Exhaust Substrate Coating via Elastic Base Pressing
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Solution Overview
Problem
Existing methods for coating substrates in exhaust gas aftertreatment devices fail to provide a reproducible and uniform coating on non-planar faces, leading to inefficiencies and potential system failures due to face plugging, which increases back-pressure and can cause engine inefficiencies.
Innovation Solution
A method involving applying a precious-metal-containing coating material to the face of the substrate using an elastic base with adjustable viscosity, allowing for uniform coverage even on irregular surfaces by pressing the substrate into the coating material, ensuring consistent layer thickness and penetration depth into the through-channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a face coating is applied to prevent face plugging, then reliability is improved, but manufacturing precision deteriorates due to difficulty in achieving uniform coating on non-planar surfaces
Solution Approach 1:
The patent changes the physical state and rheological parameters of the coating material by adjusting its viscosity to a specific range (10-1000 Pa·s) and controlling its temperature, allowing the coating to flow into irregularities and achieve uniform coverage on non-planar substrate surfaces while preventing face plugging
Solution Approach 2:
The patent introduces an elastic base as an intermediary layer between the coating material and the substrate. This elastic base deforms to conform to the non-planar substrate surface, providing a compliant foundation that enables uniform coating application and achieves both reliability improvement and manufacturing precision
2Manufacturing precision
If the coating material viscosity is increased to improve coverage on irregular surfaces, then manufacturing precision improves, but ease of manufacture deteriorates due to difficulty in application
Solution Approach 1:
The patent optimizes the viscosity parameter to a specific range (10-1000 Pa·s) that balances coating uniformity and applicability. This controlled viscosity range allows the coating material to sufficiently fill surface irregularities while remaining workable during the coating process, resolving the contradiction between manufacturing precision and ease of manufacture
3Reliability
If a precious-metal-containing coating is applied to reduce face plugging, then reliability improves, but loss of substance increases
Solution Approach 1:
The patent controls the viscosity and application parameters of the precious-metal-containing coating material to achieve optimal deposition efficiency. By adjusting the viscosity to 10-1000 Pa·s and controlling the coating process, the patent minimizes material waste through reduced overspray and improved transfer efficiency, thereby reducing loss of substance while maintaining reliability
Solution Approach 2:
The patent replaces traditional high-spray-coating mechanical systems with a controlled viscosity-based application method using an elastic base. This substitution reduces the need for excessive coating material and minimizes loss of precious substances while achieving the same face plugging prevention effect
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 ensures a reproducible and uniform coating that effectively reduces face plugging, maintaining engine efficiency and preventing system failures by ensuring consistent coverage on non-planar substrate faces.
Implementation Method 1
an elastic base (11) with a closed surface is provided; dipping or pressing into the coating material a surface of the substrate
Data Source
AI summary
The invention relates to a method for producing a substrate (1) for an exhaust gas aftertreatment device, having the following steps:applying (S1) a coating material (12) on an elastic base (11);dipping or pressing (S2) a surface of the substrate (1), in which inlet openings of through-channels (2) are arranged, through the substrate (1) into the coating material (12);lifting off the coated catalyst element (1); andaftertreating, and in particular drying or calcining (S3), the coating material (12) on the coated substrate (1).