Honeycomb Catalyst Coating With Branched Multi-Suction Timing
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Solution Overview
Problem
The suction process in coating a honeycomb substrate with a coating liquid is often rate-limiting, leading to uneven coating layers and varying quality, and existing methods to address this issue can cause further inconsistencies.
Innovation Solution
A method involving a coating liquid placement station, a branching station, and a suction station with multiple suction devices, where the substrate is transported to any vacant suction device after coating liquid placement, ensuring a predetermined time gap between placement and suction, thereby controlling the process time and maintaining coating uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the suction process is used to coat the honeycomb substrate with coating liquid, then the coating can be applied efficiently, but the suction step becomes the rate-limiting factor and causes uneven coating layers
Solution Approach 1:
The suction process is divided into multiple independent suction devices that can operate simultaneously on different substrates. Each suction device is equipped with its own suction nozzle and control system, allowing parallel processing and eliminating the bottleneck of a single rate-limiting suction step while maintaining consistent coating quality through individual control of each suction operation.
2Productivity
If multiple substrates are processed in parallel to increase productivity, then the overall processing time decreases, but the coordination complexity increases
Solution Approach 1:
The coating liquid supply system is designed with a common supply unit that serves multiple suction devices through a distributed network. This universal supply mechanism allows multiple substrates to be processed in parallel while using a single centralized coating liquid reservoir and pump system, reducing the complexity that would otherwise arise from requiring separate supply systems for each parallel processing unit.
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 allows for a faster and more consistent coating process, ensuring high-quality coating layers on honeycomb substrates, thereby enhancing the exhaust gas purification efficiency.
Implementation Method 1
relatively reducing the pressure on a second end surface side opposite to the first end surface as compared to the pressure on the first end surface side to cause the coating liquid to flow from the first end surface to the second end surface
Implementation Method 2
suctioning the substrate after the coating liquid placement from a lower end surface, to coat one or both of on the cell walls and in the cell walls of the substrate with the coating liquid
Data Source
AI summary
A method for manufacturing an exhaust gas purification catalyst device includes: (A) placing a catalyst coating layer-forming coating liquid on the upper end surface of a honeycomb substrate having a plurality of cell flow paths partitioned by cell walls in a coating liquid placing station; (B) transferring the substrate from the coating liquid placing station to a suction station; and (C) suctioning the substrate from the lower end surface in the suction station to coat the cell walls of the substrate with the coating liquid, wherein the suction station comprises two or more suction devices, and step (B) comprises (B1) transferring the substrate, on which the coating liquid has been placed, from the coating liquid placing station to a branch station, and (B2) transferring the substrate, on which the coating liquid has been placed, to an empty suction device among the suction devices of the branch station.