Uniformity Control Method for Antimicrobial Coating Production

Abstract

The present invention provides a uniformity control method for the production of antibacterial coatings, which relates to the technical field of production characteristic management. For the target antibacterial coating, the coating stage is divided, the response variables and factors of the coating uniformity are excavated and summarized, and a response surface module is constructed, in which the antibacterial factor has the first priority; uniformity indicators are obtained, bidirectional rheological characteristics analysis and thixotropic characteristics analysis under operating conditions are performed, state constraints are determined, process nodes are mapped and limited for the production process flow, pre-control process strategies are determined, and production line control management of the target antibacterial coating is executed. The method solves the technical problems of insufficient uniformity control over the entire life cycle of antibacterial coatings and limited control stability and accuracy in the prior art. By determining the uniformity defects of the response from multiple scenarios after production, the production process of the antibacterial coating is reversely guided to ensure that the uniformity distribution standards are met throughout the entire life cycle of the antibacterial coating.

Description

Technical Field

[0001] The invention relates to the technical field of production characteristic management, and in particular to a uniformity control method for antibacterial coating production. Background Art

[0002] The wide application of antimicrobial coatings in the fields of construction, home furnishing and medical treatment has promoted the continuous optimization of its production process. In the traditional production process of antimicrobial coatings, the uniformity of the coating is a key factor affecting its antimicrobial effect and performance. However, since the dispersion and reactivity of particles in the coating are affected by many factors, such as stirring speed, temperature, humidity, etc., the antimicrobial factors are unevenly distributed in the coating, which seriously affects the antimicrobial performance and durability of the coating.

[0003] At present, most of the existing technologies are directly controlled from the production process. Although the uniformity standard is achieved in production, there are still certain uniformity defects in actual applications, resulting in poor actual application effects and lack of effective technology from a practical perspective. At the same time, from a physical and chemical perspective, it has strong instability and it is difficult to effectively control the uniformity.

[0004] In summary, the existing technology still has technical problems such as insufficient control over the uniformity of the antibacterial coating throughout its life cycle, and limited control stability and accuracy. Summary of the invention

[0005] The present application provides a uniformity control method for the production of antibacterial coatings, which is used to solve the technical problems existing in the prior art of insufficient control over the uniformity of the antibacterial coating throughout its life cycle, and limited control stability and accuracy.

[0006] In view of the above problems, the present application provides a uniformity control method for the production of antibacterial coatings.

[0007] The present application provides a uniformity control method for antibacterial coating production, the method comprising: dividing the coating stage for the target antibacterial coating, wherein the coating stage includes a static stage, a load stage, and a recovery stage; traversing the coating stage, mining and summarizing the response variables and factors of the coating uniformity, and constructing a response surface module, wherein the antibacterial factor has the first priority; obtaining a uniformity index, combining the response surface module to perform a bidirectional rheological characteristic analysis and a thixotropic characteristic analysis under operating conditions, and determining state constraints; interacting with the production process flow of the target antibacterial coating, mapping and limiting optimization of process nodes based on the state constraints, and determining a pre-control process strategy; and executing production line control management of the target antibacterial coating based on the pre-control process strategy.

[0008] Furthermore, the construction of the response surface module includes: calling the test records and application records of the target antimicrobial coating to determine the sample records; traversing the coating stages and setting response nodes, wherein each coating stage corresponds to at least one response node; identifying the response nodes, regularizing the sample records based on the response variables and factors, and supervising the training of the response surface module.

[0009] Furthermore, before performing bidirectional rheological characteristic analysis and thixotropic characteristic analysis, the method includes: determining phase factors based on operating conditions, wherein the phase factors are common factors; determining dynamic factor relationships for the phase factors; and performing bidirectional rheological analysis and thixotropic analysis with the dynamic factor relationships as constraints.

[0010] Furthermore, the determination of state constraints includes: setting response time and space conditions, which are used to perform analysis period constraints; based on the dynamic element relationship and the response time and space conditions, guided by state uniformity, traversing the coating stage to perform forward stage deduction and reverse recursive positioning to determine the state constraints, which cover uniformity index defects.

[0011] Furthermore, the determination of the pre-control process strategy includes: identifying uniformity indicator defects, mapping the production process flow based on process correlation, and determining N groups of process nodes, wherein the N groups of process nodes correspond one-to-one to the state constraints, and each group of process nodes contains at least one process node; based on the state constraints, performing production limit and process optimization on the N groups of process nodes to determine the pre-control process strategy.

[0012] Furthermore, production limitation and process optimization are performed on the N groups of process nodes, including: identifying a first state constraint condition, performing production parameter control limitation on a group of process nodes, and determining a first limit constraint; judging whether the first limit constraint satisfies a first uniformity index defect; if not, taking the first limit constraint as a baseline, performing process optimization on the group of process nodes, and determining a first control node strategy.

[0013] Furthermore, it also includes: introducing production line equipment errors and environmental errors to perform node strategy compensation on the pre-control process strategy; and setting the collision avoidance principle of production control based on factor priority.

[0014] Furthermore, the execution of production line control management of the target antimicrobial coating includes: identifying the pre-control process strategy, determining the dynamic and static physical structure of the target antimicrobial coating, the physical structure including physical dimension and chemical dimension, the physical dimension being the relative distribution structure of particles and the geometric particle size structure of monomer particles, and the chemical dimension being the particle denaturation characteristics; based on the pre-control process strategy and the physical structure, the production line control management of the target antimicrobial coating is performed.

[0015] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0016] The uniformity control method for antibacterial coating production provided in the embodiment of the present application divides the coating stage for the target antibacterial coating, wherein the coating stage includes a static stage, a load stage, and a recovery stage; traverses the coating stage, mines and summarizes the response variables and factors of the coating uniformity, and constructs a response surface module, wherein the antibacterial factor has the first priority; obtains the uniformity index, and combines the response surface module to perform a bidirectional rheological characteristic analysis and a thixotropic characteristic analysis under the operating conditions to determine the state constraints; interacts with the production process flow of the target antibacterial coating, and based on the state constraints, performs mapping and limit optimization of the process nodes to determine the pre-control process strategy; based on the pre-control process strategy, executes the production line control management of the target antibacterial coating. The technical problems of insufficient uniformity control over the entire life cycle of antibacterial coatings, and limited control stability and accuracy in the prior art are solved. By determining the uniformity defects of the response from multiple scenarios after production, the production process of the antibacterial coating is reversely guided to ensure that the uniformity distribution standard is met throughout the life cycle of the antibacterial coating. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A schematic flow chart of a uniformity control method for antimicrobial coating production is provided for this application;

[0018] Figure 2 A flow chart of determining state constraints in a uniformity control method for producing antimicrobial coatings is provided for this application. DETAILED DESCRIPTION

[0019] This application provides a uniformity control method for the production of antibacterial coatings. For the target antibacterial coating, the coating stage is divided, the response variables and factors of the coating uniformity are excavated and summarized, and a response surface module is constructed. The antibacterial factor has the first priority; uniformity indicators are obtained, bidirectional rheological characteristics analysis and thixotropic characteristics analysis under operating conditions are performed, state constraints are determined, process nodes are mapped and limited for the production process flow, pre-control process strategies are determined, and production line control management of the target antibacterial coating is executed. It is used to solve the technical problems existing in the prior art of insufficient uniformity control over the entire life cycle of antibacterial coatings, and limited control stability and accuracy.

[0020] Example: Figure 1 As shown, the present application provides a uniformity control method for antibacterial coating production, the method comprising:

[0021] S1: Divide the coating into stages for the target antibacterial coating, wherein the coating stages include a static stage, a load stage, and a recovery stage;

[0022] For the entire life cycle of antimicrobial coatings, not only the production cycle, but also its subsequent application cycle should ensure the uniformity of the distribution of coatings and antimicrobial performance. At present, the uniformity control method for antimicrobial coating production provided by this application determines the corresponding uniformity defects from multiple scenarios after production, and reversely guides the production process of antimicrobial coatings to ensure that the uniformity distribution standard is met throughout the entire life cycle of the antimicrobial coating.

[0023] The cycle phases after the antibacterial coating is produced are divided into a static phase, a load phase, and a recovery phase. The state under extremely low shear load is the static phase. As the static time continues, the coating may be in a state without external force, but there will still be precipitation or stratification. It is necessary to analyze the natural stability of the antibacterial coating, especially the impact on the distribution of antibacterial properties, to ensure that the coating particles are evenly distributed in a static state to prevent precipitation or separation.

[0024] The state with constant and high shear load is regarded as the load state. For example, the antibacterial coating is subjected to external shock, transportation, coating sagging and other external forces. The rheological properties of the coating under load will directly affect its uniformity and application effect. By analyzing the uniformity and distribution of antibacterial properties of the coating under stress or flow state, the focus is on analyzing whether the antibacterial factor is still evenly distributed.

[0025] When the load is removed, the coating gradually returns to a static state, which is referred to as the recovery phase. During this process, the coating exhibits thixotropy, i.e., shear thinning and reconstruction after recovery. It is necessary to ensure that the coating can return to a uniformly distributed state, especially to remain stable in the redistribution of the antimicrobial factors.

[0026] The ultimate goal of uniform production is to ensure the uniformity of application response. Uniformity analysis and optimization can be performed on the state of the coating under different working conditions to improve the overall uniformity and performance of the coating.

[0027] S2: traverse the coating stage, mine and summarize the response variables and factors of coating uniformity, and construct a response surface module, in which the antibacterial factor has the first priority;

[0028] In the embodiment of the present application, in order to ensure the uniformity of the antibacterial coating, the response variables and influencing factors affecting the uniformity of the coating need to be identified from the three coating stages of static-load-recovery, and a response surface module is constructed. Among them, the antibacterial factor is the most critical influencing factor and has the first priority.

[0029] At different stages, the state, fluidity and uniformity of the coating are different. By traversing each stage, the influence of its response variables and factors on the uniformity of the coating is observed.

[0030] Specifically, the response variable is a quantitative indicator describing the uniformity state of the coating. For example, the response variable may include coating viscosity: reflecting flow resistance and uniformity; shear rate and shear stress: used to describe the rheological properties of the coating during the loading stage; particle distribution: particle size and distribution of antimicrobial agents, pigments and other components in the coating; thixotropy recovery time: the speed at which the coating stabilizes again after loading, reflecting the internal structure and uniformity of the coating; antimicrobial performance distribution: whether the antimicrobial factors are evenly distributed in the coating.

[0031] The factors are elements that may affect the response variables. Exemplarily, the factors may include: antimicrobial factors: the antimicrobial active ingredients in the coating, which should be uniformly distributed in each stage; temperature and humidity: environmental conditions will affect the rheological properties and uniformity of the coating; stirring rate and time: the intensity and time of the stirring process in the load stage will affect the uniformity; additives in the coating formula: different additives will affect the dispersion and stability of the coating. Among them, the activity of the antimicrobial factor may be affected by factors such as the external environment, and the specific analysis process needs to be considered to ensure the accuracy of the analysis.

[0032] Furthermore, the response surface model is a mathematical model. By summarizing the above response variables and factors, a multidimensional model of uniformity under different conditions is established to simulate and predict the change of coating uniformity and construct the response surface module.

[0033] At the same time, since antibacterial performance is the core function of the coating, the distribution and uniformity of the antibacterial factor are given priority in the design of the response surface module. Other factors in the model will be subject to ensuring the stable distribution of the antibacterial factor.

[0034] By traversing each stage of coating production, summarizing the key factors and variables affecting uniformity, and constructing a response surface module, the uniformity defects of the target antibacterial coating can be effectively located and production traceability can be performed, which can reversely guide the control and optimization of the production process to ensure the uniformity and functionality of the antibacterial coating.

[0035] In the embodiment of the present application, the response surface module is constructed, further comprising:

[0036] The test records and application records of the target antimicrobial coating are called to determine the sample records; the coating stages are traversed to set response nodes, wherein each coating stage corresponds to at least one response node; the response nodes are identified, and based on the response variables and factors, the sample records are regularized to supervise the training of the response surface module.

[0037] The test records contain performance data and test data collected by the coating in the laboratory and production process. These data may include physical properties, such as viscosity, fluidity, antibacterial properties, etc.; environmental conditions, such as temperature and humidity; and test results under different formulations. The application records refer to the performance data of the coating in actual application, such as storage status, status in transportation and handling scenarios, painting effects at customer sites, durability and antibacterial effects, etc. The test records and the application records are aggregated and screened to form a representative sample library as the sample records for subsequent analysis and modeling.

[0038] For the static stage, load stage, and recovery stage, at least one response node is set in each coating stage to collect and analyze important data of the stage. For example, based on the key time phase nodes in the stage, the time phase nodes in these stages can reflect the uniformity state of the coating and are representative. For example, for the recovery stage, the coating node, semi-curing node, and full-curing node are response nodes. By analyzing the response nodes, the uniformity state of the entire stage can be determined.

[0039] Furthermore, at each set response node, the corresponding response variables (such as viscosity, particle distribution, etc.) and factors (such as stirring time, temperature, etc.) are collected. The sample records are correspondingly regularized.

[0040] Exemplarily, the collected data are sorted and cleaned, outliers or invalid data are removed, the data are standardized for modeling analysis, and the samples are integrated into a representation model based on response nodes.

[0041] Preferably, manual annotation or prior knowledge can be introduced to conduct supervised learning on the regularized sample data to construct a response surface model that can predict the uniformity performance of the coating, so that it can accurately predict the changes in the uniformity of the coating under different stage conditions.

[0042] Preferably, the prediction accuracy of the model can be improved by continuously training and optimizing the response surface module, which is used to locate the uniformity defects in the actual application of the target antibacterial coating, so as to subsequently use this as a starting point for process production optimization control to ensure that the produced products meet the subsequent application standards.

[0043] S3: Obtaining uniformity index, and performing bidirectional rheological characteristic analysis and thixotropic characteristic analysis under operating conditions in combination with the response surface module to determine state constraint conditions;

[0044] Uniformity index refers to a quantitative parameter that measures whether the components in the coating (such as antimicrobial factors, fillers, pigments, etc.) are evenly distributed. These indicators may include: particle distribution uniformity: measure the distribution of different particles (such as antimicrobial factors, pigments, etc.) in the coating; viscosity uniformity: monitor the viscosity difference of the coating in different areas to ensure that there is no local over-thickness or over-thinness; antimicrobial factor distribution uniformity: pay special attention to the distribution of antimicrobial agents in the coating to ensure its uniformity in the coating. For example, viscosity will affect the fluidity of the antimicrobial coating, resulting in uneven coating distribution.

[0045] After obtaining the uniformity index, it is combined with the response surface module to analyze the state of the coating under current production conditions and identify potential problems or optimization space.

[0046] Among them, rheological property analysis refers to the flow behavior of the coating when subjected to external stress. Thixotropic property analysis refers to the change of the coating's structural state after being subjected to force and its recovery state after the force is removed, for example, thixotropic recovery time, thixotropic uniformity, etc.

[0047] Based on the results of the bidirectional rheological and thixotropic properties analysis, combined with the response surface module, a series of state constraints can be determined, that is, the target antibacterial coating meets the standards for the final applicability uniformity. These conditions are used to guide the adjustment of operating parameters in the coating production process.

[0048] By combining the uniformity index and the response surface module, bidirectional rheological and thixotropic properties analysis can fully understand the state changes of the coating in the actual application process. Based on these analysis results, the determined state constraints can reversely guide production operations, optimize process parameters, and ensure the uniformity of the coating throughout the production process and application energy efficiency.

[0049] In the embodiment of the present application, before performing the bidirectional rheological property analysis and the thixotropic property analysis, the following steps are also included:

[0050] Determine the stage factors based on the operating conditions, wherein the stage factors are common factors; determine the dynamic factor relationships for the stage factors; and perform bidirectional rheological analysis and thixotropic analysis with the dynamic factor relationships as constraints.

[0051] Specifically, the phased factors refer to the key factors that affect the uniformity of coating distribution and performance in each stage of the target antibacterial coating production, the static-load-recovery stage. Different stages of operating conditions involve a variety of common factors, which play a key role in each stage. For example, for a scenario in the load and recovery stage, coating and curing, coating thickness, coating frequency, coating speed, etc. will affect its uniformity state, which will be used as the operating conditions in this scenario.

[0052] In the embodiments of the present application, common factors are used for analysis to ensure that the analysis results are generally applicable and suitable for most common conditions without considering accidental influencing factors.

[0053] The dynamic element relationship refers to the follow-up change of the influence trend on uniformity accompanied by the change of common elements in the corresponding stages. It reflects the dynamic response of the coating under operating conditions. For example, the effect of temperature on viscosity: for example, as the temperature increases, the viscosity of the coating will decrease; the relationship between viscosity and thixotropy recovery time: for example, a coating with higher viscosity may take longer to return to its original state after shearing, affecting thixotropy. The dynamic element relationship is summarized based on sample records or other related retrieval data, reflecting the interaction and change rules of the coating under different operating conditions.

[0054] By determining the common phase factors under operating conditions, analyzing and establishing their dynamic factor relationships, effective constraints can be provided for bidirectional rheological analysis and thixotropic analysis, which can effectively improve the accuracy of uniformity defect positioning.

[0055] like Figure 2 As shown, in the embodiment of the present application, the determining state constraint condition further includes:

[0056] Set response space-time conditions, which are used to perform analysis cycle constraints; based on the dynamic element relationship and the response space-time conditions, guided by state uniformity, traverse the coating stage to perform forward stage deduction and reverse recursive positioning to determine the state constraint conditions, which cover uniformity index defects.

[0057] Specifically, the response time and space conditions refer to the constraints set for analysis from the time dimension and space dimension at each coating stage, which can be customized by technicians to assist in analyzing the behavior of coatings at different stages. For example, for the time dimension, such as the response duration period, etc.; for the space dimension, such as the layer distribution of the coating, the flow state and other conditions, the distribution of temperature and humidity, etc. For example, in actual scenes, the distribution of temperature and humidity is uneven, and conditional constraints are imposed on the relevant detail features to improve the actual fit of the analysis results.

[0058] Furthermore, the dynamic element relationship and the response spatiotemporal conditions are used as a baseline to create the most basic analysis scenario space, and decisions are made on this basis, which can effectively improve the accuracy of the analysis results. Specifically, with state uniformity as the focus target, for example, a uniformity coefficient can be set for vector measurement.

[0059] Then, the coating stage is traversed, and simulation analysis and deduction are performed from the static stage-load stage-recovery stage to analyze the behavior state of the target antibacterial coating, and the change trend based on uniformity is determined as a forward stage deduction. Further, based on the forward stage deduction, the uniform state of the terminal nodes of each stage is analyzed, and the uniform state of the final terminal stage, that is, starting from the recovery stage, the state of the coating in the static stage and the load stage is analyzed, and the operating factors that may cause non-uniformity in these stages are identified.

[0060] Uniformity defects are located for the process and results. At the same time, the factor standards at different stages are different, which is also convenient for tracing and locating the source of adjustment. Specifically, if the uniformity of the result meets the standard, the uniformity trend distribution of the process is not considered; if the uniformity of the result does not meet the standard, the uniformity curve of the corresponding factor in the whole stage is determined. For example, if the uniformity of an antibacterial type factor does not meet the standard, the uniformity distribution curve of the antibacterial type factor in the whole deduction cycle is determined, and the key non-uniform nodes are located for impact tracing. Through reverse analysis, it is confirmed how any problems in the recovery stage were formed in the previous stage, such as the load stage, so as to eliminate their impact during subsequent production control.

[0061] Based on the determined impact tracing results, the quality standards for production are integrated and converted as the state constraint conditions. For example, due to excessive fluidity, the solidification adhesion retention is uneven, and the viscosity is adjusted in production or additives are added for adjustment. The state constraint conditions are used to reversely guide the production uniformity control of the target antibacterial coating.

[0062] S4: Interacting the production process of the target antibacterial coating, mapping and limiting optimization of process nodes based on the state constraints, and determining the pre-control process strategy;

[0063] S5: Based on the pre-control process strategy, execute production line control management of the target antimicrobial coating.

[0064] Specifically, the entire production process of the antibacterial coating is obtained, the state constraint condition is used as the adjustment requirement, the production process is traversed to match the process-related nodes of each state constraint condition, and the matching process-related nodes are adjusted and optimized so that the adjusted coating can effectively avoid the above-mentioned uniformity problem in subsequent applications. At the same time, the uniformity of production is the most basic standard to be achieved. Specifically, the direct limit adjustment of the control parameters and the process optimization are used as the adjustment method to ensure that the uniformity standard is met and determine the pre-control process strategy.

[0065] The pre-control process strategy is transmitted to the production control system, and the full-cycle control management of the production line processing of the target antibacterial coating is carried out. The operation is monitored and adjusted in real time during the production process to ensure the uniformity and quality stability of the antibacterial coating.

[0066] In the embodiment of the present application, the determining of the pre-control process strategy also includes:

[0067] Identify uniformity indicator defects, map the production process flow based on process correlation, and determine N groups of process nodes, wherein the N groups of process nodes correspond one-to-one to the state constraints, and each group of process nodes contains at least one process node; based on the state constraints, perform production limit and process optimization on the N groups of process nodes to determine the pre-control process strategy.

[0068] The uniformity index defect refers to the specific manifestation of the uniformity problem of the coating in the actual application process. The production process is traversed, and the process correlation analysis is performed on each uniformity index defect. The process correlation refers to the mutual influence of each step in the coating production. At least one process flow node related to the production of each uniformity index is determined, and a mapping between the uniformity index defect and the corresponding process flow node is established as the N groups of process nodes, wherein each uniformity index defect corresponds to a group of process nodes.

[0069] Preferably, a matching principle for relevant process nodes can be set. For example, the process node corresponding to each uniformity index defect includes at least one key operation node, which may be related to shearing, mixing, heating, cooling, etc. of the coating.

[0070] At the same time, there is a corresponding relationship between the state constraint condition and the uniformity index defect, that is, the state constraint condition corresponds to the N groups of process nodes, and the process nodes of the mapping group are controlled and optimized by matching the corresponding state constraint conditions.

[0071] Determine the control information of the N groups of process nodes after adjustment and optimization, fuse and positively sequence the optimized control information in the process production sequence as the pre-control process strategy, and guide the production and uniformity control of the target antibacterial coating based on the pre-control process strategy.

[0072] In the embodiment of the present application, the production limit and process optimization of the N groups of process nodes are performed, and further includes:

[0073] Identify the first state constraint condition, perform production parameter control limit on a group of process nodes, and determine the first limit constraint; determine whether the first limit constraint satisfies the first uniformity index defect; if not, use the first limit constraint as a baseline to optimize the process of the group of process nodes and determine the first control node strategy.

[0074] Among them, the first state constraint condition is any one of the state constraint conditions, and the adjustment and optimization method for each state constraint condition is similar.

[0075] Specifically, identify the first state constraint, traverse the N groups of process nodes, match and map the corresponding process nodes as the group of process nodes. First, take the first state constraint as the standard, the first state constraint is the control condition set for the matched specific process node, and limit the adjustment of the control parameters of the group of process nodes, with the extreme value of the parameter modulation as the limit adjustable interval. For example, the stirring node may have an upper and lower limit of the shear rate; the temperature control node will have an allowable temperature fluctuation range, etc. Ensure that the control of the parameter adjustment operates within the set range to avoid uneven coating caused by poor operation.

[0076] Further, after the control parameters of the group of process nodes are adjusted, a first limit constraint, that is, the adjusted parameter limit information, is determined. It is determined whether the first limit constraint can satisfy the first state constraint condition, that is, whether the uniformity requirement is met. If so, the first limit constraint is used as the first control node strategy.

[0077] If it is not satisfied, for example, after the limit constraint controls the shear rate and temperature, the distribution of the paint particles after stirring is still uneven, it means that the limit constraint may not be enough to solve this problem. Other means are needed to optimize the uniformity, such as introducing new control processing means or conditions, introducing new additives, optimizing process operations, etc. Specifically, based on the first control node strategy, determine the process optimization range based on uniformity, optimize the set of process nodes until the first state constraint is met, and determine the first control node strategy.

[0078] By identifying the first state constraint and optimizing the nodes in the production process, the occurrence of coating non-uniformity problems can be effectively prevented. Even if the first limit constraint fails to completely eliminate the uniformity defect, further adjustments and improvements can be made through process optimization, and finally a reasonable control node strategy can be formulated to ensure the quality and uniformity of coating production.

[0079] In the embodiment of the present application, it also includes:

[0080] Production line equipment errors and environmental errors are introduced to perform node strategy compensation on the pre-control process strategy; based on factor priority, the collision avoidance principle of production control is set.

[0081] In the actual production process, the accuracy constraints of the production line equipment itself and the existence of environmental influences will affect the production effect to a certain extent. The equipment operation accuracy of the production line workshop is collected, such as mechanical wear, operation stability, etc., to determine the error of the production line equipment, and determine the real-time production environment and environmental influence. As the environmental error, such as environmental vibration, temperature, etc., the temperature or humidity changes in the production workshop may affect the rheology and uniformity of the coating; air pressure and air flow may affect the drying speed and particle distribution of the coating. Based on the production line equipment error and the environmental five wipes, the control compensation of the strategy node of the pre-control process strategy is performed. For example, the equipment error can be weakened by further improving the control accuracy, and the environmental error can be weakened by adjusting the environment-related auxiliary equipment, etc., to ensure the expected production effect load.

[0082] At the same time, the factor priority is determined based on the degree of correlation between production criticality and uniformity. When there is a control collision of multiple factors, control avoidance is performed based on priority. This is used as a collision avoidance principle in production control to respond to emergencies in the production process and ensure production stability and energy efficiency.

[0083] In the embodiment of the present application, the production line control management of the target antibacterial coating further includes:

[0084] Identify the pre-control process strategy, determine the dynamic and static physical structure of the target antimicrobial coating, the physical structure includes physical dimension and chemical dimension, the physical dimension is the relative distribution structure of particles and the geometric particle size structure of monomer particles, the chemical dimension is the particle denaturation characteristics; based on the pre-control process strategy and the physical structure, perform production line control management of the target antimicrobial coating.

[0085] The pre-control process strategy is a comprehensive production control solution obtained by optimizing various control nodes and limiting compensation in the coating production process. It not only includes the control of operating parameters such as temperature, shear rate, time, etc., but also includes compensation mechanisms for equipment errors and environmental errors to ensure that each process link is in the best state.

[0086] The phase structure refers to the physical and chemical properties of the target antibacterial coating in different states. Specifically, the phase structure of the coating includes the following two dimensions: from the physical dimension, the relative distribution structure of the particles refers to the microparticles in the antibacterial coating, especially how the antibacterial factors are distributed in the matrix. Ideally, these particles should be evenly distributed to avoid local excessive concentration or blank areas; the geometric particle size structure of the monomer particles: refers to the size, shape and distribution of individual particles in the coating at the microscopic level. For example, the antibacterial factor may be dispersed in the coating in the form of nano-scale particles, and its particle size structure directly affects its antibacterial effect and the uniformity of the coating. Under dynamic conditions, the relative distribution of particles will change during the stirring, flowing or coating process of the coating, which may cause temporary inhomogeneity; under static conditions, when the coating stops moving, the particles will gradually stabilize. This static distribution is particularly important for the uniformity of the final product.

[0087] From a chemical dimension, the particle denaturation characteristics refer to changes in the chemical properties of particles in the coating. For example, the antimicrobial factor may undergo chemical bond changes, or react with the coating matrix under certain conditions, which will change the chemical properties of the coating. The chemical dimension is not only related to the antimicrobial properties of the coating, but may also affect its durability, adhesion and other functional properties. For example, the activity of the antimicrobial factor changes with the environment, such as temperature and pH value, which may change, thus affecting the overall performance of the coating.

[0088] After determining the expected physical phase structure of the target antibacterial coating under the pre-control process strategy, production line control management can be carried out based on the characteristics of these structures to ensure that each link in the coating production process meets the expected physical phase property requirements.

[0089] The following is an example of management in the physical and chemical dimensions of production line control:

[0090] Particle distribution control: Ensure the uniform distribution of antimicrobial factors and other particles in the coating by optimizing stirring rate, flow control, temperature gradient, etc. Particle size control: Monitor the geometric particle size of particles in different process links to ensure that the particles will not be destroyed or agglomerated due to excessive shearing. The dispersion of particles can be controlled in real time through online particle size monitoring equipment.

[0091] Chemical denaturation control: Real-time monitoring of the chemical activity of key ingredients such as antimicrobial factors to ensure that they maintain their antimicrobial properties during production and storage. In this process, it may be necessary to control the pH value, redox potential, etc. of the production conditions to prevent the inactivation or denaturation of the antimicrobial factors. Chemical stability management: By regulating the environmental conditions of the coating (such as temperature and humidity), ensure that the chemical reaction can proceed as expected and prevent unexpected chemical denaturation. For example, control production in a low temperature environment to reduce the possibility of adverse reactions of antimicrobial factors at high temperatures.

[0092] By identifying pre-control process strategies and combining the dynamic and static phase structures of antimicrobial coatings, especially their physical and chemical dimensions, the production line control process can be effectively managed. This refined management not only helps to optimize the uniformity, antimicrobial effect and chemical stability of the coating, but also ensures that each link in the production process meets quality requirements through real-time monitoring and dynamic adjustment, thereby improving the overall performance and market competitiveness of the coating.

[0093] The uniformity control method for antibacterial coating production provided by the present application has the following technical effects:

[0094] 1. For the target antibacterial coating, divide the coating stage, explore and summarize the response variables and factors of the coating uniformity, build a response surface module, and the antibacterial factor has the first priority; obtain uniformity indicators, conduct bidirectional rheological characteristics analysis and thixotropic characteristics analysis under operating conditions, determine state constraints, map and limit optimization of process nodes for the production process, determine the pre-control process strategy, and implement production line control management of the target antibacterial coating. It solves the technical problems of insufficient control over the uniformity of the antibacterial coating throughout the life cycle, and limited control stability and accuracy in the existing technology. By determining the uniformity defects of the response from multiple scenarios after production, the production process of the antibacterial coating is reversely guided to ensure that the antibacterial coating meets the uniformity distribution standards throughout the life cycle.

[0095] 2. Divide the coating application into stages, locate the defects in uniformity in actual application, ensure that both the production process and the actual application process meet the uniformity standards, and improve the stability and practicality of the product.

[0096] 3. By constructing a response surface module, the rheological and thixotropic properties of the response variables and factors are analyzed to effectively locate uniformity defects and use this as a starting point for production optimization.

[0097] 4. Combine process optimization control with physical phase structure constraints to manage production line production control and ensure that the uniformity standards of production products meet expectations.

[0098] Through the above detailed description of the uniformity control method for the production of antibacterial coatings, those skilled in the art can clearly understand the uniformity control method for the production of antibacterial coatings in this embodiment, and the above description of the disclosed embodiments enables professionals in the field to implement or use the present application. Various modifications to these embodiments will be obvious to professionals in the field, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application will not be limited to the embodiments shown herein, but will conform to the widest range consistent with the principles and novel features disclosed herein.

Claims

1. A uniformity control method for antimicrobial coating production, characterized in that: The method comprises: For the target antibacterial coating, the coating stage is divided, wherein the coating stage includes a static stage, a load stage, and a recovery stage; Traversing the coating stage, mining and summarizing the response variables and factors of coating uniformity, and constructing a response surface module, wherein the antibacterial factor has the first priority; Obtaining uniformity indexes, and performing bidirectional rheological characteristic analysis and thixotropic characteristic analysis under operating conditions in combination with the response surface module to determine state constraint conditions; Interacting with the production process flow of the target antibacterial coating, mapping and limiting optimization of process nodes based on the state constraints, and determining a pre-control process strategy; Based on the pre-control process strategy, executing production line control management of the target antimicrobial coating; The construction of the response surface module comprises: Retrieving the test records and application records of the target antimicrobial coating and determining the sample records; Traversing the coating stages, setting response nodes, wherein each coating stage corresponds to at least one response node; Identify the response node, regularize the sample records based on the response variables and factors, and supervise the training of the response surface module; The determining state constraint condition comprises: Setting response time and space conditions, wherein the response time and space conditions are used to perform analysis period constraints; Based on the dynamic element relationship and the response time and space conditions, guided by the state uniformity, the coating stage is traversed to perform forward stage deduction and reverse recursive positioning to determine the state constraint conditions, which cover the uniformity index defects; The step of determining the pre-control process strategy comprises: Identify uniformity index defects, map the production process flow based on process relevance, and determine N groups of process nodes, wherein the N groups of process nodes correspond to the state constraint conditions one by one, and each group of process nodes includes at least one process node; Based on the state constraints, production limitation and process optimization are performed on the N groups of process nodes to determine the pre-control process strategy.

2. The uniformity control method for antibacterial coating production according to claim 1, characterized in that: Before conducting bidirectional rheological and thixotropic properties analysis, the following should be included: Determining phase factors based on operating conditions, wherein the phase factors are common factors; Determine dynamic element relationships for the phased elements; Taking the dynamic element relationship as a constraint, bidirectional rheological analysis and thixotropic analysis are performed.

3. The uniformity control method for antibacterial coating production according to claim 1, characterized in that: Performing production limitation and process optimization on the N groups of process nodes, including: Identify the first state constraint condition, perform production parameter control limit on a group of process nodes, and determine the first limit constraint; determining whether the first limit constraint satisfies a first uniformity index defect; If not, the process is optimized for the group of process nodes based on the first limit constraint as a baseline to determine a first control node strategy.

4. The uniformity control method for antibacterial coating production according to claim 1, characterized in that: The method further comprises: Introducing production line equipment errors and environmental errors to perform node strategy compensation on the pre-control process strategy; Set the collision avoidance principle for production control based on factor priorities.

5. The uniformity control method for antibacterial coating production according to claim 1, characterized in that: The execution of the production line control management of the target antimicrobial coating includes: Identify the pre-control process strategy, determine the physical structure of the target antibacterial coating under dynamic and static conditions, the physical structure includes physical dimensions and chemical dimensions, the physical dimension is the relative distribution structure of particles and the geometric size structure of monomer particles, and the chemical dimension is the particle denaturation characteristics; Based on the pre-control process strategy and the physical phase structure, production line control and management of the target antibacterial coating are performed.

Images