High Cell Density Monoliths via Paste Imprinting
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Solution Overview
Problem
Existing monolith manufacturing methods face challenges in creating high cell density structures with small channel sizes due to coating impracticality and pressure drop issues in catalysis and adsorption processes, particularly in rapid cycle swing adsorption processes.
Innovation Solution
The development of layered coated supports with passageways formed by contacting features in a composite paste between adjacent supports, allowing for high cell density monoliths with cell densities greater than current technology and featuring tortuous pathways for enhanced fluid communication, using methods like imprinting and calcining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If channel size in monolith is decreased to increase surface area, then reactivity is improved, but coating becomes impractical
Solution Approach 1:
The support structure with channels is formed first through ceramic extrusion or spiral winding, then the catalyst coating is applied in a second step using conventional coating techniques. This sequential approach allows the channels to be pre-formed at small sizes without compromising coating feasibility, as the coating is applied after the channel structure is already in place.
Solution Approach 2:
The monolith is divided into separate components: the support structure (formed by extrusion or spiral winding) and the catalyst coating (applied separately). This segmentation allows each component to be optimized independently - the support can have small channels for high surface area, while the coating can be applied using standard techniques without being constrained by the small channel dimensions.
2Area of stationary object
If channel size in monolith is decreased to increase surface area, then reactivity is improved, but pressure drop increases
Solution Approach 1:
The monolith structure incorporates varying channel dimensions and catalyst loading throughout its length. The channel geometry is optimized to provide high surface area in regions requiring it, while maintaining adequate flow passages to minimize pressure drop. The catalyst coating density and channel dimensions are locally adjusted to balance reactivity and pressure drop requirements.
3Area of stationary object
If cell density of monolith is increased to improve performance, then surface area is improved, but manufacturing becomes more difficult
Solution Approach 1:
The high cell density support structure is pre-formed through ceramic extrusion or spiral winding before catalyst coating. This preliminary formation of the complex channel network allows subsequent coating operations to proceed using conventional techniques, as the structural complexity is already established and does not interfere with the coating process.
Solution Approach 2:
The monolith is constructed as a composite structure combining the support material (ceramic or metal) with the catalyst coating. This composite approach allows the support to provide the high cell density structure while the coating layer adds the catalytic functionality, with each material optimized for its specific role.
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 enables the creation of monoliths with higher active material loadings and increased surface area, overcoming coating impracticality and pressure drop limitations, while maintaining structural integrity and flexibility.
Implementation Method 1
layering a first coated support with a second coated support by contacting the paste on the first side of the coated support with a side of the second coated support to form enclosed passageways; and calcining the layered supports to form the structure or monolith
Data Source
AI summary
The disclosure relate generally to structures, forms, and monoliths, and methods of preparing the same. This disclosure can produce uniform structured passageways or channels of active material, including adsorbent or catalyst, by imprinting or molding features into a paste on a support that can be subsequently assembled into a gas or liquid treating structure, i.e. a monolith. The paste, which can include an active material, binder, and other potential additives, can be applied to the support or pushed through a support (as in a mesh) as a thin film. The paste can be imprinted, stamped, shaped or otherwise handled to give features of desired height, shape, width, and positioning. When stacked or rolled, the features of one layer contact a subsequent layer, which seal to form passageways. The resulting structure can have high cell-density (>1000 cells per square inch) and a large volume fraction of active material.