Abstract: Disclosed is a method for preparing a zeolite-based catalyst for application on a substrate. The method consists of the steps of: preparing a chemical composition comprising tin oxide, zirconium oxide, cerium oxide, and lanthanum oxide; combining the composition with a catalyst comprising a two-phase hydrocarbon NOx reduction catalyst comprising one or more transition metals supported on a molecular sieve with a coating of one or more stabilizing oxides; and applying the resulting catalyst material to a substrate. The ratio of the catalyst to chemical composition may vary from greater than 1 to 1 to less than 50 to 1. A washcoat may be prepared using the chemical composition, which washcoat is then combined with the catalyst. The washcoat may be combined with the zeolite catalyst using high power density mixing. The resulting catalyst material will then be applied to the substrate.

Abstract: A catch pan apparatus for starting and stopping coating is disclosed for coating a downwardly moving receiving surface by curtain coating. The catch pan device includes an intercepting pan that intercepts the curtain when coating is stopped and a substantially horizontal intercepting surface that intercepts the curtain only when the catch pan moves to start or stop coating. The intercepting pan and horizontal intercepting surface intersect to create a volume that retains in the catch pan excess liquids that would otherwise spill onto the coating receiving surface as the catch pan is retracted to a non-intercepting position. The catch pan is controllably retracted at high speed through the curtain using linear servomotors such that the releasing edge of the horizontal intercepting surface passes close to the coating receiving surface at the point of curtain release. Flushed edge guides maintaining curtain width are positioned outside the lateral edges of the catch pan.

Abstract: A catch pan apparatus for starting and stopping coating is disclosed for coating a downwardly moving receiving surface by curtain coating. The catch pan device includes an intercepting pan that intercepts the curtain when coating is stopped and a substantially horizontal intercepting surface that intercepts the curtain only when the catch pan moves to start or stop coating. The intercepting pan and horizontal intercepting surface intersect to create a volume that retains in the catch pan excess liquids that would otherwise spill onto the coating receiving surface as the catch pan is retracted to a non-intercepting position. The catch pan is controllably retracted at high speed through the curtain using linear servomotors such that the releasing edge of the horizontal intercepting surface passes close to the coating receiving surface at the point of curtain release. Flushed edge guides maintaining curtain width are positioned outside the lateral edges of the catch pan.

Abstract: A web material, which is able to avoid air entrainment, comprises a surface for applying at least one layer of coating material. The web material has at least one splicing tape for connecting a preceding web and a succeeding web with respect to a transport direction of the web material. The splicing tape defines a trailing edge on the surface of the succeeding web. After the trailing edge of the splicing tape a thin layer with limited width and a rough surface is formed. Additionally, there is a method for continuous coating a web material having at least one spliced joint.

Abstract: A web material, which is able to avoid air entrainment, comprises a surface for applying at least one layer of coating material. The web material has at least one splicing tape for connecting a preceding web and a succeeding web with respect to a transport direction of the web material. The splicing tape defines a trailing edge on the surface of the succeeding web. After the trailing edge of the splicing tape a thin layer with limited width and a rough surface is formed. Additionally, there is a method for continuous coating a web material having at least one spliced joint.

Abstract: A web material, which is able to avoid air entrainment, comprises a surface for applying at least one layer of coating material. The web material has at least one splicing tape for connecting a preceding web and a succeeding web with respect to a transport direction of the web material. The splicing tape defines a trailing edge on the surface of the succeeding web. After the trailing edge of the splicing tape a thin layer with limited width and a rough surface is formed. Additionally, there is a method for continuous coating a web material having at least one spliced joint.

Abstract: A method and apparatus for preventing vortical air flow behind a free-falling curtain in a curtain coating apparatus. There is a critical region within the coating apparatus defined in part by a coating hopper, the free-falling curtain delivered from the coating hopper, a portion of the moving substrate supported on a roller to which the free-falling curtain is delivered, and an air shield located between the roller and the coating hopper. A first intake slot proximate to the moving substrate shield is used to remove boundary-layer air entrained on the moving substrate. A second intake slot positioned within the critical region is used to remove boundary-layer air entrained on the free-falling curtain. Each of the two intake slots is connected to vacuum source. One or two vacuum sources may be used.