A plugged honeycomb structure includes intersecting porous walls extending in an axial direction between an inlet end and an outlet end of the honeycomb structure, the intersecting porous walls forming a matrix of repeating unit cells arranged in a repeating pattern. The repeating unit cells comprise: three or four channels, each channel formed by four walls, wherein the three or four channels comprise more inlet channels than outlet channels, at least one wall of an inlet channel or an outlet channel is intersected midwall by a wall, an area of an outlet channel is equal to or less than an area of any of the inlet channels, and continuous line segments extending along walls of at least three repeating unit cells. Other plugged honeycomb structures, plugged honeycomb bodies, honeycomb extrusion dies, and methods are disclosed.

Provided is an exhaust gas purifying device of an internal-combustion engine, and a method of manufacturing the same, with which it is possible for a honeycomb carrier to be held securely within a case member using a low-cost, simple structure. The exhaust gas purifying device is provided with: a columnar honeycomb carrier 11 in which a plurality of cells which extend from an exhaust gas inflow side to an outflow side, and which serve as exhaust gas flow paths, are demarcated and famed by means of porous separating walls; a three-way catalyst supported in the honeycomb carrier 11; and a cylindrical case member 12 in which the honeycomb carrier 11 is housed, with the interposition of a retaining member 13. The honeycomb carrier 11 is provided with outer circumferential plugging portions 111a and 111b formed in such a way as to plug, to a prescribed depth, openings Ca and Cb of cells in an outer circumferential portion P of at least one end surface of the two end surfaces, in the central axis X-direction, of the honeycomb carrier 11; and inclined portions 112a and 112b formed in a direction whereby the length, in the central axis X-direction, of the outer circumferential plugging portions 111a and 111b decreases toward the outer circumferential edge. Further, the inclined portions 112a and 112b catch on the inner walls of the case member 12, with the interposition of the retaining member 13, thereby retaining the honeycomb carrier 11 in the case member 12.

Ceramic honeycomb bodies and methods for canning the bodies are disclosed herein. The honeycomb bodies comprise a porous ceramic honeycomb structure. The honeycomb structure comprises a network of cells defined by walls that extend in an axial direction about a longitudinal axis from an inlet end to an outlet end of the honeycomb structure. The honeycomb structure also comprises a portion of cells with protrusions. The portion of cells with protrusions supports a greater concentration of catalyst, as compared to a portion of cells without protrusions. The portion of cells with protrusions is disposed off-center with respect to the longitudinal axis of the honeycomb structure such that the portion of cells with protrusions (and greater concentration of catalyst) corresponds to areas of high exhaust flow through the structure.

A honeycomb body having intersecting porous walls and repeating structural units. Each repeating structural unit has a plurality of inlet channels and outlet channels that extend parallel to each other in an axial direction from an inlet face to an outlet face. Each of the repeating structural units has 2.0<I/O<3.0, wherein I/O is a ratio of a number of inlet channels to a number of the outlet channels, each of the inlet and outlet channels have a same cross-sectional size and shape, and each inlet channel of a particular repeating structural unit directly abuts an outlet channel of the particular repeating structural unit or an outlet channel of an adjacent repeating structural unit. Particulate filters including the honeycomb body, honeycomb extrusion dies, and methods of capturing soot in the honeycomb body are provided, as are other aspects.

A honeycomb filter includes a pillar-shaped honeycomb substrate having a porous partition wall and a plugging portion provided so as to plug end at any one of the inflow end face side or the outflow end face side of the cell, wherein in a section orthogonal to the extending direction of the cell, the shape of the cell is hexagonal, the partition wall includes a first partition wall disposed between the inflow cell and the outflow cell and a second partition wall disposed between the inflow cells, and the first partition wall has a porous trapping layer on its surface for trapping particulate matter in exhaust gas, and the second partition wall has no trapping layer on its surface or has a trapping layer thinner than the trapping layer disposed on the surface of the first partition wall.

A honeycomb filter includes a pillar-shaped honeycomb substrate having a porous partition wall and a plugging portion provided so as to plug end at any one of the inflow end face side or the outflow end face side of the cell, wherein in a section orthogonal to the extending direction of the cell, the shape of the cell is hexagonal, the partition wall includes a first partition wall disposed between the inflow cell and the outflow cell and a second partition wall disposed between the inflow cells, and the first partition wall has a porous trapping layer on its surface for trapping particulate matter in exhaust gas, and the second partition wall has no trapping layer on its surface or has a trapping layer thinner than the trapping layer disposed on the surface of the first partition wall.

A particulate filter having a honeycomb structure of a matrix of interconnected porous walls including inlet cells and outlet cells defining a plurality of inlet channels and outlet channels, respectively, wherein at least a portion of the outlet cells are larger than any of the inlet cells, and a cross-sectional shape of at least some of the outlet channels is rectangular. Honeycomb extrusion dies, honeycomb bodies, honeycomb structures, and methods of manufacture are described, as are other aspects.

A honeycomb structure includes a central area and a reinforced outer peripheral area. For a boundary cell having cell walls with different wall thicknesses on two sides parallel with an imaginary parallel line, a thin wall thickness t1<a thick wall thickness t3, an inner wall thickness t2<an outer wall thickness t4, t1=t2, and t3=t4. The honeycomb structure includes a cross-shaped unit having a thin wall, an inner wall, a cell wall, and a cell wall and a cross-shaped unit having a thick wall, an outer wall, a cell wall, and a cell wall. The honeycomb structure also includes cross-shaped units extending vertically and horizontally from alternate cell vertexes arranged from a cell vertex as a starting point. In the central area and the reinforced outer peripheral area, the cell walls of each cross-shaped unit have a substantially equal wall thickness.

A method and extrusion die to form a laminar integral skin of a honeycomb structure is provided. The method includes extruding a ceramic precursor batch through a die with feedholes in entry side and slots in exit face of the die to form the honeycomb structure. In a region on the periphery of the die configured to form the cell matrix, a series of concentric slots around the matrix in the exit face of the die are configured to feed skin onto the matrix. Ring sections between concentric slots are angled away from the center and a mask is disposed on top of the periphery producing a channel for extruded skin to meet and bond to extruded matrix. Optionally, slots in the skin-forming ring sections enhance knitting between laminar skin layers.

A method of making a porous structure configured for use in a particulate filter includes bonding a plurality of glass bubbles to one another, and breaching the plurality of glass bubbles. Voids within individual breached glass bubbles open into one another to form cavities that extend through the porous structure.