Coating Tool Asymmetric Holes Monolith Flow Control
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Solution Overview
Problem
Existing methods for coating monolithic carriers used in automotive exhaust abatement are inefficient, leading to high production costs and prolonged coating times, despite advancements in catalytic layer modification and coating strategies.
Innovation Solution
A coating tool with a second means featuring asymmetric holes that accelerate and decelerate the washcoat flow, ensuring even distribution and reducing turbulence, combined with a reversible holding mechanism using an inflatable bellow and a sensor for precise control, enhances the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional coating methods are used, then coating can be applied to monolithic carriers, but coating time is prolonged and production costs increase
Solution Approach 1:
The patent applies asymmetry by designing holes with asymmetric channel width along their axis, where the channel width is wider at the washcoat inlet side than at a point within the channels. This asymmetric geometry creates a diffuser effect that accelerates washcoat flow into the monolith while maintaining even distribution, thereby reducing coating time by 20-50% without compromising coating quality
2Productivity
If washcoat flow is accelerated to reduce coating time, then productivity improves, but turbulence increases which may compromise coating quality
Solution Approach 1:
The patent introduces an intermediary structure - the diffuser plate with asymmetric holes - that mediates between the washcoat supply and the monolith. This intermediary accelerates the washcoat flow to improve coating speed while simultaneously distributing it evenly across the monolith surface, preventing turbulence and maintaining coating uniformity
3Productivity
If conventional holes are used in coating tools, then结构简单 (structure is simple), but washcoat distribution is uneven and coating progress is slow
Solution Approach 1:
The patent applies local quality by varying the channel width at different locations within the holes. The asymmetric channel width is wider at the inlet side and narrower within the channels, creating localized flow acceleration and diffusion effects that improve washcoat distribution and coating progress speed without requiring complete structural redesign
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 tool significantly reduces coating time by 20-50% while maintaining uniformity, resulting in higher catalyst activity and lower production costs per piece.
Implementation Method 1
The asymmetric holes (3) achieve a more even distribution of the washcoat zone inside the monolithic carrier body
Implementation Method 2
The diffusor type of action helps to mitigate turbulences which otherwise might render the fast coating process undesirable
Implementation Method 3
The bellow (5) can be composed out of e.g. any rubber-like material being air-proof
Data Source
AI summary
This application concerns a tool for coating a monolithic shaped catalyst. The tool is part of a coating station and serves to hold and fix the monolith while coating is progressing.