Checkered Steel Sheet Coating for Uniform Rust Protection
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Solution Overview
Problem
Checkered steel sheets experience primary rust prevention defects due to large thickness unevenness in chemical treatment coating film layers between convex and flat parts, which is exacerbated by the uneven nature of the surface.
Innovation Solution
A coated checkered steel sheet with a zinc-based alloy layer and a chemical treatment coating film layer, where the coating thickness on flat parts is between 0.10 to 5.00 μm, and the thickness ratio between flat and convex parts is controlled between 0.2 to 5.0, ensuring uniform coating distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical treatment coating film layer is formed on checkered steel sheets to prevent primary rust prevention defects, then corrosion resistance is improved, but large thickness unevenness occurs between convex parts and flat parts
Solution Approach 1:
The patent applies different coating thicknesses to different regions of the checkered steel sheet surface. The convex parts receive a thicker coating (0.5-5.0 μm) compared to flat parts (0.1-2.0 μm), optimizing corrosion protection where needed while maintaining overall coating quality. This local differentiation resolves the contradiction by tailoring coating properties to specific surface regions.
Solution Approach 2:
The patent controls specific coating thickness parameters: flat part coating thickness of 0.1-2.0 μm, convex part coating thickness of 0.5-5.0 μm, and a thickness ratio between 0.2-5.0. By precisely managing these parameters, the invention achieves both adequate corrosion resistance and acceptable coating uniformity across the uneven surface.
2Manufacturing precision
If the coating thickness on flat parts is increased to improve uniformity, then coating thickness ratio improves, but coating material consumption increases
Solution Approach 1:
Instead of uniformly increasing coating thickness across the entire surface, the patent applies coating selectively: flat parts receive 0.1-2.0 μm while convex parts receive 0.5-5.0 μm. This local quality approach maintains acceptable thickness ratios while minimizing overall material consumption compared to a uniform thick coating.
Solution Approach 2:
The patent applies coating in varying degrees to different regions - sufficient thickness on convex parts for corrosion protection, and controlled thickness on flat parts to maintain ratio. This partial differentiation avoids the excessive material consumption that would result from uniformly thick coating across the entire surface.
Data Source
AI summary
A coated checkered steel sheet including: a substrate checkered steel sheet having convex parts with a height of 3.0 mm or less and flat parts on one sheet surface; a coating layer that includes a zinc-based alloy layer that is arranged on the sheet surface of the substrate checkered steel sheet having the convex parts and the flat parts; and a chemical treatment coating film layer provided on a surface of the coating layer; in which a coating thickness of the chemical treatment coating film layer on the flat parts of the substrate checkered steel sheet is from 0.10 to 5.00 μm on one surface, and a coating thickness ratio of the chemical treatment coating film layer between the flat parts and the convex parts of the substrate checkered steel sheet (thickness of the chemical treatment coating film layer on the flat parts/thickness of the chemical treatment coating film layer on the convex parts) is from 0.2 to 5.0.