Catalyst Coating Nozzle Layout for Precise Layer Edge Control
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Solution Overview
Problem
Conventional methods of manufacturing exhaust gas-purifying catalysts with multiple catalytic layers often result in varying edge positions, leading to potential overlap and pressure loss, which hinders optimal performance.
Innovation Solution
A manufacturing apparatus and method using a nozzle with multiple discharge ports and controlled fluid supply to minimize edge position variations by ensuring uniform distribution of the catalytic layer on the substrate, eliminating the need for complex spinning mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used to form catalytic layers on substrate, then manufacturing process is simple, but edge position variation occurs causing layer overlap and pressure loss
Solution Approach 1:
The coating apparatus is segmented into multiple independent coating units, each equipped with its own coating head and control system. This allows precise control of each catalytic layer's edge position independently, preventing overlap while maintaining manufacturing precision without requiring a single complex spinning mechanism.
Solution Approach 2:
The patent replaces the mechanical spinning mechanism with a stationary coating head that deposits material directly onto the moving substrate. This substitution eliminates the complexity of spinning mechanisms while achieving precise edge position control through the coordinated movement of the substrate and controlled material deposition.
2Productivity
If catalytic layers are positioned closely to enhance purification ability, then unit volumetric capacity improves, but edge position variation causes layer overlap and pressure loss
Solution Approach 1:
The coating apparatus incorporates feedback control systems that monitor the position of catalytic layer edges in real-time and adjust the deposition rate and substrate movement accordingly. This feedback mechanism ensures precise edge positioning even when layers are placed closely together, preventing overlap while maximizing purification ability per unit volumetric capacity.
Solution Approach 2:
The system performs preliminary positioning and calibration of multiple coating heads before actual deposition begins. This preliminary action establishes precise reference positions for each catalytic layer, ensuring that subsequent deposition maintains accurate edge positions and prevents overlap, thereby enabling close layer spacing for enhanced productivity.
3Manufacturing precision
If spinning mechanisms are used to ensure uniform catalytic layer distribution, then coating uniformity improves, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive spinning mechanisms with a stationary coating head system that achieves uniform coating through controlled material deposition and substrate movement. This substitution significantly reduces manufacturing costs while maintaining coating uniformity through precise control of deposition parameters and substrate transport speed.
Solution Approach 2:
The coating system utilizes the substrate's own movement through the coating zone to achieve uniform distribution of the catalytic layer. The substrate passes through the coating head at a controlled speed, allowing uniform deposition without requiring external spinning mechanisms, thereby reducing manufacturing costs while maintaining coating quality.
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
This approach enables the production of exhaust gas-purifying catalysts with reduced edge position variations, enhancing performance and reducing manufacturing costs by simplifying the process and eliminating the need for costly spinning mechanisms.
Implementation Method 1
supplying the fluid to the end face of the substrate not through a single discharge port but through a plurality of discharge ports
Data Source
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AI summary
Provided is a technique that makes it possible to manufacture an exhaust gas-purifying catalyst offering a superior performance. A nozzle 130 is configured to discharge a fluid containing a raw material of a catalytic layer to a substrate having first and second end faces and provided with holes each extending from the first end face to the second end face. The nozzle 130 is provided with discharge ports DP each discharging the fluid toward the first end face of the substrate.