Method and apparatus of manufacturing exhaust gas-purifying catalyst and nozzle used therefor

• US 9,227,184 B2
• Filed: 10/03/2011
• Issued: 01/05/2016
• Est. Priority Date: 04/03/2009
• Status: Active Grant

• Current Assignee: Cataler Corporation (Toyota Motor Corporation)
• Original Assignee: Cataler Corporation (Toyota Motor Corporation)
• Inventors: Nakano, Atsushi, Mizuno, Shigeki, Matsumoto, Shigeji, Sekine, Hiroshi, Matsui, Suguru
• Primary Examiner(s): Yuan, Dah-Wei D
• Assistant Examiner(s): Pence, Jethro M
• Application Number:
  US13/251,761
• Publication Number:
  US 20120021896A1
• Time in Patent Office: 1,555 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0215 Coating
• CPC Class Codes: B05B 1/14 with multiple outlet openings B05B1/02, B05B1/26 take precedence; with strainers in or outside the outlet opening
• CPC Class Codes: B05B 12/02 for controlling time, or sequence, of delivery
• CPC Class Codes: B05C 5/0241 for applying liquid or other fluent material to elongated work, e.g. wires, cables, tubes
• CPC Class Codes: B05C 7/02 the liquid or other fluent material being projected
• CPC Class Codes: B05D 7/22 to internal surfaces, e.g. of tubes

Abstract

A nozzle is configured to discharge a fluid containing a raw material of a catalytic layer to a substrate having first and second end faces and provided with holes each extending from the first end face to the second end face. The nozzle is provided with discharge ports each discharging the fluid toward the first end face of the substrate.

Claims

1. A nozzle configured to discharge a fluid containing a raw material of a catalytic layer to a substrate, the substrate having first and second end faces and being provided with holes each extending from the first end face toward the second end face, the substrate transferred to a position opposite to the nozzle when the fluid is discharged and transferred to a distant position from the position opposite to the nozzle, the nozzle being provided with discharge ports each discharging the fluid toward the first end face of the substrate,

wherein the nozzle comprises:

a hollow portion defining an internal space therein and provided with first and second openings connecting the internal space and an external space outside the hollow portion with each other, the hollow portion being configured such that the fluid is supplied to the internal space through the first opening; and

a plate-like portion covering the second opening and provided with the discharge ports, the discharge ports configured to discharge the fluid toward the first end face of the substrate,

wherein the discharge ports have greater diameters at a periphery of an arrangement of the discharge ports than at a center of the arrangement of the discharge ports, and

wherein a ratio of the diameter of the discharge ports that are arranged at the center of the arrangement with respect to the diameter of the discharge ports that are arranged at the periphery of the arrangement is 0.7 or less.

2. The nozzle according to claim 1, wherein the plate-like portion includes first to fourth regions, the second region surrounding the first region, the third region surrounding the first and second regions, and the fourth region surrounding the first to third regions,

wherein the discharge ports includes one or more discharge ports and second to fourth discharge ports, the one or more first discharge ports being provided in the first region, and the second to fourth discharge ports being provided in the second to fourth regions, respectively, and

wherein the first discharge ports have a diameter smaller than a diameter of the fourth discharge ports.

3. The nozzle according to claim 2, wherein the diameter of the first discharge ports is smaller than diameters of the second and third discharge ports.

4. The according to claim 3, wherein the second discharge ports have a diameter smaller than a diameter of the third discharge ports and the diameter of the fourth discharge ports.

5. The nozzle according to claim 4, wherein the diameter of the third discharge ports is smaller than the diameter of the fourth discharge ports.

6. The nozzle according to claim 4, wherein the discharge ports are arranged such that a density of the discharge ports is the highest at a position spaced apart from a center of the plate-like portion.

7. The nozzle according to claim 6, further comprising a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

8. The nozzle according to claim 4, further comprising a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

9. The nozzle according to claim 2, wherein the discharge ports are arranged such that a density of the discharge ports is the highest at a position spaced apart from a center of the plate-like portion.

10. The nozzle according to claim 9, further comprising a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

11. The nozzle according to claim 2, further comprising a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

12. The nozzle according to claim 1, wherein the discharge ports are arranged such that a density of the discharge ports is the highest at a position spaced apart from a center of the plate-like portion.

13. The nozzle according to claim 12, further comprising a deflector located in the hollow body,

wherein the deflector divides internal into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

14. The nozzle according to claim 1, further comprising a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion.

15. A nozzle configured to discharge a fluid containing a raw material of a catalytic layer to a substrate, the substrate having first and second end faces and being provided with holes each extending from the first end face toward the second end face, the substrate transferred to a position opposite to the nozzle when the fluid is discharged and transferred to a distant position from the position opposite to the nozzle, the nozzle being provided with discharge ports each discharging the fluid toward the first end face of the substrate,

wherein the nozzle comprises:

a hollow portion defining an internal space therein and provided with first and second openings connecting the internal space and an external space outside the hollow portion with each other, the hollow portion being configured such that the fluid is supplied to the internal space through the first opening;

a plate-like portion covering the second opening and provided with the discharge ports, the discharge ports configured to discharge the fluid toward the first end of the substrate; and

a deflector located in the hollow body,

wherein the deflector divides the internal space into a downstream region adjacent to the plate-like portion and an upstream region interposed between the downstream region and the first opening, the deflector being provided with through-holes connecting the upstream and downstream regions with each other, and

wherein the deflector includes a center portion provided with first through-holes as some of the through-holes and a peripheral portion surrounding the center portion and provided with second through-holes as the remainders of the through-holes, a ratio of a total area occupied by the first through-holes with respect to an area of the center portion being smaller than a ratio of a total area occupied by the second through-holes with respect to an area of the peripheral portion, and

wherein the deflector includes a first mesh and a second mesh having a smaller diameter and a smaller mesh size as compared with the first mesh, the first mesh and the second mesh stacked together such that their centers substantially coincide with each other, the mesh size of the first mesh is set within a range of 0.5 to 2 mm, and the mesh size of the second mesh is set within a range of 0.2 to 1.5 mm.