Porous Catalyst Support Coating for Faster Deep-Pore Deposition
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Solution Overview
Problem
Conventional methods for coating large-sized porous catalyst supports, such as those used in ship exhaust gas treatment, are inefficient due to long coating times and low deposition in pores, requiring precise quantitative control which is difficult to achieve.
Innovation Solution
A pressure dispersion method involving a slurry injection system with a container that applies positive pressure opposite to the injection direction, dispersing the slurry into the channels and pores of the support, using a pressurization step to enhance deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dipping method or quantitative coating method is used to coat large-sized porous catalyst supports, then coating can be achieved, but coating time is long and productivity is low
Solution Approach 1:
The patent applies pneumatic pressure dispersion to inject catalyst slurry into the porous support channels. A pressure source forces the slurry through injection nozzles into the support's channel system, enabling rapid coating throughout the entire support structure including deep pore penetration, thereby dramatically reducing coating time compared to conventional dipping methods
Solution Approach 2:
The patent prepares the coating system in advance by filling a container with catalyst slurry before the coating process. The support is positioned with its lower end at the container opening, and the injection system is pre-configured, allowing the coating operation to proceed immediately when pressure is applied, eliminating setup time during actual coating
2Manufacturing precision
If conventional coating methods are used on porous supports, then coating is achieved, but deposition in pores is insufficient
Solution Approach 1:
The pressurized slurry injection system forces catalyst slurry deep into the porous support's pore structure. The pressure differential drives slurry through the channel network and into pores, ensuring adequate deposition quantity and uniform distribution throughout the support volume, addressing both penetration depth and uniformity requirements
3Manufacturing precision
If quantitative slurry injection is used to achieve uniform coating, then coating uniformity is improved, but control complexity and device complexity increase
Solution Approach 1:
The patent uses pressure-controlled slurry injection where a pressure source regulates slurry flow into the support channels. This pneumatic control mechanism provides inherent flow regulation and uniform distribution without requiring complex electronic control systems, sensors, or feedback mechanisms, thereby achieving coating uniformity with simpler device architecture
Solution Approach 2:
The pressure dispersion system allows the slurry to naturally distribute itself throughout the porous support structure through pressure-driven flow. The support's own channel geometry guides the slurry distribution, reducing the need for external control mechanisms to achieve uniform coating
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 significantly reduces coating time and improves deposition efficiency, ensuring the slurry penetrates deeply into the pores, resulting in a high-quality catalytic converter suitable for ships.
Implementation Method 1
applying a positive pressure at an upper end of the catalyst support while moving the bottom of the container upward
Implementation Method 2
the catalyst slurry is dispersed and penetrates into the pores of the support
Data Source
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AI summary
A method for coating a monolithic porous catalyst support having a plurality of channels formed in a longitudinal direction with a catalyst slurry, and a device therefor are proposed. A pressure dispersion coating device for a porous catalyst support includes: a slurry quantitative input means; a container (201) being variable in volume, having an open upper part thereof into which a slurry is input by the slurry quantitative input means, and having a bottom thereof movable; a container moving means (210) fastened to one side of the container; a moving means (202) fastened to a lower part of the container and having a shaft connected to the bottom of the container; an overflow outlet (206) being formed on a side part of the container and provided with a valve; and a pressurizing means (205) disposed on the open upper part of the container.