Coating Color Matching via Spectrophotometric Layer Segmentation
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Solution Overview
Problem
Existing methods for matching and applying coatings on damaged assets face challenges due to the complexity of coating mixtures, aging of coatings, and differences in lighting conditions, leading to inaccuracies in color matching and potential mismatches upon application.
Innovation Solution
A computer-implemented method and system that utilizes a graphical user interface to retrieve spectrophotometer data from a target asset, retrieve closest match colors from a database, and display selectable color tiles with sub-component options for adjusting formulations, ensuring accurate and realistic color matches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If basic color comparison on a display screen is used, then the overall color match appears suitable, but close inspection reveals small deviations in color that may not be apparent during the coating determination process
Solution Approach 1:
The coating system is divided into multiple layers (base coat, clear coat, underbody coating) that can be individually analyzed. The spectrophotometric analysis separates the contribution of each layer to the overall color, allowing precise identification of color deviations caused by specific layers rather than treating the coating as a single homogeneous entity.
Solution Approach 2:
A computational model acts as an intermediary between the physical coating and the visual assessment. The model simulates how different layers interact with light and combines their individual color contributions to predict the overall appearance, bridging the gap between simple visual inspection and complex physical measurement.
2Reliability
If multiple layers or added ingredients are used to achieve a particular coating effect, then the desired color and texture are obtained, but the formulation complexity increases and may lead to mismatches
Solution Approach 1:
The coating formulation is segmented into distinct functional components (base coat, clear coat, underbody coating, effect pigments) that can be independently characterized and adjusted. This allows the system to identify which specific layer or ingredient is causing a color mismatch and adjust only that component rather than reformulating the entire multi-layer system.
Solution Approach 2:
The system adjusts formulation parameters (concentrations of pigments, ratios of coating layers) based on spectrophotometric data to achieve the desired color match. By changing specific parameters in the formulation rather than the entire formulation, the system maintains reliability while reducing complexity.
3Productivity
If a closest match color is selected based on display screen appearance, then the selection process is efficient, but the applied coating may have a very different appearance in person
Solution Approach 1:
The system replaces subjective visual assessment with objective spectrophotometric measurement. Instead of relying on human perception of color on display screens or paint chips, the system uses precise instrumental measurement to quantify color properties and compare them against the target coating, eliminating the discrepancy between screen appearance and actual appearance.
Solution Approach 2:
The system provides feedback by comparing the measured color properties of the target coating with the proposed match coating and identifying specific deviations. This feedback loop allows operators to adjust the formulation or selection to achieve an accurate match, rather than relying on a single visual assessment that may be misleading.
4Adaptability or versatility
If effect pigments such as flake, metallic, or gonioapparent pigments are added to the formulation, then the coating provides enhanced visual effects, but the overall color effect varies significantly in certain lighting conditions
Solution Approach 1:
The system performs preliminary spectrophotometric measurement of the target coating under controlled lighting conditions before formulation matching. This preliminary characterization captures the specific optical properties of effect pigments in the target coating, providing a reference standard that guides the formulation of the match coating to achieve similar lighting-dependent effects.
Solution Approach 2:
The system adjusts formulation parameters related to effect pigments (type, concentration, orientation) to match the optical properties of the target coating. By precisely controlling these parameters based on spectrophotometric data, the system achieves consistent visual effects across different lighting conditions rather than relying on trial and error.
Data Source
AI summary
A computer-implemented method can include providing via a digital display a graphical user interface including one or more selectable elements for retrieving spectrophotometer data measured from a target asset. The method also includes receiving spectrophotometer data from an end user of the graphical user interface, and retrieving from a database a plurality of closest match colors corresponding to the spectrophotometer data. In addition, the method can include displaying a plurality of selectable color tiles corresponding to the retrieved closest match colors, and further displaying an image for each of one or more selectable sub-component options corresponding to one or more alternate formulas for at least one of the selectable color tiles. The method further includes displaying both the adjusted formula and related sub-components corresponding to the user modifications, as well as options to select the color as a coating for eventual application.