A high cordierite phase honeycomb ceramic, a preparation method and application thereof

Abstract

The application discloses high cordierite phase honeycomb ceramics and a preparation method and application thereof, the high cordierite phase honeycomb ceramics have a cordierite phase content of greater than or equal to 98%, the total content of impurities Na2O, K2O, CaO, TiO2 and Fe2O3 in the high cordierite phase honeycomb ceramics is less than 3%, and the impurity content also satisfies the following formula: 0 < (Na2O+K2O+CaO) / (TiO2+Fe2O3) < 0.3.In the application, the content of cordierite phase in the honeycomb ceramics is increased, and the contents of mullite, spinel and other impurities are reduced, so that the prepared honeycomb ceramics have a low thermal expansion coefficient, and the thermal stability and mechanical strength of the honeycomb ceramics are improved, and finally the overall performance and service life of a catalytic converter are improved.

Description

Technical Field

[0001] This invention relates to the field of honeycomb ceramic preparation technology, and more specifically, to a high cordierite phase honeycomb ceramic, its preparation method, and its application. Background Technology

[0002] Honeycomb ceramics have wide applications in modern industry, serving as key components in internal combustion engines, boilers, chemical reaction equipment, and fuel cell reformers. Their core use is as catalyst supports, enabling efficient catalytic reactions through the supported catalyst and also trapping particulate matter in exhaust gas treatment. For example, in diesel engine exhaust treatment, straight-through honeycomb ceramics coated with a V2O5-WO3 / TiO2 catalyst can effectively trap nitrogen oxides (NOx). x The process efficiently converts nitrogen (N2) and water (H2O) into harmless gases, helping vehicles meet emission standards. As a core component of mobile source exhaust treatment systems, the performance of honeycomb ceramics largely depends on the purity of the cordierite phase. However, under current technological conditions, the low purity of the cordierite phase has become a major bottleneck restricting its performance improvement. Summary of the Invention

[0003] The purpose of this invention is to overcome the problems existing in the prior art and provide a high cordierite phase honeycomb ceramic, its preparation method and application.

[0004] The technical problem solved by this invention is achieved by the following technical solution.

[0005] This invention provides a high cordierite phase honeycomb ceramic, wherein the cordierite phase content in the high cordierite phase honeycomb ceramic is ≥98%, and the total content of impurities Na2O, K2O, CaO, TiO2 and Fe2O3 in the high cordierite phase honeycomb ceramic is <3%, and the impurity content also satisfies the following formula: 0 < (Na2O + K2O + CaO) / (TiO2 + Fe2O3) < 0.3.

[0006] The present invention also provides a method for preparing the above-mentioned high cordierite phase honeycomb ceramic, comprising the following steps: The raw materials, binder, lubricant, and water are mixed to obtain the blank; The billet is subjected to vacuum degassing, mud refining, extrusion, cutting, and microwave drying to obtain a dry billet body; After the dry blank is sintered in sections, it is cooled to room temperature to obtain a honeycomb ceramic carrier.

[0007] The present invention also provides an application of the above-mentioned cordierite phase honeycomb ceramic in automobile exhaust treatment.

[0008] The present invention has the following beneficial effects: The high-purity cordierite phase honeycomb ceramic provided by this invention has a cordierite phase content of ≥98%, that is, a crystal phase purity of ≥98%, and basically contains no or only a small amount of impurity phases. This can greatly reduce the thermal expansion coefficient of the honeycomb ceramic, improve the thermal stability and mechanical strength of the honeycomb ceramic, and make it better suited for the catalytic degradation and filtration of harmful components in automobile exhaust. Detailed Implementation

[0009] The present application will be further described in detail below with reference to the embodiments and examples. These embodiments and examples are only for illustrating the present application and are not intended to limit the scope of the present application. The purpose of providing these embodiments and examples is to make the disclosure of the present application more thorough and comprehensive. It should also be understood that the present application can be implemented in many different forms and is not limited to the embodiments and examples described herein. Those skilled in the art can make various modifications or alterations without departing from the spirit of the present application, and the equivalent forms obtained also fall within the protection scope of the present application. In addition, numerous specific details are set forth in the following description to provide a fuller understanding of the present application. It should be understood that the present application can be implemented without one or more of these details.

[0010] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0011] In this application, "optionally," "optionally," and "optional" mean that something is optional, that is, it means that it is selected from either "with" or "without." If there are multiple "optional" entries in a technical solution, unless otherwise specified, and there are no contradictions or mutual constraints, each "optional" entry shall be independent.

[0012] In this application, the terms "first aspect," "second aspect," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or quantity, nor should they be construed as implicitly indicating the importance or quantity of the indicated technical features. Moreover, "first aspect," "second aspect," etc., serve only as a non-exhaustive enumeration and should be understood not to constitute a closed limitation on quantity.

[0013] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0014] In this application, when numerical intervals (i.e., numerical ranges) are mentioned, unless otherwise specified, the distribution of selectable numerical values ​​within the numerical interval is considered continuous, and includes the two endpoints of the numerical interval (i.e., the minimum and maximum values), as well as every numerical value between these two endpoints. Unless otherwise specified, when a numerical interval refers only to integers within that numerical interval, it includes the two endpoint integers of the numerical range, as well as every integer between the two endpoints, which is equivalent to directly listing every integer. When multiple numerical ranges are provided to describe features or characteristics, these numerical ranges can be merged. In other words, unless otherwise specified, the numerical ranges disclosed in this application should be understood to include any and all subranges included therein. The "numerical value" in the numerical interval can be any quantitative value, such as a number, percentage, ratio, etc. The term "numerical interval" can be broadly included to include percentage intervals, ratio intervals, proportion intervals, etc.

[0015] All references to this application are incorporated herein by reference as if each document were individually incorporated herein by reference. Unless they conflict with the purpose and / or technical solution of this application, all cited references are incorporated herein by reference in their entirety and for all purposes. When references are cited in this application, the definitions of relevant technical features, terms, nouns, phrases, etc., are also incorporated herein by reference. Examples and preferred embodiments of the cited technical features may also be incorporated herein by reference, but only to the extent that they enable the implementation of this application. It should be understood that when the cited content conflicts with the description in this application, this application shall prevail or modifications shall be made adaptably to the description in this application.

[0016] In a first aspect, the present invention provides a high cordierite phase honeycomb ceramic, wherein the cordierite phase content in the high cordierite phase honeycomb ceramic is ≥98%, and the total content of impurities Na2O, K2O, CaO, TiO2 and Fe2O3 in the high cordierite phase honeycomb ceramic is <3%, and the impurity content also satisfies the following formula: 0<(Na2O+K2O+CaO) / (TiO2+Fe2O3)<0.3.

[0017] Impurities such as mullite and spinel in honeycomb ceramics not only significantly increase the coefficient of thermal expansion of the material (e.g., the coefficient of thermal expansion of mullite is 5.0 × 10⁻⁶), but also... -6 / ℃, much higher than the 0.16×10 of cordierite. -6 The temperature of the catalyst can drop by 0.5℃, which can lead to a significant decrease in thermal shock resistance, damage the continuity of grain boundaries, weaken the mechanical strength of the material, damage the structure and thermal properties of the support, interfere with coating application, poison the active components of the catalyst, and ultimately reduce the overall performance and service life of the catalyst.

[0018] To meet the high requirements for honeycomb ceramics in emission standards, the present invention provides a honeycomb ceramic with a high-purity cordierite phase. In this honeycomb ceramic with a high-purity cordierite phase, the content of the cordierite phase is ≥98%, that is, the crystal phase purity is ≥98%, and there is basically no or only a small amount of impurity phase. Thus, the thermal expansion coefficient of the honeycomb ceramic can be greatly reduced, and the thermal stability and mechanical strength of the honeycomb ceramic can be improved, making it better suitable for the catalytic degradation and filtration of harmful components in automobile exhaust.

[0019] In some optional embodiments, the composition of the high-cordierite-phase honeycomb ceramic includes: 48.2 - 51.2% of SiO2, 33.9 - 36.9% of Al2O3, 12.0 - 15.0% of MgO, and impurities <3%.

[0020] In some optional embodiments, the thermal expansion coefficient of the honeycomb ceramic at room temperature - 800 °C is less than 0.5×10 -6 / °C, and the thermal expansion coefficient at 400 - 600 °C is less than 0.9×10 -6 / °C.

[0021] In some optional embodiments, the raw materials for preparing the high-cordierite-phase ceramic carrier include inorganic raw materials, binders, lubricants, and water; Optionally, the inorganic raw materials include the following components in mass percentages: 35 - 45% of flaky talc, 8% - 15% of flaky kaolin, 20% - 30% of calcined kaolin, 2% - 10% of silicon oxide, 8% - 20% of alumina, and 0 - 10% of aluminum hydroxide; Optionally, the morphology index of the flaky talc is 0.5 - 0.6. Among them, the content of CaO in the flaky talc is less than 0.05%, the content of Fe2O3 is between 1.0 - 3%, and 7 μm < D50 < 15 μm. In the present invention, by controlling the impurity content of the talc with the most impurities in the raw materials, controlling the content of CaO below 0.5%, and controlling the content of Fe2O3 between 1.0 - 3%, a small amount of Fe 3+ and Ti 4+ are used as mineralizing agents to promote the formation of the cordierite crystal phase, while avoiding performance deterioration caused by excessive impurities.

[0022] Optionally, the D50 of the flaky talc > the D50 of the flaky kaolin > the D50 of the aluminum hydroxide, the alumina, or the calcined kaolin > the D50 of the silicon oxide, and the difference in D50 between each level of inorganic raw materials is between 0.5 - 8 microns; Optionally, the particle size range of the flaky talc is: 9μm ≤ D50 ≤ 15μm, the particle size range of the flaky kaolin is: 3μm < D50 < 9μm, the particle size range of the calcined kaolin is: 1.7μm ≤ D50 ≤ 7.0μm, the particle size range of the silicon oxide is: 1.0μm < D50 < 4.0μm, the particle size range of the aluminum oxide is: 1.0μm < D50 < 6.0μm, and the particle size range of the aluminum hydroxide is: 2.0μm ≤ D50 ≤ 7.3μm; Preferably, the lubricant includes at least one of alkyl polyethers, fatty alcohol polyoxyethylene ethers, potassium silicate, ethylenediamine tetramethylene phosphonic acid, tall oil, acrylic acid, stearic acid, and stearates; Preferably, the binder includes at least one of hydroxypropyl methylcellulose, xanthan gum, methylcellulose, methylcellulose derivatives, mushroom powder, polyvinyl alcohol, and starch ether.

[0023] The present invention also provides a high-cordierite-phase honeycomb ceramic, the preparation raw materials of which include inorganic raw materials, a binder, a lubricant, and water, and the inorganic raw materials include flaky kaolin, calcined kaolin, flaky talc, silicon oxide, aluminum oxide, and aluminum hydroxide. The inorganic raw materials are proportioned, controlling the flaky talc as the raw material with the largest particle size and the silicon oxide as the raw material with the smallest particle size. While the large-particle talc controls the cordierite orientation, through the filling of each level of inorganic raw materials, a denser packing structure is formed. The large-particle-size talc serves as the main framework particle: talc decomposes into MgO and SiO2 first during sintering, and its particle morphology can support the green body structure, avoiding excessive shrinkage and deformation during the sintering process. The small-particle-size SiO2 has a large specific surface area and high activity, and can quickly undergo solid-phase reactions with MgO decomposed from talc and Al2O3 decomposed from kaolin, promoting the formation of the cordierite main crystal phase and reducing the content of impurity phases. Controlling the firing curve and temperature field promotes liquid-phase sintering and crystal orientation growth, controlling its heating rate at a specific temperature, so that the content of the cordierite crystal phase in the crystal phase of the honeycomb ceramic is far higher than 98%.

[0024] In some optional embodiments, the high-cordierite-phase honeycomb ceramic has one or more of the following characteristics: a. The honeycomb density of the high-cordierite-phase honeycomb ceramic is 200 - 900 cpsi; b. The radial size of the high-cordierite-phase honeycomb ceramic is 93 - 330.2 mm; c. The size of the high-cordierite-phase honeycomb ceramic in the longitudinal axis direction is 50 - 304.8 mm; d. The wall thickness of the high-cordierite-phase honeycomb ceramic is 2 - 8 mil.

[0025] In some optional embodiments, the high-cordierite-phase honeycomb ceramic has one or more of the following characteristics: a. The compressive strength of the high-cordierite-phase honeycomb ceramic is as follows: the compressive strength along the A-axis ≥ 5 MPa, and the compressive strength along the B-axis ≥ 1.4 MPa; b. The isostatic pressure strength of the high-cordierite-phase honeycomb ceramic ≥ 3.0 MPa; c. The thermal shock resistance of the high-cordierite-phase honeycomb ceramic: from room temperature to 700 °C, no cracking after three cycles.

[0026] Second, the present invention also provides a preparation method for the above-mentioned high-cordierite-phase honeycomb ceramic, including the following steps: Mix raw materials, a binder, a lubricant, and water to obtain a blank; After subjecting the blank to vacuum degassing, clay refining, extrusion, blank cutting, and microwave drying, a dry blank body is obtained; After subjecting the dry blank body to segmented sintering, it is cooled to room temperature to obtain a honeycomb ceramic carrier.

[0027] In some optional embodiments, the raw materials for preparing the high-cordierite-phase ceramic carrier include inorganic raw materials, a binder, a lubricant, and water; Optionally, the morphology index of the flaky talc is 0.5 - 0.6, where the CaO content in the flaky talc is less than 0.05%, the Fe₂O₃ content is between 1.0 - 3%, and 7 μm < D50 < 15 μm; Optionally, D50 of the flaky talc > D50 of the flaky kaolin > D50 of the aluminum hydroxide, the alumina, or the calcined kaolin > D50 of the silica, and the difference in D50 between the inorganic raw materials at each level is between 0.5 - 8 microns; Optionally, the particle size range of the flaky talc is: 9 μm ≤ D50 ≤ 15 μm, the particle size range of the flaky kaolin is: 3 μm < D50 < 9 μm, the particle size range of the calcined kaolin is: 1.7 μm ≤ D50 ≤ 7.0 μm, the particle size range of the silica is: 1.0 μm < D50 < 4.0 μm, the particle size range of the alumina is: 1.0 μm < D50 < 6.0 μm, and the particle size range of the aluminum hydroxide is: 2.0 μm ≤ D50 ≤ 7.3 μm; Optionally, the inorganic raw materials include the following components by mass percentage: flaky talc 35 - 45%, flaky kaolin 8% - 15%, calcined kaolin 20% - 30%, silica 2 - 10%, alumina 8 - 20%, and aluminum hydroxide 0 - 10%; Preferably, the lubricant includes at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, potassium silicate, ethylenediamine tetramethylene phosphonic acid, tall oil, acrylic acid, stearic acid, and stearate; Preferably, the binder includes at least one of hydroxypropyl methylcellulose, xanthan gum, methylcellulose, methylcellulose derivatives, mushroom powder, polyvinyl alcohol, and starch ether.

[0028] In some alternative embodiments, the dry blank is subjected to a multi-stage programmed heating process to prepare a honeycomb ceramic carrier; The multi-stage programmed temperature rise process includes: heating the dry green body from room temperature to 600℃ at a rate of 10-30℃ / h, then heating it to 1405-1435℃ at a rate of 50-80℃ / h, and holding it at 1405-1435℃ for 180-800 minutes. The honeycomb ceramic carrier is prepared by subjecting the dry green body to this multi-stage programmed temperature rise process. Specifically, multi-stage temperature-controlled sintering is employed. The first stage involves slow heating to cross the low-temperature sensitive zone, reducing stress concentration cracking of the green body, controlling the heat diffusion rate, and preventing sintering cracking caused by temperature differences. The second stage is a critical transition stage in the sintering process. Too rapid a heating rate can lead to insufficient contact between raw material particles, hindering solid-phase reactions in the high-temperature section, ultimately resulting in residual impurities such as mullite and corundum, reducing the purity of the cordierite main crystalline phase. Too slow a heating rate may cause some raw materials to undergo premature local over-reaction, forming unstable intermediate phases, which in turn interferes with the subsequent uniform formation of the cordierite main crystalline phase. In the final heat preservation stage, the appropriate heat preservation temperature and time are controlled to ensure that the raw materials react fully, suppress the formation of impurity phases such as mullite and cristobalite, and obtain high-purity cordierite main crystal phase.

[0029] As can be seen from the above, the preparation method of high cordierite phase honeycomb ceramics provided by the present invention controls the amount of impurities in the raw materials, particularly talc, controls the CaO content to be below 0.05%, and controls the Fe2O3 content to be between 1% and 2.5%, utilizing a small amount of Fe... 3+ As a mineralizer to promote the formation of cordierite crystal phase while avoiding performance degradation due to excessive impurities, a gradation method is employed between raw materials. Flaky talc is controlled as the largest particle size material, and silica as the smallest. Large talc particles control the orientation of cordierite, while inorganic raw materials at various stages fill the gaps, forming a denser packing structure. Large particles form a framework below 1100℃, while small particles such as kaolin form a dense structure above 1400℃. Multi-stage temperature-controlled sintering is used to control the firing curve and temperature field, promoting liquid-phase sintering and directional crystal growth. The heating rate is controlled at specific temperatures, resulting in a cordierite crystal phase content exceeding 98%. This further reduces the axial thermal expansion coefficient, making it below 0.5 × 10⁻⁶ at room temperature to 800℃. -6 ℃ -1 The coefficient of thermal expansion at 400-600℃ is less than 0.9×10⁻⁶. -6 ℃ -1 Furthermore, it enhances the thermal shock resistance of the honeycomb ceramic, enabling it to withstand more than three cycles at 700 degrees Celsius without cracking. Its isostatic compressive strength is also higher than 3.0 MPa.

[0030] Thirdly, the present invention also provides an application of the above-mentioned cordierite honeycomb ceramic in automobile exhaust treatment.

[0031] The present invention will be further described below with reference to embodiments.

[0032] Example 1 37.8% of flaky talc with a particle size of 9.5 μm, a morphology index of 0.52, a CaO content of 0.24%, and a Fe2O3 content of 2.3%, 8.5% of flaky kaolin with a particle size of 3.2 μm, 5.1% of silica with a particle size of 1.2 μm, 8.2% of alumina with a particle size of 1.3 μm, 10.1% of aluminum hydroxide with a particle size of 3.2 μm, 30.1% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5.0% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3.0% of molding aid and 36.0% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0033] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 180 min, and then cooled to obtain the product.

[0034] Example 2 39.2% of flaky talc with a particle size of 11.2 μm, a morphology index of 0.54, a CaO content of 0.11%, and a Fe2O3 content of 1.1%, 10.6% of flaky kaolin with a particle size of 5.8 μm, 4.6% of silica with a particle size of 1.2 μm, 10.6% of alumina with a particle size of 1.3 μm, 8.3% of aluminum hydroxide with a particle size of 3.2 μm, 28.5% of calcined kaolin with a particle size of 1.9 μm, and a binder accounting for 5.5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0035] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1415°C at a rate of 60°C / h and held at that temperature for 360 min, and then cooled to obtain the product.

[0036] Example 3 41.1% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (7.8 μm particle size), 3.6% of silica (3.4 μm particle size), 12.2% of alumina (5.2 μm particle size), 6.5% of aluminum hydroxide (6.3 μm particle size), 26.7% of calcined kaolin (6.6 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0037] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1425°C at a rate of 70°C / h and held at that temperature for 540 min, and then cooled to obtain the product.

[0038] Example 4 43.4% of flaky talc with a particle size of 14.8 μm, a morphology index of 0.56, a CaO content of 0.41%, and a Fe2O3 content of 2.1%, 15.2% of flaky kaolin with a particle size of 7.8 μm, 3.4% of silica with a particle size of 3.4 μm, 14.1% of alumina with a particle size of 5.2 μm, 4.4% of aluminum hydroxide with a particle size of 6.3 μm, 23.4% of calcined kaolin with a particle size of 1.9 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0039] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1435°C at a rate of 80°C / h and held at that temperature for 720 min, and then cooled to obtain the product.

[0040] Example 5 41.5% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (5.8 μm particle size), 6.2% of silica (1.2 μm particle size), 16.7% of alumina (5.2 μm particle size), 2.8% of aluminum hydroxide (3.2 μm particle size), 26.3% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0041] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0042] Example 6 38.6% of flaky talc with a particle size of 13.4 μm, a morphology index of 0.58, a CaO content of 0.29%, and a Fe2O3 content of 1.8%, 8.9% of flaky kaolin with a particle size of 5.8 μm, 9.8% of silica with a particle size of 3.4 μm, 19.8% of alumina with a particle size of 1.3 μm, 2.6% of aluminum hydroxide with a particle size of 3.2 μm, 20.5% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0043] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1415°C at a rate of 60°C / h and held for 180 min, and then cooled to obtain the product.

[0044] Example 7 40.1% of flaky talc with a particle size of 11.2 μm, a morphology index of 0.54, a CaO content of 0.11%, and a Fe2O3 content of 1.1%, 9.3% of flaky kaolin with a particle size of 3.2 μm, 9.1% of silica with a particle size of 3.4 μm, 19.3% of alumina with a particle size of 5.2 μm, 0% of aluminum hydroxide, 21.1% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0045] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1425°C at a rate of 70°C / h and held at that temperature for 360 min, and then cooled to obtain the product.

[0046] Example 8 42.3% of flaky talc (9.5 μm particle size, morphology index 0.52, CaO content 0.24%, Fe2O3 content 2.3%), 11.5% of flaky kaolin (5.8 μm particle size), 8.4% of silica (3.4 μm particle size), 18.2% of alumina (1.3 μm particle size), 3.3% of aluminum hydroxide (6.3 μm particle size), 22.9% of calcined kaolin (1.9 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0047] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1435°C at a rate of 80°C / h and held at that temperature for 540 min, and then cooled to obtain the product.

[0048] Example 9 42.8% of flaky talc with a particle size of 14.8 μm, a morphology index of 0.56, a CaO content of 0.41%, and a Fe2O3 content of 2.1%, 13.7% of flaky kaolin with a particle size of 7.8 μm, 7.3% of silica with a particle size of 1.2 μm, 19.4% of alumina with a particle size of 1.3 μm, 1.0% of aluminum hydroxide with a particle size of 6.3 μm, 24.3% of calcined kaolin with a particle size of 6.6 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0049] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held for 720 min, and then cooled to obtain the product.

[0050] Example 10 42.4% of flaky talc with a particle size of 14.8 μm, a morphology index of 0.56, a CaO content of 0.41%, and a Fe2O3 content of 2.1%, 14.8% of flaky kaolin with a particle size of 7.8 μm, 4.1% of silica with a particle size of 3.4 μm, 15.8% of alumina with a particle size of 5.2 μm, 4.7% of aluminum hydroxide with a particle size of 3.2 μm, 25.6% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0051] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1415°C at a rate of 60°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0052] Example 11 40.4% of flaky talc with a particle size of 13.4 μm, a morphology index of 0.58, a CaO content of 0.29%, and a Fe2O3 content of 1.8%, 12.4% of flaky kaolin with a particle size of 5.8 μm, 6.6% of silica with a particle size of 1.2 μm, 13.4% of alumina with a particle size of 1.3 μm, 7.2% of aluminum hydroxide with a particle size of 6.3 μm, 25.8% of calcined kaolin with a particle size of 1.9 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0053] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1425°C at a rate of 70°C / h and held at that temperature for 180 min, and then cooled to obtain the product.

[0054] Example 12 40.6% of flaky talc with a particle size of 13.4 μm, a morphology index of 0.58, a CaO content of 0.29%, and a Fe2O3 content of 1.8%, 12.1% of flaky kaolin with a particle size of 5.8 μm, 6.3% of silica with a particle size of 3.4 μm, 11.6% of alumina with a particle size of 5.2 μm, 9.9% of aluminum hydroxide with a particle size of 6.3 μm, 25.1% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0055] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1435°C at a rate of 80°C / h and held at that temperature for 360 min, and then cooled to obtain the product.

[0056] Example 13 41.4% of flaky talc with a particle size of 11.2 μm, a morphology index of 0.54, a CaO content of 0.11%, and a Fe2O3 content of 1.1%, 11.6% of flaky kaolin with a particle size of 5.8 μm, 5.4% of silica with a particle size of 1.2 μm, 12.8% of alumina with a particle size of 5.2 μm, 8.1% of aluminum hydroxide with a particle size of 3.2 μm, 24.5% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0057] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 540 min, and then cooled to obtain the product.

[0058] Example 14 40.3% of flaky talc (9.5 μm particle size, morphology index 0.52, CaO content 0.24%, Fe2O3 content 2.3%), 12.8% of flaky kaolin (3.2 μm particle size), 5.8% of silica (1.2 μm particle size), 13.2% of alumina (5.2 μm particle size), 7.6% of aluminum hydroxide (3.2 μm particle size), 22.4% of calcined kaolin (6.6 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0059] The obtained green body was heated from room temperature to 600°C at a rate of 30°C / h, then heated to 1415°C at a rate of 60°C / h and held for 720 min, and then cooled to obtain the product.

[0060] Example 15 40.7% of flaky talc with a particle size of 11.2 μm, a morphology index of 0.54, a CaO content of 0.11%, and a Fe2O3 content of 1.1%, 14.2% of flaky kaolin with a particle size of 7.8 μm, 6.6% of silica with a particle size of 3.4 μm, 13.3% of alumina with a particle size of 1.3 μm, 8.4% of aluminum hydroxide with a particle size of 6.3 μm, 20.2% of calcined kaolin with a particle size of 4.8 μm, and a binder accounting for 5% of the inorganic raw materials were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of the inorganic raw materials were added as molding aid and 36% of the inorganic raw materials were wet-mixed for 10 minutes at a rotation speed of 50 Hz. After kneading and molding, the mixture was then microwave-dried.

[0061] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1425°C at a rate of 70°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0062] Comparative Example 1 40.8% of flaky talc (7.2 μm particle size, morphology index 0.41, CaO content 0.18%, Fe2O3 content 0.68%), 12.8% of flaky kaolin (5.8 μm particle size), 6.2% of silica (1.2 μm particle size), 16.4% of alumina (5.2 μm particle size), 2.6% of aluminum hydroxide (3.2 μm particle size), 26.6% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0063] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0064] Comparative Example 2 41.3% of flaky talc (19.7 μm particle size, morphology index 0.62, CaO content 0.59%, Fe2O3 content 2.7%), 12.3% of flaky kaolin (1.4 μm particle size), 6.2% of silica (1.2 μm particle size), 16.1% of alumina (5.2 μm particle size), 2.3% of aluminum hydroxide (3.2 μm particle size), 26.4% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0065] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0066] Comparative Example 3 41.5% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (1.4 μm particle size), 6.2% of silica (7.4 μm particle size), 16.7% of alumina (7.6 μm particle size), 2.8% of aluminum hydroxide (1.1 μm particle size), 26.2% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0067] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 50°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0068] Comparative Example 4 41.5% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (5.8 μm particle size), 6.2% of silica (1.2 μm particle size), 16.7% of alumina (5.2 μm particle size), 2.8% of aluminum hydroxide (3.2 μm particle size), 26.3% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0069] The obtained green body was heated from room temperature to 600°C at a rate of 20°C / h, then heated to 1395°C at a rate of 50°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0070] Comparative Example 5 41.5% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (5.8 μm particle size), 6.2% of silica (1.2 μm particle size), 16.7% of alumina (5.2 μm particle size), 2.8% of aluminum hydroxide (3.2 μm particle size), 26.3% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0071] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1445°C at a rate of 40°C / h and held at that temperature for 780 min, and then cooled to obtain the product.

[0072] Comparative Example 6 41.5% of flaky talc (13.4 μm particle size, morphology index 0.58, CaO content 0.29%, Fe2O3 content 1.8%), 12.4% of flaky kaolin (5.8 μm particle size), 6.2% of silica (1.2 μm particle size), 16.7% of alumina (5.2 μm particle size), 2.8% of aluminum hydroxide (3.2 μm particle size), 26.3% of calcined kaolin (4.8 μm particle size), and 5% of binder (considered inorganic raw materials) were added to a plow-type mixer and dry-mixed for 15 minutes at a rotation speed of 50 Hz. After dry mixing, 3% of molding aid (considered inorganic raw materials) and 36% of water were added for wet mixing for 10 minutes at a rotation speed of 50 Hz. The mixture was then kneaded, shaped, and subsequently microwave-dried.

[0073] The obtained green body was heated from room temperature to 600°C at a rate of 25°C / h, then heated to 1405°C at a rate of 40°C / h and held at that temperature for 900 min, and then cooled to obtain the product.

[0074] Test Results The table below shows the test results of the honeycomb ceramics prepared in the examples and comparative examples.

[0075]

[0076] As can be seen from the table above: Examples 1-15 demonstrate that by strictly controlling the CaO and Fe2O3 impurity content of the talc raw material, the particle size distribution of each inorganic raw material, and the sintering process, the cordierite phase content can be effectively controlled to be >99%, and the coefficient of thermal expansion (CTE) at room temperature to 800℃ can be ≤0.5×10⁻⁶. -6 / ℃, the coefficient of thermal expansion (CTE) at 400-600℃ is ≤0.9×10 -6 / ℃, thermal shock resistance can reach 700℃ without cracking, isostatic compressive strength ≥3MPa.

[0077] Comparative Example 1 uses small-particle-size talc, which has a low morphology index and cannot guide the orderly growth of cordierite grains, resulting in a disordered distribution of cordierite phase, and even grain agglomeration or pores, which destroys the expansion inhibition effect, increases the overall CTE, and reduces the thermal shock performance.

[0078] Comparative Example 2 uses large-particle-size talc, which has a high content of CaO and Fe2O3 impurities. Larger-particle-size talc has a smaller specific surface area, significantly reducing its contact area with raw materials such as kaolin and alumina. This increases the difficulty of element diffusion during sintering, leading to incomplete reactions. This directly results in a reduced amount of low-CTE cordierite main crystalline phase formed. Meanwhile, CaO and Fe2O3 impurities easily combine with raw materials such as silicon oxide and alumina to form high-CTE impurity phases such as calcium silicate, calcium aluminate, and iron silicates, resulting in a material with low cordierite phase content, high CTE, and poor thermal shock resistance.

[0079] Comparative Example 3 used large-particle-size silica, large-particle-size alumina, and small-particle-size aluminum hydroxide. The large-particle-size SiO2 and Al2O3 have smaller specific surface areas, resulting in fewer contact points with talc particles. This leads to longer diffusion paths for elements (Mg, Al, Si) among the three, significantly reducing reaction efficiency and preventing the complete formation of the cordierite phase, thus increasing the CTE. The incomplete reaction between large-particle-size SiO2 and Al2O3 and talc creates voids or unreacted layers at the particle interfaces. These defects become stress concentration points during thermal cycling, easily accumulating thermal stress and inducing cracks, ultimately leading to poorer overall thermal shock stability of the material.

[0080] In Comparative Example 4, lowering the holding temperature resulted in incomplete reaction during sintering, forming cordierite and leaving unstable transition phases such as mullite and spinel. The CTE of these transition phases is significantly higher than that of cordierite, leading to an increased CTE in the product. Cordierite grains formed at low temperatures are small and dispersed, with weak intergranular interfaces, making it easy for unreacted raw materials or impurities to remain at the grain boundaries. During thermal shock, grain boundaries, as weak points, are prone to separation or fracture, resulting in a significant decrease in the overall thermal shock resistance of the material.

[0081] In Comparative Example 5, increasing the insulation temperature causes the already formed cordierite phase to decompose into impurity phases such as magnesium aluminum spinel and cristobalite, directly leading to a reduction in the cordierite phase and an increase in CTE. High temperatures accelerate the growth of cordierite grains, resulting in uneven grain size. The significant difference in thermal expansion between coarse grains and surrounding fine grains makes it easy for strong stress concentrations to form at the grain boundaries during thermal cycling, which in turn triggers grain boundary cracking, ultimately causing the material to crack or fragment directly during thermal shock.

[0082] Comparative Example 6, with its extended holding time, although the holding temperature was not high, still resulted in energy accumulation. This caused the already formed cordierite phase to slowly decompose into high-CTE impurity phases such as magnesium aluminum spinel and cristobalite (SiO2), directly reducing the total amount of cordierite phase and increasing CTE. Prolonged holding also allowed cordierite grains to continue growing, forming "abnormal grains" with significant size differences. The significant difference in thermal expansion coefficients between the coarse grains and the surrounding fine grains led to intense stress concentration at the grain boundaries during thermal cycling, easily causing grain boundary cracking and ultimately resulting in direct fragmentation during thermal shock.

[0083] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A high-cordierite phase honeycomb ceramic, characterized in that, In the high cordierite-phase honeycomb ceramic, the content of cordierite phase is ≥ 98%, the total content of impurities Na₂O, K₂O, CaO, TiO₂ and Fe₂O₃ in the high cordierite-phase honeycomb ceramic is < 3%, and the impurity content also satisfies the following formula: 0 < (Na₂O + K₂O + CaO) / (TiO₂ + Fe₂O₃) < 0.

3.

2. The high-cordierite phase honeycomb ceramic according to claim 1, characterized in that, The composition of the high cordierite-phase honeycomb ceramic includes: SiO₂ 48.2 - 51.2%, Al₂O₃ 33.9 - 36.9%, MgO 12.0 - 15.0% and impurities < 3%.

3. The high-cordierite phase honeycomb ceramic according to claim 2, characterized in that, The coefficient of thermal expansion of honeycomb ceramics is less than 0.5 × 10⁻⁶ at a temperature between room temperature and 800°C. -6 / ℃, the coefficient of thermal expansion at 400-600℃ is less than 0.9×10 -6 / ℃.

4. The high-cordierite phase honeycomb ceramic according to claim 1, characterized in that, The preparation raw materials of the high cordierite-phase ceramic carrier include inorganic raw materials, binders, lubricants and water; Optionally, the inorganic raw materials include the following components by mass percentage: flaky talc 35 - 45%, flaky kaolin 8% - 15%, calcined kaolin 20% - 30%, silica 2 - 10%, alumina 8 - 20% and aluminum hydroxide 0 - 10%; Optionally, the morphology index of the flaky talc is 0.5 - 0.6, wherein the CaO content in the flaky talc is less than 0.05%, the Fe₂O₃ content is between 1.0 - 3%, and 7μm < D50 < 15μm; Optionally, D50 of the flaky talc > D50 of the flaky kaolin > D50 of the aluminum hydroxide, the alumina or the calcined kaolin > D50 of the silica, and the difference in D50 of each level of inorganic raw materials is between 0.5 - 8 microns; Optionally, the particle size range of the flaky talc is: 9μm ≤ D50 ≤ 15μm, the particle size range of the flaky kaolin is: 3μm < D50 < 9μm, the particle size range of the calcined kaolin is: 1.7μm ≤ D50 ≤ 7.0μm, the particle size range of the silica is: 1.0μm < D50 < 4.0μm, the particle size range of the alumina is: 1.0μm < D50 < 6.0μm, and the particle size range of the aluminum hydroxide is: 2.0μm ≤ D50 ≤ 7.3μm; Preferably, the lubricant includes at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, potassium metasilicate, ethylenediamine tetramethylene phosphonic acid, tall oil, acrylic acid, stearic acid, stearate; Preferably, the binder includes at least one of hydroxypropyl methylcellulose, xanthan gum, methylcellulose, methylcellulose derivative, mushroom powder, polyvinyl alcohol, starch ether.

5. The high-cordierite phase honeycomb ceramic according to any one of claims 1-4, characterized in that, The high cordierite-phase honeycomb ceramic has one or more of the following characteristics: a. The honeycomb density of the high cordierite-phase honeycomb ceramic is 200 - 900 cpsi; b. The radial dimension of the high cordierite-phase honeycomb ceramic is 93 - 330.2 mm; c. The dimension of the high cordierite-phase honeycomb ceramic in the longitudinal axis direction is 50 - 304.8 mm; d. The wall thickness of the high cordierite-phase honeycomb ceramic is 2 - 8 mil.

6. The high-cordierite phase honeycomb ceramic according to any one of claims 1-4, characterized in that, The high cordierite-phase honeycomb ceramic has one or more of the following characteristics: a. The compressive strength of the high cordierite-phase honeycomb ceramic is: the compressive strength along the A axis ≥ 5 MPa, and the compressive strength along the B axis ≥ 1.4 MPa; b. The isostatic pressure strength of the high cordierite-phase honeycomb ceramic ≥ 3.0 MPa; c. Thermal shock resistance of the high cordierite phase honeycomb ceramic: It does not crack after three cycles from room temperature to 700 °C.

7. A method for preparing a high-cordierite phase honeycomb ceramic according to any one of claims 1-6, characterized in that, It includes the following steps: Mix raw materials, binder, lubricant, and water to obtain a green body. After subjecting the green body to vacuum degassing, clay refining, extrusion, blank cutting, and microwave drying, a dry green body is obtained. After subjecting the dry green body to segmented sintering and then cooling to room temperature, a honeycomb ceramic carrier is obtained.

8. The preparation method according to claim 7, characterized in that, The raw materials for preparing the high cordierite phase ceramic carrier include inorganic raw materials, binder, lubricant, and water. Optionally, the morphology index of the flaky talc is 0.5 - 0.

6. Among them, the CaO content in the flaky talc is less than 0.05%, the Fe2O3 content is between 1.0 - 3%, and 7μm < D50 < 15μm. Optionally, D50 of the flaky talc > D50 of the flaky kaolin > D50 of the aluminum hydroxide, the alumina, or the calcined kaolin > D50 of the silica, and the difference in D50 of each level of inorganic raw materials is between 0.5 - 8 microns. Optionally, the particle size range of the flaky talc is: 9μm ≤ D50 ≤ 15μm, the particle size range of the flaky kaolin is: 3μm < D50 < 9μm, the particle size range of the calcined kaolin is: 1.7μm ≤ D50 ≤ 7.0μm, the particle size range of the silica is: 1.0μm < D50 < 4.0μm, the particle size range of the alumina is: 1.0μm < D50 < 6.0μm, and the particle size range of the aluminum hydroxide is: 2.0μm ≤ D50 ≤ 7.3μm. Optionally, the inorganic raw materials include the following components by mass percentage: 35 - 45% of flaky talc, 8% - 15% of flaky kaolin, 20% - 30% of calcined kaolin, 2 - 10% of silica, 8 - 20% of alumina, and 0 - 10% of aluminum hydroxide. Preferably, the lubricant includes at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, potassium silicate, ethylenediamine tetramethylene phosphonic acid, tall oil, acrylic acid, stearic acid, and stearate. Preferably, the binder includes at least one of hydroxypropyl methylcellulose, xanthan gum, methylcellulose, methylcellulose derivatives, mushroom powder, polyvinyl alcohol, and starch ether.

9. The preparation method according to claim 7, characterized in that, Subject the dry green body to multi - stage programmed temperature - rising treatment to prepare a honeycomb ceramic carrier. The multi - stage programmed temperature - rising treatment includes: heating the dry green body from room temperature to 600 °C at a heating rate of 10 - 30 °C / h, then heating to 1405 - 1435 °C at a heating rate of 50 - 80 °C / h, and holding at 1405 - 1435 °C for 180 min - 800 min.

10. Application of the cordierite phase honeycomb ceramic according to any one of claims 1 - 6 in automotive exhaust gas treatment.

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