Catalyst Coating Process for Honeycomb Substrates With Air-Blast Suction
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Solution Overview
Problem
The existing suction method for coating catalyst solutions on honeycomb substrates results in waste and increased production costs due to solution leakage and adhesion to reservoir tools, especially with high-viscosity coatings, leading to quality defects.
Innovation Solution
A method involving simultaneous suction and blasting of compressed air onto the reservoir tool's inner sides during coating, using a specific tool configuration and pressure differentials to stabilize the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coating solution viscosity is increased to reduce leakage and control coating length, then coating precision is improved, but adhesion to the reservoir tool inner walls occurs, causing insufficient coating amount and quality defects
Solution Approach 1:
Compressed air is blasted onto the inner walls of the reservoir tool before the coating solution is supplied, creating a preliminary protective air layer that prevents adhesion. This preliminary action ensures that when the high-viscosity coating solution is later introduced, it does not adhere to the reservoir walls, thereby maintaining both coating precision and reliability
Solution Approach 2:
The invention uses compressed air (pneumatics) to blow onto the inner walls of the reservoir tool, creating a gas barrier that prevents the coating solution from adhering to the tool surfaces. This pneumatic approach allows the use of high-viscosity coating solutions without the adhesion problems that would otherwise occur
2Loss of substance
If the coating solution viscosity is increased to prevent leakage, then production cost is reduced, but adhesion to the reservoir tool occurs, resulting in insufficient coating amount
Solution Approach 1:
Compressed air is blasted onto the inner walls of the reservoir tool before the coating solution is supplied, creating a preliminary protective air layer that prevents adhesion. This preliminary action ensures that when the high-viscosity coating solution is later introduced, it does not adhere to the reservoir walls, thereby maintaining both coating precision and reliability
Solution Approach 2:
The invention uses compressed air (pneumatics) to blow onto the inner walls of the reservoir tool, creating a gas barrier that prevents the coating solution from adhering to the tool surfaces. This pneumatic approach allows the use of high-viscosity coating solutions without the adhesion problems that would otherwise occur
3Productivity
If the suction method is used to coat the catalyst solution, then coating efficiency is improved, but leakage from the suction side edge occurs, increasing production cost
Solution Approach 1:
The invention uses compressed air (pneumatics) to blow onto the inner walls of the reservoir tool, creating a gas barrier that prevents the coating solution from adhering to the tool surfaces. This pneumatic approach allows the use of high-viscosity coating solutions without the adhesion problems that would otherwise occur
Solution Approach 2:
The invention changes the physical parameters of the coating solution by increasing its viscosity, which reduces leakage during the suction coating process.配合使用高粘度涂料可以抑制涂料从吸侧边缘泄漏，从而提高涂覆效率并减少涂料浪费
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 method prevents solution adhesion to the reservoir tool while ensuring precise coating to the desired length, reducing waste and defects, thus producing high-quality exhaust gas purification catalyst devices.
Implementation Method 1
blasting compressed air from above onto the inner sides of the reservoir wall of the coating solution reservoir tool
Implementation Method 2
lowering the pressure in the cell flow channels below the pressure of the coating solution reservoir to introduce the catalyst coating layer-forming coating solution in the coating solution reservoir into the cell flow channels
Data Source
AI summary
A method for manufacturing an exhaust gas purification catalyst device, the method including: (A) disposing a substrate wherein open ends on one side of multiple cell flow paths face upward and face downward on the other side, installing a coating liquid retention tool having a retention wall at the upper-end section of the substrate, and forming a coating liquid retention part; (B) supplying a coating liquid for forming a catalyst coat layer to the retention part; (C) reducing pressure within the cell flow paths below coating liquid retention part pressure, thereby coating substrate partition walls with the coating liquid; (D) spraying the inner side of the retention wall of the coating liquid retention tool with compressed air from above; and (E) firing the substrate coated with the coating liquid for forming a catalyst coat layer, the step (C) and the step (D) being performed simultaneously.