Catalyst Monolith Pallet with Segmented Support Bars
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Solution Overview
Problem
The existing methods for coating catalyst monoliths with a honeycomb arrangement suffer from insufficient or uneven catalyst coating due to the obstruction of outer passageways by support rings with inward lips, leading to blockages and incomplete coating.
Innovation Solution
A pallet with two or more support bars extending across the inside of a ring, without a radially inward lip, is used to support the catalyst monolith during coating, allowing for balanced support and unobstructed vacuum application, ensuring even coating across all passageways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a support ring with an inward lip is used to support the monolith, then the monolith is supported and balanced during coating, but the outer passageways are blocked from vacuum pull, resulting in insufficient or uneven catalyst coating
Solution Approach 1:
The support ring is segmented into multiple discrete support bars (at least two) spaced apart from each other, rather than forming a continuous ring. This segmentation allows vacuum to pass through the gaps between bars to reach outer passageways while still providing adequate support for the monolith during coating.
Solution Approach 2:
The inward lip that was previously present on the support ring is completely removed or extracted. The support structure consists only of discrete bars without any radial inward projections, eliminating the obstruction that was blocking vacuum access to outer passageways.
2Strength
If a continuous support ring with lip is used, then structural support is provided, but vacuum cannot access outer passageways, causing blockage and incomplete coating
Solution Approach 1:
The continuous support ring is divided into separate support bars, creating gaps that allow vacuum access. This segmentation maintains sufficient structural support while enabling complete coating of all passageways including outer ones.
Solution Approach 2:
The support structure provides localized support at specific positions (where the bars are located) rather than continuous support. This local support approach is sufficient for balancing the monolith during coating while allowing vacuum penetration through the unsupported gap regions.
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 results in improved catalyst coating coverage, particularly on peripheral passageways, with consistent coating distribution from the outermost edges to the center, significantly reducing uncoated regions.
Implementation Method 1
applying a vacuum to draw the catalyst slurry through the monolith and passageways, thereby forming a catalyst coating on the surfaces of the passageways
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A pallet for supporting a catalyst monolith during coating, comprising a ring with two or more support bars extending across the inside of the ring.