Adhesive-Free Flocking Powder Coating for Anti-Rust Surfaces
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Solution Overview
Problem
Existing flocking methods require the use of adhesives, which increase processing time, manufacturing costs, and environmental burden, and are inefficient in recycling and achieving desired properties like anti-rust and sound attenuation.
Innovation Solution
A flocking powder coated article that uses a powder coating material with thermosetting or thermoplastic resin, where flocking organic fillers are embedded and project from the coating film, eliminating the need for adhesives and allowing for improved anti-rust and sound attenuation properties without organic solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive-coating procedure is used to adhere short fibers, then flocking state can be achieved, but number of procedures increases and processing time is extended
Solution Approach 1:
The patent combines the adhesive-coating function and the coating film formation into a single powder coating material. The powder coating material contains both the resin that forms the coating film and the adhesive function to hold the flocking organic filler, eliminating the need for a separate adhesive-coating procedure.
Solution Approach 2:
The powder coating material serves multiple functions: it forms the protective coating film, provides anti-rust properties, and acts as the adhesive to fix the flocking organic filler. This multi-functional material replaces the traditional separate adhesive coating, reducing the number of procedures.
2Reliability
If adhesive is used in liquid form to fix flocking organic filler, then adhesion is achieved, but recycling of falling short fibers becomes difficult
Solution Approach 1:
The patent changes the physical state of the adhesive from liquid to powder form. The powder coating material is applied and then cured to form a solid coating film that firmly holds the flocking organic filler. This solid state makes it easier to recycle falling short fibers compared to liquid adhesive.
3Reliability
If traditional coating and adhesive-coating procedures are used, then anti-rust property and flocking state are achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the anti-rust coating function and the flocking adhesive function into a single powder coating material. This eliminates the need for separate adhesive-coating procedures and reduces the number of drying steps, thereby lowering manufacturing costs while maintaining anti-rust properties.
4Reliability
If many adhesives containing organic solvents are used, then adhesion is achieved, but environmental burden increases
Solution Approach 1:
The patent changes the adhesive from liquid form containing organic solvents to a powder form. The powder coating material is cured to form a solid coating film that provides adhesion without requiring organic solvents, thereby reducing environmental burden.
Solution Approach 2:
The patent eliminates the harmful organic solvents from the adhesive by using a powder coating material that cures to form the adhesive bonding. This converts the harmful liquid adhesive into a beneficial solid coating that provides both protection and adhesion without environmental harm.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces processing time and costs, enhances anti-rust and sound attenuation properties, and facilitates easier recycling and adjustment of coating thickness, while minimizing environmental impact.
Implementation Method 1
the powder coating material is made to exert the function of an adhesive
Implementation Method 2
By curing the thermosetting resin contained in the powder coating material or solidifying the thermoplastic resin contained in the powder coating material, a coating film is formed
Implementation Method 3
By curing the thermosetting resin contained in the powder coating material or solidifying the thermoplastic resin contained in the powder coating material
Implementation Method 4
In the electrostatic flocking method, by making the short fibers flying due to electrostatic force stuck into and adhered to the adhesive-coated surface
Data Source
AI summary
This flocking powder coated article comprises a base material (10) and a flocking coating layer (11). The flocking coating layer (11) includes: a coating film (110) constituted by a powder coating, and a portion of a flocking organic filler (13) buried in the powder coating; and a flocking layer (111) constituted by another portion of the flocking organic filler (13) projecting from the coating film (110). This flocking powder coated article does not have an adhesive layer for fixing the flocking organic filler (13).