EP4299194A1 - Appareil de revêtement - Google Patents
Appareil de revêtement Download PDFInfo
- Publication number
- EP4299194A1 EP4299194A1 EP22181902.2A EP22181902A EP4299194A1 EP 4299194 A1 EP4299194 A1 EP 4299194A1 EP 22181902 A EP22181902 A EP 22181902A EP 4299194 A1 EP4299194 A1 EP 4299194A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- substrate
- face
- liquid coating
- substrates
- slurry
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000576 coating method Methods 0.000 title claims description 42
- 239000011248 coating agent Substances 0.000 title claims description 41
- 239000000758 substrate Substances 0.000 claims abstract description 117
- 239000007788 liquid Substances 0.000 claims abstract description 42
- 239000006255 coating slurry Substances 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 31
- 230000004323 axial length Effects 0.000 claims description 4
- 230000005661 hydrophobic surface Effects 0.000 claims description 3
- 230000002441 reversible effect Effects 0.000 claims description 2
- 239000003054 catalyst Substances 0.000 abstract description 8
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 239000002002 slurry Substances 0.000 description 23
- 239000007789 gas Substances 0.000 description 12
- 238000009826 distribution Methods 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 239000011148 porous material Substances 0.000 description 7
- 230000003197 catalytic effect Effects 0.000 description 6
- 239000003344 environmental pollutant Substances 0.000 description 6
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- 238000001035 drying Methods 0.000 description 5
- 241000264877 Hippospongia communis Species 0.000 description 4
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 4
- 238000001354 calcination Methods 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 150000002739 metals Chemical class 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
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- 239000000463 material Substances 0.000 description 3
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- 239000002243 precursor Substances 0.000 description 3
- 239000011232 storage material Substances 0.000 description 3
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- 238000006243 chemical reaction Methods 0.000 description 2
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- 239000010949 copper Substances 0.000 description 2
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- 229910052773 Promethium Inorganic materials 0.000 description 1
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- 229910052772 Samarium Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 229910052775 Thulium Inorganic materials 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- HEHRHMRHPUNLIR-UHFFFAOYSA-N aluminum;hydroxy-[hydroxy(oxo)silyl]oxy-oxosilane;lithium Chemical compound [Li].[Al].O[Si](=O)O[Si](O)=O.O[Si](=O)O[Si](O)=O HEHRHMRHPUNLIR-UHFFFAOYSA-N 0.000 description 1
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 description 1
- 239000007900 aqueous suspension Substances 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000007084 catalytic combustion reaction Methods 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- OGPBJKLSAFTDLK-UHFFFAOYSA-N europium atom Chemical compound [Eu] OGPBJKLSAFTDLK-UHFFFAOYSA-N 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- KJZYNXUDTRRSPN-UHFFFAOYSA-N holmium atom Chemical compound [Ho] KJZYNXUDTRRSPN-UHFFFAOYSA-N 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 230000000116 mitigating effect Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 125000001190 organyl group Chemical group 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- GPNDARIEYHPYAY-UHFFFAOYSA-N palladium(ii) nitrate Chemical compound [Pd+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O GPNDARIEYHPYAY-UHFFFAOYSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229910052670 petalite Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- NWAHZABTSDUXMJ-UHFFFAOYSA-N platinum(2+);dinitrate Chemical compound [Pt+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O NWAHZABTSDUXMJ-UHFFFAOYSA-N 0.000 description 1
- AAIMUHANAAXZIF-UHFFFAOYSA-L platinum(2+);sulfite Chemical compound [Pt+2].[O-]S([O-])=O AAIMUHANAAXZIF-UHFFFAOYSA-L 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- VQMWBBYLQSCNPO-UHFFFAOYSA-N promethium atom Chemical compound [Pm] VQMWBBYLQSCNPO-UHFFFAOYSA-N 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910052851 sillimanite Inorganic materials 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
- 229910052642 spodumene Inorganic materials 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 230000008685 targeting Effects 0.000 description 1
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 238000002604 ultrasonography Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
- B05C5/002—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the work consisting of separate articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C7/00—Apparatus specially designed for applying liquid or other fluent material to the inside of hollow work
- B05C7/04—Apparatus specially designed for applying liquid or other fluent material to the inside of hollow work the liquid or other fluent material flowing or being moved through the work; the work being filled with liquid or other fluent material and emptied
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
- B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
- B05C11/11—Vats or other containers for liquids or other fluent materials
Definitions
- the present invention is directed to an apparatus and a respective process, which can be used in the production of exhaust catalysts.
- the present apparatus is used for supplying the liquid coating slurry to substrates, like honeycomb monoliths.
- Automotive exhaust abatement is of great importance as numbers of cars are growing tremendously, especially in East Asian countries.
- Several clean air acts around the world try to keep the pollution of the air by automobiles at respective low levels.
- more and more stringent legislation forces car manufacturers and suppliers to apply techniques for abatement of noxious pollutants stemming from internal combustion engines of vehicles.
- One area of techniques concerns the catalytic combustion of exhaust pollutants on or in so-called honeycomb monoliths either of the flow-through or the wall-flow type.
- the coating techniques can be divided in two general classes.
- a first class is concerned with a coating strategy in which the liquid coating slurry is subjected to the vertically orientated substrate (i.e. support body or monolith carrier) from below.
- the second class of coating techniques discusses the application of the liquid coating slurry to the top of the vertically orientated substrate.
- a top-down coating technique in which a substrate coating apparatus comprises means for dosing a pre-determined quantity of a liquid component, said quantity being such that it is substantially wholly retained within the intended support, liquid component containment means locatable on the top of a substrate to receive said quantity of liquid component, and pressure means capable of withdrawing the liquid component from the containment means into at least a portion of the substrate.
- the EP1900442A1 and the EP2415522A1 are concerned with the problem of applying an even liquid washcoat slurry on the top end of the substrate monoliths. This is important because an uneven distribution of the liquid slurry (washcoat) leads to an uneven distribution of the washcoat within the channels of such substrates after the suction step. This problem is said to be solved in these patent applications by rotating the substrate monolith or by applying a special nozzle technique.
- the present invention is also concerned with the problem of metering a liquid coating slurry on the top end face of a monolith substrate in a way that the liquid coating slurry is distributed evenly over an area of the top end face of the substrate before it is going to be sucked and/or pressed into the substrate by applying a pressure difference across the channels of the respective substrate.
- the apparatus and the process involved should be advantageous in view of the prior art techniques from an economical and/or ecological point of view.
- an apparatus for coating substrates with a catalytically active liquid coating slurry wherein the substrates have two end faces, a circumferential surface and an axial length and are traversed from the first end face to the second end face by a multiplicity of channels, said apparatus comprises
- the apparatus according to the invention comprises a containment means.
- This containment means is to hold the liquid coating slurry (i.e. washcoat) supplied by the dosing unit for a certain while and instantaneously supply substantially all of the washcoat slurry on the top end face of the substrate. This serves for a good distribution of the washcoat over this end face which in turn leads to an even distribution of the washcoat in the substrate channels upon establishing a pressure difference versus the substrate channels.
- the containment means preferably has a pot-like design with a collar and a bottom plate, the latter being able to reversibly open and close as stipulated above.
- the present apparatus is designed such that the distance between the substrate top end face and the bottom plate of the containment means is between 2 - 20 cm (measured from bottom plate with closed flaps to top end face of the substrate; see Fig. 1 ). If the distance is too large the velocity of the falling washcoat will be too high and it would already by hitting the top end face of the substrate intrude into the channels leading finally to an uneven distribution of the washcoat within the substrate. If the distance is too low the flaps may not be able to open accordingly because they may hit the top end face of the substrate.
- the flaps To open and close the flaps it is preferred if they are arranged such that they can rotate around an axis of rotation.
- the flaps at the endpoints of this rotational axis are fixed to the collar of the containment means in such a way that they can be rotated around the axis of rotation.
- the rotation can be rendered by means know to the skilled worker, e.g. pneumatic, electric or mechanic triggers.
- flaps have a wing-like profile with a length (L) and can be flipped around an axis laying parallel to the length (L). It is more preferred if the axis of rotation of the flaps is positioned such that in an open mode operation point most of the profile of each flap perpendicular to the axis of rotation is located between the axis of rotation and the top end face of the substrate (see Fig. 1 ). This serves for a better pouring of the washcoat slurry over the top end face of the substrate without having much washcoat being slingshot away by flaps opening rapidly. Instead the liquid coating slurry within the containment means preferably shall just fall onto the top end face of the substrate with other momentums being minimized as much as possible.
- the surface of the flaps at least partially has a hydrophobic surface.
- the liquid coating slurry normally is based on a water suspension. With a hydrophobic surface substantially no water and insoluble constituents of the suspension will adhere to the flaps. Even better waterrepelling surfaces may be achieved using the so called lotus effect on the surface of the flaps ( https://de.wikipedia.org/wiki/Lotos sure ). Hence, it is considered very advantageous if the flaps at least partially comprise a surface showing said lotus effect.
- the coating of a substrate normally starts with engaging the substrate in a holding unit, i.e. a coating chamber in a vertical orientation, the substrate now having a top end face and a bottom end face.
- the holding unit can be any known to the skilled worker. Some examples are shown in the cited literature.
- the holding unit comprises an inflatable bladder to engage the substrate as described.
- the dosing unit supplies the liquid coating slurry into the containment means having the flaps closed.
- the dosing unit can be any known to the skilled worker, like a shower head, a nozzle, or those mentioned in cited literature.
- the containment means are located right above the substrate. After the slurry has been filled into the containment means the flaps open fast and the slurry falls onto the top end face of the substrate.
- a unit for applying a pressure difference versus the substrate is used to force the slurry into the channels of the substrate.
- the substrate is removed from the holding unit by deflating the bladder and is further processed e.g. by drying and optionally calcining it.
- the slurry in the containment means can be leveled out by vibration or agitation through a gas stream or an ultrasound.
- the introduction of the slurry into the substrate starts when the falling slurry hit the substrate.
- This is advantageous especially for thin washcoats having a low viscosity of 1 - 1000 mPas, preferably 10 - 600 mPas at 20 °C, respectively at a shear rate of 20 s-1 (measured according to DIN ISO 1652 - as valid at the application date).
- the pressure difference versus the substrate is advantageously already established before the slurry hits the top end face of the substrate.
- washcoat may first be submitted to the top end face of the substrate in total and only afterwards the unit for applying a pressure difference versus the substrate is used to force the slurry into the channels of the substrate.
- the skilled worker will find the best mode for his coating problem.
- the apparatus of the invention can be further equipped with a means to turn the substrates upside down within said apparatus.
- the substrate can be flipped around and can be coated again in the same manner and with the same apparatus from the other side being the top end face now.
- the holding unit of the apparatus of the invention is arranged in a rotatory turntable device.
- the substrates thus can be moved towards and away from the dosing unit and the containment means by moving the turntable around an axis of rotation.
- Several process steps like flipping the substrates, providing the slurry onto the top end face and introducing the slurry into the substrates can be performed in parallel by preferably using the apparatus with a turntable comprising several holding units.
- the unit for applying a pressure difference versus the substrate is preferably a suction unit.
- the slurry is introduced by sucking it from the bottom end of the substrate through its channels.
- no liquid coating slurry leaves the substrate, meaning that the amount of washcoat and the vacuum applied is such that all washcoat is retained in the substrate.
- the present invention is directed to a method for coating substrates with a liquid coating slurry providing the catalytic activity, wherein the substrates have two end faces, a circumferential surface and an axial length and are traversed from the first end face to the second end face by a multiplicity of channels, wherein each substrate is vertically orientated and a dosing unit supplies the liquid coating slurry into a containment means, and applying a pressure difference versus the substrate, wherein an apparatus as defined above is used.
- the method according to the invention is performed twice with on substrate.
- the method comprises the steps of:
- Said processes can be done with or without any drying of the substrate in between. In view of a better cycle time no drying step is performed in between the coating steps. The skilled worker knows how to establish the respective devices to perform this process. The information given for the apparatus can be applied mutatis mutandis for the processes of the invention.
- the washcoat can be introduced as a slurry under conditions that are predetermined to form a washcoat layer along a length of the channels of the substrate that is up to but preferably less than 100% of the total length of the monolith carrier; more preferably a length equal to or greater than about 50% and less than 80%; and yet more preferably a length equal to or greater than about 55% and equal to or less than about 70%, although any length less than 100% may be desirable based on application.
- Targeting less than 100% of the total length of the carrier also provides further benefits including, though not limited to, mitigating the unintended leakage of washcoat slurry through the opposite end face of the substrate; and suppressing particle size and compositional drift issues (e.g., formation of a gradient), thereby promoting a uniform surface of the applied catalyst layer.
- the substrate coated according to the present invention is a flow-through or a wall-flow monolith.
- Flow-through substrates have fine, parallel gas flow passages extending from an inlet to an outlet face of the substrate, such that passages are open to fluid flow there through.
- the passages which are essentially straight paths from their fluid inlet to their fluid outlet, are defined by walls on which or in which the catalytic material is coated as a washcoat so that the gases flowing through the passages contact the catalytic material.
- the flow passages of the monolithic substrate are thin-walled channels, which can be of any suitable cross-sectional shape and size such as trapezoidal, rectangular, square, sinusoidal, hexagonal, oval, circular, etc.
- Such structures may contain from about 400 - 900 or more gas inlet openings (i.e., cells) per square inch of cross section (62 - 140 cells/cm 2 ).
- the wall thicknesses i.e. the thickness of the walls which separate the channels of the substrate from one another, are usually from about 0.005 cm to about 0.25 cm.
- the substrate to be coated according to the invention may preferably also be a honeycomb wall-flow filter.
- Wall-flow substrates useful for supporting the coating compositions have a plurality of fine, substantially parallel gas flow passages extending along the longitudinal axis of the substrate. Typically, each passage is blocked at one end of the substrate body, with alternate passages blocked at opposite end-faces.
- Specific wall-flow substrates for use in the inventive process include thin porous walled honeycombs through which the fluid stream passes without causing too great an increase in back pressure or pressure drop across the article. Normally, the presence of a clean wall-flow article will create a back pressure of 0.036 psi to 10 psi.
- the above-mentioned substrates are preferably metal or ceramic-like monoliths, the latter are made out of any suitable refractory material, e.g., cordierite, cordierite-alumina, silicon nitride, zircon mullite, spodumene, aluminasilica magnesia, zircon silicate, sillimanite, a magnesium silicate, zircon, petalite, alumina, an aluminosilicate and the like.
- suitable refractory material e.g., cordierite, cordierite-alumina, silicon nitride, zircon mullite, spodumene, aluminasilica magnesia, zircon silicate, sillimanite, a magnesium silicate, zircon, petalite, alumina, an aluminosilicate and the like.
- suitable refractory material e.g., cordierite, cordierite-alumina, silicon nitride
- suitable for the production of exhaust gas catalysts for motor vehicles according to the present process they preferably have a porosity of more than 20%, generally from 20% to 70%, in particular from 35% to 65% prior to coating [measured according to DIN 66133 as of the application date].
- the mean pore size is at least 1 ⁇ m, e.g. from 1.5 ⁇ m to 25 ⁇ m, preferably more than 3 ⁇ m, in particular from 5 ⁇ m to 18 ⁇ m prior to coating [measured according to DIN 66134 as of the application date].
- Finished substrates suitable for the exhaust gas catalysis of motor vehicles which originally have a mean pore size of 5 to 18 ⁇ m and a porosity of 25% to 65% are particularly advantageous.
- ceramic wall-flow filter substrates which are e.g. suitable for the production of exhaust gas filters for motor vehicles according to the present process, they preferably have a porosity of more than 40%, generally from 40% to 75%, in particular from 45% to 70% [measured according to DIN 66133 as of the application date].
- the mean pore size is at least 7 ⁇ m, e.g. from 7 ⁇ m to 34 ⁇ m, preferably more than 10 ⁇ m, in particular from 10 ⁇ m to 20 ⁇ m or from [measured according to DIN 66134 as of the application date].
- Finished substrates suitable for exhaust gas catalysis of motor vehicles have a mean pore size of 10 to 33 ⁇ m and a porosity of 45% to 65% are particularly advantageous.
- the substrate is a wall-flow filter.
- coating / to coat is to be understood to mean the application of catalytically active materials and/or storage components for noxious exhaust pollutants on a substantially inert substrate which may be constructed in the manner of an above-described wall-flow filter or flow-through monolith. After drying and calcining the established coating performs the actual catalytic function and contains storage materials and/or catalytically active metals which are usually deposited in highly dispersed form on temperature-stable, large-surface-area metal oxides (see below).
- the coating is carried out usually by means of the application of a liquid coating slurry of the storage materials and/or catalytically active components - also referred to as a washcoat - onto and/or into (into the pores of) the wall of the inert substrate.
- a liquid coating slurry of the storage materials and/or catalytically active components also referred to as a washcoat - onto and/or into (into the pores of) the wall of the inert substrate.
- the support is dried and, if appropriate, calcined at elevated temperatures.
- the coating may be composed of one layer or constructed from a plurality of layers which are applied to a substrate one above the other (in multi-layer form) and/or offset with respect to one another (in zones).
- the liquid coating medium/slurry is, for example, a suspension or dispersion ("washcoat") for coating exhaust gas catalysts (flow-through monoliths or filters) for motor vehicles which contains the storage materials and/or catalytically active materials or precursors thereof and/or inorganic oxides such as zeolites, like CHA, AEI, AFX or similar 8-ring zeolites, or refractory oxides like aluminum oxide, titanium dioxide, zirconium oxide or a combination thereof, it being possible for the refractory oxides to be doped with silicon or lanthanum, for example.
- the zeolites can be exchanged with metal cations like Fe and/or Cu.
- Noble metals such as platinum, palladium, gold, rhodium, iridium, osmium, ruthenium and combinations thereof can also be used as catalytically active components.
- metals can also be present as alloys with one another or with other metals or as oxides.
- the metals can also be present as precursors, such as nitrates, sulfites or organyls of said noble metals and mixtures thereof, and, in particular, palladium nitrate, palladium sulfite, platinum nitrate, platinum sulfite or Pt(NH 3 ) 4 (NO 3 ) 2 can be used in the liquid coating medium.
- the catalytically active component can then be obtained from the precursor.
- a suspension or dispersion of an inorganic oxide can initially be used for coating, after which, in a subsequent coating step, a suspension or dispersion which contains one or more catalytically active components can be applied.
- the liquid coating medium it is also possible for the liquid coating slurry to contain both components.
- the liquid coating slurry has a viscosity of from 10 - 2000 mPas at 20°C and a shear rate of 20 s-1.
- the present invention may encompass a coating station which comprises the apparatus according to the present invention.
- the preferred embodiments of the process and/or the apparatus disclosed apply mutatis mutandis to the coating station. This is the case, in particular, for the more mechanical aspects discussed in connection with the above-mentioned process and/or apparatus, like e.g. rotatory turntable, robot arm for loading and unloading or turning around the substrate within the holding unit and the possibility to coat the substrate monoliths from both end sides.
- the present invention allows to perform an advantageous top-down coating process.
- the invention can be applied with liquid coating slurries for exhaust gas catalyst production, the slurries having a broad range of viscosity.
- Low viscous as well as high viscous washcoats can be extremely evenly coated either on flow-through or wall-flow substrates ( Fig. 2 ).
- the even distribution of the washcoat within such substrates leads to optimized back-pressure, filtration efficiency and catalytic performance. This was not apparent to the skilled worker before the invention was made.
- a flow through substrate (Cordierite, 4.66" diameter ⁇ 4.5" length, 600/4 cells per square inch/mils) was coated using the dosing unit with an alumina containing washcoat with a viscosity of 1200 mPas at 20 s-1 .
- the monolith was engaged into a coating station vertically and a respective amount of washcoat was submitted to the top end face by an apparatus with containment means according to the invention. After submission of the washcoat it was sucked from below into the monolith, which was then dried and calcined under normal conditions.
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EP22181902.2A EP4299194A1 (fr) | 2022-06-29 | 2022-06-29 | Appareil de revêtement |
CN202310772180.4A CN117299461A (zh) | 2022-06-29 | 2023-06-28 | 涂覆设备 |
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EP22181902.2A EP4299194A1 (fr) | 2022-06-29 | 2022-06-29 | Appareil de revêtement |
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WO1997048500A1 (fr) | 1996-06-21 | 1997-12-24 | Engelhard Corporation | Procede pour revetir un substrat |
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EP1900442A1 (fr) | 2005-07-07 | 2008-03-19 | Cataler Corporation | Dispositif et procédé d enduction de matériau de base |
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WO2011080525A1 (fr) | 2010-01-04 | 2011-07-07 | Johnson Matthey Plc | Procédé de revêtement d'un substrat monolithique avec un constituant de catalyseur |
EP2415522A1 (fr) | 2009-04-03 | 2012-02-08 | Cataler Corporation | Procédé et dispositif de fabrication d'un catalyseur de contrôle d'émission de gaz d'échappement et buse utilisée avec le dispositif |
JP2014076415A (ja) * | 2012-10-09 | 2014-05-01 | Cataler Corp | スラリー供給ノズルとそれを用いた排ガス浄化用触媒の製造装置および製造方法 |
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WO2015145122A2 (fr) | 2014-03-25 | 2015-10-01 | Johnson Matthey Public Limited Company | Procédé de revêtement d'un substrat filtrant |
EP3648885A1 (fr) | 2017-07-06 | 2020-05-13 | Umicore AG & Co. KG | Procédé d'application d'un revêtement multicouche humide sur humide sur un substrat |
-
2022
- 2022-06-29 EP EP22181902.2A patent/EP4299194A1/fr active Pending
-
2023
- 2023-06-28 CN CN202310772180.4A patent/CN117299461A/zh active Pending
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WO1999047260A1 (fr) | 1998-03-19 | 1999-09-23 | Johnson Matthey Public Limited Company | Appareil de revetement de support monolithique et son procede de fabrication |
US6627257B1 (en) | 1998-08-20 | 2003-09-30 | Degussa-Huls Aktiengesellschaft | Process for coating the flow channels in a monolithic catalyst carrier with a coating dispersion |
US6478874B1 (en) | 1999-08-06 | 2002-11-12 | Engelhard Corporation | System for catalytic coating of a substrate |
US6753294B1 (en) | 1999-08-13 | 2004-06-22 | Johnson Matthey Public Limited Company | Catalytic wall-flow filter |
US6548105B2 (en) | 2000-03-23 | 2003-04-15 | Dmc2 Degussa Metals Catalysts Cerdec Ag | Method for partially coating a carrier body |
US20020178707A1 (en) | 2001-04-23 | 2002-12-05 | Vance Fredrick W. | Method of making wall-flow monolith filter |
US20080107806A1 (en) | 2004-08-21 | 2008-05-08 | Umicore Ag & Co.Kg | Method for Coating a Wall Flow Filter With a Coating Composition |
EP1900442A1 (fr) | 2005-07-07 | 2008-03-19 | Cataler Corporation | Dispositif et procédé d enduction de matériau de base |
US9144796B1 (en) | 2009-04-01 | 2015-09-29 | Johnson Matthey Public Limited Company | Method of applying washcoat to monolithic substrate |
EP2415522A1 (fr) | 2009-04-03 | 2012-02-08 | Cataler Corporation | Procédé et dispositif de fabrication d'un catalyseur de contrôle d'émission de gaz d'échappement et buse utilisée avec le dispositif |
WO2011080525A1 (fr) | 2010-01-04 | 2011-07-07 | Johnson Matthey Plc | Procédé de revêtement d'un substrat monolithique avec un constituant de catalyseur |
JP2014076415A (ja) * | 2012-10-09 | 2014-05-01 | Cataler Corp | スラリー供給ノズルとそれを用いた排ガス浄化用触媒の製造装置および製造方法 |
WO2015145122A2 (fr) | 2014-03-25 | 2015-10-01 | Johnson Matthey Public Limited Company | Procédé de revêtement d'un substrat filtrant |
EP3648885A1 (fr) | 2017-07-06 | 2020-05-13 | Umicore AG & Co. KG | Procédé d'application d'un revêtement multicouche humide sur humide sur un substrat |
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