Coating Color Adjustment With Batch-Aware Optical Data
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Solution Overview
Problem
Existing color adjustment methods in paint production are inaccurate due to variations in colorant strength characteristics of colorants from batch to batch, leading to inefficiencies in achieving a sufficient color match between sample and reference coatings.
Innovation Solution
A computer-implemented method that adapts optical data of individual color components in the sample coating formulation to minimize model bias caused by colorant strength variations, using a physical model and numerical optimization algorithms to calculate an adjusted sample coating formulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional color adjustment methods using fixed optical data are used, then the process is simple, but the color match accuracy deteriorates due to colorant strength variations between batches
Solution Approach 1:
The patent applies preliminary action by adapting the optical data of colorants before the actual color adjustment process. The system pre-processes the optical constants (K/S values) of individual color components based on measured color data from reference coatings, creating corrected optical data that accounts for batch-to-batch variations. This preliminary adaptation of optical parameters enables more accurate color predictions in subsequent adjustment steps, resolving the contradiction between accuracy and complexity by preparing the system in advance rather than during the adjustment process itself.
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting the optical constants (K/S values) of colorants based on measured color data. Instead of using fixed, manufacturer-provided optical data, the system modifies these parameters to reflect actual batch characteristics. The optical data adaptation process changes the absorption and scattering coefficients of individual color components, allowing the color prediction model to compensate for variations in colorant strength, thereby improving color match accuracy while maintaining a systematic approach to the adjustment process.
2Reliability
If reduced amounts of pigment pastes are used in initial coating formulation, then the risk of overshooting color is reduced, but the residual color difference increases requiring more adjustment steps
Solution Approach 1:
The patent applies feedback by measuring the actual color of reference coatings and using this measured data to adapt the optical parameters of colorants. The system creates a feedback loop where measured color values (reflectance spectra) are compared with predicted values, and the optical data is adjusted accordingly. This feedback mechanism allows the system to learn from actual batch performance and compensate for deviations, enabling more accurate color predictions that reduce the need for multiple adjustment iterations while maintaining reliable color matching.
Solution Approach 2:
The patent uses preliminary action by pre-adapting optical data for each color component before formulating the coating. The system calculates corrected K/S values for individual colorants based on reference coating measurements, then uses these adapted parameters to determine the initial pigment paste quantities. This preliminary optimization of optical parameters enables more accurate initial formulation calculations, reducing residual color differences and minimizing the number of adjustment steps required, thereby improving productivity without sacrificing reliability.
3Manufacturing precision
If batch-to-batch variations in colorant strength are not compensated, then the process is straightforward, but the color match quality deteriorates
Solution Approach 1:
The patent applies segmentation by treating the colorant system as composed of individual color components rather than as a bulk pigment paste. The system separates the total color effect into contributions from individual colorants, each with its own adapted optical parameters (K/S values). This segmentation allows the system to independently adjust the optical data for each color component based on its specific batch characteristics, enabling precise compensation for colorant strength variations. By working with individual color components rather than bulk materials, the system achieves higher color match quality while managing complexity through a systematic, component-level approach.
Data Source
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AI summary
Aspects described herein generally relate to methods and systems for matching the color of a sample coating to the color of a reference coating. More specifically, aspects described herein relate to methods and systems for determining an adapted modified sample coating formulation which, when applied onto a substrate, sufficiently matches the color of a reference coating by determining adjusted optical data for each individual color component present within the sample coating formulation and using said adjusted optical data to determine the modified sample coating formulation. Use of the adjusted optical data for each individual color component present within the sample coating formulation within the color adjustment process allows to compensate variations of colorant strength characteristics of colorants in paint production. The adjustment of said optical data allows to improve the quality and/or accuracy of the modified sample coating formulation, thus reducing the number of modification steps necessary to obtain the desired color of the sample coating in relation to the reference coating.