Coating Additive Analysis via Automated Bubble Break Rate Imaging
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Solution Overview
Problem
Current methods for assessing foam control agents in coatings are subjective and lack accuracy, particularly in evaluating bubble break rates, which are crucial for determining foam control efficiency and compatibility, leading to difficulties in differentiating between sample coating candidates.
Innovation Solution
A product testing apparatus equipped with a microscopic imaging device and data processing system that captures images of substrate coatings, filters lighting variations, identifies objects of interest, and quantifies their properties, generating signals indicative of their performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional visual observation methods are used to assess bubble break rates, then the assessment process is simple and quick, but the accuracy and repeatability of the measurements are poor due to subjective evaluation
Solution Approach 1:
The patent replaces the manual visual observation system with an automated image processing system. A microscope captures images of foam bubbles, and computer algorithms automatically analyze bubble break rates, eliminating subjective human evaluation and significantly improving measurement accuracy and repeatability.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the bubble break phenomenon and the measurement result. The algorithm processes microscope images to automatically detect, track, and quantify bubble break rates, providing objective and repeatable measurements without direct human intervention.
2Measurement precision
If arbitrary ranking systems are used to differentiate sample coating candidates, then the assessment method is simple to implement, but the ability to differentiate between samples is weak and results are difficult to compare
Solution Approach 1:
The patent replaces arbitrary subjective ranking systems with quantitative image analysis. The system automatically measures bubble break rates, bubble size distributions, and foam coverage percentages, providing objective numerical data that enables precise differentiation and comparison between sample coating candidates.
Solution Approach 2:
The patent transforms qualitative foam assessment into quantitative measurements by analyzing multiple parameters including bubble break rate (percentage of bubbles broken over time), bubble size distribution, and foam coverage percentage. These measurable parameters provide precise differentiation between samples.
3Reliability
If foam knockdown tests in surfactant solutions are used to evaluate foam control agents, then the test procedure is standardized and reproducible, but the results are not representative of actual paint system performance
Solution Approach 1:
The patent adapts the assessment system to evaluate foam control specifically within paint systems rather than using generic surfactant solutions. By imaging and analyzing bubbles in actual coating applications, the system provides locally relevant performance data that reflects real-world paint system behavior while maintaining standardized image capture and analysis procedures.
Data Source
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AI summary
A product testing apparatus is described as having one or more imager configured to capture one or more images of a sample having a substrate coating applied to a substrate, a processor in communication with the one or more imager, and a non-transitory processor readable medium, in communication with the processor, The non-transitory processor readable medium stores processor executable instructions that when executed cause the processor to receive the one or more images from the one or more imager. The processor then processes the one or more image by filtering lighting variations in the pixels of the image to identify one or more objects of interest in the one or more image of the cured / uncured substrate coating. The processor quantifies one or more property of the one or more objects of interest. The processor executable instructions then cause the processor to generate one or more signal indicative of the quantification of the one or more objects of interest.