Buff-coated article with variably partially cured tie layer
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Solution Overview
Problem
Existing buff-coating methods are limited by the material nature of the powder and substrate, resulting in inconsistent and slower deposition of powders onto various substrates, lacking uniformity and efficiency.
Innovation Solution
A method involving a variably partially cured tie coat is used to control the deposition of a buff-coat by applying a tie layer on the substrate and then buff-coating a powder onto it, allowing for tunable and improved adhesion and uniformity across a wide range of substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional buff-coating methods are used, then powder can be deposited onto substrate, but the deposition amount is limited by material nature and lacks uniformity
Solution Approach 1:
The patent introduces a tie layer as an intermediary substance between the substrate and the buff-coat powder. This tie layer, composed of curable material, mediates the interaction between substrate and powder, enabling controlled adhesion and uniform deposition across diverse substrate types without being limited by material compatibility issues
Solution Approach 2:
The patent utilizes partial curing of the tie layer as a controllable parameter to optimize powder deposition. By controlling the degree of curing (partially cured rather than fully cured), the tie layer maintains appropriate tackiness and surface properties that enable uniform powder adhesion while allowing adjustment for different substrate and powder combinations
2Quantity of substance
If maximum powder deposition is achieved, then coating coverage is improved, but manufacturing speed is reduced
Solution Approach 1:
The patent applies the tie layer to the substrate before buff-coating the powder. This preliminary action prepares the surface with controlled adhesion properties, allowing faster buff-coating operations to achieve maximum powder deposition without the trade-off that plagues traditional methods where higher deposition required slower processing
3Device complexity
If buff-coating is performed without tie layer, then process is simpler, but control over deposition amount is limited
Solution Approach 1:
The patent controls the degree of curing of the tie layer as a key parameter to optimize powder deposition. By adjusting curing conditions (partial vs. full curing), the process achieves precise control over how much powder adheres to the substrate, providing tunable deposition control while maintaining a relatively simple overall process structure
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 approach enables increased control over the amount of powder deposition, resulting in faster and more uniform buff-coat formation on various substrates without the need for binders, enhancing the manufacturing speed and quality of the coating process.
Implementation Method 1
a tie layer disposed on at least a portion of the major surface
Implementation Method 2
buff-coating means frictionally contacting a powder with a surface of a substrate under buffing conditions such that some of the powder adheres to the surface of the substrate
Data Source
AI summary
A method of making a buff-coated article includes disposing a tie layer on at least a portion of a major surface of a substrate and buff-coating a powder onto at least a portion of the tie layer. Buff-coated articles are also disclosed.