Angle Grind Coating Apparatus for Hard Substrates
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Solution Overview
Problem
Existing thermal spray coating techniques are costly, have low adhesion strength on small or curved substrates, and are not suitable for coating hard materials like glass, requiring a more cost-effective and technically viable method for surface preparation and coating.
Innovation Solution
The angle grind coating apparatus uses a workpiece holder with a tensioned spring and a grinding wheel mounted perpendicular to the tool material, rotated by an angle grinder to generate a stream of swarf particles that are deposited onto a target surface, allowing for efficient coating on metal, polymer, and ceramic substrates with adjustable parameters for varying substrate types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal spray coating technique is used, then coating can be applied onto substrate, but equipment cost is high and adhesion strength is low on small substrates
Solution Approach 1:
The invention extracts the essential coating function from complex thermal spray equipment by using a simple angle grinder with a grinding wheel to generate coating material. The angle grinder is a common, inexpensive tool that can be easily replaced or adjusted, eliminating the need for expensive specialized thermal spray guns while maintaining coating capability.
Solution Approach 2:
The invention uses disposable or easily replaceable grinding wheels as the coating source. Instead of requiring expensive, specialized thermal spray equipment, the grinding wheel can be replaced when worn, providing a cost-effective solution that maintains coating functionality without the high equipment costs and complexity of thermal spray systems.
2Adaptability or versatility
If thermal spray method is used, then coating can be applied, but it is not suitable for hard substrates like glass
Solution Approach 1:
The invention changes the fundamental parameters of the coating process by using mechanical grinding instead of thermal spraying. The angle grinder generates coating material through mechanical abrasion and heat generation during grinding, creating a different physical state and delivery mechanism that is effective on hard substrates like glass, whereas thermal spray fails on such materials.
3Ease of manufacture
If traditional thermal spray equipment is used, then coating can be applied, but the setup is expensive and not cost-effective
Solution Approach 1:
The invention extracts the coating function from expensive thermal spray equipment and implements it using a common angle grinder. The angle grinder is a widely available, inexpensive tool that can be easily replaced, eliminating the need for costly specialized equipment while maintaining the ability to apply coatings effectively.
Solution Approach 2:
The invention replaces expensive, complex thermal spray equipment with inexpensive, easily replaceable grinding wheels. The grinding wheels are cheap and can be replaced when worn, providing a cost-effective solution that eliminates the high equipment costs and complexity associated with thermal spray systems.
4Strength
If thermal spray technique is used, then coating can be applied, but adhesion strength is low on substrates of small curvature
Solution Approach 1:
The invention uses the dynamic rotation of the angle grinder wheel to generate coating material that can adapt to various substrate geometries. The rotational motion creates a consistent coating delivery mechanism that works effectively on small substrates and curved surfaces, improving adhesion strength compared to static thermal spray methods.
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 method provides a cost-effective and versatile coating solution with improved adhesion strength, suitable for hard materials like glass, and allows for coating on contoured surfaces with high precision and portability, using a compact and lightweight setup.
Implementation Method 1
The workpiece holder has a tensioned spring to apply an upward thrust force to the tool material
Implementation Method 2
rotation of the grinding wheel generates a stream of swarf particles from the tool material
Implementation Method 3
an angle grinder to enable rotation of the grinding wheel over the tool material at a predefined Rotations Per Minute (RPM)
Implementation Method 4
The stream of swarf particles is deposited over a target surface fixed at a pre-set standoff distance from the angle grind coating apparatus
Data Source
AI summary
An angle grind coating apparatus and method for providing a coating onto materials is described. The angle grind coating apparatus comprising workpiece holder (102) assembled for holding tool material (104) and is assembled over base (106) provided over a fixture (108). The workpiece holder (102) has a spring assembly (110) to apply an upward thrust force to the tool material (104) and a grinding wheel (114) is mounted perpendicular to the workpiece holder (102) to enable grinding of the tool material (104) fixed in front and just below the grinding wheel (114) to align the fixture (108) with the grinding wheel (114). The angle grind coating apparatus comprises an angle grinder (116) to enable rotation of the grinding wheel (114) over the tool material (104) at a predefined Rotations Per Minute (RPM), such that rotation of the grinding wheel (114) generates a stream of swarf particles (118) from the workpiece/tool material 104 and are deposited over a target surface fixed (120) at a pre-set standoff distance from the angle grind coating apparatus.