CN106588066A - 一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体及其制备方法 - Google Patents

一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体及其制备方法 Download PDF

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CN106588066A
CN106588066A CN201611062811.XA CN201611062811A CN106588066A CN 106588066 A CN106588066 A CN 106588066A CN 201611062811 A CN201611062811 A CN 201611062811A CN 106588066 A CN106588066 A CN 106588066A
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cordierite
filter body
ceramic filter
honeycomb ceramic
raw material
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王春艳
孙敏
朱增赞
丁运刚
万马
詹望成
卢冠忠
柳琼
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Kailong Lanfeng New Material Technology Co Ltd
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Abstract

本发明公开了一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体及其制备方法，其组成成分如下：基础原料，二氧化钛、粘结剂、甘油、水用量分别为基础原料的0.5～0.8wt％、2～8wt％、2～8wt％、水25～35wt％；所述基础原料的组成成分如下：堇青石粗颗粒70～80wt％、堇青石细颗粒10～20wt％、滑石1～4wt％、氢氧化铝1～4wt％、高岭土3～6wt％、锂辉石1～4wt％，总和为100％；将上述成分经充分混合、捏合、练泥、陈腐、成型、微波干燥、特殊的封孔工艺和高温烧结得到过滤体；本发明以堇青石粗、细颗粒为主要原料，通过调整颗粒级配，获得不同孔隙率和孔径的过滤体；同时过滤体具有热膨胀系数低、机械强度好、耐高温等特点，可用于不同环境下对机动车柴油机碳烟颗粒的捕集。

Description

一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过 滤体及其制备方法
技术领域
本发明涉及汽车尾气净化的技术领域，具体涉及一种用于柴油机碳烟颗粒捕集技术。
背景技术
柴油机由于具有热效率高、燃油经济性好、使用寿命长等优点。近年来得到越来越广泛的应用。但柴油机在使用过程中会排放大量的微粒，它们能长时间悬浮在空中，严重污染环境，影响人类的健康。因此，世界许多国家先后制定了限制柴油车微粒排放的法规，而且排放限值越来越低。微粒捕集技术是实现柴油机微粒排放控制最为有效和简单的技术之一，其中壁流式蜂窝陶瓷过滤体是目前最常用的颗粒捕集器。其原理是利用过滤器的孔道进口与相邻出口前后交替封堵技术，使排气从壁面穿过而达到过滤颗粒的目的。目前，堇青石具有原材料广泛且便宜且技术设备要求低等特点被广泛用作颗粒捕集器的制作材料。综合性能优异的堇青石质颗粒捕集器一直是国内各企业和蜂窝陶瓷科研单位研究的课题。
中国发明专利CN101612499A报道了一种壁流式蜂窝陶瓷的制备方法，采用堇青石质蜂窝陶瓷材质与碳颗粒或有机高分子颗粒专用造孔剂相结合，产品孔隙率50％～52％，微孔平均孔径为8～13μm，但其抗压强度偏低。
中国发明专利CN 103449840A公开了一种高温废气净化用壁流式蜂窝陶瓷过滤体，该过滤器以堇青石、苏州土、钛酸铝、氧化铝为基础原料，以核桃壳粉为造孔剂，产品性能指标如下：气孔率44.2％、抗压强度23.5MPa、平均孔径13.2μm、热膨胀系数1.65×10-6/℃，但此类过滤体用于工业废气的净化处理，未提及是否可用于柴油机碳烟颗粒捕集。
中国发明专利CN105833620A发明了一种半通式蜂窝陶瓷颗粒物过滤器，所用的造孔剂为天然纤维或聚氯乙烯或聚乙烯醇或甲基丙烯酸甲酯或淀粉；主要性能指标为：孔隙率为40％～65％，微孔平均孔径为8～20μm，抗压强度大于18MPa，热膨胀系数小于1.0×10-6/℃，但烧成工艺较难控制，因此难以进行大规模生产。
发明内容
本发明的目的在于提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体及其制备方法，利用堇青石颗粒之间的堆积填充，获得热膨胀系数低、机械强度好、耐高温、抗腐蚀、碳烟过滤率高、气孔率高且孔径可调的过滤体，可用于不同环境下对机动车柴油机碳烟颗粒的捕集；而且制备工艺稳定可靠，易于控制，从而有利于推广和应用。
本发明的目的通过以下技术方案予以实现：
本发明提供的一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、粘结剂、甘油、水用量分别为基础原料的0.5～0.8wt％、2～8wt％、2～8wt％、水25～35wt％；
所述基础原料的组成成分如下：
堇青石粗颗粒70～80wt％、堇青石细颗粒10～20wt％、滑石1～4wt％、氢氧化铝1～4wt％、高岭土3～6wt％、锂辉石1～4wt％，总和为100％。
所述堇青石粗颗粒中位粒径为100～150μm、堇青石细颗粒中位粒径为0.1～0.8μm，可以保证蜂窝陶瓷过滤体具有高气孔率和合适的孔径分布；
所述粘结剂为甲基纤维素。
一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体的制备方法，包括如下步骤：
步骤一、按上述组成成分称取堇青石粗颗粒、堇青石细颗粒、滑石、氢氧化铝、高岭土、锂辉石、二氧化钛、甲基纤维素，加入到混料机混合60min，得到粉体混合物；
步骤二、将甘油与水加入到上述粉体混合物中捏合60min得到均匀泥料，捏合过程中控制泥料温度在30℃以下；
步骤三、将上述泥料放入真空练泥机混炼2次，真空度小于0.09MPa，然后陈腐24h形成塑性泥坯；
步骤四、将上述塑性泥坯放入挤压机，在模具的引导下形成蜂窝状泥坯，模具孔密度为200孔/平方英寸；泥料挤出后切割成湿坯体，放入微波干燥箱内烘干定型，得到干坯体；
步骤五、将上述干坯体端面切割平整后，获得整齐的蜂窝端面，对蜂窝端面进行交叉间隔封孔，干燥后进行修边和外圆磨，得到过滤体泥坯；
步骤六、将上述过滤体泥坯放入高温烧结炉内，以5℃/分钟的升温速率加热到1310℃，并保温8小时，然后自然冷却至100℃即制备得过滤体。
本发明具有有益效果，以堇青石粗颗粒和堇青石细颗粒为主要原料，在不添加造孔材的条件下，调整颗粒级配，利用粗细颗粒之间的堆积填充，获得不同孔隙率和孔径的壁流式蜂窝陶瓷过滤体；原料中的二氧化钛可以在高温下形成钛酸铝成分，从而降低产品的热膨胀系数，提高热稳定性；原料中的锂辉石在烧结过程中作为助溶剂，降低了堇青石的熔点，堇青石细颗粒熔融为液相，受表面张力作用，渗入粗颗粒表面之间将其粘结，形成堇青石骨架，颗粒之间形成均匀的空隙；同时由于本发明不含造孔材而加大过滤体的强度，避免了在烧结过程中排胶开裂现象；本发明的制造工艺简单，原材料价格低廉，易于实现。
具体实施方式
下面结合实施例对本发明的技术方案做进一步详细说明。
实施例1
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.5wt％、6wt％、6wt％、30wt％；
所述基础原料的组成成分如下：堇青石粗颗粒80wt％、堇青石细颗粒10wt％、滑石2wt％、氢氧化铝4wt％、高岭土3wt％、锂辉石1wt％，总和为100％。
所述堇青石粗颗粒中位粒径为100μm；
所述堇青石细颗粒中位粒径为0.1μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法，包括如下步骤：
步骤一、按上述配方称取堇青石粗颗粒、堇青石细颗粒、滑石、氢氧化铝、高岭土、锂辉石、二氧化钛、甲基纤维素，加入到混料机混合60min得到粉体混合物；
步骤二、将甘油与水加入到上述粉体混合物中捏合60min得到均匀泥料，捏合过程中控制泥料温度在30℃以下；
步骤三、将上述泥料放入真空练泥机混炼2次(真空度0.09MPa以下)，然后陈腐24h形成塑性泥坯；
步骤四、将上述塑性泥坯放入挤压机，在模具的引导下形成蜂窝状泥坯，模具孔密度为200孔/平方英寸；泥料挤出后切割成湿坯体，放入微波干燥箱内烘干定型，得到干坯体；
步骤五、将上述干坯体端面切割平整后，获得整齐的蜂窝端面，对蜂窝端面进行交叉间隔封孔，干燥后进行修边和外圆磨，得到过滤体泥坯；
步骤六、将上述过滤体泥坯放入高温烧结炉内，以5℃/分钟的升温速率加热到1310℃，并保温8小时，然后自然冷却至100℃即制备得过滤体。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率49.5％、平均孔径11.4μm、A轴抗压强度20.9MPa、B轴抗压强度3.24MPa、C轴抗压强度0.33MPa，热膨胀系数1.68×10-6/℃。
实施例2
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.6wt％、6wt％、6wt％、30wt％；
所述基础原料的组成成分如下：堇青石粗颗粒75wt％、堇青石细颗粒15wt％、滑石4wt％、氢氧化铝1wt％、高岭土3wt％、锂辉石2wt％，总和为100％。
所述堇青石粗颗粒中位粒径为150μm；
所述堇青石细颗粒中位粒径为0.5μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法，同实施例1。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率51.2％、平均孔径13.6μm、A轴抗压强度19.8MPa、B轴抗压强度3.18MPa、C轴抗压强度0.32MPa，热膨胀系数1.57×10-6/℃。
实施例3
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.7wt％、6wt％、6wt％、30wt％；
所述基础原料的组成成分如下：堇青石粗颗粒70wt％、堇青石细颗粒20wt％、滑石1.5wt％、氢氧化铝1.5wt％、高岭土6wt％、锂辉石1wt％，总和为100％。
所述堇青石粗颗粒中位粒径为150μm；
所述堇青石细颗粒为中位粒径0.8μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法同实施例1。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率50.3％、平均孔径12.8μm、A轴抗压强度23.5MPa、B轴抗压强度3.58MPa、C轴抗压强度0.39MPa，热膨胀系数1.54×10-6/℃。
实施例4：
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.8wt％、6wt％、6wt％、30wt％；
堇青石粗颗粒80wt％、堇青石细颗粒10wt％、滑石1wt％、氢氧化铝2wt％、高岭土3wt％、锂辉石4wt％，总和为100％。
另添加所述堇青石粗颗粒中位粒径为130μm；
所述堇青石细颗粒中位粒径为0.1μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法同实施例1。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率53.6％、平均孔径14.9μm、A轴抗压强度21.8MPa、B轴抗压强度3.46MPa、C轴抗压强度0.37MPa，热膨胀系数1.56×10-6/℃。
实施例5：
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.5wt％、8wt％、2wt％、25wt％；
堇青石粗颗粒75wt％、堇青石细颗粒12wt％、滑石3wt％、氢氧化铝2wt％、高岭土5wt％、锂辉石3wt％，总和为100％。
另添加所述堇青石粗颗粒中位粒径为120μm；
所述堇青石细颗粒中位粒径为0.4μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法同实施例1。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率53.6％、平均孔径14.5μm、A轴抗压强度17.8MPa、B轴抗压强度3.75MPa、C轴抗压强度0.27MPa，热膨胀系数1.51×10-6/℃。
实施例6：
本发明提供一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中二氧化钛、甲基纤维素、甘油、水用量分别为基础原料的0.7wt％、2wt％、8wt％、35wt％；
堇青石粗颗粒77wt％、堇青石细颗粒10wt％、滑石2wt％、氢氧化铝3wt％、高岭土4wt％、锂辉石4wt％，总和为100％。
另添加所述堇青石粗颗粒中位粒径为140μm；
所述堇青石细颗粒中位粒径为0.5μm；
上述堇青石壁流式蜂窝陶瓷过滤体的制备方法同实施例1。
本实施例堇青石壁流式蜂窝陶瓷过滤体的性能指标如下：气孔率52.7％、平均孔径13.5μm、A轴抗压强度18.8MPa、B轴抗压强度3.51MPa、C轴抗压强度0.42MPa，热膨胀系数1.63×10-6/℃。
经过试验论证，本发明相对于现有技术由于不含造孔材而加大了过滤体的强度，避免了在烧结过程中排胶开裂现象，本发明以堇青石粗颗粒和堇青石细颗粒为主要原料，在不添加造孔材的条件下，通过合理设计堇青石的粒径组成，达到调整蜂窝陶瓷过滤体孔隙率及孔径的目的；同时本发明所得的过滤体具有热膨胀系数低、机械强度好、耐高温、抗腐蚀、碳烟过滤率高等特点，可用于不同环境下对机动车柴油机碳烟颗粒的捕集。
以上所述仅为本发明的较佳实例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (4)

1.一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其特征在于，其组成成分如下：基础原料、二氧化钛、粘结剂、甘油、水，其中，二氧化钛、粘结剂、甘油、水用量分别为基础原料的0.5～0.8wt％、2～8wt％、2～8wt％、水25～35wt％；所述基础原料的组成成分如下：堇青石粗颗粒70～80wt％、堇青石细颗粒10～20wt％、滑石1～4wt％、氢氧化铝1～4wt％、高岭土3～6wt％、锂辉石1～4wt％，总和为100％。
2.根据权利要求1所述的一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其特征在于，所述堇青石粗颗粒中位粒径为100～150μm、细颗粒中位粒径为0.1～0.8μm。
3.根据权利要求1或2所述的一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体，其特征在于，所述粘结剂为甲基纤维素。
4.一种用于柴油机碳烟颗粒捕集的堇青石质壁流式蜂窝陶瓷过滤体的制备方法，其特征在于，包括以下步骤：
步骤一、称取堇青石粗颗粒、堇青石细颗粒、滑石、氢氧化铝、高岭土、锂辉石、二氧化钛、甲基纤维素，加入到混料机混合60min，得到粉体混合物；
步骤二、将甘油与水加入到上述粉体混合物中捏合60min得到均匀泥料，捏合过程中控制泥料温度在30℃以下；
步骤三、将上述泥料放入真空练泥机混炼2次，真空度小于0.09MPa，然后陈腐24h形成塑性泥坯；
步骤四、将上述塑性泥坯放入挤压机，在模具的引导下形成蜂窝状泥坯，模具孔密度为200孔/平方英寸；泥料挤出后切割成湿坯体，放入微波干燥箱内烘干定型，得到干坯体；
步骤五、将上述干坯体端面切割平整后，获得整齐的蜂窝端面，对蜂窝端面进行交叉间隔封孔，干燥后进行修边和外圆磨，得到过滤体泥坯；
步骤六、将上述过滤体泥坯放入高温烧结炉内，以5℃/分钟的升温速率加热到1310℃，并保温8小时，然后自然冷却至100℃即制备得过滤体。
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