Board Coating Method for Concrete Molds Using High-Pressure Air Drying
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Solution Overview
Problem
Existing coating methods for boards used in concrete product production are inefficient, leading to surface corrosion, high defective rates, and environmental pollution, as they require frequent application of oil-based coatings that are costly, difficult to dispose of, and do not provide long-lasting protection against corrosion and abrasion.
Innovation Solution
A coating method involving the removal of residues from the board surface using high-pressure air, followed by spraying and rapid drying of a bisphenol A epoxy resin or phenoxy resin-based coating liquid, which is applied in a manufacturing or transfer process to ensure a durable, corrosion-resistant layer that maintains vibration transmission and separability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an oil coating agent is applied to the board surface, then corrosion resistance is improved, but the coating must be applied daily which increases time consumption and labor cost
Solution Approach 1:
The patent changes the chemical composition parameters of the coating agent from conventional oil-based to a specific formulation containing 5-20 parts anti-rust agent, 75-90 parts kerosene, and 5-20 parts solvent. This parameter optimization enables the coating to achieve long-lasting corrosion protection without requiring daily reapplication, thus resolving the contradiction between reliability and time consumption
Solution Approach 2:
Instead of using expensive stainless steel boards that are durable but costly, the patent applies a cheap coating formulation to ordinary steel boards. This approach provides effective corrosion protection at low cost, replacing the need for expensive long-lasting materials while avoiding the time-consuming maintenance of conventional coatings
2Reliability
If an oil coating agent is applied to the board surface, then corrosion protection is achieved, but the coating liquid spreads in air causing environmental pollution and health hazards
Solution Approach 1:
The patent introduces a spray device as an intermediary tool to apply the coating liquid uniformly and controllably onto the board surface. This intermediary mechanism prevents the coating liquid from spreading uncontrollably in the air, thereby eliminating environmental pollution and health hazards while maintaining effective corrosion protection
Solution Approach 2:
The patent converts the potentially harmful property of the coating liquid (its tendency to spread in air) into a benefit by using the spray device to distribute it uniformly as a fine mist. This controlled dispersion ensures complete coverage of the board surface for effective protection while preventing uncontrolled spreading that causes pollution
3Ease of operation
If a Teflon coating layer is formed on the molding apparatus, then demoulding is facilitated, but vibration transmission to concrete is reduced
Solution Approach 1:
The patent applies local quality by coating only the specific areas of the board that contact concrete, rather than forming a complete Teflon layer. This localized coating provides sufficient demoulding facilitation at contact points while preserving the board's overall vibration transmission capability, resolving the contradiction between ease of operation and force transmission
4Ease of manufacture
If ordinary steel is used for the board, then cost is reduced and workability is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent creates a composite protection system by combining ordinary steel board with a specially formulated coating layer. The ordinary steel provides excellent workability and structural strength, while the coating layer (comprising anti-rust agent, kerosene, and solvent) provides corrosion resistance. This composite approach resolves the contradiction between ease of manufacture and reliability
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
The method provides a long-lasting, corrosion-resistant coating that reduces defective rates and production costs while minimizing environmental pollution, allowing for rapid coating and improved durability of both the board and concrete products.
Implementation Method 1
removing residues existing on an outer surface of the board by blowing high-pressure air to an upper surface and a lower surface of the board
Implementation Method 2
drying the coating liquid by blowing high-pressure air to the outer surface of the board
Data Source
AI summary
A coating method of a board for producing a concrete product and a board coated by the same are proposed. The coating method is advantageous in that the whole surface of a board can be rapidly coated and dried to prevent surface corrosion of the board and to prevent further corrosion on a damaged surface of the board, thus improving the durability of the board and the quality of the produced concrete products. The coating method includes: removing residues existing on an outer surface of the board by blowing high-pressure air to an upper surface and a lower surface of the board for producing a concrete product; coating by spraying coating liquid to the outer surface of the board from which the residues have been removed; and drying the coating liquid by blowing high-pressure air to the outer surface of the board.