Honeycomb Catalyst Coating Nozzle Guard Against Clogging

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Solution Overview

Problem

Existing methods for coating honeycomb substrates with catalyst metal solutions face issues with nozzle discharge opening clogging, leading to non-uniform coating over long periods, particularly in low humidity environments.

Innovation Solution

A production method using a shower nozzle with multiple discharge openings and a guard surrounding them, where the guard protrudes and is positioned to maintain a moist environment around the openings, preventing clogging and ensuring uniform coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If solution is supplied for a long period of time, then productivity is improved, but discharge openings of the nozzle clog and coating uniformity deteriorates

Engineering Contradiction:

Improvecoating durationVSAvoidcoating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The guard protrudes from the nozzle surface before solution supply begins, creating a moisture-retaining structure in advance. This preliminary action ensures that the discharge openings remain moist during prolonged operation, preventing clogging and maintaining coating uniformity throughout the extended coating period.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If guard protrudes from discharge openings, then clogging is prevented and coating uniformity is improved, but device complexity increases

Engineering Contradiction:

Improvecoating uniformityVSAvoidnozzle structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The guard is formed as a thin-walled protruding structure that extends from the nozzle surface. This thin-film approach provides the necessary moisture retention function while minimizing structural complexity and material usage, balancing coating uniformity improvement with device simplicity.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If guard surrounds discharge openings, then clogging is prevented over long periods, but nozzle manufacturing complexity increases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidnozzle fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The guard structure is designed with optimized parameters including protrusion length (5-50mm) and positioning relative to discharge openings. By carefully controlling these dimensional parameters, the nozzle achieves reliable clogging prevention during continuous operation while remaining manufacturable using standard fabrication processes.

Inventive Principle:

Principle #35Parameter changes

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 method effectively prevents nozzle clogging and ensures uniform coating of honeycomb substrates over extended periods, even in low humidity conditions, by maintaining a moist environment around the discharge openings.

Implementation Method 1

a guard which surrounds the plurality of discharge openings

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

supplying a solution containing catalyst metal from a shower nozzle to an upper part of a honeycomb substrate

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 3

firing the honeycomb substrate coated with the solution

Methodology Applied

Scientific EffectFiring: Heat Treatment

Data Source

PatentUS12121858B2Manufacturing method for exhaust gas purification device

Publication Date: 2024.10.22 CATALER CORP

AI summary

A production method of an exhaust gas purification device includes the steps of supplying a solution containing a catalyst metal from a shower nozzle to an upper part of a honeycomb substrate, coating the honeycomb substrate with the solution, and firing the honeycomb substrate coated with the solution, wherein the shower nozzle has a plurality of discharge openings for discharging the solution and a guard which surrounds the plurality of discharge openings.