Radially Zoned Catalyst Coating Without Outer Surface Waste
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Solution Overview
Problem
Existing catalyst support bodies have inefficiencies due to the outer surface being coated with catalyst material, which is not utilized during operation, leading to costly cleaning and regaining processes to recover unused material.
Innovation Solution
A method and device for coating a catalyst support body with an outer surface free from catalyst material by using a sealing cover and spring-loaded rods to prevent contact between the outer surface and slurry, allowing for radial coating within the support body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the catalyst support body is dipped into the slurry to coat the inner channels, then the catalyst material is introduced into the support body, but the outer surface is also wetted with slurry causing waste of catalyst material
Solution Approach 1:
A sealing member is introduced as an intermediary element between the slurry and the outer surface of the catalyst support body. The sealing member prevents direct contact between the slurry and the outer surface, allowing the slurry to be drawn into the inner channels through capillary action without wetting the outer surface. This resolves the contradiction by enabling catalyst material introduction while preventing catalyst material waste.
2Ease of manufacture
If the outer surface is cleaned and brushed to remove excess catalyst material, then the manufacturing cost is reduced, but additional processing steps are required
Solution Approach 1:
The sealing member is installed before the slurry dipping process to prevent catalyst material from adhering to the outer surface in the first place. This preliminary protective action eliminates the need for subsequent cleaning, brushing, or blasting operations, thereby simplifying the manufacturing process without adding device complexity.
3Productivity
If the outer surface is left coated with catalyst material, then the manufacturing process is simplified, but the catalyst material is not utilized efficiently during operation
Solution Approach 1:
The sealing member acts as a mediator that enables the manufacturing process to be simple (dipping the support body into slurry) while simultaneously ensuring that catalyst material is only deposited where needed (inner channels). This resolves the contradiction by allowing ease of manufacture to coexist with high catalyst material utilization efficiency.
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 and device enable efficient use of catalyst material by preventing unnecessary coating on the outer surface, reducing manufacturing costs and improving the utilization of catalyst material.
Implementation Method 1
techniques for introducing catalyst material into a monolithic catalyst support body involve introducing a first open end of the support body into the slurry and drawing the slurry through the channels of the catalyst support body
Data Source
AI summary
This disclosure relates to devices and methods for coating various portions of catalyst support bodies, such as radially-zoned catalyst support bodies, such as those used in catalytic converters for treating exhaust gas streams of internal combustion engines.