In a process for manufacturing a catalytic converter component, a ceramic unit is used that has been prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure in which tubular passages extend along the extrusion, the passages bounded by walls dividing adjacent passages from one another. The unit is obtained by cutting off a length of the extrusion and curing and firing it. The process further comprises flowing insulation material from one end of the unit into selected ones of the elongate passages, vaporizing a moisture content of the insulation material to form pores and curing the insulation material by using microwave irradiation to solidify the pores. The passages are selected so that the cured insulation material forms an internal thermal insulating barrier between a core zone of the unit and a radially outer zone of the unit.

The present invention is directed to a certain method of catalytically coating a honeycomb monolith, in particular a so-called flow-through monolith. These types of monoliths can be quite precisely be coated by a method using an indirect coating via a displacement body. The present invention further improves this method through controlling the process by monitoring the certain measures.

A plugged honeycomb structure has a plurality of cells defined by partition walls to become through channels for fluid, one end of each of the predetermined cells is plugged by a plugging member, the other end of each of the residual cells is plugged by the plugging member, the partition wall is made of a cordierite component as a main component, and a value obtained by dividing Young's modulus of a plugging structure portion formed by the partition walls and the plugging member by Young's modulus of a cell structure portion formed by the partition walls is in a range of 1.05 to 2.00.

A plugged honeycomb structure has a plurality of cells defined by partition walls to become through channels for fluid, one end of each of the predetermined cells is plugged by a plugging member, the other end of each of the residual cells is plugged by the plugging member, the partition wall is made of a cordierite component as a main component, and a value obtained by dividing Young's modulus of a plugging structure portion formed by the partition walls and the plugging member by Young's modulus of a cell structure portion formed by the partition walls is in a range of 1.05 to 2.00.

A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

A method of plugging a honeycomb body includes mixing a plugging mixture at a mixing temperature, wherein the plugging mixture comprises a plurality of inorganic particles, inorganic binder, organic binder, and water; dispensing the plugging mixture into a patty mold at a dispensing temperature; cooling the plugging mixture within the patty mold to a cooled temperature, such that a cement patty is formed; and pressing the cement patty into a plurality of channels in a honeycomb body, wherein the mixing temperature and the dispensing temperature are above a hydration point temperature of the organic binder in the plugging mixture, and the cooled temperature is below the hydration point temperature of the organic binder in the plugging mixture.

A pillar shaped honeycomb structure, including: an outer peripheral wall; and a porous partition wall disposed inside the outer peripheral wall, the a porous partition wall defining a plurality of cells, each of the cells extending from one end face to other end face to form a flow path, wherein a surface of the porous partition wall in the cells comprise a collecting layer having an average pore diameter lower than that of the porous partition wall; and wherein magnetic particles having a Curie point of 700° C. or higher are provided either or both between the surfaces of the porous partition wall and the collecting layer, and on the collecting layer.

A pillar shaped honeycomb structure, including: an outer peripheral wall; and a porous partition wall disposed inside the outer peripheral wall, the a porous partition wall defining a plurality of cells, each of the cells extending from one end face to other end face to form a flow path, wherein a surface of the porous partition wall in the cells comprise a collecting layer having an average pore diameter lower than that of the porous partition wall; and wherein magnetic particles having a Curie point of 700° C. or higher are provided either or both between the surfaces of the porous partition wall and the collecting layer, and on the collecting layer.

A pillar shaped honeycomb structure includes: a porous partition wall that defines a plurality of cells, the cells forming flow paths for a fluid, the cells extending from an inflow end face to an outflow end face; and an outer peripheral wall located at the outermost circumference. The cells include: a plurality of cells A wherein a side of the inflow end face is opened and the outflow end face has a plugged portion; and a plurality of cells B wherein a side of the outflow end face is opened and the inflow end face has a plugged portion, the cells B being arranged alternately with the cells A. One or both of the plugged portion of the cells A and the plugged portions of the cells B contain a magnetic substance and glass.

A pillar shaped honeycomb structure includes: a porous partition wall that defines a plurality of cells, the cells forming flow paths for a fluid, the cells extending from an inflow end face to an outflow end face; and an outer peripheral wall located at the outermost circumference. The cells include: a plurality of cells A wherein a side of the inflow end face is opened and the outflow end face has a plugged portion; and a plurality of cells B wherein a side of the outflow end face is opened and the inflow end face has a plugged portion, the cells B being arranged alternately with the cells A. One or both of the plugged portion of the cells A and the plugged portions of the cells B contain a magnetic substance and glass.