Catalytic Face Coating for Monolithic Substrates
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Solution Overview
Problem
Carbon deposits such as soot and coke accumulate on the cell walls of catalytic substrates, reducing the open frontal area and leading to increased back pressure and decreased gas flow, which existing coating methods fail to effectively prevent or mitigate.
Innovation Solution
A system and method for applying a catalytic coating to the outwardly facing edges of monolithic catalytic substrates using a coating liquid or slurry containing precious and base metals, which is applied via a specialized applicator that ensures uniform deposition and maintains the flow of exhaust gases by reducing soot accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon deposits accumulate on cell walls, then the substrate structure remains intact, but the open frontal area reduces and back pressure increases
Solution Approach 1:
The patent applies a face coating to the substrate before carbon deposits can significantly accumulate and cause problems. This preliminary protective action prevents the worsening of gas flow rate while maintaining structural integrity, by creating a barrier that reduces soot accumulation at the cell openings from the outset
Solution Approach 2:
The patent converts the harmful effect of carbon deposits into a beneficial outcome by applying a catalytic face coating that actively prevents soot accumulation. The coating transforms the potential harm of carbon buildup into a benefit by reducing deposits and maintaining open frontal area, thereby preserving gas flow rate while the substrate structure remains intact
2Reliability
If a coating is applied to the substrate face, then soot accumulation is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The face coating is applied in a straightforward manner that allows the substrate to receive the coating treatment efficiently. The process is designed to be self-contained, where the coating application system handles the entire process of depositing the catalytic material on the substrate face, reducing manual intervention and simplifying the overall manufacturing complexity while maintaining reliable resistance to soot accumulation
3Strength
If the cell wall thickness is increased, then structural strength is improved, but the open frontal area decreases
Solution Approach 1:
The patent applies a face coating specifically to the outwardly-facing edges of the cell walls, providing localized catalytic activity where it is most needed for preventing soot accumulation. This local application of coating material enhances the functional properties at critical locations without requiring increased cell wall thickness, thereby maintaining both structural strength and open frontal area
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
The solution effectively reduces soot and coke deposits, maintaining gas flow and preventing increased back pressure by uniformly depositing catalytic metals on the substrate's cell walls, thereby extending the substrate's operational life and efficiency.
Implementation Method 1
transferred from an absorbent applicator to the face of the monolithic catalytic substrate
Implementation Method 2
coating liquid applicator comprises an inside core and an outside nap
Implementation Method 3
coats the outwardly-facing edges of the walls forming a monolithic catalytic substrate with a coating liquid comprising a solution and/or slurry containing precious and/or base metals
Implementation Method 4
reduce or eliminate the amount of soot and coke deposits
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The principles and embodiments of the present invention relate generally to systems and methods for applying a catalytic coating to the outwardly facing edges of the cell walls of a catalytic substrate to reduce the amount of soot that accumulates at the entrances of the substrate cells that can increase back pressure and reduce the flow of exhaust gases through the substrate.