Honeycomb Catalyst Coating with Parallel Suction Steps
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Solution Overview
Problem
The existing production methods for exhaust gas purification catalysts face issues with non-uniform slurry distribution due to prolonged standby times of the shower nozzle, leading to clogging and non-uniform catalyst coat layer formation, particularly when using larger volumes of wall-flow type honeycomb base materials.
Innovation Solution
Implementing multiple suction devices to perform suction steps simultaneously, reducing the time required for each suction operation and minimizing the standby time of the shower nozzle, thereby preventing clogging and ensuring uniform slurry distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single suction device is used to draw slurry into the honeycomb base material, then the equipment complexity is reduced, but the standby time of the shower nozzle increases causing outlet clogging
Solution Approach 1:
The single suction operation is segmented into multiple sequential suction steps performed by multiple suction devices. The slurry drawing process is divided into parallel operations where different suction devices operate on different base materials simultaneously, reducing the overall cycle time and minimizing shower nozzle standby time.
Solution Approach 2:
Multiple suction devices are combined to work in parallel on multiple honeycomb base materials simultaneously. This merging of operations allows the system to maintain continuous production flow, reducing the idle time of the shower nozzle between successive coating operations.
2Manufacturing precision
If the suction time per device is increased to ensure complete slurry absorption, then the coating uniformity improves, but the total production time increases
Solution Approach 1:
The total suction time requirement is segmented across multiple parallel operations. Each suction device operates for a shorter duration, but multiple devices work simultaneously to achieve the same total throughput, maintaining coating quality while increasing production speed.
Solution Approach 2:
The system dynamically coordinates multiple suction devices to operate in parallel with optimized timing. By distributing the workload across multiple devices and adjusting their operation sequences, the system achieves both complete slurry absorption for uniform coating and reduced overall production time.
3Reliability
If multiple suction devices are used to reduce standby time, then the shower nozzle clogging is prevented, but the equipment complexity increases
Solution Approach 1:
The suction function is segmented into multiple independent devices that can operate autonomously in parallel. This segmentation allows the system to maintain continuous operation with reduced standby time, preventing nozzle clogging while keeping each individual suction device relatively simple in design.
4Volume of moving object
If the production line processes larger volume wall-flow type honeycomb base materials, then the catalyst capacity increases, but the suction time per device increases causing longer standby time
Solution Approach 1:
The suction operation for large-volume base materials is segmented across multiple parallel devices. Each device handles a portion of the total workload, reducing the individual suction time and thereby minimizing the shower nozzle standby time while still accommodating large-volume base materials effectively.
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 approach enhances the productivity and quality reliability of the catalyst coat layer by preventing nozzle clogging and ensuring uniform distribution, even with larger base materials, thus improving the overall performance of the exhaust gas purification catalyst.
Implementation Method 1
a suction step of performing suction multiple times on the base material to which the slurry has been supplied
Data Source
Figure 1~2
Figure 3
AI summary
The present disclosure provides a production method for producing an exhaust gas purification catalyst with a reduced standby time of a shower nozzle. The method includes: a slurry supply step of supplying a catalyst metal-containing slurry from a shower nozzle to one end of a honeycomb base material; a first suction step of pressurizing or depressurizing the base material on which the slurry has been supplied, in a direction of the other end of the base material by using a first suction device to draw the slurry supplied, into the base material; and a second suction step of further pressurizing or depressurizing the base material after the first suction step, in the direction of the other end of the base material by using a second suction device. The slurry supply step and the first and second suction steps are performed in parallel in the same production line.