Ceramic Catalyst Support Base Coating for Thermal Shock Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ceramic catalyst supports face a challenge in maintaining high thermal shock resistance and low coefficient of thermal expansion when coated with catalytic materials, as the oxide constituents of the catalyst penetrate the ceramic microstructure, reducing thermal properties.
Innovation Solution
A base coating comprising a polyvinyl alcohol homopolymer and a blocked isocyanate crosslinker is applied to ceramic catalyst supports, which prevents unwanted penetration of secondary coating materials and maintains the thermal properties of the ceramic support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If oxide constituents of catalyst coating are applied to ceramic catalyst supports, then catalyst loading sufficient for effective catalytic treatment is achieved, but the oxide constituents penetrate into the microstructure of the ceramic supports, increasing the thermal expansion coefficient and reducing thermal shock resistance
Solution Approach 1:
A base coating composed of polyvinyl alcohol and blocked isocyanate crosslinker is applied as an intermediary layer between the ceramic catalyst support and the catalytic coating. This base coating acts as a barrier that prevents oxide constituents from the catalytic coating from penetrating into the ceramic support's microstructure, thereby maintaining the support's thermal expansion coefficient and thermal shock resistance while still allowing sufficient catalyst loading to be achieved.
2Quantity of substance
If oxide constituents of catalyst coating are applied to ceramic catalyst supports, then catalyst loading sufficient for effective catalytic treatment is achieved, but the thermal shock resistance of the ceramic support is reduced
Solution Approach 1:
The base coating serves as a protective intermediary layer that isolates the ceramic catalyst support from the catalytic coating. By preventing direct contact and penetration of oxide constituents into the support, the base coating preserves the support's inherent thermal shock resistance while enabling the application of sufficient catalyst loading for effective catalytic treatment.
3Stability of the object's composition
If base coating is applied to prevent oxide penetration, then thermal properties of ceramic support are maintained, but additional coating steps are required
Solution Approach 1:
The harmful penetration function is extracted and separated from the catalytic coating application process. By applying the base coating first and then the catalytic coating in sequential steps, the patent extracts the protective function from the catalytic coating itself, allowing each layer to perform its specific function without interfering with the other.
Solution Approach 2:
The base coating is applied as a preliminary action before the catalytic coating. This preliminary coating establishes the barrier function in advance, preventing oxide penetration before the catalytic coating is applied, thereby maintaining thermal properties while enabling subsequent catalyst loading.
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 method provides sufficient catalyst loading for effective catalytic treatment while preserving the thermal properties of the ceramic catalyst supports, ensuring high gas permeability and low thermal expansion coefficients.
Implementation Method 1
a base coating comprising at least one polyvinyl alcohol homopolymer and at least one blocked isocyanate crosslinker
Implementation Method 2
drying and curing the coating
Data Source
AI summary
The disclosure relates to methods for coating ceramic catalyst supports with a base coating, said method comprising, in part, providing an aqueous mixture comprising at least one polyvinyl alcohol homopolymer and at least one blocked isocyanate crosslinker, and to ceramic catalyst supports having a base coating comprising at least one polyvinyl alcohol homopolymer and at least one blocked isocyanate crosslinker.