A low water absorption acid-resistant honeycomb ceramic and its preparation method

Abstract

The present invention provides a low water absorption acid-resistant honeycomb ceramic, which is composed of a number of hexagonal columnar ceramic unit frames. The feature lies in that fillers with smooth surfaces and smooth transitions to the inner walls are provided at the inner corners, reducing the water absorption rate, enhancing the structural stability, and considering aerodynamics to ensure high efficiency. The fillers form the inner channels into circular shapes, optimizing the airflow characteristics. The composite filler contains high-purity alumina, acid-resistant strengthener, water absorption rate regulator, and sintering aids, possessing excellent properties such as acid resistance, low water absorption rate, and high strength. The preparation method includes steps such as preparing the unit frames, combining the structures, injecting the fillers, curing and trimming, and sintering. The production efficiency is improved through mechanized injection and precise control. It also involves steps of fine-tuning the fillers and cleaning the pipelines to optimize the filling effect and maintain stable performance. This honeycomb ceramic is applicable to fields such as catalysis and filtration, and has broad application prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic materials, and specifically to a low water absorption acid-resistant honeycomb ceramic and its preparation method. Background Art

[0002] Due to its unique honeycomb structure and excellent physical and chemical properties, honeycomb ceramics have broad application prospects in fields such as catalytic conversion, heat exchange, filtration, and adsorption. However, traditional honeycomb ceramics often have the problem of 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 frames, due to structural discontinuity and the existence of tiny gaps, these areas are prone to becoming "hot spots" for water retention and accumulation, further exacerbating the water absorption phenomenon and stress concentration problems.

[0003] In order to reduce the water absorption of honeycomb ceramics and improve their moisture resistance, researchers have tried various methods, such as changing the formulation of ceramic raw materials, optimizing the sintering process, and performing surface treatment. However, these methods often have limited effects and may introduce new process complexities and cost problems. In addition, how to enhance the structural integrity and durability of honeycomb ceramics while maintaining their high efficiency is also a long-standing technical problem that has troubled the industry.

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

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

[0006] The above technical object of the present invention is achieved through the following technical solutions: A low water absorption acid-resistant honeycomb ceramic includes a plurality of ceramic unit frames in the shape of hexagonal prism columns and combined in a honeycomb shape;

[0007] Filling materials are provided at each inner corner inside the ceramic unit frame, the surfaces of the filling materials are smooth, and they are smoothly transitioned with the inner walls of the ceramic unit frames.

[0008] In some embodiments, each of the filling materials constructs 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.

[0009] In some embodiments, the filler is a ceramic composite material.

[0010] A method for preparing honeycomb ceramics, which is used to prepare the above-mentioned low water absorption acid-resistant honeycomb ceramics, includes the following steps:

[0011] a) Prepare ceramic unit frames: Use mold forming technology to prepare green blanks of multiple ceramic unit frames.

[0012] b) Combine the honeycomb structure: Combine the ceramic unit frames into a complete honeycomb ceramic blank according to the honeycomb structure.

[0013] c) Prepare filling pipes: For each ceramic unit frame, prepare a pipe that is tangent to and in contact with its inner wall, and holes corresponding to each inner angle of the ceramic unit frame are opened on the pipe.

[0014] d) Inject the filler: Inject the filler into the pipe through the open end of the pipe, and the filler overflows from the holes and flows into each inner angle of the ceramic unit frame.

[0015] e) Cure and trim: After filling, let the filler cure, remove the pipe, and trim the inner and outer surfaces of the ceramic unit frame.

[0016] f) Sinter: Place the honeycomb ceramic blank in a high-temperature kiln for sintering to obtain a honeycomb ceramic product with low water absorption and acid-resistant characteristics.

[0017] In some embodiments, in step e), after the filler is filled, the inserted pipe is rotated.

[0018] In some embodiments, after step e), it further includes cleaning the filler adhered to the outer surface of the pipe.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] The low water absorption 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 a humid environment by setting fillers at the inner corners and optimizing their shape, size and distribution. Specifically, the design of the filler effectively fills the inner corners of the inner frame of the ceramic unit, blocks the retention path of moisture in these areas, significantly reduces the water absorption rate, and improves the stability of the ceramics in a humid environment. At the same time, the smooth transition between the filler and the inner wall of the ceramic enhances the structural integrity of the ceramic unit frame, reduces the risk of breakage caused by stress concentration, and improves the overall strength and durability of the ceramics.

[0021] In addition, the preparation method of the present invention realizes precise filling at each inner corner of the ceramic unit frame by opening holes corresponding one by one 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, improving the accuracy and efficiency of filling. Since the filling process is carried out on the assembled honeycomb ceramic blank, it also avoids the extra workload caused by filling each ceramic unit frame separately.

[0022] More importantly, although the filler is added to the inner corners, the design of the present invention takes into account the factors of gas dynamics to ensure that the filler does not hinder the smooth flow of gas. By carefully designing and optimizing the shape, size and distribution of the filler, the present invention ensures that gas can flow smoothly through the honeycomb ceramic structure, maintaining its high efficiency in applications such as catalysis and filtration. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a schematic structural view of the honeycomb ceramic of the present invention;

[0024] Figure 2 is a detailed structural view of the ceramic unit frame of the honeycomb ceramic of the present invention.

[0025] In the figure: 100, honeycomb ceramic; 1, ceramic unit frame; 2, filler. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] The embodiments of the present invention will be described in detail below. The examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are intended to explain the present invention and should not be construed as limiting the present invention.

[0027] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional 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 thus should not be construed as limiting the present invention.

[0028] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, "a plurality of" means two or more unless otherwise specifically defined.

[0029] In the present invention, unless otherwise clearly specified and defined, terms such as "mounted", "connected", "joined", "fixed", etc. shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0030] As Figure 1-2 shown, this embodiment provides a low water absorption acid-resistant honeycomb ceramic, which is characterized in that:

[0031] It includes a number of ceramic unit frames 1 in the shape of hexagonal prism columns and combined into a honeycomb shape;

[0032] At each inner corner inside the ceramic unit frame 1, there is a filler 2. The surface of the filler 2 is smooth, and it is smoothly transitioned with the inner wall of the ceramic unit frame 1.

[0033] 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 ceramic unit inner frame, avoiding the retention and accumulation of moisture in these areas, thus 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. Moreover, although the filler 2 is added to the inner corners, its design takes into account aerodynamics to ensure that the filler 2 does not impede the smooth flow of gas, thus maintaining the high efficiency of the honeycomb ceramic 100 in applications such as catalysis and filtration.

[0034] Specifically, the fillers 2 are precisely placed at each inner corner of the ceramic unit frame 1. 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 corners, reduces the direct contact area between moisture and the ceramic material, and thus lowers the water absorption rate. When moisture attempts to penetrate, it encounters the physical barrier of the fillers 2 and is forced to flow along the ceramic surface rather than seep into the ceramic interior. Additionally, the application of the fillers 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, improving the overall strength and durability of the ceramic. At the same time, the design of the fillers 2 takes into account aerodynamics, ensuring that they provide additional structural support to the ceramic without affecting gas flow. Moreover, although the addition of the fillers 2 may increase some air flow resistance, the present invention ensures that gas can smoothly pass through the honeycomb ceramic 100 structure through careful design and optimization of the shape, size, and distribution of the fillers 2. In this way, the honeycomb ceramic 100 can maintain high working performance in applications such as catalytic conversion, heat exchange, filtration, and adsorption.

[0035] In summary, the present invention cleverly solves the problems of high water absorption rate and easy breakage of the traditional honeycomb ceramic 100 in a humid environment by setting the fillers 2 at the inner corners, providing a more reliable and efficient solution for the wide application of the honeycomb ceramic 100.

[0036] In some embodiments, such as Figure 2As shown, each filler 2 constructs the inner channel of the ceramic unit frame 1 into a circular channel, which 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 constructing the inner channel into a circle 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 gas circulation efficiency. 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, improving 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 and industrial waste gas purification. 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 shape mutations, making the entire structure more evenly stressed when subjected to external pressure or temperature changes, thereby improving the compressive strength and durability of the ceramic. In addition, in filtration or adsorption applications, the circular channel design helps reduce the accumulation and clogging 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.

[0037] In some embodiments, the filler 2 is a ceramic composite material. Preferably, the composite material is composed of the following components:

[0038] Main component: high-purity alumina (Al2O3), accounting for 60%-80%, due to its excellent acid resistance, high hardness and low water absorption properties;

[0039] Acid-resistant enhancer: A mixture of silicon dioxide (SiO2) and zirconium oxide (ZrO2), accounting for 10%-25%, used to further improve the material's resistance to acid corrosion;

[0040] 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 lowest possible level by precisely controlling its content;

[0041] 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.

[0042] First, by selecting high-purity alumina as the main component and adding silica and zirconium oxide as acid-resistant enhancers, the composite material exhibits extremely high chemical stability in acidic environments, can effectively resist the erosion of various acidic media, and ensure the long-term stable operation of the honeycomb ceramic 100 in harsh chemical environments. Secondly, by precisely controlling the content of magnesium oxide or calcium oxide as a water absorption rate regulator, the composite material achieves extremely low water absorption, maintaining structural stability and performance durability even in humid environments, avoiding problems such as material expansion and strength loss caused by water absorption. In addition, the sintering aid added to the composite material promotes the densification sintering process of the material, significantly improving the density, hardness and flexural strength of the material, making the honeycomb ceramic 100 more resistant to mechanical stress and extending its service life. Moreover, the composite material has good processing properties, is easy to form into a precise filler 2 shape, and is tightly integrated 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 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 huge application potential in waste gas treatment, acid mist purification, wastewater treatment and other application scenarios in the fields of chemical industry, metallurgy, environmental protection, etc., providing efficient and reliable technical support for energy conservation, emission reduction and environmental protection in these fields.

[0043] This embodiment also provides a method for preparing a honeycomb ceramic, which is used to prepare the above-mentioned low water absorption and acid-resistant honeycomb ceramic, comprising the following steps:

[0044] a) Preparation of ceramic unit frames 1: First, a plurality of preforms of ceramic unit frames 1 are produced using a mold forming technique according to the preset hexagonal frame size and shape. Ceramic raw materials with high fire resistance, low water absorption, and acid resistance are selected to ensure stable performance of the final product.

[0045] b) Assembling a honeycomb structure: Assembling the prepared ceramic unit frames 1 in a honeycomb structure to form a complete honeycomb ceramic 100 green body, and placing it flat on a workbench; ensuring that each ceramic unit frame 1 is closely arranged to form regular honeycomb pores;

[0046] c) Prepare a filling pipe: For each ceramic unit frame 1, prepare a pipe that is tangential to and in contact with the inner wall of the unit frame. One end of the pipe should be closed and the other open. The closed end should extend into the interior of the ceramic unit frame 1, while the open end should remain outside. Multiple holes of equal height should be opened on the pipe according to the position and number of the internal corners of the ceramic unit frame 1, ensuring that the holes correspond to the internal corners one by one.

[0047] d) Inject filler 2: Through the open end of the pipe, inject the pre-prepared filler 2 into the pipe; during the injection process, the level of the filler 2 in the pipe gradually rises and overflows from each hole one by one, flowing into each inner corner of the ceramic unit frame 1 to achieve the filling of the inner corner space;

[0048] e) Curing and trimming: After filling, let the filler 2 cure naturally in the ceramic unit frame 1 or use an appropriate heating method to accelerate its curing process; after curing, carefully remove the inserted pipe and trim the inner and outer surfaces of the ceramic unit frame 1 to ensure that the surfaces are flat and smooth without any excess filler 2 overflowing;

[0049] f) Sintering: Place the honeycomb ceramic 100 green body after filling and trimming in a high-temperature kiln for sintering; during the sintering process, the ceramic material will be further densified, and at the same time, the filler 2 will be tightly combined with the ceramic unit frame 1 to form an integrated structure; after sintering, the honeycomb ceramic 100 product with low water absorption and acid resistance characteristics can be obtained.

[0050] The above method realizes the precise filling of each inner corner of the ceramic unit frame 1 by opening holes corresponding one by one to the inner corners of the ceramic unit frame 1 and injecting the filler 2 into the pipe. 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. Moreover, since the filler 2 is injected through the pipe and precisely filled into the inner corners, it will not block the pores between the ceramic unit frames 1, ensuring that gas can pass smoothly through the honeycomb ceramic 100 structure and maintaining its high efficiency in applications such as catalysis and filtration. In summary, this preparation method simplifies the production process and improves the 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 green body, it also avoids the extra workload caused by filling each ceramic unit frame 1 separately.

[0051] In some embodiments, in step e), after the filler 2 is filled completely, the inserted pipe is rotated slowly and evenly. The rotation of the pipe drives the fine adjustment of the filler 2 between the pipe and the inner corner of the ceramic unit frame 1, making the filler 2 distribute more evenly at the inner corner of the ceramic unit frame 1 and achieving the effect of a smooth and flat surface. After the rotation is completed, the inserted pipe is carefully removed, and the filler 2 on the inner and outer surfaces and the inner corners of the ceramic unit frame 1 is carefully trimmed to ensure that there is no excess filler 2 overflowing and a smooth transition is formed with the inner wall of the ceramic unit frame 1. By rotating the pipe, the distribution of the filler 2 at the inner corner of the ceramic unit frame 1 can be finely adjusted to make it more uniform, thus avoiding the accumulation or shortage of the filler 2 and optimizing the filling effect. Moreover, rotating the pipe can drive the filler 2 to move slightly, making the surface of the filler 2 smooth and flat, improving the overall appearance quality of the honeycomb ceramic 100. And the smooth and flat surface of the filler 2 reduces the risk of structural damage caused by stress concentration and enhances the structural stability of the ceramic unit frame 1.

[0052] In some embodiments, after step e), there is also a step of cleaning the filler 2 adhered to the outer surface of the pipe. Specifically, a soft brush or a gas blowing device is used to gently remove the excess filler 2 adhered to the outer wall of the pipe to ensure that the outer surface of the pipe is clean without residue. This step aims to prevent the filler 2 adhered 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, thus maintaining the overall appearance cleanliness and performance stability of the honeycomb ceramic 100. If the excess filler 2 remains on the outer wall of the pipe, it may fall off during subsequent processing or use and enter the pores of the honeycomb ceramic 100, affecting the gas flow efficiency or catalytic effect. Through the cleaning step, this problem can be effectively avoided to ensure the performance stability of the honeycomb ceramic 100.

[0053] This specific embodiment is only an interpretation of the present invention and is not a limitation of the present invention. Those skilled in the art can make modifications to this embodiment without creative contributions according to needs after reading this specification, but as long as it is within the scope of the claims of the present invention, it is protected by the patent law.

Claims

1. A low water absorption acid-resistant honeycomb ceramic, characterized by: 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); 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).

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

3. A method for preparing a honeycomb ceramic, the method being used to prepare the low water absorption and acid-resistant honeycomb ceramic according to any one of claims 1 to 2, characterized in that: The following steps are involved: a) preparing a ceramic unit frame (1): preparing a plurality of preforms of the ceramic unit frame (1) by using a mold forming technology; b) combining honeycomb structure: combining 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 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 with low water absorption and acid resistance.

4. The method for preparing a honeycomb ceramic according to claim 3, wherein: In step e), after the filling of the filling material (2) is completed, the inserted pipe is rotated.

5. The method for preparing a honeycomb ceramic according to claim 3, wherein: After step e), the method further includes cleaning the filler (2) adhered to the outer surface of the pipe.

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