Hierarchical Fibrous Honeycomb Ceramics with High Load Capability and Low Light-Off Temperature for the Next-Generation Auto Emissions Standards

Novel and stringent automotive exhaust gas emissions standards are urgently needed to counter the problems posed by the worsening global climate and environment. However, the traditional cordierite-based honeycomb ceramics substrates with ultimate pore density have seriously restricted the establishment of new emission standards. Herein, we introduce a novel robust substrate with tailored volume-specific surface area and low heat capacity. This substrate employs the synergy of high-strength ceramic fibers and ultrathin TiO₂ nanosheets. The micro-sized fibers provide support to ensure structural strength during the catalytic reaction, while the nanosheets play the dual role of connecting the fibers and providing a high surface area for catalyst immobilization. The new three-dimensional (3D) microarchitecture exhibits a high volume-specific surface area of 3.59×10⁴ cm²/cm³, a compressive strength of 2.01 MPa, and remarkable stability after high-speed air erosion at 800 °C. The honeycomb-like structure exhibit low resistance to gas flow. Furthermore, after loading with Pt and Pd nanoparticles, the composite 3D microarchitecture delivered an excellent catalytic performance and prominent structural stability, with a super low light-off temperature of 150 °C. The outstanding mechanical and thermal stability and the high surface area and light-off temperature of the new substrate indicate its potential for use as a highly efficient catalytic carrier to meet the next-generation auto emissions standards.