Fluid Feed Ring for Uniform Catalyst Coating
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Solution Overview
Problem
Existing substrate coating methods for emissions control devices often result in uneven coating profiles, leading to inadequate coverage in some areas and excessive coating in others, which can increase pressure loss and reduce the effectiveness of the substrate in treating exhaust gases.
Innovation Solution
A fluid feed ring with a distribution channel and multiple outlet apertures arranged around the inner face to ensure even distribution of the catalyst component onto the piston face, allowing for faster and more uniform coating of the substrate channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If washcoat is applied to substrate using conventional methods, then coating is achieved, but uneven coating profiles result with inadequate coverage in some areas and excessive coating in others
Solution Approach 1:
The fluid feed ring is segmented into multiple outlet apertures arranged around its inner face, allowing the washcoat liquid to be distributed from multiple locations simultaneously. This segmentation of the feeding mechanism enables uniform coating across the substrate channels by delivering liquid from different angular positions around the channel circumference.
Solution Approach 2:
The outlet apertures are positioned at specific locations around the inner face of the fluid feed ring to target specific regions of the substrate channels. This local quality approach ensures that washcoat liquid is delivered precisely where needed on the piston face, creating consistent coating thickness across different areas of the substrate.
2Manufacturing precision
If excessive coating is applied to substrate, then coverage is improved, but pressure loss increases
Solution Approach 1:
Instead of applying excessive washcoat liquid to ensure coverage, the invention uses partial action by distributing the liquid through multiple outlet apertures that deliver precise amounts to specific locations. This controlled partial delivery achieves complete coverage without over-coating, thereby avoiding increased pressure loss.
3Productivity
If coating is applied faster, then productivity is improved, but coating uniformity may be compromised
Solution Approach 1:
The multiple outlet apertures enable continuous and simultaneous delivery of washcoat liquid across multiple locations on the substrate channels. This continuous multi-point feeding maintains coating uniformity while increasing productivity, as liquid is applied concurrently from several apertures rather than sequentially from a single point.
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 fluid feed ring enhances the evenness of the coating process, preventing uncoated areas and reducing pressure loss, thereby improving the substrate's performance in treating exhaust gases by ensuring consistent coverage of the catalyst component across the substrate channels.
Implementation Method 1
a vacuum generator for applying a vacuum to open ends of the plurality of channels at an upper end of the substrate
Implementation Method 2
a piston for introducing, by pushing or injecting, a liquid comprising a catalyst component into the substrate via or through open ends of the plurality of channels at a lower end of the substrate
Data Source
AI summary
A fluid feed ring (5), a substrate coating apparatus (1) and a method are provided for coating a substrate (2) with a catalyst component. The fluid feed ring (5) comprises an annular body (40) having an inner face (45) bounding a central bore of the fluid feed ring. A fluid feed port (47) receives the liquid and a plurality of outlet apertures (50) on the inner face of the annular body discharge the liquid onto a piston face (23) of the substrate coating apparatus (1). A distribution channel (51) extending at least part-way around the annular body (40) provides fluid communication between the fluid feed port (47) and the plurality of outlet apertures (50).