Gasoline particulate trap carrier, preparation method and gasoline particulate trap

Abstract

The present application relates to a gasoline particulate trap carrier, a preparation method and a gasoline particulate trap, wherein the gasoline particulate trap carrier includes talc, kaolin, alumina, silica, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent uses caprolactam. The caprolactam used by the pore-forming agent in the present application is liquid under high temperature conditions, and the bonding state with talc and kaolin is solid-liquid bonding, and the mixture is more uniform, does not agglomerate, and can effectively control the uniformity of the pore-forming agent firing dispersion, and can undergo hydrolysis reaction under a water environment to produce small molecules or high molecular weight polymers such as 6-aminocaproic acid and polyamide PA6 of different molecular weights, thereby forming a composite system pore-forming agent. By controlling the water content, heating temperature and heating time, the type and quantity of the polymer generated can be controlled, and then the composite system composition is controlled, and finally the key parameters such as porosity and median pore size distribution in the product are controlled, thereby improving the porosity of the gasoline particulate trap GPF carrier.

Description

Technical Field

[0001] The present application relates to the technical field of automobile exhaust treatment, and in particular to a gasoline particulate trap carrier, a preparation method and a gasoline particulate trap. Background Art

[0002] Exhaust gases emitted by internal combustion systems that use hydrocarbon fuels such as gaseous hydrocarbons, gasoline or diesel fuel can cause air pollution. Among the many pollutants in these exhaust gases are hydrocarbons and oxygen-containing compounds, the latter including nitrogen oxides (NOx) and carbon monoxide (CO). Over the years, as emission standards have become stricter, the automotive industry has attempted to reduce the amount of pollutants emitted by automobile engine systems, so gasoline particulate filters (GPF) have begun to be widely installed on cars. The gasoline particulate filter GPF consists of a honeycomb body and a pore-blocking part. The compartments separated by porous walls constitute the honeycomb body, and the pore-blocking part forms an intersection at the inlet and outlet ends of the honeycomb body. The exhaust gas discharged by the engine passes through the inlet end of the honeycomb filter, and the fine particles carried by the gas are continuously accumulated and trapped by interception, collision, diffusion, gravity sedimentation, etc. The gas passes through the porous partition wall into the adjacent compartment and flows out.

[0003] Therefore, in order to improve the filtration efficiency, the gasoline particulate filter GPF is required to have a higher porosity and uniform pore distribution. However, it is difficult to achieve narrow pore distribution in the pores of traditional ceramic honeycombs, which is prone to sintering cracking. In addition, the increase in porosity will lead to a decrease in the median pore size, which will lead to an increase in back pressure and a decrease in static pressure strength. At the same time, defects may occur during transportation, catalyst coating, and packaging. Severe cracking may occur, resulting in product scrapping. How to effectively increase the porosity and ensure uniform pore distribution is of utmost importance.

[0004] Some related technologies have developed an aluminum titanate ceramic green body using a pore former, and starch and graphite are used as pore formers to prepare a gasoline particulate filter GPF carrier.

[0005] The above scheme uses powders such as starch and graphite as pore formers, which are dispersed into the blank system through organic binders and surfactants. Due to the restrictions on mixed dispersion, during the blank firing process, the pores are unevenly distributed, the porosity can only reach 40%-50%, and the pore size distribution is uneven. Summary of the invention

[0006] The embodiments of the present application provide a gasoline particulate filter carrier, a preparation method and a gasoline particulate filter to solve the problem that in the related art, powders such as starch and graphite are used as pore formers, and the pore formers are dispersed into the blank system through organic adhesives and surfactants. Due to the restrictions on mixed dispersion, during the blank firing process, the distribution of pores is uneven, the porosity can only reach 40%-50%, and the pore size distribution is uneven.

[0007] In a first aspect, a gasoline particulate filter carrier is provided, wherein the gasoline particulate filter carrier comprises talc, kaolin, alumina, silica, a pore former, an active agent and a solvent, wherein the pore former is caprolactam.

[0008] In some embodiments, the gasoline particulate filter carrier includes, by weight, 40 to 45 parts of talc, greater than 0 part and less than or equal to 70 parts of kaolin, 0 to 20 parts of alumina, 5 to 15 parts of silica, 20 to 40 parts of pore formers, 1 to 5 parts of active agents and 15 to 30 parts of solvents.

[0009] In some embodiments, the kaolin includes one or more of calcined kaolin and raw kaolin.

[0010] In some embodiments, the kaolin is calcined kaolin, and the amount of the calcined kaolin is greater than 0 parts and less than or equal to 40 parts by weight.

[0011] In some embodiments, the kaolin is raw kaolin, and the amount of the raw kaolin is greater than 0 parts and less than or equal to 30 parts by weight.

[0012] In some embodiments, the kaolin uses calcined kaolin and raw kaolin. In terms of weight, the calcined kaolin is used in an amount greater than 0 part and less than or equal to 40 parts, and the raw kaolin is used in an amount greater than 0 part and less than or equal to 30 parts.

[0013] In some embodiments, the active agent includes one or more of sodium stearate, sodium laurate and sodium myristate.

[0014] In some embodiments, the solvent includes one or more of tap water and deionized water.

[0015] In a second aspect, a method for preparing a gasoline particulate filter carrier as described above is provided, comprising the following steps:

[0016] The talc, kaolin, alumina, silica, a pore former, an active agent and a solvent are mixed uniformly to prepare a mud material;

[0017] Extruding the clay material into a shape to obtain a green embryo;

[0018] The green embryo is placed in a kiln, water vapor is introduced into the kiln, and the green embryo is fired to obtain the gasoline particulate trap carrier.

[0019] In some embodiments, talc, kaolin, alumina, silica, a pore-forming agent, an active agent and a solvent are uniformly mixed to prepare a slurry, which specifically comprises the following steps:

[0020] The pore-forming agent is heated at a first temperature for a first time, and then mixed with kaolin and talc to obtain a first mixture, and the first mixture is kept warm at a second temperature for standby use;

[0021] After mixing the solvent, the activator, the aluminum oxide and the silicon dioxide to obtain a second mixed material, the second mixed material is heated at a third temperature for a second time for standby use;

[0022] The first mixed material and the second mixed material are mixed to form a slurry.

[0023] In some embodiments, the first temperature is 70-90°C;

[0024] And / or, the first time is 0.5 to 2 hours;

[0025] And / or, the second temperature is 70-90°C;

[0026] And / or, the third temperature is 70-90° C.;

[0027] And / or, the second time is 0.5-2h.

[0028] In some embodiments, the clay material is extruded to obtain a green embryo, which specifically includes the following steps:

[0029] heating the extrusion die and the clamping tooling to a fourth temperature;

[0030] The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0031] In some embodiments, the fourth temperature is 70-90°C.

[0032] In some embodiments, before placing the green embryo into the kiln, the preparation method further comprises the following steps:

[0033] The raw embryo is subjected to cutting, plugging and skinning processes.

[0034] In some embodiments, introducing water vapor into the kiln specifically comprises the following steps:

[0035] introducing water vapor, heating the kiln from room temperature to a fifth temperature at a first heating rate, and controlling the humidity in the kiln to a designed humidity;

[0036] When the fifth temperature is reached, the introduction of water vapor is stopped, and the temperature is kept at the fifth temperature for the third time.

[0037] In some embodiments, the first heating rate is 10 to 50° C. / hour;

[0038] And / or, the fifth temperature is 200-280° C.;

[0039] And / or, the designed humidity is 10-50%;

[0040] And / or, the third time is 0 to 5 hours.

[0041] In some embodiments, firing the green embryo specifically comprises the following steps:

[0042] First, heating to a sixth temperature at a second heating rate and keeping the temperature for a fourth time;

[0043] Then, the temperature is raised to a seventh temperature at a third heating rate and kept at the temperature for a fifth time to convert the green body into ceramic;

[0044] Finally, cool down to room temperature at the first cooling rate.

[0045] In some embodiments, the second heating rate is 10-100° C. / hour;

[0046] and / or, the sixth temperature is 450-800° C.;

[0047] and / or, the fourth time is 6 to 12 hours;

[0048] and / or, the third heating rate>50°C / hour;

[0049] and / or, the seventh temperature ≥ 1350°C;

[0050] and / or, the fifth time is 8 to 20 hours;

[0051] And / or, the first cooling rate is greater than 100° C. / hour.

[0052] In some embodiments, after the green embryo is fired, the preparation method further comprises the following steps:

[0053] Take it out and perform edge grinding and edge fencing.

[0054] In a third aspect, a gasoline particulate filter is provided, comprising any gasoline particulate filter carrier as described above.

[0055] The beneficial effects of the technical solution provided by this application include:

[0056] The embodiments of the present application provide a gasoline particulate filter carrier, a preparation method and a gasoline particulate filter. The gasoline particulate filter carrier provided by the present application uses caprolactam as its pore-forming agent. Caprolactam is a white crystalline powder with a relatively low melting point of about 68-71°C and a boiling point of 268°C. Therefore, caprolactam is liquid at high temperature, and its bonding state with talc and kaolin is solid-liquid bonding. Compared with conventional solid pore-forming agents such as starch and graphite bonded by adhesives, it can reduce a medium, can be mixed more evenly, and can effectively control the uniformity of the pore-forming agent's firing and dispersion.

[0057] The caprolactam used in the pore-forming agent in this application can undergo a hydrolysis reaction in a water environment to produce small molecules or high molecular weight polymers such as 6-aminocaproic acid and polyamide PA6 of different molecular weights, thereby forming a composite system pore-forming agent. By controlling the water content, heating temperature and heating time, the type and quantity of the generated polymers can be controlled, and then the composition of the composite system can be controlled, and finally the key parameters such as the porosity and median pore size distribution in the product can be controlled, thereby improving the porosity of the gasoline particulate filter GPF carrier. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0059] Figure 1 This is a flow chart of the method for preparing a gasoline particulate filter carrier provided in an embodiment of the present application. DETAILED DESCRIPTION

[0060] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0061] The embodiment of the present application provides a gasoline particulate filter carrier, which can solve the problem that in the related art, powders such as starch and graphite are used as pore formers, and the pore formers are dispersed into the blank system through organic adhesives and surfactants. Due to the restrictions on mixed dispersion, during the blank firing process, the pores are unevenly distributed, the porosity can only reach 40%-50%, and the pore size distribution is uneven.

[0062] The embodiment of the present application provides a gasoline particulate filter carrier, which is characterized by:

[0063] The gasoline particulate filter carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam.

[0064] The gasoline particulate filter carrier provided in the present application uses caprolactam as its pore-forming agent. Caprolactam is a white crystalline powder with a relatively low melting point of about 68-71°C and a boiling point of 268°C. Therefore, caprolactam is liquid at high temperature, and its bonding state with talc and kaolin is solid-liquid bonding. Compared with conventional solid pore-forming agents such as starch and graphite bonded by adhesives, it can reduce a medium, can be mixed more evenly, and not agglomerated, and can effectively control the uniformity of the pore-forming agent's firing and dispersion.

[0065] The caprolactam used in the pore-forming agent in this application can undergo a hydrolysis reaction in a water environment to produce small molecules or high molecular weight polymers such as 6-aminocaproic acid and polyamide PA6 of different molecular weights, thereby forming a composite system pore-forming agent. By controlling the water content, heating temperature and heating time, the type and quantity of the generated polymers can be controlled, and then the composition of the composite system can be controlled, and finally the key parameters such as the porosity and median pore size distribution in the product can be controlled, thereby improving the porosity of the gasoline particulate filter GPF carrier.

[0066] As a preferred embodiment, the gasoline particulate filter carrier includes, by weight, 40 to 45 parts of talc, greater than 0 part and less than or equal to 70 parts of kaolin, 0 to 20 parts of alumina, 5 to 15 parts of silica, 20 to 40 parts of pore formers, 1 to 5 parts of active agents and 15 to 30 parts of solvents.

[0067] The kaolin includes one or more of calcined kaolin and raw kaolin.

[0068] When the kaolin is calcined kaolin, the amount of the calcined kaolin is greater than 0 parts and less than or equal to 40 parts by weight.

[0069] When the kaolin is raw kaolin, the amount of the raw kaolin is greater than 0 parts and less than or equal to 30 parts by weight.

[0070] When the kaolin uses calcined kaolin and raw kaolin, the calcined kaolin is used in an amount greater than 0 part and less than or equal to 40 parts, and the raw kaolin is used in an amount greater than 0 part and less than or equal to 30 parts by weight.

[0071] The active agent includes one or more of sodium stearate, sodium laurate and sodium myristic acid. Preferably, the active agent is sodium stearate.

[0072] The solvent includes one or more of tap water and deionized water. Preferably, the solvent is deionized water.

[0073] See also Figure 1 As shown, the present application also provides a method for preparing a gasoline particulate filter carrier, which comprises the following steps:

[0074] 101: Mix talc, kaolin, alumina, silica, pore former, surfactant and solvent evenly to make mud.

[0075] 102: Extruding the clay material into a shape to obtain a green embryo.

[0076] 103: placing the green embryo into a kiln, introducing water vapor into the kiln, and firing the green embryo to obtain the gasoline particulate filter carrier.

[0077] Wherein, in step 101, talc, kaolin, alumina, silica, a pore-forming agent, an active agent and a solvent are uniformly mixed to form a mud material, which specifically includes the following steps:

[0078] 201: After heating the pore-forming agent at a first temperature for a first time, the pore-forming agent is mixed with kaolin and talc to obtain a first mixture, and the first mixture is kept warm at a second temperature for standby use.

[0079] The first temperature may be determined according to actual preparation requirements. For example, as an example, the first temperature is 70-90°C.

[0080] The first time can be determined according to actual preparation needs. For example, as an example, the first time is 0.5-2h.

[0081] The second temperature can be determined according to actual preparation requirements. For example, as an example, the second temperature is 70-90°C.

[0082] 202: After mixing the solvent, the activator, the aluminum oxide and the silicon dioxide, a second mixture is obtained, and the second mixture is heated at a third temperature for a second time for standby use.

[0083] The third temperature may be determined according to actual preparation requirements. For example, as an example, the third temperature is 70-90°C.

[0084] The second time can be determined according to actual preparation needs. For example, as an example, the second time is 0.5 to 2 hours.

[0085] 203: Mix the first mixed material and the second mixed material to form a mud material, which can be further stirred for later use.

[0086] Among them, in step 102, the clay material is extruded and formed to obtain a green embryo, which specifically includes the following steps:

[0087] 301: Heat the extrusion die and the clamping tooling to a fourth temperature.

[0088] The fourth temperature may be determined according to actual preparation requirements. For example, as an example, the fourth temperature is 70-90°C.

[0089] 302: Load the clay material into the extrusion die, and clamp the extrusion die with the clamping tool to perform extrusion molding to form a green embryo.

[0090] Before placing the green embryo into the kiln, the preparation method further comprises the following steps:

[0091] The raw embryo is subjected to cutting, plugging and skinning processes.

[0092] In step 103, water vapor is introduced into the kiln, which specifically includes the following steps:

[0093] 401: introducing water vapor, and at the same time heating the kiln from room temperature to a fifth temperature at a first heating rate, and controlling the humidity in the kiln at a designed humidity.

[0094] The first heating rate can be determined according to actual preparation requirements. For example, as an example, the first heating rate is 10 to 50° C. / hour.

[0095] The fifth temperature may be determined according to actual preparation requirements. For example, as an example, the fifth temperature is 200-280°C.

[0096] The design humidity can be determined according to actual preparation requirements. For example, as an example, the design humidity is 10-50%.

[0097] 402: When the fifth temperature is reached, the introduction of water vapor is stopped, and the temperature is kept at the fifth temperature for a third time.

[0098] The third time can be determined according to actual preparation needs. For example, as an example, the third time is 0 to 5 hours.

[0099] In step 103, the green embryo is fired, which specifically includes the following steps:

[0100] 501: firstly heating to the sixth temperature at the second heating rate, and keeping the temperature for the fourth time.

[0101] The second heating rate can be determined according to actual preparation requirements. For example, as an example, the second heating rate is 10-100° C. / hour.

[0102] The sixth temperature may be determined according to actual preparation requirements. For example, as an example, the sixth temperature is 450-800° C.

[0103] The fourth time can be determined according to actual preparation needs. For example, as an example, the fourth time is 6 to 12 hours.

[0104] 502: The temperature is raised to the seventh temperature at the third heating rate and maintained for the fifth time to transform the green body into ceramic.

[0105] The third heating rate may be determined according to actual preparation requirements. For example, as an example, the third heating rate is greater than 50° C. / hour.

[0106] The seventh temperature can be determined according to actual preparation requirements. For example, as an example, the seventh temperature is ≥ 1350°C.

[0107] The fifth time can be determined according to actual preparation needs. For example, as an example, the fifth time is 8 to 20 hours.

[0108] 503: Finally, the temperature is lowered to room temperature at the first cooling rate.

[0109] The first cooling rate may be determined according to actual preparation requirements. For example, as an example, the first cooling rate is greater than 100° C. / hour.

[0110] In step 103, after the green embryo is fired, the preparation method further comprises the following steps: taking it out, and performing edge grinding and edge surrounding treatment.

[0111] The present application also provides a gasoline particulate filter, which includes the above-mentioned gasoline particulate filter carrier.

[0112] The present application is described in detail below through examples and comparative examples.

[0113] Example 1

[0114] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0115] In terms of weight, the gasoline particulate filter carrier includes 40 parts of talc, 0 parts of calcined kaolin, 30 parts of raw kaolin, 20 parts of caprolactam, 10 parts of aluminum oxide, 10 parts of silicon dioxide, 1 part of an active agent and 15 parts of deionized water.

[0116] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0117] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0118] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0119] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0120] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0121] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0122] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0123] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 30° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 30%.

[0124] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 5 hours.

[0125] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 10° C. / hour, and then kept at that temperature for a fourth time of 8 hours.

[0126] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at the temperature for a fifth time, so as to transform the green body into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 10 hours.

[0127] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0128] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0129] Example 2

[0130] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0131] In terms of weight, the gasoline particulate filter carrier includes 45 parts of talc, 40 parts of calcined kaolin, 0 parts of raw kaolin, 20 parts of caprolactam, 10 parts of alumina, 10 parts of silicon dioxide, 1 part of an active agent and 15 parts of deionized water.

[0132] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0133] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0134] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0135] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0136] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0137] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0138] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0139] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 10° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 30%.

[0140] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 4 hours.

[0141] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 80° C. / hour, and then kept at that temperature for a fourth time of 8 hours.

[0142] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at that temperature for a fifth time, so that the green body is converted into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 12 hours.

[0143] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0144] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0145] Example 3

[0146] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0147] The gasoline particulate filter carrier includes, by weight, 40 parts of talc, 5 parts of calcined kaolin, 25 parts of raw kaolin, 30 parts of caprolactam, 20 parts of alumina, 5 parts of silica, 3 parts of an active agent and 20 parts of deionized water.

[0148] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0149] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0150] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0151] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0152] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0153] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0154] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0155] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 20° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 40%.

[0156] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 3 hours.

[0157] (9) First, the temperature is raised to a sixth temperature of 500°C at a second heating rate of 50°C / hour, and then kept at that temperature for a fourth time of 8 hours.

[0158] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at the temperature for a fifth time, so that the green body is converted into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 15 hours.

[0159] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0160] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0161] Example 4

[0162] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0163] The gasoline particulate filter carrier includes 45 parts of talc, 10 parts of calcined kaolin, 20 parts of raw kaolin, 30 parts of caprolactam, 20 parts of alumina, 5 parts of silicon dioxide, 3 parts of an active agent and 20 parts of deionized water in parts by weight.

[0164] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0165] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0166] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0167] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0168] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0169] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0170] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0171] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 40° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 50%.

[0172] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 3 hours.

[0173] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 20° C. / hour, and then kept at that temperature for a fourth time of 10 hours.

[0174] (10) The temperature is then raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time to transform the green body into ceramics, wherein the third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 16 hours.

[0175] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0176] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0177] Example 5

[0178] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0179] The gasoline particulate filter carrier includes 40 parts of talc, 20 parts of calcined kaolin, 20 parts of raw kaolin, 40 parts of caprolactam, 0 parts of alumina, 15 parts of silicon dioxide, 5 parts of an active agent and 30 parts of deionized water in parts by weight.

[0180] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0181] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0182] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0183] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0184] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0185] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0186] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0187] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 25° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 15%.

[0188] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 2 hours.

[0189] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 30° C. / hour, and then kept at that temperature for a fourth time of 10 hours.

[0190] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time, so as to transform the green body into ceramics. The third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 18 hours.

[0191] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0192] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0193] Example 6

[0194] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0195] The gasoline particulate filter carrier includes 45 parts of talc, 25 parts of calcined kaolin, 10 parts of raw kaolin, 40 parts of caprolactam, 0 parts of alumina, 15 parts of silicon dioxide, 5 parts of an active agent and 30 parts of deionized water in parts by weight.

[0196] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0197] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0198] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0199] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0200] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0201] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0202] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0203] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 50° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 10%.

[0204] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 0 hour.

[0205] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 100° C. / hour, and then maintained at that temperature for a fourth time of 10 hours.

[0206] (10) The temperature is then raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time to transform the green body into ceramics, wherein the third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 20 hours.

[0207] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0208] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0209] Example 7

[0210] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0211] The gasoline particulate filter carrier includes, by weight, 40 parts of talc, 20 parts of calcined kaolin, 20 parts of raw kaolin, 30 parts of caprolactam, 10 parts of alumina, 10 parts of silica, 3 parts of an active agent and 20 parts of deionized water.

[0212] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0213] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0214] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0215] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0216] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0217] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0218] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0219] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 25° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 20%.

[0220] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 0 hour.

[0221] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 100° C. / hour, and then maintained at that temperature for a fourth time of 8 hours.

[0222] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at that temperature for a fifth time, so that the green body is converted into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 12 hours.

[0223] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0224] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0225] Example 8

[0226] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0227] The gasoline particulate filter carrier includes, by weight, 45 parts of talc, 20 parts of calcined kaolin, 20 parts of raw kaolin, 30 parts of caprolactam, 10 parts of alumina, 10 parts of silica, 3 parts of an active agent and 20 parts of deionized water.

[0228] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0229] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0230] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0231] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0232] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0233] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0234] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0235] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 30° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 25%.

[0236] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 1 hour.

[0237] (9) First, the temperature is raised to a sixth temperature of 500°C at a second heating rate of 50°C / hour, and then kept at that temperature for a fourth time of 8 hours.

[0238] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at the temperature for a fifth time, so that the green body is converted into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 15 hours.

[0239] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0240] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0241] Example 9

[0242] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0243] The gasoline particulate filter carrier includes 40 parts of talc, 25 parts of calcined kaolin, 15 parts of raw kaolin, 30 parts of caprolactam, 15 parts of alumina, 10 parts of silicon dioxide, 3 parts of an active agent and 20 parts of deionized water in parts by weight.

[0244] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0245] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0246] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0247] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0248] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0249] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0250] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0251] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 35° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 30%.

[0252] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 2 hours.

[0253] (9) First, the temperature is raised to a sixth temperature of 500°C at a second heating rate of 50°C / hour, and then kept at that temperature for a fourth time of 8 hours.

[0254] (10) Then, the temperature is raised to a seventh temperature at a third heating rate and kept at that temperature for a fifth time, so that the green body is converted into ceramics. The third heating rate is 80° C. / hour, the seventh temperature is 1400° C., and the fifth time is 12 hours.

[0255] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0256] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0257] Example 10

[0258] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0259] The gasoline particulate filter carrier includes 45 parts of talc, 25 parts of calcined kaolin, 15 parts of raw kaolin, 35 parts of caprolactam, 15 parts of alumina, 10 parts of silicon dioxide, 3 parts of an active agent and 20 parts of deionized water in parts by weight.

[0260] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0261] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0262] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0263] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0264] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0265] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0266] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0267] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 40° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 35%.

[0268] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 3 hours.

[0269] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 50° C. / hour, and then kept at that temperature for a fourth time of 10 hours.

[0270] (10) The temperature is then raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time to transform the green body into ceramics, wherein the third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 15 hours.

[0271] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0272] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0273] Embodiment 11

[0274] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0275] The gasoline particulate filter carrier includes 40 parts of talc, 20 parts of calcined kaolin, 15 parts of raw kaolin, 35 parts of caprolactam, 10 parts of alumina, 10 parts of silicon dioxide, 3 parts of an active agent and 20 parts of deionized water in parts by weight.

[0276] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0277] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0278] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0279] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0280] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0281] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0282] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0283] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 45° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 40%.

[0284] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 4 hours.

[0285] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 50° C. / hour, and then kept at that temperature for a fourth time of 10 hours.

[0286] (10) The temperature is then raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time to transform the green body into ceramics, wherein the third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 12 hours.

[0287] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0288] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0289] Example 12

[0290] A gasoline particulate trap carrier comprises talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam, the solvent is deionized water, and the active agent is sodium stearate.

[0291] The gasoline particulate filter carrier includes 45 parts of talc, 20 parts of calcined kaolin, 15 parts of raw kaolin, 35 parts of caprolactam, 10 parts of alumina, 10 parts of silicon dioxide, 3 parts of an active agent and 20 parts of deionized water in parts by weight.

[0292] The method for preparing the gasoline particulate filter carrier comprises the following steps:

[0293] (1) The pore-forming agent is heated at a first temperature of 80° C. for a first time of 1 hour, and then mixed with kaolin and talc to obtain a first mixture. The first mixture is kept warm at a second temperature of 80° C. for later use.

[0294] (2) The solvent, the activator, the aluminum oxide and the silicon dioxide are mixed to obtain a second mixture, and the second mixture is heated at a third temperature of 80° C. for a second time of 1 hour for use.

[0295] (3) The first mixed material and the second mixed material are mixed to form a slurry.

[0296] (4) The extrusion die and the clamping tool are heated to a fourth temperature of 80°C.

[0297] (5) The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

[0298] (6) Cutting, plugging and veneer treatment are performed on the green embryo, and then the green embryo is placed in a kiln.

[0299] (7) Steam is introduced to raise the temperature of the kiln from room temperature to a fifth temperature of 260° C. at a first heating rate of 50° C. / hour, and the humidity in the kiln is controlled at a designed humidity of 50%.

[0300] (8) When the fifth temperature reaches 260° C., the introduction of water vapor is stopped, and the fifth temperature of 260° C. is maintained for a third time of 5 hours.

[0301] (9) First, the temperature is raised to a sixth temperature of 500° C. at a second heating rate of 50° C. / hour, and then kept at that temperature for a fourth time of 10 hours.

[0302] (10) The temperature is then raised to a seventh temperature at a third heating rate and maintained at that temperature for a fifth time to transform the green body into ceramics, wherein the third heating rate is 100° C. / hour, the seventh temperature is 1400° C., and the fifth time is 15 hours.

[0303] (11) Finally, the temperature is lowered to room temperature at a first cooling rate, wherein the first cooling rate is greater than 100° C. / hour.

[0304] (12) taking out, and performing edge grinding and edge surrounding treatment to obtain the gasoline particulate filter carrier.

[0305] Comparative Example 1

[0306] A gasoline particulate filter GPF carrier is prepared using conventional starch as a pore-forming agent.

[0307] The dosage and firing conditions of each embodiment are shown in Table 1 and Table 2:

[0308] Table 1

[0309]

[0310]

[0311] Table 2

[0312]

[0313] The porosity, median pore size, and pore size distribution parameters of the GPF carriers prepared in Examples 1-12 were tested, and the results were compared with those of Comparative Example 1. The test results are shown in Tables 3 and 4 below.

[0314] Table 3

[0315]

[0316] Table 4

[0317]

[0318] According to the test results of Tables 3 and 4, it can be seen that compared with the GPF carrier prepared with conventional starch as a pore-forming agent, the porosity of the carrier prepared in the present application is higher, reaching 66.1%, and from the data of P1 and P2, the data of the embodiment are better than the comparative example, indicating that the pore size distribution is more uniform, which can effectively improve the static pressure strength of the GPF carrier and improve the filtration efficiency.

[0319] In the description of the present application, it should be noted that the terms "upper", "lower", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a connection between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0320] It should be noted that, in this application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0321] The above description is only a specific implementation of the present application, so that those skilled in the art can understand or implement the present application. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features applied for herein.

Claims

1. A method for preparing a gasoline particulate filter carrier, characterized in that: The gasoline particulate filter carrier comprises talc, kaolin, alumina, silica, a pore-forming agent, an active agent and a solvent, wherein the pore-forming agent is caprolactam; The active agent includes one or more of sodium stearate, sodium laurate and sodium myristate; The preparation method comprises the following steps: The talc, kaolin, alumina, silica, a pore former, an active agent and a solvent are mixed uniformly to prepare a mud material; Extruding the clay material into a shape to obtain a green embryo; placing the green embryo into a kiln, introducing water vapor into the kiln, and firing the green embryo to obtain the gasoline particulate trap carrier; The talc, kaolin, alumina, silicon dioxide, a pore-forming agent, an active agent and a solvent are mixed uniformly to prepare a mud material, which specifically comprises the following steps: The pore-forming agent is heated at a first temperature for a first time, and then mixed with kaolin and talc to obtain a first mixture, and the first mixture is kept warm at a second temperature for standby use; After mixing the solvent, the activator, the aluminum oxide and the silicon dioxide to obtain a second mixed material, the second mixed material is heated at a third temperature for a second time for standby use; Mixing the first mixed material and the second mixed material to form a slurry; The first temperature is 70-90° C.; And / or, the first time is 0.5 to 2 hours; And / or, the second temperature is 70-90°C; And / or, the third temperature is 70-90° C.; And / or, the second time is 0.5-2h; The step of introducing water vapor into the kiln specifically comprises the following steps: introducing water vapor, heating the kiln from room temperature to a fifth temperature at a first heating rate, and controlling the humidity in the kiln to a designed humidity; When the fifth temperature is reached, the introduction of water vapor is stopped, and the temperature is kept at the fifth temperature for a third time; The first heating rate is 10 to 50°C / hour; And / or, the fifth temperature is 200-280° C.; And / or, the designed humidity is 10-50%; And / or, the third time is 0 to 5 hours.

2. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: In terms of weight, the gasoline particulate filter carrier includes 40 to 45 parts of talc, more than 0 parts and less than or equal to 70 parts of kaolin, 0 to 20 parts of aluminum oxide, 5 to 15 parts of silicon dioxide, 20 to 40 parts of pore formers, 1 to 5 parts of active agents and 15 to 30 parts of solvents.

3. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: The kaolin includes one or more of calcined kaolin and raw kaolin.

4. The method for preparing a gasoline particulate filter carrier according to claim 3, characterized in that: The kaolin is calcined kaolin, and the amount of the calcined kaolin is greater than 0 parts and less than or equal to 40 parts by weight.

5. The method for preparing a gasoline particulate filter carrier according to claim 3, characterized in that: The kaolin is raw kaolin, and the amount of the raw kaolin is greater than 0 parts and less than or equal to 30 parts by weight.

6. The method for preparing a gasoline particulate filter carrier according to claim 3, characterized in that: The kaolin includes calcined kaolin and raw kaolin. In terms of weight, the calcined kaolin is used in an amount greater than 0 part and less than or equal to 40 parts, and the raw kaolin is used in an amount greater than 0 part and less than or equal to 30 parts.

7. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: The solvent includes one or more of tap water and deionized water.

8. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: Extruding the clay material into a shape to obtain a green embryo specifically comprises the following steps: heating the extrusion die and the clamping tooling to a fourth temperature; The clay material is loaded into the extrusion die, and the extrusion die is clamped by the clamping tool to perform extrusion molding to form a green embryo.

9. The method for preparing a gasoline particulate filter carrier according to claim 8, characterized in that: The fourth temperature is 70-90°C.

10. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: Before placing the green embryo into the kiln, the preparation method further comprises the following steps: The raw embryo is subjected to cutting, plugging and skinning processes.

11. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: The green embryo is fired, which specifically comprises the following steps: First, heating to a sixth temperature at a second heating rate and keeping the temperature for a fourth time; Then, the temperature is raised to a seventh temperature at a third heating rate and kept at the temperature for a fifth time to convert the green body into ceramic; Finally, cool down to room temperature at the first cooling rate.

12. The method for preparing a gasoline particulate filter carrier according to claim 11, characterized in that: The second heating rate is 10-100°C / hour; and / or, the sixth temperature is 450-800° C.; and / or, the fourth time is 6 to 12 hours; and / or, the third heating rate>50°C / hour; and / or, the seventh temperature ≥ 1350°C; and / or, the fifth time is 8 to 20 hours; And / or, the first cooling rate is greater than 100° C. / hour.

13. The method for preparing a gasoline particulate filter carrier according to claim 1, characterized in that: After the green embryo is fired, the preparation method further comprises the following steps: Take it out and perform edge grinding and edge fencing.

14. A gasoline particulate trap, characterized in that: The method comprises a method for preparing a gasoline particulate filter carrier as claimed in any one of claims 1 to 13.

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