TEPZZ__648B_T

(19)

(11)

EP 2 116 348 B1

EUROPEAN PATENT SPECIFICATION

(12)

(45) Date of publication and mention

(51) Int Cl.:

B28B 11/00 (2006.01)

C04B 41/00 (2006.01)

of the grant of the patent:

02.01.2013 Bulletin 2013/01

C04B 35/195 (2006.01)

C04B 41/45 (2006.01)

(86) International application number:

(21) Application number: 07831965.4

PCT/JP2007/072235

(22) Date of filing: 09.11.2007

(87) International publication number:

WO 2008/081654 (10.07.2008 Gazette 2008/28)

(54) METHOD FOR MANUFACTURING SEALING HONEYCOMB STRUCTURE

VERFAHREN ZUR HERSTELLUNG EINER ABDICHTENDEN WABENSTRUKTUR
PROCD PERMETTANT DE FABRIQUER UNE STRUCTURE NID DABEILLES
DTANCHISATION
(84) Designated Contracting States:
AT BE BG CH CY CZ DE DK EE ES FI FR GB GR
HU IE IS IT LI LT LU LV MC MT NL PL PT RO SE
SI SK TR

TOKUNAGA, Takeshi
Nagoya-shi
Aichi 467-8530 (JP)

(74) Representative: Paget, Hugh Charles Edward et al

(30) Priority: 05.01.2007 JP 2007000375
(43) Date of publication of application:
11.11.2009 Bulletin 2009/46

(73) Proprietor: NGK Insulators, Ltd.

Nagoya-shi, Aichi 467-8530 (JP)

Mewburn Ellis LLP

33 Gutter Lane
London
EC2V 8AS (GB)

(56) References cited:

EP-A- 1 800 730
JP-A- 01 221 216

WO-A1-2006/062141
JP-A- 2005 218 209

(72) Inventors:

EP 2 116 348 B1

ITO, Koichi
Nagoya-shi
Aichi 467-8530 (JP)

PATENT ABSTRACTS OF JAPAN 2008, & JP 2008

055346 A (DENSO CORP.), 13 March 2008
(2008-03-13)

Note: Within nine months of the publication of the mention of the grant of the European patent in the European Patent
Bulletin, any person may give notice to the European Patent Office of opposition to that patent, in accordance with the
Implementing Regulations. Notice of opposition shall not be deemed to have been filed until the opposition fee has been
paid. (Art. 99(1) European Patent Convention).
Printed by Jouve, 75001 PARIS (FR)

EP 2 116 348 B1
Description
Technical Field
5

[0001] The present invention relates to a manufacturing method of a plugged honeycomb structure which can preferably
be used in a filter such as a diesel particulate filter and in which predetermined cells at an end surface of the structure
are plugged.
Background Art

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[0002] As a dust collecting filter typified by a diesel particulate filter (DPF), a filter having a honeycomb structure and
made of a ceramic is used. Such a filter has a honeycomb structure having a large number of cells which are separated
and formed by porous partition walls so as to constitute channels of a fluid, and each cell is plugged on one end portion
opposite to that of an adjacent cell so that each end surface of the honeycomb structure has a checkered pattern.
[0003] When an exhaust gas including fine particles such as particulates is passed from one end surface of the filter
(a plugged honeycomb structure), the exhaust gas flows into the structure from the cells having the end portions which
are not plugged on the one end surface, passes through the porous partition walls and enters the other cells having end
portions which are not plugged on the other end surface of the structure. Then, when the exhaust gas passes through
the partition walls, the fine particles in the exhaust gas are trapped by the partition walls, and the cleaned exhaust gas
from which the fine particles have been removed is discharged from the other end surface of the honeycomb structure.
[0004] Usually, to manufacture the plugged honeycomb structure having such a configuration, a method is employed
in which as shown in Fig. 2, a mask film 4 to constitute a mask is attached to an end surface of a honeycomb substrate
1, holes 3 are provided at positions corresponding to opening end portions (cell opening end portions 7) of predetermined
cells 2a and 2b of the mask film 4, and an end portion of the honeycomb substrate 1 is submerged into a container 5 in
which a plugging slurry 6 is stored, whereby the plugging slurry 6 is allowed to permeate the predetermined cell opening
end portions 7 through the holes 3 of the mask film 4 (e.g., see Patent Document 1).
[0005] In a case where the opening end portions of the predetermined cells are plugged by such a method, the slurry
6 for plugging does not sometimes permeate into a desired depth of the cells 2a and 2b. Moreover, the permeation depth
of the plugging slurry in the cells 2a and 2b is not sometimes uniform, and there has been a problem that it is difficult to
manufacture a homogeneous plugged honeycomb structure. In a case where the permeation depth of the plugging slurry
which permeates the respective cells to be plugged is not uniform, fluctuations are generated in a pressure loss of each
cell of the resultant plugged honeycomb structure, and a disadvantage that deviation is generated in a deposited amount
of filtered matters or the like easily occurs.
[0006] As a concerned conventional technology for solving the above problems, a method is disclosed in which the
plugging slurry having thixotropy is used, and the plugging slurry is allowed to permeate the predetermined cells of the
honeycomb substrate while vibrated (e.g., see Patent Documents 2 and 3).
[0007] However, even in the methods disclosed in Patent Documents 2 and 3, there is a case where the plugging
slurry 6 does not always permeate into the desired depth of the cells 2a and 2b, and the permeation depth is not uniform.
Since a device for vibrating the plugging slurry is required, there is a tendency that manufacturing facilities to be used
become huge and complicated.
[0008]
[Patent Document 1]
[Patent Document 2]
[Patent Document 3]

JP-A 2001-300922
JP-A 6-190218
JP-A 6-190224

WO 2006/062141 describes a method of producing a sealed honeycomb structure body. Sealing sections are formed
in cells of the honeycomb structure body. A slurry which is the material for the sealing sections is stored in a storage
container, such that a boundary face of the slurry is flat. Then, that end face of a honeycomb structure body which is
provided with a sealing section forming a mask covering opening end sections of cells excluding the sealing cells of the
honeycomb structure body is pressed to the slurry stored in the storage container. Thereby, the slurry is introduced into
the inside of cells to form the sealing sections.
JP 01-221216 describes a method for preventing generation of defects such as bubbles in a molded product formed
from a liquid resin. A product having an undercut is molded by a molding device. A closed mold molding consists of top
and bottom parts and a core mold. Casting ports are formed on the lower most parts of a gap in the mold which has the
form of the intended product. Air removal holes of fine diameter for discharging air from inside the gap are formed on
uppermost parts of the gap. Casting ports and air removal holes are positioned offset from one another. Mixed liquid

EP 2 116 348 B1

resin is introduced through the casting port. By provision of the air holes, turbulent flow in the mixed liquid resin and
inclusion of air are apparently reduced.
JP 2005-218209 describes an apparatus for assembling an electric rotating machine. The assembling apparatus has a
base for placing frame of the electric rotating machine on a top surface thereof, the base having a hole in the centre. A
lower mold is elevatably fitted into the hole in the base and holds a mold material intermediate between the top surface
of the base and inner and outer faces of the frame. The apparatus further comprises a biasing means for upwardly
biasing the lower mold. An upper mold is disposed above the base, and guides a stator of the electric rotating machine
into the frame. The upper mold abuts the lower mold. A pressing means for elevating the upper mold is also provided.
A deaeration bore is formed through the upper mold.

10

Disclosure of the Invention

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[0009] The present invention has been developed in view of such problems of the conventional technology, and an
object thereof is to provide a manufacturing method of a plugged honeycomb structure in which a plugging slurry can
uniformly be allowed to permeate into a desired depth of cells, and a product defect such as plugging failure is hardly
generated easily.
[0010] That is, according to the present invention, there is provided the following manufacturing method of a plugged
honeycomb structure.
[0011] [1] A manufacturing method of a plugged honeycomb structure including a cylindrical honeycomb substrate in
which a plurality of cells having two opening end portions are separated by partition walls and formed so as to communicate
with both end surfaces of the honeycomb substrate, and plugging portions arranged so as to plug one of the two opening
end portions of the cells and form a complementary checkered pattern with one end surface and the other end surface
of the honeycomb substrate, the method comprising: an attaching step of attaching mask films to both the end surfaces
of the honeycomb substrate, respectively; a first perforation step of making slurry permeation holes at portions of the
mask films corresponding to the one opening end portion of each of the predetermined cells; a second perforation step
of making deaeration holes having a diameter of 0.02 to 0.8 mm at portions of the mask films facing the portions provided
with the slurry permeation holes via the cells; a filling step of submerging both the end surfaces of the honeycomb
substrate to which the mask films have been attached into a plugging slurry having a viscosity of 0.5 to 2000 Pas,
respectively, and filling the one opening end portion of each of the predetermined cells with the plugging slurry to obtain
a slurry filled substrate; and a firing step of firing the resultant slurry filled substrate.
[0012] [2] The manufacturing method of the plugged honeycomb structure according to the above [1], wherein the
deaeration holes have a diameter in a range of 0.05 to 0.4 mm.
[0013] [3] The manufacturing method of the plugged honeycomb structure according to the above [1] or [2], wherein
the plugging slurry has a viscosity in a range of 1 to 1500 Pas.
[0014] [4] The manufacturing method of the plugged honeycomb structure according to any one of the above [1] to
[3], wherein the plugging slurry has thixotropy, and the one opening end portion of each of the predetermined cells is
filled with the plugging slurry while vibrating the plugging slurry.
[0015] According to the manufacturing method of the plugged honeycomb structure of the present invention, it is
possible to easily manufacture the plugged honeycomb structure in which the plugging slurry can be allowed to uniformly
permeate into a desired depth of the cells and a product defect such as plugging failure is hardly generated easily.
Brief Description of the Drawings
[0016]

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[Fig. 1] Fig. 1 is a schematic diagram showing one embodiment of a manufacturing method of a plugged honeycomb
structure according to the present invention;
[Fig. 2] Fig. 2 is a schematic diagram showing a conventional state in which a plugging slurry is allowed to permeate
cell opening end portions;
[Fig. 3] Fig. 3 is a perspective view showing one example of the plugged honeycomb structure;
[Fig. 4] Fig. 4 is a photograph of a partially sectional structure of a plugged honeycomb structure manufactured in
Example 1; and
[Fig. 5] Fig. 5 is a photograph of a partially sectional structure of a plugged honeycomb structure manufactured in
Comparative Example 1.

55

Description of Reference Numerals

[0017]

1: honeycomb substrate, 2, 2a, 2b: cell, 3: hole, 3a: slurry permeation hole, 3b: deaeration hole, 4: mask film,

EP 2 116 348 B1
5: container, 6: plugging slurry, 7: cell opening end portion, 10: partition wall, 11: first end surface, 15: plugging portion,
20: slurry filled substrate, 21: second end surface, 25: outer peripheral wall, 27, 29: end surface, 30: plugged honeycomb
structure, X: diameter of deaeration hole
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Best Mode for Carrying out the Invention

[0018] The best mode for carrying out the present invention will hereinafter be described, but it should be understood
that the present invention is not limited to the following embodiment and that appropriate modification, improvement and
the like added to the following embodiment based on ordinary knowledge of a person skilled in the art fall in the scope
of the present invention.
[0019] Fig. 1 is a schematic diagram showing a part of one embodiment of a manufacturing method of a plugged
honeycomb structure according to the present invention. The manufacturing method of the plugged honeycomb structure
according to the present embodiment is a method of manufacturing a plugged honeycomb structure 30 in which opening
end portions (cell opening end portions 7) of predetermined cells 2 of a cylindrical honeycomb substrate 1 provided with
a plurality of cells 2 separated by partition walls 10 between end surfaces (a first end surface 11, a second end surface
21) are filled with a plugging slurry 6, and then fired to form plugging portions 15 at the predetermined cell opening end
portions 7. Further details of the manufacturing method of the plugged honeycomb structure according to the present
invention will hereinafter be described.
[0020] In the manufacturing method of the plugged honeycomb structure according to the present embodiment, first
the cylindrical honeycomb substrate 1 provided with the plurality of cells 2 separated by the partition walls 10 so as to
communicate the first end surface 11 and the second end surface 21 is prepared (Fig. 1(a)).
[0021] To prepare the honeycomb substrate 1, first there is used, as a material, powder of one type of material selected
from the group consisting of a ceramic such as cordierite, mullite, alumina, spinel, zirconia, silicon carbide, a silicon
carbide-cordierite based composite material, a silicon-silicon carbide based composite material, silicon nitride, lithium
aluminum silicate, aluminum titanate or zeolite; a metal such as an Fe-Cr-Al based metal; and a combination of these
materials. To this material, a binder such as methyl cellulose or hydroxyl propoxyl methyl cellulose is added, and further
a surfactant and water are added to obtain a mixed material. Subsequently, the resultant mixed material is formed into
a clay having plasticity, extruded and formed into a honeycomb shape, and then dried or fired, so that the honeycomb
substrate 1 can be prepared.
[0022] An attaching step attaches mask films 4a and 4b to the first end surface 11 and the second end surface 21 of
the honeycomb substrate 1, respectively (Fig. 1(b)). There is not any special restriction on a type of the mask films 4a
and 4b, but it is preferable that film can be melted by heat and also be perforated by irradiation with laser light. It is
preferable to use, as the mask films 4a and 4b, a film having an adhesive layer so as to be fixed on the end surface (the
first end surface 11, the second end surface 21) of the honeycomb substrate 1. Specific examples of such a film include
a film including a base layer constituted of a polymer material such as polyester, polyolefin or halogenated polyolefin,
and the adhesive layer laminated on this base layer and constituted of an acrylic adhesive material. From viewpoints of
strength and ease of making holes, it is preferable that a thickness of the mask films 4a and 4b is about 10 to 100 mm.
[0023] A first perforation step makes slurry permeation holes 3a at portions of the mask films 4a and 4b corresponding
to the predetermined cell opening end portions 7 (Fig. 1(c)). The slurry permeation holes 3a function as inflow ports for
allowing a plugging slurry to flow into the cell opening end portions 7 in the subsequent step. It is to be noted that it is
preferable to set a diameter of the slurry permeation holes 3a to 30 to 70% of an opening area of the slurry permeation
holes 3a, because the plugging slurry having a viscosity described later easily permeates the holes in a satisfactory
state. It is further preferable to set the diameter to 40 to 60%, and it is especially preferable to set the diameter to around
50%.
[0024] A second perforation step makes deaeration holes 3b at portions of the mask films 4a and 4b facing the portions
provided with the slurry permeation holes 3a via the cells 2 (Fig. (d)). The deaeration holes 3b function as outflow ports
for discharging, from the cells, air which has been introduced in the cells 2 and which cannot flow outwards, in a case
where the plugging slurry is passed into the cell opening end portions 7 through the slurry permeation holes 3a.
[0025] A diameter X of the deaeration holes is set to 0.02 to 0.8 mm, preferably 0.04 to 0.6 mm, further preferably
0.05 to 0.4 mm. The diameter X of the deaeration holes is set to this numerical value range, whereby it is difficult (or
impossible) to allow the plugging slurry having the viscosity described later to flow outwards or inwards through the
deaeration holes 3b, but inflow and outflow of the air are facilitated (or can be performed). Therefore, even in a case
where the end surfaces of the honeycomb substrate 1 to which the mask films 4a and 4b having the slurry permeation
holes 3a and the deaeration holes 3b have been attached are submerged into the plugging slurry 6, the plugging slurry
6 easily permeates the cell opening end portions 7 from the slurry permeation holes 3a, but does not easily permeate
the portions from the deaeration holes 3b (Fig. 1(e)).
[0026] There is not any special restriction on a method of making the slurry permeation holes 3a and the deaeration
holes 3b in the mask films 4a and 4b, but, for example, a method of making the holes by laser irradiation is preferable.

EP 2 116 348 B1

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Moreover, the slurry permeation holes 3a and the deaeration holes 3b may be made one by one in the mask films 4a
and 4b with one needle, or a large number of the slurry permeation holes 3a and the deaeration holes 3b may collectively
be made using bundle needles planted on the plate having a pitch corresponding to that of the cells 2 to be perforated.
In addition, it is preferable that images of the first end surface 11 and the second end surface 21 of the honeycomb
substrate 1 are processed to extract positions of the cells 2 in which the slurry permeation holes 3a and the deaeration
holes 3b are to be made, and the slurry permeation holes 3a and the deaeration holes 3b are made at the extracted
positions by use of a laser marker, so that even the honeycomb substrate 1 in which the pitch and an opening shape of
the cells 2 are not constant can flexibly be handled. It is to be noted that in a case where the slurry permeation holes
and the deaeration holes are made by the laser irradiation, to regulate diameters of these holes, intensity of laser may
appropriately be regulated.
[0027] A filling step first submerges the first end surface 11 and the second end surface 21 to which the mask films
4a and 4b of the honeycomb substrate 1 have been attached into the plugging slurry 6 having a predetermined viscosity,
respectively, and fills the cell opening end portions 7 with the plugging slurry 6 to obtain a slurry filled substrate 20 (Figs.
1(e) and (f)). The plugging slurry has a viscosity of 0.5 to 2000 Pas, preferably 1 to 1500 Pas. The viscosity of the
plugging slurry is set to this numerical value range, whereby it is difficult (or impossible) for the plugging slurry to flow
inwards or outwards through the deaeration holes 3b having the diameter (X) in the above numerical value range, but
the inflow and outflow of the air are facilitated (or can be performed). Therefore, even when the first end surface 11 and
the second end surface 21 of the honeycomb substrate 1 are submerged into the plugging slurry 6, respectively, the
plugging slurry 6 easily permeates the cell opening end portions 7 through the slurry permeation holes 3a, but does not
remarkably easily permeate the portions from the deaeration holes 3b. Therefore, the plugging slurry 6 does not remarkably easily permeate the cells 2 which are not to be permeated by the plugging slurry 6, a plugging defect is not easily
generated, and hence a manufacturing yield can be improved. Furthermore, with regard to the air in the cells 2, the
plugging slurry 6 permeates the cells 2 through the slurry permeation holes 3a, whereby the air is quickly discharged
from the deaeration holes 3b. Therefore, a plugged honeycomb structure can easily be manufactured in which the
plugging slurry 6 can uniformly permeate into a desired depth of the cells 2 and in which plugging portions have high
reliability.
[0028] It is to be noted that in a case where the plugging slurry 6 having thixotropy is used, when the plugging slurry
6 permeates the cell opening end portions 7, it is preferable to fill the cell opening end portions 7 with the plugging slurry
6 while vibrating the slurry by use of an ultrasonic generator or the like, because the plugging slurry 6 can more uniformly
permeate into the desired depth of the cells 2.
[0029] The plugging slurry can be prepared by mixing at least ceramic powder and a dispersion medium for the slurry.
Preferable examples of the dispersion medium for the slurry include an organic solvent such as acetone, ethanol or
methanol, and water.
[0030] To the plugging slurry, if necessary, an additive such as a binder or deflocculant may further be added. There
is not any special restriction on a type of the ceramic powder, but, for example, silicon carbide powder, cordierite powder
or the like may preferably be used. As the binder, a resin such as polyvinyl alcohol (PVA) may be used, but it is more
preferable to use a thermal gel setting binder having a property of gelating by heating. As the thermal gel setting binder,
methyl cellulose may preferably be used.
[0031] After the slurry filled substrate 20 is obtained, if necessary, the slurry filled substrate is dried, and heated and/or
fired, so that the plugged honeycomb structure 30 provided with the plugging portions 15 can be manufactured (Fig. 1
(g)). It is to be noted that in general, the plugged honeycomb structure 30 can be manufactured by performing the filling
step of filling the predetermined cell opening end portions 7 with the plugging slurry 6, and then performing the firing,
but the filling step may be performed with respect to an unfired honeycomb structure formed body (a dried body), or a
fired honeycomb structure body.
[0032] For example, as shown in Fig. 3, in the plugged honeycomb structure 30 manufactured according to the manufacturing method of the plugged honeycomb structure of the present invention, as long as the plurality of cells 2 are
separated by the porous partition walls and extend from one end surface 27 to the other end surface 29 in an axial
direction and the cells 2 have the plugging portions 15 arranged at either of the end surfaces 27 and 29 so as to plug
the end surfaces, there is not any restriction on a shape of the structure. It is to be noted that reference numeral 25 in
Fig. 3 is an outer peripheral wall which surrounds an outer periphery of the partition walls.
[0033] A sectional shape of the plugged honeycomb structure crossing an extending direction of the cells at right
angles can appropriately be adopted from a circular shape, an elliptic shape, a race-track shape, a quadrangular shape
and the like based on an application and an installation place. A sectional shape of the cell crossing the extending
direction of the cell at right angles may be selected from a polygonal shape such as a triangular shape, a quadrangular
shape or a hexagonal shape, a substantially polygonal shape, a circular shape and a substantially circular shape such
as an elliptic shape. A cell density is usually set to 6 to 2000 cells/square inch (0.9 to 311 cells/cm2), preferably about
50 to 1000 cells/square inch (7.8 to 155 cells/cm 2). When the plugged honeycomb structure 30 (see Fig. 3) is used as
a catalyst carrier or a filter, it is preferable that the partition walls and the outer peripheral wall 25 are porous.

EP 2 116 348 B1
Example
[0034] The present invention will hereinafter specifically be described in accordance with examples, but the present
invention is not limited to these examples.
5

(Preparation of Honeycomb Substrate)

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[0035] A mixed material made of cordierite, an organic binder, a pore former and water was formed into a honeycomb
shape, and then dried to prepare a cylindrical honeycomb substrate having an outer diameter of 140 mm and a length
of 150 mm. In the prepared honeycomb substrate, a cell had a square sectional shape crossing an extending direction
of the cell at right angles, partition walls had a thickness of about 0.3 mm, a cell density was 300 cells/square inch, and
a cell pitch was 1.5 mm.
(Preparation of Plugging slurry)

15

[0036] Appropriate amounts of methyl cellulose, glycerin and water were added to cordierite powder, and kneaded to
prepare four types of plugging slurries having viscosities of 1 Pads, 1000 Pads, 1500 Pads and 2000 Pads.
(Example 1)
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[0037] Mask films (material: polyester, thickness: mm, trade name "Masking Tape", manufactured by 3M Co.) were
attached to both end surfaces (a first end surface and a second end surface) of one of honeycomb substrates, and slurry
permeation holes were made at portions of the attached mask films corresponding to predetermined cell opening end
portions (so as to obtain a checkered pattern) by use of laser. Subsequently, deaeration holes having a diameter of 0.05
mm were made at portions of the mask films facing the portions provided with the slurry permeation holes via cells by
use of the laser. Afterward, the first end surface of the honeycomb substrate was submerged into a depth of 5 mm in a
plugging slurry having a viscosity of 1 Pas to fill the cell opening end portions with the plugging slurry through the slurry
permeation holes of the mask film.
[0038] After pulling up the honeycomb substrate from the plugging slurry, the honeycomb substrate was dried at 100C
for 120 seconds. Afterward, in the same manner as in the above first end surface, the second end surface of the
honeycomb substrate was submerged into the plugging slurry to fill the cell opening end portions at the other end surface
of the honeycomb substrate with the plugging slurry. The honeycomb substrate was dried at 100C for 120 seconds,
and fired for 50 hours to manufacture a plugged honeycomb structure.
[0039] When an average plugging depth (mm) of the plugging portions of the manufactured plugged honeycomb
structure was measured, the depth was 5.00 mm at the first end surface, the depth was 4.98 mm at the second end
surface, and an average of the depths of the first and second end surfaces was 4.99 mm. It is to be noted that an average
achievement ratio of the plugging depth with respect to a target depth (5 mm) was 100%. Moreover, a photograph of a
partially sectional structure of the plugged honeycomb structure manufactured in Example 1 is shown in Fig. 4.

40

(Examples 2 to 6 and Comparative Examples 1 to 6)

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[0040] Plugged honeycomb structures were manufactured in the same manner as in Example 1 except that a perforation
method of deaeration holes, a diameter (X) of the deaeration holes, a viscosity of a plugging slurry and a vibration
frequency were set to a method and numeric values shown in Table 1, respectively. Plugging portions of the manufactured
plugged honeycomb structures were measured in the same manner as in Example 1. Results are shown in Table 1.
Moreover, a photograph of a partially sectional structure of the plugged honeycomb structure manufactured in Comparative Example 1 is shown in Fig. 5.
[0041]

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Laser

Laser

Laser

Laser

Laser

Laser

Laser

Laser

Example 3

Example 4

Example 5

Example 6

Comparative
Example 1

Comparative
Example 2

Comparative
Example 3

Comparative
Example 4

Comparative
Example 5

Comparative
Example 6
1

0.1

0.1

0.01

0.8

0.1

0.1

0.1

0.02

0.02

2000

2500

0.4

0.5

0.5

0.5

2000

2000

1000

0.5

0.5

35

60

60

60

60

60

60

60

60

4.98

1.88

5.21

3.64

4.53

3.11

4.64

4.53

5.01

4.69

4.70

4.68

First end
surface

*1: Difficult for plugging slurry to permeate

*2: Plugging slurry slightly easily permeates by vibrating slurry, but it is difficult for slurry to permeate
*3: Plugging slurry permeates from deaeration holes

Pin

Example 2

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Laser

50

Example 1

45

[00 41]

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Vibration
frequency
(Hz)

25

Diameter (X)
of deaeration
hole (mm)

20

4.88

1.05

5.12

3.33

2.22

1.59

4.50

4.49

5.00

4.63

4.33

4.35

Second end
surface

4.93

1.47

5.17

3.49

3.38

2.35

4.57

4.51

5.01

4.66

4.52

4.52

Average of
first and
second end
surfaces

Average plugging depth (mm)

15

Viscosity of
plugging
slurry
(Pads)

99%

29%

103%

70%

68%

47%

91%

90%

100%

93%

90%

90%

Average target
depth
achievement
ratio (%)

10

Perforation
method of
deaeration
holes

30

[Table 1]

*3

*1

*3

*1

*2

*1

Remarks

EP 2 116 348 B1

EP 2 116 348 B1

[0042] As shown in Table 1, in the methods of Examples 1 to 5, as compared with the methods of Comparative
Examples 1 to 5, it is clear that the plugging slurry permeates into a desired depth and the plugging portion having a
sufficient depth is formed. According to the methods of Examples 1 to 5, it is clear that the plugged honeycomb structure
having an excellent quality can be manufactured without causing the plugging failure. It is to be noted that for reference,
in a case where a plugging slurry having a viscosity in excess of 2500 Pas is used, the plugging slurry does not easily
retain properties of the slurry, and it has been difficult for the plugging slurry to permeate the cells.
Industrial Applicability

10

[0043] A manufacturing method of a plugged honeycomb structure according to the present invention is preferable as
a method of manufacturing a plugged honeycomb structure for use in a filter such as DPF.

Claims
15

1.

20

an attaching step of attaching mask films (4) to both the end surfaces (11, 21) of the honeycomb substrate (1),
respectively;
a first perforation step of making slurry permeation holes (3a) at portions of the mask films (4) corresponding
to the one opening end portion (7) of each of the predetermined cells (2, 2a, 2b);
a second perforation step of making deaeration holes (3b) having a diameter of 0.02 to 0.8 mm at portions of
the mask films (4) facing the portions provided with the slurry permeation holes (3a) via the cells (2, 2a, 2b);
a filling step of submerging both the end surfaces (11, 21) of the honeycomb substrate (1) to which the mask
films (4) have been attached into a plugging slurry (6) having a viscosity of 0.5 to 2000 Pas, respectively, and
filling the one opening end portion (7) of each of the predetermined cells (2, 2a, 2b) with the plugging slurry (6)
to obtain a slurry filled substrate (20); and
a firing step of firing the resultant slurry filled substrate (20).

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35

A manufacturing method of a plugged honeycomb structure (30) including a cylindrical honeycomb substrate (1) in
which a plurality of cells (2, 2a, 2b) having two opening end portions (7) are separated by partition walls (10) and
formed so as to communicate with both end surfaces (11, 21) of the honeycomb substrate (30), and plugging portions
(15) arranged so as to plug one of the two opening end portions (7) of the cells (2, 2a, 2b) and form a complementary
checkered pattern with one end surface (11) and the other end surface (21) of the honeycomb substrate (30), the
method comprising:

2.

The manufacturing method of the plugged honeycomb structure (30) according to claim 1, wherein the deaeration
holes (3b) have a diameter in a range of 0.05 to 0.4 mm.

3.

The manufacturing method of the plugged honeycomb structure (30) according to claim 1 or 2, wherein the plugging
slurry (6) has a viscosity in a range of 1 to 1500 Pas.

4.

The manufacturing method of the plugged honeycomb structure (30) according to claim 1 or 2, wherein the plugging
slurry (6) has thixotropy, and
the one opening end portion (7) of each of the predetermined cells (2, 2a, 2b) is filled with the plugging slurry (6)
while vibrating the plugging slurry (6).

40

45

Patentansprche
1.
50

Herstellungsverfahren fr eine verschlossene Wabenstruktur (30), das Folgendes umfasst: ein zylinderfrmiges
Wabensubstrat (1), in dem eine Vielzahl von Zellen (2, 2a, 2b) mit zwei ffnungsendabschnitten (7) durch Trennwnde (10) getrennt sind und so ausgebildet sind, dass sie mit beiden Endflchen (11, 21) des Wabensubstrats
(30) kommunizieren, und Verschlussabschnitte (15), die so angeordnet sind, dass sie einen der beiden ffnungsendabschnitte (7) der Zellen (2, 2a, 2b) verschlieen und mit der einen Endflche (11) und der anderen Endflche
(21) des Wabensubstrats komplementre Schachbrettmuster bilden, wobei das Verfahren Folgendes umfasst:

55

einen Schritt des Aufbringens von Abdeckfilmen (4) auf beide Endflchen (11, 21) des Wabensubstrats (1);
einen ersten Perforationsschritt, bei dem Aufschlmmungseindringlcher (3a) in dem einen ffnungsendabschnitt (7) jeder der vorbestimmten Zellen (2, 2a, 2b) entsprechenden Teilen der Abdeckfilme (4) hergestellt

EP 2 116 348 B1
werden;
einen zweiten Perforationsschritt, bei dem Entlftungslcher (3b) mit einem Durchmesser von 0,02 bis 0,8 mm
in Teilen der Abdeckfilme (4) hergestellt werden, die den mit den Aufschlmmungseindringlchern (3a) bereitgestellten Teilen durch die Zellen (2, 2a, 2b) hindurch zugewandt sind;
einen Befllungsschritt, bei dem beide Endflchen (11, 21) des Wabensubstrats (1), auf die die Abdeckfilme
(4) aufgebracht wurden, in eine Verschlussaufschlmmung (6) mit einer Viskositt von 0,5 bis 2.000 Pas
getaucht werden und der eine ffnungsendabschnitt (7) jeder der vorbestimmten Zellen (2, 2a, 2b) mit der
Verschlussaufschlmmung (6) gefllt wird, um ein mit Aufschlmmung geflltes Substrat (20) zu erhalten; und
einen Schritt des Brennens des resultierenden mit Aufschlmmung gefllten Substrats (20).

10

2.

Verfahren zur Herstellung einer verschlossenen Wabenstruktur (30) nach Anspruch 1, worin die Entlftungslcher
(3b) einen Durchmesser im Bereich von 0,05 bis 0,4 mm aufweisen.

3.

Verfahren zur Herstellung einer verschlossenen Wabenstruktur (30) nach Anspruch 1 oder 2, worin die Verschlussaufschlmmung (6) eine Viskositt im Bereich von 1 bis 1.500 Pas aufweist.

4.

Verfahren zur Herstellung einer verschlossenen Wabenstruktur (30) nach Anspruch 1 oder 2, worin die Verschlussaufschlmmung (6) thixotrop ist und
der eine ffnungsendabschnitt (7) jeder der vorbestimmten Zellen (2, 2a, 2b) mit der Verschlussaufschlmmung
(6) befllt wird, whrend diese in Vibration versetzt wird.

15

20

Revendications
25

1.

30

une tape de fixation consistant fixer des films de masque (4) aux deux surfaces dextrmit (11, 21) du
substrat de nid dabeilles (1), respectivement ;
une premire tape de perforation consistant raliser des trous de permation de pte (3a) au niveau des
parties des films de masque (4) correspondant ladite une partie dextrmit douverture (7) de chacune des
cellules (2, 2a, 2b) prdtermines ;
une deuxime tape de perforation consistant raliser des trous de dsaration (3b) ayant un diamtre de
0,02 0,8 mm au niveau des parties des films de masque (4) faisant face aux parties pourvues des trous de
permation de pte (3a) via les cellules (2, 2a, 2b) ;
une tape de remplissage consistant submerger les deux surfaces dextrmit (11, 21) du substrat de nid
dabeilles (1) auxquelles les films de masque (4) ont t fixs dans une pte dobturation (6) ayant une viscosit
de 0,5 2.000 Pa.s, respectivement, et remplir ladite une partie dextrmit douverture (7) de chacune des
cellules (2, 2a, 2b) prdtermines avec la pte dobturation (6) pour obtenir un substrat rempli de pte (20) ; et
une tape de cuisson consistant cuire le substrat rempli de pte (20) rsultant.

35

40

45

50

55

Procd de fabrication dune structure en nid dabeilles obture (30) comprenant un substrat de nid dabeilles (1)
cylindrique dans lequel une pluralit de cellules (2, 2a, 2b) comportant deux parties dextrmit douverture (7) sont
spares par des parois de sparation (10) et sont formes de manire communiquer avec les deux surfaces
dextrmit (11, 21) du substrat de nid dabeilles (30), et des parties dobturation (15) agences de manire obturer
lune des deux parties dextrmit douverture (7) des cellules (2, 2a, 2b) et former un motif en damier complmentaire avec une surface dextrmit (11) et lautre surface dextrmit (21) du substrat de nid dabeilles (30), le
procd comprenant :

2.

Procd de fabrication de la structure en nid dabeilles obture (30) selon la revendication 1, dans lequel les trous
de dsaration (3b) ont un diamtre dans une plage de 0,05 0,4 mm.

3.

Procd de fabrication de la structure en nid dabeilles obture (30) selon la revendication 1 ou 2, dans lequel la
pte dobturation (6) a une viscosit dans une plage de 1 1.500 Pa.s.

4.

Procd de fabrication de la structure en nid dabeilles obture (30) selon la revendication 1 ou 2, dans lequel la
pte dobturation (6) a une thixotropie, et
ladite une partie dextrmit douverture (7) de chacune des cellules (2, 2a, 2b) prdtermines est remplie avec
la pte dobturation (6) tout en faisant vibrer la pte dobturation (6).

EP 2 116 348 B1

10

EP 2 116 348 B1

11

EP 2 116 348 B1

12

EP 2 116 348 B1
REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the readers convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

JP 2001300922 A [0008]
JP 6190218 A [0008]
JP 6190224 A [0008]

13

WO 2006062141 A [0008]
JP 1221216 A [0008]
JP 2005218209 A [0008]