WO2025140503A1 - 陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体 - Google Patents

陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体 Download PDF

Info

Publication number
WO2025140503A1
WO2025140503A1 PCT/CN2024/143045 CN2024143045W WO2025140503A1 WO 2025140503 A1 WO2025140503 A1 WO 2025140503A1 CN 2024143045 W CN2024143045 W CN 2024143045W WO 2025140503 A1 WO2025140503 A1 WO 2025140503A1
Authority
WO
WIPO (PCT)
Prior art keywords
compartment
unit body
silicon carbide
carbide powder
ceramic unit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/CN2024/143045
Other languages
English (en)
French (fr)
Inventor
舒琳翔
王晓杰
崔明山
高春晓
吕玉兴
霍希云
杨军
申亮
赵西辉
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shandong Sinocera Functional Material Co Ltd
Original Assignee
Shandong Sinocera Functional Material Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shandong Sinocera Functional Material Co Ltd filed Critical Shandong Sinocera Functional Material Co Ltd
Priority to EP24909202.4A priority Critical patent/EP4628713A4/en
Publication of WO2025140503A1 publication Critical patent/WO2025140503A1/zh
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/24491—Porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/24492—Pore diameter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/62625—Wet mixtures
    • C04B35/62635—Mixing details
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C04B38/0009—Honeycomb structures characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/063—Preparing or treating the raw materials individually or as batches
    • C04B38/0635—Compounding ingredients
    • C04B38/0645—Burnable, meltable, sublimable materials
    • C04B38/0675—Vegetable refuse; Cellulosic materials, e.g. wood chips, cork, peat, paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1021—Platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1023—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/92—Dimensions
    • B01D2255/9205—Porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2455—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the whole honeycomb or segments
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3206—Magnesium oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3208—Calcium oxide or oxide-forming salts thereof, e.g. lime
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3213—Strontium oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205—Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3215—Barium oxides or oxide-forming salts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3817—Carbides
    • C04B2235/3826—Silicon carbides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/428—Silicon
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54—Particle size related information
    • C04B2235/5463—Particle size distributions
    • C04B2235/5472—Bimodal, multi-modal or multi-fraction
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602—Making the green bodies or pre-forms by moulding
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/658—Atmosphere during thermal treatment
    • C04B2235/6583—Oxygen containing atmosphere, e.g. with changing oxygen pressures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/661—Multi-step sintering
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/661—Multi-step sintering
    • C04B2235/662—Annealing after sintering
    • C04B2235/663—Oxidative annealing
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607—Thermal properties, e.g. thermal expansion coefficient
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63416—Polyvinylalcohols [PVA]; Polyvinylacetates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/6342—Polyvinylacetals, e.g. polyvinylbutyral [PVB]
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63448—Polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63488—Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/636—Polysaccharides or derivatives thereof
    • C04B35/6365—Cellulose or derivatives thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2370/00—Selection of materials for exhaust purification
    • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/10—Carbon or carbon oxides
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/12—Hydrocarbons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/14—Nitrogen oxides

Definitions

  • the invention relates to the field of honeycomb ceramic catalysis, and in particular to a ceramic unit body, a honeycomb ceramic carrier and a preparation method thereof, and an exhaust gas catalytic core.
  • the object of the present invention is to provide a ceramic unit body, a honeycomb ceramic carrier and a preparation method thereof, and an exhaust gas catalytic core, which can be coated with a soot oxidation catalyst and a DPF oxidation catalyst at the same time to improve the conversion rate of exhaust gas and the capture efficiency of particles in the exhaust gas.
  • the present invention provides the following technical solutions:
  • a ceramic unit body wherein two ends of the ceramic unit body in the longitudinal direction are respectively an air inlet end and an air outlet end, and the ceramic unit body has a plurality of compartments separated by partition walls and extending in the longitudinal direction of the ceramic unit body;
  • the partition wall is provided with a plurality of pores connecting the first compartment and the second compartment; the average pore diameter of the pores opening on the first compartment side is Di, the average pore diameter of the pores opening on the second compartment side is Do, and Di ⁇ Do.
  • the number of openings on the first compartment side is at least two, and the aperture of at least one of the openings on the first compartment side is smaller than the aperture of the pore opening on the second compartment side;
  • the average pore size Di ⁇ [8,20] of the pores on one side of the first compartment is in micrometers, preferably, Di ⁇ [12,20], in micrometers;
  • the average pore size of the opening of the pore on one side of the second compartment is Do ⁇ [11,23], in micrometers, preferably, Do ⁇ [15,23], in micrometers.
  • the cross-sections of the first compartment and the second compartment are both square or rectangular;
  • first compartments and the second compartments are alternately arranged in a checkerboard pattern in a cross section of the ceramic unit body.
  • the thickness of the partition wall is 75 to 250 ⁇ m, preferably 125 to 200 ⁇ m;
  • the cross-sectional area of the first compartment is greater than the cross-sectional area of the second compartment, or the cross-sectional area of the first compartment is smaller than the cross-sectional area of the second compartment, or the cross-sectional area of the first compartment is equal to the cross-sectional area of the second compartment.
  • the distribution density of the pores on the partition wall i.e., the porosity, is 35-55%;
  • the cell density of the compartment in the ceramic unit body is 200-500 meshes.
  • the present invention also provides the following technical solutions:
  • a method for preparing the above ceramic unit body comprising the following steps:
  • A1 dry-mixing silicon carbide powder, silicon powder, alkaline earth metal carbonate, metal oxide powder, additives, binders and pore-forming agents to obtain a dry mix
  • step A2 wet-mixing the dry mixture obtained in step A1 with water and a lubricant to obtain a wet mixture
  • the wet mixing time is 1 to 20 minutes, and the wet mixing speed is 50 to 200 rpm;
  • step A1 based on the total amount of the silicon carbide powder being 100 wt.%, the first silicon carbide powder accounts for 70 to 95 wt.% of the total silicon carbide powder, and the second silicon carbide powder accounts for 5 to 30 wt.% of the total silicon carbide powder.
  • the alkaline earth metal carbonate is selected from at least one of magnesium carbonate, strontium carbonate, barium carbonate and calcium carbonate.
  • the pore-forming agent is selected from at least one of walnut powder, graphite, benzoic acid, starch, ammonium bicarbonate, ammonium chloride, polymethyl methacrylate, and expanded microspheres.
  • the present invention provides a wall-flow honeycomb ceramic carrier capable of simultaneously loading a DOC oxidation catalyst (i.e., a soot oxidation catalyst) and a DPF oxidation catalyst, wherein the regeneration temperature equilibrium point after loading is lower, and the capture efficiency and exhaust gas conversion rate are similar to those of a DOC+DPF exhaust gas treatment system, while saving the volume and cost of a diesel vehicle exhaust system; specifically, by controlling the pore density of the carrier and increasing the opening area on the outlet side of the carrier, the contact area between the catalyst and the reaction gas is increased, and both DOC and DPF catalysts can be coated simultaneously, wherein the exhaust gas conversion rate and particle capture efficiency are similar to those of a DOC+DPF exhaust system, saving the volume and cost of a diesel vehicle waste exhaust system.
  • a DOC oxidation catalyst i.e., a soot oxidation catalyst
  • DPF oxidation catalyst i.e., a soot oxidation catalyst
  • FIG1 is a schematic diagram of the appearance of a honeycomb ceramic carrier in which the cross-sectional area of the first compartment is larger than the cross-sectional area of the second compartment provided by the first embodiment of the present invention
  • FIG2 is a schematic structural diagram of the honeycomb ceramic carrier in FIG1 at a first viewing angle
  • FIG. 4 is a schematic structural diagram of a honeycomb ceramic carrier in which the cross-sectional area of the first compartment is equal to the cross-sectional area of the second compartment provided by the second embodiment of the present invention at a second viewing angle;
  • FIG5 is a partial enlarged schematic diagram of area B in FIG4 ;
  • FIG7 is a schematic cross-sectional view of a portion of the pores on the partition wall in FIG6 ;
  • FIG. 8 is a flowchart of a method for preparing a ceramic unit body provided in a third embodiment of the present invention.
  • FIG9 is a flowchart of a method for preparing a honeycomb ceramic substrate according to a fourth embodiment of the present invention.
  • FIG. 13 is a SEM morphology of the pores of the honeycomb ceramic carrier provided in the fifth embodiment of the present invention after partial enlargement of the aperture sampling area on one side of the first compartment;
  • any specific numerical value disclosed herein is not limited to the exact value of the numerical value, but should be understood to also cover values close to the exact value, such as all possible numerical values within the range of ⁇ 5% of the exact value.
  • the endpoint values of the range, the endpoint values and the specific point values in the range, and the specific point values can be arbitrarily combined to obtain one or more new numerical ranges, and these new numerical ranges should also be regarded as specifically disclosed herein.
  • any matters or items not mentioned are directly applicable to those known in the art without any change.
  • any embodiment described in the present disclosure can be freely combined with one or more other embodiments described in the present disclosure, and the technical solutions or technical ideas formed thereby are regarded as part of the original disclosure or original record of the present invention, and should not be regarded as new contents that have not been disclosed or anticipated in the present disclosure, unless a person skilled in the art considers that the combination is obviously unreasonable.
  • DOC recorded in the specification of the present invention refers to Diesel Oxidation Catalyst; DPF refers to Diesel Particulate Filter.
  • soot particles described in the specification of the present invention are composed of dry soot, liquid hydrocarbons and a small amount of sulfate.
  • the soot particles can be regarded as the product produced during the incomplete combustion of diesel.
  • the ceramic unit body, honeycomb ceramic carrier and exhaust gas catalytic core provided by the present invention can promote the efficiency of passive regeneration of the soot particles, where "passive regeneration” refers to "removing particulate matter in the particle trap by reducing the activation energy of the oxidation reaction of the soot particles without external energy or intervention, and only using the heat brought by the exhaust gas to complete the reaction.”
  • Di represents the average pore size of the openings of the pores on the first compartment side
  • Do represents the average pore size of the openings of the pores on the second compartment side.
  • cell density refers to the number of compartments per square inch of area, in mesh; wherein the compartments include both the first compartment and the second compartment.
  • the above-mentioned tail gas catalyst core can be used for catalytic purification of tail gas or waste gas, and more specifically, can be used for waste gas or tail gas generated by incomplete combustion of diesel.
  • the compartment density of the compartment in the cross section of the ceramic unit body is 200 to 500 meshes. It is worth noting that the compartment density of the ceramic unit body is set within this range. On the one hand, it can reduce the air pressure difference between the air inlet side 01 and the air outlet side 02 of the ceramic unit body. It can be understood that the smaller the air pressure difference, the more conducive to the circulation of gas and the purification reaction; on the other hand, the appropriate compartment density can ensure that the ceramic unit body has sufficient rigidity to avoid deformation, brittle fracture and other problems during service. In addition, under certain conditions, a larger compartment density can increase the coating area of the catalyst to facilitate the full promotion of the reaction.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 300 mesh mold with a wall thickness of 3mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.02MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained by sequentially performing steps such as splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.946mm2
  • the cross-sectional area of the second compartment is 1.177mm2 .
  • silicon carbide powder of which the first silicon carbide powder accounts for 88.5wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 11.5wt.% of the total silicon carbide powder, 20% of metal silicon powder, 1% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 1% of auxiliary agent, 9% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5 minutes and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60 minutes; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 300 mesh mold with a wall thickness of 6mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.946mm2
  • the cross-sectional area of the second compartment is 1.177mm2 .
  • 59wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 88wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 12wt.% of the total silicon carbide powder, 20% of metal silicon powder, 1% of alkaline earth metal carbonate, 1% of metal oxide powder, 1% of additives, 7% of binder, and 3% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 300 mesh mold with a wall thickness of 8mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.946mm2
  • the cross-sectional area of the second compartment is 1.177mm2 .
  • 61wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 86wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 14wt.% of the total silicon carbide powder, 20% of metal silicon powder, 1.5% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 0.5% of additives, 6.5% of binder, and 3% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 7% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 400 mesh mold with a wall thickness of 3mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.04MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.550mm2
  • the cross-sectional area of the second compartment is 0.912mm2 .
  • the second silicon carbide powder accounts for 8.3wt.% of the total silicon carbide powder
  • 18% of metal silicon powder 2% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 1.5% of additives, 7% of binder, and 3% of pore-forming agent
  • a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm.
  • 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 400 mesh mold with a wall thickness of 6mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.550mm2
  • the cross-sectional area of the second compartment is 0.912mm2 .
  • 63wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 90wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 10wt.% of the total silicon carbide powder, 19% of metal silicon powder, 1% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 0.5% of additives, 6% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 6% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 400 mesh mold with a wall thickness of 8mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.550mm2
  • the cross-sectional area of the second compartment is 0.912mm2 .
  • the second silicon carbide powder accounts for 25wt.% of the total silicon carbide powder, 16% of metal silicon powder, 2% of alkaline earth metal carbonate, 1% of metal oxide powder, 1.5% of additives, 7.5% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 500 mesh mold with a wall thickness of 3mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained by sequentially performing steps such as splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.188mm2
  • the cross-sectional area of the second compartment is 0.716mm2 .
  • 61wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 84wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 16wt.% of the total silicon carbide powder, 17% of metal silicon powder, 1.5% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 1% of additive, 7% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 500 mesh mold with a wall thickness of 6mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.05MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained by sequentially performing steps such as splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.188mm2
  • the cross-sectional area of the second compartment is 0.716mm2 .
  • 61wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 75wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 25wt.% of the total silicon carbide powder, 15% of metal silicon powder, 2% of alkaline earth metal carbonate, 1% of metal oxide powder, 1% of auxiliary agent, 8% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 8% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 500 mesh mold with a wall thickness of 8mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.05MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained by sequentially performing steps such as splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.188mm2
  • the cross-sectional area of the second compartment is 0.716mm2 .
  • 58wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 86wt.% of the total silicon carbide powder, the second silicon carbide powder accounts for 14wt.% of the total silicon carbide powder, 16% of metal silicon powder, 2% of alkaline earth metal carbonate, 0.5% of metal oxide powder, 1% of auxiliary agent, 9% of binder, and 4% of pore-forming agent are added to a plow mixer for dry mixing for 15 minutes, with a rotation speed of 95rpm. After the dry mixing, 9.5% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the obtained raw material mixture is added to a double-shaft kneading machine for kneading for 60min; after the kneaded mud is kneaded, it is put into an extruder and extruded into a unit body using a 300 mesh mold with a wall thickness of 6mil. Then, microwave drying, pore plugging, degreasing, oxygen-free sintering, and oxidation sintering are performed. During the oxidation sintering process, the outlet of the unit body is negatively pressured to allow air to pass through the inlet side of the unit body, the porous partition wall, and the outlet side in sequence. The negative pressure at the outlet is -0.03MPa.
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.946mm2
  • the cross-sectional area of the second compartment is 1.177mm2 .
  • the silicon carbide honeycomb ceramic carrier that can be coated with an oxidation catalyst is obtained through the steps of splicing, grinding, and skin grafting.
  • the cross-sectional area of the first compartment of the honeycomb ceramic unit body provided in this embodiment is 1.550mm2
  • the cross-sectional area of the second compartment is 0.912mm2 .
  • 57wt.% of silicon carbide powder of which the first silicon carbide powder accounts for 84wt.% of the total silicon carbide powder
  • the second silicon carbide powder accounts for 16wt.% of the total silicon carbide powder
  • 17% of metal silicon powder 2% of alkaline earth metal carbonate
  • 1% of metal oxide powder 1% of additive
  • 9% of binder 4% of pore-forming agent
  • a plow mixer for dry mixing for 15min, with a rotation speed of 95rpm.
  • 9% of lubricant and 35% of water by mass fraction of the raw materials are added for wet mixing, with a wet mixing time of 5min and a rotation speed of 95rpm.
  • the porosity of the honeycomb ceramic carrier obtained in the above-mentioned embodiments and comparative examples was obtained by drainage method.
  • the pore volume was tested by mercury intrusion method, which was measured by using a mercury intrusion instrument (MicroActive AutoPore V 9600 Version 2.03.00) of Micromeritics Corporation of the United States, by making a sample block with a length, width and height of 10mm*10mm*15mm.
  • the test method was the national standard: GB/T21650.1-2008, and the results are shown in Table 2 below.
  • the surface to be tested is placed in a scanning electron microscope (model: JS/YQ SEM-101) for scanning, the magnification is 400 times, 5 to 8 samples are randomly sampled, and a 500 ⁇ m*500 ⁇ m area is taken from each sample; (2) The pore size of the 1st to Nth (N is 5 to 8) regions is measured, and the average pore size Dn (n is 1 to N) of each region is calculated; (3) The average value D of D1 to Dn is calculated, and the standard deviation ⁇ of the above group of average value data is calculated as follows: sqrt((( D1 -D) 2+ ( D2 -D) 2 + whil+( Dn -D) 2 )/N), where n is 1 to N; (4) when the standard deviation ⁇ is less than 1.5 ⁇ m, the average value is valid, that is, D is the average pore size on one side of the partition wall; the average pore sizes on the inlet and outlet sides are obtained, and the results are shown in Table 2 below.
  • the thermal conductivity testing method of the honeycomb ceramic carriers obtained in the above embodiments and comparative examples is as follows: The thermal conductivity of the honeycomb ceramic carriers of the above invention is tested using an LFA 467 laser thermal conductivity meter at a temperature range of 25 to 500°C and a heating range of 50K/min and is listed in the following Table 2.
  • the “average pore size Di at the air inlet end” in Table 2 refers to the “average pore size of the opening of the pore on the air inlet side”
  • the “average pore size Do at the air outlet end” in Table 2 refers to the “average pore size of the opening of the pore on the air outlet side”
  • the “aperture difference between the air outlet end and the air inlet end” in Table 2 refers to the “difference between the average pore size of the opening of the pore on the air inlet side and the average pore size of the opening of the pore on the air outlet side”.
  • the carriers prepared in Examples 1 to 19 were coated with catalysts and subjected to back pressure amplification tests.
  • the PN23 test method for the carriers coated with DOC and DPF catalysts was as follows: the World Harmonized Transient Cycle (WHTC) was used to measure PN>23nm. The test results are shown in Table 3.
  • WHTC World Harmonized Transient Cycle
  • the DOC oxidation catalyst is coated inside the filter wall of the particle filter from the gas outlet end.
  • the precious metals in the catalyst inside the filter wall include Pt and Pd.
  • the mass ratio of Pt to Pd is 5:1-0:1, and the concentration of the precious metals is 10g/ft 3 -20g/ft 3 .
  • the mesh number of Comparative Example 1 is relatively high, and its NOx and HC conversion rates are similar to those of the embodiment, but its high mesh number greatly increases the amount of catalyst coating, which is not conducive to cost saving.
  • Comparative Examples 2 and 3 do not use negative pressure to extract air from the outlet side of the unit body, and the oxidation effect is not significant, so that the inlet side pore diameter is the same, and the oxidation sintering is less, and the pore diameter is larger.
  • the PN value measured after the WHTC cycle is higher, and the NOx and HC conversion rates are slightly lower.
  • the reduction in mesh number in Example 16 leads to an increase in the active regeneration conversion temperature and the regeneration equilibrium temperature point, which is not conducive to energy consumption.
  • Example 17 Compared with Example 1, Example 17 has a thicker wall thickness, which is not conducive to reducing the back pressure, and the thicker wall thickness will make its heat conduction slower, thereby increasing its active regeneration conversion temperature and regeneration equilibrium temperature point; the low porosity of Example 18 will also lead to a higher back pressure; the high porosity of Example 19 makes the structure of the honeycomb ceramic unstable and the compressive strength low. At the same time, the increased porosity reduces the thermal conductivity of the honeycomb ceramic carrier, thereby increasing the active regeneration conversion temperature and regeneration equilibrium temperature point after the carrier is coated with a catalyst.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Combustion & Propulsion (AREA)
  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • General Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Geometry (AREA)
  • Biomedical Technology (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Toxicology (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Filtering Materials (AREA)

Abstract

一种陶瓷单元体，陶瓷单元体两端分别为进气端（01）和出气端（02），且陶瓷单元体具有多个由隔壁相隔断的、沿陶瓷单元体的纵向延伸的隔室；隔室包括在陶瓷单元体中的横截面内交替布置的第一隔室（11）和第二隔室（12），第一隔室（11）在进气端（01）的一侧开放、在出气端（02）的一侧封堵，第二隔室（12）在进气端（01）的一侧封堵、在出气端（02）的一侧开放；其中，隔壁上设有多个将第一隔室（11）和第二隔室（12）相连通的气孔；气孔在第一隔室（11）一侧开口的平均孔径为Di，气孔在第二隔室（12）一侧开口的平均孔径为Do，且Di小于Do。该陶瓷单元体可提高废气净化效率。还提供了一种具备该陶瓷单元体的蜂窝陶瓷载体及其制备方法、一种具备该陶瓷单元体的尾气催化芯体。

Description

陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体 技术领域
本发明涉及蜂窝陶瓷催化领域，具体涉及一种陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体。
背景技术
柴油车尾气排放污染物主要包括一氧化碳(CO)、碳氢化合物(HC)、氮氧化物(NOx)和颗粒物(又称PM，由干碳烟、液态烃类和少量硫酸盐组成)等。通常，在废气净化装置中，在排放废气的排气管线上设置有依次安装的碳烟氧化催化剂(DOC)、柴油碳烟过滤器(DPF)、还原剂喷射器和选择性催化还原(SCR)装置。发动机产生的废气依次应用于碳烟氧化催化剂、柴油烟灰过滤器和选择性催化还原装置。废气中所含的有害物质被去除。DOC将废气中所含的一氧化碳和碳氢化合物氧化成二氧化碳，过滤器收集废气中含有的颗粒物(PM)，并选择性催化还原。该装置使用从还原剂喷射器喷射的还原剂或氮组来吸附废气中所含的氮氧化物。柴油颗粒过滤器(DPF)一般涂覆有催化剂，其具有氧化积聚的碳烟(soot)以及氧化一氧化碳和烃的功能。如果催化剂在过滤器中的负载水平足够高，可以将位于上游的碳烟氧化催化剂的功能集成进DPF中。
因此，如何提高废气的转化率以及对于废弃中的颗粒的捕集效率，亟待解决。
发明内容
本发明的目的在于提供一种陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体，可同时涂敷碳烟氧化催化剂和DPF氧化催化剂，以提高对于废气的转化率以及对于废气中的颗粒的捕集效率。
为达上述目的，本发明提供如下技术方案：
一种陶瓷单元体，所述陶瓷单元体的纵向上的两端分别为进气端和出气端，且所述陶瓷单元体具有多个由隔壁相隔断的、沿所述陶瓷单元体的纵向延伸的隔室；
所述隔室包括在所述陶瓷单元体中的横截面内交替布置的第一隔室和第二隔室，所述第一隔室在所述进气端的一侧开放、在所述出气端的一侧封堵，所述第二隔室在所述进气端的一侧封堵、在所述出气端的一侧开放；
其中，所述隔壁上设有多个将所述第一隔室和第二隔室相连通的气孔；所述气孔在所述第一隔室一侧开口的平均孔径为Di，所述气孔在第二隔室一侧开口的平均孔径为Do，且Di<Do。
本发明的一些实施例中，在至少一个所述气孔中，其在所述第一隔室一侧开口的数量为至少两个，所述在第一隔室一侧开口中的至少一个的孔径均小于该气孔在所述第二隔室一侧开口的孔径；
和/或，在至少一个所述气孔中，其在所述第二隔室一侧的开口的数量为至少两个，所述在第二隔室一侧的开口中的至少一个的孔径均大于该气孔在所述第一隔室一侧的开口的孔径。
本发明的一些实施例中，所述气孔在所述第一隔室一侧的平均孔径Di∈[8,20]，单位为微米，优选的，Di∈[12,20]，单位为微米；
和/或，所述气孔在所述第二隔室一侧的开口的平均孔径Do∈[11,23]，单位为微米，优选的，Do∈[15,23]，单位为微米。
本发明的一些实施例中，所述第一隔室和第二隔室的横截面的形状均为正方形或矩形；
和/或，所以第一隔室和第二隔室在所述陶瓷单元体的横截面内呈棋盘格形式交替布置。
本发明的一些实施例中，所述隔壁的厚度为75～250μm，优选为125～200μm；
和/或，所述第一隔室的横截面积大于所述第二隔室的横截面积，或者是所述第一隔室的横截面积小于所述第二隔室的横截面积，或者是所述第一隔室的横截面积等于所述第二隔室的横截面积。
本发明的一些实施例中，所述气孔在所述隔壁上的分布密度，即孔隙率为35～55％；
和/或，所述隔室在所述陶瓷单元体的孔道密度为200～500目。
为达上述目的，本发明还提供以下技术方案：
一种制备上述陶瓷单元体的方法，所述方法包括以下步骤：
A1，将碳化硅粉末、硅粉末、碱土金属碳酸盐、金属氧化物粉末、助剂、粘结剂和造孔剂干混，得到干混料；
A2，将所述步骤A1所得干混料与水、润滑剂湿混，得到湿混料；
A3，将所述步骤A2所得湿混料捏合、练泥、挤出成型、干燥、堵孔、脱脂、烧结，得到所述陶瓷单元体；
其中，所述步骤A3中的烧结包括依次进行的无氧烧结和氧化烧结，所述氧化烧结的过程为：让已完成无氧烧结的坯体的进气端暴露于空气，对坯体的出气端进行负压抽提，使空气从坯体的进气端依次经由第一隔室、气孔、第二隔室进而从所述出气端离开所述坯体，以形成所述气孔，使得所述气孔在所述第二隔室一侧的开口的平均孔径Do大于在所述第一隔室一侧的开口的平均孔径Di；
优选的，采用犁刀高速混合机进行所述干混，干混时长为10～30min，干混转速为50～200rpm；
优选的，湿混时长为1～20min，湿混转速为50～200rpm；
优选的，采用双轴捏合机进行捏合，捏合时长为30～180min。
本发明的一些实施例中，所述步骤A1中，所述负压抽提采用的负压压力大小为(-0.05)～(-0.02)MPa。
本发明的一些实施例中，所述步骤A1中，所述碳化硅粉末包括平均粒径为20～30μm的第一碳化硅粉末和平均粒径为3～8μm的第二碳化硅粉末。
本发明的一些实施例中，所述步骤A1中，以所述碳化硅粉末的总量为100wt.％计，所述第一碳化硅粉末在总的所述碳化硅粉末中的占比为70～95wt.％，所述第二碳化硅粉末在总的所述碳化硅粉末中的占比为5～30wt.％。
本发明的一些实施例中，所述步骤A1中，以总原料的质量为100wt.％计，所述碳化硅粉末的占比为50～75wt.％、优选50～65wt.％，所述硅粉末的占比为15～25wt.％、优选15～20wt.％，所述碱土金属碳酸盐的占比为1～2wt.％、所述金属氧化物粉末的占比为0.2～1wt.％、所述助剂的占比为0.5～1.5wt.％、所述粘结剂的占比为6～15wt.％，所述造孔剂的占比为3～18wt.％，所述润滑剂的占比为5～11wt.％。
本发明的一些实施例中，所述硅粉末的平均粒径为3～10μm，所述碱土金属碳酸盐的平均粒径为2～6μm，所述金属氧化物的平均粒径为3～8μm，所述造孔剂的平均粒径为8～40μm。
本发明的一些实施例中，所述碱土金属碳酸盐选自碳酸镁、碳酸锶、碳酸钡、碳酸钙中的至少一种。
本发明的一些实施例中，所述金属氧化物为氧化铝。
本发明的一些实施例中，所述助剂选自膨润土、高岭土中的至少一种。
本发明的一些实施例中，所述粘结剂选自有机醇类、月桂酸钾、改性纤维素、聚氧化乙烯、聚乙烯吡咯烷酮中的至少一种。
本发明的一些实施例中，所述造孔剂选自核桃粉、石墨、苯甲酸、淀粉、碳酸氢铵、氯化铵、聚甲基丙烯酸甲酯、膨胀微球中的至少一种。
本发明的一些实施例中，所述润滑剂为甘油。
为达上述目的，本发明还提供以下技术方案：
一种蜂窝陶瓷载体，所述蜂窝陶瓷载体由上述的陶瓷单元体或者由上述的方法制得的陶瓷单元体构成，各所述陶瓷单元体在所述蜂窝陶瓷载体的横截面内分布且相接，且所述陶瓷单元体的纵向与所述蜂窝陶瓷载体的纵向相同。
本发明的一些实施例中，所述蜂窝陶瓷载体的热导率为5～30W/m·K，优选为10～30W/m·K，更优选为13～25W/m·K。
本发明的一些实施例中，所述蜂窝陶瓷载体为圆柱体或多棱柱。
为达上述目的，本发明还提供以下技术方案：
一种用于制备上述的蜂窝陶瓷载体的方法，其特征在于，所述方法包括以下步骤：
B1，提供上述的陶瓷单元体，或者提供由上述的方法制得的陶瓷单元体；
B2，将所述陶瓷单元体依次经过拼接、磨皮、植皮处理后，得到所述的蜂窝陶瓷载体。
为达上述目的，本发明还提供以下技术方案：
一种尾气催化芯体，所述尾气催化芯体包括：
上述的蜂窝陶瓷载体或者由上述的方法制得的蜂窝陶瓷载体；
第一催化剂，施加于所述蜂窝陶瓷载体的第一隔室的内壁面；
第二催化剂，施加于所述蜂窝陶瓷载体的第二隔室的内壁面。
本发明的一些实施例中，所述尾气催化芯体用于催化含有烟碳颗粒的尾气，所述第一催化剂用于促进所述烟碳颗粒的氧化，所述第二催化剂用于催化一氧化碳、碳氢化物和氮氧化物的转化。
其它适用领域由本公开中提供的描述将变得显而易见。
发明内容中的描述和具体例子仅意在进行说明而无意限制本公开的范围。
与现有技术相比，本发明提供的技术方案获得了以下有益效果：
本发明提供了一种能够同时负载DOC氧化催化剂(即碳烟氧化催化剂)与DPF氧化催化剂的壁流式蜂窝陶瓷载体，其负载后的再生温度平衡点更低，捕集效率、废气转化率与DOC+DPF废气处理系统相近，同时节约柴油车排放系统的体积与成本；具体的，通过控制载体的孔道密度，提高载体出口侧的开孔面积，增加了催化剂和反应气体的接触面积，可以同时涂覆DOC和DPF两种催化剂，其废气的转化率、颗粒的捕集效率与DOC+DPF的排气系统相近，节省柴油车废弃排气系统体积与成本。
附图说明
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施方案，对于本领域技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明第一实施方式提供的第一隔室横截面积大于第二隔室横截面积的蜂窝陶瓷载体的外观示意图；
图2为图1中的蜂窝陶瓷载体在第一观察视角下的结构示意图；
图3为图2中A区域的局部放大示意图；
图4为本发明第二实施方式提供的第一隔室横截面积与第二隔室横截面积相等的蜂窝陶瓷载体在第二观察视角下的结构示意图；
图5为图4中B区域的局部放大示意图；
图6为图1中的蜂窝陶瓷载体沿其纵长方向剖开的剖面结构示意图；
图7为图6中部分隔壁上气孔的剖面示意图；
图8为本发明第三实施方式提供的陶瓷单元体的制备方法的流程框图；
图9为本发明第四实施方式提供的蜂窝陶瓷载体的制备方法的流程框图；
图10为本发明第五实施方式提供的蜂窝陶瓷载体的气孔在第一隔室一侧的孔径采样区域的SEM形貌图；
图11为本发明第五实施方式提供的蜂窝陶瓷载体的气孔在第二隔室一侧的孔径采样区域的SEM形貌图；
图12为本发明第五实施方式提供的蜂窝陶瓷载体的气孔在第一隔室一侧的孔径采样区域局部放大后的SEM形貌图；
图13为本发明第五实施方式提供的蜂窝陶瓷载体的气孔在第一隔室一侧的孔径采样区域局部放大后的SEM形貌图；
图14为本发明第五实施方式提供的蜂窝陶瓷载体的隔壁的SEM形貌图。
本发明说明书附图中的主要附图标记说明如下：
01-进气侧；02-出气侧；11-第一隔室；12-第二隔室。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整的描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。应当理解的是，此处所描述的具体实施方式仅用于说明和解释本发明，并不用于限制本发明。
在本文中所披露的任何具体数值(包括数值范围的端点)都不限于该数值的精确值，而应当理解为还涵盖了接近该精确值的值，例如在该精确值±5％范围内的所有可能的数值。并且，对于所披露的数值范围而言，在该范围的端点值之间、端点值与范围内的具体点值之间，以及各具体点值之间可以任意组合而得到一个或多个新的数值范围，这些新的数值范围也应被视为在本文中具体公开。
本公开所用的术语仅为了描述特定的示例性实施方案而无意作为限制。除非上下文清楚地另行指明，否则如本公开中所用的那样单数形式“一个”、“一种”和“该”可旨在也包括复数形式。术语“包含”、“包括”、“含有”和“具有”是包容性的，因此说明了所述特征、要素、组合物、步骤、整数、操作和/或组分的存在，但不排除一种或更多种其它特征、整数、步骤、操作、元件、组分和/或其集合的存在或加入。尽管开放式术语"包括"应被理解为用于描述和要求保护本公开中所述的各种实施方案的非限制性术语，但在某些方面中，该术语相反地可替代地理解为更具限制性和局限性的术语，如“由……组成”或“基本由……组成”。由此，对叙述组合物、材料、组分、要素、特征、整数、操作和/或工艺步骤的任意给定实施方案，本公开还特别包括由或基本由此类所述组合物、材料、组分、要素、特征、整数、操作和/或工艺步骤组成的实施方案。在“由……组成”的情况下，替代实施方案排除任何附加的组合物、材料、组分、要素、特征、整数、操作和/或工艺步骤，而在“基本由……组成”的情况下，从此类实施方案中排除实质上影响基本和新颖特性的任何附加的组合物、材料、组分、要素、特征、整数、操作和/或工艺步骤，但是不实质上影响基本和新颖特性的任何组合物、材料、组分、要素、特征、整数、操作和/或工艺步骤可以包括在该实施方案中。
本公开中描述的任何方法步骤、工艺和操作不应解释为必定要求它们以所论述或展示的特定次序实施，除非明确确定为一定的实施次序。还要理解的是，除非另行说明，可以使用附加或替代步骤。
本发明中，除了明确说明的内容之外，未提到的任何事宜或事项均直接适用本领域已知的那些而无需进行任何改变。而且，本公开描述的任何实施方式均可以与本公开描述的一种或多种其他实施方式自由结合，由此形成的技术方案或技术思想均视为本发明原始公开或原始记载的一部分，而不应被视为是本公开未曾披露或预期过的新内容，除非本领域技术人员认为该结合明显不合理。
除非另有说明，本文所用的术语具有与本领域技术人员通常所理解的相同的含义，如果术语在本文中有定义，且其定义与本领域的通常理解不同，则以本文的定义为准。
除非另有说明，本文中提到％时，是指wt.％。
值得说明的是，本发明说明书中记载的DOC指的是Diesel Oxidation Catalyst，即柴油氧化催化剂；DPF指的是Diesel Particulate Filter，即柴油颗粒过滤器。
值得说明的是，本发明说明书中记载的碳烟颗粒，又称PM，由干碳烟、液态烃类和少量硫酸盐组成，碳烟颗粒可以视为柴油在不充分燃烧过程中产生的产物，本发明提供的陶瓷单元体、蜂窝陶瓷载体以及尾气催化芯体可以促进该碳烟颗粒的被动再生的效率，其中“被动再生”指的是“指利用降低碳烟颗粒氧化反应的活化能来实现颗粒捕捉器内颗粒物的去除，而无需外部提供能量或干预，仅使用尾气带来的热量即可完成反应。”
在本公开上下文中，Di表示气孔在第一隔室一侧的开口的平均孔径，Do表示气孔在第二隔室一侧的开口的平均孔径。
在本公开上下文中，孔道密度是指每平方英寸面积内隔室的数目，单位为目；其中所述隔室包括第一隔室和第二隔室两者。
值得说明的是，本发明的一些实施例中，上述的尾气催化芯体可以用于尾气或废气的净化催化处理，更具体的，可以是用于对于柴油经过不完全燃烧产生的废气或尾气。
第一方面
参见图1至图7，一种陶瓷单元体，参见图6，所述陶瓷单元体的纵向上的两端分别为进气端01和出气端02，且所述陶瓷单元体具有多个由隔壁相隔断的、沿所述陶瓷单元体的纵向延伸的隔室；参见图2至图5，所述隔室包括在所述陶瓷单元体的横截面内交替布置的第一隔室11和第二隔室12；参见图6和图7，所述第一隔室11在所述进气端01的一侧开放、在所述出气端02的一侧封堵，所述第二隔室12在所述进气端01的一侧封堵、在所述出气端02的一侧开放；其中，参见图7，所述气孔在所述第一隔室11一侧开口的平均孔径为Di，所述气孔在所述第二隔室12一侧开口的平均孔径为Do，且Di<Do。
值得说明的是，因本发明还提供了一种由多个上述陶瓷单元体构成的蜂窝陶瓷载体，因此本发明说明书在介绍上述陶瓷单元体的构造时，可以参考上述蜂窝陶瓷载体的结构示意图。
具体的，本发明提供的这种陶瓷单元体，在其内部的两种隔室之间的隔壁具有独特的构造设计：参见图6和图7，气孔在所述第一隔室11一侧开口的平均孔径Di小于所述气孔在所述第二隔室12一侧的开口的平均孔径Do，换言之隔壁上每个气孔几乎呈现出锥形结构，即各个气孔的孔径均具有“孔径沿着气流行进方向而逐渐增大”的趋势；其中，小孔径的进气通口可以将未燃烧氧化反应完全的碳烟颗粒阻挡在锥形气孔之外，使得该些碳烟颗粒暂时先停留于第一隔室11内，本发明的一些实施例中的第一隔室11内涂敷有可催化该些碳烟颗粒能够充分氧化反应完全的催化剂，当该些碳烟颗粒在第一隔室11受催化剂催化而充分氧化反应完全之后，可在气流的携带下进入锥形气孔并到达第二隔室12；此外，锥形气孔的大孔径出气通口一方面可以避免气流携带的颗粒残留于气孔内部造成堵塞，另一方面可允许涂敷于第二隔室12内的催化剂能够有一部分也被涂敷于该锥形气孔的出气通口的周围，即增大了用于涂敷于第二隔室12内的催化剂的涂敷面积，可以理解的是，催化剂涂敷面积越大则有利于充分促进反应的进行。
本发明的一些实施例中，在至少一个所述气孔中，其在所述第一隔室11一侧的开口的数量为至少两个，所述在第一隔室11一侧的开口中的至少一个的孔径均小于该气孔与所述第二隔室12一侧的开口的孔径。具体的，参见图7中左侧的气孔，其具有两个在第一隔室11一侧的进气开口以及一个在第二隔室12一侧的出气开口，即，来自第一隔室11的气体经由该两个进气开口进入该气孔内部并且最终经由该气孔的唯一出气开口进入到第二隔室12中。
本发明的一些实施例中，在至少一个所述气孔中，其在所述第二隔室12一侧的开口的数量为至少两个，所述在第二隔室12一侧的开口中的至少一个的孔径均大于该气孔在所述第一隔室11一侧的开口的孔径。具体的，参见图7中右侧的气孔，其仅具有一个在第一隔室11一侧的进气开口但具有两个在第二隔室12一侧的出气开口，即，来自第一隔室11的气体经由该唯一进气开口进而该气孔内部并且最终经由该气孔的两个出气开口进入到第二隔室12中。
本发明的一些实施例中，所述气孔在所述第一隔室11一侧开口的平均孔径Di∈[8,20]，单位为微米，优选的，Di∈[12,20]，单位为微米。可以理解的是，关于Di的尺寸范围选取，最好是能够将柴油不充分燃烧而生成的碳烟颗粒隔绝于气孔之外，如此，在本发明的一些实施例中，当第一隔室11内涂敷了可促进上述碳烟颗粒充分氧化燃烧的催化剂，满足上述Di尺寸设计原则的气孔就可以将碳烟颗粒暂时先隔绝于第一隔室11内，待碳烟颗粒充分然后之后再在气流携带下穿过气孔到达第二隔室12。
本发明的一些实施例中，所述气孔在所述第二隔室12一侧开口的平均孔径Do∈[11,23]，单位为微米，优选的，Do∈[15,23]，单位为微米。值得说明的是，锥形气孔的较大孔径构造，可在后续给第二隔室12涂敷催化剂时，增大该催化剂的涂敷面积，而催化剂涂敷面积越大越利于反应的催化进行。
本发明的一些实施例中，所述第一隔室11和第二隔室12的横截面的形状均为正方形或矩形。可以理解的是，具有正方形横截面形状或者矩形横截面形状的一个第一隔室11，其四面都是与之相邻的第二隔室12，如此便可令进入第一隔室11的气体在离开之后即可直接进入第二隔室12中，提升了陶瓷单元体的构造紧凑度，减少空间以及材料的浪费。
本发明的一些实施例中，所以第一隔室11和第二隔室12在所述陶瓷单元体的横截面内呈棋盘格形式交替布置；该设计构思可以提升陶瓷单元体的构造紧凑度，能减少空间以及材料的浪费。
本发明的一些实施例中，所述隔壁的厚度为3～10mil(约75～250μm)，优选为5～8mil(约125～200μm)。值得说明的是，陶瓷单元体的隔壁厚度设置在该范围内，一方面可以减少陶瓷单元体的进气侧01与出气侧02之间的气压差，可以理解的是，该气压差越小越利于气体的流通以及净化反应的进行，壁厚越大则气孔的深度越大进而气流在气孔内流动路径更长最终会导致陶瓷单元体进气侧01和出气侧02之间的气压差变大；另一方面，适当的壁厚可以保证陶瓷单元体具有足够的刚度，避免服役过程中发生变形、脆断等问题。
本发明的一些实施例中，所述陶瓷单元体的孔隙率为35～55％，优选35～45％。孔隙率为孔隙的体积与材料总体积的比率。值得说明的是，陶瓷单元体的孔隙率设置在该范围内，一方面可以减少陶瓷单元体的进气侧01与出气侧02之间的气压差，可以理解的是，该气压差越小越利于气体的流通以及净化反应的进行；另一方面，适当的孔隙率可以保证陶瓷单元体具有足够的刚度，避免服役过程中发生变形、脆断等问题。
本发明的一些实施例中，所述气孔在所述隔壁上的分布密度，也称为孔隙率为35～55％。该“分布密度”指的是气孔的横截面面积与隔壁的面积之比。值得说明的是，陶瓷单元体的气孔的分布密度设置在该范围内，一方面可以减少陶瓷单元体的进气侧01与出气侧02之间的气压差，可以理解的是，该气压差越小越利于气体的流通以及净化反应的进行；另一方面，适当的气孔分布密度可以保证陶瓷单元体具有足够的刚度，避免服役过程中发生变形、脆断等问题。
本发明的一些实施例中，所述隔室在所述陶瓷单元体的横截面的隔室密度，也就是孔道密度为200～500目。值得说明的是，陶瓷单元体的隔室密度设定在该范围内，一方面可以减少陶瓷单元体的进气侧01与出气侧02之间的气压差，可以理解的是，该气压差越小越利于气体的流通以及净化反应的进行；另一方面，适当的隔室密度可以保证陶瓷单元体具有足够的刚度，避免服役过程中发生变形、脆断等问题。此外，一定条件下，隔室密度较大则可以增大催化剂的涂敷面积，以利于充分促进反应进行。
本发明的一些实施例中，所述第一隔室的横截面积大于所述第二隔室的横截面积。值得说明的是，较大的第一隔室可充分降低过滤器捕集烟碳颗粒后的蜂窝陶瓷背压，减少能耗，同时第一隔室涂覆的氧化催化剂含量更高，可有效转化捕集的烟碳颗粒，在较低温度下被动再生转化烟碳颗粒更多，减少过滤器的主动再生。
本发明的一些实施例中，所述第一隔室的横截面积小于所述第二隔室的横截面积。
本发明的一些实施例中，所述第一隔室的横截面积等于所述第二隔室的横截面积。
第二方面
参见图8，一种制备上述陶瓷单元体的方法，包括以下步骤：A1，将碳化硅粉末、硅粉末、碱土金属碳酸盐、金属氧化物粉末、助剂、粘结剂和造孔剂干混；A2，将所述步骤A1所得干混料与水、润滑剂湿混；A3，将所述步骤A2所得湿混料捏合、练泥、挤出成型、干燥、堵孔、脱脂、烧结，得到所述陶瓷单元体；其中，所述步骤A3中的烧结包括依次进行的无氧烧结和氧化烧结，所述氧化烧结的过程为：让已完成无氧烧结的坯体的进气端01暴露于空气，对坯体的出气端02进行负压抽提，使空气从坯体的进气端01依次经由第一隔室11、气孔、第二隔室12进而从所述出气端02离开所述坯体，以形成所述气孔，使得所述气孔在所述第二隔室12一侧的开口的平均孔径Do大于在所述第一隔室11一侧的开口的平均孔径Di。
可以理解的是，在制备上述的陶瓷单元体时，由于采用了“在原料中造孔剂”的方式来造孔，这使得最终得到产品中隔壁上各个气孔的形貌不一；然而，本发明通过“先无氧烧结、再氧化烧结”的方式来制备陶瓷单元体，令气孔靠近进气侧01的一端先发生氧化，使得该位置的小尺寸的硅经过氧化变成具有更大尺寸的二氧化硅，以使绝大部分的气孔都能实现“进气通口的孔径小于出气通口的孔径，进而获得具有锥形结构的气孔”的效果。
本发明的一些实施例中，采用犁刀高速混合机进行所述干混，干混时长为10～30min，干混转速为50～200rpm。
本发明的一些实施例中，湿混时长为1～20min，湿混转速为50～200rpm。
本发明的一些实施例中，采用双轴捏合机进行捏合，捏合时长为30～180min。
本发明的一些实施例中，所述步骤A1中，所述负压抽提采用的负压压力大小为(-0.05)～(-0.02)MPa。
本发明的一些实施例中，所述步骤A1中，所述碳化硅粉末包括平均粒径为20～30μm的第一碳化硅粉末和平均粒径为3～8μm的第二碳化硅粉末。
本发明的一些实施例中，所述步骤A1中，以所述碳化硅粉末的总量为100wt.％计，所述第一碳化硅粉末在总的所述碳化硅粉末中的占比为70～95wt.％，所述第二碳化硅粉末在总的所述碳化硅粉末中的占比为5～30wt.％。
本发明的一些实施例中，所述步骤A1和A2中，以总原料的质量为100wt.％计，所述碳化硅粉末的占比为50～75wt.％、优选50～65wt.％，所述硅粉末的占比为15～25wt.％、优选15～20wt.％，所述碱土金属碳酸盐的占比为1～2wt.％、所述金属氧化物粉末的占比为0.2～1wt.％、所述助剂的占比为0.5～1.5wt.％、所述粘结剂的占比为6～15wt.％，所述造孔剂的占比为3～18wt.％，所述润滑剂的占比为5～11wt.％。所述总原料的质量百分比为各原料的质量百分比总和，其中不计入水的质量。
本发明的一些实施例中，所述硅粉末的平均粒径为3～10μm，所述碱土金属碳酸盐的平均粒径为2～6μm，所述金属氧化物的平均粒径为3～8μm，所述造孔剂的平均粒径为8～40μm。
本发明的一些实施例中，所述碱土金属碳酸盐选自碳酸镁、碳酸锶、碳酸钡、碳酸钙中的至少一种。
本发明的一些实施例中，所述金属氧化物选自氧化铝、氧化钛中的至少一种。
本发明的一些实施例中，所述助剂选自膨润土、高岭土中的至少一种。
本发明的一些实施例中，所述粘结剂选自有机醇类、月桂酸钾、改性纤维素、聚氧化乙烯、聚乙烯吡咯烷酮中的至少一种。所述有机醇包括一元醇、二元醇和多元醇，优选C1-C8，更优选C1-C4的一元醇、二元醇和多元醇。所述有机醇的实例包括但不限于1,2-丙二醇、乙二醇、丁二醇、1,3-丙二醇、季戊四醇。所述改性纤维素包括但不限于羟甲基纤维素、羟乙基纤维素、羟丙基纤维素、甲基纤维素、乙基纤维素、丙基纤维素。
本发明的一些实施例中，所述造孔剂选自核桃粉、石墨、苯甲酸、淀粉、碳酸氢铵、氯化铵、聚甲基丙烯酸甲酯、膨胀微球中的至少一种。
本发明的一些实施例中，所述润滑剂为甘油。
第三方面
一种蜂窝陶瓷载体，由上述的陶瓷单元体或者由上述的方法制得的陶瓷单元体构成，各所述陶瓷单元体在所述蜂窝陶瓷载体的横截面内分布且相接，且所述陶瓷单元体的纵向与所述蜂窝陶瓷载体的纵向相同。
本发明的一些实施例中，所述蜂窝陶瓷载体的热导率为5～30W/m·K，优选为10～30W/m·K，更优选为13～25W/m·K。
本发明的一些实施例中，所述蜂窝陶瓷载体为圆柱体或多棱柱。
第四方面
参见图9，本发明提供一种用于制备上述的蜂窝陶瓷载体的方法，包括以下步骤：B1，提供上述的陶瓷单元体，或者提供由上述的方法制得的陶瓷单元体；B2，将所述陶瓷单元体依次经过拼接、磨皮、植皮处理后，得到所述的蜂窝陶瓷载体。
第五方面
本发明提供一种尾气催化芯体，包括：上述的蜂窝陶瓷载体或者由上述的方法制得的蜂窝陶瓷载体；第一催化剂，施加于所述蜂窝陶瓷载体的第一隔室11的内壁面；第二催化剂，施加于所述蜂窝陶瓷载体的第二隔室12的内壁面；参见图6和图7，所述第一隔室11在所述进气端01的一侧开放、在所述出气端02的一侧封堵，所述第二隔室12在所述进气端01的一侧封堵、在所述出气端02的一侧开放。
本发明的一些实施例中，所述尾气催化芯体用于催化含有烟碳颗粒的尾气，所述第一催化剂用于促进所述烟碳颗粒的氧化，所述第二催化剂用于催化一氧化碳、碳氢化物和氮氧化物。
本发明的一些实施例中，所述第一催化剂是DPF，即Diesel Particle Filter，即柴油颗粒过滤器；所述第二催化剂是DOC，即Diesel Oxidation Catalyst，即柴油氧化催化剂。
本发明设计了上述的陶瓷单元体、蜂窝陶瓷载体以及尾气催化芯体，其构思在于，提供一种集成DPF与DOC的功能的同时充分利用壁流式蜂窝陶瓷的孔道结构，同时负载DPF氧化催化剂与DOC氧化催化剂，有效减小后处理系统的总体积和成本的碳化硅DPF和DOC蜂窝陶瓷载体是非常重要的，其负载后的再生温度平衡点更低，捕集效率、废气转化率与DPF+DOC废气处理系统相近。同时节约柴油车排放系统的体积与成本。
本发明提供的这一种可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体，通过控制载体的孔道密度，提高载体出口侧的开孔面积，增加了催化剂和反应气体的接触面积。可以同时涂覆DPF和DOC两种催化剂，其废气的转化率、颗粒的捕集效率与DPF+DOC的排气系统相近，节省柴油车废弃排气系统体积与成本。
实施例1
在该实施例中，54.5wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为88wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为12wt.％、19％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、10％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为3mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.02MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例2
在该实施例中56.5wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为88.5wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为11.5wt.％、20％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例3
在该实施例中，59wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为88wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为12wt.％、20％的金属硅粉、1％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、7％的粘结剂、3％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为8mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例4
在该实施例中，61wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为86wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为14wt.％、20％的金属硅粉、1.5％的碱土金属碳酸盐、0.5％的金属氧化物粉末、0.5％的助剂、6.5％的粘结剂、3％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入7％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为3mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.04MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例5
在该实施例中，60wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为91.7wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为8.3wt.％、18％的金属硅粉、2％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1.5％的助剂、7％的粘结剂、3％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例6
在该实施例中，63wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为90wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为10wt.％、19％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、0.5％的助剂、6％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入6％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为8mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例7
在该实施例中，60wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为75wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为25wt.％、16％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1.5％的助剂、7.5％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用500目壁厚为3mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.188mm2，第二隔室的横截面积为0.716mm2。
实施例8
在该实施例中，61wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为84wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为16wt.％、17％的金属硅粉、1.5％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、7％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用500目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.05MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.188mm2，第二隔室的横截面积为0.716mm2。
实施例9
在该实施例中，61wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为75wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为25wt.％、15％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、8％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用500目壁厚为8mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.05MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.188mm2，第二隔室的横截面积为0.716mm2。
实施例10
在该实施例中，58wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为86wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为14wt.％、16％的金属硅粉、2％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入9.5％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例11
在该实施例中，55wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为93wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为17wt.％、15％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、0.5％的助剂、7％的粘结剂、15％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入6％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例12
在该实施例中，59wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为87wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为13wt.％、18％的金属硅粉、2％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、13.5％的粘结剂、5％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例13
在该实施例中，51wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为84wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为16wt.％、15％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、7％的粘结剂、15％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入8％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例14
在该实施例中，56wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为82wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为18wt.％、18％的金属硅粉、2％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、9％的粘结剂、3％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10.5％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用500目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.188mm2，第二隔室的横截面积为0.716mm2。
实施例15
在该实施例中，54wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为89wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为11wt.％、16％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、6.5％的粘结剂、15％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入6％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用500目壁厚为8mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.188mm2，第二隔室的横截面积为0.716mm2。
实施例16
在该实施例中，56wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为82wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为18wt.％、17％的金属硅粉、2％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、9.5％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用200目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为2.372mm2，第二隔室的横截面积为1.428mm2。
实施例17
在该实施例中，54wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为84wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为16wt.％、17％的金属硅粉、1.5％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10.5％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为12mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
实施例18
在该实施例中，58wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为83wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为17wt.％、18％的金属硅粉、1.5％的碱土金属碳酸盐、0.5％的金属氧化物粉末、1％的助剂、10％的粘结剂、2％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入9％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
实施例19
在该实施例中，50wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为90wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为10wt.％、15％的金属硅粉、1％的碱土金属碳酸盐、0.5％的金属氧化物粉末、0.5％的助剂、6％的粘结剂、20％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入7％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
对比例1
在该实施例中，57wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为86wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为14wt.％、16％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用600目壁厚为3mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，并在氧化烧结过程中，对单元体出口端负压式抽提，使空气依次经过单元体入口侧、多孔质隔壁、出口侧。其中，出口端负压为-0.03MPa。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为0.884mm2，第二隔室的横截面积为0.531mm2。
对比例2
在该实施例中，57wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为84wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为16wt.％、17％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入9％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用300目壁厚为3mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，氧化烧结无负压式抽提过程。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.946mm2，第二隔室的横截面积为1.177mm2。
对比例3
在该实施例中，57wt.％的碳化硅粉末，其中第一碳化硅粉末在总的碳化硅粉末中的占比为86wt.％，第二碳化硅粉末在总的碳化硅粉末中的占比为14wt.％、16％的金属硅粉、2％的碱土金属碳酸盐、1％的金属氧化物粉末、1％的助剂、9％的粘结剂、4％的造孔剂加入至犁刀式混料机中干混15min，旋转速度为95rpm，干混结束后加入10％的润滑剂和原料质量分数的35％的水进行湿混，湿混时间5min，旋转速度为95rpm。得到的原料混合物加入双轴捏合机中进行捏合60min；将捏合完的泥料进行练泥后，投入到挤出机后使用400目壁厚为6mil的模具挤出单元体。随后经过微波干燥、堵孔、脱脂、无氧烧结、氧化烧结，氧化烧结无负压式抽提过程。后续依次经过拼接、磨皮、植皮等步骤得到上述可涂覆氧化催化剂的碳化硅蜂窝陶瓷载体。该实施例提供的蜂窝陶瓷单元体的第一隔室的横截面积为1.550mm2，第二隔室的横截面积为0.912mm2。
上述实施例1～19以及对比例1～3的原料种类列于下表1中。
表1实施例1～19以及对比例1～3的原料种类(碳化硅粉末、硅粉末、润滑剂未列出)

上述各实施例及对比例所得蜂窝陶瓷载体的孔隙率采用排水法测试获得。孔容的测试方法为压汞法，通过将单元体制成长宽高为10mm*10mm*15mm的样块，使用美国麦克企业的压汞仪(MicroActive AutoPore V 9600 Version 2.03.00)测得。测试方法为国家标准：GB/T21650.1-2008，结果见下表2。
上述各实施例及对比例所得蜂窝陶瓷载体的气孔位于进气侧的开口的平均孔径与气孔位于出气侧的开口的平均孔径，采用以下方式获取：(1)将蜂窝陶瓷载体中隔壁制成多个1mm*1mm的样片，样片区分进口侧与出口侧，测试过程对同一侧测试，将待测面置于扫描电镜(型号：JS/YQ SEM-101)中扫描，放大倍数为400倍，随机取样5～8个样片，每个样片取一个500μm*500μm区域；(2)对第1～N(N为5～8)区域的孔径进行测量，并计算各区域的孔径的平均值Dn(n为1～N)；(3)计算D1～DN的平均值D，并计算上述一组平均值数据的标准差σ＝sqrt(((D1-D)2+(D2-D)2+......+(Dn-D)2)/N)，其中n为1～N；(4)当标准差σ低于1.5μm时，该平均值有效，即D为该隔壁一侧的平均孔径；获得进口侧与出口侧的平均孔径，结果见下表2。
上述各实施例及对比例所得蜂窝陶瓷载体的热导率测试方法：使用LFA 467激光热导仪温度区间为25～500℃，升温区间为50K/min的条件下测试出上述发明的蜂窝陶瓷载体热导率列入下表2中。
值得说明的是，表2中的“入气孔端平均孔径Di”指的是“气孔位于进气侧的开口的平均孔径”，表2中的“出气孔端平均孔径Do”指的是“气孔位于出气侧的开口的平均孔径”，表2中的“出气孔端和入气孔端孔径差值”指的是“气孔位于进气侧的开口的平均孔径与气孔位于出气侧的开口的平均孔径之间的差值”。
表2各实施例及对比例所得蜂窝陶瓷载体的性能参数


将实施例1～19所制备出的载体，进行催化剂涂覆，并对其进行背压增幅测试，对涂覆DOC和DPF催化剂的载体的PN23测试方法：采用世界统一瞬态循环(WHTC，World Harmonized Transient Cycle)测得PN＞23nm的数据，其测试结果如表3所示。
其NO、CO和HC的转化率，并测试再生平衡温度点和起燃温度。其测试结果如表3所示。
涂覆催化剂：DOC氧化催化剂和DPF氧化催化剂为含有贵金属的催化剂浆料，所述浆料涂层中含有氧化铝、和/或稀土元素构成的氧化物。
DPF氧化催化剂涂覆在进气孔道壁面上，浆料涂层中的贵金属包含Pt和Pd，Pt和Pd的质量比为1:0-5:1，贵金属的浓度为10g/ft3-20g/ft3。
DOC氧化催化剂从出气端涂覆在颗粒过滤器的过滤壁内，过滤壁内的催化剂中的贵金属包含Pt和Pd，Pt和Pd的质量比为5:1-0:1，贵金属浓度为10g/ft3-20g/ft3。
表3各实施例及对比例所得蜂窝陶瓷载体的催化性能

通过上表3可以看出：本发明实施例1-19中，其Do(出口侧隔壁孔径)-Di(入口侧隔壁孔径)满足大于3μm，也就是说本发明中过滤器满足高捕集效率，可同时负载DOC氧化催化剂和DPF氧化催化剂，且负载后对NOx、CO、HC转化率较高。
具体地，对比例1的目数较高，其NOx和HC的转化率与实施例相近，但其高目数导致催化剂的涂覆量大大提高，不利于节约成本。对比例2、3和实施例相比，因未采用负压式从单元体出口侧抽提空气，氧化效果不显著，使得其进口侧孔径相同时间氧化烧结较少，孔径较大，其经过WHTC循环测得的PN值较高，NOx和HC的转化率略低。实施例16与实施例1，目数的降低，导致了主动再生转化温度和再生平衡温度点的提升，不利于能耗。实施例17相对于实施例1，其壁厚更高，不利于降低背压，且较厚的壁厚会使其导热更慢，使其主动再生转化温度和再生平衡温度点的提升；实施例18的低孔隙率同样会导致较高的背压；实施例19的高孔隙率，使得蜂窝陶瓷的结构不稳，抗压强度较低，同时加高的孔隙率降低了蜂窝陶瓷载体的热导率，使其该载体涂覆催化剂后的主动再生转化温度和再生平衡温度点的提升。
因此，本发明对制备过程中的氧化烧结手段，和进出口直径差值进行改进而制备的过滤器，其兼具DOC氧化催化剂和DPF氧化催化剂，能够有效提高过滤效率和排放物的转化效率，降低催化剂的涂覆被压增幅，进而降低汽车能耗。
以上所述，仅为本发明的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本发明的保护范围之内。因此，本发明的保护范围应以所述权利要求的保护范围为准。此外，说明书中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实施例的说明只是用于帮助理解本发明的方法及其核心思想，本说明书内容不应理解为对本发明的限制。

Claims (19)

  1. 一种陶瓷单元体，其特征在于，所述陶瓷单元体的纵向上的两端分别为进气端(01)和出气端(02)，且所述陶瓷单元体具有多个由隔壁相隔断的、沿所述陶瓷单元体的纵向延伸的隔室；
    所述隔室包括在所述陶瓷单元体中的横截面内交替布置的第一隔室(11)和第二隔室(12)，所述第一隔室(11)在所述进气端(01)的一侧开放、在所述出气端(02)的一侧封堵，所述第二隔室(12)在所述进气端(01)的一侧封堵、在所述出气端(02)的一侧开放；
    其中，所述隔壁上设有多个将所述第一隔室和第二隔室相连通的气孔；所述气孔在所述第一隔室(11)一侧开口的平均孔径为Di，所述气孔在第二隔室(12)一侧开口的平均孔径为Do，且Di<Do。
  2. 根据权利要求1所述的陶瓷单元体，其特征在于，在至少一个所述气孔中，其在所述第一隔室(11)一侧开口的数量为至少两个，所述在第一隔室(11)一侧开口中的至少一个的孔径均小于该气孔在所述第二隔室(12)一侧开口的孔径；
    和/或，在至少一个所述气孔中，其在所述第二隔室(12)一侧的开口的数量为至少两个，所述在第二隔室(12)一侧的开口中的至少一个的孔径均大于该气孔在所述第一隔室(11)一侧的开口的孔径。
  3. 根据权利要求1或2所述的陶瓷单元体，其特征在于，所述气孔在所述第一隔室(11)一侧的平均孔径Di∈[8,20]，单位为微米，优选的，Di∈[12,20]，单位为微米；
    和/或，所述气孔在所述第二隔室(12)一侧的开口的平均孔径Do∈[11,23]，单位为微米，优选的，Do∈[15,23]，单位为微米。
  4. 根据权利要求1至3中任一项所述的陶瓷单元体，其特征在于，所述第一隔室(11)和第二隔室(12)的横截面的形状均为正方形或矩形；
    和/或，所以第一隔室(11)和第二隔室(12)在所述陶瓷单元体的横截面内呈棋盘格形式交替布置。
  5. 根据权利要求1至4中任一项所述的陶瓷单元体，其特征在于，所述隔壁的厚度为75～250μm，优选为125～200μm；
    和/或，所述第一隔室(11)的横截面积大于所述第二隔室(12)的横截面积，或者是所述第一隔室(11)的横截面积小于所述第二隔室(12)的横截面积，或者是所述第一隔室(11)的横截面积等于所述第二隔室(12)的横截面积。
  6. 根据权利要求1至5中任一项所述的陶瓷单元体，其特征在于，所述陶瓷单元体的孔隙率为35～55％；
    和/或，所述隔室在所述陶瓷单元体的孔道密度为200～500目。
  7. 一种制备如权利要求1至6中任一项所述陶瓷单元体的方法，其特征在于，所述方法包括以下步骤：
    A1，将碳化硅粉末、硅粉末、碱土金属碳酸盐、金属氧化物粉末、助剂、粘结剂和造孔剂干混，得到干混料；
    A2，将所述步骤A1所得干混料与水、润滑剂湿混，得到湿混料；
    A3，将所述步骤A2所得湿混料捏合、练泥、挤出成型、干燥、堵孔、脱脂、烧结，得到所述陶瓷单元体；
    其中，所述步骤A3中的烧结包括依次进行的无氧烧结和氧化烧结，所述氧化烧结的过程为：让已完成无氧烧结的坯体的进气端(01)暴露于空气，对坯体的出气端(02)进行负压抽提，使空气从坯体的进气端(01)依次经由第一隔室(11)、气孔、第二隔室(12)进而从所述出气端(02)离开所述坯体，以形成所述气孔，使得所述气孔在所述第二隔室(12)一侧的开口的平均孔径Do大于在所述第一隔室(11)一侧的开口的平均孔径Di；
    优选的，采用犁刀高速混合机进行所述干混，干混时长为10～30min，干混转速为50～200rpm；
    优选的，湿混时长为1～20min，湿混转速为50～200rpm；
    优选的，采用双轴捏合机进行捏合，捏合时长为30～180min。
  8. 根据权利要求7所述的方法，其特征在于，所述步骤A3中，所述负压抽提采用的负压压力大小为(-0.05)～(-0.02)MPa。
  9. 根据权利要求7或8所述的方法，其特征在于，所述步骤A1中，所述碳化硅粉末包括平均粒径为20～30μm的第一碳化硅粉末和平均粒径为3～8μm的第二碳化硅粉末。
  10. 根据权利要求7至9中任一项所述的方法，其特征在于，所述步骤A1中，以所述碳化硅粉末的总量为100wt.％计，所述第一碳化硅粉末在总的所述碳化硅粉末中的占比为70～95wt.％，所述第二碳化硅粉末在总的所述碳化硅粉末中的占比为5～30wt.％。
  11. 根据权利要求7至10中任一项所述的方法，其特征在于，所述步骤A1中，以总原料的质量为100wt.％计，所述碳化硅粉末的占比为50～75wt.％、优选50～65wt.％，所述硅粉末的占比为15～25wt.％、优选15～20wt.％，所述碱土金属碳酸盐的占比为1～2wt.％、所述金属氧化物粉末的占比为0.2～1wt.％、所述助剂的占比为0.5～1.5wt.％、所述粘结剂的占比为6～15wt.％，所述造孔剂的占比为3～18wt.％，所述润滑剂的占比为5～11wt.％。
  12. 根据权利要求7至11中任一项所述的方法，其特征在于，所述硅粉末的平均粒径为3～10μm，所述碱土金属碳酸盐的平均粒径为2～6μm，所述金属氧化物的平均粒径为3～8μm，所述造孔剂的平均粒径为8～40μm。
  13. 根据权利要求7至12中任一项所述的方法，其特征在于，其具有一个或多个以下特征：
    所述碱土金属碳酸盐选自碳酸镁、碳酸锶、碳酸钡、碳酸钙中的至少一种；
    所述金属氧化物选自氧化铝、氧化钛中的至少一种；
    所述助剂选自膨润土、高岭土中的至少一种；
    所述粘结剂选自有机醇类、月桂酸钾、改性纤维素、聚氧化乙烯、聚乙烯吡咯烷酮中的至少一种；
    所述造孔剂选自核桃粉、石墨、苯甲酸、淀粉、碳酸氢铵、氯化铵、聚甲基丙烯酸甲酯、膨胀微球中的至少一种；
    所述润滑剂为甘油。
  14. 一种蜂窝陶瓷载体，其特征在于，所述蜂窝陶瓷载体由如权利要求1至6中任一项所述的陶瓷单元体或者由权利要求7至13中任一项所述的方法制得的陶瓷单元体构成，各所述陶瓷单元体在所述蜂窝陶瓷载体的横截面内分布且相接，且所述陶瓷单元体的纵向与所述蜂窝陶瓷载体的纵向相同。
  15. 根据权利要求14所述的蜂窝陶瓷载体，其特征在于，所述蜂窝陶瓷载体的热导率为5～30W/m·K，优选为10～30W/m·K，更优选为13～25W/m·K。
  16. 根据权利要求14或15所述的蜂窝陶瓷载体，其特征在于，所述蜂窝陶瓷载体为圆柱体或多棱柱。
  17. 一种用于制备如权利要求14至16中任一项所述的蜂窝陶瓷载体的方法，其特征在于，所述方法包括以下步骤：
    B1，提供如权利要求1至6中任一项所述的陶瓷单元体，或者提供由如权利要求7至13中任一项所述的方法制得的陶瓷单元体；
    B2，将所述陶瓷单元体依次经过拼接、磨皮、植皮处理后，得到所述的蜂窝陶瓷载体。
  18. 一种尾气催化芯体，其特征在于，所述尾气催化芯体包括：
    如权利要求14至16中任一项所述的蜂窝陶瓷载体或者由权利要求17所述的方法制得的蜂窝陶瓷载体；
    第一催化剂，施加于所述蜂窝陶瓷载体的第一隔室(11)的内壁面；
    第二催化剂，施加于所述蜂窝陶瓷载体的第二隔室(12)的内壁面。
  19. 根据权利要求18所述的尾气催化芯体，其特征在于，所述尾气催化芯体用于催化含有烟碳颗粒的尾气，所述第一催化剂用于促进所述烟碳颗粒的氧化，所述第二催化剂用于催化一氧化碳、碳氢化物和氮氧化物的转化。
PCT/CN2024/143045 2024-09-24 2024-12-27 陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体 Pending WO2025140503A1 (zh)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP24909202.4A EP4628713A4 (en) 2024-09-24 2024-12-27 CERAMIC UNIT, HONEYCOMB CERAMIC SUPPORT AND ITS PREPARATION PROCESS, AND EXHAUST GAS CATALYTIC CORE

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN202411341241.2A CN119288647A (zh) 2024-09-24 2024-09-24 陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体
CN202411341241.2 2024-09-24

Publications (1)

Publication Number Publication Date
WO2025140503A1 true WO2025140503A1 (zh) 2025-07-03

Family

ID=94157133

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2024/143045 Pending WO2025140503A1 (zh) 2024-09-24 2024-12-27 陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体

Country Status (4)

Country Link
EP (1) EP4628713A4 (zh)
JP (1) JP7849554B2 (zh)
CN (1) CN119288647A (zh)
WO (1) WO2025140503A1 (zh)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040068971A1 (en) * 2002-10-10 2004-04-15 Ngk Insulators, Ltd. Honeycomb structure, method for manufacturing honeycomb structure, and exhaust gas purification system using honeycomb structure
CN1900494A (zh) * 2001-09-13 2007-01-24 日立金属株式会社 陶瓷蜂窝状过滤器
CN101959571A (zh) * 2007-10-12 2011-01-26 日立金属株式会社 堇青石质陶瓷蜂窝过滤器及其制造方法
JP2012013059A (ja) * 2010-07-05 2012-01-19 Mitsubishi Motors Corp 排ガス浄化装置
CN110894156A (zh) * 2018-09-12 2020-03-20 揖斐电株式会社 蜂窝结构体

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5419371B2 (ja) 2008-03-17 2014-02-19 日本碍子株式会社 触媒担持フィルタ
JP5208886B2 (ja) 2008-09-03 2013-06-12 日本碍子株式会社 触媒担持フィルタ
JP5208897B2 (ja) 2008-10-09 2013-06-12 日本碍子株式会社 ハニカムフィルタ
JP2010111567A (ja) 2008-10-09 2010-05-20 Ngk Insulators Ltd ハニカム構造体
JP5452943B2 (ja) 2009-02-02 2014-03-26 日本碍子株式会社 ハニカム構造体、及びハニカム触媒体
JP6956139B2 (ja) * 2019-04-26 2021-10-27 株式会社Ｓｏｋｅｎ 排ガス浄化フィルタ
JP6947200B2 (ja) 2019-05-15 2021-10-13 株式会社デンソー 排ガス浄化フィルタ
JP6940787B2 (ja) * 2019-07-31 2021-09-29 株式会社デンソー 排ガス浄化フィルタ

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1900494A (zh) * 2001-09-13 2007-01-24 日立金属株式会社 陶瓷蜂窝状过滤器
US20040068971A1 (en) * 2002-10-10 2004-04-15 Ngk Insulators, Ltd. Honeycomb structure, method for manufacturing honeycomb structure, and exhaust gas purification system using honeycomb structure
CN101959571A (zh) * 2007-10-12 2011-01-26 日立金属株式会社 堇青石质陶瓷蜂窝过滤器及其制造方法
JP2012013059A (ja) * 2010-07-05 2012-01-19 Mitsubishi Motors Corp 排ガス浄化装置
CN110894156A (zh) * 2018-09-12 2020-03-20 揖斐电株式会社 蜂窝结构体

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP4628713A4 *

Also Published As

Publication number Publication date
CN119288647A (zh) 2025-01-10
JP7849554B2 (ja) 2026-04-21
EP4628713A1 (en) 2025-10-08
JP2026058313A (ja) 2026-04-03
EP4628713A4 (en) 2026-01-07

Similar Documents

Publication Publication Date Title
EP2103342B1 (en) Catalyst-carrying filter
JP5726414B2 (ja) 触媒担持フィルタ、及び排ガス浄化システム
JP5208897B2 (ja) ハニカムフィルタ
EP2105200B1 (en) Catalyst-carrying filter
CN107269355B (zh) 蜂窝结构体
JP5390438B2 (ja) ハニカム触媒体
EP2105199B1 (en) Catalyst-carrying filter
CN108625935B (zh) 尾气净化装置
JP5775512B2 (ja) ハニカムフィルタ及びハニカムフィルタの製造方法
WO2005037405A1 (ja) ハニカム構造体
JPWO2006041174A1 (ja) セラミックハニカム構造体
WO2005039738A1 (ja) ハニカム構造体
JP2003210922A (ja) セラミックハニカムフィルタ
CN108386254A (zh) 封孔蜂窝结构体
CN101432068A (zh) 废气净化用催化剂
JP2008178767A (ja) ディーゼル酸化触媒
JP6074306B2 (ja) ハニカム構造体
JP6043227B2 (ja) ハニカム構造体
WO2025140503A1 (zh) 陶瓷单元体、蜂窝陶瓷载体及其制备方法、尾气催化芯体
CN113039004A (zh) 具有不同水力直径的通道阵列的蜂窝体及其制造方法
KR101933917B1 (ko) Dpf의 채널 내부 표면 상 촉매 코팅방법
CN224032665U (zh) 蜂窝结构体
EP3617465A1 (en) Device for treating exhaust gas from engine and method for manufacturing said device

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 2024909202

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 2024909202

Country of ref document: EP

Effective date: 20250630

121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24909202

Country of ref document: EP

Kind code of ref document: A1

WWP Wipo information: published in national office

Ref document number: 2024909202

Country of ref document: EP