Washcoat Showerhead Partition for Uniform Substrate Coating
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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 sides.
Innovation Solution
A substrate coating apparatus featuring a headset with a partition comprising multiple holes and a headset seal with a cantilevered portion is used to maintain a gap between the washcoat showerhead and the substrate's surface, ensuring even distribution and preventing washcoat accumulation, with the partition and headset seal working together to draw the washcoat through the substrate via suction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If washcoat is applied directly to non-planar substrate surfaces, then the coating process is simple, but washcoat accumulates in grooves leading to uneven distribution
Solution Approach 1:
A planar partition is introduced as an intermediary element between the washcoat showerhead and the non-planar substrate surface. The partition provides a flat reference surface that ensures uniform washcoat distribution, while the washcoat is subsequently drawn through the substrate by suction, preventing accumulation in grooves and cut-outs.
Solution Approach 2:
The coating system is segmented into distinct functional zones: a washcoat application zone above the partition, a distribution zone through the partition holes, and a substrate coating zone. This segmentation allows independent optimization of each zone, with the partition ensuring uniform distribution regardless of substrate surface variations.
2Area of stationary object
If washcoat is applied to substrates with grooves, then complete surface coverage is achieved, but washcoat is wasted and passages may be blocked
Solution Approach 1:
Suction is applied to the substrate before or during washcoat application to pre-establish a pressure gradient. This preliminary action ensures that washcoat is immediately drawn into the substrate passages upon contact, preventing accumulation in grooves and reducing waste while maintaining complete surface coverage.
Solution Approach 2:
A suction system using vacuum pressure is employed to draw washcoat through the substrate. The pneumatic force counteracts gravitational accumulation in grooves and ensures controlled washcoat distribution into passages, preventing both waste and passage blocking.
3Productivity
If the washcoat showerhead is positioned close to the substrate for efficient coating, then coating efficiency is improved, but washcoat leaks down the sides
Solution Approach 1:
The planar partition acts as a mediator that allows the showerhead to be positioned close to the substrate for efficient coating while preventing side leakage. The partition creates a contained distribution zone where washcoat is directed through holes onto the substrate, and suction prevents overflow down the sides.
4Manufacturing precision
If suction force is applied to draw washcoat through substrate, then uniform distribution is achieved, but washcoat may be pulled through completely and emerge from lower surface
Solution Approach 1:
The suction force is applied locally at the substrate surface, creating a controlled pressure gradient that draws washcoat into passages without excessive force. The partition holes provide localized distribution points that ensure uniform infiltration into the substrate structure, preventing complete pull-through while maintaining uniformity.
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 results in a more even washcoat profile, reduces waste, prevents washcoat from leaking down the substrate's sides, and maintains operational efficiency by ensuring consistent catalytic activity across the substrate.
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
The disclosure relates to a substrate coating apparatus that comprises a source of a washcoat; a washcoat showerhead for discharging the washcoat towards an upper surface of a substrate; a conduit fluidly connecting the source of the washcoat to the washcoat showerhead for supplying washcoat to the washcoat showerhead; a headset for engaging the substrate to locate the upper surface of the substrate below the washcoat showerhead; and a vacuum generator for drawing the washcoat discharged from the washcoat showerhead through the substrate. The headset comprises a partition comprising a plurality of holes, the partition being located in between the washcoat showerhead and the upper surface of the substrate when the substrate is engaged in the headset so as to maintain a first gap between a lower face of the partition and the upper surface of the substrate.