Washcoat Distribution Through a Partition for Uneven Substrates
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Solution Overview
Problem
The challenge lies in achieving a uniform washcoat profile on substrates with non-planar surfaces during the coating process, as washcoat tends to accumulate in grooves or cut-outs, leading to uneven distribution, waste, and potential blocking of passage openings, while also facing issues with sealing to prevent washcoat loss down the substrate sides.
Innovation Solution
A substrate coating apparatus is designed with a headset and partition system, where the partition has a plurality of holes to maintain a gap between the washcoat showerhead and the substrate's upper surface, and a headset seal with a cantilevered portion to engage the substrate's sidewall, ensuring even washcoat distribution and preventing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If washcoat is discharged directly onto the upper surface of the substrate, then the coating process is simple, but washcoat accumulates in grooves or cut-outs leading to uneven distribution and potential blocking of passage openings
Solution Approach 1:
A partition with a plurality of holes is introduced as an intermediary component between the washcoat showerhead and the substrate. The partition receives washcoat from the showerhead and distributes it through its holes onto the substrate surface, preventing direct discharge and accumulation in grooves while maintaining a substantially flat washcoat profile across the substrate.
2Productivity
If washcoat is discharged onto the substrate surface, then coating is achieved, but washcoat may leak down the substrate sides causing waste and loss
Solution Approach 1:
The partition acts as a mediator that controls washcoat distribution, and a headset seal with a cantilevered portion engages the substrate sidewall to form a seal. This prevents washcoat from leaking down the sides of the substrate during the coating process, reducing waste and maintaining coating efficiency.
3Manufacturing precision
If the washcoat showerhead is positioned close to the substrate surface, then coating precision is improved, but washcoat may bridge or short-circuit across the surface
Solution Approach 1:
The partition with holes serves as an intermediary that maintains a controlled gap between the showerhead and substrate. It distributes washcoat through its holes, preventing direct contact and potential bridging while ensuring even distribution across the substrate surface, thereby eliminating harmful short-circuiting effects.
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 configuration ensures a substantially even washcoat profile, reduces waste, and effectively prevents washcoat from leaking down the substrate sides, enhancing the operational efficiency and visual integrity of the coated substrates.
Implementation Method 1
passing the washcoat through the holes in the partition, onto the upper surface of the substrate and into the substrate, at least in part by applying a suction force to a lower surface of the substrate
Data Source
AI summary
A method of coating a substrate with a washcoat is disclosed. The method comprises engaging the substrate with a headset of a substrate coating apparatus so as to locate an upper surface of the substrate below a washcoat showerhead of the substrate coating apparatus; and discharging a washcoat out of the washcoat showerhead towards the upper surface of the substrate; and drawing the washcoat through the substrate by applying a suction force to a lower surface of the substrate.