Patent ID: 8585945
Filing Date: 2013-11-19
Classification: C04B,F01N,Y10T

Abstract:
1. A method of producing a honeycomb structure, comprising: forming a ceramic block by bonding a plurality of honeycomb units that have a plurality of cells partitioned by cell walls using a bonding layer made of a bonding material, or forming a ceramic block by a single honeycomb unit that has a plurality of cells partitioned by cell walls and providing a coating layer made of a coating material on an outer peripheral portion of the ceramic block; providing a paste of at least one of the bonding and coating materials which includes particles of a foaming material on the outer peripheral portion of the ceramic block; blowing the foaming material, said foaming material having a coefficient of expansion in a range of approximately 2 times to approximately 10 times and the particles of the foaming material having a diameter in a range of approximately 1 μm to approximately 50 μm, so that the particles have a diameter less than approximately 500 μm after said blowing; and evaporating the foaming material and forming bubble marks having a diameter in a range of approximately 100 μm to approximately 300 μm in the bonding layer and/or the coating layer, so that the bonding layer and/or the coating layer includes only bubble marks having diameters that are approximately 300 μm or less, and the diameter of each of the bubble marks in the bonding layer and/or the coating layer after said evaporating is in a range of approximately 100 μm to approximately 300 μm.