Honeycomb ceramic carrier, method for its production and catalytic body containing the same

Abstract

The present application provides a honeycomb ceramic carrier, a preparation method thereof, and a catalytic body containing the honeycomb ceramic carrier, the honeycomb ceramic carrier comprising: a body; a plurality of compartments with hollow structures in the body, the compartments penetrating through the body to form a honeycomb structure; wherein the compartments have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section does not have an inner recess or a chamfer. The present application improves the structural strength of the ceramic carrier for carrying catalysts, and reduces the bending phenomenon of the partition wall of the thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, thereby improving the yield.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of ceramic carrier catalysts, in particular to a honeycomb ceramic carrier, a preparation method thereof and a catalytic body containing the honeycomb ceramic carrier. BACKGROUND

[0002] With the upgrading of motor vehicle exhaust emission regulations, the emission limits of harmful gases such as carbon monoxide (CO), hydrocarbons (HC x H y ), nitrogen oxides (NO x ) and the like are becoming increasingly stringent, which puts higher requirements on the pore density and wall thickness of the honeycomb ceramic carrier. High-density, thin-walled honeycomb ceramic materials can make the harmful substances in the exhaust gas react more quickly with the noble metal coating on the surface of the ceramic material to be harmless.

[0003] At present, the honeycomb ceramic carriers provided by the prior art still have the following problems to be solved urgently: 1. As the pore density of the carrier increases and the wall thickness decreases, the difficulty of forming the product increases, and the forming of the thin-walled product is prone to cause the bending of the partition wall, which will have a serious impact on the overall performance of the carrier; 2. The bent lattice wall will affect the flow of exhaust gas in the catalytic converter and cause uneven heat conduction of the partition wall, reducing the catalytic efficiency; 3. The bent partition wall may block the gas passage, affecting the exhaust gas treatment efficiency and causing the engine performance to decrease; 4. The bent partition wall will reduce the structural strength and stability of the cordierite honeycomb ceramic, shorten the service life and require frequent replacement or maintenance; 5. The high-pore-density, thin-walled carrier generally has a right-angle or rounded structure, and the stress concentration at the right angle is easy to cause damage to the carrier, which shortens the service life and affects the overall performance of the carrier, and in addition, the flow resistance of the mold mud is large, which is easy to cause the bending of the partition wall and reduce the yield.

[0004] Therefore, how to improve the structural strength of the ceramic carrier for carrying catalysts and reduce the bending phenomenon of the partition wall of the thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, so as to improve the yield, needs to be solved urgently. SUMMARY

[0005] The purpose of the present application is to provide a honeycomb ceramic carrier, a preparation method thereof and a catalytic body containing the honeycomb ceramic carrier, so as to improve the structural strength of the honeycomb ceramic carrier for carrying catalysts and reduce the bending phenomenon of the partition wall of the thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, so as to improve the yield.

[0006] In order to achieve the above purpose, the present application provides the following technical solutions:

[0007] A honeycomb ceramic carrier, comprising:

[0008] a body;

[0009] a plurality of compartments with hollow structures in the body, the compartments penetrating through the body to form a honeycomb structure;

[0010] wherein the compartments have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section does not have an inner recess or a chamfer.

[0011] In some embodiments of the present application, in one of the compartments, two top angles in the pair of opposite angles with the inner recess or the chamfer have the same shape and size;

[0012] Alternatively, in one of the compartments, two top angles in the pair of opposite angles with the inner recess or the chamfer have different shapes and / or different sizes.

[0013] In some embodiments of the present application, four of the compartments constitute a repeating unit, and the repeating unit has a center of symmetry;

[0014] wherein the top angles of the four compartments in the repeating unit, which are located inside the repeating unit, have the inner recess or the chamfer, or the top angles of the four compartments in the repeating unit, which are located inside the repeating unit, do not have the inner recess or the chamfer.

[0015] In some embodiments of the present application, the number of the compartments is at least twelve;

[0016] wherein each of the compartments constitutes a quarter of at least two repeating units.

[0017] In some embodiments of the present application, in one of the repeating units, the top angles of the four compartments, which are located inside the repeating unit and have the inner recess or the chamfer, are enclosed, and form a reinforced intersection point at the position of the center of symmetry;

[0018] Alternatively, in one of the repeating units, the top angles of the four compartments, which are located inside the repeating unit and have the outer convex right angle, are enclosed, and form a common intersection point at the position of the center of symmetry.

[0019] In some embodiments of the present application, the inner recess is an inner recessed right angle, a rounded corner or an inner recessed flower corner;

[0020] wherein the inner recessed right angle is configured to be recessed inward with respect to the interior of the compartment in which it is located, and the rounded corner is configured to be convex outward or recessed inward with respect to the interior of the compartment in which it is located.

[0021] In some embodiments of the present application, the honeycomb ceramic carrier has a water absorption rate of 14-28%.

[0022] In some embodiments of the present application, the honeycomb ceramic carrier has one or more of the following characteristics:

[0023] The water absorption of the honeycomb ceramic carrier is 14-28%;

[0024] The compressive strength of the ceramic carrier in the longitudinal direction is 9-10.5 MPa;

[0025] The coefficient of thermal expansion CTE of the ceramic carrier in the longitudinal direction is 0.2x10 -6 -0.5x10 -6 ℃ -1 in the temperature range of 25-800℃;

[0026] The isostatic strength of the ceramic carrier is 3.1-6.3 MPa;

[0027] The thermal shock parameter TSP of the ceramic carrier is 650-750℃, preferably 700-750℃;

[0028] The size of the ceramic carrier in the longitudinal direction is 3-5.5 inch;

[0029] The radial size of the ceramic carrier is 3.7-5.6 inch;

[0030] In the ceramic carrier, the density of the cells is 600-1200 cpsi;

[0031] In the ceramic carrier, the thickness of the partition wall between two adjacent cells is 2-4 mil.

[0032] In some embodiments of the present application, in each of the cells, the two vertices of the pair of opposite angles without the inner recess or chamfer are right angles, each right angle is composed of two first straight line segments, one of the first straight line segments has a length of A1, and the other first straight line segment has a length of B1;

[0033] Each vertex of the pair of opposite angles with the inner recess is composed of two second straight line segments, one of the second straight line segments has a length of A2, and the other second straight line segment has a length of B2;

[0034] Wherein, (A2 / A1)*100% = 5-25%, preferably 15-25%, and (B2 / B1)*100% = 5-25%, preferably 15-25%.

[0035] In some embodiments of the present application, in each of the cells, the two vertices of the pair of opposite angles without the inner recess or chamfer are right angles, each right angle is composed of two first straight line segments, one of the first straight line segments has a length of A1, and the other first straight line segment has a length of B1;

[0036] Each of the two top corners of the pair of opposite corners with the chamfer is composed of a third straight line segment, a projection length of the third straight line segment in a direction of one of the first straight line segments is A3, and a projection length of the third straight line segment in a direction of the other first straight line segment is B3;

[0037] (A3 / A1)*100% = 5-25%, preferably 15-25%, (B3 / B1)*100% = 5-25%, preferably 15-25%.

[0038] In some embodiments of the present application, in each of the compartments, two top corners of the pair of opposite corners without the inner recess or chamfer are right angles, each of the right angles is composed of two first straight line segments, a length of one of the first straight line segments is A1, and a length of the other first straight line segment is B1;

[0039] Each of the two top corners of the pair of opposite corners with the inner recess is composed of an arc line segment, a projection length of the arc line segment in a direction of one of the first straight line segments is A4, and a projection length of the arc line segment in a direction of the other first straight line segment is B4;

[0040] (A4 / A1)*100% = 5-25%, preferably 15-25%, (B4 / B1)*100% = 5-25%, preferably 15-25%.

[0041] In some embodiments of the present application, in each of the compartments, two top corners of the pair of opposite corners without the inner recess or chamfer are right angles, each of the right angles is composed of two first straight line segments, a length of one of the first straight line segments is A1, and a length of the other first straight line segment is B1;

[0042] Each of the two top corners of the pair of opposite corners with the inner recess is composed of four fourth straight line segments connected in sequence, a sum of projection lengths of the four fourth straight line segments in a direction of one of the first straight line segments is A5, and a sum of projection lengths of the four fourth straight line segments in a direction of the other first straight line segment is B5;

[0043] (A5 / A1)*100% = 5-25%, preferably 15-25%, (B5 / B1)*100% = 5-25%, preferably 15-25%.

[0044] In some embodiments of the present application, the raw materials of the ceramic carrier include inorganic raw materials, organic additives, binders, and water.

[0045] The inorganic raw material is talc, kaolin, alumina and optionally silicon oxide, aluminum hydroxide, wherein the talc is preferably flaky talc, more preferably flaky talc with D50 = 5-20 μm; the kaolin is preferably raw kaolin and / or cooked kaolin, the raw kaolin is more preferably flaky raw kaolin, the flaky raw kaolin is more preferably flaky raw kaolin with D50 = 5-20 μm, the cooked kaolin is more preferably cooked kaolin with D50 = 4-15 μm, the silicon oxide is preferably silicon oxide with D50 = 1-10 μm, and the alumina is preferably alumina with D50 = 1-10 μm;

[0046] The organic auxiliary agent is at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, xanthan gum, potassium silicate, and random polyether of glycerol;

[0047] The binder is at least one of hydroxymethyl cellulose, ethyl cellulose, and carboxymethyl cellulose.

[0048] In some embodiments of the present application, the talc accounts for 20-40 wt.%, the kaolin accounts for 20-60 wt.%, the alumina accounts for 10-20 wt.%, the silicon oxide accounts for 0-10 wt.%, the organic auxiliary agent accounts for 2-10 wt.% of the total amount of inorganic raw material, the binder accounts for 3-15 wt.% of the total amount of inorganic raw material, and the water accounts for 25-50 wt.% of the total amount of inorganic raw material, based on 100 wt.% of the total amount of inorganic raw material.

[0049] Preferably, the kaolin includes 10-30 wt.% of flaky raw kaolin and 10-30 wt.% of cooked kaolin, based on 100 wt.% of the total amount of inorganic raw material.

[0050] To achieve the above object, the present application further provides the following technical solutions:

[0051] A preparation method of a honeycomb ceramic carrier, the preparation method comprising the following steps:

[0052] S1, mixing inorganic raw materials to obtain dry materials;

[0053] S2, sequentially mixing the dry materials obtained in step S1 with an organic auxiliary agent, a binder, and water through wet mixing, kneading, pugging, extrusion molding, drying, and cutting to obtain a green body;

[0054] S3, sintering the green body obtained in step S2 to obtain the honeycomb ceramic carrier described above;

[0055] In the extrusion forming process in the step S2, the cells of the honeycomb ceramic carrier are formed, and the cells have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section does not have an inner recess or a chamfer.

[0056] In some embodiments of the present application, in the step S3, the heating rate and the sintering temperature at least at some time points change with the sintering time during the sintering process.

[0057] In some embodiments of the present application, in the step S3, the sintering temperature is 1000-1450℃, the sintering time is at least 13h, and the heating rate is greater than 25℃ / h.

[0058] In some embodiments of the present application, in the step S2, the wet mixing comprises: putting the dry materials, the binder and the organic auxiliary agent into a plowshare mixer for dry mixing, and then wet mixing after water spraying;

[0059] The wet mixing comprises: putting the raw materials after the wet mixing into a meshed pug mill, and pugging under vacuum condition;

[0060] The extrusion forming comprises: putting the raw materials after the pugging into an extruder, preferably at least one selected from a single-screw extruder, a double-screw extruder or a hydraulic extruder, for forming;

[0061] The drying comprises: drying and forming by using a microwave drying machine;

[0062] The cutting comprises: cutting by using a green body cutting machine.

[0063] To achieve the above object, the present application further provides the following technical solutions.

[0064] A catalytic body, comprising the honeycomb ceramic carrier described above, and a catalyst is coated on the inner wall surface of the cells of the honeycomb ceramic carrier;

[0065] Preferably, the thickness of the catalyst coating at the vertex angle position with the inner recess or chamfer structure is 0.06-0.08μm, and the thickness of the catalyst coating at other positions is 0.07μm.

[0066] Other applicable fields will become apparent from the description provided in the present disclosure.

[0067] The description in the summary and the specific examples are only intended to illustrate but not to limit the scope of the present disclosure.

[0068] Compared with the prior art, the present application has the following beneficial effects by the above technical solutions:

[0069] The present application improves the structural strength of a ceramic carrier for carrying a catalyst, and reduces the cell wall bending phenomenon of a thin-walled ceramic carrier having a honeycomb structure without increasing the degree of die wear, thereby improving the yield. BRIEF DESCRIPTION OF DRAWINGS

[0070] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the embodiments will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without any creative effort based on these drawings.

[0071] Figure 1 A structural schematic diagram of a cell of a honeycomb ceramic carrier according to the first embodiment of the present application;

[0072] Figure 2 A structural schematic diagram of a cell of a honeycomb ceramic carrier according to the second embodiment of the present application;

[0073] Figure 3 A structural schematic diagram of a cell of a honeycomb ceramic carrier according to the third embodiment of the present application;

[0074] Figure 4 A structural schematic diagram of a cell of a honeycomb ceramic carrier according to the fourth embodiment of the present application;

[0075] Figure 5 A structural schematic diagram of a cell of a honeycomb ceramic carrier according to the fifth embodiment of the present application;

[0076] Figure 6 A size schematic diagram of a cell of a honeycomb ceramic carrier according to the first embodiment of the present application;

[0077] Figure 7 A size schematic diagram of a cell of a honeycomb ceramic carrier according to the second embodiment of the present application;

[0078] Figure 8 A size schematic diagram of a cell of a honeycomb ceramic carrier according to the third embodiment of the present application;

[0079] Figure 9 A size schematic diagram of a cell of a honeycomb ceramic carrier according to the fourth embodiment of the present application;

[0080] Figure 10 A size schematic diagram of a cell of a honeycomb ceramic carrier according to the fifth embodiment of the present application;

[0081] Figure 11 A structural schematic diagram of a honeycomb ceramic carrier according to an embodiment of the present application;

[0082] Figure 12 Fig. 1 is a schematic cross-sectional view of a honeycomb ceramic substrate according to an embodiment of the present application; Figure 11 Fig. 1 is a schematic cross-sectional view of a honeycomb ceramic substrate according to an embodiment of the present application;

[0083] Figure 13 Fig. 1 is a schematic cross-sectional view of a honeycomb ceramic substrate according to an embodiment of the present application;

[0084] The main reference signs in the drawings that are used to explain embodiments of the present application are explained as follows:

[0085] 1 - body; 2 - compartment; 31 - reinforced intersection; 32 - ordinary intersection. DETAILED DESCRIPTION

[0086] The technical solutions in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all the other embodiments obtained by a person skilled in the art without any creative work fall within the scope of protection of the present application. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present application, and are not used to limit the present application.

[0087] Any specific numerical values (including the endpoints of numerical ranges) disclosed herein are not to be construed as limiting, but rather as approximations. When numerical ranges are disclosed herein, they are to be construed as having endpoints that are not inclusive of the endpoints. Any numerical value, however, can include any reasonable amount that is nearby to the stated value, for example, within ranges of +5% of the stated value. Also, any numerical range disclosed herein is intended to include any and all derived numerical ranges, for example, ranges of values from the lower endpoint to the upper endpoint of the disclosed range, ranges of values from the lower endpoint to any other point in the range, and ranges of values from any other point in the range to the upper endpoint. All such ranges are intended to be specifically included.

[0088] The terminology used by the present disclosure is intended to be interpreted in only a descriptive manner and not as a limitation on the scope of the particular exemplary embodiments. As used throughout this disclosure, the singular forms "a," "an," and "the" include plural reference unless the context clearly dictates otherwise. The terms "comprises," "comprising," "includes," "including," "contains," and "containing," are inclusive and therefore specify the presence of stated features, integers, compositions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, compositions, steps, operations, elements, components, and / or groups thereof. Although the open-ended term "comprising," when used in the description or the claims, is intended to be interpreted as a non-limiting term, in certain aspects the term "comprising" can alternatively be construed as the more restrictive term "consisting of" or "consisting essentially of." Thus, any given embodiment reciting a composition, material, component, element, feature, integer, operation, and / or process step is intended to encompass not only the described embodiment, but also "consisting of" and "consisting essentially of" embodiments, including where the "consisting of" and "consisting essentially of" embodiments include additional composition, material, component, element, feature, integer, operation, and / or process step(s) that do not materially affect the basic and novel characteristics of the described embodiment.

[0089] Any method steps, processes, and operations described in the present disclosure are not to be construed as necessarily requiring their performance in the particular order in which they are discussed or illustrated unless expressly stated as such. It is also to be understood that additional or alternative steps can be employed, unless otherwise stated.

[0090] In this application, unless otherwise stated, any of the terms used are intended to apply directly to those known in the art without any change, except for the explicitly stated content. Moreover, any of the embodiments 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 considered to be part of the original disclosure or original description of the present application, and should not be considered as new content that has not been disclosed or anticipated by the present disclosure, unless the combination is considered to be obviously unreasonable by those skilled in the art.

[0091] Unless otherwise indicated, the terms used herein have the same meaning as generally understood by those skilled in the art, and if the term is defined herein and is different from the generally understood meaning, the definition herein shall prevail.

[0092] Unless otherwise indicated, references in this document to % are meant to refer to wt.%.

[0093] It is worth noting that "cpsi" in the context of the present application refers to "channels per square inch", which is commonly known as "mesh", and "mil" in the context of the present application refers to "mil" or "milli-inch", which is a unit of length, and the conversion relationship is 1 inch = 1000 mil, 1 mil = 25.4 μm (micrometer), 25.4 mm = 1000 mil.

[0094] In the context of the present application, calcined kaolin and metakaolin are used interchangeably.

[0095] It is worth noting that the "coefficient of thermal expansion" in the context of the present application refers to the ratio of the change in length of a solid substance in a certain direction when the temperature changes by 1 °C to its length at 20 °C (i.e. the standard laboratory environment); further, the coefficient of thermal expansion of the ceramic carrier as described in the present application refers to the coefficient of thermal expansion of the ceramic carrier in the longitudinal direction; it is worth emphasizing that the longitudinal axis of the ceramic carrier is the A-axis, which is well known to those skilled in the art.

[0096] It can be understood that the "water absorption rate" in the context of the present application refers to the ratio of the dry mass to the mass after water absorption to saturation. The water absorption rate as described in the present application is measured under the following standard: the ceramic carrier provided by the present application is made into a sample block of 25*25*25 mm±0.5 mm, and the dry mass of the sample block is weighed; after 10 minutes of vacuum pumping, the sample block is boiled using a microwave oven, and after being placed at room temperature, the excess water on the sample block is blown off using an air gun, and the mass of the sample block is weighed for water absorption rate calculation; the dry mass is the sample taken out of the kiln without additional drying.

[0097] It is worth noting that the "ratio of the size of the top corner of the non-externally convex right angle design to the length of the corner" in the context of the present application refers to the proportion of the non-externally convex right angle design structure occupying the length of the side of the quadrilateral compartment; the "thickness of the partition wall between the two adjacent compartments" refers to the thickness of the porous wall between the compartments, which is the thickness between the lengths of the sides of the quadrilateral compartment not occupied by the non-externally convex right angle design structure; the "size of the longitudinal axis of the ceramic carrier" refers to the distance from the inlet end to the outlet end of the honeycomb structure ceramic carrier; the "radial size of the ceramic carrier" refers to the diameter of the inlet end face or outlet end face of the honeycomb structure ceramic carrier. The cross-sectional shape of the carrier in some embodiments is any one of a circle, an ellipse, a polygon, etc. In the case of an ellipse, the radial size refers to the length of the major axis. In the case of a polygon or other shape, the radial size refers to the longest dimension of the shape.

[0098] First aspect

[0099] See Figure 11 and Figure 12 A honeycomb ceramic carrier includes: a body 1; a plurality of hollow compartments 2 within the body 1, the compartments 2 penetrating the body 1 to form a honeycomb structure; wherein, the compartment 2 has a quadrilateral cross-section, one pair of opposite corners of the quadrilateral cross-section has a concave portion or a chamfer, and the other pair of opposite corners of the quadrilateral cross-section does not have a concave portion or a chamfer.

[0100] In existing technologies, ceramic carriers with high porosity and thin-walled structures generally have straight-through compartments with right angles or rounded corners. However, right-angle locations are prone to stress concentration, leading to overall damage to the ceramic carrier and thus reducing product lifespan and affecting its overall performance. Furthermore, the mold clay used to press out the right-angled structure suffers from high flow resistance due to the inherent morphological properties of the right angle shape, easily causing the inner walls of the ceramic carrier's compartments to bend or skew, resulting in low product yield. This invention provides a honeycomb ceramic carrier with a "quadrilateral cross-section, one pair of opposite corners having concave or chamfered straight-through compartments, and the other pair of opposite corners not having concave or chamfered sections." This design reduces the bending of thin-walled honeycomb ceramic compartments without increasing wear on the honeycomb ceramic mold, thereby significantly improving product yield.

[0101] See Figures 1 to 12 In some embodiments of the present invention, in one of the compartments 2, in a pair of opposite corners having the recess or chamfer, the two apex corners have the same shape and size.

[0102] In some embodiments of the present invention, in one of the compartments 2, the two apex corners of a pair of opposite corners having the recess or chamfer have different shapes and / or different sizes.

[0103] See Figures 1 to 12 In some embodiments of the present invention, the four compartments 2 constitute a repeating unit having a center of symmetry; wherein the apex corners of the four compartments 2 located inside the repeating unit have the recesses or chamfers.

[0104] See Figures 1 to 12 In some embodiments of the present invention, the four compartments 2 constitute a repeating unit having a center of symmetry; wherein, the apex corners of the four compartments 2 located inside the repeating unit have the concave portion or chamfer, and the apex corners of the four compartments 2 located inside the repeating unit do not have the concave portion or chamfer.

[0105] See Figures 1 to 5 , Figure 11 as well as Figure 12 In some embodiments of the present invention, the number of compartments 2 is at least twelve; wherein each compartment 2 constitutes a quarter portion of at least two repeating units.

[0106] See Figures 1 to 5 , Figure 11 as well as Figure 12 In some embodiments of the present invention, in a repeating unit, the four compartments 2 located inside the repeating unit and forming convex right-angled apex corners enclose each other and form a common intersection 32 at the position of the center of symmetry.

[0107] See Figures 1 to 5 , Figure 11 as well as Figure 12 In some embodiments of the present invention, in a repeating unit, the four compartments 2 located inside the repeating unit and having the concave portion or chamfered apex corners enclose each other and form a reinforcing intersection 31 at the location of the center of symmetry.

[0108] See Figures 1 to 5 , Figure 11 as well as Figure 12 The radial dimension of the reinforced intersection 31 is obviously larger than that of the ordinary intersection 32. It is understandable that, under the same parameters, the increase in the radial dimension of the structure at this point can improve the structural strength of the honeycomb ceramic carrier, thereby enhancing the durability of the honeycomb ceramic carrier and reducing or even avoiding adverse phenomena such as distortion and deformation of the inner wall of the partition.

[0109] See Figure 1 and Figure 6 In some embodiments of the present invention, the concave portion is a concave right angle, which is configured to be concave relative to the interior of the compartment 2 in which it is located.

[0110] See Figure 3 , Figure 4 , Figure 7 and Figure 8 In some embodiments of the present invention, the concave portion is a rounded corner, which is configured to convex or concave relative to the interior of the compartment 2 in which it is located.

[0111] In some embodiments of the present invention, the water absorption rate of the cellular ceramic carrier is 14-28%, preferably 16-24%. The water absorption rate is, for example, 14%, 16%, 18%, 20%, 22%, 24%, 26%, and 28%, any range of these values, and any value falling between the above values.

[0112] In some embodiments of the present invention, the compressive strength of the ceramic carrier in the longitudinal direction is 9 to 10.5 MPa. The compressive strength is, for example, 9 MPa, 9.1 MPa, 9.2 MPa, 9.3 MPa, 9.4 MPa, 9.5 MPa, 9.6 MPa, 9.7 MPa, 9.8 MPa, 9.9 MPa, 10 MPa, 10.1 MPa, 10.2 MPa, 10.3 MPa, 10.4 MPa, and 10.5 MPa, any range of these values, and any value falling between these values.

[0113] In some embodiments of the present invention, the coefficient of thermal expansion (CTE) of the ceramic carrier in the longitudinal direction is 0.2 x 10⁻⁶ within a temperature range of 25–800°C. -6 ~0.5×10 -6 ℃ -1 The coefficient of thermal expansion is, for example, 0.2 × 10⁻⁶. -6 ℃ -1 0.25×10 -6 ℃ -1 0.3×10 -6 ℃ -1 0.35×10 -6 ℃ -1 0.4×10 -6 ℃ -1 0.45×10 -6 ℃ -1 0.5×10 -6 ℃ -1 , any range consisting of these values ​​and any value falling between the above values.

[0114] In some embodiments of the present invention, the isostatic compressive strength of the ceramic support is 3.1 to 6.3 MPa. The isostatic compressive strength is, for example, 3.1 MPa, 3.3 MPa, 3.5 MPa, 3.7 MPa, 4 MPa, 4.2 MPa, 4.4 MPa, 4.6 MPa, 4.8 MPa, 5 MPa, 5.2 MPa, 5.4 MPa, 5.6 MPa, 5.8 MPa, 6 MPa, 6.1 MPa, and 6.3 MPa, any range of these values, and any value falling between these values.

[0115] In some embodiments of the present invention, the thermal shock parameter (TSP) of the ceramic carrier is 650°C to 750°C, preferably 700°C to 750°C.

[0116] In some embodiments of the present invention, the longitudinal length of the ceramic carrier is 3 to 5.5 inches. The longitudinal length is, for example, 3 inches, 3.2 inches, 3.4 inches, 3.6 inches, 3.8 inches, 4 inches, 4.2 inches, 4.4 inches, 4.6 inches, 4.8 inches, 5 inches, 5.2 inches, 5.4 inches, and 5.5 inches, any range of these values, and any value falling between these values.

[0117] In some embodiments of the invention, the radial dimension of the ceramic carrier is 3.7 to 5.6 inches. Examples of radial dimensions include 3.7 inches, 3.8 inches, 4 inches, 4.2 inches, 4.4 inches, 4.6 inches, 4.8 inches, 5 inches, 5.2 inches, 5.4 inches, and 5.6 inches, any range of these values, and any value falling between these values.

[0118] In some embodiments of the present invention, the density of the compartment 2 in the ceramic carrier is 600–1200 cpsi. The compartment is, for example, 600 cpsi, 700 cpsi, 800 cpsi, 900 cpsi, 1000 cpsi, 1100 cpsi, and 1200 cpsi, any range of these values, and any value falling between the above values.

[0119] In some embodiments of the present invention, the wall thickness of two adjacent compartments 2 in the ceramic carrier is 2 to 4 mil.

[0120] See Figure 1 and Figure 6 In some embodiments of the present invention, in each of the compartments 2, the two vertices of a pair of opposite corners without the concave portion or chamfer are right angles, each right angle being composed of two first straight line segments, one of which has a length of A1 and the other has a length of B1; each vertices of a pair of opposite corners with the concave portion are composed of two second straight line segments, one of which has a length of A2 and the other has a length of B2; wherein (A2 / A1)*100% = 5-25%, preferably 15-25%, and (B2 / B1)*100% = 5-25%, preferably 15-25%.

[0121] See Figure 2 and Figure 7In some embodiments of the present application, in each of the compartments 2, the two corners of the pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1, and the other of which has a length of B1; each corner of the pair of opposite corners with the chamfer is composed of a third straight line segment, the projection length of the third straight line segment in the direction of one of the first straight line segments is A3, and the projection length of the third straight line segment in the direction of the other first straight line segment is B3; wherein (A3 / A1)*100% = 5-25%, preferably 15-25%, (B3 / B1)*100% = 5-25%, preferably 15-25%.

[0122] Referring to Figure 3 , Figure 4 , Figure 7 and Figure 8 In some embodiments of the present application, in each of the compartments 2, the two corners of the pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1, and the other of which has a length of B1; each corner of the pair of opposite corners with the chamfer is composed of a third straight line segment, the projection length of the third straight line segment in the direction of one of the first straight line segments is A3, and the projection length of the third straight line segment in the direction of the other first straight line segment is B3; wherein (A3 / A1)*100% = 5-25%, preferably 15-25%, (B3 / B1)*100% = 5-25%, preferably 15-25%.

[0123] Referring to Figure 5 and Figure 10 In some embodiments of the present application, in each of the compartments 2, the two corners of the pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1, and the other of which has a length of B1; each corner of the pair of opposite corners with the chamfer is composed of a third straight line segment, the projection length of the third straight line segment in the direction of one of the first straight line segments is A3, and the projection length of the third straight line segment in the direction of the other first straight line segment is B3; wherein (A3 / A1)*100% = 5-25%, preferably 15-25%, (B3 / B1)*100% = 5-25%, preferably 15-25%.

[0124] It can be understood that the present application provides a straight-through honeycomb ceramic body with special cells, the cells are quadrilaterals with a pair of special diagonal structures, and the cells are arranged in mirror symmetry with adjacent cells in the honeycomb ceramic body. The special structure of the cell diagonal includes a bevel, an inner arc edge, an outer arc edge and an inner right angle structure. The honeycomb ceramic carrier with the structure improves the cell wall bending problem, and the yield rate, comprehensive performance of the carrier are similar to those of a four-bevel and round-corner honeycomb ceramic, the wear of the honeycomb ceramic mold is reduced; the special cell structure can improve the plasticity of the clay, reduce and avoid the cell wall bending phenomenon, improve the compression resistance of the honeycomb ceramic body, and improve the yield rate. The structure can reduce the wear amount of the mold and reduce the coating amount of the catalyst.

[0125] In some embodiments of the present application, the raw materials of the ceramic carrier include inorganic raw materials, organic additives, binders and water.

[0126] In some embodiments of the present application, the inorganic raw materials are talc, kaolin, alumina and optional silicon oxide, aluminum hydroxide.

[0127] In some embodiments of the present application, the talc is preferably flaky talc, and more preferably flaky talc with D50=5-20 μm.

[0128] In some embodiments of the present application, the kaolin is preferably raw kaolin and / or cooked kaolin, the raw kaolin is more preferably flaky raw kaolin, the flaky raw kaolin is more preferably flaky raw kaolin with D50=5-20 μm, and the cooked kaolin is more preferably cooked kaolin with D50=4-15 μm.

[0129] In some embodiments of the present application, the silicon oxide is preferably silicon oxide with D50=1-10 μm, and the alumina is preferably alumina with D50=1-10 μm.

[0130] In some embodiments of the present application, the organic additive is at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, xanthan gum, potassium silicate, and random polyether of glycerol.

[0131] In some embodiments of the present application, the binder is at least one of hydroxymethyl cellulose, ethyl cellulose and carboxymethyl cellulose.

[0132] In some embodiments of the present application, the talc accounts for 20-40 wt.%, the kaolin accounts for 20-60 wt.%, the alumina accounts for 10-20 wt.%, the silica accounts for 0-10 wt.%, the organic additive accounts for 2-10 wt.%, the binder accounts for 3-15 wt.%, and the water accounts for 25-50 wt.%, based on the total amount of inorganic raw materials being 100 wt.%.

[0133] Preferably, the kaolin comprises 10-30 wt.% of tabular raw kaolin and 10-30 wt.% of cooked kaolin, based on the total amount of inorganic raw materials being 100 wt.%.

[0134] The second aspect

[0135] Referring to Figure 13 A method for preparing a honeycomb ceramic carrier, comprising the following steps: S1, mixing inorganic raw materials to obtain dry materials; S2, obtaining a green body by sequentially performing wet mixing, kneading, pugging, extrusion molding, drying, and cutting on the dry materials obtained in the step S1, an organic additive, a binder, and water; S3, obtaining the honeycomb ceramic carrier described above by sintering the green body obtained in the step S2; wherein the cells 2 of the honeycomb ceramic carrier are formed during the extrusion molding in the step S2, the cells 2 have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section does not have an inner recess or a chamfer.

[0136] In some embodiments of the present application, in the step S3, the heating rate and the sintering temperature at least at some time points change with the sintering time during the sintering process.

[0137] In some embodiments of the present application, in the step S3, the sintering temperature is 1000-1450℃, the sintering time is at least 13 h, and the heating rate is greater than 25℃ / h.

[0138] In some embodiments of the present application, in the step S2, the wet mixing comprises: putting the dry materials, the binder, and the organic additive into a plowshare mixer to perform dry mixing, and then performing wet mixing after water spraying; the pugging comprises: putting the raw materials after the wet mixing into a mesh pug mill to perform pugging under vacuum conditions; the extrusion molding comprises: putting the raw materials after the pugging into an extruder, preferably at least one selected from a single-screw extruder, a double-screw extruder, or a hydraulic extruder, to perform molding, and then obtaining the cells 2 through a mold; the drying comprises: performing drying molding by using a microwave dryer; and the cutting comprises: performing cutting by using a green body cutting machine.

[0139] By the above preparation method, a straight-through honeycomb ceramic body with a special compartment can be obtained, the compartment is a quadrilateral with a pair of special diagonal structures, and the compartments are arranged in mirror symmetry with adjacent compartments in the honeycomb ceramic body. The product has uniform stress distribution, uniform clay extrusion, high yield, good compression resistance and shock resistance, reduces catalyst coating, and has small mold loss. The straight-through honeycomb ceramic special structure body of the application reduces the carrier wave wall, improves the yield, increases the compression strength, reduces the coating amount of noble metal, and prolongs the service life of the mold. That is, the yield of the honeycomb ceramic carrier with the special structure is about 10%-20% higher than that of the right-angle structure, the service life of the mold is much higher than that of the quadrangular round structure, the change amount of the slot width of the mold is between 0.1-0.2 mil per 5000 meters of extrusion, which is similar to the change amount of the slot width of the rectangular structure mold, and the coating thickness of the noble metal at the special structure is about 1 / 2 of that of the right-angle structure. The honeycomb ceramic carrier with the quadrilateral compartment with a pair of special diagonal structures of the application has higher yield than the right-angle structure, reduces the coating amount of noble metal, and increases the service life of the mold with the advantages of the round structure and the right-angle structure.

[0140] Third aspect

[0141] A catalyst body comprising the honeycomb ceramic carrier described above, wherein a catalyst is coated on the inner wall surface of the compartment 2 of the honeycomb ceramic carrier; preferably, the coating thickness of the catalyst at the vertex position with the inner recess or chamfer structure is 0.06-0.08 μm, and the coating thickness of the catalyst at the remaining positions is 0.07 μm.

[0142] Example 1

[0143] In this example, 35 wt.% of flaky talc, 19.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 5 wt.% of silicon oxide, 15.2 wt.% of aluminum oxide, 8.0 wt.% of a binder, and 3.9 wt.% of a lubricant accounting for 8.0 wt.% of the total amount of inorganic raw materials are added to a plow mixer for dry mixing for 10 min at a rotation speed of 500 rpm; after the dry mixing, 32 wt.% of water relative to the inorganic raw materials is added for wet mixing, and the wet mixing time is 15 min at a rotation speed of 500 rpm; then a honeycomb structure is extruded using a 600-mesh mold with a diameter of 3.7 inches; the cutting length is 3.1 inches; then drying is performed at 50°C for 0.3 h; the obtained green body is first heated for 7 h at 250-310°C for glue removal, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0144] Example 2

[0145] In this example, 25 wt.% of flaky talc, 24.8 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% relative to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 750-mesh mold having a diameter of 4.66 inches, and the cut length was 3.1 inches. The green body was then dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0146] Example 3

[0147] In this example, 30.6 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% relative to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 800-mesh mold having a diameter of 4.66 inches, and the cut length was 5 inches. The green body was then dried at 50°C for 0.3 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0148] Example 4

[0149] In this example, 36 wt.% of tabular talc, 19.2 wt.% of tabular raw kaolin, 24.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm. After the dry-mixing, 33 wt.% of water was added to the inorganic raw materials and wet-mixed for 15 min at a rotation speed of 500 rpm. Then, a honeycomb structure was extruded using a die having 1200 meshes and a diameter of 5.2 inches. The cutting length was 3.94 inches. Then, drying was performed at 50°C for 0.4 h. The green body obtained was first heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0150] Example 5

[0151] In this example, 36 wt.% of tabular talc, 19.2 wt.% of tabular raw kaolin, 24.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm. After the dry-mixing, 33 wt.% of water was added to the inorganic raw materials and wet-mixed for 15 min at a rotation speed of 500 rpm. Then, a honeycomb structure was extruded using a die having 1200 meshes and a diameter of 5.2 inches. The cutting length was 3.94 inches. Then, drying was performed at 50°C for 0.4 h. The green body obtained was first heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0152] Example 6

[0153] In this example, 25 wt.% of flaky talc, 29.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 1.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 50 wt.% relative to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 600-mesh mold having a diameter of 3.7 inches, and the cut length was 3.1 inches. The green body was then dried at 50°C for 0.3 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0154] Example 7

[0155] In this example, 30 wt.% of flaky talc, 23.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 14.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% relative to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 750-mesh mold having a diameter of 3.7 inches, and the cut length was 3.1 inches. The green body was then dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0156] Example 8

[0157] In this example, 38 wt.% of flaky talc, 12 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 17 wt.% of aluminum oxide, and 7 wt.% of a binder and 7 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet mixed by adding water in a proportion of 30 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 800 mesh mold having a diameter of 3.7 inches, and the cut length was 3.1 inches. The green body was then dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0158] Example 9

[0159] In this example, 40 wt.% of flaky talc, 20.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 11.2 wt.% of aluminum oxide, and 6 wt.% of a binder and 9 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet mixed by adding water in a proportion of 29 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 900 mesh mold having a diameter of 4.66 inches, and the cut length was 3.1 inches. The green body was then dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0160] Example 10

[0161] In this example, 25 wt.% of flaky talc, 24.2 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.8 wt.% of aluminum oxide, and 10 wt.% of a binder and 2.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, water was added in a proportion of 45 wt.% based on the inorganic raw materials after the dry mixing was completed, and wet mixing was performed for 15 min at a rotation speed of 500 rpm, and then a honeycomb structure was extruded using a die having 1200 meshes and a diameter of 4.66 inches, the cutting length was 5 inches, and then drying was performed at 50°C for 0.4 h, and the green body obtained was first degreased by heating at 250-310°C for 7 h, then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0162] Example 11

[0163] In this example, 30 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 6 wt.% of silicon oxide, 11.8 wt.% of aluminum oxide, and 9.2 wt.% of a binder and 2.6 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, water was added in a proportion of 39 wt.% based on the inorganic raw materials after the dry mixing was completed, and wet mixing was performed for 15 min at a rotation speed of 500 rpm, and then a honeycomb structure was extruded using a die having 600 meshes and a diameter of 5.2 inches, the cutting length was 3.94 inches, and then drying was performed at 50°C for 0.5 h, and the green body obtained was first degreased by heating at 250-310°C for 7 h, then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0164] Example 12

[0165] In this example, 37 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm; after the dry mixing, 33 wt.% of water was added for wet mixing, and the wet mixing was performed for 15 min at a rotation speed of 500 rpm; then a honeycomb structure was extruded using a 600-mesh mold with a diameter of 5.2 inches; the cutting length was 3.94 inches; then drying was performed at 50°C for 0.4 h; the green body obtained was first heated for 7 h at 250-310°C to remove the binder, then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0166] Example 13

[0167] In this example, 30 wt.% of flaky talc, 23.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 15.2 wt.% of aluminum oxide, and 6.5 wt.% of a binder and 5.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm; after the dry mixing, 33 wt.% of water was added for wet mixing, and the wet mixing was performed for 15 min at a rotation speed of 500 rpm; then a honeycomb structure was extruded using a 750-mesh mold with a diameter of 5.2 inches; the cutting length was 3.94 inches; then drying was performed at 50°C for 0.4 h; the green body obtained was first heated for 7 h at 250-310°C to remove the binder, then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0168] Example 14

[0169] In this example, 33 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 5 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 2 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% with respect to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. Thereafter, a honeycomb structure was extruded using a 750-mesh mold having a diameter of 5.2 inches, and the length of the cut pieces was 3.94 inches. The green body was dried at 50°C for 0.4 h, and then degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0170] Example 15

[0171] In this example, 33 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 5 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 2 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% with respect to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. Thereafter, a honeycomb structure was extruded using a 750-mesh mold having a diameter of 5.2 inches, and the length of the cut pieces was 3.94 inches. The green body was dried at 50°C for 0.4 h, and then degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0172] Comparative Example 1

[0173] In this example, 36 wt.% of flaky talc, 20.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 12.2 wt.% of aluminum oxide, and 9 wt.% of a binder and 5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% with respect to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. Then, a honeycomb structure was extruded using a mold having a mesh size of 600 and a diameter of 3.7 inches, and the length of the cut pieces was 3.1 inches. Then, the green body was dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0174] Comparative Example 2

[0175] In this example, 32 wt.% of flaky talc, 21.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 7 wt.% of a binder and 6 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 33 wt.% with respect to the inorganic raw materials for 15 min at a rotation speed of 500 rpm. Then, a honeycomb structure was extruded using a mold having a mesh size of 750 and a diameter of 4.66 inches, and the length of the cut pieces was 3.1 inches. Then, the green body was dried at 50°C for 0.4 h, and then heated at 250-310°C for 7 h to remove the binder, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0176] Comparative Example 3

[0177] In this example, 25 wt.% of flaky talc, 20.2 wt.% of flaky raw kaolin, 32.6 wt.% of calcined kaolin, 5 wt.% of silicon oxide, 17.2 wt.% of aluminum oxide, and 3 wt.% of a binder and 10 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 28 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a mold having 800 meshes and a diameter of 4.66 inches, and the length of the cut pieces was 5 inches. The green body was then dried at 50°C for 0.4 h, and then degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0178] Comparative Example 4

[0179] In this example, 39 wt.% of flaky talc, 10.2 wt.% of flaky raw kaolin, 30.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 15 wt.% of a binder and 2 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet-mixed by adding water in a proportion of 50 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a mold having 600 meshes and a diameter of 3.7 inches, and the length of the cut pieces was 3.1 inches. The green body was then dried at 50°C for 0.4 h, and then degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0180] Comparative Example 5

[0181] In this example, 30 wt.% of flaky talc, 29.8 wt.% of flaky raw kaolin, 15 wt.% of calcined kaolin, 10 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 2 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet mixed by adding water in a proportion of 45 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 750-mesh mold having a diameter of 4.66 inches, and the cut length was 3.1 inches. The green body was then dried at 50 °C for 0.4 h, and then degreased by heating at 250-310 °C for 7 h, and then fired at 1430 °C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0182] Comparative Example 6

[0183] In this example, 25 wt.% of flaky talc, 28.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 10 wt.% of a binder and 3.5 wt.% of a lubricant based on the total amount of inorganic raw materials were dry mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, and then wet mixed by adding water in a proportion of 46 wt.% based on the inorganic raw materials for 15 min at a rotation speed of 500 rpm. The honeycomb structure was then extruded using a 800-mesh mold having a diameter of 4.66 inches, and the cut length was 5 inches. The green body was then dried at 50 °C for 0.4 h, and then degreased by heating at 250-310 °C for 7 h, and then fired at 1430 °C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0184] Comparative Example 7

[0185] In this example, 31 wt.% of flaky talc, 29.2 wt.% of flaky raw kaolin, 10.6 wt.% of calcined kaolin, 10 wt.% of silicon oxide, 19.2 wt.% of aluminum oxide, and 7 wt.% of a binder and 6 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, water was added in a proportion of 36 wt.% based on the inorganic raw materials after the dry-mixing was completed, and wet-mixing was performed for 15 min at a rotation speed of 500 rpm, and then a honeycomb structure was extruded using a 750-mesh mold having a diameter of 4.66 inches, the cutting length was 5 inches, and then drying was performed at 50°C for 0.4 h, and the green body obtained was first degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0186] Comparative Example 8

[0187] In this example, 31 wt.% of flaky talc, 29.2 wt.% of flaky raw kaolin, 10.6 wt.% of calcined kaolin, 10 wt.% of silicon oxide, 19.2 wt.% of aluminum oxide, and 7 wt.% of a binder and 6 wt.% of a lubricant based on the total amount of inorganic raw materials were dry-mixed in a plow mixer for 10 min at a rotation speed of 500 rpm, water was added in a proportion of 36 wt.% based on the inorganic raw materials after the dry-mixing was completed, and wet-mixing was performed for 15 min at a rotation speed of 500 rpm, and then a honeycomb structure was extruded using a 750-mesh mold having a diameter of 4.66 inches, the cutting length was 5 inches, and then drying was performed at 50°C for 0.4 h, and the green body obtained was first degreased by heating at 250-310°C for 7 h, and then fired at 1430°C for 6 h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0188] Comparative Example 9

[0189] In this embodiment, 29 wt.% of flake talc, 25.8 wt.% of flake raw kaolin, 25 wt.% of calcined kaolin, 4 wt.% of silica, 16.2 wt.% of alumina, 3.5 wt.% of binder and 10 wt.% of lubricant (accounting for the total inorganic raw materials) were added to a plow-type mixer and dry-mixed for 10 minutes at a rotation speed of 500 rpm. After dry mixing, water at a ratio of 28 wt.% relative to the inorganic raw materials was added for wet mixing for 15 minutes at a rotation speed of 500 rpm. Subsequently, a honeycomb structure was extruded using a 750-mesh die with a diameter of 4.66 inches and a cutting length of 5 inches. The structure was then dried at 50°C for 0.4 hours. The resulting green body was first heated at 250-310°C for 7 hours to remove the binder, then fired at 1430°C for 6 hours, and finally naturally cooled to obtain the honeycomb ceramic carrier.

[0190] The parameters of the above embodiments and comparative examples are listed in Table 1 below.

[0191] Table 1. Parameter comparison of each embodiment and comparative example.

[0192]

[0193]

[0194]

[0195] Example 2 differs from Example 1 in that the pore density and diameter are changed to create a honeycomb ceramic structure.

[0196] Example 3 differs from Example 1 in that the pore density, wall thickness, length, and diameter are changed to create a honeycomb ceramic structure.

[0197] Compared with Example 1, Example 4 changed the pore density, wall thickness, length, diameter, and proportion of special structures to create a honeycomb ceramic structure.

[0198] Example 5 differs from Example 1 in that it modifies the pore density, wall thickness, length, diameter, and proportion of special structures to create a honeycomb ceramic structure.

[0199] Compared to Example 1, Example 6 changed the compartment structure and the proportion of special structures to create a honeycomb ceramic structure.

[0200] Compared to Example 1, Example 7 changed the pore density and the proportion of special structures to create a honeycomb ceramic structure.

[0201] Compared with Example 1, Example 8 changed the pore density, wall thickness, and proportion of special structures to produce a honeycomb ceramic structure.

[0202] Example 9 A honeycomb ceramic structure was made by changing the cell density, diameter, and special structure ratio relative to Example 1.

[0203] Example 10 A honeycomb ceramic structure was made by changing the cell density, diameter, length, and special structure ratio relative to Example 1.

[0204] Example 11 A honeycomb ceramic structure was made by changing the diameter, length, and special structure ratio relative to Example 1.

[0205] Example 12 A honeycomb ceramic structure was made by changing the wall thickness, diameter, length, and special structure ratio relative to Example 1.

[0206] Example 13 A honeycomb ceramic structure was made by changing the cell density, diameter, length, and special structure ratio relative to Example 1.

[0207] Example 14 A honeycomb ceramic structure was made by changing the cell density, wall thickness, diameter, length, and special structure ratio relative to Example 1.

[0208] Example 15 A honeycomb ceramic structure was made by changing the cell density, wall thickness, diameter, length, and special structure ratio relative to Example 1.

[0209] Comparative Example 1 A honeycomb ceramic structure was made by changing the cell structure relative to Example 1.

[0210] Comparative Example 2 A honeycomb ceramic structure was made by changing the cell structure, cell density, and diameter relative to Example 1.

[0211] Comparative Example 3 A honeycomb ceramic structure was made by changing the cell structure, cell density, wall thickness, diameter, and length relative to Example 1.

[0212] Comparative Example 4 A honeycomb ceramic structure was made by changing the cell structure, diameter, and length relative to Example 1.

[0213] Comparative Example 5 A honeycomb ceramic structure was made by changing the cell structure, cell density, and length relative to Example 1.

[0214] Comparative Example 6 A honeycomb ceramic structure was made by changing the cell structure, cell density, wall thickness, and length relative to Example 1.

[0215] Comparative Example 7 A honeycomb ceramic structure was made by changing the cell density, length, and diameter relative to Example 1.

[0216] Comparative Example 8 changed the cell density, length, diameter, special structure proportion, and produced a honeycomb ceramic structure relative to Example 1.

[0217] Comparative Example 9 changed the cell density, length, diameter, compartment structure, special structure proportion, and produced a honeycomb ceramic structure relative to Example 1.

[0218] The performance test results of the honeycomb ceramic carriers obtained in each of the above examples and comparative examples are listed in Table 2 below.

[0219] Table 2 Performance test results of the honeycomb ceramic carriers obtained in each of the examples and comparative examples

[0220]

[0221]

[0222] Table 2 is a performance comparison of the cordierite honeycomb ceramic carriers produced in each of the examples and comparative examples, mainly involving the specific specifications, carrier yield, thermal expansion coefficient, thermal shock, isostatic pressing, catalyst coating thickness, change in die slot width, A-axis compressive strength, etc. The thermal expansion coefficient is tested by a thermal dilatometer from room temperature to 800°C. The A-axis compressive strength is tested by a servo computer universal material testing machine using a 25±0.5mm sample block. The thermal shock is tested by a muffle furnace, which is heated to 650°C for 30min, and the product is taken out and placed at room temperature without cracking. The catalyst coating thickness is obtained by image testing.

[0223] The change in die slot width is obtained by image testing. The change in die slot width before and after production is tested for every 5000 meters of cordierite honeycomb ceramic carrier produced.

[0224] As can be seen from Examples 1-15 in Table 2, the compressive strength of the honeycomb ceramic carrier with special structure compartments is similar to that of the honeycomb ceramic carrier with all rounded corners in Comparative Examples 4-6. The compressive strength of the honeycomb ceramic carrier with special structure compartments is higher than that of Comparative Examples 1-3, and the yield is much higher than that of Comparative Examples 1-3, which is basically 20% higher. The precious metal coating thickness of the honeycomb ceramic carrier with special structure compartments is much lower than that of Comparative Examples 1-3, which is basically 50% lower. Compared with Comparative Examples 4-6, the wear degree of the die of Examples 1-15 is very low, and the change in die slot width per 5000 meters of the special compartment mechanism is about 10% of the full rounded corner structure, greatly improving the service life of the die and reducing the cost of the product. Compared with Comparative Examples 4-6, the yield of Examples 1-15 is 10% higher, and a special angle proportion exceeding 30% will greatly reduce the yield.

[0225] In addition, the "thermal shock resistance" in the present application specification is also called thermal stability, the ability of the material to withstand severe temperature changes or alternating hot and cold within a certain initial temperature range without being damaged, and the temperature that can withstand alternating hot and cold without being damaged is the thermal shock parameter, which is generally measured after three cycles of experiments. The honeycomb ceramic structure does not crack after three thermal cycles at the above-mentioned temperature, and the isostatic pressure test method is as follows: the sample is wrapped with a rubber sleeve and placed in an isostatic pressure tester filled with water, and the pressure is applied and maintained for 5 minutes without cracking sound. The above carrier can complete the test under 2-7 MPa.

[0226] The honeycomb ceramic has the following structural characteristics: the thermal expansion coefficient (CTE) measured at 25°C to 800°C is 0.2x10 -6 ~0.5x10 -6 ℃ -1 , and the thermal shock parameter (TSP) of the honeycomb ceramic structure is 650-750℃, i.e. the honeycomb ceramic structure does not crack after three thermal cycles at the above-mentioned temperature, and the isostatic pressure test method is as follows: the sample is wrapped with a rubber sleeve and placed in an isostatic pressure tester filled with water, and the pressure is applied and maintained for 5 minutes without cracking sound. The above carrier can complete the test under 2-7 MPa.

[0227] The above is only a specific embodiment of the present application, but the protection scope of the present application is not limited thereto, and any skilled person in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims. In addition, specific examples are applied in the specification to describe the principles and embodiments of the present application, and the above examples are only used to help understand the method and core idea of the present application, and the content of the specification should not be understood as a limitation of the present application.

Claims

1. A honeycomb ceramic substrate, characterized by, The honeycomb ceramic carrier comprises: a body (1); a plurality of cells (2) with hollow structure in the body (1), the cells (2) penetrating through the body (1) to form a honeycomb structure; wherein the cells (2) have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section has no inner recess or chamfer; four cells (2) constitute a repeating unit, and in each repeating unit, each cell (2) and the cell (2) adjacent thereto are arranged in mirror symmetry.

2. The honeycomb ceramic carrier of claim 1, wherein, In one cell (2), two top angles in the pair of opposite angles with the inner recess or chamfer have the same shape and size. Alternatively, in one cell (2), two top angles in the pair of opposite angles with the inner recess or chamfer have different shapes and / or different sizes.

3. The honeycomb ceramic substrate of claim 1, wherein, The repeating unit has a center of symmetry; wherein the top angles of the four cells (2) in the repeating unit, which are located inside the repeating unit, have the inner recess or chamfer, or the top angles of the four cells (2) in the repeating unit, which are located inside the repeating unit, have no inner recess or chamfer.

4. The honeycomb ceramic substrate of claim 3, wherein, The number of the cells (2) is at least twelve; wherein each cell (2) constitutes one fourth of at least two repeating units.

5. The honeycomb ceramic substrate of claim 3, wherein, In one repeating unit, the top angles of the four cells (2) with the inner recess or chamfer, which are located inside the repeating unit, are enclosed, and form a reinforced intersection point (31) at the position of the center of symmetry; Alternatively, in one repeating unit, the top angles of the four cells (2) with the outer convex right angle, which are located inside the repeating unit, are enclosed, and form a common intersection point (32) at the position of the center of symmetry.

6. The honeycomb ceramic substrate of claim 1 wherein, The inner recess is an inner recessed right angle, a rounded corner or an inner recessed flower corner; wherein the inner recessed right angle is configured to be recessed inward with respect to the interior of the cell (2) where it is located, and the rounded corner is configured to be convex outward or recessed inward with respect to the interior of the cell (2) where it is located.

7. The honeycomb ceramic substrate of any one of claims 1-6, wherein, The honeycomb ceramic carrier has one or more of the following characteristics: The water absorption of the honeycomb ceramic carrier is 14-28%; The compressive strength of the honeycomb ceramic carrier in the longitudinal direction is 9-10.5 MPa; The honeycomb ceramic carrier has a coefficient of thermal expansion CTE in the longitudinal axis direction of 0.2 x 10 -6 ~0.5 x 10 -6 ℃ -1 in a temperature range of 25 to 800°C. The isostatic strength of the honeycomb ceramic carrier is 3.1-6.3 MPa; The thermal shock parameter TSP of the ceramic carrier is 650-750℃; The size of the ceramic carrier in the longitudinal direction is 3-5.5 inches; The radial size of the ceramic carrier is 3.7-5.6 inches; In the ceramic carrier, the density of the cells (2) is 600-1200 cpsi; and / or, the thickness of the partition wall between two adjacent cells (2) in the ceramic carrier is 2-4 mil.

8. The honeycomb ceramic substrate of claim 7, wherein, The thermal shock parameter TSP of the ceramic carrier is 700-750℃.

9. The honeycomb ceramic substrate of any one of claims 1-6, wherein, In each of the compartments (2), two top corners in a pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1 and the other has a length of B1; Each top corner in a pair of opposite corners with the inner recess is composed of two second straight line segments, one of which has a length of A2 and the other has a length of B2; Wherein, (A2 / A1)*100%=5~25%, (B2 / B1)*100%=5~25%.

10. The honeycomb ceramic substrate of claim 9, wherein, (A2 / A1)*100%=15~25%, (B2 / B1)*100%=15~25%.

11. The honeycomb ceramic substrate of any one of claims 1-6, wherein, In each of the compartments (2), two top corners in a pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1 and the other has a length of B1; Each top corner in a pair of opposite corners with the chamfer is composed of a third straight line segment, the projection length of which in the direction of one of the first straight line segments is A3 and the projection length of which in the direction of the other of the first straight line segments is B3; Wherein, (A3 / A1)*100%=5~25%, (B3 / B1)*100%=5~25%.

12. The honeycomb ceramic substrate of claim 11, wherein, (A3 / A1)*100%=15~25%, (B3 / B1)*100%=15~25%.

13. The honeycomb ceramic substrate of any one of claims 1-6, wherein, In each of the compartments (2), two top corners in a pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1 and the other has a length of B1; Each top corner in a pair of opposite corners with the inner recess is composed of an arc line segment, the projection length of which in the direction of one of the first straight line segments is A4 and the projection length of which in the direction of the other of the first straight line segments is B4; Wherein, (A4 / A1)*100%=5~25%, (B4 / B1)*100%=5~25%.

14. The honeycomb ceramic substrate of claim 13, wherein, (A4 / A1)*100%=15~25%, (B4 / B1)*100%=15~25%.

15. The honeycomb ceramic substrate of any one of claims 1-6, wherein, In each of the compartments (2), two top corners in a pair of opposite corners without the inner recess or the chamfer are right angles, each of which is composed of two first straight line segments, one of which has a length of A1 and the other has a length of B1; Each top corner in a pair of opposite corners with the inner recess is composed of four fourth straight line segments connected in sequence, the sum of the projection lengths of which in the direction of one of the first straight line segments is A5 and the sum of the projection lengths of which in the direction of the other of the first straight line segments is B5; Wherein, (A5 / A1)*100%=5~25%, (B5 / B1)*100%=5~25%.

16. The honeycomb ceramic substrate of claim 15, wherein, (A5 / A1)*100% = 15~25%, (B5 / B1)*100% = 15~25%.

17. The honeycomb ceramic substrate of any one of claims 1-6, wherein, The raw materials of the ceramic carrier include inorganic raw materials, organic additives, binders and water; The inorganic raw materials are talc, kaolin, alumina and optionally silicon oxide, aluminum hydroxide; The organic additives are at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, xanthan gum, potassium metasilicate, and random polyether of glycerol; The binders are at least one of hydroxymethyl cellulose, ethyl cellulose, and carboxymethyl cellulose.

18. The honeycomb ceramic substrate of claim 17, wherein, At least one of the following characteristics is possessed: The talc is flaky talc; The kaolin is raw kaolin and / or cooked kaolin; The silicon oxide is silicon oxide with D50 = 1~10 μm; The alumina is alumina with D50 = 1~10 μm.

19. The honeycomb ceramic substrate of claim 18, wherein, At least one of the following characteristics is possessed: The raw kaolin is flaky raw kaolin; The flaky raw kaolin is flaky raw kaolin with D50 = 5~20 μm; The cooked kaolin is cooked kaolin with D50 = 4~15 μm.

20. The honeycomb ceramic substrate of claim 17, wherein, The talc accounts for 20~40 wt.% of the total amount of inorganic raw materials, the kaolin accounts for 20~60 wt.% of the total amount of inorganic raw materials, the alumina accounts for 10~20 wt.% of the total amount of inorganic raw materials, the silicon oxide accounts for 0~10 wt.% of the total amount of inorganic raw materials, the organic additives account for 2~10 wt.% of the total amount of inorganic raw materials, the binders account for 3~15 wt.% of the total amount of inorganic raw materials, and the water accounts for 25~50 wt.% of the total amount of inorganic raw materials.

21. The honeycomb ceramic substrate of claim 20, wherein, The kaolin includes 10~30 wt.% of flaky raw kaolin and 10~30 wt.% of cooked kaolin, based on 100 wt.% of the total amount of inorganic raw materials.

22. The method of manufacturing a honeycomb ceramic according to any one of claims 1 to 21, characterized in that, The preparation method Comprises the following steps: S1, mixing inorganic raw materials to obtain dry materials; S2, obtaining green bodies by sequentially mixing the dry materials obtained in step S1 with organic additives, binders, and water through wet mixing, kneading, pugging, extrusion molding, drying, and cutting; S3, obtaining the honeycomb ceramic carrier by sintering the green bodies obtained in step S2; In the extrusion molding process in step S2, the cells (2) of the honeycomb ceramic carrier are formed, the cells (2) have a quadrilateral cross section, one pair of opposite angles of the quadrilateral cross section has an inner recess or a chamfer, and the other pair of opposite angles of the quadrilateral cross section does not have an inner recess or a chamfer.

23. The preparation method according to claim 22, characterized in that, In the sintering process in step S3, the heating rate and the sintering temperature at least partially change with the sintering time.

24. The method of claim 22, wherein, In step S3, the sintering temperature is 1000℃~1450℃, the sintering time is at least 13h, and the heating rate is greater than 25℃ / h.

25. The preparation method according to claim 22, characterized in that, In step S2, the wet mixing comprises: putting the dry materials, binders, and organic additives into a plowshare mixer for dry mixing, and then wet mixing after water spraying; The pugging comprises: putting the materials after wet mixing into a mesh pug mill for pugging under vacuum conditions; The extrusion molding comprises: putting the materials after pugging into an extruder for molding, and then obtaining the cells (2) through a mold; The drying includes drying and molding using a microwave dryer. The cutting includes cutting using a dough cutting machine.

26. The method of claim 25, wherein, In the extrusion molding, at least one of a single screw extruder, a double screw extruder, or a hydraulic extruder is used as the extruder.

27. A catalytic body, characterized by The catalytic body includes the honeycomb ceramic carrier according to any one of claims 1 to 21, and a catalyst is coated on the inner wall surface of the cells (2) of the honeycomb ceramic carrier.

28. The catalytic body of claim 27, wherein, The catalyst coating thickness at the vertex position having the inner recess or chamfer structure is 0.06 to 0.08 mm, and the coating thickness at the remaining positions is 0.07 mm.

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