Method for manufacturing at least one area of a filter structure, in particular for a particulate filter in the exhaust gas system of an internal combustion engine

Abstract

A method for manufacturing at least one area of a filter structure, in particular for a particulate filter in the exhaust gas system of an internal combustion engine, includes the following steps: a. manufacturing a mixture from a sintering metal powder and an organic binder; b. manufacturing a sheet from the mixture; c. structuring the sheet; and d. sintering.

1 - 14 . (canceled) 
   
   
       15 . A method for manufacturing at least one area of a filter structure in an exhaust gas system of an internal combustion engine, comprising:
 manufacturing a mixture from a sintering metal powder and an organic binder;   manufacturing a sheet from the mixture;   structuring the sheet; and   performing a sintering operation.   
   
   
       16 . The method as recited in  claim 15 , further comprising:
 before the structuring step, manufacturing multilayer green sheets from the sheet manufactured; and   structuring the multilayer green sheets.   
   
   
       17 . The method as recited in  claim 15 , wherein the sheet and/or the multilayer green sheet have a sintering metal powder size distribution gradient and/or density distribution gradient. 
   
   
       18 . The method as recited in  claim 15 , wherein the sheet is produced by sheet spreading, sheet casting, or sheet extrusion. 
   
   
       19 . The method as recited in  claim 15 , wherein the structuring takes place at a temperature in the range of 80° C. to 150° C., preferably in the range of 80° C. to 90° C. 
   
   
       20 . The method as recited in  claim 15 , wherein the structuring is achieved by embossing. 
   
   
       21 . The method as recited in  claim 20 , wherein embossing plates and/or structured laminating rollers whose surface structure is mapped on the sheet or the multilayer green sheet are used for embossing. 
   
   
       22 . The method as recited in  claim 15 , wherein a sintering metal powder having a grain size of approximately 1 μm to 150 μm, preferably 40 μm to 70 μm, more preferably 50 μm to 60 μm, is used. 
   
   
       23 . The method as recited in  claim 15 , wherein the sintering metal powder is processed in step a with approximately 2% to 8% by weight of acrylate binder and a volatile organic solvent to form a spreadable slurry. 
   
   
       24 . The method as recited in  claim 23 , wherein the volatile organic solvent is butyl acetate or alcohol. 
   
   
       25 . The method as recited in  claim 15 , wherein the sheet or the multilayer green sheet is structured on both sides. 
   
   
       26 . The method as recited in  claim 25 , wherein the sheet or the multilayer green sheet is given a double-sided waffle structure. 
   
   
       27 . The method as recited in  claim 15 , wherein the sheet or the multilayer green sheet is additionally bonded to a supporting structure. 
   
   
       28 . The method as recited in  claim 27 , wherein a metallic fabric, a metallic mesh, or a perforated sheet is used as the supporting structure.