CN-122010589-A - Honeycomb ceramic carrier and preparation method and application thereof

CN122010589ACN 122010589 ACN122010589 ACN 122010589ACN-122010589-A

Abstract

The invention provides a honeycomb ceramic carrier, a preparation method and application thereof. The honeycomb ceramic carrier comprises a plurality of silicon carbide ceramic unit bodies and a plurality of hole blocking parts, wherein the hole blocking parts are prepared by sintering raw materials comprising silicon carbide, aluminum oxide, strontium carbonate, metallic silicon and additives, the ratio of the bending strength of an A axis of the ceramic unit bodies to the bending strength of the hole blocking parts is 1 (0.8-1.9), the bending strength of the A axis of the ceramic unit bodies is 2.5-38.5 mpa, and the bending strength of the hole blocking parts is 3-35 mpa. The scheme provided by the invention ensures that the bending strength of the carrier and the bending strength of the ceramic unit body have higher matching degree, thereby improving the yield while ensuring the excellent performance of the carrier.

Inventors

LI XINJIAN
WANG XIAOJIE
FU MEILI
SHU LINXIANG
LV YUXING
Huo Xiyun
YANG JUN

Assignees

山东国瓷功能材料股份有限公司

Dates

Publication Date: 20260512
Application Date: 20260107

Claims (12)

1. A honeycomb ceramic carrier comprising: a plurality of silicon carbide ceramic unit bodies having a plurality of compartments partitioned by partition walls and extending in a longitudinal direction of the ceramic unit bodies, the compartments forming fluid flow paths extending from an inlet end face to an outlet end face; The hole blocking parts are arranged at the end parts of the air inlet end face and the air outlet end face of the ceramic unit body, and are made of raw materials containing silicon carbide, aluminum oxide, strontium carbonate, metal silicon and additives through sintering; The ratio of the bending strength of the ceramic unit body A axis to the bending strength of the hole blocking part is 1 (0.8-1.9), the bending strength of the ceramic unit body A axis is 2.5-38.5 MPa, and the bending strength of the hole blocking part is 3-35 MPa.
2. The honeycomb ceramic carrier according to claim 1, wherein a ratio of a flexural strength of the ceramic unit body a axis to a flexural strength of the plugged portion is 1 (0.8 to 1.2).
3. The honeycomb ceramic carrier according to claim 1 or 2, wherein the mass ratio of the alumina, the strontium carbonate and the metallic silicon is 1 (0.69-6.5): 10-52.
4. The honeycomb ceramic carrier according to claim 1 or 2, wherein the hole blocking portion is made by sintering raw materials comprising the following components in parts by weight: 60-80 parts of silicon carbide, 0 To 14.5 parts of metallic silicon, 3-1.25 Parts of aluminum oxide, 0.16 To 1.68 parts of strontium carbonate, 7-10 Parts of additive.
5. The honeycomb ceramic carrier according to claim 4, wherein the silicon carbide comprises a first particle size silicon carbide having a D50 of 30 μm to 50 μm and a second particle size silicon carbide having a D50 of 15 μm to 30 μm.
6. The honeycomb ceramic carrier according to claim 4, wherein the additive comprises 2 to 5 parts of binder a and 3 to 5.5 parts of lubricant a; Optionally, the binder a comprises one or more of polyvinyl alcohol, glycerol, ethylcellulose, polyethylene glycol, methylcellulose, potassium laurate, and carboxymethyl cellulose; optionally, the lubricant a comprises one or more of glycerin, polyacrylamide gel, paraffin oil and vegetable oil.
7. The honeycomb ceramic carrier according to claim 1 or 2, wherein the ceramic unit body is prepared by sintering raw materials comprising the following components in parts by weight: 75-85 parts of silicon carbide, 15-25 Parts of metal silicon, 0.2 To 3 parts of alkaline earth metal oxide, 15-25 Parts of a binder B, 25-35 Parts of pore-forming agent, 0.5 To 1 part of clay, 3.5-5 Parts of lubricant B; Optionally, the alkaline earth metal oxide comprises one or more of beryllium oxide, magnesium oxide, calcium oxide, strontium oxide, and barium oxide; Optionally, the binder B includes one or more of polyvinyl alcohol, glycerol, ethylcellulose, polyethylene glycol, methylcellulose, potassium laurate, and carboxymethyl cellulose; optionally, the lubricant B comprises one or more of glycerol, polyacrylamide gel, paraffin oil and vegetable oil; optionally, the pore-forming agent comprises one or more of walnut powder, graphite, benzoic acid, starch, ammonium bicarbonate, ammonium chloride, polymethyl methacrylate and expanded microspheres; optionally, the clay comprises one or more of kaolin, bentonite, montmorillonite, diatomaceous earth, perlite, illite, and petrolatum.
8. The honeycomb ceramic carrier according to claim 1 or 2, wherein the hole blocking portion comprises the following components in percentage by weight: 70% -94% of silicon carbide, 2% -7% Of silicon dioxide, 3% -8% Of silicon, 0.1 To 2 percent of strontium oxide, 0.1% -2% Of aluminum oxide; And/or, the ceramic unit body comprises the following components in percentage by weight: 60% -75% of silicon carbide, Silica 5% -15%, 15% -30% Of silicon, Alkaline earth metal oxide 0.1-2.5%, 0.1% -2.5% Of aluminum oxide.
9. The honeycomb ceramic carrier according to any one of claims 1 to 8, wherein the honeycomb ceramic carrier satisfies at least one of the following conditions (1) to (3): (1) The porosity of the honeycomb ceramic carrier is 40% -70%; (2) The shrinkage of the honeycomb ceramic carrier is less than 5%; (3) The pore channel density of the honeycomb ceramic carrier is 150 cpsi-500 cpsi.
10. A method for preparing the honeycomb ceramic carrier according to any one of claims 1 to 9, comprising the steps of: s10, providing raw materials comprising silicon carbide, aluminum oxide, strontium carbonate, metallic silicon and additives, and mixing the raw materials to obtain a honeycomb ceramic plug Kong Liao; S30, providing the ceramic unit body, and S50, plugging holes of the ceramic unit body by adopting the honeycomb ceramic plugging material, and obtaining the honeycomb ceramic carrier through sintering, splicing and end face polishing.
11. Use of the honeycomb ceramic carrier according to any one of claims 1 to 9 or the honeycomb ceramic carrier obtained by the production method according to claim 10 as a catalyst carrier in exhaust gas treatment.
12. A method for predicting the bending strength of the plugging portion in the honeycomb ceramic carrier according to any one of claims 1 to 9 or the honeycomb ceramic carrier obtained by the preparation method according to claim 10, comprising the steps of: s20, obtaining the weight parts of silicon carbide, strontium carbonate and aluminum oxide in the raw materials of the hole plugging part of the honeycomb ceramic carrier, and And S40, calculating the bending strength of the hole blocking part according to a formula Z= 1.7622 ×e (0.0563·Si+0.7616·Sr+0.9898·Al) , wherein Z is the bending strength of the hole blocking part, si is the weight part of silicon carbide, sr is the weight part of strontium carbonate, and Al is the weight part of aluminum oxide.

Description

Honeycomb ceramic carrier and preparation method and application thereof Technical Field The invention relates to the technical field of honeycomb ceramics, in particular to a honeycomb ceramic carrier, a preparation method and application thereof. Background Honeycomb ceramics, particularly structures made of silicon carbide (SiC) ceramic materials, have found wide application in the modern industry. These structures play a key role in various devices such as internal combustion engines, boilers, chemical reaction devices, and fuel cell reformers. Their main functions are as a catalyst carrier, exploiting its catalytic action, and collecting particulates during exhaust gas treatment, such as trapping Particulate Matter (PM) in the exhaust gas emitted by a diesel engine. These ceramic honeycomb structures are commonly used as Diesel Particulate Filters (DPFs) with individual cells separated by their unique partition designs to form wall flow filters. The wall flow type honeycomb ceramics need to be subjected to staggered hole blocking, so that the wall flow type effect can be achieved, the performance of the hole blocking material has larger influence on the honeycomb ceramics, most of the current technologies mainly focus on matching the thermal expansion coefficient of the hole blocking material with that of the honeycomb ceramics, the purpose of improving the thermal shock resistance of the honeycomb ceramics is achieved, the cracking phenomenon of the honeycomb ceramics after multiple temperature rising and lowering is reduced, and silicon carbide powder is generally adopted as a main material of the hole blocking material. However, such plugging materials tend to have wear resistance or hardness that does not match the ceramic honeycomb matrix. The mismatch in wear resistance or hardness means that the plugging material and the honeycomb ceramic behave differently under the same wear conditions. If the plugging material has poor wear resistance, it wears away in a short period of time, resulting in exposure and susceptibility to damage to the honeycomb ceramic. In contrast, if the wear resistance of the pore blocking material is too strong, the pore blocking material can exert stress on the compartment in the end face grinding process, and the compartment is easy to crack or fall off. In addition, the honeycomb ceramic silicon carbide unit strips contain more pore-forming materials, so that the wear resistance and the hardness of the honeycomb ceramic silicon carbide unit strips are reduced after sintering. In the related art, a pore-forming agent is added into a pore-blocking material to reduce the wear resistance and hardness of the pore-blocking material as well, so that the wear resistance and hardness of the pore-blocking material are matched, but the addition of the pore-forming material in the pore-blocking material easily causes the conditions of exposed smoke and the like of honeycomb ceramics, particles cannot be trapped, and the rate of defective products is increased. It is therefore important to find a new method for regulating the hardness and wear resistance of pore blocking materials. Disclosure of Invention The invention aims to provide a honeycomb ceramic carrier and a preparation method and application thereof, wherein the hardness and wear resistance of a plugging material are regulated and controlled by adding metal silicon, aluminum oxide and strontium carbonate into a traditional silicon carbide plugging material so as to ensure that the bending strength of a plugging part and a ceramic unit body in the honeycomb ceramic carrier is matched, thereby avoiding the damage of the honeycomb ceramic carrier in the end face grinding process during the preparation of the honeycomb ceramic carrier, further improving the yield of the honeycomb ceramic carrier in the preparation process, ensuring that the honeycomb ceramic carrier has higher mechanical strength and thermal shock resistance, and the preparation method is simple and low in cost. In order to achieve the above purpose, the present invention provides the following technical scheme: A honeycomb ceramic carrier comprising: a plurality of silicon carbide ceramic unit bodies having a plurality of compartments partitioned by partition walls and extending in a longitudinal direction of the ceramic unit bodies, the compartments forming fluid flow paths extending from an inlet end face to an outlet end face; The hole blocking parts are arranged at the end parts of the air inlet end face and the air outlet end face of the ceramic unit body, and are made of raw materials containing silicon carbide, aluminum oxide, strontium carbonate, metal silicon and additives through sintering; The ratio of the bending strength of the ceramic unit body A shaft to the bending strength of the hole blocking portion is 1 (0.8-1.9), the bending strength of the ceramic unit body A shaft is 2.5-38.5 MPa, and the bending strength of the hole blocking portion is