Preparation Method Of Foam Ceramic Filter

The mainstream preparation process of foam ceramic filter is organic foam impregnation method, also known as replication method. This method uses polyurethane (polyurethane) foam plastic as carrier, impregnates ceramic slurry made of refractory aggregate, binder, sintering aid, etc., squeezes out excess slurry to make the slurry uniformly coated on the foam skeleton, and then dries and fires at high temperature. According to the sintering mechanism, foam ceramic filter can be divided into two types: bonding type and sintering type.

In terms of process optimization, the secondary slurry coating process can improve the mechanical strength of the filter at room temperature. The specific slurry formulation, such as the composite of silicon carbide, alumina, silica sol and aluminosilicate fiber, can affect the performance when fired at 1200-1300°C. A foam ceramic filter with high slag resistance and high thermal stability has silicon carbide as the main mineral phase and amorphous silicon oxide with dispersed boron nitride as the bonding phase [9]. In terms of structural innovation, Xingye Co., Ltd.'s 2024 patent involves a composite filter structure design of "foam structure layer + wave-shaped electrospun layer". Regarding installation structure innovation, Luoyang Rongshi's 2025 patent involves an installation structure for a high-purity zirconium foam ceramic filter that is easy to disassemble and replace.