A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

A thin-walled honeycomb body (100) having a plurality of repeating cell structures (110) formed of intersecting porous thick walls (112V, 112H) and thin walls (114V, 114H). Each repeating cell structure (110) is bounded on its periphery by the thick walls (112V, 122H) of a first transverse thickness (Tk) and the thin walls (114V, 114H) have a second transverse thickness (Tt) that subdivides each repeating cell structure (110) into between 7 and 36 individual cells (108). In the thin-walled honeycomb body (100), the first transverse thickness (Tk) of the thick walls (112V, 112H) is less than or equal to 0.127 mm (0.005 inch) and the second transverse thickness (Tt) of the thin walls (114V, 114H) is less than or equal to 0.0635 mm (0.0025 inch), and Tk>Tt. Honeycomb extrusion dies and methods of manufacturing the thin-walled honeycomb body (100) having thick walls (112V, 112H) and thin walls (114V, 114H) are provided.

A honeycomb extrusion die (120) includes a die body (302) including an inlet face (306) and an exit face. The die body (302) has slot inlets (309) and a plurality of pins (320, 500) disposed between the slot inlets (309) and the exit face. The plurality of pins (320, 500) include side surfaces (322, 500B) configured to define a matrix of intersecting slots (324), wherein the matrix of intersecting slots (324) has slot exit (509) widths at the exit face. Divots (526) extend into a plurality of the side surfaces (322, 500B) between the slot inlets (309) and the exit face. Each individual divot (526) has a divot depth (D55) extending into a side surface (500A, 500B, 502A, 502B) of the side surfaces (322, 500B). A ratio between a slot exit width (W53) W53 of an individual slot (324) and the divot depth (D55) of an individual divot (526) extending into a side surface (500A, 500B, 502A, 502B) of the individual slot (324) is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.

A honeycomb extrusion die (120) includes a die body (302) including an inlet face (306) and an exit face. The die body (302) has slot inlets (309) and a plurality of pins (320, 500) disposed between the slot inlets (309) and the exit face. The plurality of pins (320, 500) include side surfaces (322, 500B) configured to define a matrix of intersecting slots (324), wherein the matrix of intersecting slots (324) has slot exit (509) widths at the exit face. Divots (526) extend into a plurality of the side surfaces (322, 500B) between the slot inlets (309) and the exit face. Each individual divot (526) has a divot depth (D55) extending into a side surface (500A, 500B, 502A, 502B) of the side surfaces (322, 500B). A ratio between a slot exit width (W53) W53 of an individual slot (324) and the divot depth (D55) of an individual divot (526) extending into a side surface (500A, 500B, 502A, 502B) of the individual slot (324) is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.

A honeycomb body (300) including a plurality of radially-extending walls (322) intersecting with a plurality of circumferentially-extending walls (324), the plurality of radially-extending walls (322) and the plurality of circumferentially-extending walls (324) form a plurality of circumferential zones (334A, 334B, 334C) of cells (308). The plurality of circumferential zones (334A, 334B, 334C) of cells (308) includes a first zone of cells (334A) including two or more first rings of cells (330) and having a first cell density, and a second zone of cells (334B) including two or more rings of cells (330) having varying cell densities across the two or more rings of cells. Other structures and extrusion dies are disclosed.

Construction components and systems fabricated using extruded materials are disclosed. A particular embodiment includes: a sheet fabricated from an extruded material; and a core structure internal to the sheet, the core structure including voids, the voids being triangular-shaped and arranged in an alternately inverted pattern.

Construction components and systems fabricated using extruded materials are disclosed. A particular embodiment includes: a sheet fabricated from an extruded material; and a core structure internal to the sheet, the core structure including voids, the voids being triangular-shaped and arranged in an alternately inverted pattern.

A method for producing a honeycomb structure according to the present invention includes: a preparation step of preparing a honeycomb structure element 2 having plurality of slits 12; and a filling step of filling the plurality of slits 12 with a filling material 13 by a contacting member 3 by feeding the filling material 13 to an outer peripheral surface 20 of the honeycomb structure element 2, and rotating the honeycomb structure element 2 while pressing a tip portion 3a of the contacting member 3 inclined at an angle relative to a normal line 20a of the outer peripheral surface 20 of the honeycomb structure element 2 against the outer peripheral surface 20 with a force, to obtain the honeycomb structure having the plurality of slits 12 filled with the filling material 13.

A method for producing a honeycomb structure according to the present invention includes: a preparation step of preparing a honeycomb structure element 2 having plurality of slits 12; and a filling step of filling the plurality of slits 12 with a filling material 13 by a contacting member 3 by feeding the filling material 13 to an outer peripheral surface 20 of the honeycomb structure element 2, and rotating the honeycomb structure element 2 while pressing a tip portion 3a of the contacting member 3 inclined at an angle relative to a normal line 20a of the outer peripheral surface 20 of the honeycomb structure element 2 against the outer peripheral surface 20 with a force, to obtain the honeycomb structure having the plurality of slits 12 filled with the filling material 13.

In a process for manufacturing a component for an emissions treatment unit, green ceramic product is extruded through a die to form an extrusion having a honeycomb substrate structure with an array of parallel, linear tubular cells extending along its length, the cells bounded by walls dividing adjacent cells from one another. A ceramic unit is obtained by cutting off, curing and firing a length of the extrusion a length of the extrusion. Following the firing, a mixture of a flowable, uncured curable material and a particulate metal component is injected from an end of the ceramic unit into selected ones of the cells so as to block the selected cells over at least a part of their lengths while maintaining all of the walls of the ceramic unit. The injected mixture is then cured to render it solid.