Method and apparatus for coating a carrier

Patent metadata

Field	Value
Publication number	US-10994269-B2
Application number	US-201916534662-A
Country	US
Kind code	B2
Filing date	Aug 7, 2019
Priority date	Apr 17, 2003
Publication date	May 4, 2021
Grant date	May 4, 2021

Abstract

Disclosed is a method and a corresponding apparatus for coating open-pored bodies with at least one coating suspension, the coating suspension having solids and solutes in a liquid medium in a quantity in wet state which is to correspond to at least a required target quantity, and the coating operation having a variation in the applied wet coating quantity from one body to the other. The method includes steps of: coating the body with an actual quantity of the coating suspension, which is always larger than the required target quantity taking the variation of the coating operation into account, determining the difference between the actual quantity and the required target quantity, and reducing the difference between actual quantity and target quantity by removing still wet coating suspension.

First claim

The invention claimed is:

1. A method for coating a carrier body, comprising:
delivering an initial quantity of wet coating suspension to the carrier body and then removing a first surplus quantity of wet coating suspension from the carrier body to leave a first excess quantity of wet coating suspension on the carrier body, the first excess quantity of wet coating suspension being greater than a predetermined target quantity of the wet coating suspension that is necessary for achieving a target catalytic activity;
determining, after removing the first surplus quantity of wet coating suspension, and prior to any further removal of wet coating suspension from the carrier body, a differential quantity representing a difference between the first excess quantity and the target quantity, and
removing a second surplus quantity of wet coating suspension from the carrier body to leave a second excess quantity of wet coating suspension on the carrier body; the second surplus quantity of wet coating suspension being based on the determined differential between the first excess quantity and the target quantity, and the second excess quantity being less than the first excess quantity and greater than the target quantity.

2. The method according to claim 1 , wherein
removal of the first surplus quantity is performed to deliberately yield a first excess quantity that is within a predetermined overload range.

3. The method according to claim 2 , wherein
the overload range is defined by a mean quantity value that is the sum of the target quantity and a variation quantity associated with the coating process.

4. The method according to claim 3 , wherein
the overload range is 105%±5% of the target quantity.

5. The method according to claim 4 , wherein
the second excess quantity is in a range of 101%±0.5% of the target quantity.

6. The method according to claim 3 , wherein
the overload range is 103%±3% of the target quantity.

7. The method according to claim 6 , wherein
the second excess quantity is in a range of 101%±0.5% of the target quantity.

8. The method according to claim 3 , wherein
the variation quantity is based, at least in part, on the properties of the coating suspension used in the coating process.

9. The method according to claim 3 , wherein
the variation quantity is based, at least in part, on the properties of the carrier body to be coated in the coating process.

10. The method according to claim 1 , wherein
removal of the second surplus is performed by adjusting the intensity, the duration, or both the intensity and the duration of a second surplus removal action based on the differential quantity between the first excess quantity and the target quantity.

11. The method according to claim 10 , wherein
adjustments to the second surplus removal action are made with reference to tabulated data that identifies adjustment parameters based on the differential quantity.

12. The method according to claim 10 , wherein the process further comprises
determining, after removing the second surplus quantity, a second differential quantity representing a difference between the second excess quantity and the target quantity.

13. The method according to claim 12 , wherein
adjustments to the second surplus removal action are made, through a closed-loop control, based on second differential quantity results from prior carrier bodies in a coating campaign.

14. The method according to claim 12 , wherein
the second differential is determined by weighing the carrier body.

15. The method according to claim 1 , wherein
the differential quantity is determined by weighing the carrier body.

Assignees

• Umicore Ag & Co Kg

Inventors

• Harris Michael
• Detterbeck Dieter
• Lox Egbert
• Kreuzer Thomas

Classifications

• B01J37/0215 Primary

  Coating · CPC title

• B01J35/57

  Honeycombs · CPC title

• B05D1/16 Primary

  Flocking otherwise than by spraying · CPC title

• B05D3/0493

  using vacuum · CPC title

• B05D7/22

  to internal surfaces, e.g. of tubes · CPC title