EA042058B1 - DEVICE AND METHOD FOR COATING FROM POROUS OXIDE ON SUBSTRATES - Google Patents

Description

The description relates to apparatus and methods for applying porous oxide coatings to substrates. In particular, it relates to the coating of substrates used for exhaust gas cleaning.

Prerequisites for the creation of the invention

The exhaust scrubbing substrate may typically be a monolithic substrate provided with channels for the through flow of exhaust gases. The substrate may be coated, which may be a catalytic coating. The substrate can be coated with a porous oxide that passes through the channels of the substrate. Various methods are known for applying a coating to a substrate. One such method includes applying a porous oxide coating to a first surface of the substrate (e.g., the top surface) and exposing the opposite, second surface (e.g., bottom surface) of the substrate to at least a low vacuum to move the porous oxide coating through the channels. After coating, the substrate can be dried and baked.

The substrate may have a flow-through design, in which each channel is open on both the first and second sides of the substrate, and the channel extends along the entire length of the substrate. Therefore, the exhaust gases entering through the first surface of the substrate into the channel pass through the substrate within the same channel until the exhaust gases exit the second surface of the substrate. Alternatively, the substrate may be in the form of a filter substrate in which some channels are connected to the first surface of the substrate and other channels are connected to the second surface of the substrate. In this configuration, the exhaust gases entering through the first surface of the substrate into the first channel pass along the first channel partially along the substrate and then pass through the filter wall of the substrate into the second channel. The exhaust gases then pass through said second channel and exit the second surface of the substrate. This design has become known in the art as a flow wall filter.

The coated flow substrate may comprise a three-way catalyst (TWC), a selective catalytic reduction catalyst (SCR), a diesel oxidation catalyst (DOC), a NOx lean oxidation trap catalyst (LNT), an ammonia slip prevention catalyst (ASC), a combined selective catalytic reduction catalyst and an ammonia slip prevention catalyst (SCR/ASC) or a passive NOx adsorbent (PNA).

The coated filter substrate may, for example, be a catalytic particulate filter (CSF) containing an oxidation catalyst, a selective catalytic reduction filter (SCRF) containing a selective catalytic reduction (SCR) catalyst, a lean oxidation NOx trap filter (LNTF) , containing a NOx adsorbent composition, a gasoline particle filter (GPF) containing a three-way catalyst composition or a filter substrate containing a selective catalytic reduction (SCR) catalyst and an ammonia slip prevention catalyst (ASC).

The substrate is made of ceramic or metal material. For example, aluminum titanate, cordierite (SiO ₂ -Al ₂ O ₃ -MgO), silicon carbide (SiC), Fe-Cr-Al alloy, Ni-Cr-Al alloy or stainless steel alloy.

The substrate is usually a body with a substrate, uniform in its cross section along the longitudinal length. Generally, the body with the substrate may have a circular or near-circular cross-sectional shape, although other cross-sectional shapes such as square and rectangular are possible. The top surface of the backed package can be defined as the surface that is on top during coating, and similarly, the bottom surface of the backed package can be defined as the surface that is at the very bottom during coating. As a rule, the flat top and bottom surfaces are perpendicular to the longitudinal axis of the body with the substrate.

Some specialized substrates may have a non-planar top surface and/or bottom surface. For example, the top surface may be provided with a groove or cutout for inserting another piece. For example, an emission control sensor may be mounted in a groove or cutout when the substrate is embedded in the emission control system. In another example, the top surface may be concave or convex over part or all of the surface.

When coating substrates, it is generally desirable to achieve a substantially flat porous oxide coating profile, i.e. achieve a leading edge or edge of the porous oxide coating (indicating interfaces between the coated and uncoated portions of the substrate) that is generally flat or perpendicular to the longitudinal axis of the channels.

It has been found that applying porous oxide coatings to substrates having a non-planar top surface or bottom surface presents certain difficulties. The porous oxide coating applied to the top surface may advantageously collect or accumulate in the groove or notch. This can lead to difficulties in accurately controlling the distribution of the porous oxide coating as it is vacuum drawn into the body with the substrate, and in particular in achieving a substantially flat profile of the porous oxide coating. For example, an uneven profile can be obtained in the substrate, i.e. non-planar profile of porous

- 1 042058 oxide, when the porous oxide coating is then drawn through the substrate. The reason could be, for example, a large amount of porous oxide coating covering the groove or cutout and thus being drawn into the body with the substrate, further in the area below the groove or cutout. An uneven profile of the porous oxide coating can adversely affect the performance of the substrate. For example, uneven profiles may result in some areas of the substrate being uncoated (which reduces the catalytic efficiency of the substrate) or some areas of the substrate being unintentionally coated more than once in areas where multiple porous oxide coatings will be applied (which may adversely increase back pressure of the substrate). In some cases, the porous oxide coating may be fully pulled through the body with the substrate and out of the bottom surface. This process can result in excess porous oxide coating as well as potentially blocking the channel openings on the bottom surface of the substrate.

Alternatively, or additionally, there may be a problem with sufficiently sealing the backed package to prevent loss of the porous oxide coating from the sides of the backed package. This situation may present a particular problem in cases where the groove or notch extends up to the side wall of the body with the substrate. Contamination of the sidewall of the substrate with the porous oxide coating may also result in visually noticeable degradation of the substrate and may obscure visual identification of features that may be provided on the sidewall of the substrate, such as barcodes for tracking, etc.

Alternatively, or additionally, there may be a problem in achieving even distribution of the porous oxide coating over the top surface of some substrates, even though they have a flat top surface. For example, said substrate may have a viscosity threshold below which the channels absorb the porous oxide coating too rapidly to prevent it from being completely or evenly distributed over the top surface. As a result, this can lead to an increase in the amount of porous oxide coating entering the channels immediately below the coating outlet, and hence to uneven distribution.

Statement of the Invention

In the first aspect of the present description, a method for coating a substrate with a porous oxide is provided, consisting of the following steps:

engaging the substrate with the substrate coater head such that the upper surface of the substrate is under the substrate coater sprayer;

positioning a baffle between the atomizer and the top surface of the substrate, the baffle having a plurality of holes and positioned in the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate;

discharging the porous oxide coating from the atomizer onto the upper surface of the baffle; and passing the porous oxide coating through the apertures in the baffle onto the upper surface of the substrate and into the substrate, at least partially, by a suction force applied to the lower surface of the substrate.

In a second aspect of the present disclosure, a substrate coating apparatus is provided, comprising the following components:

porous oxide coating source;

an atomizer for discharging the porous oxide coating onto the upper surface of the substrate;

a passage fluidly connecting the porous oxide coating source to the porous oxide coating gun for supplying the porous oxide coating to the porous oxide coating gun;

a head for engaging the substrate to place the upper surface of the substrate under the atomizer; and a vacuum generator for drawing the porous oxide coating discharged from the head through the substrate;

wherein the head comprises a baffle with a plurality of holes, and the baffle is positioned between the atomizer and the top surface of the substrate when the substrate is engaged with the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate.

In a third aspect of the present disclosure, a substrate coating system is provided, comprising a substrate coating apparatus of the above aspect and a substrate, wherein the top surface of the substrate is non-planar; and additionally, the top surface of the substrate may include a molding, such as a groove or notch, that extends up to the side wall of the substrate, thereby forming a gap therein.

In a fourth aspect of the present disclosure, there is provided a baffle capable of being used in a substrate coater, the baffle having a disc-shaped body;

a disk-shaped body having a thickness between the upper and lower surfaces of 5 to 15 mm,

- 2 042058 additionally from 7.5 to 12.5 mm, additionally 10 mm;

partition, including more than 500 holes, additionally more than 1000 holes, additionally more than 1500 holes, additionally more than 2000 holes;

and each of the holes has a diameter of 1 to 3 mm, an additional diameter of 2 mm;

moreover, the percentage of open area of the partition, defined as the percentage of the total area of the upper surface of the partition, which consists of holes, is from 35 to 55%, additionally from 40 to 50%, additionally about 45%.

Advantageously, in any of the above aspects, the use of a multi-hole baffle helps prevent porous oxide coating from accumulating, for example, in a groove or notch in the top surface of the substrate when the top surface is not planar. This has been found to result in less detrimental effect on the profile of the porous oxide coating and less dragging of the coating from the bottom surface of the substrate.

In particular, in any of the above aspects, a suction force may be applied during a certain time period for the release of the porous oxide coating onto the top surface of the baffle. For example, this time interval may be 5 s, preferably 3 s, more preferably 1 s. As a result, there is an advantage of limiting or preventing the porous oxide coating from reaching the upper surface of the substrate prior to application of the suction force. In this way, the collection or accumulation of the porous oxide coating in any groove or cutout on the top surface can be prevented or at least significantly reduced, since the porous oxide coating in contact with the top surface of the substrate can be immediately drawn into the body of the substrate with the help of the applied suction power.

Further, in any of the above aspects, providing a first gap between the bottom surface of the baffle and the top surface of the substrate provides the advantage of minimizing and/or preventing bonding between the baffle and the substrate before or after suction is applied to the bottom surface of the substrate, for example, to prevent any capillary action between the septum and the upper surface of the substrate.

Any of the aspects (first to fourth) may also contain one or more of the following features.

The baffle may be positioned in a fixed position with respect to the head. The first gap can be from 2 to 7 mm, additionally 5 mm. Thus, the first gap can be optimized not only to minimize or prevent bonding with the coating, but also to control and/or limit further distribution of the porous oxide coating. For example, the nebulizer configuration may be chosen to achieve the desired initial distribution of the porous oxide coating on the top surface of the baffle. Thus, it may be desirable that the first gap is not too large, otherwise the porous oxide coating may be subject to additional undesirable degradation, for example through mixing of separate streams, splashes, rebounds, etc. Thus, the first gap of 2 to 7 mm proved to be the most effective.

It is possible to use a disc-shaped baffle with a thickness between the upper and lower surfaces of 5 to 15 mm, additionally 7.5 to 12.5 mm, additionally 10 mm. It turned out that it is advantageous to limit the thickness of the partition from 5 to 15 mm, which allows minimizing the additional external pressure of the substrate coating system.

The baffle may be located in the head to provide a second gap between the lower surface of the atomizer and the upper surface of the baffle from 80 to 130 mm. A distance of 80 to 130 mm has been found to optimize the distribution of the coating on the top surface of the baffle when spray applied.

More than 500 holes, additionally more than 1000 holes, additionally more than 1500 holes, additionally more than 2000 holes can be placed in the partition. The diameter of each hole can be from 1 to 3 mm, optionally 2 mm. The percentage of open area of the partition, defined as the percentage of the total area of the upper surface of the partition, which consists of holes, is from 35 to 55%, additionally from 40 to 50%, additionally about 45%. The advantage is that the baffle can be optimized to minimize or prevent seepage of the porous oxide coating through it onto the top surface of the substrate before suction is applied, while limiting additional system back pressure and ensuring good distribution of the coating over the baffle and, hence, along the upper surface of the substrate.

The head may further comprise a seal, and the baffle may be positioned in the head above the seal.

As is known, the upper surface of the substrate is not necessarily flat.

In addition, the top surface of the substrate may include a molding, such as a groove or notch, that extends up to the side wall of the substrate, thereby forming a gap therein. The substrate happens

- 3 042058 coated in a flow-through design (for example, a monolithic substrate) and can be filtered (for example, a filter substrate with flow walls). The porous oxide coating may be catalytic. The catalytic coating may consist of a three-way catalyst (TWC), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), a NOx lean oxidation trap catalyst (LNT), an ammonia slip prevention catalyst (ASC), a combined selective catalytic reduction catalyst, and an ammonia slip prevention catalyst (SCR/ASC); and a passive NOx adsorbent (PNA). The viscosity of the porous oxide coating can be from 3 to 9000 centipoise.

In a fifth aspect of the present disclosure, a method for coating a substrate with a porous oxide using a substrate coater is provided:

engaging the substrate with the substrate coater head such that the upper surface of the substrate is under the substrate coater sprayer;

discharging the porous oxide coating from the atomizer onto the upper surface of the substrate;

drawing the porous oxide coating through the substrate by applying a suction force to the bottom surface of the substrate; wherein the step of engaging the substrate with the head includes engaging the head seal with the substrate, wherein the head seal includes a perimeter portion enclosing the head, and an inclined portion descending from the perimeter portion, which engages with the side wall of the substrate.

In a sixth aspect of the present disclosure, a substrate coating apparatus is provided, comprising a porous oxide coating source;

an atomizer for discharging the porous oxide coating onto the upper surface of the substrate;

a passage fluidly connecting the porous oxide coating source to the porous oxide coating gun for supplying the porous oxide coating to the porous oxide coating gun;

a head for engaging the substrate to place the upper surface of the substrate under the atomizer; and a vacuum generator for drawing the porous oxide coating discharged from the head through the substrate;

wherein the head includes a substrate engagement seal, a head seal that includes a perimeter portion enclosing the head, and an inclined portion descending from the perimeter portion that engages with the side wall of the substrate.

In a seventh aspect of the present disclosure, a head seal for engaging a substrate is provided, a head seal that includes a perimeter portion enclosing the head and an inclined portion descending from the perimeter that engages with the side wall of the substrate.

Any of the aspects (fifth through seventh) may also contain one or more of the following features.

The perimeter part may comprise an annular part, optionally a round or oval part, which completely encloses the head.

The inclined part may be arcuate.

The length of the inclined part can be from 105 to 300% of the length of the gap in the side wall, additionally from 105 to 200% of the length of the gap in the side wall.

The inclined part may have a central angle of 45 to 120°, optionally from 45 to 90°, optionally from 65 to 75°.

The inclined part may extend at an angle of 0 to 15° relative to a plane perpendicular to the perimeter part; additionally at an angle of 0 to 10° relative to the plane perpendicular to the perimetric part; additionally at an angle of approximately 3° relative to a plane perpendicular to the perimeter portion.

When the substrate engages with the head, the inclined part of the seal can be bent predominantly in the radial direction.

The lower edge of the sloping part can protrude freely outwards and can thus be designed to bend predominantly in the radial direction.

The sloping portion can engage with an area of the side wall of the substrate whose height is at least 5 mm greater than the depth of the gap in the side wall of the substrate.

The sloping part may extend downwardly at least 20 mm below the bottom surface of the perimeter part, additionally at least 30 mm below the bottom surface of the perimeter part, further at least 40 mm below the edge of the surface of the perimeter part.

The perimeter part and the sloping part may be formed as a single block or may be separated from each other. The perimeter part and the inclined part can be made of different materials.

At the very least, the inclined portion may be made up of a flexible material.

The inclined part can have a scleroscope hardness from 35A to 45A, additionally 40A.

- 4 042058

The head may comprise a rigid support frame supporting a perimeter portion of its seal and an inclined seal portion which may extend below the bottom surface of the rigid support frame.

The lower edge of the inclined part can protrude freely outward from the rigid support frame.

The top surface of the substrate is not necessarily flat.

The upper surface of the substrate may include a molding, such as a groove or notch, that extends to the side wall of the substrate, thereby forming a gap therein, while the guides of the sloped portion above the gap prevent the coating from flowing out of the gap down the side wall of the substrate.

The substrate is coated in a flow-through design (for example, a monolithic substrate) and can be filtered (for example, a filter substrate with flow walls).

The porous oxide coating may be catalytic. The catalytic coating may consist of a three-way catalyst (TWC), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), a NOx lean oxidation trap catalyst (LNT), an ammonia slip prevention catalyst (ASC), a combined selective catalytic reduction catalyst, and an ammonia slip prevention catalyst (SCR/ASC); and a passive NOx adsorbent (PNA).

The first through fourth aspect elements may be combined with the fifth through seventh aspect elements, and vice versa. For example, the substrate coater may be provided with a baffle according to the second aspect and a head seal according to the sixth aspect.

In the present description, all references to viscosity refer to the viscosity of the fluid measured using a Brookfield viscometer equipped with a small sample adapter and connection spindle, with a controlled sample temperature at 25°C. These viscometers are available from Brookfield Engineering Laboratories, Inc., Middleboro, Massachusetts, USA.

All measurements were carried out at a shear rate of 14 s ^-1 . As will be apparent to one skilled in the art, the spindle, rotation speed, and model of the viscometer are selected based on fluid viscosity to ensure that the viscometer's % Torque will have a minimum measurement value of more than 10% and a maximum measurement value of less than 100%. , it is not possible for the viscometer torque % to have a minimum measurement greater than 0% and a maximum measurement less than 100%. The following spindles were used to measure the viscosity in the present specification.

The viscosity range from 3 to 100 cps was measured using an SC4-18 spindle at 10.6 rpm on an LV viscometer.

The viscosity range from 100 to 500 cps was measured using an SC4-28 spindle at 50 rpm on an LV viscometer.

The viscosity range from 500 to 9000 cps was measured using an SC4-28 spindle at 50 rpm on an RV viscometer.

Brief description of graphic materials

Aspects and embodiments of the present disclosure will be set forth by way of example only with reference to the accompanying drawings, in which:

in fig. 1 is a schematic representation of a substrate coating apparatus in cross section;

in fig. 2 is a schematic enlarged view of the area shown in FIG. 1;

in fig. 3 shows a perspective view of the substrate;

in fig. 4 is a schematic view of a substrate of the type shown in FIG. 3, in terms of the apparatus for coating the substrate;

in fig. 5 is a perspective view of the bottom of a head seal for a substrate coater;

in fig. 6 is a bottom view of the head seal of FIG. 5;

in fig. 7 is a side elevational view of the head shown in FIG. 5;

in fig. 8 is a cross-sectional view of the head seal shown in FIG. 5;

in fig. 9 is a photograph of a portion of a substrate coater including a head seal of the type shown in FIG. 5;

in fig. 10 is a cross-sectional view of a portion of a substrate coater including a baffle;

in fig. 11 is a perspective view of the top of the baffle shown in FIG. 10;

in fig. 12 is a top perspective view of the baffle shown in FIG. 10;

in fig. 13 is an enlarged side view of the baffle shown in FIG. 10;

in fig. 14 is a side view of the substrate after porous oxide coating;

in fig. 15 is a perspective view of the top of the substrate after porous oxide coating;

- 5 042058 in FIG. 16 is a side view of the subdivided substrate after porous oxide coating;

in fig. 17 is a bottom view of the substrate shown in FIG. 16, before splitting into parts.

Detailed description of the invention

In the present description and the appended claims, the singular forms include references to the plural, unless the context clearly requires otherwise. Thus, for example, reference to a catalyst includes a mixture of two or more catalysts, and the like.

In the present description, the term approximately also includes a specific meaning. For example, approximately 45% includes approximately 45% as well as 45% within this value.

The skilled reader will appreciate that one or more features of one aspect or embodiment of the present disclosure may be combined with one or more features of any other aspect or embodiment of the present disclosure, unless the immediate context indicates otherwise.

In FIG. 1 is a schematic cross-sectional view of a non-limiting example of a substrate coater 1 that can be used to coat a substrate 10 with a porous oxide.

The device 1 for coating the substrate may include a dispenser 2 with a housing 40 containing a device for activating the dispenser. As shown, the dispenser may include a piston 41 which is axially movable within the opening 42 to expel fluid from the outlet 43 to a channel 35 located downstream of the distributor 2.

The substrate coating apparatus 1 may further comprise a hopper 3 forming a reservoir 30 with an outlet 31 connected to the outlet 43 of the distributor 2 via a membrane valve 32. The hopper 3 may be filled with a porous oxide coating that has been prepared and premixed in another place. The porous oxide coating may be injected into reservoir 30, or may be fed by gravity into reservoir 30 via suitable tubes.

The outlet port 43 of the distributor 2 is hydraulically connected to the port 35, which in turn may be fluidly ducted with the metering valve 4. The atomizer 5 for coating the porous oxide may be connected to the bottom surface of the metering valve 4, with the atomizer 5 positioned above substrate 10.

The substrate 10 may be placed and positioned between the head mount 6 and the tray insert 8. A vacuum device, which includes a vacuum cone 7, may be positioned under the substrate 10.

In FIG. 2 shows an enlarged part of the substrate coater 1 shown in FIG. 1 and shows in more detail how the substrate 10 can be positioned relative to the porous oxide coating gun 5 and the head attachment 6.

In FIG. 1 and 2 show a substrate 10 of the type of body 11 which has a uniform cross-sectional shape along its longitudinal length. Typically, the substrate body 11 may have a circular or nearly circular cross-sectional shape. The substrate body 11 may be positioned to extend between the head mount 6 and the tray insert 8 such that the top surface 12 of the substrate body 11 is at the top and the bottom surface 13 of the substrate body 11 is at the bottom. The upper surface 12 and the lower surface 13 are flat, and they are perpendicular to the longitudinal axis of the substrate body 11.

The head mount 6 may include a seal 15 that engages with an upper edge enclosing the top surface 12 of the substrate body 11. The head seal 15 may comprise an annular gap that completely encloses the head mount 6.

The porous oxide coating gun 5 can be positioned above the head mount 6 and preferably can be aligned with the head mount 6 and the substrate 10 so that the central longitudinal axis x of the porous oxide coating gun 5 coincides with the central longitudinal axis of both the mounts. head 6 and substrate body 11 as shown in FIG. 2.

The porous oxide coating gun 5 may include a gun body 21 to which a gun plate 23 can be connected on the underside by means of bolts 26. An adapter plate 27 can be connected to the top side of the gun body 21 also by way of bolts 28.

The atomizer body 21 may include a centrally located opening that forms an inlet 22 of the atomizer cavity 24 formed between the atomizer body 21 and the atomizer plate 23. The axis of the inlet 22 may coincide with the longitudinal axis x. The adapter adapter plate 27 may also include a centrally located hole which may coincide with the longitudinal axis x and be sized to receive the central portion 20 of the atomizer body 21. The metering valve 4 can be placed in the fluid flow with an inlet

- 6 042058 of the body 21 of the atomizer and be held in it.

The atomizer plate 23 may be provided with a set of nozzle holes 25 .

In use, diaphragm valve 32 opens and the porous oxide coating is drawn into opening 42 from reservoir 30 by moving the piston to the right (as shown in FIG. 1). The membrane valve 32 is then closed and the dose of the porous oxide coating is then displaced through the channel 35 by the action of the piston 41 of the distributor 2 to the left (as shown in FIG. 1). The porous oxide coating passes through the metering valve 4 and the inlet 22 into the cavity 24 of the distributor. The porous oxide coating then passes through the nozzle openings 25 and falls down to contact the top surface 12 of the substrate 10. The porous oxide coating is then drawn through the channels of the substrate 10. The pulling of the porous oxide coating through the substrate 10 is actuated, at least in part, suction force applied to the bottom surface 13 of the substrate 10 by the vacuum cone 7.

In FIG. 3 shows a substrate 110 that has a substrate body 111 with a top surface 112, a bottom surface 113, and a side wall 108. The top edge 107 extends around the top surface 112. The PO substrate shown is typically cylindrical in shape with one cylindrical side wall 108. a substrate 110 of another shape, such as an oval, square, or rectangular top surface with one or more (eg, four) side walls.

Top surface 112 is provided with a groove or notch 114, referred to as groove 114 for ease of understanding. Groove 114 can be of various shapes and lengths. Groove 114 may be shaped and sized to accept, in whole or in part, another component, such as an emissions control sensor.

The groove 114 prevents the top surface 112 from being flat. Groove 114 may extend across the entire diameter of top surface 112. Alternatively, as shown in FIG. 3, groove 114 may partially extend along the diameter of top surface 112. Groove 114 may extend through one or both ends to sidewall 108 such that one or more gaps 109 are formed in sidewall 108 and one or more breaks at top edge 107. As shown in FIG. 3, one gap 109 is provided.

Groove 114 may have various cross-sectional shapes when cut perpendicular to its length. Groove 114 shown in FIG. 3 has a semi-circular cross-sectional shape. However, other shapes may be used depending on the shape of the component to be placed in the groove 114. The groove 109 may in principle have the same shape as the groove 114.

In FIG. 4 shows some aspects of the present disclosure in which a portion of the substrate coater 100 according to the present disclosure, modified from the substrate coater 1, allows for preferential coating of substrates having non-planar top and/or bottom surfaces. The substrate coating apparatus 100 will only be described as an example for coating the substrate 110 in FIG. 3. However, it should be understood that this is not intended to be limiting, and the substrate coater 100 can be advantageously used to coat other substrates.

The elements of the substrate coater 100 are the same or substantially the same as those of the substrate coater 1 shown in FIG. 1 and 2 and are designated by like reference numerals, for example 1 and 101, 10 and 110, and will not be described in more detail. The above description should be mentioned.

However, the seal 115 of the nozzle of the substrate coater 101 is different from the seal 15 of the head of the substrate coater 1 shown in FIG. 2.

In particular, as shown in FIG. 5-8, the head seal 115 includes a perimeter portion 116 for enclosing the head 106 and an inclined portion 117 that extends from the perimeter portion 116 and is configured to engage with the side wall 108 of the substrate 110.

As shown in FIG. 6 and 7, the perimeter portion preferably includes a circular or oval annular portion that completely surrounds the head 106 when installed. The perimeter portion 116 may define a central opening 120 enclosed by an inner edge 121. The inner edge 121 may be positioned perpendicular to the surfaces of the perimeter portion 116. Alternatively, the inner edge 121 may be shouldered, grooved, or tapered as desired.

The sloped portion 117 may be located on or near the inner edge 121 of the perimeter portion 116. The sloping portion 117 may be arcuate. In particular, this is useful when the side wall 108 of the substrate 110 is cylindrical. The inclined portion 117 may have a central angle of 45 to 120°, optionally 45 to 90°, optionally 65 to 75°. The length of the ramp 117 may alternatively or additionally be 105 to 300% of the length of the gap 109 in the side wall 108, further 105 to 200% of the length of the gap 109 in the side wall 108.

The sloping portion 117 may extend downwardly at least 20 mm below the bottom surface of the perimeter portion 116, additionally at least 30 mm below the bottom surface of the perimeter.

- 7 042058 of the metric part 116, additionally at least 40 mm below the edge of the surface of the perimetric part 116.

As seen in FIG. 6 and 8, the sloping portion 117 may have a depth in the radial direction of 2.5 to 5.0 mm.

As clearly shown in FIG. 8, the sloping portion 117 may extend at an angle of 0° to 15° with respect to a plane perpendicular to the perimeter portion 116; additionally at an angle a from 0 to 10° relative to the plane perpendicular to the perimetric part 116; additionally at an angle a of approximately 3° relative to a plane perpendicular to the perimeter portion 116.

The perimeter portion 116 and the sloping portion 117 are preferably made as a single unit, although they may be formed separately and then installed together inside the head 106.

The perimeter portion 116 and the inclined portion 117 may be formed from different materials, such as differently shaped materials. However, it may be preferred that they are formed from the same material.

At least the inclined portion 117 may be composed of a flexible material. The perimeter portion 116 and/or the slope portion 117 may be formed from a material having a scleroscope hardness of 35A to 45A, further 40A. The perimeter portion 116 and the slope portion 117 may be formed from rubber, elastomer, or other sealing material. Non-limiting examples of suitable materials are silicone rubber and EPDM, for example based on silicone rubber with a scleroscope hardness of 40 and EPDM with a hardness of 40.

As shown in FIG. 4, the seal 115 is installed in the head 106. The perimeter portion 116 may completely surround the head 106 around the perimeter. Slanted portion 117 is shown extending downwardly from perimeter portion 116. Lower edge 123 of ramped portion 117 is free to protrude from the head mounting frame, and thus be flexable in a predominantly radial direction, as most clearly shown in the photograph of FIG. 9 (FIG. 9 also illustrates the elements of the baffle 200, which will be described below).

When the substrate 110 is engaged by the head 106, in which the substrate 110 can be lifted into engagement by the head 106, the sloping portion 117 of the head seal 115 can be bent in a predominantly radial direction to accommodate the substrate 110. easy and secure engagement of the substrate 110 by the head 106 during lifting of the substrate. Thus, it is possible to adjust some resistance of the substrate 110 to lateral displacement by the head 106 by bending the sloping portion 117.

As an addition or alternative, setting the sloped portion 117 at an angle of 0 to 15° with respect to a plane perpendicular to the perimeter portion 116 may also help the head 106 to more easily and securely engage the substrate 110 during lifting of the substrate. Thus, some resistance of the substrate 110 to lateral displacement by the head 106 can be adjusted by setting the angle of the ramp 117.

In FIG. 4 shows substrate 110 with groove 114 engaged with head 106. Perimeter portion 116 may be tightly engaged with top edge 107 of substrate 110. This engagement may be provided with inner edge 121 of perimeter portion 116.

The sloping portion 117 may engage with the side wall portion 108 of the substrate 110. As shown in FIG. 4, it is preferable that the sloping portion 117 is directed against the gap 109 to prevent the coating from flowing out of the gap 109 down the side wall 108 of the substrate. The sloped portion 117 may have a height of at least 5 mm greater than the depth of the gap 109 in the side wall 108 of the substrate 110.

As indicated above, the length of the sloping portion 117 may be from 105 to 300% of the length of the gap 109 in the side wall 108, further from 105 to 200% of the length of the gap 109 in the side wall 108. In this way, stability against some angular displacement of the substrate 110 can be achieved. , i.e. the sloping portion 117 will retain sufficient length to completely seal the gap 109.

During operation of the substrate coater 101, a suction force is applied to the bottom surface of the substrate 110 by a vacuum cone. The advantage is that the flexibility and/or relative thinness of the sloped portion 117 allows it to engage more closely with the side wall 108 due to the suction force. This increases the stability of the seal between the ramp 117 and the substrate 110.

During operation of the device shown in Fig. 4, similar to the substrate coater 1, the porous oxide coating passes through the metering valve 104 and the inlet 122 into the atomizer cavity 124. The porous oxide coating then passes through the nozzle openings 125 and falls down to contact the top surface 112 of the substrate 110. The porous oxide coating is then drawn through the channels of the substrate 110. The pulling of the porous oxide coating through the substrate 110 is actuated, at least in part, suction force applied to the bottom surface 113 of the substrate 110 by the vacuum cone 7. During this process, a portion of the coating may accumulate or collect in the groove 114. The porous oxide coating may extend along the groove 114. prevents or significantly reduces any leakage of the coating from the gap 109 down the side

- 8 042058 wall 108.

In FIG. 10 shows some aspects of the present disclosure in which the substrate coater is provided with a baffle 200 located between the coating gun and the top surface of the substrate. The baffle 200 will be described below in the context of the description of the substrate coater 101 shown in FIG. 4-9 by way of example only. The baffle 200 may be used in another apparatus for coating the substrate. Be that as it may, a partial improvement in performance is achieved by using a baffle 200 in combination with a head seal 115 having an inclined portion 117 as described above.

As clearly shown in FIG. 11-13, the baffle 200 includes a housing 205 with a plurality of openings 202. The housing 205 may be disc-shaped, as well as an upper surface 204 and a lower surface 203. The housing 205 in FIG. 12 has a round shape. However, the septum 200 may have other shapes and can be adapted to suit the size and shape of a particular head.

The partition wall 200 may have a thickness between the top surface 204 and the bottom surface 203 of 5 to 15 mm, optionally 7.5 to 12.5 mm, optionally 10 mm.

The baffle 200 can have more than 500 holes 202, more than 1000 more holes 202, more than 1500 more holes 202, more than 2000 more holes 202. Each of the holes 202 can have a diameter of 1 to 3 mm, optionally 2 mm. Holes 202 may be evenly spaced or randomly spaced.

The percentage of open area of the baffle 200, defined as the percentage of the total area of the top surface 204 of the baffle 200, which is composed of openings 202, is 35 to 55%, optionally 40 to 50%, optionally about 45%.

The baffle 200 may be placed between the coating gun 105 and the top surface 112 of the substrate 110 when the substrate 110 is engaged with the head 106 to provide a first gap between the bottom surface 203 of the baffle 200 and the top surface 112 of the substrate 110. The first gap may be 2 to 7 mm, additional 5 mm.

In addition or alternatively, a baffle 200 may be located in the head 106 to maintain a second gap between the bottom surface of the coating atomizer 105 and the top surface 204 of the baffle. The second gap can be from 80 to 130 mm.

It is desirable to fix the baffle 200 in the head 106 in such a way that it remains stationary relative to the body of the head 106.

Baffle 200 may be made of metal, plastic, or other rigid material. Non-limiting examples of suitable materials include polyvinyl chloride (PVC), acetal, nylon 66, and Accura 25.

As shown in FIG. 10, baffle 200 is preferably positioned in head 106 above seal 115.

A substrate coater 101 having a baffle 200 is suitable for a substrate coating method 110, which method includes the following steps:

engaging the substrate 110 with the head 106 so that the top surface 112 of the substrate 110 is under the atomizer 105 of the substrate coating apparatus 101;

positioning a baffle 200 between the coating atomizer 105 and the top surface 112 of the substrate 110, with the baffle 200 located in the head 106 to maintain a first gap between the bottom surface 203 of the baffle 200 and the top surface 112 of the substrate 110;

discharging the porous oxide coating from the nebulizer 105 onto the top surface 204 of the baffle 200 and passing the porous oxide coating through the apertures 202 in the baffle 200 onto the top surface 112 of the substrate 110 and into the substrate 110 at least partially by suction applied to the bottom surface 113 substrates 110.

Examples

In FIG. 14 is a side view of a substrate 110 which has been coated using a substrate coater 1 of the type shown in FIG. 1 and 2, i.e. without the use of a head seal 115 or a septum 200 as described herein. As can be seen, coating 150 leaked from gap 109 at the end of groove 114 in substrate and glass down the side wall 108 of substrate 110 during application. could also lead to obscuring the visual identification of features 151 that may be provided on the side wall 108 of the substrate.

In FIG. 15 is a perspective view of a substrate 110 which has been coated using a substrate coater 1 of the type shown in FIG. 1 and 2, i.e. without the use of a head seal 115 or a septum 200 as described herein. As can be seen, during application, excess coating 150 collects on sections of groove 114 that have not been properly introduced into the channels by vacuum. This can lead to excess

- 9 042058 covering and blocking some channels, which in turn can cause an increase in back pressure during use.

In FIG. 16 and 17 respectively show a side view of the subdivided substrate 110 after porous oxide coating and a bottom view of the substrate 110 after coating but before separation. The coating was applied using a substrate coater 1 of the type shown in FIG. 1 and 2, i.e. without the use of a head seal 115 or a septum 200 as described herein. As seen in FIG. 16, the resulting coating profile appears to be very uneven, with the first profile section 152a having a greater height of the substrate 110 than the second section 152b. Indeed, in this example, the porous oxide coating in the second profile portion 152b has spread over the entire lower surface 113 of the substrate 110, resulting in the coating being pulled through. You can see this also in Fig. 17 where the drag area is represented by dark areas. It should be noted that the second portion 152b of the coating profile is aligned with the groove 114, i. e. the coating has passed through the through channels just below the groove 114. This process can result in excess porous oxide coating as well as potentially blocking the channel openings on the bottom surface 113 of the substrate 110.

As a comparative example, Fig. 14-17, where the coating was applied using a substrate coater 100 according to the present disclosure, comprising a head seal 115 and a baffle 200. The substrate was separated after coating, and a side view and a back view were analyzed. It has been found that the use of a substrate coater 100 of the present disclosure, comprising a head seal 115 and a baffle 200, produces a much more uniform coating profile than shown in FIG. 16 and completely prevents the coating from being pulled, as shown in FIG. 17. In particular, the use of the substrate coater 100 of the present disclosure has produced an average desired coating depth along the profile to meet a given coating depth requirement. No coating retention was observed in the groove of the substrate as shown in FIG. 15 and the channels of the substrate were not blocked by the coating. Unlike the example shown in FIG. 14, no significant amount of coating was observed or formed on the substrate side.

Other aspects and embodiments of the present description are set forth in the following paragraphs.

Item A1. Method for coating a substrate with a porous oxide using a substrate coater:

engaging the substrate with the substrate coater head such that the upper surface of the substrate is under the substrate coater sprayer;

positioning a baffle between the atomizer and the top surface of the substrate, the baffle having a plurality of holes and positioned in the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate;

discharging the porous oxide coating from the atomizer onto the upper surface of the baffle; and passing the porous oxide coating through the apertures in the baffle onto the upper surface of the substrate and into the substrate, at least partially, by a suction force applied to the lower surface of the substrate.

Item A2. A method according to claim A1, wherein the septum is fixed with respect to the head.

Item A3. A method according to claim A1 or A2, wherein the first gap is 2 to 7 mm, additionally 5 mm.

Item A4. The method according to any one of the preceding claims, wherein the septum is disc-shaped and the thickness between the upper and lower surface is from 5 to 15 mm, additionally from 7.5 to 12.5 mm, additionally 10 mm.

Item A5. A method according to any one of the preceding claims, wherein the baffle is located in the head to provide a second gap between the bottom surface of the coating gun and the top surface of the baffle of 80 to 130 mm.

Item A6. The method according to any preceding claim, wherein the barrier comprises more than 500 holes, more than 1000 more holes, more than 1500 more holes, more than 2000 more holes.

Item A7. The method according to any preceding claim, wherein the holes have a diameter of 1 to 3 mm, additionally 2 mm.

Item A8. The method according to any one of the preceding claims, wherein the percentage of open area of the septum, defined as the percentage of the total area of the upper surface of the septum, which consists of holes, is from 35 to 55%, further from 40 to 50%, further about 45%.

Item A9. The method according to any one of the preceding claims, wherein the head further comprises a seal and the baffle is located in the head above the seal.

Item A10. The method according to any preceding claim, wherein the top surface of the substrate is non-planar.

- 10 042058

Item A11. The method according to any one of the preceding claims, wherein the upper surface of the substrate comprises a molding, such as a groove or notch, which extends up to the side wall of the substrate, thereby forming a gap therein.

Item A12. The method according to any of the preceding claims, wherein the substrate is coated in a flow-through design (eg, a monolithic substrate) and may be filterable (eg, a filter substrate with flow-through walls).

Item A13. The method according to any one of the preceding claims, wherein the porous oxide coating is formed by a catalytic coating consisting of a three-way catalyst (TWC), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), a NOx lean oxidation trap catalyst (LNT), a catalyst an ammonia slip prevention (ASC), a combined selective catalytic reduction catalyst and an ammonia slip prevention catalyst (SCR/ASC), and a passive NOx adsorbent (PNA).

Item A14. The method according to any one of the preceding claims, which uses a coating with a viscosity of 3 to 9000 cps, further 3 to 54 cps, further 32 to 576 cps, further 23 to 422 cps, further 250 to 4500 cps, further 500 to 9000 sp.

Item A15. The method according to any of the preceding paragraphs, further comprising the steps of any of paragraphs B1-B14.

Item A16. A device for applying a coating on a substrate, containing a source of coating from a porous oxide;

an atomizer for discharging the porous oxide coating onto the upper surface of the substrate;

a passage fluidly connecting the porous oxide coating source to the porous oxide coating gun for supplying the porous oxide coating to the porous oxide coating gun;

a head for engaging the substrate to place the upper surface of the substrate under the atomizer; and a vacuum generator for drawing the porous oxide coating discharged from the head through the substrate;

wherein the head comprises a baffle with a plurality of holes, and the baffle is positioned between the atomizer and the top surface of the substrate when the substrate is engaged with the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate.

Item A17. A substrate coating apparatus according to A16, wherein the septum is fixed in the head in a fixed manner with respect to the body of the head.

Item A18. A substrate coating apparatus according to A16 or A17, wherein the first gap is 2 to 7 mm, additionally 5 mm.

Item A19. A substrate coating device according to any one of claims A16-A18, wherein the baffle is disc-shaped and the thickness between the top and bottom surface is 5 to 15 mm, optionally 7.5 to 12.5 mm, optionally 10 mm.

Item A20. A substrate coater according to any one of the preceding claims, wherein the baffle is located in the die to provide a second gap between the bottom surface of the coating gun and the top surface of the baffle of 80 to 130 mm.

Item A21. A substrate coating apparatus according to any of A16-A20, wherein the baffle comprises more than 500 holes, more than 1000 holes, more than 1500 holes, more than 2000 holes.

Item A22. A substrate coating apparatus according to any of A16A21, wherein the holes have a diameter of 1 to 3 mm, additionally 2 mm.

Item A23. A substrate coater according to any one of A16-A22, wherein the percentage of open area of the baffle, defined as a percentage of the total area of the top surface of the baffle, which is composed of apertures, is 35 to 55%, further 40 to 50 %, additionally approximately 45%.

Item A24. A substrate coating apparatus according to any one of claims A16A23, wherein the head further comprises a seal and the baffle is located in the head above the seal.

Item A25. An apparatus for coating a substrate according to any one of paragraphs A16A24, further comprising an apparatus according to any one of paragraphs B16-B29.

Item A26. A substrate coating system, including a substrate coating apparatus according to any one of paragraphs A16-A25 and a substrate, wherein the upper surface of the substrate is not planar; and additionally, the top surface of the substrate may include a molding, such as a groove or notch, that extends up to the side wall of the substrate, thereby forming a gap therein.

Item A27. Substrate coating system according to paragraph A26, further comprising elements according to paragraph B31 or B32.

Item A28. The baffle is configured for use in a substrate coating device, the baffle having a disc-shaped body;

- 11 042058 disc-shaped body having a thickness between the upper and lower surface of 5 to 15 mm, additionally from 7.5 to 12.5 mm, additionally 10 mm;

partition, including more than 500 holes, additionally more than 1000 holes, additionally more than 1500 holes, additionally more than 2000 holes;

and each of the holes has a diameter of 1 to 3 mm, an additional diameter of 2 mm;

moreover, the percentage of open area of the partition, defined as the percentage of the total area of the upper surface of the partition, which consists of holes, is from 35 to 55%, additionally from 40 to 50%, additionally about 45%.

Item B1. Method for coating a substrate with a porous oxide using a substrate coater:

engaging the substrate with the substrate coater head such that the upper surface of the substrate is under the substrate coater sprayer;

discharging the porous oxide coating from the atomizer onto the upper surface of the substrate;

drawing the porous oxide coating through the substrate by applying a suction force to the bottom surface of the substrate;

wherein the step of engaging the substrate with the head includes engaging the head seal with the substrate, wherein the head seal includes a perimeter portion enclosing the head, and an inclined portion descending from the perimeter portion, which engages with the side wall of the substrate.

Item B2. The method according to claim B1, in which the perimeter part contains an annular part, additionally a round or oval part, completely enclosing the head.

Item VZ. The method according to claim B1 or B2, wherein the top surface of the substrate is non-planar.

Item B4. A method according to any one of claims B1-B3, wherein the inclined portion is arcuate.

Item B5. The method according to any one of claims B1-B4, wherein the upper surface of the substrate comprises a molding, such as a groove or cutout, extending to the side wall of the substrate, thereby forming a gap in it, while the guides of the inclined part above the gap prevent the coating from flowing out of the gap down the side wall of the substrate.

Item B6. The method according to claim B5, wherein the length of the sloped portion is 105 to 300% of the length of the sidewall gap, further 105 to 200% of the length of the sidewall gap.

Item B7. The method according to any one of claims B1-B6, wherein the inclined portion has a central angle of 45 to 120°, further 45 to 90°, further 65 to 75°.

Item B8. The method according to any one of paragraphs B1-B7, in which the inclined part extends at an angle of 0 to 15° relative to a plane perpendicular to the perimeter part; additionally at an angle of 0 to 10° relative to the plane perpendicular to the perimetric part; additionally at an angle of approximately 3° relative to a plane perpendicular to the perimeter portion.

Item B9. A method according to any one of claims B1 to B8, wherein, when the substrate engages with the head, the inclined part of the seal is folded predominantly in the radial direction.

Item B10. The method according to any one of claims B1-B9, wherein the lower edge of the sloping portion protrudes freely and thus is able to bend predominantly in the radial direction.

Item B11. The method according to any one of claims B1-B10, wherein the sloped part engages with a side wall region of the substrate whose height is at least 5 mm greater than the depth of the gap in the side wall of the substrate.

Item B12. The method according to any one of claims B1-B11, wherein the sloping part extends downwardly at least 20 mm below the bottom surface of the perimeter part, additionally at least 30 mm below the bottom surface of the perimeter part, additionally at least 40 mm below the bead surface of the perimeter.

Item B13. The method according to any one of claims B1-B12, wherein the substrate is coated in a flow-through design (for example, a monolithic substrate) and can be filtered (for example, a filter substrate with flow walls).

Item B14. A process according to any one of claims B1-B13, wherein the porous oxide coating supports a catalytic coating consisting of a three-way catalyst (TWC), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), a lean oxidation NOx scavenger catalyst ( LNT), an ammonia slip prevention catalyst (ASC), a combined selective catalytic reduction catalyst and an ammonia slip prevention catalyst (SCR/ASC), and a passive NOx adsorbent (PNA).

Item B15. The method according to any one of paragraphs B1-B14, further comprising the steps of any one of paragraphs A1-A14.

Item B16. A device for applying a coating on a substrate, containing a source of coating from a porous oxide;

an atomizer for discharging the porous oxide coating onto the upper surface of the substrate;

channel fluidly connecting the porous oxide coating source to the porous oxide coating gun for supplying the porous oxide coating to the spray gun

- 12 042058 porous oxide coating;

a head for engaging the substrate to place the upper surface of the substrate under the atomizer; and a vacuum generator for drawing the porous oxide coating discharged from the head through the substrate;

wherein the head includes a substrate engagement seal, a head seal that includes a perimeter portion enclosing the head, and an inclined portion descending from the perimeter portion that engages with the side wall of the substrate.

Item B17. A device for applying a coating on a substrate according to item B16, in which the perimeter part contains an annular part, additionally a round or oval part, completely enclosing the head.

Item B18. A substrate coating apparatus according to B16 or B17, wherein the sloping portion engages a side wall region of the substrate whose height is at least 5 mm greater than the depth of the gap in the side wall of the substrate.

Item B19. A substrate coater according to any one of claims B16-B18, wherein the sloped portion extends downwardly at least 20 mm below the bottom surface of the perimeter portion, further at least 30 mm below the bottom surface of the perimeter portion, further at least measure 40 mm below the edge of the surface of the perimetric part.

Item B20. A substrate coating apparatus according to any one of claims B16-B19, wherein the sloped portion extends at an angle of 0° to 15° with respect to a plane perpendicular to the perimeter portion; additionally at an angle of 0 to 10° relative to the plane perpendicular to the perimetric part; additionally at an angle of approximately 3° relative to a plane perpendicular to the perimeter portion.

Item B21. A substrate coating apparatus according to any one of claims B16-B20, wherein the head comprises a rigid support frame supporting a perimeter portion of its seal and an inclined seal portion that extends below the bottom surface of the rigid support frame.

Item B22. A substrate coater according to any one of claims B16-B21, wherein the lower edge of the sloping portion protrudes freely from the rigid head frame.

Item B23. A substrate coating apparatus according to any one of B16B22, wherein the sloping portion has an arcuate shape.

Item B24. A substrate coating apparatus according to any one of claims B16-B23, wherein the inclined portion has a central angle of 45 to 120°, optionally 45 to 90°, optionally 65 to 75°.

Item B25. A substrate coating apparatus according to any one of B16B24, wherein the sloped portion has a radial depth of 2.5 to 5.0 mm.

Item B26. A substrate coating apparatus according to any one of claims B16B25, wherein the perimeter and slope portions are formed as a single unit.

Item B27. A substrate coater according to any one of B15B24, wherein the perimeter and slope portions are separated.

Item B28. A substrate coating apparatus according to any one of claims B16B27, wherein the perimeter and slope portions are formed from different materials.

Item B29. A substrate coater according to any one of B16B28, wherein the sloped portion has a scleroscope hardness of 35A to 45A, further 40A.

Item B30. An apparatus for coating a substrate according to any one of paragraphs B16B29, further comprising an apparatus according to any one of paragraphs A16-A24.

Item B31. A substrate coating system comprising a substrate coating apparatus according to any one of claims B16-B30 and a substrate, wherein the upper surface of the substrate is not planar.

Item B32. The substrate coating system of claim B31, wherein the top surface of the substrate includes a molding, such as a groove or notch, that extends to a side wall of the substrate, thereby forming a gap therein.

Item B33. A substrate coating system according to paragraphs B31-B32, further comprising elements according to paragraph A26 or A27.

Item B34. Head seal for substrate engagement, head seal, which comprises a perimeter part enclosing the head, and an inclined part descending from the perimeter part, which engages with the side wall of the substrate.

Item B35. A head seal according to B34, wherein the sloping portion is arcuate.

Item B36. Head seal according to item B34 or B35, where the sloping part has a central angle of 45 to 120°, optionally 45 to 90°, optionally 65 to 75°.

Item B37. A head seal according to any one of B34-B36, wherein the sloping portion has a radial depth of 2.5 to 5.0 mm.

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Claims (13)

Item B38. A head seal according to any one of B34-B37, wherein the perimeter and sloping portions are formed as a single unit. Item B39. A head seal according to any one of B34-B37, wherein the perimeter and slope portions are separated. Item B40. A head seal according to any one of B34-B39, wherein the perimeter and slope portions are formed from different materials. Item B41. A head seal according to any of B34-B40, wherein the ramp has a scleroscope hardness of 35A to 45A, additionally 40A. CLAIM 1. The method of coating a substrate with a porous oxide using a substrate coater: engaging the substrate with the substrate coater head such that the upper surface of the substrate is under the substrate coater sprayer; positioning a baffle between the atomizer and the top surface of the substrate, the baffle having a plurality of holes and positioned in the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate; discharging the porous oxide coating from the atomizer onto the upper surface of the baffle; and passing the porous oxide coating through the apertures in the baffle onto the upper surface of the substrate and into the substrate, at least partially, by a suction force applied to the lower surface of the substrate. 2. The method according to claim 1, in which the septum is fixed in relation to the head. 3. Method according to claim 1 or 2, wherein the first gap is 2 to 7 mm, additionally 5 mm. 4. The method according to any preceding claim, wherein the septum is disc-shaped and the thickness between the upper and lower surfaces is 5 to 15 mm, optionally 7.5 to 12.5 mm, optionally 10 mm. 5. A method according to any one of the preceding claims, wherein the baffle is located in the head to provide a second gap between the bottom surface of the coating gun and the top surface of the baffle of 80 to 130 mm. 6. A method according to any one of the preceding claims, wherein the percentage of open area of the baffle, defined as a percentage of the total area of the upper surface of the baffle composed of apertures, is from 35% to 55%, further from 40% to 50%, further about 45%. 7. A method according to any one of the preceding claims, wherein the top surface of the substrate comprises a molding, such as a groove or notch, extending up to the side wall of the substrate, thereby forming a gap therein. 8. A device for applying a coating to a substrate, containing a porous oxide coating source; a spray gun for discharging the porous oxide coating onto the upper surface of the substrate; a conduit fluidly connecting the porous oxide coating source to the porous oxide coating gun for supplying the porous oxide coating to the porous oxide coating gun; a head for engaging the substrate to place the upper surface of the substrate under the nebulizer; and a vacuum generator for drawing the porous oxide coating discharged from the head through the substrate; wherein the head comprises a baffle with a plurality of holes, and the baffle is positioned between the atomizer and the top surface of the substrate when the substrate is engaged with the head to provide a first gap between the bottom surface of the baffle and the top surface of the substrate. 9. An apparatus for coating a substrate according to claim 8, wherein the septum is fixed in the head in a fixed manner with respect to the body of the head. 10. A substrate coating apparatus according to claim 8 or 9, wherein the first gap is 2 to 7 mm, further 5 mm. 11. The substrate coating device according to any one of claims 8 to 10, wherein the percentage of open area of the partition, defined as the percentage of the total area of the upper surface of the partition, consisting of holes, is from 35 to 55%, optionally from 40 to 50%, optionally approximately 45%. 12. A substrate coating apparatus according to any one of claims 8 to 11, wherein the head further comprises a seal and the baffle is positioned in the head above the seal. 13. A substrate coating system comprising a substrate coating device according to any one of claims 8 to 12 and a substrate, wherein the upper surface of the substrate is not planar; and how to complement -