Coating Cross Bar Structure for Drainage and Electrical Contact
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Solution Overview
Problem
Current cross bars for powder coating and e-coating are not versatile, as traditional powder coating cross bars are not suited for e-coating due to inadequate drainage and excess paint buildup, while e-coating bars are open, leading to inefficient electrical connections and increased manufacturing complexity.
Innovation Solution
A cross bar design featuring multiple sets of drain holes and embosses for accommodating hangers, allowing for effective drainage and cleaning, suitable for both powder coating and e-coating processes, formed by punching or cutting in sheet metal and folded for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional powder coating cross bars are used for e-coating, then manufacturing complexity is reduced, but drainage is inadequate and excess liquid builds up
Solution Approach 1:
The cross bar is segmented with multiple drain holes distributed across its structure, including in the horizontal bar and vertical arms. This segmentation of drainage function allows liquid to exit at multiple locations simultaneously, solving the drainage inadequacy while keeping the overall cross bar structure simple and manufacturable.
Solution Approach 2:
The cross bar design achieves universality by incorporating features suitable for both powder coating and e-coating processes. The solid structure with strategic drain holes allows it to function effectively in liquid e-coating environments while maintaining the electrical connectivity needed for powder coating applications.
2Ease of operation
If e-coating cross bars are used for powder coating, then drainage is improved, but electrical connection effectiveness decreases due to open structure
Solution Approach 1:
The cross bar applies local quality by having different properties in different regions: the horizontal bar contains drain holes for liquid evacuation, while the vertical arms maintain solid construction for reliable electrical connection to hangers. This localized differentiation allows the single component to satisfy both drainage and electrical conductivity requirements.
3Manufacturing precision
If cross bar is dipped in e-coating liquid, then complete coating coverage is achieved, but excess liquid adheres to cross bar and hangers requiring cleaning
Solution Approach 1:
The drain holes extract excess liquid from the cross bar structure during and after the e-coating dip process. By providing dedicated exit paths for liquid through the horizontal bar and vertical arms, the design removes excess coating material before it can adhere to the cross bar and hangers, minimizing cleaning requirements while maintaining complete part coverage.
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
The cross bar design enables efficient use in both coating processes by facilitating drainage and cleaning, reducing manufacturing complexity and the need for multiple parts, while maintaining effective electrical connections and coating quality.
Implementation Method 1
An opposite electrical charge is provided to and passed through the cross bar and the part(s) hung therefrom. The cross bar and associated parts are passed through the powder, and due to the opposite electrical forces, the powder adheres to the part(s).
Implementation Method 2
The cross bar may comprise a number of drain holes. The drain holes may be configured to permit the draining of liquid used in e-coating
Data Source
AI summary
A cross bar for powder coating and electronic coating, and methods for forming the same. A connector extends between a front portion and a rear portion. Embosses are located in the front and rear portions to connect with each other. Drain holes are provided at spaced intervals along the front and rear portions, offset from one another.