Catalyst Applicator Tool With Flexible Partition for Slurry Control

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Solution Overview

Problem

Existing catalyst coating processes often result in the formation of a catalyst slurry coating on the inner peripheral surface of the outer cylinder extension portion, complicating the manufacturing process of exhaust gas-purifying catalyst devices.

Innovation Solution

A tool for a catalyst coating apparatus featuring a flexible partition member with an elastic curtain that is inserted into the outer cylinder to prevent the catalyst slurry from adhering to the inner peripheral surface of the outer cylinder extension portion by using a combination of elastic deformation and suction to guide the slurry onto the honeycomb substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the outer cylinder extension portion protrudes beyond the honeycomb substrate end surface to maintain structural integrity, then the mechanical strength is improved, but the catalyst slurry adheres to the inner peripheral surface causing manufacturing complexity

Engineering Contradiction:

Improvemechanical strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The space around the honeycomb substrate is segmented into a coating region (inside the partition member) and a non-coating region (outer cylinder extension portion) by introducing the partition member. This segmentation allows selective coating only where needed while preserving the structural function of the outer cylinder extension portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition member acts as an intermediary barrier between the catalyst slurry supply and the outer cylinder extension portion. It mediates the coating process by allowing slurry to reach the honeycomb substrate while blocking access to the outer cylinder inner peripheral surface, thus preventing unwanted adhesion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a rigid partition member is used to prevent slurry adhesion, then the prevention effect is improved, but the device complexity and difficulty of insertion increase

Engineering Contradiction:

Improveprevention effectVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A flexible partition member made of elastic material is used instead of a rigid structure. This flexible membrane maintains the prevention function by forming a barrier against slurry while being easily insertable and adaptable to the cylindrical space, reducing device complexity compared to rigid alternatives.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The partition member is designed to be dynamically adjustable through elastic deformation. It can be inserted in a relaxed state, then expanded or positioned to form an effective barrier. This dynamic behavior simplifies the insertion process and reduces the complexity of the overall device structure.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If the partition member is made of elastic material to improve ease of insertion, then the ease of operation is improved, but the ability to maintain precise positioning decreases

Engineering Contradiction:

Improveease of insertionVSAvoidpositioning precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The elastic properties of the partition member are optimized to achieve a balance between insertability and positioning precision. By controlling parameters such as elastic modulus, thickness, and dimensions, the partition member can be easily inserted while maintaining sufficient rigidity to hold its position and effectively prevent slurry adhesion during the coating process.

Inventive Principle:

Principle #35Parameter changes

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

Effectively prevents the formation of a catalyst slurry coating on the inner peripheral surface of the outer cylinder extension portion, facilitating smoother manufacturing processes and ensuring uniform coating on the honeycomb substrate.

Implementation Method 1

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

by using a combination of elastic deformation and suction to guide the slurry onto the honeycomb substrate

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentEP4635624A1Tool for catalyst applicator, and catalyst applicator

Publication Date: 2025.10.22 CATALER CORP

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AI summary

A tool for a catalyst coating apparatus to a honeycomb substrate of an exhaust gas-purifying catalyst is inserted into an outer cylinder having an axial length longer than an axial length of the honeycomb substrate supported by the outer cylinder in a state where an axial direction of the honeycomb substrate is arranged in a vertical direction. The tool comprises a cylindrical partition member having flexibility. An outer peripheral surface of the partition member faces an inner peripheral surface of an outer cylinder extension portion of the outer cylinder protruding upward with respect to an upper end surface of the honeycomb substrate. When the catalyst slurry is supplied to the upper end surface of the honeycomb substrate and an inside of an inner peripheral surface of the partition member, a lower end of the partition member is disposed in a vicinity of an upper end surface of the honeycomb substrate.