Catalyst Support Coating via Sealing Element
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Solution Overview
Problem
Existing methods for coating catalyst support bodies result in unwanted catalyst material being applied to the outer surface, which is not in contact with exhaust gases, leading to inefficiency and additional costly cleaning steps to recover the unused material.
Innovation Solution
A sealing element is used to cover the outer rim of the catalyst support body during the coating process, preventing contact between the slurry and the outer surface while allowing the slurry to be introduced into the channels, ensuring all channels are coated without contaminating the outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the catalyst support body is immersed in slurry to coat the channels, then the catalyst material is introduced into the channels, but the outer surface of the support body is wetted or coated with slurry causing waste of precious catalyst material
Solution Approach 1:
The support body is segmented into internal channels and outer surface regions. The sealing element divides the space around the input end, allowing slurry to enter only the channels while preventing contact with the outer surface, thus segmenting the coating process to apply catalyst only where needed.
Solution Approach 2:
The harmful effect of slurry contacting the outer surface is extracted and isolated using a sealing element. The sealing element removes the unwanted coating from the outer surface by preventing slurry contact in the first place, while the channels still receive the catalyst slurry.
2Ease of manufacture
If the outer surface is cleansed to remove catalyst material, then the unused catalyst material can be regained and the outer surface is clean, but additional cleaning steps increase manufacturing cost and time
Solution Approach 1:
The sealing element is applied beforehand to the input end of the support body before the slurry coating process begins. This preliminary action prevents catalyst material from depositing on the outer surface in the first place, eliminating the need for subsequent cleaning operations and reducing manufacturing time.
3Manufacturing precision
If the sealing element covers the input end circumference, then contact between slurry and outer surface is prevented, but the sealing element must be precisely positioned to ensure all channels are coated
Solution Approach 1:
The sealing element is made of flexible material that can deform to conform to the input end circumference of the support body. This flexibility allows the sealing element to maintain a reliable seal without requiring extremely precise positioning, simplifying the overall coating mechanism while ensuring complete channel coverage.
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 method effectively prevents catalyst material from being applied to the outer surface, optimizing the use of precious materials and reducing manufacturing costs by eliminating the need for additional cleaning steps, while ensuring complete channel coverage within the catalyst support body.
Implementation Method 1
a sealing element which covers (the outer rim of) the outer surface of a catalyst support body (at one end of the support body) and thereby inhibits any contact between slurry and outer surface of the support body during immersion of (a part of) the support body in the slurry
Implementation Method 2
a vacuum is applied to the opposed open end, thereby drawing the slurry into the channels
Implementation Method 3
the liquid is removed from the catalyst support body by drying and the catalyst particles remain within channels of the catalyse support body
Data Source
Figure 1a~1d
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a method for coating a catalyst support body, which comprises: providing the catalyst support body as well as slurry located within a pan; introducing an open input end of the catalyst support body into the slurry; and, subsequently, directing an amount of the slurry though the input end and into the inside of the catalyst support body. At least a part of the circumference of the input end is covered with an impermeable sealing element while slurry is directed through the open end. In this way, contact between slurry and a circumferential outer surface of the catalyst support body is prevented and slurry is provided through the open end to an inner surface of the catalyst support body. Further, the invention relates to a loading platform for carrying out the method. The inventive assembly comprises a loading platform adapted for releasably holding a catalyst support body, and a cover mechanism having a sealing holder and a ring shaped sealing element attached to the sealing holder. The cover mechanism further comprises a first lifting mechanism connected to the sealing holder, wherein the first lifting mechanism provides a moving direction for the sealing holder along a longitudinal axis of the sealing element relative to the loading platform. In addition, the invention relates to a coating station comprising the loading platform. The coating station comprises a slurry pan and a second lifting mechanism providing a relative moving direction between the pan and the loading platform. The first lifting mechanism is synchronized with the second lifting mechanism by a synchronization device.