Thin-walled cordierite honeycomb ceramic material with high porosity and narrow pore size distribution and method of making

By using specific inorganic components and sintering processes, the problems of high porosity and narrow pore size distribution of honeycomb ceramic carriers were solved, achieving efficient carbon soot particle capture and low back pressure, reducing production costs and thermal stress risks.

CN122010592BActive Publication Date: 2026-07-07安徽奥福精细陶瓷有限公司 +2
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Patent Information

Authority / Receiving Office
CN · China
Patent Type
Patents(China)
Current Assignee / Owner
安徽奥福精细陶瓷有限公司
Filing Date
2026-04-15
Publication Date
2026-07-07

AI Technical Summary

Technical Problem

Existing technologies struggle to achieve narrow pore size distribution while maintaining high porosity, resulting in a tradeoff between carbon soot particle capture efficiency and back pressure in honeycomb ceramic carriers. Furthermore, the use of expensive organic pore-forming agents increases costs and the risk of thermal stress during the sintering process.

Method used

The inorganic solid components are flaky, narrow-particle-size, high-iron-content talc, spherical alumina, spherical silica, and shaped coarse silicon carbide. By controlling the particle size and oxidation reaction during sintering, well-connected micropores are formed, avoiding the use of organic pore-forming agents. Combined with negative pressure sintering technology, the raw material ratio and extrusion pressure are optimized.

Benefits of technology

It achieves high porosity (51-63%) and narrow pore size distribution (D90/D10≤3.5), reduces costs, improves carbon soot particulate matter capture efficiency, reduces back pressure, and ensures the strength and thermal expansion coefficient stability of the green body.

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Abstract

This invention relates to the field of honeycomb ceramic technology, specifically to a thin-walled cordierite honeycomb ceramic material with high porosity and narrow pore size distribution, and its preparation method. The inorganic solid component exhibits a lamellar, narrow-particle-size distribution with high iron content and a talc aspect ratio greater than or equal to 20; the sphericity of both spherical alumina and spherical silica is greater than or equal to 98%, and the mass percentage of the amorphous phase in the spherical silica is greater than or equal to 99.0%; the morphology of the shaped coarse silicon carbide particles is ellipsoidal, with a particle size D... 50 The particle size is 25-35 μm, D. 90 With particle size D 10 The ratio is less than or equal to 3.0 μm. By using shaped coarse silicon carbide instead of expensive organic pore-forming agents, high porosity can be achieved with only a small amount, significantly reducing raw material costs. By controlling the particle size distribution of the raw materials, the micropore distribution is significantly narrowed, meeting the stringent requirements for high PN capture efficiency and low back pressure.
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