Quantitative Catalyst Slurry Coating via Vacuum Distribution
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Solution Overview
Problem
Existing methods for coating monolithic catalyst supports with slurry face challenges in achieving precise, uniform coating of channels, often resulting in excessive slurry discharge and contamination of coating films.
Innovation Solution
A quantitative coating apparatus and method that uses physical pressure to introduce a predetermined amount of catalyst slurry into the channels of a monolithic support, followed by vacuum application to ensure uniform distribution across the channel walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If vacuum is used to draw catalyst slurry upward through channels, then slurry can be introduced into channels, but excessive slurry is discharged and uniform coating is difficult to achieve
Solution Approach 1:
The patent applies preliminary action by first introducing a predetermined quantity of slurry into the channels before applying vacuum. The slurry is charged into the channels in advance, and then vacuum is applied to distribute it uniformly. This sequence prevents excessive slurry discharge and ensures uniform coating by controlling the slurry introduction step before the distribution step.
2Manufacturing precision
If slurry transmissible film is used to pass slurry, then quantitative coating can be achieved, but film clogging and contamination occurs with repetitive usage
Solution Approach 1:
The patent extracts and eliminates the slurry transmissible film from the coating system. Instead of using a film that can clog and contaminate with repetitive usage, the invention introduces slurry directly into the channels using a vacuum chamber. This removes the problematic film component while maintaining the ability to achieve quantitative coating through direct slurry charging and vacuum distribution.
3Quantity of substance
If monolithic support is dipped into slurry, then coating can be applied, but excessive slurry must be removed by gravity discharge
Solution Approach 1:
The patent applies preliminary action by charging a predetermined quantity of slurry into the channels before the coating process. Instead of dipping the support into excess slurry and then removing the excess, the invention预先 introduces the exact amount of slurry needed into the channels using vacuum. This prevents excessive slurry discharge and eliminates the need for gravity discharge removal steps.
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 allows for nearly complete coating of channels with minimal slurry discharge, ensuring uniformity and reducing contamination risks associated with repetitive use of coating films.
Implementation Method 1
a vacuum means (105)
Implementation Method 2
the catalyst slurry is drawn by the vacuum applied to the end of the support opposite to the immersed end thereof
Implementation Method 3
uses physical pressure to introduce a predetermined amount of catalyst slurry into the channels
Implementation Method 4
followed by vacuum application to ensure uniform distribution across the channel walls
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Disclosed herein is a method of coating a catalyst support, in which a monolithic catalyst support provided therein with a plurality of longitudinally formed channels is quantitatively coated with catalyst slurry applied to post-treatment of exhaust gas, including the steps of: introducing catalyst slurry into a quantitative container whose bottom is vertically moved; moving a catalyst support to the top of a container such that the bottom of the catalyst support and top of the container are horizontally disposed each other; sealing the bottom of the catalyst support and the top of the container from the outside; moving the bottom of the container upward; and applying a vacuum to the channels of the catalyst support.