Coating Roller for Monolithic Substrate End Surfaces
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Solution Overview
Problem
Existing methods for coating monolithic substrates in emissions control devices lack a practical and automated approach for uniformly coating only the end surfaces without inadvertently applying the coating to the channels, leading to inefficiencies and potential wastage of materials like platinum group metal salts.
Innovation Solution
An automated method and apparatus that uses a coating roller to apply a liquid specifically to the end surface of a monolithic substrate, with a conveying device to position the substrate and a liquid applicator to load the roller, ensuring precise control and minimal liquid ingress into the channels, utilizing a cylindrical coating roller that rotates within a trough containing the liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used to coat monolithic substrates, then the internal walls of channels can be coated, but it is difficult to automatically and uniformly coat only the end surfaces without liquid ingress into the channels
Solution Approach 1:
The coating process is segmented into two distinct stages: first coating the internal channel walls using conventional methods, then separately coating the end surfaces using a roller applicator. This segmentation allows each coating operation to be optimized independently, achieving precise end surface coating without liquid ingress into channels.
Solution Approach 2:
A roller applicator serves as an intermediary device between the liquid coating material and the end surface. The roller picks up liquid from a reservoir and applies it to the end surface through controlled contact, preventing direct liquid flow into the channels while ensuring uniform coating distribution.
2Productivity
If automated coating methods are implemented, then productivity increases, but manufacturing precision for end surface only coating decreases
Solution Approach 1:
The roller applicator is designed to automatically pick up liquid coating material from the reservoir and apply it to the end surface without requiring manual intervention. The roller's rotation and contact with the end surface are automatically controlled, maintaining consistent coating thickness and preventing liquid ingress while enabling continuous high-speed operation.
Solution Approach 2:
The system controls coating parameters including roller speed, contact pressure, and liquid viscosity to optimize both productivity and precision. By adjusting these parameters, the system achieves uniform coating application at high speeds while preventing liquid from entering the channels.
3Reliability
If more liquid is applied to ensure complete end surface coverage, then coating coverage improves, but material wastage increases
Solution Approach 1:
The roller applicator acts as a controlled intermediary that picks up a precise amount of liquid from the reservoir and transfers it to the end surface. This controlled transfer mechanism ensures complete coverage of the end surface while preventing excessive liquid application that would cause material wastage or liquid ingress into the channels.
Solution Approach 2:
The system optimizes liquid application parameters including roller immersion depth in the liquid reservoir, roller rotation speed, and contact pressure with the end surface. These parameter adjustments ensure that the minimum necessary liquid amount is applied for complete coverage, minimizing material wastage while maintaining reliable coating 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 solution allows for a uniform and controlled coating of the end surface of monolithic substrates, preventing liquid from entering the channels and ensuring even coating depth across all channels, thereby improving the efficiency and accuracy of emissions control device manufacturing to meet stringent environmental regulations.
Implementation Method 1
applying a liquid onto an end surface of the monolithic substrate by contacting the end surface with the coating roller loaded with the liquid
Data Source
AI summary
A method of coating an end surface of a monolithic substrate with a liquid is described and an apparatus therefor. The method comprises: (a) conveying a monolithic substrate to or toward a coating roller; and (b) applying a liquid onto an end surface of the monolithic substrate by contacting the end surface with the coating roller loaded with the liquid.