, the
bottom plate 101, transported from outside by a conveyor 325, is
placed on a pallet 312a of a jig assembling pallet conveyer 312 by
the robot arm 314A.
[0162] Next, when, after the pallet 312a has been moved by a
predetermined distance toward the conveyor 323 side with the bottom
plate 101 being placed thereon, the jig assembling pallet belt
conveyor 312 is stopped, a predetermined number of ceramic molded
bodies 11 that have been transported from outside by a molded body
carry-in conveyor 319 and then placed on the molded body receiving
unit 318 with the side faces thereof being made in contact with one
another are shifted by the robot arm 313 having a suction unit
313a, and placed on the bottom plate 101 with intervals between
them.
[0163] Therefore, in the degreasing jig assembling apparatus 311,
the robot arm 313 functions as a molded body mounting
mechanism.
[0164] Next, the cover member 102, transported from outside by a
conveyor 324, is grasped by the robot arm 315, and attached to the
bottom plate 101 on which the ceramic molded bodies 11 have been
mounted, in a manner so as to cover the ceramic molded bodies
11.
[0165] Therefore, in the degreasing jig assembling apparatus 311,
the robot arm 315 functions as a cover member attaching
mechanism.
[0166] Next, after the pallet 312a have been moved by a
predetermined distance toward the conveyor 323 side, the jig
assembling belt conveyor 312 is again stopped, and the degreasing
jig 100 on which the ceramic molded bodies 11 have been mounted,
with the cover member 102 being attached thereto, is grasped by the
robot arm 314B, and placed on the conveyor 323.
[0167] Thereafter, the degreasing jig 100 is carried out to an
apparatus used in the next process (for example, degreasing
process) by the conveyor 323.
[0168] The pallet 312a, on the other hand, is moved toward the
conveyor 325 side so as to carry the next bottom plate 101, and
stopped at a predetermined position.
[0169] In the case of the jig assembling pallet conveyor 312
comprising the degreasing jig assembling apparatus 311 also, upon
stoppage, it is desirable to shift from a moving state with a
moving speed of about 1.5 m/min or less to the stopped state.
[0170] In the degreasing jig assembling apparatus 311 in the
embodiment as shown in FIG. 6, the conveyor used for carrying the
degreasing jig 100, which forms the degreasing jig assembling
apparatus, may be a belt conveyor, a chain conveyor, a roller
conveyor or the like aside from the pallet conveyor.
[0171] As described above, the degreasing jig assembling apparatus
according to an embodiment of the present invention may have
structures as shown in FIGS. 5 and 6.
[0172] In the degreasing jig assembling apparatus as shown in FIGS.
5 and 6, specific examples of the molded body carry-in conveyors
219, 319 and conveyors 224, 225, 323 to 325 include a belt
conveyor, a chain conveyor, a roller conveyor, a pallet conveyor
and the like, in the same manner as the degreasing jig assembling
apparatus 111 shown in FIG. 1.
[0173] Moreover, although not particularly shown in the drawings,
the degreasing jig assembling apparatus according to an embodiment
of the present invention may have a table in place of the jig
assembling pallet conveyor, for example, in the degreasing jig
assembling apparatus having the structure as shown in FIG. 6.
[0174] In this structure, the table is always stopped, and after
ceramic molded bodies have been mounted on the degreasing jig, by
moving the bottom plate, the ceramic molded body and the cover
member onto the table in this order by the robot arms, this may be
placed on the conveyor to be carried out to an apparatus used in
the next process, or the table is configured to be movable through
rails and the like, and the table may be moved along the rails and
the like in the same manner as the pallet of the pallet conveyor
(that is, moved to the end portion next to each conveyor).
[0175] Moreover, in the degreasing jig assembling apparatus having
the structure shown in FIG. 6, the number of robot arms is not
particularly limited to four, and may be less than four or more
than four, and in a case where the number of robot arms is less
than four, one robot arm is allowed to have a plurality of
functions.
[0176] The degreasing jig assembling apparatus according to an
embodiment of the present invention having the above-mentioned
structure automatically carries out a holding process of ceramic
molded bodies on the degreasing jig so that the ceramic molded
bodies can be held on the degreasing jig efficiently without the
need for manual labor.
[0177] The following description will discuss a degreasing jig
disassembling apparatus according to an embodiment of the present
invention.
[0178] A degreasing jig disassembling apparatus according to an
embodiment of the present invention includes a robot arm; and a
table or a conveyor on which a degreasing jig comprising a bottom
plate and a cover member is placed, a ceramic molded body being
mounted on the degreasing jig upon degreasing the ceramic molded
body, the degreasing jig on which the ceramic molded body is
mounted being disassembled on the table or the conveyor, wherein
the degreasing jig disassembling apparatus further comprising a
cover member detaching mechanism that detaches the cover member
attached in a manner so as to cover the ceramic molded body mounted
on the bottom plate placed on the table or the conveyor, by using
the robot arm.
[0179] Referring to the drawings, the following description will
discuss a degreasing jig disassembling apparatus according to an
embodiment of the present invention.
[0180] FIG. 7 is a conceptual view that schematically shows the
outline of the degreasing jig disassembling apparatus according to
an embodiment of the present invention.
[0181] As shown in FIG. 7, the component members of a degreasing
jig disassembling apparatus according to an embodiment of the
present invention are the almost same of those of the
above-mentioned degreasing jig assembling apparatus according to an
embodiment of the present invention.
[0182] In other words, as shown in FIG. 7, a degreasing jig
disassembling apparatus 131 is provided with two robot arms 134
(134A and 134B), two robot arms 135 (135A and 135B), and also has a
rotation table 132 serving as a table for placing thereon a
degreasing jig 100 on which a ceramic molded body 11 is mounted is
placed.
[0183] This degreasing jig disassembling apparatus 131
automatically carries out processes for detaching the cover member
102 from the degreasing jig 100, comprised of a cover member 102
and a bottom plate 101, in which the cover member 102 is attached
onto the bottom plate 101 on which the degreased ceramic molded
body 11 is mounted in a manner so as to cover the ceramic molded
body 11. Here, the degreasing jig 100 has been explained in the
description of the degreasing jig assembling apparatus.
[0184] In the degreasing jig disassembling apparatus 131, the
degreasing jig 100 that has been transported by a conveyor 143,
with the degreased ceramic molded body 11 being mounted thereon, is
first placed on the rotation table 132 by the robot arm 134A. Here,
the robot arm 134A has the same structure as the robot arm 114 that
has been explained.
[0185] Next, when the rotation table is shifted by about 1/4
rotation, the cover member 102 is detached from the bottom plate
101 by the robot arm 135A. The robot arm 135A has the same
structure as the robot arm 115 that has already been discussed, and
with the frame member 102b of the cover member 102 being grasped by
the grasping unit 135a of the robot arm 135A, the grasping unit
135a is moved upward so that the supporting member 102a is drawn
from a through hole 101a formed in the bottom plate 101; thus, the
cover member 102 can be detached.
[0186] Therefore, in the degreasing jig disassembling apparatus
131, the robot arm 135A functions as a cover member detaching
mechanism.
[0187] Here, the rotation table 132 repeatedly rotates and stops
intermittently.
[0188] When the rotation table 132 successively rotates, the bottom
plate 101 on which the degreased ceramic molded body 11 is placed
is grasped by the robot arm 134B having a grasping mechanism at
this time, and delivered to the bottom plate transporting conveyor
139, and the bottom plate 101, as it is, is transported to an
apparatus used in the next process. Here, the robot arm 134B has
the same structure as the robot arm 114 that has been
explained.
[0189] Here, after the rotation table 132 has further rotated, the
detached cover member 102 is placed on a conveyor 144 by the robot
arm 135B, and carried out. Here, the robot arm 135B has the same
structure as the robot arm 115 that has already been explained.
[0190] With respect to specific examples of the bottom plate
transporting conveyor 139 and conveyors 143, 144 to be installed in
the degreasing jig disassembling apparatus, conveyors, such as a
belt conveyor, a chain conveyor, a roller conveyor and a pallet
conveyor, are listed.
[0191] Moreover, in the degreasing jig disassembling apparatus
shown in FIG. 7, the number of robot arms is not particularly
limited to four, and may be less than four or more than four, and
in a case where the number of robot arms is less than four, one
robot arm is allowed to have a plurality of functions.
[0192] Moreover, the structure of the degreasing jig disassembling
apparatus of the present invention is not limited to the structure
with a rotation table as shown in FIG. 7, and, for example,
structures having conveyors as shown in FIGS. 8(a) and 8(b) may be
used.
[0193] FIGS. 8(a) and 8(b) are conceptual views that respectively
show other examples of the degreasing jig disassembling apparatus
according to an embodiment of the present invention.
[0194] A degreasing jig disassembling apparatus 231, shown in FIG.
8(a), is provided with two robot arms 234, 235, and a jig
disassembling belt conveyor 232 that functions as a conveyor that
carries the degreasing jig 100 with the ceramic molded body 11
being mounted thereon.
[0195] This degreasing jig disassembling apparatus 231 also
automatically carries out processes for detaching the cover member
102 from the degreasing jig 100, comprised of a cover member 102
and a bottom plate 101, in which the cover member 102 is attached
onto the bottom plate 101 on which the degreased ceramic molded
body 11 is placed in a manner so as to cover the ceramic molded
body 11. Here, the degreasing jig 100 has already been
explained.
[0196] Moreover, in the degreasing jig disassembling apparatus 231,
the robot arm 234 has the same structure as the robot arm 134 shown
in FIG. 7, and the robot arm 235 has the same structure as the
robot arm 135 shown in FIG. 7.
[0197] In the degreasing jig disassembling apparatus 231, the
degreasing jig 100 that has been transported by a conveyor with the
degreased ceramic molded body 11 being mounted thereon, is first
placed on a jig disassembling belt conveyor 232 by the robot arm
234.
[0198] Next, the cover member 102 is detached from the bottom plate
101 by the robot arm 235, and the cover member 102 thus detached is
transported outside by a conveyor 244.
[0199] Therefore, in the degreasing jig disassembling apparatus
231, the robot arm 235 functions as a cover member detaching
mechanism.
[0200] Here, during this operation, the conveyor 244 is
stopped.
[0201] When the jig disassembling belt conveyor 232 is shifted, the
bottom plate 101 from which the cover member 102 is detached, with
the ceramic molded body 11 being mounted thereon, as it is, is
transported to an apparatus used in the next process such as firing
process.
[0202] After the disassembling operations have been completed on
the jig disassembling belt conveyor 232, the bottom plate 101 on
which the ceramic molded body 11 is mounted may be switched to and
carried on another conveyor, and transported to an apparatus used
in the next process.
[0203] In the degreasing jig disassembling apparatus 231, the jig
disassembling belt conveyor 232 is a conveyor that is moved
intermittently, and upon stopping of the jig disassembling belt
conveyor 232, it is desirable to shift from a moving state with a
moving speed of about 1.5 m/min or less to the stopped state.
[0204] In the case where the moving speed immediately before the
shift to the stopped state is more than about 1.5 m/min, upon
stopping, the ceramic molded body 11 might be moved on the bottom
plate 101 due to force of inertia.
[0205] If the degreased ceramic molded body 11 is moved on the
bottom plate 101, the degreased ceramic molded bodies 11 might be
made in contact with each other when moved, or the degreased
ceramic molded body 11 might be made in contact with the cover
member 102 to cause damages to the degreased ceramic molded
body.
[0206] Moreover, upon shifting from the moving state of a moving
speed of about 1.5/min or less to the stopped state, the jig
disassembling belt conveyor 232 may shift from the moving state to
the stopped state instantaneously, or the jig disassembling belt
conveyor 232 may shift from the moving state through gradually
reducing of the moving speed to the stopped state.
[0207] Therefore, when the ceramic molded bodies 11 placed on the
bottom plate 101 are transported at a speed of more than about 1.5
m/min, the moving speed is desirably reduced to a speed of about
1.5 m/min or less once, prior to the stoppage, and then directed to
the stopped state.
[0208] In the degreasing jig disassembling apparatus 231 in the
embodiment shown in FIG. 8(a), the conveyor comprising the
degreasing jig assembling apparatus for placing degreasing jig 100
thereon may be a chain conveyor, a roller conveyor, a pallet
conveyor or the like aside from the belt conveyor.
[0209] Moreover, in the degreasing jig disassembling apparatus
shown in FIG. 8(a), the number of robot arms is not particularly
limited to two, and one robot arm may be allowed to have two
functions.
[0210] The degreasing jig disassembling apparatus according to an
embodiment of the present invention may have a structure shown in
FIG. 8(b).
[0211] A degreasing jig disassembling apparatus 331, shown in FIG.
8(b), is provided with two robot arms 334 (334A, 334B), a robot arm
335 and a jig disassembling pallet conveyor 332 that functions as a
conveyor used for carrying the degreasing jig 100 on which
degreased ceramic molded bodies 11 are mounted.
[0212] This degreasing jig disassembling apparatus 331 also
automatically carries out the processes for detaching the cover
member 102 from the degreasing jig 100, comprised of a cover member
102 and a bottom plate 101, in which the cover member 102 is
attached onto the bottom plate 101 on which the degreased ceramic
molded body 11 is placed in a manner so as to cover the ceramic
molded body 11. Here, the degreasing jig 100 has already been
explained.
[0213] Moreover, in the degreasing jig disassembling apparatus 331,
the robot arm 334 has the same structure as the robot arm 134 shown
in FIG. 7, and the robot arm 335 has the same structure as the
robot arm 135 shown in FIG. 7.
[0214] In the degreasing jig disassembling apparatus 331, first,
the degreasing jig 100, which has been transported by a conveyor
343, with degreased ceramic molded bodies 11 being mounted thereon,
is placed on a pallet 332a of a jig disassembling pallet conveyer
332 by the robot arm 334A.
[0215] Next, after the pallet 332a has been moved by a
predetermined distance toward the bottom plate transporting
conveyor 339 side with the degreasing jig 100 being placed thereon,
the jig disassembling pallet belt conveyor 332 is stopped, and the
cover member 102 is detached from the bottom plate 101 of the
degreasing jig 100 placed on the pallet 332a by the robot arm 235,
and the detached cover member 102 is transported outside by a
conveyor 344.
[0216] Therefore, in the degreasing jig disassembling apparatus
331, the robot arm 335 functions as a cover member detaching
mechanism.
[0217] Next, after the pallet 332a have been moved by a
predetermined distance toward the bottom plate transporting
conveyor 339 side, the jig disassembling belt conveyor 332 is again
stopped, and the bottom plate 101 from which the cover member 102
has been detached is placed on the bottom plate transporting
conveyor 339, with the degreased ceramic molded bodies 11 being
mounted thereon, by the robot arm 334B, and the bottom plate, as it
is, is transported to an apparatus used in the next process such as
a firing process by the bottom plate transporting conveyor 339.
[0218] Thereafter, the pallet 332a is moved toward the conveyor 343
side and stopped at a predetermined position so that the next
degreasing jig 100 is placed thereon.
[0219] In the case of the jig disassembling pallet conveyor 332
comprising the degreasing jig disassembling apparatus 331 also,
upon stoppage, it is desirable to shift from a moving state with a
moving speed of about 1.5 m/min or less to the stopped state.
[0220] In the degreasing jig disassembling apparatus 331 in the
embodiment as shown in FIG. 8(b), the conveyor used for carrying
the degreasing jig 100, which comprises the degreasing jig
disassembling apparatus, may be a belt conveyor, a chain conveyor,
a roller conveyor or the like aside from the pallet conveyor.
[0221] Moreover, in the degreasing jig disassembling apparatus
having the structure shown in FIG. 8(b), the number of robot arms
is not particularly limited to three, and may be less than three or
more than three, and in a case where the number of robot arms is
less than three, one robot arm is allowed to have a plurality of
functions.
[0222] As described above, the degreasing jig disassembling
apparatus according to an embodiment of the present invention may
have the structures shown in FIGS. 8(a) and 8(b).
[0223] Here, in the degreasing jig disassembling apparatus as shown
in FIGS. 8(a) and 8(b), specific examples of the bottom plate
transporting conveyor 339 and conveyors 243, 244, 343 to 344
include a belt conveyor, a chain conveyor, a roller conveyor, a
pallet conveyor and the like, in the same manner as the degreasing
jig disassembling apparatus 131 shown in FIG. 7.
[0224] Moreover, although not particularly shown in the drawings,
the degreasing jig disassembling apparatus according to an
embodiment of the present invention may have a table in place of
the jig disassembling pallet conveyor, for example, in the
degreasing jig disassembling apparatus having the structure as
shown in FIG. 8(b).
[0225] In this structure, the table is always stopped, and by a
robot arm, a placing process of the degreasing jig on which
degreased ceramic molded bodies have been mounted onto the table of
the degreasing jig, a detaching process of the cover member from
the bottom plate and a shifting process of the bottom plate on
which the ceramic molded bodies have been mounted to the conveyor
may be carried out in this order, or the table is configured to be
movable through rails and the like, and the table may be moved
along the rails and the like in the same manner as the
above-mentioned pallet of the pallet conveyor.
[0226] The degreasing jig disassembling apparatus according to an
embodiment of the present invention having the above-mentioned
structure can automatically carry out the disassembling processes
of the degreasing jig efficiently without the need for manual
labor.
[0227] The following description will discuss a degreasing jig
circulating apparatus according to an embodiment of the present
invention.
[0228] The degreasing jig circulating apparatus according to an
embodiment of the present invention includes a degreasing jig
assembling apparatus including a robot arm, and a table or a
conveyor on which a degreasing jig comprising a bottom plate and a
cover member is placed, a ceramic molded body being mounted on the
degreasing jig upon degreasing the ceramic molded body, the ceramic
molded body being mounted on the degreasing jig on the table or the
conveyor; a degreasing furnace that degreases the ceramic molded
body mounted on the degreasing jig; a degreasing jig disassembling
apparatus comprising a robot arm, and a table or a conveyor on
which the degreasing jig is placed, the degreasing jig on which the
ceramic molded body is mounted being disassembled on the table or
the conveyor; a cover member transporting conveyor that transports
the cover member that has been detached by the degreasing jig
disassembling apparatus to the degreasing jig assembling apparatus;
and a bottom plate transporting conveyor that transports the bottom
plate on which the ceramic molded body is mounted, with the cover
member being detached, wherein the degreasing jig assembling
apparatus comprising: a molding body mounting mechanism that mounts
the ceramic molded body at a predetermined position on the bottom
plate placed on the table or the conveyor by using the robot arm; a
cover member attaching mechanism that attaches the cover member to
the bottom plate in a manner so as to cover the ceramic molded body
mounted on the bottom plate; and a jig delivering mechanism that
delivers the degreasing jig on which the ceramic molded body is
mounted to the degreasing furnace, the degreasing jig disassembling
apparatus comprising: a jig receiving mechanism that receives the
degreasing jig on which the ceramic molded body is mounted from the
degreasing furnace; a cover member detaching mechanism that
detaches the cover member attached in a manner so as to cover the
ceramic molded body mounted on the bottom plate placed on the table
or the conveyor, by using the robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which the
ceramic molded body is mounted, with the cover member being
detached, to the bottom plate transporting conveyor.
[0229] Referring to FIG. 9, the following description will discuss
the degreasing jig circulating apparatus according to an embodiment
of the present invention.
[0230] FIG. 9 is a conceptual view that schematically shows the
outline of the degreasing jig circulating apparatus according to an
embodiment of the present invention.
[0231] A degreasing jig circulating apparatus 110 is provided with
a degreasing jig assembling apparatus 111, a degreasing furnace
151, a degreasing jig disassembling apparatus 131, cover member
transporting conveyors 161A to 161C and a bottom plate transporting
conveyor 139.
[0232] With respect to the degreasing jig assembling apparatus 111
and the degreasing jig disassembling apparatus 131, the degreasing
jig assembling apparatus 111 (see FIG. 1) and the degreasing jig
disassembling apparatus 131 (see FIG. 7), which have already been
explained, can be used respectively, and the detailed description
thereof will be omitted.
[0233] Here, the degreasing jig circulating apparatus 110 will be
described in accordance with a flow of the ceramic molded body
11.
[0234] In the degreasing jig circulating apparatus 110 according to
an embodiment of the present invention, ceramic molded bodies 11,
transported by the molding body carry-in conveyor 119, are mounted
on the degreasing jig 100 comprised of a cover member 102
transported by a cover member transporting conveyor 161C (conveyor
124 in FIG. 1) and a bottom plate 101 transported by a conveyor 125
in the degreasing jig assembling apparatus 111.
[0235] The degreasing jig 100 on which the ceramic molded bodies 11
have been mounted is placed on an inter-furnace transporting
conveyor 156 (conveyor 123, in FIG. 1) in the degreasing furnace
151 by the robot arm 114B, and after carrying out a degreasing
process at a predetermined temperature (normally, 200 to
500.degree. C.) in the degreasing furnace 151, this is further
transported to the degreasing jig disassembled device 131 by an
inter-furnace transporting conveyor 156 (conveyor 143, in FIG.
7).
[0236] In the degreasing jig circulating apparatus 110, the robot
arm 114B functions as a jig delivering mechanism.
[0237] Next, the ceramic molded bodies 11 that have been degreased
are shifted to the degreasing jig disassembling apparatus 131 by
the robot arm 134A where the degreasing jig 100 is then
disassembled to the bottom plate 101 on which the ceramic molded
bodies 11 have been mounted and the cover member 102, and the
bottom plate 101 bearing the ceramic molded bodies 11 is
transported to the bottom plate transporting conveyor 139 by the
robot arm 134B, and carried out to an apparatus used in the next
process by the conveyor. Moreover, the cover member 102 is placed
on a cover member transporting conveyor 161A (conveyor 144 in FIG.
7) by the robot arm 135B, and returned to the degreasing jig
assembling apparatus 111 by the cover member transporting conveyor
161.
[0238] In the degreasing jig circulating apparatus 110, the robot
arm 134A functions as the jig receiving mechanism, and the robot
arm 134B functions as the bottom plate delivering mechanism.
[0239] Here, after the next process (for example, firing process),
the bottom plate 101 from which the resulting ceramic molded bodies
have been taken out may be returned to the degreasing jig
assembling apparatus 111 through a conveyor.
[0240] Here, with respect to the degreasing furnace 151 comprising
the degreasing jig circulating apparatus 110, not particularly
limited, conventionally known degreasing furnace may be used. The
degreasing furnace may be a continuous furnace or a batch furnace;
however, from the viewpoints of improving the working efficiency
and easiness in applicability to an automatic system, the
continuous furnace is desirably used.
[0241] With respect to the conveyors installed in the degreasing
furnace, examples thereof include a belt conveyor, a chain
conveyor, a roller conveyor and the like.
[0242] Here, the cover member transporting conveyor 161 comprising
the degreasing jig circulating apparatus 110 is comprised of three
conveyors (cover member transporting conveyors 161A to 161C), and
by successively passing the cover member 102 from the cover member
transporting conveyor 161A to the cover member transporting
conveyor 161C, the cover member 102 can be transported from the
degreasing jig disassembling apparatus 131 to the degreasing jig
assembling apparatus 111.
[0243] Here, the delivering processes of the cover member between
the respective cover member transporting conveyors can be carried
out by using robot arms and the like, not shown.
[0244] Here, in the degreasing jig circulating apparatus 110 shown
in FIG. 9, the cover member transporting conveyor 161 is comprised
of three cover member transporting conveyors; however, the cover
member transporting conveyor may be formed by one conveyor.
[0245] Moreover, in order to improve the transporting efficiency, a
part or all of the cover member transporting conveyor may be formed
into multiple stages of two stages or more.
[0246] Specific examples of the cover member transporting conveyor
include: a belt conveyor, a chain conveyor, a roller conveyor and
the like. In the case where the cover member transporting conveyor
is comprised of a plurality of cover member transporting conveyors,
the kinds of the respective cover member transporting conveyors may
be the same or different from each other.
[0247] With respect to the structure of the degreasing jig
circulating apparatus according to an embodiment of the present
invention, not limited to the structure as shown in FIG. 9 which
has the degreasing jig assembling apparatus provided with a
rotation table and the degreasing jig disassembling apparatus
provided with a rotation table, for example, structures as shown in
FIGS. 10 and 11 may be used.
[0248] FIGS. 10 and 11 are conceptual views that schematically show
the outlines of other examples of the degreasing jig circulating
apparatus according to an embodiment of the present invention
respectively.
[0249] A degreasing jig circulating apparatus 210 shown in FIG. 10
is provided with a degreasing jig assembling apparatus 211 (see
FIG. 5), a degreasing furnace 251, a degreasing jig disassembling
apparatus 231 (see FIG. 8(a)), cover member transporting conveyors
261 (261A to 261C) and a bottom plate transporting conveyor
239.
[0250] In the degreasing jig circulating apparatus 210, the bottom
plate transporting conveyor 239 is combined to a jig disassembling
belt conveyor 232 that functions as a conveyor comprising the
degreasing jig disassembling apparatus 231 as an integral unit.
[0251] In the degreasing jig assembling apparatus 211 of the
degreasing jig circulating apparatus 210, ceramic molded bodies 11
are placed on the bottom plate 101 transported by the conveyor 225
on the jig assembling belt conveyor 212 and the cover member 102,
transported by the cover member transporting conveyor 261C
(conveyor 224 in FIG. 5), is further attached thereto so that the
ceramic molded bodies 11 are mounted on the degreasing jig 100.
[0252] Moreover, the degreasing jig 100 is transported toward the
degreasing furnace 251 by the jig assembling belt conveyor 212
functioning as a conveyor, and further placed on the inter-furnace
transporting conveyor 256 by the robot arm 216 having a grasping
unit 216a, installed near the end of the jig assembling belt
conveyor 212.
[0253] Therefore, in the degreasing jig assembling apparatus, the
robot arm 216 functions as a jig delivering mechanism.
[0254] Here, in the degreasing jig circulating apparatus 210, the
jig assembling belt conveyor 212 and the inter-furnace transporting
conveyor 256 may be combined into an integral unit and disposed
movably and continuously. In this case, the robot arm 216 is
unnecessary.
[0255] In this case, the jig assembling belt conveyor 212 is
allowed to have both of the functions as the conveyor and the jig
delivering mechanism.
[0256] Thereafter, a degreasing process is carried out on the
ceramic molded bodies 11 mounted on the degreasing jig 100 at a
predetermined temperature in the degreasing furnace 251, and the
degreasing jig 100 is further transported toward the degreasing jig
disassembling apparatus 231 by the inter-furnace transporting
conveyor 256 (conveyor 243, in FIG. 8(a)), and then placed on the
jig disassembling belt conveyor 232 of the degreasing jig
disassembling apparatus 231 by the robot arm 234. Therefore, in the
degreasing jig circulating apparatus 210, the robot arm 234
functions as a jig receiving mechanism.
[0257] In the degreasing jig disassembling apparatus 231, the cover
member 102 is detached by the robot arm 235 on the jig
disassembling belt conveyor 232, and the cover member 102 is placed
on the cover member transporting conveyor 261A (conveyor 244 in
FIG. 8(a)) by the robot arm 235 so that it is returned to the
degreasing jig assembling apparatus 211 by the cover member
transporting conveyor 261. In contrast, the bottom plate 101 on
which the ceramic molded bodies 11 have been placed is carried out
to an apparatus used in the next process by the jig disassembling
belt conveyor 232. In the degreasing jig circulating apparatus 210,
the jig disassembling belt conveyor 232 functions as a bottom plate
delivering mechanism.
[0258] Here, the bottom plate 101 from which, after the next
process (for example, firing process), the resulting ceramic molded
bodies have been taken out may be returned to the degreasing jig
assembling apparatus 211 through a conveyor.
[0259] Moreover, in the degreasing jig circulating apparatus 210,
the inter-furnace transporting conveyor 256 and the jig
disassembling belt conveyor 232 may be integrally formed and
disposed movably and continuously. In this case, the robot arm 234
is unnecessary.
[0260] The degreasing furnace 251 and the cover member transporting
conveyor 261, which comprises the degreasing jig circulating
apparatus 210, have the same structures as the degreasing furnace
151 and the cover member transporting conveyor 161 comprising the
degreasing jig circulating apparatus 110.
[0261] The degreasing jig circulating apparatus according to an
embodiment of the present invention may have a structure as shown
in FIG. 11.
[0262] A degreasing jig circulating apparatus 310 shown in FIG. 11
is provided with a degreasing jig assembling apparatus 311 (see
FIG. 6), a degreasing furnace 351, a degreasing jig disassembling
apparatus 331 (see FIG. 8(b)), cover member transporting conveyors
361 (361A to 361C) and a bottom plate transporting conveyor
339.
[0263] In the degreasing jig circulating apparatus 310, ceramic
molded bodies 11 are mounted on the bottom plate 101 transported by
a conveyor 325 on a jig assembling pallet conveyor 312 and the
cover member 102, transported by a cover member transporting
conveyor 361C (conveyor 324 in FIG. 6), is further attached thereto
so that the ceramic molded bodies 11 are mounted on the degreasing
jig 100, in the degreasing jig assembling apparatus 311.
[0264] Moreover, the degreasing jig 100 on which the ceramic molded
bodies 11 have been mounted is further transported, and then placed
on the inter-furnace transporting conveyor 356 by the robot arm
314B.
[0265] Therefore, in the degreasing jig assembling apparatus 311,
the robot arm 314B functions as a jig delivering mechanism.
[0266] Thereafter, a degreasing process is carried out on the
ceramic molded bodies 11 mounted on the degreasing jig 100 at a
predetermined temperature in the degreasing furnace 351, the
degreasing jig 100 is transported toward the degreasing jig
disassembling apparatus 331 by an inter-furnace transporting
conveyor 356 (conveyor 343 in FIG. 8(b)), and then placed on a jig
disassembling pallet conveyor 332 of the degreasing jig
disassembling apparatus 331 by the robot arm 334A. Therefore, in
the degreasing jig circulating apparatus 310, the robot arm 334A
functions as a jig receiving mechanism.
[0267] In the degreasing jig disassembling apparatus 331, after the
degreasing jig 100 has been switched to and placed on the jig
disassembling pallet conveyor 332 from the inter-furnace
transporting conveyor 356 by the robot arm 334A, the pallet 332a is
moved toward the vicinity of the robot arm 335, and the cover
member 102 is then detached by the robot arm 335 so that the cover
member 102 is placed on a cover member transporting conveyor 361A
(conveyor 344 in FIG. 8(b)) by the robot arm 335, and then returned
to the degreasing jig assembling apparatus 311 by the cover member
transporting conveyor 361.
[0268] In contrast, the bottom plate 101 on which the ceramic
molded bodies 11 have been mounted is placed on the bottom plate
transporting conveyor 339 by the robot arm 334B so that the bottom
plate 101, as it is, is transported to an apparatus used in the
next process by the bottom transporting conveyor 339. Therefore, in
the degreasing jig circulating apparatus 310, the robot arm 334B
functions as a bottom plate delivering mechanism.
[0269] Here, the bottom plate 101 from which, after the next
process (for example, firing process), the resulting ceramic molded
bodies have been taken out may be returned to the degreasing jig
assembling apparatus 311 through a conveyor.
[0270] Here, the degreasing furnace 351 and the cover member
transporting conveyor 361, which comprises the degreasing jig
circulating apparatus 310, respectively have the same structures as
the degreasing furnace 151 and the cover member transporting
conveyor 161 comprising the degreasing jig circulating apparatus
110.
[0271] The degreasing jig circulating apparatus according to an
embodiment of the present invention may have structures as shown in
FIGS. 10 and 11.
[0272] In the degreasing jig circulating apparatus that has been
explained, each of the degreasing jig assembling apparatus and the
degreasing jig disassembling apparatus that constitute the
degreasing jig circulating apparatus is provided with a table or a
conveyor in the same embodiment; however, the above-mentioned
degreasing jig circulating apparatus may be comprised of a
degreasing jig assembling apparatus and a degreasing jig
disassembling apparatus that are provided with respectively
different tables or conveyors.
[0273] In other words, for example, the degreasing jig circulating
apparatus may be comprised of a degreasing jig assembling apparatus
provided with a rotation table and a degreasing jig disassembling
apparatus provided with a jig disassembling belt conveyor, or may
be comprised of a degreasing jig assembling apparatus provided with
a jig assembling belt conveyor and a degreasing jig disassembling
apparatus provided with a jig disassembling pallet conveyor.
[0274] The degreasing jig circulating apparatus according to an
embodiment of the present invention, which has the above-mentioned
structure, makes it possible to automatically carry out a sequence
of processes including a process for placing a ceramic molded body
on the degreasing jig, a degreasing process, a disassembling
process of the degreasing jig, a process for transporting a cover
member to the degreasing jig assembling apparatus and a process for
transporting the bottom plate to the post process; therefore, it
becomes possible to degrease the ceramic molded body efficiently
without the need for manual labor, and also to utilize the cover
member repeatedly.
[0275] The following description will discuss a method for
degreasing a ceramic molded body according to an embodiment of the
present invention.
[0276] The method for degreasing a ceramic molded body according to
an embodiment of the present invention includes degreasing the
ceramic molded body by passing a degreasing jig on which the
ceramic molded body is mounted through inside of a degreasing
furnace, using a degreasing jig circulating apparatus, the
degreasing jig circulating apparatus comprising: a degreasing jig
assembling apparatus comprising a robot arm, and a table or a
conveyor on which the degreasing jig comprising a bottom plate and
a cover member is placed, the ceramic molded body being mounted on
the degreasing jig upon degreasing the ceramic molded body, the
ceramic molded body being mounted on the degreasing jig on the
table or the conveyor; the degreasing furnace that degreases the
ceramic molded body mounted on the degreasing jig; a degreasing jig
disassembling apparatus comprising a robot arm, and a table or a
conveyor on which the degreasing jig is placed, the degreasing jig
on which the ceramic molded body is mounted being disassembled on
the table or the conveyor; a cover member transporting conveyor
that transports the cover member that has been detached by the
degreasing jig disassembling apparatus to the degreasing jig
assembling apparatus; and a bottom plate transporting conveyor that
transports the bottom plate on which the ceramic molded body is
mounted, with the cover member being detached, wherein the
degreasing jig assembling apparatus comprising: a molding body
mounting mechanism that mounts the ceramic molded body at a
predetermined position on the bottom plate placed on the table or
the conveyor by using the robot arm; a cover member attaching
mechanism that attaches the cover member to the bottom plate in a
manner so as to cover the ceramic molded body mounted on the bottom
plate; and a jig delivering mechanism that delivers the degreasing
jig on which the ceramic molded body is mounted to the degreasing
furnace, the degreasing jig disassembling apparatus comprising: a
jig receiving mechanism that receives the degreasing jig on which
the ceramic molded body is mounted from the degreasing furnace; a
cover member detaching mechanism that detaches the cover member
attached in a manner so as to cover the ceramic molded body mounted
on the bottom plate placed on the table or the conveyor, by using
the robot arm; and a bottom plate delivering mechanism that
delivers the bottom plate on which the ceramic molded body is
mounted, with the cover member being detached, to the bottom plate
transporting conveyor.
[0277] In the method for degreasing a ceramic molded body according
to an embodiment of the present invention, the ceramic molded body
is degreased by using a degreasing jig circulating apparatus. Here,
with respect to the degreasing jig circulating apparatus, the
aforementioned degreasing jig circulating apparatus according to an
embodiment of the present invention can be desirably used.
[0278] The following description will discuss desirable degreasing
conditions and the like by exemplifying a case in which a
pillar-shaped honeycomb molded body having a large number of cells
longitudinally placed in parallel with one another with a cell wall
therebetween is used as the ceramic molded body that is an object
to be degreased.
[0279] Of course, with respect to the object to be degreased in the
degreasing method of the present invention, not limited to the
honeycomb molded body, various ceramic molded bodies may be used as
the object to be degreased.
[0280] In the degreasing method according to an embodiment of the
present invention, first, a honeycomb molded body is carried in a
degreasing jig assembling apparatus, and the honeycomb molded body
is mounted on the degreasing jig in the degreasing jig assembling
apparatus.
[0281] With respect to the method of mounting the honeycomb molded
body onto the degreasing jig in the degreasing jig assembling
apparatus, the same method as the method explained in the
degreasing jig assembling apparatus according to an embodiment of
the present invention is used; therefore, the description thereof
is omitted.
[0282] Next, the honeycomb molded body held by the degreasing jig
is carried into a degreasing furnace, and degreased.
[0283] Specific degreasing conditions are not generally determined
since they are varied depending on the size, shape and the like of
the honeycomb molded body; however, for example, when the size of
the honeycomb molded body is set in a range of 34 mm.times.34
mm.times.15 to 40 mm, it is desirable to place honeycomb molded
bodies mutually with intervals of 5 to 8 mm, and to carry out a
degreasing process at a temperature in a range from 200 to
500.degree. C. for 2 to 4 hours.
[0284] Next, the degreasing jig with the degreased honeycomb molded
bodies being mounted thereon is transported to the degreasing jig
disassembling apparatus where the cover member is detached from the
bottom plate on which the honeycomb molded bodies are placed, and
the cover member is transported to the cover member transporting
conveyor, while the honeycomb molded bodies which are being placed
on the bottom plate are carried out to an apparatus used in the
next process; thus, the degreasing process of the honeycomb molded
bodies is completed.
[0285] With respect to the method of detaching the cover member
from the bottom plate in the degreasing jig disassembling
apparatus, the same method as the method explained in the
description of the degreasing jig disassembling apparatus according
to an embodiment of the present invention is used; therefore, the
description thereof is omitted.
[0286] The cover member, detached in the degreasing jig
disassembling apparatus, is returned to the degreasing jig
assembling apparatus through the cover member transporting
conveyor.
[0287] Therefore, the cover member can be utilized repeatedly.
[0288] Here, with respect to the structure of the cover member
transporting conveyor, the explanation has already been given in
the description of the degreasing jig circulating apparatus
according to an embodiment of the present invention; therefore, the
description thereof is omitted.
[0289] Moreover, the bottom plate of the degreasing jig is
desirably configured so as to be also used as the firing jig.
[0290] Normally, the honeycomb molded body after degreasing process
have been carried out thereon is successively fired; however, upon
completion of the degreasing process, the honeycomb molded body is
fragile and easily damaged, and it is not desirable to grasp the
honeycomb molded body so as to move it to the firing jig after the
degreasing process.
[0291] Therefore, the cover member is desirably detached with the
degreased honeycomb molded bodies being mounted on the bottom plate
comprising the degreasing jig, and a frame-shaped side wall member,
which forms side walls, is placed on the bottom plate to form a
firing jig, and firing jigs, each having this structure, are
desirably stacked, thereby carrying out a firing process.
[0292] In the case where a degreasing process is carried out on a
honeycomb molded body by using a degreasing jig constituted by a
plurality of members as disclosed in Japanese Unexamined Patent
Application Publication No. 2001-19560, it is necessary to carry
out processes such as a degreasing jig assembling process used for
placing a honeycomb molded body in a degreasing jig prior to the
degreasing process and a degreasing jig disassembling process used
for taking out the honeycomb molded body that has been degreased
from the degreasing jig after the degreasing process, and in an
attempt to use the degreasing jig repeatedly, after use, the
degreasing jig needs to be transported to an apparatus used in the
degreasing jig assembling process. In the case where these
operations are carried out through manual labor, it sometimes
becomes difficult to improve the working speed and
productivity.
[0293] Moreover, since the receiving base to be repeatedly used, as
disclosed in WO 2005/024326 A1, is configured to carry out a drying
process on a honeycomb molded body, its heat resistant temperature
is too low to be used for a degreasing process, and since the
receiving base has a structure on which a honeycomb molded body is
simply placed, it is not applicable to the above-mentioned
degreasing method using the degreasing jig constituted by a
plurality of members.
[0294] In the method for degreasing a ceramic molded body according
to an embodiment of the present invention having the
above-mentioned arrangement, since the degreasing jig assembling
apparatus, the degreasing furnace, the degreasing jig disassembling
apparatus, the cover member transporting conveyor and the bottom
plate transporting conveyor are used, it becomes possible to
automatically carry out a sequence of processes including a process
for placing a ceramic molded body on the degreasing jig, a
degreasing process, a disassembling process of the degreasing jig,
a process for transporting a cover member to the degreasing jig
assembling apparatus and a process for transporting the bottom
plate to a post process, and consequently to degrease the ceramic
molded body efficiently without the need for manual labor.
[0295] The following description will discuss a method for
manufacturing a honeycomb structured body according to an
embodiment of the present invention.
[0296] The method for manufacturing a honeycomb structured body
according to an embodiment of the present invention is a method for
manufacturing a honeycomb structured body comprising a honeycomb
fired body, including: producing a pillar-shaped honeycomb molded
body having a large number of cells longitudinally placed in
parallel with one another with a cell wall therebetween by molding
a ceramic material, degreasing the honeycomb molded body mounted on
a degreasing jig; and firing the degreased honeycomb molded body to
manufacture a honeycomb fired body, wherein the degreasing of the
honeycomb molded body is carried out by using a degreasing jig
circulating apparatus, the degreasing jig circulating apparatus
comprising: a degreasing jig assembling apparatus comprising a
robot arm, and a table or a conveyor on which a degreasing jig
comprising a bottom plate and a cover member is placed, a honeycomb
molded body being mounted on the degreasing jig upon degreasing the
honeycomb molded body, the honeycomb molded body being mounted on
the degreasing jig on the table or the conveyor; a degreasing
furnace that degreases the honeycomb molded body mounted on the
degreasing jig; a degreasing jig disassembling apparatus comprising
a robot arm, and a table or a conveyor on which the degreasing jig
is placed, the degreasing jig on which the honeycomb molded body is
mounted being disassembled on the table or the conveyor; a cover
member transporting conveyor that transports the cover member that
has been detached by the degreasing jig disassembling apparatus to
the degreasing jig assembling apparatus; and a bottom plate
transporting conveyor that transports the bottom plate on which the
honeycomb molded body is mounted, with the cover member being
detached, the degreasing jig assembling apparatus comprising: a
molding body mounting mechanism that mounts the honeycomb molded
body at a predetermined position on the bottom plate placed on the
table or the conveyor by using the robot arm; a cover member
attaching mechanism that attaches the cover member to the bottom
plate in a manner so as to cover the honeycomb molded body mounted
on the bottom plate; and a jig delivering mechanism that delivers
the degreasing jig on which the honeycomb molded body is mounted to
the degreasing furnace, the degreasing jig disassembling apparatus
comprising: a jig receiving mechanism that receives the degreasing
jig on which the honeycomb molded body is mounted from the
degreasing furnace; a cover member detaching mechanism that
detaches the cover member attached in a manner so as to cover the
honeycomb molded body mounted on the bottom plate placed on the
table or the conveyor, by using the robot arm; and a bottom plate
delivering mechanism that delivers the bottom plate on which the
honeycomb molded body is mounted, with the cover member being
detached, to the bottom plate transporting conveyor.
[0297] The honeycomb structured body to be manufactured by using
the manufacturing method according to an embodiment of the present
invention may be comprised of a honeycomb fired body formed by
firing a honeycomb molded body having a large number of cells
longitudinally placed in parallel with one another with a cell wall
therebetween. Therefore, the honeycomb structured body may have a
structure in which pillar-shaped honeycomb molded bodies, each
having a large number of cells longitudinally placed in parallel
with one another with a cell wall therebetween, are fired and a
plurality of the resulting honeycomb fired bodies are combined with
one another by interposing sealing material layers (adhesive
layers) (see FIG. 13), or may be a pillar shaped honeycomb
structured body comprised of a single honeycomb sintered body
obtained by firing a honeycomb molded body having a large number of
cells longitudinally placed in parallel with one another with a
cell wall therebetween. In the present specification, the former
honeycomb structured body in which a plurality of honeycomb fired
bodies are combined with one another by interposing sealing
material layers (adhesive layers) is referred to as an aggregated
honeycomb structured body, and the latter pillar-shaped honeycomb
structured body comprised of a single honeycomb sintered body is
referred to as an integral honeycomb structured body.
[0298] FIG. 13 is a perspective view that schematically shows one
example of a honeycomb structured body, FIG. 14(a) is a perspective
view that schematically shows a honeycomb fired body used for
forming the honeycomb structured body, and FIG. 14(b) is a
cross-sectional view taken along line A-A.
[0299] In the honeycomb structured body 30, a plurality of
honeycomb fired bodies 40 as shown in FIG. 14(a) are bound to one
another by interposing sealing material layers (adhesive layers) 31
to form a honeycomb block 33, and a sealing material layer (coat
layer) 32 is further formed on the outer periphery of this
honeycomb block 33.
[0300] Moreover, as shown in FIGS. 14(a) and 14(b), the honeycomb
fired body 40 has a large number of cells 41 longitudinally placed
in parallel with one another (see "a" in FIG. 14(a)) so that each
cell wall 43 that separates the cells 41 is allowed to function as
a filter.
[0301] In other words, as shown in FIG. 14(b), each of the cells
41, formed in the honeycomb fired body 40, is sealed with a
plugging material layer 42 at either one of ends on its exhaust gas
inlet side and exhaust gas outlet side so that exhaust gases that
have entered one cell 41 are discharged from another cell 41 after
having always passed through each cell wall 43 that separates the
cells 41; thus, when exhaust gases pass through the cell wall 43,
particulates are captured by the cell wall 43 so that the exhaust
gases are purified.
[0302] With respect to the main component of a material for the
honeycomb structured body to be manufactured by the manufacturing
method according to an embodiment of the present invention,
examples thereof include: nitride ceramic materials, such as
aluminum nitride, silicon nitride, boron nitride and titanium
nitride, carbide ceramic materials, such as silicon carbide,
zirconium carbide, titanium carbide, tantalum carbide and tungsten
carbide, and oxide ceramic materials, such as alumina, zirconia,
cordierite, mullite, aluminum titanate, and the like. Among these,
powder of silicon carbide that has a high heat resistant property,
superior mechanical properties and a high thermal conductivity is
desirably used. Here, materials, such as a silicon-containing
ceramic material obtained by blending metal silicon in the
above-mentioned ceramic material and a ceramic material that is
combined by silicon or a silicate compound, may also be used, and
for example, a material in which metal silicon is blended in
silicon carbide is desirably used.
[0303] The following description will discuss the method for
manufacturing a honeycomb structured body according to an
embodiment of the present invention by exemplifying the method for
manufacturing a honeycomb structured body mainly composed of
silicon carbide in the order of successive processes.
[0304] First, inorganic powder, such as silicon carbide powders
having different average particle diameters, and an organic binder
are dry-mixed to prepare mixed powder, and a liquid-state
plasticizer, a lubricant and water are mixed to prepare a mixed
liquid, and the mixed powder and the mixed liquid are mixed by
using a wet-mixing device so that a wet mixture for use in
manufacturing a molded body is prepared.
[0305] With respect to the particle diameter of the silicon carbide
powder, although not particularly limited, those which are less
susceptible to shrinkage in the succeeding firing process are
desirably used, and for example, mixed powder, prepared by
combining 100 parts by weight of powder having an average particle
diameter from 0.3 to 50 .mu.m with 5 to 65 parts by weight of
powder having an average particle diameter from 0.1 to 1.0 .mu.m,
is desirably used.
[0306] In order to adjust the pore diameter and the like of the
honeycomb fired body, it is necessary to adjust the firing
temperature; however, the pore diameter can be adjusted by
adjusting the particle diameter of the inorganic powder.
[0307] With respect to the above-mentioned organic binder, not
particularly limited, examples thereof include: methyl cellulose,
carboxymethyl cellulose, hydroxyethyl cellulose, polyethylene
glycol and the like. Among these, methylcellulose is more desirably
used.
[0308] In general, the compounding amount of the above-mentioned
binder is desirably set to 1 to 10 parts by weight with respect to
100 parts by weight of the inorganic powder.
[0309] With respect to the above-mentioned plasticizer, not
particularly limited, for example, glycerin and the like may be
used.
[0310] Moreover, with respect to the lubricant, not particularly
limited, for example, polyoxyalkylene-based compounds, such as
polyoxyethylene alkyl ether and polyoxy propylene alkyl ether, may
be used.
[0311] Specific examples of the lubricant include: polyoxyethylene
monobutyl ether, polyoxypropylene monobutyl ether and the like.
[0312] Here, the plasticizer and the lubricant are not necessarily
contained in the mixed liquid depending on cases.
[0313] Upon preparing the wet mixture, a dispersant solution may be
used, and with respect to the dispersant solution, examples thereof
include: water, an organic solvent such as benzene, alcohol such as
methanol, and the like.
[0314] Moreover, a molding auxiliary may be added to the wet
mixture.
[0315] With respect to the molding auxiliary, not particularly
limited, examples thereof include: ethylene glycol, dextrin, fatty
acid, fatty acid soap, polyalcohol and the like.
[0316] Furthermore, a pore forming agent, such as balloons that are
fine hollow spheres composed of oxide-based ceramics, spherical
acrylic particles and graphite, may be added to the above-mentioned
wet mixture, if necessary.
[0317] With respect to the above-mentioned balloons, not
particularly limited, for example, alumina balloons, glass
micro-balloons, shirasu balloons, fly ash balloons (FA balloons),
mullite balloons and the like may be used. Among these, alumina
balloons are more desirably used.
[0318] Here, with respect to the wet mixture using silicon carbide
powder, prepared as described above, the temperature thereof is
desirably set to 28.degree. C. or less. When the temperature is too
high, the organic binder tends to gelate.
[0319] Moreover, the rate of organic components in the wet mixture
is desirably set to 10% by weight or less, and the content of
moisture is desirably set from 8 to 20% by weight.
[0320] Next, the wet mixture is extrusion-molded by an
extrusion-molding method and the like. The molded body obtained
through the extrusion molding is cut by a cutting machine so that a
honeycomb molded body, which has the same shape as the
pillar-shaped honeycomb fired body 40 shown in FIGS. 14(a) and
14(b), and has no plugged cells, is manufactured.
[0321] Next, with respect to the honeycomb molded body, a
predetermined amount of plug material paste that forms plugs is
filled into either one of the ends of each cell, if necessary, so
that predetermined cells are sealed.
[0322] More specifically, upon manufacturing a honeycomb structured
body that functions as a ceramic filter, either one of the ends of
each cell is sealed.
[0323] Moreover, prior to the plugging process of the honeycomb
molded body, a drying process may be carried out thereon, if
necessary, and in this case, the drying process may be carried out
by using a drying apparatus, such as a microwave drying apparatus,
a hot-air drying apparatus, a reduced-pressure drying apparatus, a
dielectric drying apparatus and a frozen drying apparatus.
[0324] With respect to the plug material paste, although not
particularly limited, those plug material pastes that allow the
plugs manufactured through post processes to have a porosity in a
range from 30 to 75% are desirably used, and, for example, the same
material as that of the wet mixture may be used.
[0325] The filling process of the plug material paste can be
carried out on demand, and when the plug material paste has been
filled thereto, for example, the resulting honeycomb structured
body obtained through the post process is desirably used as a
honeycomb filter, and in the case where no plug material paste has
been filled thereto, for example, the honeycomb structured body
obtained through the post process is desirably used as a catalyst
supporting carrier.
[0326] Next, a degreasing process is carried out on the honeycomb
molded body with the plug material paste filled therein, by using a
degreasing jig circulating apparatus.
[0327] With respect to the degreasing method by the use of the
degreasing jig circulating apparatus, since the explanation has
been given as the degreasing method according to an embodiment of
the present invention, the description thereof is omitted.
[0328] Next, the honeycomb molded body on which the degreasing
process has been carried out is fired under predetermined
conditions (for example, at 1400 to 2300.degree. C.) so that a
pillar-shaped honeycomb fired body having a plurality of cells
longitudinally placed in parallel with one another with a cell wall
therebetween, with either one of the ends of each cell being
sealed, is manufactured.
[0329] Here, with respect to the firing conditions for the
honeycomb molded body, those conditions conventionally used upon
manufacturing a filter made from a porous ceramic material may be
used.
[0330] In this case, upon carrying out the firing process, after
the completion of the degreasing process, the degreased honeycomb
molded body that has been placed on the bottom plate of the
degreasing jig, as it is, is desirably transported to a firing
apparatus so that the firing process is carried out on the
honeycomb molded body. The reasons for this arrangement are the
same as those described earlier.
[0331] Therefore, the bottom plate of the degreasing jig to be used
in the manufacturing method according to an embodiment of the
present invention is desirably configured to be also used as a
firing jig. Moreover, the bottom plate transporting conveyor, which
comprises the degreasing jig circulating apparatus, is desirably
configured so as to also transport the bottom plate on which the
honeycomb molded body that has been degreased is mounted, with its
cover member detached, to the firing process (firing
apparatus).
[0332] Referring to the drawings, the following description will
discuss these degreasing process and firing process in more
detail.
[0333] FIG. 12 is an explanatory drawing that schematically shows
examples of the firing process and the degreasing process in the
manufacturing method according to an embodiment of the present
invention.
[0334] As shown in FIG. 12, in the degreasing process and the
firing process of the manufacturing method according to an
embodiment of the present invention, a honeycomb molded body 11,
which has been transported by a molded body carry-in conveyor 119
from the preceding process (for example, the plug material paste
filling process) by the molded body carry-in conveyor 119, is first
mounted on a degreasing jig 100 in the degreasing jig assembling
apparatus 111 that has already been explained.
[0335] Thus, the honeycomb molded body 11, mounted on the
degreasing jig 100, is degreased in the degreasing furnace 151, and
further transported to the degreasing jig disassembling apparatus
131 that has already been explained. In the degreasing jig
disassembling apparatus 131, the cover member 102 is detached from
the bottom plate 101, and the honeycomb molded body 11 in its
placed state on the bottom plate 101 is transported to a firing
apparatus 171 by a bottom plate transporting conveyor 139.
Moreover, the cover member is returned from the degreasing jig
disassembling apparatus 131 to the degreasing jig assembling
apparatus 111 by the cover member transporting conveyor 161.
[0336] The honeycomb molded body 11, transported to the firing
apparatus 171, in its placed state on the bottom plate 101, is
fired in the firing apparatus 171 under predetermined conditions.
Thereafter, the resulting honeycomb fired body 13 is taken out of
the firing jig (not shown) including the bottom plate 101, and
transported to an apparatus used in the next process by a conveyor
159.
[0337] Here, after the honeycomb fired body 13 has been taken out,
the bottom plate 101 is returned from the firing apparatus to the
degreasing jig assembling apparatus by the cover member
transporting conveyor 161.
[0338] By carrying out these degreasing process and firing process,
the degreasing jig, comprised of the bottom plate and the cover
member, can be used repeatedly, and since the honeycomb molded body
that has been degreased need not be grasped to be transported, the
degreasing process and the firing process can be desirably carried
out.
[0339] In this case, the degreasing process and the firing process
have been explained by using the degreasing jig assembling
apparatus 111 shown in FIG. 1 as the degreasing jig assembling
apparatus, as well as by using the degreasing jig disassembling
apparatus 131 shown in FIG. 7 as the degreasing jig disassembling
apparatus; however, in the present processes, the degreasing jig
assembling apparatus according to an embodiment of the present
invention can be used as the degreasing jig assembling apparatus,
and the degreasing jig disassembling apparatus according to an
embodiment of the present invention can be used as the degreasing
jig disassembling apparatus.
[0340] Moreover, in the firing apparatus 171, a frame member
forming side walls and a lid member are further placed on the
bottom plate on which the honeycomb molded body that has been
degreased is placed in a manner so as to cover the honeycomb molded
body, and the firing process is desirably carried out in a state in
which the periphery of the honeycomb molded body is surrounded by
the firing jig comprised of the bottom plate, the frame member and
the lid member. Moreover, the firing process may be carried out in
a state in which the firing jigs of this kind have been piled up in
multiple stages.
[0341] Next, an applying process of a sealing material paste
serving as a sealing material layer (adhesive layer) onto side
faces of the honeycomb fired body with an even thickness, and a
piling up process of another honeycomb fired body onto this sealing
material paste layer is successively repeated so that an aggregate
of honeycomb fired bodies having a predetermined size is
manufactured.
[0342] With respect to the sealing material paste, examples thereof
include a material made from an inorganic binder, an organic binder
and inorganic fibers and/or inorganic particles.
[0343] With respect to the inorganic binder, for example, silica
sol, alumina sol and the like may be used. Each of these may be
used alone or two or more kinds of these may be used in
combination. Among the inorganic binders, silica sol is more
desirably used.
[0344] With respect to the organic binder, examples thereof include
polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl
cellulose and the like. Each of these may be used alone or two or
more kinds of these may be used in combination. Among the organic
binders, carboxymethyl cellulose is more desirably used.
[0345] With respect to the inorganic fibers, examples thereof
include ceramic fibers, such as silica-alumina, mullite, alumina
and silica. Each of these may be used alone or two or more kinds of
these may be used in combination. Among the inorganic fibers,
alumina fibers are more desirably used.
[0346] With respect to the inorganic particles, examples thereof
include carbides, nitrides and the like, and specific examples
include inorganic powder and the like made from silicon carbide,
silicon nitride and boron nitride. Each of these may be used alone,
or two or more kinds of these may be used in combination. Among the
inorganic particles, silicon carbide having superior thermal
conductivity is desirably used.
[0347] Moreover, a pore forming agent, such as balloons that are
fine hollow spheres composed of an oxide-based ceramic material,
spherical acrylic particles and graphite, may be added to the
above-mentioned sealing material paste, if necessary.
[0348] With respect to the above-mentioned balloons, not
particularly limited, for example, alumina balloons, glass
micro-balloons, shirasu balloons, fly ash balloons (FA balloons),
mullite balloons and the like may be used. Among these, alumina
balloons are more desirably used.
[0349] Next, this aggregate of honeycomb fired bodies is heated so
that the sealing material paste layers are dried and solidified to
form sealing material layers (adhesive layers).
[0350] Next, the aggregate of honeycomb fired bodies in which a
plurality of honeycomb fired bodies have been combined with one
another by interposing sealing material layers (adhesive layers) is
cut by using a diamond cutter or the like so that a cylindrical
honeycomb block is manufactured.
[0351] Then, a sealing material layer (coat layer) is formed on the
periphery of the honeycomb block by using the above-mentioned
sealing material paste so that a honeycomb structured body in which
a sealing material layer (coat layer) is formed on the periphery of
a cylindrical honeycomb block having a structure in which a
plurality of honeycomb fired bodies are combined with one another
by interposing sealing material layers (adhesive layers) is
manufactured.
[0352] Thereafter, a catalyst is supported on the honeycomb
structured body on demand. The supporting process of the catalyst
may be carried out on the honeycomb fired bodies prior to being
formed into an aggregate.
[0353] In the case where a catalyst is supported thereon, an
alumina film having a high specific surface area is desirably
formed on the surface of the honeycomb structured body, and a
co-catalyst and a catalyst such as platinum are applied onto the
surface of the alumina film.
[0354] With respect to the method for forming the alumina film on
the surface of the honeycomb structured body, for example, a method
in which the honeycomb structured body is impregnated with a
solution of a metal compound containing aluminum such as
Al(NO.sub.3).sub.3 and then heated and a method in which the
honeycomb structured body is impregnated with a solution containing
alumina powder and then heated, are proposed.
[0355] With respect to the method for applying a co-catalyst to the
alumina film, for example, a method in which the honeycomb
structured body is impregnated with a solution of a metal compound
containing a rare-earth element, such as Ce(NO.sub.3).sub.3, and
then heated is proposed.
[0356] With respect to the method for applying a catalyst to the
alumina film, for example, a method in which the honeycomb
structured body is impregnated with a solution of diammine dinitro
platinum nitric acid
([Pt(NH.sub.3).sub.2(NO.sub.2).sub.2]HNO.sub.3, platinum
concentration: 4.53% by weight) and then heated is proposed.
[0357] Moreover, a catalyst may be applied through a method in
which after the catalyst has been preliminarily applied to alumina
particles, the honeycomb structured body is impregnated with a
solution containing the alumina powder bearing the catalyst applied
thereto, and then heated.
[0358] Here, the above-mentioned method for manufacturing a
honeycomb structured body relates to an aggregated honeycomb
structured body; however, the honeycomb structured body to be
manufactured by the method according to an embodiment of the
present invention may be a honeycomb structured body (an integral
honeycomb structured body) in which a pillar-shaped honeycomb block
comprises one honeycomb fired body.
[0359] Here, desirably, the aggregated honeycomb structured body is
mainly composed of silicon carbide or a material formed by blending
metal silicon in silicon carbide, and desirably, the integral
honeycomb structured body is mainly composed of a material such as
cordierite and aluminum titanate.
[0360] Upon manufacturing such an integral honeycomb structured
body, first, a honeycomb molded body of this kind is formed by
using the same method as the manufacturing method for an aggregated
honeycomb structured body except that the size of a honeycomb
molded body to be molded through the extrusion-molding process is
more than that in the case of the aggregated honeycomb structured
body.
[0361] Next, in the same manner as the manufacturing method for the
aggregated honeycomb structured body, a drying process and a plug
material paste filling process are carried out, if necessary, and
degreasing and firing processes are carried out in the same manner
as the manufacturing method for the aggregated honeycomb structured
body so that a honeycomb block is manufactured, and sealing
material layers (coat layers) are formed, if necessary, so that an
integral honeycomb structured body can be manufactured. Moreover, a
catalyst may be supported on the integral honeycomb structured body
as well, by using the above-mentioned method.
[0362] By using the abovementioned method for manufacturing the
honeycomb structured body according to an embodiment of the present
invention, it is possible to desirably manufacture a honeycomb
structured body having a predetermined shape.
[0363] With respect to the honeycomb structured body, the foregoing
explanation has been given mainly on a honeycomb filter that is
used for collecting particulates in exhaust gases; however, the
honeycomb structured body may also be desirably used as a catalyst
supporting carrier (honeycomb catalyst) that purifies exhaust
gases.
EXAMPLES
Example 1
[0364] Powder of .alpha.-type silicon carbide having an average
particle diameter of 10 .mu.m (250 kg), powder of .alpha.-type
silicon carbide having an average particle diameter of 0.5 .mu.m
(100 kg) and an organic binder (methyl cellulose) (20 kg) were
mixed to prepare a mixed powder.
[0365] Next, separately, a lubricant (Uniloop, made by NOF Corp.)
(12 kg), a plasticizer (glycerin) (5 kg) and water (65 kg) were
mixed to prepare a liquid mixture, and this liquid mixture and the
mixed powder were mixed by using a wet mixing machine so that a wet
mixture was prepared.
[0366] Next, this wet mixture was transported to an extrusion
molding machine by using a transporting apparatus, and charged into
a raw material charging port of the extrusion molding
apparatus.
[0367] The wet mixture was then extrusion-molded into a molded body
having the same shape as shown in FIGS. 14(a) and 14(b) except that
ends of the cells had not been sealed.
[0368] Next, after the honeycomb molded body had been dried by
using a drying apparatus in which microwaves and hot air were used
in combination, and a plug material paste having the same
composition as the wet mixture was filled into predetermined
cells.
[0369] Next, a degreasing process and a firing process were carried
out on the honeycomb molded body by using the degreasing jig
circulating apparatus 210 according to an embodiment of the present
invention and a firing apparatus (see FIGS. 10 and 12).
[0370] Here, the degreasing conditions were set to 400.degree. C.
for 3 hours. At this time, the respective honeycomb molded bodies
were placed on the bottom plate of the degreasing jig with an
interval of 6 mm.
[0371] Moreover, the firing conditions were set to 2200.degree. C.
for 3 hours under a normal-pressure argon atmosphere.
[0372] After these degreasing and firing processes, a honeycomb
fired body, made of a silicon carbide sintered body, which had a
porosity of 40%, an average pore diameter of 12.5 .mu.m, a size of
34.3 mm.times.34.3 mm.times.254 mm, the number of cells (cell
density) of 46.5/cm.sup.2 and a thickness of each cell wall of 0.25
mm, was manufactured.
[0373] Moreover, in the degreasing jig circulating apparatus 210,
both of a jig assembling belt conveyor 212 comprising a degreasing
jig assembling apparatus 211 and a jig disassembling belt conveyor
232 comprising a degreasing jig disassembling apparatus 231 were
being intermittently moved.
[0374] More specifically, upon transporting, the belt conveyors
were moved at a moving speed of 3.0 m/min, and upon shifting from
the moving state to the stopped state, the moving speed of 3.0
m/min was first lowered to a moving speed of 0.5 m/min (moving
speed before the stoppage), and the belt conveyers then shifted to
stopped state.
[0375] By using a heat resistant sealing material paste containing
30% by weight of alumina fibers having an average fiber length of
20 .mu.m, 21% by weight of silicon carbide particles having an
average particle diameter of 0.6 .mu.m, 15% by weight of silica
sol, 5.6% by weight of carboxymethyl cellulose and 28.4% by weight
of water, a large number of the honeycomb fired bodies were bonded
to one another, and dried at 120.degree. C., and then cut by using
a diamond cutter so that a cylindrical honeycomb block having a
sealing material layer (adhesive layer) with a thickness of 1.0 mm
was manufactured.
[0376] Next, silica-alumina fibers (average fiber length: 100
.mu.m, average fiber diameter: 10 .mu.m) (23.3% by weight), which
served as inorganic fibers, silicon carbide powder having an
average particle diameter of 0.3 .mu.m (30.2% by weight), which
served as inorganic particles, silica sol (SiO.sub.2 content in the
sol: 30% by weight) (7% by weight), which served as an inorganic
binder, carboxymethyl cellulose (0.5% by weight), which served as
an organic binder, and water (39% by weight) were mixed and kneaded
to prepare a sealing material paste.
[0377] Next, a sealing material paste layer having a thickness of
0.2 mm was formed on the peripheral portion of the honeycomb block
by using the above-mentioned sealing material paste. Further, this
sealing material paste layer was dried at 120.degree. C. so that a
cylindrical honeycomb structured body having a size of 143.8 mm in
diameter.times.254 mm in length, with a sealing material layer
(coat layer) formed on the outer periphery, was manufactured.
[0378] By using the method of the present example, a honeycomb
structured body having a desired shape was manufactured.
[0379] Moreover, in the present example, after the cover member had
been detached, the degreased honeycomb molded body was visually
observed, and no honeycomb molded body having defects such as
cracks was found. Here, the number of samples for the visual
observation was 300 pcs (pieces).
Example 2
[0380] By carrying out basically the same processes as those up to
the manufacture of the honeycomb fired body of Example 1, a
honeycomb fired body was manufactured.
[0381] Provided that, the intermittent moving embodiments of the
jig assembling belt conveyor 212 comprising a degreasing jig
assembling apparatus 211 and the jig disassembling belt conveyor
232 comprising a degreasing jig disassembling apparatus 231 in the
degreasing jig circulating apparatus 210 were changed as follows:
upon transporting, the belt conveyors were moved at a moving speed
of 3.0 m/min, and upon shifting from the moving state to the
stopped state, the moving speed of 3.0 m/min was first lowered to a
moving speed of 1.5 m/min (moving speed before the stoppage), and
the belt conveyers then shifted to stopped state.
[0382] In the present example, after the cover member had been
detached, the degreased honeycomb molded body was visually
observed, and no honeycomb molded body having defects such as
cracks was found. Here, the number of samples for the visual
observation was 300 pcs.
Example 3
[0383] By carrying out basically the same processes as those up to
the manufacture of the honeycomb fired body of Example 1, a
honeycomb fired body was manufactured.
[0384] Provided that, the intermittent moving embodiments of the
jig assembling belt conveyor 212 comprising a degreasing jig
assembling apparatus 211 and the jig disassembling belt conveyor
232 comprising a degreasing jig disassembling apparatus 231 in the
degreasing jig circulating apparatus 210 were changed as follows:
upon transporting, the belt conveyors were moved at a moving speed
of 3.0 m/min, and upon shifting from the moving state to the
stopped state, the moving speed of 3.0 m/min was first lowered to a
moving speed of 0.05 m/min (moving speed before the stoppage), and
the belt conveyers then shifted to stopped state.
[0385] Moreover, in the present example, after the cover member had
been detached, the degreased honeycomb molded body was visually
observed, and no honeycomb molded body having defects such as
cracks was found. Here, the number of samples for the visual
observation was 300 pcs.
Reference Example 1
[0386] By carrying out basically the same processes as those up to
the manufacture of the honeycomb fired body of Example 1, a
honeycomb fired body was manufactured.
[0387] Provided that, the intermittent moving embodiments of the
jig assembling belt conveyor 212 comprising a degreasing jig
assembling apparatus 211 and the jig disassembling belt conveyor
232 comprising a degreasing jig disassembling apparatus 231 in the
degreasing jig circulating apparatus 210 were changed as follows:
upon transporting, the belt conveyors were moved at a moving speed
of 3.0 m/min, and upon shifting from the moving state to the
stopped state, the belt conveyors shifted directly to the stopped
state without being temporarily reduced to a moving speed before
the stoppage.
[0388] Moreover, in the present reference example, after the cover
member had been detached, the degreased honeycomb molded body was
visually observed, and it was found that 1% (three) of the
honeycomb molded bodies had defects such as cracks. Here, the
number of samples for the visual observation was 300 pcs.
[0389] Obviously, numerous modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *