Low-water-absorption acid-resistant honeycomb ceramic and preparation method thereof

Abstract

The invention provides a low-water-absorption acid-resistant honeycomb ceramic, which is formed by combining a plurality of hexagonal frame cylindrical ceramic unit frames, and is characterized in that a filler which has a smooth surface and is in smooth transition with the inner wall is arranged at the inner corner of the honeycomb ceramic, so that the water absorption is reduced, the structural stability is enhanced, and the airflow dynamics is considered to ensure the high-efficiency performance. And the inner side channel is constructed to be circular by the filling material, so that the airflow characteristic is optimized. The filler of the composite material comprises high-purity aluminum oxide, an acid-resistant enhancer, a water absorption regulator and a sintering aid, and the composite material has the excellent properties of acid resistance, low water absorption, high strength and the like. The preparation method comprises the steps of unit frame preparation, structure combination, filler injection, curing finishing, sintering and the like, and the production efficiency is improved through mechanical injection and accurate control. The invention further relates to the steps of fine adjustment of the filler and pipeline cleaning so as to optimize the filling effect and keep stable performance. The honeycomb ceramic is suitable for the fields of catalysis, filtration and the like, and has wide application prospects.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic materials, in particular to an acid-resistant honeycomb ceramic with low water absorption and a preparation method thereof. Background Art

[0002] Honeycomb ceramics have broad application prospects in the fields of catalytic conversion, heat exchange, filtration and adsorption due to their unique honeycomb structure and excellent physical and chemical properties. However, traditional honeycomb ceramics often have high water absorption in humid environments, which leads to a decline in their performance and even structural damage in some extreme cases, seriously affecting their service life and application effects. Especially at the inner corners of the ceramic unit frame, due to structural discontinuities and the existence of tiny gaps, these areas are prone to become "hot spots" for water retention and accumulation, further exacerbating the problem of water absorption and stress concentration.

[0003] In order to reduce the water absorption rate of honeycomb ceramics and improve their moisture resistance, researchers have tried a variety of methods, such as changing the formula of ceramic raw materials, optimizing the sintering process, and performing surface treatment. However, these methods often have limited effects and may introduce new process complexity and cost issues. In addition, how to maintain the high efficiency of honeycomb ceramics while enhancing their structural integrity and durability has long been a technical problem that has plagued the industry.

[0004] On the other hand, traditional honeycomb ceramic preparation methods often have problems such as cumbersome filling process, uneven filling, and low production efficiency. Especially when filling the inner corners, it is often difficult to achieve accurate and efficient filling due to the small space and difficult control. This not only affects the final performance of the product, but also increases the scrap rate and cost in the production process. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides a low water absorption and acid-resistant honeycomb ceramic and a preparation method thereof, aiming to solve the problems of high water absorption and easy breakage of traditional honeycomb ceramics and to improve the stability and durability of the ceramics in a humid environment.

[0006] The above technical objectives of the present invention are achieved through the following technical solutions: a low water absorption acid-resistant honeycomb ceramic, comprising a plurality of ceramic unit frames in the shape of hexagonal columns and combined into a honeycomb shape; Filling material is provided at each inner corner of the ceramic unit frame. The surface of the filling material is smooth and the filling material smoothly transitions to the inner wall of the ceramic unit frame.

[0007] In some embodiments, each of the fillers configures the inner channel of the ceramic unit frame into a circular channel, and the circular channel is tangent to the inner wall of the ceramic unit frame.

[0008] In some embodiments, the filler is a ceramic composite material.

[0009] A method for preparing a honeycomb ceramic, the method is used to prepare the above-mentioned low water absorption acid-resistant honeycomb ceramic, comprising the following steps: a) preparing ceramic unit frames: preparing a plurality of ceramic unit frame blanks by using mold forming technology; b) Combined honeycomb structure: The ceramic unit frames are combined into a complete honeycomb ceramic body according to the honeycomb structure; c) Prepare a filling pipe: for each ceramic unit frame, prepare a pipe that is tangent to and in contact with its inner wall, and the pipe is provided with holes corresponding to each inner corner of the ceramic unit frame; d) Injecting filler: injecting filler into the pipe through the open end of the pipe, and the filler overflows from the holes and flows into each inner corner of the ceramic unit frame; e) Curing and finishing: After filling, let the filling material solidify, remove the pipe, and trim the inner and outer surfaces of the ceramic unit frame; f) Sintering: The honeycomb ceramic body is placed in a high-temperature kiln for sintering to obtain a honeycomb ceramic product with low water absorption and acid resistance.

[0010] In some embodiments, in step e), after the filling of the filling material is completed, the inserted pipe is rotated.

[0011] In some embodiments, after step e), the method further includes cleaning the filler adhered to the outer surface of the pipe.

[0012] Compared with the prior art, the present invention has the following beneficial effects: The low water absorption and acid-resistant honeycomb ceramics and the preparation method thereof proposed by the present invention cleverly solve the problems of high water absorption and easy breakage of traditional honeycomb ceramics in humid environments by setting fillers at the inner corners and optimizing their shape, size and distribution. Specifically, the design of the fillers effectively fills the inner corners of the inner frame of the ceramic unit, blocks the retention path of water in these areas, significantly reduces the water absorption rate, and improves the stability of the ceramic in a humid environment. At the same time, the smooth transition between the fillers and the inner wall of the ceramic enhances the structural integrity of the ceramic unit frame, reduces the risk of breakage due to stress concentration, and improves the overall strength and durability of the ceramic.

[0013] In addition, the preparation method of the present invention realizes accurate filling of each inner corner of the ceramic unit frame by opening holes corresponding to the inner corners of the ceramic unit frame and injecting filler into the pipeline. This method not only simplifies the production process and improves production efficiency, but also ensures that the filler can flow into each inner corner evenly and accurately, thereby improving the accuracy and efficiency of filling. Since the filling process is carried out on the assembled honeycomb ceramic blank, the extra workload caused by filling each ceramic unit frame separately is also avoided.

[0014] More importantly, although fillers are added to the inner corners, the design of the present invention takes into account air flow dynamics to ensure that the fillers do not hinder the smooth flow of gas. By carefully designing and optimizing the shape, size and distribution of the fillers, the present invention ensures that the gas can pass smoothly through the honeycomb ceramic structure, maintaining its high efficiency in applications such as catalysis and filtration. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the structure of the honeycomb ceramic of the present invention; Figure 2 It is a detailed structural diagram of the ceramic unit frame of the honeycomb ceramic of the present invention.

[0016] In the figure: 100, honeycomb ceramic; 1, ceramic unit frame; 2, filling material. DETAILED DESCRIPTION

[0017] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0018] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, and are only for the convenience of describing the present invention 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 invention.

[0019] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0020] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like 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 an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0021] like Figure 1-2 As shown, this embodiment provides a low water absorption acid-resistant honeycomb ceramic, characterized in that: It includes a plurality of ceramic unit frames 1 in the shape of hexagonal columns and combined into a honeycomb shape; Filling material 2 is provided at each inner corner of the ceramic unit frame 1 . The surface of the filling material 2 is smooth and smoothly transitions with the inner wall of the ceramic unit frame 1 .

[0022] The working principle of the present invention is mainly based on physical barrier and structural optimization. The design of the filler 2 effectively fills the inner corners of the inner frame of the ceramic unit, avoiding the retention and accumulation of moisture in these areas, thereby significantly reducing the penetration of moisture into the interior of the ceramic material, reducing the water absorption rate, and improving the stability of the ceramic in a humid environment. In addition, the application of the filler 2 not only fills the tiny gaps at the inner corners, but also enhances the structural integrity of the ceramic unit frame 1 through its smooth transition with the inner wall of the ceramic, reducing the risk of breakage caused by stress concentration. And although the filler 2 is added to the inner corners, its design takes into account the gas flow dynamics to ensure that the filler 2 does not hinder the smooth flow of gas, thereby maintaining the high efficiency of the honeycomb ceramic 100 in applications such as catalysis and filtration.

[0023] Specifically, the filler 2 is precisely placed at each inner corner of the ceramic unit frame 1, and these fillers 2 have a smooth surface and form a smooth transition with the inner wall of the ceramic. This design effectively blocks the retention path of moisture at the inner corner, reduces the direct contact area between moisture and the ceramic material, and thus reduces the water absorption rate. When moisture tries to penetrate, it will encounter the physical barrier of the filler 2 and be forced to flow along the surface of the ceramic instead of penetrating into the interior of the ceramic. In addition, the application of the filler 2 not only solves the problem of moisture retention, but also optimizes the structure of the ceramic unit frame 1 by filling the gaps at the inner corners. This reduces the risk of structural damage caused by stress concentration at the inner corners and improves the overall strength and durability of the ceramic. At the same time, the design of the filler 2 takes into account the airflow dynamics to ensure that it provides additional structural support for the ceramic without affecting the gas flow. And although the addition of the filler 2 may increase some airflow resistance, the present invention ensures that the gas can smoothly pass through the honeycomb ceramic 100 structure by carefully designing and optimizing the shape, size and distribution of the filler 2. In this way, the honeycomb ceramic 100 can maintain efficient working performance in applications such as catalytic conversion, heat exchange, filtration and adsorption.

[0024] In summary, the present invention cleverly solves the problems of high water absorption and easy breakage of the traditional honeycomb ceramic 100 in a humid environment by arranging the filler 2 at the inner corner, and provides a more reliable and efficient solution for the wide application of the honeycomb ceramic 100.

[0025] In some embodiments, Figure 2As shown, each filler 2 configures the inner channel of the ceramic unit frame 1 into a circular channel, and the circular channel is tangent to the inner wall of the ceramic unit frame 1; the design of the circular channel further optimizes the flow characteristics of the airflow through the honeycomb ceramic 100, so that the gas can be more evenly and smoothly distributed when flowing through each ceramic unit frame 1. Specifically, by configuring the inner channel to be circular and tangent to the inner wall, the present invention ensures that the gas can move along a continuous, smooth and unobstructed path when flowing through the ceramic unit frame 1. This design reduces the turbulence and eddy currents that may be generated when the airflow passes through traditional polygonal or irregularly shaped channels, thereby reducing the airflow resistance and improving the flow efficiency of the gas. Secondly, in catalytic applications, the uniform distribution of gas is crucial to catalytic efficiency. The design of the circular channel promotes full contact between the gas and the catalyst surface, and improves the efficiency and uniformity of the catalytic reaction. This has significant technical advantages for application scenarios that require efficient catalytic conversion, such as automobile exhaust treatment, industrial waste gas purification, etc. Moreover, the tangent design of the circular channel and the inner wall not only optimizes the airflow from the perspective of fluid mechanics, but also enhances the stability of the ceramic unit frame 1 from the perspective of structural mechanics. The tangent design reduces the stress concentration points caused by the sudden change of shape, so that the entire structure is more evenly stressed when subjected to external pressure or temperature changes, thereby improving the compressive strength and durability of the ceramic. And in filtering or adsorption applications, the design of the circular channel helps to reduce the accumulation and blockage of particulate matter. Compared with sharp or irregularly shaped channels, circular channels are less likely to capture and retain solid particles, thereby extending the service life of the honeycomb ceramic 100 and reducing maintenance costs.

[0026] In some embodiments, the filler 2 is a ceramic composite material. Preferably, the composite material consists of the following components: Main component: high-purity alumina (Al2O3), accounting for 60%-80%, because of its excellent acid resistance, high hardness and low water absorption; Acid-resistant enhancer: A mixture of silicon dioxide (SiO2) and zirconium oxide (ZrO2), accounting for 10%-25%, used to further enhance the material's resistance to acid corrosion; Water absorption regulator: a small amount of magnesium oxide (MgO) or calcium oxide (CaO), accounting for no more than 5%, can effectively adjust the water absorption of the composite material to the minimum by precisely controlling its content; Sintering aids: such as yttrium oxide (Y2O3) or lanthanum oxide (La2O3), accounting for about 1%-5%, to promote the densification sintering of composite materials and improve the density and mechanical strength of the material.

[0027] First, by selecting high-purity alumina as the main component and adding silicon dioxide and zirconium oxide as acid-resistant enhancers, the composite material exhibits extremely high chemical stability in an acidic environment, can effectively resist the erosion of various acidic media, and ensure the long-term stable operation of the honeycomb ceramic 100 in a harsh chemical environment. Secondly, by accurately regulating the content of magnesium oxide or calcium oxide as a water absorption rate regulator, the composite material achieves extremely low water absorption, and can maintain the stability of the structure and the durability of the performance even in a humid environment, avoiding the problems of material expansion and strength reduction caused by water absorption. In addition, the sintering aid added to the composite material promotes the densification sintering process of the material, significantly improves the density, hardness and flexural strength of the material, so that the honeycomb ceramic 100 has a stronger resistance when subjected to mechanical stress, and prolongs the service life. Moreover, the composite material has good processing performance, is easy to be formed into a precise filler 2 shape, and is closely combined with the ceramic unit frame 1, ensuring the integrity and consistency of the honeycomb ceramic 100 structure. At the same time, its material has good compatibility with the ceramic unit frame 1, reducing the interface problems caused by material differences. And because the composite material has multiple excellent properties such as acid resistance, low water absorption, and high strength, this honeycomb ceramic 100 has great application potential in waste gas treatment, acid mist purification, wastewater treatment and other application scenarios in the fields of chemical industry, metallurgy, and environmental protection, providing efficient and reliable technical support for energy conservation, emission reduction and environmental protection in these fields.

[0028] This embodiment also provides a method for preparing a honeycomb ceramic, which is used to prepare the above-mentioned low water absorption acid-resistant honeycomb ceramic, and comprises the following steps: a) Preparation of ceramic unit frames 1: First, according to the preset hexagonal frame column size and shape, a plurality of ceramic unit frame 1 blanks are prepared by using a mold forming technology; ceramic raw materials with high fire resistance, low water absorption and acid resistance are selected to ensure stable performance of the final product; b) Combining honeycomb structure: combining the prepared ceramic unit frames 1 according to the honeycomb structure to form a complete honeycomb ceramic 100 green body, and placing it flat on the workbench; ensuring that each ceramic unit frame 1 is closely arranged to form regular honeycomb pores; c) Prepare a filling pipe: for each ceramic unit frame 1, prepare a pipe that is tangent to and in contact with its inner wall; one end of the pipe is closed and the other end is open, the closed end extends into the interior of the ceramic unit frame 1, and the open end remains outside; on the pipe, according to the position and number of each inner corner of the ceramic unit frame 1, open a plurality of holes of equal height to ensure that the holes correspond to the inner corners one by one; d) Injecting the filling material 2: injecting the pre-prepared filling material 2 into the pipe through the open end of the pipe; during the injection process, the material level of the filling material 2 in the pipe gradually rises, and overflows from each hole one by one, flows into each inner corner of the ceramic unit frame 1, and fills the inner corner space; e) Curing and trimming: After filling, let the filler 2 cure naturally in the ceramic unit frame 1 or use appropriate heating methods to accelerate its curing process; after curing, carefully remove the inserted pipes and trim the inner and outer surfaces of the ceramic unit frame 1 to ensure that the surface is flat and smooth without excess filler 2 overflowing; f) Sintering: The filled and trimmed honeycomb ceramic 100 green body is placed in a high-temperature kiln for sintering; during the sintering process, the ceramic material will be further densified, and the filler 2 and the ceramic unit frame 1 will be tightly combined to form an integrated structure; after the sintering is completed, a honeycomb ceramic 100 product with low water absorption and acid resistance can be obtained.

[0029] The above method realizes accurate filling of each inner corner of the ceramic unit frame 1 by opening holes corresponding to the inner corners of the ceramic unit frame 1 and injecting the filler 2 into the pipeline. This method ensures that the filler 2 can flow into each inner corner evenly and accurately, improving the accuracy and efficiency of filling. And the injection of the filler 2 fills the inner corners of the ceramic unit frame 1, and optimizes the overall structure of the ceramic through a smooth transition with the inner wall of the ceramic. This not only reduces the risk of water retention and penetration, but also enhances the structural integrity and durability of the ceramic. And because the filler 2 is injected through the pipeline and accurately filled into the inner corner, it will not block the pores between the ceramic unit frames 1, ensuring that the gas can smoothly pass through the honeycomb ceramic 100 structure, maintaining its high efficiency in applications such as catalysis and filtration. In summary, the preparation method simplifies the production process and improves production efficiency by mechanized injection of the filler 2 and precise control of the filling process. At the same time, since the filling process is carried out on the assembled honeycomb ceramic 100 blank, the extra workload caused by filling each ceramic unit frame 1 separately is also avoided.

[0030] In some embodiments, in step e), after the filling material 2 is filled, the inserted pipe is rotated slowly and evenly, and the filling material 2 between the pipe and the inner corner of the ceramic unit frame 1 is fine-tuned by the rotation of the pipe, so that the filling material 2 is more evenly distributed at the inner corner of the ceramic unit frame 1, and the surface is smooth and flat. After the rotation is completed, the inserted pipe is carefully removed, and the inner and outer surfaces and the filling material 2 at the inner corner of the ceramic unit frame 1 are carefully trimmed to ensure that no excess filling material 2 overflows and forms a smooth transition with the inner wall of the ceramic unit frame 1. Through the rotation of the pipe, the distribution of the filling material 2 at the inner corner of the ceramic unit frame 1 can be fine-tuned to make it more uniform, thereby avoiding the accumulation or missing of the filling material 2 and optimizing the filling effect. In addition, the rotating pipe can drive the filling material 2 to move slightly, so that the surface of the filling material 2 is smooth and flat, and the overall appearance quality of the honeycomb ceramic 100 is improved. And the flat and smooth surface of the filling material 2 reduces the risk of structural damage caused by stress concentration and enhances the structural stability of the ceramic unit frame 1.

[0031] In some embodiments, after step e), the step of cleaning the filler 2 adhered to the outer surface of the pipe is also included. Specifically, a soft brush or an air blowing device is used to gently remove excess filler 2 adhered to the outer wall of the pipe to ensure that the outer surface of the pipe is clean and free of residue. This step is intended to prevent the filler 2 attached to the outer wall of the pipe from contaminating or scratching the outer surface of the ceramic unit frame 1 when the pipe is removed, thereby maintaining the overall neat appearance and stable performance of the honeycomb ceramic 100. If excess filler 2 remains on the outer wall of the pipe, it may fall off during subsequent processing or use, enter the pores of the honeycomb ceramic 100, and affect the gas circulation efficiency or catalytic effect. Through the cleaning step, this problem can be effectively avoided to ensure the stable performance of the honeycomb ceramic 100.

[0032] This specific embodiment is merely an explanation of the present invention and is not a limitation of the present invention. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed. However, as long as they are within the scope of the claims of the present invention, they are protected by the patent law.

Claims

1. A low water absorption acid-resistant honeycomb ceramic, characterized in that: It comprises a plurality of ceramic unit frames (1) in the shape of hexagonal columns and combined into a honeycomb shape; Filling material (2) is provided at each inner corner of the ceramic unit frame (1); the surface of the filling material (2) is smooth and smoothly transitions with the inner wall of the ceramic unit frame (1).

2. The low water absorption acid-resistant honeycomb ceramic according to claim 1, characterized in that: Each of the fillers (2) configures the inner channel of the ceramic unit frame (1) into a circular channel, and the circular channel is tangent to the inner wall of the ceramic unit frame (1).

3. The low water absorption acid-resistant honeycomb ceramic according to claim 1, characterized in that: The filler (2) is a ceramic composite material.

4. A method for preparing a honeycomb ceramic, the method being used for preparing the low water absorption and acid-resistant honeycomb ceramic according to any one of claims 1 to 3, characterized in that: The following steps are involved: a) preparing a ceramic unit frame (1): preparing a plurality of ceramic unit frames (1) in the form of a blank by using a mold forming technology; b) Combining honeycomb structure: combining the ceramic unit frames (1) into a complete honeycomb ceramic (100) body according to the honeycomb structure; c) preparing a filling pipe: for each ceramic unit frame (1), preparing a pipe that is tangent to and in contact with the inner wall of the ceramic unit frame (1), and providing holes on the pipe that correspond to each inner corner of the ceramic unit frame (1); d) injecting the filler (2): injecting the filler (2) into the pipe through the open end of the pipe, and the filler (2) overflows from the hole and flows into each inner corner of the ceramic unit frame (1); e) Curing and finishing: After the filling is completed, the filling material (2) is allowed to cure, the pipe is removed, and the inner and outer surfaces of the ceramic unit frame (1) are trimmed; f) Sintering: placing the honeycomb ceramic (100) green body in a high-temperature kiln for sintering to obtain a honeycomb ceramic (100) product having low water absorption and acid resistance.

5. The method for preparing a honeycomb ceramic according to claim 4, characterized in that: In step e), after the filling of the filling material (2) is completed, the inserted pipe is rotated.

6. The method for preparing a honeycomb ceramic according to claim 4, characterized in that: After step e), the method further includes cleaning the filler (2) adhered to the outer surface of the pipeline.

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