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

Abstract

This invention provides a honeycomb ceramic support, its preparation method, and a catalyst containing the honeycomb ceramic support. The honeycomb ceramic support comprises: a body; a plurality of hollow compartments within the body, the compartments penetrating the body to form a honeycomb structure; wherein each compartment has a quadrilateral cross-section, one pair of opposite corners of the quadrilateral cross-section having a concave portion or a chamfer, and the other pair of opposite corners of the quadrilateral cross-section not having a concave portion or a chamfer. This invention improves the structural strength of the ceramic support used to carry the catalyst and reduces the wall bending phenomenon of the thin-walled ceramic support with a honeycomb structure without increasing mold wear, thereby improving the yield.

Description

Honeycomb ceramic carrier, preparation method thereof and catalytic body containing the honeycomb ceramic carrier Technical Field

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

[0002] With the upgrading of vehicle exhaust emission regulations, carbon monoxide (CO), hydrocarbons (C x H y ) and nitrogen oxides (NO x ) are becoming increasingly stringent, placing higher demands on the pore density and wall thickness of honeycomb ceramic substrates. High-density, thin-walled honeycomb ceramic materials enable harmful substances in exhaust gas to react more quickly with the precious metal coating on the ceramic surface, resulting in a harmless catalytic reaction.

[0003] At present, the honeycomb ceramic carriers provided by the existing technology still have the following problems that need to be solved urgently: 1. As the carrier pore density increases and the wall thickness decreases, the difficulty of product molding increases. The molding of thin-walled products easily leads to bending of the partition walls, and the bending of the partition walls of the carrier will have a serious impact on the overall performance of the carrier; 2. The curved lattice walls will affect the flow of exhaust gas in the catalyst, and cause uneven heat conduction of the partition walls, reducing the catalytic efficiency; 3. The curved partition walls may block the gas channel, affect the exhaust gas treatment efficiency, and cause engine performance to decline; 4. The curved partition walls will reduce the structural strength and stability of the cordierite honeycomb ceramics, shorten the service life, and require frequent replacement or maintenance; 5. Currently, high-pore density, thin-walled carriers are generally right-angle or rounded-angle structures. The stress concentration at the right angles can easily lead to damage to the carrier, and the short service life affects the comprehensive performance of the carrier. Secondly, the flow resistance of the right-angle structure mold mud is large, which can easily lead to bending of the partition walls and low yield.

[0004] Therefore, how to improve the structural strength of the ceramic carrier used to carry the catalyst and reduce the bending phenomenon of the partition walls of the thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, thereby improving the yield, needs to be solved urgently. Summary of the Invention

[0005] The purpose of the present invention is to provide a honeycomb ceramic carrier, a preparation method thereof and a catalytic body containing the honeycomb ceramic carrier, so as to improve the structural strength of the honeycomb ceramic carrier used to carry the catalyst, and reduce the bending phenomenon of the partition walls of the thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, thereby improving the yield.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A honeycomb ceramic substrate, comprising:

[0008] ontology;

[0009] a plurality of cells with hollow structures within the body, the cells penetrating the body to form a honeycomb structure;

[0010] The compartment has a quadrilateral cross section, a pair of opposite corners of the quadrilateral cross section have an inner recess or chamfer, and the other pair of opposite corners of the quadrilateral cross section do not have an inner recess or chamfer.

[0011] In some embodiments of the present invention, in one of the compartments, in a pair of opposite corners having the inner recess or chamfer, the two top corners have the same shape and size;

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

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

[0014] Wherein, the top corners of the four compartments in the repeating unit, which are located inside the repeating unit, have the recessed portion or chamfered angle, or the top corners of the four compartments in the repeating unit, which are located inside the repeating unit, do not have the recessed portion or chamfered angle.

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

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

[0017] In some embodiments of the present invention, in a repeating unit, the top corners of the four compartments located inside the repeating unit and having the inner recess or chamfer are enclosed to form a reinforced intersection at the position of the symmetry center;

[0018] Alternatively, in a repeating unit, the vertices of the four compartments located inside the repeating unit and forming outwardly convex right angles are enclosed and form a common intersection at the position of the symmetry center.

[0019] In some embodiments of the present invention, the inner concave portion is an inner concave right angle, a rounded angle, or an inner concave flower angle;

[0020] The concave right angle is configured to be concave relative to the interior of the compartment where it is located, and the rounded corner is configured to be convex or concave relative to the interior of the compartment where it is located.

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

[0022] In some embodiments of the present invention, the honeycomb ceramic substrate has one or more of the following features:

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

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

[0025] The thermal expansion coefficient CTE of the ceramic carrier in the longitudinal direction in the temperature range of 25 to 800°C is 0.2x10 -6 ~0.5×10 -6 ℃ -1 ;

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

[0027] The thermal shock parameter TSP of the ceramic carrier is 650°C to 750°C, preferably 700°C to 750°C;

[0028] The longitudinal dimension of the ceramic carrier is 3 to 5.5 inches;

[0029] The radial dimension of the ceramic carrier is 3.7 to 5.6 inches;

[0030] In the ceramic carrier, the density of the compartment is 600 to 1200 cpsi;

[0031] The thickness of the partition wall between two adjacent compartments in the ceramic carrier is 2 to 4 mils.

[0032] In some embodiments of the present invention, in each of the compartments, both vertex angles of a pair of opposite corners without the inner recess or chamfer are right angles, and each right angle is formed by two first straight line segments, one of the first straight line segments has a length of A1, and the other of the first straight line segments has a length of B1;

[0033] Each vertex of a pair of diagonal corners having the inner concave portion is formed by two second straight line segments, wherein the length of one second straight line segment is A2, and the length of the other second straight line segment is B2;

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

[0035] In some embodiments of the present invention, in each of the compartments, both vertex angles of a pair of opposite corners without the inner recess or chamfer are right angles, and each right angle is formed by two first straight line segments, one of the first straight line segments has a length of A1, and the other of the first straight line segments has a length of B1;

[0036] Each vertex of a pair of opposite corners with the chamfered corners is formed by a third straight line segment, the projection length of the third straight line segment in the direction of one of the first straight line segments is A3, and the projection length of the third straight line segment in the direction of the other of the first straight line segments is B3;

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

[0038] In some embodiments of the present invention, in each of the compartments, both vertex angles of a pair of opposite corners without the inner recess or chamfer are right angles, and each right angle is formed by two first straight line segments, one of the first straight line segments has a length of A1, and the other of the first straight line segments has a length of B1;

[0039] Each vertex of a pair of diagonal corners having the inner concave portion is formed by an arc segment, the projection length of the arc segment in the direction of one of the first straight line segments is A4, and the projection length of the arc segment in the direction of the other of the first straight line segments is B4;

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

[0041] In some embodiments of the present invention, in each of the compartments, both vertex angles of a pair of opposite corners without the inner recess or chamfer are right angles, and each right angle is formed by two first straight line segments, one of the first straight line segments has a length of A1, and the other of the first straight line segments has a length of B1;

[0042] Each vertex of a pair of diagonal corners having the inner concave portion is formed by four sequentially connected fourth straight line segments, the sum of the projected lengths of the four fourth straight line segments in the direction of one first straight line segment is A5, and the sum of the projected lengths of the four fourth straight line segments in the direction of another first straight line segment is B5;

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

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

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

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

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

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

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

[0050] In order to achieve the above object, the present invention also provides the following technical solutions:

[0051] A method for preparing a honeycomb ceramic substrate, comprising the following steps:

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

[0053] S2, the dry material obtained in step S1 is mixed with an organic additive, a binder, and water in sequence through wet mixing, kneading, slurry preparation, extrusion molding, drying, and cutting to obtain a green body;

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

[0055] The compartment of the honeycomb ceramic carrier is formed during the extrusion molding process in step S2, and the compartment has a quadrilateral cross section, a pair of diagonal corners of the quadrilateral cross section have an inner recess or chamfer, and the other pair of diagonal corners of the quadrilateral cross section do not have an inner recess or chamfer.

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

[0057] In some embodiments of the present invention, in step S3, the sintering temperature is 1000° C. to 1450° C., the sintering time is at least 13 hours, and the heating rate is greater than 25° C. / h.

[0058] In some embodiments of the present invention, in step S2, the wet mixing includes: putting the dry material, binder, and organic additive into a plowshare mixer for dry mixing, and then spraying water and wet mixing;

[0059] The mud kneading comprises: putting the wet-mixed raw materials into a mesh mud kneading machine and kneading the mud under vacuum conditions;

[0060] The extrusion molding comprises: feeding the raw material after the mud is kneaded into an extruder, preferably at least one selected from a single-screw extruder, a twin-screw extruder or a hydraulic extruder, to form the raw material;

[0061] The drying comprises: using a microwave dryer to dry and shape;

[0062] The cutting includes: cutting with a blank cutting machine.

[0063] In order to achieve the above object, the present invention also provides the following technical solutions:

[0064] A catalyst body, comprising the above-mentioned honeycomb ceramic carrier, wherein the inner wall surface of the compartment of the honeycomb ceramic carrier is coated with a catalyst;

[0065] Preferably, the catalyst coating thickness at the top corner positions having the inner concave portion or chamfered structure is 0.06-0.08 μm, and the coating thickness at other positions is 0.07 μm.

[0066] Further areas of applicability will become apparent from the description provided in this disclosure.

[0067] The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0068] Compared with the prior art, the present invention has the following beneficial effects through the above technical solution:

[0069] The present invention improves the structural strength of a ceramic carrier for carrying a catalyst and reduces the bending phenomenon of partition walls of a thin-walled ceramic carrier with a honeycomb structure without increasing the degree of mold wear, thereby improving the yield. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some implementation plans of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0071] FIG1 is a schematic structural diagram of a compartment of a honeycomb ceramic support provided in a first embodiment of the present invention;

[0072] FIG2 is a schematic structural diagram of a compartment of a honeycomb ceramic support provided in a second embodiment of the present invention;

[0073] FIG3 is a schematic structural diagram of a compartment of a honeycomb ceramic support provided in a third embodiment of the present invention;

[0074] FIG4 is a schematic structural diagram of a compartment of a honeycomb ceramic support provided in a fourth embodiment of the present invention;

[0075] FIG5 is a schematic structural diagram of a compartment of a honeycomb ceramic support provided in a fifth embodiment of the present invention;

[0076] FIG6 is a schematic diagram showing the dimensions of the compartments of the honeycomb ceramic support provided in the first embodiment of the present invention;

[0077] FIG7 is a schematic diagram showing the dimensions of the compartments of the honeycomb ceramic support provided in the second embodiment of the present invention;

[0078] FIG8 is a schematic diagram showing the dimensions of the compartments of the honeycomb ceramic support provided in the third embodiment of the present invention;

[0079] FIG9 is a schematic diagram showing the dimensions of the compartments of the honeycomb ceramic support provided in the fourth embodiment of the present invention;

[0080] FIG10 is a schematic diagram showing the dimensions of the compartments of the honeycomb ceramic support provided in the fifth embodiment of the present invention;

[0081] FIG11 is a schematic structural diagram of a honeycomb ceramic substrate provided in one embodiment of the present invention;

[0082] FIG12 is a schematic cross-sectional view of the honeycomb ceramic substrate in FIG11 ;

[0083] FIG13 is a flow chart of a preparation method provided in one embodiment of the present invention.

[0084] The main reference numerals in the drawings of this specification are described as follows: 1-main body; 2-compartment; 31-reinforced intersection; 32-ordinary intersection. DETAILED DESCRIPTION

[0085] The technical solutions in the embodiments of the present invention will be described clearly and completely below. Obviously, the embodiments described are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention. It should be understood that the specific embodiments described herein are only used to illustrate and explain the present invention and are not intended to limit the present invention.

[0086] Any specific numerical value disclosed herein (including the endpoints of a numerical range) is not limited to the exact value of the numerical value, but should be understood to also include values ​​close to the exact value, such as all possible values ​​within ±5% of the exact value. Moreover, for a disclosed numerical range, any combination of the endpoints of the range, between the endpoints and the specific points in the range, and between the specific points can be used to generate one or more new numerical ranges, and these new numerical ranges should also be considered to be specifically disclosed herein.

[0087] The terms used in this disclosure are intended only to describe specific exemplary embodiments and are not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" as used in this disclosure may be intended to also include plural forms. The terms "comprising", "including", "containing" and "having" are inclusive, and therefore illustrate the presence of the features, elements, compositions, steps, integers, operations and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or their collections. Although the open term "comprising" should be understood as a non-limiting term for describing and claiming the various embodiments described in this disclosure, in some aspects, the term may alternatively be understood as a more restrictive and limited term, such as "consisting of" or "substantially consisting of". Thus, for any given embodiment of a narration composition, material, component, element, feature, integer, operation and / or process step, the disclosure also particularly includes an embodiment consisting of or substantially consisting of such a composition, material, component, element, feature, integer, operation and / or process step. In the case of "consisting of," alternative embodiments exclude any additional compositions, materials, components, elements, features, integers, operations and / or process steps, while in the case of "consisting essentially of," any additional compositions, materials, components, elements, features, integers, operations and / or process steps that materially affect the basic and novel characteristics are excluded from such embodiments, but any compositions, materials, components, elements, features, integers, operations and / or process steps that do not materially affect the basic and novel characteristics may be included in such embodiments.

[0088] Any method steps, processes, and operations described in this disclosure are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless expressly identified as a certain order of performance. It is also to be understood that additional or alternative steps may be used unless otherwise stated.

[0089] In this application, except for the contents explicitly described, any matters or issues not mentioned are directly applicable to those known in the art without any changes. Moreover, any embodiment described in this disclosure can be freely combined with one or more other embodiments described in this disclosure, and the technical solutions or technical ideas formed thereby are deemed to be part of the original disclosure or original record of this application, and should not be regarded as new content not disclosed or anticipated in this disclosure, unless a person skilled in the art considers that the combination is obviously unreasonable.

[0090] Unless otherwise specified, the terms used herein have the same meaning as commonly understood by those skilled in the art. If a term is defined herein and its definition is different from the commonly understood meaning in the art, the definition herein shall prevail.

[0091] Unless otherwise stated, when % is mentioned herein, it means wt.%.

[0092] It is worth noting that "cpsi" in this application specification refers to channels per square inch, which means "the number of channels per square inch of cross-section", which is generally referred to as "mesh size"; and "mil" in this application specification refers to "mil" or "milliinch", which is a unit of length, and the conversion relationship is 1 inch (inch) = 1000 mil (mil), 1 mil = 25.4 μm (micrometer), and 25.4 mm = 1000 mil.

[0093] In the context of the present invention, calcined kaolin is used interchangeably with cooked kaolin.

[0094] It should be noted that the "thermal expansion coefficient" in this application specification refers to the ratio of the change in length of a solid material in a certain direction when the temperature changes by 1°C to its length at 20°C (i.e., standard laboratory environment); further, the thermal expansion coefficient of the ceramic carrier recorded in this application specification refers to the thermal expansion coefficient in the longitudinal direction of the ceramic carrier; it is worth emphasizing that, as is well known to those skilled in the art, the longitudinal axis of the above-mentioned ceramic carrier refers to the A-axis.

[0095] It is understood that the "water absorption rate" in this application specification refers to the dry mass and the mass after saturation after the ceramic carrier sample is placed in water and absorbed water to saturation. The water absorption rate recorded in this application specification is measured under the following standards: the ceramic carrier provided by the present invention is made into a sample block of 25*25*25mm±0.5mm, and the dry weight of the sample block is weighed; after vacuuming with a vacuum pump for 10 minutes, it is boiled in a microwave oven, and after being placed at room temperature, the excess water of the sample block is blown away with an air gun, and the weight of the sample block is weighed to calculate the water absorption rate; the dry weight is the sample taken out of the kiln without additional drying.

[0096] It should be noted that the "ratio of the size of the top angle with the non-convex right-angle design to the side length where the top angle is located" in the specification of this application refers to the ratio of the side length of the quadrilateral compartment occupied by the non-convex right-angle design structure; "the thickness of the partition wall between two adjacent compartments" refers to the thickness of the porous wall between the compartments, which is the thickness between the sides of the quadrilateral compartment not occupied by the non-convex right-angle design structure; "the size of the ceramic carrier in the longitudinal direction" refers to the distance from the inlet end to the outlet end of the honeycomb structure ceramic carrier; "the radial size of the ceramic carrier" refers to the diameter of the inlet end face or the outlet end face of the honeycomb structure ceramic carrier. The cross-sectional shape of the carrier in some embodiments is any one of a circle, an ellipse, and a polygon. In the case of an ellipse, the radial size refers to the size of the major axis of the ellipse. In the case of a polygon or other shape, the radial size refers to the longest dimension of the shape.

[0097] First aspect

[0098] Referring to Figures 11 and 12, a honeycomb ceramic carrier includes: a main body 1; a plurality of compartments 2 with a hollow structure in the main body 1, the compartments 2 passing through the main body 1 to form a honeycomb structure; wherein the compartments 2 have a quadrilateral cross-section, a pair of diagonal corners of the quadrilateral cross-section have an inner recess or chamfer, and the other pair of diagonal corners of the quadrilateral cross-section do not have an inner recess or chamfer.

[0099] In the prior art, ceramic carriers with high pore density and thin-walled structures generally have straight-through compartments with right angles or rounded corners. The stress concentration at the right-angle position is prone to damage to the entire ceramic carrier, thereby reducing the product's service life and affecting the comprehensive performance of the carrier. Secondly, the mold clay used to press out the right-angle structure also has the disadvantage of large flow resistance due to the inherent morphological properties of the right-angle shape itself, which easily leads to bending and crooked inner walls of the ceramic carrier's compartments, thereby resulting in low product yield. The present invention provides a honeycomb ceramic carrier with a "quadrilateral cross-section, a pair of opposite corners of the quadrilateral cross-section having a straight-through compartment with an inner recess or chamfer, and the other pair of opposite corners of the quadrilateral cross-section having no inner recess or chamfer." This can reduce the bending of thin-walled honeycomb ceramic partitions without increasing the degree of wear on the honeycomb ceramic mold, thereby significantly improving the product yield.

[0100] 1 to 12 , in some embodiments of the present invention, in one of the compartments 2 , in a pair of opposite corners having the inner recess or chamfer, the two top corners have the same shape and size.

[0101] In some embodiments of the present invention, in one of the compartments 2 , in a pair of opposite corners having the inner recess or chamfer, the two top corners have different shapes and / or different sizes.

[0102] Referring to Figures 1 to 12, in some embodiments of the present invention, the four compartments 2 constitute a repeating unit having a center of symmetry; wherein the top corners of the four compartments 2 in the repeating unit, located inside the repeating unit, have the recessed portion or chamfer.

[0103] Referring to Figures 1 to 12, in some embodiments of the present invention, the four compartments 2 constitute a repeating unit, and the repeating unit has a center of symmetry; wherein, the top corners of the four compartments 2 in the repeating unit that are located inside the repeating unit have the recessed portion or chamfered portion, and the top corners of the four compartments 2 in the repeating unit that are located inside the repeating unit do not have the recessed portion or chamfered portion.

[0104] 1 to 5 , 11 and 12 , in some embodiments of the present invention, the number of the compartments 2 is at least twelve; wherein each of the compartments 2 constitutes a quarter of at least two of the repeating units.

[0105] Referring to Figures 1 to 5, 11 and 12, in some embodiments of the present invention, in a repeating unit, the four compartments 2, which are located inside the repeating unit and have outwardly convex right angles, are enclosed and form a common intersection 32 at the position of the symmetry center.

[0106] Referring to Figures 1 to 5, 11 and 12, in some embodiments of the present invention, in a repeating unit, the top corners of the four compartments 2 located inside the repeating unit and having the recessed portion or chamfered angle are enclosed, and a reinforced intersection 31 is formed at the position of the symmetry center.

[0107] Referring to Figures 1 to 5, 11 and 12, the radial dimension of the reinforced intersection 31 is obviously larger than the radial dimension of the ordinary intersection 32; it can be understood that, when other parameters are the same, the increase in the radial dimension of the structure at this location can improve the structural strength of the honeycomb ceramic carrier, thereby enhancing the durability of the honeycomb ceramic carrier, reducing or even avoiding the occurrence of adverse phenomena such as distortion and deformation of the inner wall of the compartment.

[0108] 1 and 6 , in some embodiments of the present invention, the recessed portion is a recessed right angle, and the recessed right angle is configured to be recessed relative to the interior of the compartment 2 where it is located.

[0109] 3 , 4 , 7 and 8 , in some embodiments of the present invention, the inner recess is a rounded corner, and the rounded corner is configured to be convex or concave relative to the interior of the compartment 2 where it is located.

[0110] In some embodiments of the present invention, the water absorption rate of the honeycomb ceramic support is 14-28%, preferably 16-24%. The water absorption rate is, for example, 14%, 16%, 18%, 20%, 22%, 24%, 26% and 28%, any range consisting of these values ​​and any value falling between the above values.

[0111] In some embodiments of the present invention, the compressive strength of the ceramic carrier in the longitudinal direction is 9 to 10.5 MPa. The compressive strength is, for example, 9 MPa, 9.1 MPa, 9.2 MPa, 9.3 MPa, 9.4 MPa, 9.5 MPa, 9.6 MPa, 9.7 MPa, 9.8 MPa, 9.9 MPa, 10 MPa, 10.1 MPa, 10.2 MPa, 10.3 MPa, 10.4 MPa, and 10.5 MPa, any ranges consisting of these values, and any values ​​falling between the above values.

[0112] In some embodiments of the present invention, the thermal expansion coefficient CTE of the ceramic carrier in the longitudinal direction within the temperature range of 25 to 800° C. is 0.2×10 -6 ~0.5×10 -6 ℃ -1 The thermal expansion coefficient is, for example, 0.2×10 -6 ℃ -1 , 0.25×10 -6 ℃ -1 , 0.3×10 -6 ℃ -1 , 0.35×10 -6 ℃ -1 , 0.4×10 -6 ℃ -1 , 0.45×10 -6 ℃ -1 , 0.5×10 -6 ℃ -1 , any ranges consisting of these values ​​and any values ​​falling between the above values.

[0113] In some embodiments of the present invention, the isostatic strength of the ceramic support is 3.1 to 6.3 MPa. The isostatic strength is, for example, 3.1 MPa, 3.3 MPa, 3.5 MPa, 3.7 MPa, 4 MPa, 4.2 MPa, 4.4 MPa, 4.6 MPa, 4.8 MPa, 5 MPa, 5.2 MPa, 5.4 MPa, 5.6 MPa, 5.8 MPa, 6 MPa, 6.1 MPa, and 6.3 MPa, any ranges consisting of these values, and any values ​​falling between the above values.

[0114] In some embodiments of the present invention, the thermal shock parameter TSP of the ceramic carrier is 650°C to 750°C, preferably 700°C to 750°C.

[0115] In some embodiments of the present invention, the longitudinal length of the ceramic carrier is 3 to 5.5 inches. The longitudinal length is, for example, 3 inches, 3.2 inches, 3.4 inches, 3.6 inches, 3.8 inches, 4 inches, 4.2 inches, 4.4 inches, 4.6 inches, 4.8 inches, 5 inches, 5.2 inches, 5.4 inches, and 5.5 inches, any ranges consisting of these values, and any values ​​falling between the above values.

[0116] In some embodiments of the present invention, the radial dimension of the ceramic carrier is 3.7 to 5.6 inches, such as 3.7 inches, 3.8 inches, 4 inches, 4.2 inches, 4.4 inches, 4.6 inches, 4.8 inches, 5 inches, 5.2 inches, 5.4 inches, and 5.6 inches, any ranges formed by these values, and any values ​​falling between the above values.

[0117] In some embodiments of the present invention, in the ceramic carrier, the density of the compartment 2 is 600 to 1200 cpsi. The density of the compartment is, for example, 600 cpsi, 700 cpsi, 800 cpsi, 900 cpsi, 1000 cpsi, 1100 cpsi, and 1200 cpsi, any range consisting of these values, and any value falling between the above values.

[0118] In some embodiments of the present invention, the thickness of the wall between two adjacent compartments 2 in the ceramic carrier is 2-4 mil.

[0119] Referring to Figures 1 and 6, in some embodiments of the present invention, in each of the compartments 2, the two vertices in a pair of diagonals without the recessed portion or chamfered angle are right angles, and each right angle is composed of two first straight line segments, the length of one first straight line segment is A1, and the length of the other first straight line segment is B1; each vertices in a pair of diagonals with the recessed portion is composed of two second straight line segments, the length of one second straight line segment is A2, and the length of the other second straight line segment is B2; wherein, (A2 / A1)*100%=5~25%, preferably 15~25%, (B2 / B1)*100%=5~25%, preferably 15~25%.

[0120] Referring to Figures 2 and 7, in some embodiments of the present invention, in each of the compartments 2, the two vertices in a pair of opposite corners without the recessed portion or chamfer are right angles, and each right angle is composed of two first straight line segments, the length of one first straight line segment is A1, and the length of the other first straight line segment is B1; each vertices in a pair of opposite corners with the chamfer is composed of a third straight line segment, the projection length of the third straight line segment in the direction of one first straight line segment is A3, and the projection length of the third straight line segment in the direction of the other first straight line segment is B3; wherein, (A3 / A1)*100%=5~25%, preferably 15~25%, (B3 / B1)*100%=5~25%, preferably 15~25%.

[0121] Referring to Figures 3, 4, 7 and 8, in some embodiments of the present invention, in each of the compartments 2, the two vertex angles in a pair of diagonals without the recessed portion or chamfered angle are both right angles, and each right angle is composed of two first straight line segments, the length of one first straight line segment is A1, and the length of the other first straight line segment is B1; each vertex angle in a pair of diagonals with the recessed portion is composed of an arc segment, the projection length of the arc segment in the direction of one first straight line segment is A4, and the projection length of the arc segment in the direction of the other first straight line segment is B4; wherein, (A4 / A1)*100%=5~25%, preferably 15~25%, (B4 / B1)*100%=5~25%, preferably 15~25%.

[0122] Referring to Figures 5 and 10, in some embodiments of the present invention, in each of the compartments 2, the two vertices in a pair of diagonals without the recessed portion or chamfered angle are both right angles, and each right angle is composed of two first straight line segments, the length of one first straight line segment is A1, and the length of the other first straight line segment is B1; each vertices in a pair of diagonals with the recessed portion is composed of four fourth straight line segments connected in sequence, the sum of the projection lengths of the four fourth straight line segments in the direction of one first straight line segment is A5, and the sum of the projection lengths of the four fourth straight line segments in the direction of another first straight line segment is B5; wherein, (A5 / A1)*100%=5~25%, preferably 15~25%, (B5 / B1)*100%=5~25%, preferably 15~25%.

[0123] It can be understood that the present invention provides a straight-through honeycomb ceramic body with special compartments, and the compartments are quadrilaterals with a pair of special diagonal structures. In the honeycomb ceramic body, the compartments are arranged in a mirror-symmetrical manner with the adjacent compartments. The special structures of the diagonals of the compartments include beveled edges, inner arc edges, outer arc edges, and inner right-angle structures. The honeycomb ceramic carrier with this structure improves the problem of wall bending, and its yield rate and comprehensive performance of the carrier are similar to those of honeycomb ceramics with four chamfers and rounded corners, reducing the wear of the honeycomb ceramic mold; the above-mentioned special compartment structure can improve the fluidity of the mud material, reduce and avoid the bending of the wall, improve the compressive strength of the honeycomb ceramic body, and improve the yield rate. This structure can reduce the amount of wear on the mold and reduce the amount of catalyst coating.

[0124] In some embodiments of the present invention, the raw materials of the ceramic carrier include inorganic raw materials, organic additives, binders and water.

[0125] In some embodiments of the present invention, the inorganic raw materials are talc, kaolin, alumina, and optionally silicon oxide and aluminum hydroxide.

[0126] In some embodiments of the present invention, the talc is preferably flaky talc, more preferably flaky talc with D50=5-20 μm.

[0127] In some embodiments of the present invention, the kaolin is preferably raw kaolin and / or cooked kaolin, the raw kaolin is more preferably flaky raw kaolin, the flaky raw kaolin is more preferably flaky raw kaolin with D50=5-20 μm, and the cooked kaolin is more preferably cooked kaolin with D50=4-15 μm.

[0128] In some embodiments of the present invention, the silicon oxide is preferably silicon oxide with a D50 of 1 to 10 μm, and the aluminum oxide is preferably aluminum oxide with a D50 of 1 to 10 μm.

[0129] In some embodiments of the present invention, the organic auxiliary agent is at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, xanthan gum, potassium laurate, and glycerol random polyether.

[0130] In some embodiments of the present invention, the binder is at least one of hydroxymethyl cellulose, ethyl cellulose, and carboxymethyl cellulose.

[0131] In some embodiments of the present invention, based on the total amount of inorganic raw materials as 100wt.%, the talc accounts for 20-40wt.%, the kaolin accounts for 20-60wt.%, the aluminum oxide accounts for 10-20wt.%, the silicon oxide accounts for 0-10wt.%, the organic additive accounts for 2-10wt.% relative to the total amount of inorganic raw materials, the binder accounts for 3-15wt.% relative to the total amount of inorganic raw materials, and the water accounts for 25-50wt.% relative to the total amount of inorganic raw materials.

[0132] Preferably, the kaolin comprises 10-30 wt.% of flaky raw kaolin and 10-30 wt.% of cooked kaolin, based on 100 wt.% of the total amount of inorganic raw materials.

[0133] Second aspect

[0134] Referring to Figure 13, a method for preparing a honeycomb ceramic carrier includes the following steps: S1, mixing inorganic raw materials to obtain dry materials; S2, mixing the dry materials obtained in step S1 with organic additives, binders, and water in sequence through wet mixing, kneading, mud kneading, extrusion molding, drying, and cutting to obtain a green body; S3, sintering the green body obtained in step S2 to obtain the above-mentioned honeycomb ceramic carrier; wherein, during the extrusion molding process in step S2, a compartment 2 of the honeycomb ceramic carrier is formed, and the compartment 2 has a quadrilateral cross-section, a pair of opposite corners of the quadrilateral cross-section have an inner recess or chamfer, and the other pair of opposite corners of the quadrilateral cross-section do not have an inner recess or chamfer.

[0135] In some embodiments of the present invention, in step S3, during the sintering process, the heating rate and the sintering temperature at least partially vary with the sintering time.

[0136] In some embodiments of the present invention, in step S3, the sintering temperature is 1000° C. to 1450° C., the sintering time is at least 13 hours, and the heating rate is greater than 25° C. / h.

[0137] In some embodiments of the present invention, in step S2, the wet mixing includes: putting the dry material, binder, and organic additive into a plow mixer for dry mixing, and then wet mixing after spraying water; the mud kneading includes: putting the raw materials after wet mixing into a mesh mud kneading machine for mud kneading under vacuum conditions; the extrusion molding includes: putting the raw materials after mud kneading into an extruder, preferably selected from at least one of a single-screw extruder, a twin-screw extruder or a hydraulic extruder, for molding, and then obtaining the compartment 2 through a mold; the drying includes: using a microwave dryer for drying and molding; the cutting includes: using a blank cutting machine for cutting.

[0138] Through the above-mentioned preparation method, a straight-through honeycomb ceramic body with special compartments can be obtained. The compartments are quadrilaterals with a pair of special diagonal structures. In the honeycomb ceramic body, the compartments are arranged in a mirror-symmetrical manner with adjacent compartments. The product has uniform stress distribution, uniform slurry extrusion, high yield rate, good pressure and shock resistance, reduced catalyst coating, and low mold loss. The straight-through honeycomb ceramic special structure of the present invention achieves the effects of reduced carrier wave walls, improved yield rate, increased compressive strength, reduced precious metal coating amount, and enhanced mold service life. That is, the yield rate of the honeycomb ceramic carrier of this special structure is about 10%-20% higher than that of the right-angle structure, and the service life of the mold is much longer than that of the four-corner rounded structure. The change in the mold groove width per 5000 meters of extrusion is between 0.1-0.2 mil, which is similar to the change in the groove width of the rectangular structure mold. The coating thickness of the precious metal at the special structure is about 1 / 2 of that of the right-angle structure. The honeycomb ceramic carrier of the present invention with a pair of quadrilateral compartments with special diagonal structures has an improved yield rate and reduced precious metal coating amount compared to the right-angle structure. The service life of the mold with rounded corners is increased, and it combines the advantages of rounded corners and right-angle structures.

[0139] The third aspect

[0140] A catalytic body comprises the above-mentioned honeycomb ceramic carrier, wherein the inner wall surface of the compartment 2 of the honeycomb ceramic carrier is coated with a catalyst; preferably, the catalyst coating thickness at the top corner position having the inner concave portion or chamfered structure is 0.06 to 0.08 μm, and the coating thickness at the remaining positions is 0.07 μm.

[0141] Example 1

[0142] In this embodiment, 35wt.% of flaky talc, 19.2wt.% of flaky raw kaolin, 25.6wt.% of calcined kaolin, 5wt.% of silicon oxide, 15.2wt.% of aluminum oxide, and 8.0wt.% of a binder and 3.9wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 32wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 600-mesh, 3.7-inch diameter die; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.3h; the obtained green body is first heated at 250-310°C for 7h to remove binder, and then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0143] Example 2

[0144] In this embodiment, 25wt.% of flaky talc, 24.8wt.% of flaky raw kaolin, 30wt.% of calcined kaolin, 4wt.% of silicon oxide, 16.2wt.% of aluminum oxide, and 8.6wt.% of a binder and 3.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 33wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to remove binder, and then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0145] Example 3

[0146] In this embodiment, 30.6wt.% of flaky talc, 22.2wt.% of flaky raw kaolin, 30wt.% of calcined kaolin, 4wt.% of silicon oxide, 13.2wt.% of aluminum oxide, and 8.6wt.% of a binder and 3.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 33wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; then, a honeycomb structure is extruded using an 800-mesh, 4.66-inch diameter die; the cut length is 5 inches; then, it is dried at 50°C for 0.3h; the obtained green body is first heated at 250-310°C for 7h to debind, then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0147] Example 4

[0148] In this embodiment, 35wt.% of flaky talc, 14.2wt.% of flaky raw kaolin, 30wt.% of calcined kaolin, 4.6wt.% of silicon oxide, 16.2wt.% of aluminum oxide, 7.6wt.% of a binder and 3.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 35wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 900 mesh die with a diameter of 4.66 inches; the cut length is 3.94 inches; the honeycomb structure is then dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to remove binder, then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0149] Example 5

[0150] In this embodiment, 36 wt.% of flaky talc, 19.2 wt.% of flaky raw kaolin, 24.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 1200 mesh and 5.2 inch diameter die; the cut length is 3.94 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0151] Example 6

[0152] In this embodiment, 25wt.% of flaky talc, 29.2wt.% of flaky raw kaolin, 25.6wt.% of calcined kaolin, 4wt.% of silicon oxide, 16.2wt.% of aluminum oxide, and 12wt.% of a binder and 1.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 50wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 600-mesh, 3.7-inch diameter die; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.3h; the obtained green body is first heated at 250-310°C for 7h to remove binder, and then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0153] Example 7

[0154] In this embodiment, 30 wt.% of flaky talc, 23.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 14.2 wt.% of aluminum oxide, and 8.6 wt.% of a binder and 3.5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 3.7 inches; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0155] Example 8

[0156] In this embodiment, 38 wt.% of flaky talc, 12 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 17 wt.% of aluminum oxide, and 7 wt.% of a binder and 7 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 30 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; then, a honeycomb structure is extruded using an 800 mesh and 3.7 inch diameter die; the cut length is 3.1 inches; then, it is dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to debind, then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0157] Example 9

[0158] In this embodiment, 40 wt.% of flaky talc, 20.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 11.2 wt.% of aluminum oxide, and 6 wt.% of a binder and 9 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 29 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 900 mesh, 4.66 inch diameter die; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0159] Example 10

[0160] In this embodiment, 25wt.% of flaky talc, 24.2wt.% of flaky raw kaolin, 30wt.% of calcined kaolin, 4wt.% of silicon oxide, 16.8wt.% of aluminum oxide, 10wt.% of a binder and 2.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 45wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 1200 mesh die with a diameter of 4.66 inches; the cut length is 5 inches; and the honeycomb structure is then dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to remove binder, and then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0161] Example 11

[0162] In this embodiment, 30 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 30 wt.% of calcined kaolin, 6 wt.% of silicon oxide, 11.8 wt.% of aluminum oxide, and 9.2 wt.% of a binder and 2.6 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 39 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 600 mesh, 5.2 inch diameter die; the cut length is 3.94 inches; and the honeycomb structure is then dried at 50°C for 0.5 hours. The obtained green body is first heated at 250-310°C for 7 hours to remove binder, then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0163] Example 12

[0164] In this embodiment, 37 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 25.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, 8.6 wt.% of a binder and 3.5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 600 mesh, 5.2 inch diameter die; the cut length is 3.94 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours. The obtained green body is first heated at 250-310°C for 7 hours to remove binder, then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0165] Example 13

[0166] In this embodiment, 30 wt.% of flaky talc, 23.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 15.2 wt.% of aluminum oxide, and 6.5 wt.% of a binder and 5.5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 5.2 inches; the cut length is 3.94 inches; the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0167] Example 14

[0168] In this embodiment, 33 wt.% of flaky talc, 22.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 5 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 2 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh, 5.2 inch diameter die; the cut length is 3.94 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0169] Example 15

[0170] In this embodiment, 20 wt.% of flaky talc, 25.2 wt.% of flaky raw kaolin, 30.6 wt.% of calcined kaolin, 8 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 10 wt.% of a binder and 3.5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 41 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh, 5.2 inch diameter die; the cut length is 3.94 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0171] Comparative Example 1

[0172] In this embodiment, 36 wt.% of flaky talc, 20.2 wt.% of flaky raw kaolin, 26.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 12.2 wt.% of aluminum oxide, and 9 wt.% of a binder and 5 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 600 mesh, 3.7 inch diameter die; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0173] Comparative Example 2

[0174] In this embodiment, 32 wt.% of flaky talc, 21.2 wt.% of flaky raw kaolin, 28.6 wt.% of calcined kaolin, 3 wt.% of silicon oxide, 13.2 wt.% of aluminum oxide, and 7 wt.% of a binder and 6 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 33 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0175] Comparative Example 3

[0176] In this embodiment, 25wt.% of flaky talc, 20.2wt.% of flaky raw kaolin, 32.6wt.% of calcined kaolin, 5wt.% of silicon oxide, 17.2wt.% of aluminum oxide, and 3wt.% of a binder and 10wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 28wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; then, a honeycomb structure is extruded using an 800-mesh, 4.66-inch diameter die; the cut length is 5 inches; then, it is dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to debind, then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0177] Comparative Example 4

[0178] In this embodiment, 39 wt.% of flaky talc, 10.2 wt.% of flaky raw kaolin, 30.6 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 15 wt.% of a binder and 2 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 50 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 600 mesh, 3.7 inch diameter die; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0179] Comparative Example 5

[0180] In this embodiment, 30 wt.% of flaky talc, 29.8 wt.% of flaky raw kaolin, 15 wt.% of calcined kaolin, 10 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, and 12 wt.% of a binder and 2 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 45 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 3.1 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0181] Comparative Example 6

[0182] In this embodiment, 25wt.% of flaky talc, 28.2wt.% of flaky raw kaolin, 26.6wt.% of calcined kaolin, 4wt.% of silicon oxide, 16.2wt.% of aluminum oxide, and 10wt.% of a binder and 3.5wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, water with a ratio of 46wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; then, a honeycomb structure is extruded using an 800-mesh, 4.66-inch diameter die; the cut length is 5 inches; then, it is dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to debind, then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0183] Comparative Example 7

[0184] In this embodiment, 31 wt.% of flaky talc, 29.2 wt.% of flaky raw kaolin, 10.6 wt.% of calcined kaolin, 10 wt.% of silicon oxide, 19.2 wt.% of aluminum oxide, and 7 wt.% of a binder and 6 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 36 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 5 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0185] Comparative Example 8

[0186] In this embodiment, 25wt.% of flaky talc, 24.8wt.% of flaky raw kaolin, 30wt.% of calcined kaolin, 4wt.% of silicon oxide, 16.2wt.% of aluminum oxide, and 5wt.% of a binder and 8wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plowshare mixer and dry mixed for 10 minutes at a rotation speed of 500rpm; after the dry mixing is completed, 29wt.% of water relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 5 inches; and the honeycomb structure is then dried at 50°C for 0.4h; the obtained green body is first heated at 250-310°C for 7h to remove binder, and then sintered at 1430°C for 6h, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0187] Comparative Example 9

[0188] In this embodiment, 29 wt.% of flaky talc, 25.8 wt.% of flaky raw kaolin, 25 wt.% of calcined kaolin, 4 wt.% of silicon oxide, 16.2 wt.% of aluminum oxide, 3.5 wt.% of a binder and 10 wt.% of a lubricant accounting for the total amount of inorganic raw materials are added to a plow mixer and dry mixed for 10 minutes at a rotation speed of 500 rpm; after the dry mixing is completed, water with a ratio of 28 wt.% relative to the inorganic raw materials is added for wet mixing for 15 minutes at a rotation speed of 500 rpm; a honeycomb structure is then extruded using a 750 mesh die with a diameter of 4.66 inches; the cut length is 5 inches; and the honeycomb structure is then dried at 50°C for 0.4 hours; the obtained green body is first heated at 250-310°C for 7 hours to remove binder, and then sintered at 1430°C for 6 hours, and then naturally cooled to obtain the honeycomb ceramic carrier.

[0189] The parameters of the above embodiments and comparative examples are compared and listed in Table 1 below.

[0190] Table 1 Parameter comparison of various embodiments and comparative examples

[0191] In Example 2, compared with Example 1, the cell density and diameter were changed to produce a honeycomb ceramic structure.

[0192] In Example 3, compared with Example 1, the cell density, wall thickness, length, and diameter were changed to produce a honeycomb ceramic structure.

[0193] Compared with Example 1, Example 4 changes the pore density, wall thickness, length, diameter, and special structure ratio to produce a honeycomb ceramic structure.

[0194] Compared with Example 1, Example 5 changes the pore density, wall thickness, length, diameter, and special structure ratio to produce a honeycomb ceramic structure.

[0195] Compared with Example 1, Example 6 changes the compartment structure and the proportion of special structures to produce a honeycomb ceramic structure.

[0196] Compared with Example 1, Example 7 changes the pore density and the proportion of special structures to produce a honeycomb ceramic structure.

[0197] Compared with Example 1, Example 8 changes the pore density, wall thickness, and special structure ratio to produce a honeycomb ceramic structure.

[0198] Compared with Example 1, Example 9 changes the pore density, diameter, and special structure ratio to produce a honeycomb ceramic structure.

[0199] Compared with Example 1, Example 10 changes the cell density, diameter, length, and special structure ratio to produce a honeycomb ceramic structure.

[0200] Compared with Example 1, Example 11 changes the diameter, length, and proportion of special structures to produce a honeycomb ceramic structure.

[0201] Compared with Example 1, Example 12 changes the wall thickness, diameter, length, and proportion of special structures to produce a honeycomb ceramic structure.

[0202] Compared with Example 1, Example 13 changes the pore density, diameter, length, and special structure ratio to produce a honeycomb ceramic structure.

[0203] Compared with Example 1, Example 14 changes the pore density, wall thickness, diameter, length, and special structure ratio to produce a honeycomb ceramic structure.

[0204] Compared with Example 1, Example 15 changes the pore density, wall thickness, diameter, length, and special structure ratio to produce a honeycomb ceramic structure.

[0205] In Comparative Example 1, compared with Example 1, the cell structure was changed to produce a ceramic honeycomb structure.

[0206] In Comparative Example 2, compared with Example 1, the cell structure, cell density, and diameter were changed to produce a honeycomb ceramic structure.

[0207] In Comparative Example 3, compared with Example 1, the cell structure, pore density, wall thickness, diameter, and length were changed to produce a honeycomb ceramic structure.

[0208] In Comparative Example 4, compared with Example 1, the cell structure, diameter, and length were changed to produce a honeycomb ceramic structure.

[0209] In Comparative Example 5, compared with Example 1, the cell structure, cell density, and length were changed to produce a honeycomb ceramic structure.

[0210] In Comparative Example 6, compared with Example 1, the cell structure, cell density, wall thickness, and length were changed to produce a honeycomb ceramic structure.

[0211] In Comparative Example 7, compared with Example 1, the cell density, length, and diameter were changed to produce a honeycomb ceramic structure.

[0212] In Comparative Example 8, compared with Example 1, the cell density, length, diameter, and special structure ratio were changed to produce a honeycomb ceramic structure.

[0213] In Comparative Example 9, compared with Example 1, the cell density, length, diameter, compartment structure, and special structure ratio were changed to produce a honeycomb ceramic structure.

[0214] The performance test results of the honeycomb ceramic substrates obtained in the above embodiments and comparative examples are listed in Table 2 below.

[0215] Table 2 Performance test results of honeycomb ceramic substrates obtained in various embodiments and comparative examples

[0216] Table 2 compares the performance of the cordierite honeycomb ceramic carriers prepared in various embodiments and comparative examples, mainly involving specific specifications, carrier yield, thermal expansion coefficient, thermal shock, isostatic pressing, catalyst coating thickness, change in mold slot width, A-axis compressive strength, and other test results. The thermal expansion coefficient was measured using a thermal dilatometer to test the deformation of the product from room temperature to 800°C; the A-axis compressive strength was measured using a servo computerized universal material testing machine using a 25±0.5 mm sample; the thermal shock was measured using a muffle furnace heated to 650°C for 30 minutes, then removed and quenched at room temperature without cracking. The catalyst coating thickness was measured using an imaging instrument.

[0217] Mold slot width change: obtained through imaging testing. The change in mold slot width before and after production is measured for every 5,000 meters of cordierite honeycomb ceramic carrier produced.

[0218] As can be seen from Examples 1 to 15 in Table 2, the compressive strength of the honeycomb ceramic carrier with special structure compartments is similar to the compressive strength of the honeycomb ceramic carrier with rounded corners in Comparative Examples 4 to 6. The compressive strength of the honeycomb ceramic carrier with special structure compartments is higher than that of Comparative Examples 1 to 3, and its yield is much higher than that of Comparative Examples 1-3, basically more than 20% higher. The thickness of the precious metal coating of the honeycomb ceramic carrier with special structure compartments is much lower than that of Comparative Examples 1-3, basically 50% lower. Compared with Comparative Examples 4 to 6, the degree of wear on the mold in Examples 1 to 15 is very low. The change in the mold groove width per 5,000 meters of extrusion of the special compartment mechanism is about 10% of that of the fully rounded structure, which greatly improves the service life of the mold and reduces the cost of the product. Compared with Comparative Examples 4 to 6, the yield of Examples 1 to 15 is 10% higher. If the special corners account for more than 30%, the yield will be greatly reduced.

[0219] In this application, "thermal shock resistance," also known as thermal shock resistance or thermal stability, refers to a material's ability to withstand drastic temperature changes or alternating hot and cold temperatures within a certain starting temperature range without damage. This temperature at which a material can withstand alternating hot and cold temperatures without damage is the thermal shock parameter, typically measured after three cycles. The material undergoes three thermal cycles at the aforementioned temperatures without cracking. The isostatic pressure test involves wrapping the sample in a rubber sleeve, placing it in a water-filled isostatic pressure tester, applying pressure, and maintaining the pressure for 5 minutes without cracking. The aforementioned carrier can complete this test at temperatures between 2 and 7 MPa.

[0220] The honeycomb ceramic has the following structural characteristics, and the thermal expansion coefficient (CTE) measured at 25°C to 800°C is 0.2x10 -6 ~0.5×10 -6 ℃ -1 The thermal shock parameter (TSP) of the honeycomb ceramic structure is 650-750°C, which means it will not crack after three thermal cycles at the above temperature. The isostatic pressure test method is as follows: the sample is wrapped with a rubber sleeve and placed in an isostatic pressure tester filled with water. Pressure is applied and maintained for 5 minutes without cracking sound. The above-mentioned carrier can complete the test at 2-7MPa.

[0221] The above is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art who is familiar with the technical field can easily think of changes or replacements within the technical scope disclosed by the present invention, which should be included in the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims. In addition, the principle and implementation of the present invention are explained in detail in the specification using specific examples. The description of the above embodiments is only used to help understand the method of the present invention and its core idea. The content of this specification should not be understood as limiting the present invention.

Claims

1. A honeycomb ceramic carrier, characterized in that, The honeycomb ceramic carrier includes: A body (1); A plurality of compartments (2) with a hollow structure inside the body, and the compartments (2) penetrate the body (1) to form a honeycomb structure; Wherein, the compartment (2) has a quadrilateral cross-section, a pair of opposite corners of the quadrilateral cross-section have concave portions or chamfers, and the other pair of opposite corners of the quadrilateral cross-section do not have concave portions or chamfers.

2. The honeycomb ceramic carrier according to claim 1, characterized in that, In one of the compartments (2), among the pair of opposite corners having the concave portion or chamfer, the two top corners have the same shape and size; Or, in one of the compartments (2), among the pair of opposite corners having the concave portion or chamfer, the two top corners have different shapes and / or different sizes.

3. The honeycomb ceramic carrier according to claim 1 or 2, characterized in that, Four of the compartments (2) form a repeating unit, and this repeating unit has a symmetry center; Wherein, among the four compartments (2) in this repeating unit, the top corners located inside the repeating unit have the concave portion or chamfer, or among the four compartments (2) in this repeating unit, the top corners located inside the repeating unit do not have the concave portion or chamfer.

4. The honeycomb ceramic carrier according to any one of claims 1 to 3, characterized in that, The number of the compartments (2) is at least twelve; Wherein, each of the compartments (2) constitutes a quarter part of at least two repeating units.

5. The honeycomb ceramic carrier according to any one of claims 1 to 4, characterized in that, In a repeating unit, the top corners of the four compartments (2) located inside the repeating unit and having the concave portion or chamfer enclose, and a strengthening intersection point (31) is formed at the position of the symmetry center; Or, in a repeating unit, the top corners of the four compartments (2) located inside the repeating unit and being outward convex right angles enclose, and a common intersection point (32) is formed at the position of the symmetry center.

6. The honeycomb ceramic carrier according to any one of claims 1 to 5, characterized in that, The concave portion is a concave right angle, a rounded corner or a concave flower angle; Wherein, the concave right angle is configured to be concave with respect to the inside of the compartment (2) where it is located, and the rounded corner is configured to be outward convex or concave with respect to the inside of the compartment (2) where it is located.

7. The honeycomb ceramic carrier according to any one of claims 1 to 6, characterized in that, The honeycomb ceramic carrier has one or more of the following characteristics: The water absorption rate of the honeycomb ceramic carrier is 14-28%; The compressive strength of the honeycomb ceramic carrier in the longitudinal axis direction is 9-10.5 MPa; The honeycomb ceramic carrier has a coefficient of thermal expansion (CTE) in the longitudinal axis direction within the temperature range of 25 to 800 °C of 0.2x10 -6 ~0.5×10 -6 °C -1 ; The isostatic pressing strength of the honeycomb ceramic carrier is 3.1-6.3 MPa; The thermal shock parameter TSP of the ceramic carrier is 650 °C - 750 °C, preferably 700 °C - 750 °C; The size of the ceramic carrier in the longitudinal axis direction is 3-5.5 inches; The radial size of the ceramic carrier is 3.7-5.6 inches; In the ceramic carrier, the density of the compartments (2) is 600-1200 cpsi; And / or, the thickness of the partition wall between two adjacent compartments (2) in the ceramic carrier is 2-4 mil.

8. The honeycomb ceramic carrier according to any one of claims 1 to 7, characterized in that, In each of the compartments (2), both of the two top corners in the pair of opposite corners without the concave portion or chamfer are right angles, and each right angle is composed of two first straight line segments, the length of one of the first straight line segments is A1, and the length of the other first straight line segment is B1; Each vertex angle of a pair of diagonals with the concave portion is composed of two second straight line segments, where the length of one of the second straight line segments is A2 and the length of the other second straight line segment is B2; Among them, (A2 / A1)*100% = 5 - 25%, preferably 15 - 25%, (B2 / B1)*100% = 5 - 25%, preferably 15 - 25%.

9. The honeycomb ceramic carrier according to any one of claims 1 to 8, characterized in that, In each of the compartments (2), two vertex angles of a pair of diagonals without the concave portion or chamfer are both right angles, and each right angle is composed of two first straight line segments, where the length of one of the first straight line segments is A1 and the length of the other first straight line segment is B1; Each vertex angle of a pair of diagonals with the chamfer is composed of a third straight line segment, and the projection length of the third straight line segment in the direction of one of the first straight line segments is A3, and the projection length of the third straight line segment in the direction of the other first straight line segment is B3; Among them, (A3 / A1)*100% = 5 - 25%, preferably 15 - 25%, (B3 / B1)*100% = 5 - 25%, preferably 15 - 25%.

10. The honeycomb ceramic carrier according to any one of claims 1 to 9, characterized in that, In each of the compartments (2), two vertex angles of a pair of diagonals without the concave portion or chamfer are both right angles, and each right angle is composed of two first straight line segments, where the length of one of the first straight line segments is A1 and the length of the other first straight line segment is B1; Each vertex angle of a pair of diagonals with the concave portion is composed of an arc segment, and the projection length of the arc segment in the direction of one of the first straight line segments is A4, and the projection length of the arc segment in the direction of the other first straight line segment is B4; Among them, (A4 / A1)*100% = 5 - 25%, preferably 15 - 25%, (B4 / B1)*100% = 5 - 25%, preferably 15 - 25%.

11. The honeycomb ceramic carrier according to any one of claims 1 to 10, characterized in that, In each of the compartments (2), two vertex angles of a pair of diagonals without the concave portion or chamfer are both right angles, and each right angle is composed of two first straight line segments, where the length of one of the first straight line segments is A1 and the length of the other first straight line segment is B1; Each vertex angle of a pair of diagonals with the concave portion is composed of four fourth straight line segments connected in sequence, and the total projection length of the four fourth straight line segments in the direction of one of the first straight line segments is A5, and the total projection length of the four fourth straight line segments in the direction of the other first straight line segment is B5; Among them, (A5 / A1)*100% = 5 - 25%, preferably 15 - 25%, (B5 / B1)*100% = 5 - 25%, preferably 15 - 25%.

12. The honeycomb ceramic carrier according to any one of claims 1 to 11, characterized in that, The raw materials of the ceramic carrier include inorganic raw materials, organic additives, binders and water; The inorganic raw materials are talc, kaolin, alumina and optionally silica and aluminum hydroxide. Among them, the talc is preferably flaky talc, more preferably flaky talc with D50 = 5 - 20 μm; the kaolin is preferably raw kaolin and / or calcined kaolin. The raw kaolin is more preferably flaky raw kaolin, and the flaky raw kaolin is more preferably flaky raw kaolin with D50 = 5 - 20 μm. The calcined kaolin is more preferably calcined kaolin with D50 = 4 - 15 μm. The silica is preferably silica with D50 = 1 - 10 μm, and the alumina is preferably alumina with D50 = 1 - 10 μm; The organic additives are at least one of alkyl polyether, fatty alcohol polyoxyethylene ether, xanthan gum, potassium silicate, and random polyether of glycerol; The binder is at least one of hydroxymethyl cellulose, ethyl cellulose, and carboxymethyl cellulose.

13. The honeycomb ceramic carrier according to any one of claims 1 to 12, characterized in that, Based on the total amount of inorganic raw materials being 100 wt.%, the proportion of talc is 20 - 40 wt.%, the proportion of kaolin is 20 - 60 wt.%, the proportion of alumina is 10 - 20 wt.%, the proportion of silica is 0 - 10 wt.%, the proportion of the organic additives relative to the total amount of inorganic raw materials is 2 - 10 wt.%, the proportion of the binder relative to the total amount of inorganic raw materials is 3 - 15 wt.%, and the proportion of water relative to the total amount of inorganic raw materials is 25 - 50 wt.%, Preferably, the kaolin includes 10 - 30 wt.% of flaky raw kaolin and 10 - 30 wt.% of calcined kaolin, based on the total amount of inorganic raw materials being 100 wt.%.

14. The method for preparing the honeycomb ceramic carrier according to any one of claims 1 to 13, characterized in that, The preparation method comprises the following steps: S1, mixing the inorganic raw materials to obtain a dry material; S2, after successively subjecting the dry material obtained in step S1, the organic additives, the binder, and water to wet mixing, kneading, clay refining, extrusion molding, drying, and cutting, a green body is obtained; S3, sintering the green body obtained in step S2 to obtain the honeycomb ceramic carrier; Among them, in the extrusion molding process in step S2, the compartments (2) of the honeycomb ceramic carrier are formed. The compartments (2) have a quadrilateral cross-section, and a pair of opposite corners of the quadrilateral cross-section have concave portions or chamfers, and the other pair of opposite corners of the quadrilateral cross-section do not have concave portions or chamfers.

15. The preparation method according to claim 14, characterized in that, In step S3, during the sintering process, the heating rate and sintering temperature at least at some moments change with the sintering time.

16. The preparation method according to claim 14 or 15, characterized in that, In step S3, the sintering temperature is 1000°C - 1450°C, the sintering duration is at least 13 h, and the heating rate is greater than 25°C / h.

17. The preparation method according to any one of claims 14 to 16, characterized in that, In step S2, the wet mixing includes: putting the dry material, the binder, and the organic additives into a plowshare mixer for dry mixing, and then spraying water for wet mixing; The clay refining includes: putting the raw materials after wet mixing into a screen clay refiner and carrying out clay refining under vacuum conditions; The extrusion molding includes: putting the raw materials after clay refining into an extruder, preferably at least one selected from a single-screw extruder, a twin-screw extruder, or a hydraulic extruder, for shaping, and then obtaining the compartments (2) through a mold; The drying includes: drying and forming by using a microwave dryer; The cutting includes: cutting by using a green body cutting machine.

18. A catalytic body, characterized in that, The catalyst body includes the honeycomb ceramic carrier as described in any one of claims 1 to 13, and a catalyst is coated on the inner wall surface of the compartment (2) of the honeycomb ceramic carrier; Preferably, the coating thickness of the catalyst at the vertex position with the concave portion or chamfer structure is 0.06 to 0.08 μm, and the coating thickness at the remaining positions is 0.07 μm.

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