Cordierite Honeycomb Pore Control for Low Pressure Filtration
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Solution Overview
Problem
Honeycomb structures with high cordierite crystals face challenges in achieving both high particulate collection efficiency and low pressure loss performance, due to broad pore diameter distributions and difficulty in controlling pore formation during firing.
Innovation Solution
A honeycomb structure comprising 80.0 to 94.0% cordierite as the main crystalline phase, with ceria in a secondary phase, and porous partition walls having a specific pore diameter distribution (D90−D10)/D50≤1.2, along with a manufacturing method that includes controlled firing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cordierite crystals are increased to ensure thermal shock resistance and strength, then thermal shock resistance is improved, but pore diameter distribution becomes broad making it difficult to achieve both high particulate collection efficiency and low pressure loss performance
Solution Approach 1:
The invention changes the chemical composition parameters by adding ceria (0.1-5.0 wt%) to the cordierite-based raw material composition. This parameter change modifies the firing behavior to produce a narrower pore diameter distribution while maintaining high cordierite crystal content (80-95%), thereby resolving the contradiction between thermal shock resistance and pore distribution control.
Solution Approach 2:
The invention creates a composite material system combining cordierite crystals with ceria additives. This composite approach allows the cordierite to provide thermal shock resistance while the ceria modifies the sintering process to achieve narrower pore distribution, enabling both high particulate collection efficiency and low pressure loss performance.
2Strength
If cordierite crystals are increased to increase strength, then strength is improved, but pore diameter distribution becomes broad making it difficult to achieve both high particulate collection efficiency and low pressure loss performance
Solution Approach 1:
The invention modifies the raw material composition by incorporating ceria (0.1-5.0 wt%), which changes the sintering characteristics during firing. This parameter change enables the formation of narrower pore diameter distribution even when high cordierite crystal content (80-95%) is present, thereby maintaining both strength and improved pore distribution for better filtration performance.
Solution Approach 2:
The invention develops a composite ceramic material consisting of cordierite crystals reinforced with ceria. The ceria component acts as a sintering aid that controls pore formation, allowing the material to achieve both high mechanical strength from cordierite and narrow pore distribution for optimal filtration characteristics.
3Reliability
If conventional firing methods are used with high cordierite content, then thermal shock resistance is achieved, but it becomes difficult to achieve both high particulate collection efficiency and low pressure loss performance
Solution Approach 1:
The invention changes the chemical composition by adding ceria (0.1-5.0 wt%) to the cordierite-based raw material. This modification alters the firing process to produce narrower pore diameter distribution, enabling the honeycomb structure to achieve both high thermal shock resistance and improved filtration performance with lower pressure loss.
Solution Approach 2:
The invention creates a composite ceramic system where ceria enhances the performance of cordierite-based materials. The ceria-cordierite composite achieves superior dual performance: maintaining the excellent thermal shock resistance of cordierite while achieving narrow pore distribution for high particulate collection efficiency and low pressure loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The structure achieves both high particulate collection efficiency and low pressure loss performance, leveraging the thermal shock resistance of cordierite while optimizing pore distribution and manufacturing processes.
Implementation Method 1
cordierite crystals synthesized (fired) from multiple raw materials such as magnesia source, silica source, and alumina source tend to have a broad pore diameter distribution
Implementation Method 2
the porous partition walls have a porosity of 60% or more as measured by a mercury porosimetry; and for the porous partition walls, a cumulative 10% pore diameter (D10), a cumulative 50% pore diameter (D50) and a cumulative 90% pore diameter (D90) from a small pore side satisfy a relationship (D90−D10)/D50≤1.2
Data Source
AI summary
A honeycomb structure includes a plurality of cell channels passing through an inside of the honeycomb structure and partitioned by porous partition walls, wherein the honeycomb structure includes 80.0 to 94.0% by mass of cordierite as a main crystalline phase and ceria contained in a secondary crystalline phase; the porous partition walls have a porosity of 60% or more as measured by a mercury porosimetry; and for the porous partition walls, a cumulative 10% pore diameter (D10), a cumulative 50% pore diameter (D50) and a cumulative 90% pore diameter (D90) from a small pore side satisfy a relationship (D90−D10)/D50≤1.2, in a volume-based cumulative pore diameter distribution as measured by the mercury porosimetry.