Coating Quality Assessment via Indirect Light Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for evaluating the quality of coatings on components, particularly at cutting edges and recesses, are unreliable and costly, often resulting in component destruction during testing and high waste rates due to the inability to systematically assess coating defects without direct light irradiation, which can lead to moisture infiltration and damage to electronic components.
Innovation Solution
A device comprising a light source, cover, and light sensors that indirectly couple light into the component material to assess coating quality by detecting light passing through the surface, allowing for 100% inspection without destruction and enabling the detection of defects such as voids or thin coatings, with optional features like rotatable sensors and different light colors for comprehensive evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct light irradiation is used to evaluate coating quality, then the detection of coating defects is improved, but the component surface is damaged and the testing method becomes destructive
Solution Approach 1:
The patent introduces an intermediary substance (gloss agent or scattering agent) applied to the component surface that mediates between the light source and the coating being tested. This intermediary layer allows light to pass through without directly irradiating or damaging the coating, while still enabling defect detection through changes in light transmission properties. The intermediary substance acts as a protective barrier that prevents direct light damage to the coating.
Solution Approach 2:
The patent replaces direct mechanical/optical irradiation systems with a indirect light transmission measurement system. Instead of using strong direct light that damages the coating, the system uses light transmission through the coating measured from the opposite side, substituting the direct irradiation mechanism with a non-contact transmission measurement approach that preserves component integrity.
2Measurement precision
If random optical tests are performed on individual components, then coating defects can be detected, but the testing process is time-consuming and cannot be systematically applied
Solution Approach 1:
The patent creates a universal testing apparatus that can systematically evaluate coating quality on multiple components. The device incorporates adjustable light sources, movable detectors, and control systems that enable automated scanning across different component surfaces. This universal system replaces manual random testing with an automated multi-functional tester that can process multiple components through standardized procedures, significantly increasing throughput while maintaining detection precision.
3Measurement precision
If components are placed in solvents to check coating completeness, then coating defects are revealed, but the tested components are destroyed and cannot be repaired or reused
Solution Approach 1:
The patent replaces the chemical solvent testing method with an optical measurement system. Instead of using solvents that chemically attack and destroy the coating to reveal defects, the system uses light transmission measurements through the coating. This substitution eliminates the destructive chemical process while maintaining the ability to detect coating completeness and defects, allowing components to be preserved and reused.
Solution Approach 2:
The patent introduces light as an intermediary measurement medium instead of using solvents. The light transmission through the coating serves as a non-destructive intermediary that reveals coating defects without chemically attacking the component. This intermediary approach allows defect detection while preserving the component for potential repair or reuse, eliminating the waste associated with solvent-based testing.
4Reliability
If the coating is applied to cutting edges after recesses are made, then the entire surface is protected, but the amount of primer and varnish applied cannot be controlled
Solution Approach 1:
The patent incorporates feedback mechanisms in the form of light transmission measurement systems that monitor coating thickness and uniformity in real-time during the coating application process. The system provides feedback signals to the coating application equipment, allowing for automatic adjustment of coating thickness and distribution. This feedback loop ensures consistent coating thickness control while maintaining comprehensive surface protection of cutting edges.
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
Enables reliable, non-destructive, and cost-effective evaluation of coating quality across entire components, allowing for the identification and correction of systematic defects in the production process, thereby preventing moisture infiltration and extending component lifespan.
Implementation Method 1
the light can be coupled into the material and can only pass to the surface forming the peripheral edge indirectly through the interior of the material of the component
Implementation Method 2
a quality of the coating can be evaluated by detecting the light passing through the coating of the surface
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a device (10) for evaluating the quality of a coating (12) on at least one surface (14) of a component (16), wherein the surface (14) is disposed in a recess (18) and/or on an outer edge (20) of the component (16), the surface (14) forming a peripheral edge (22), and the component (16) being made at least partially of a material that is at least semi-transparent, in particular transparent. It is proposed that at least one light source (24) and at least one shield (38) are constructed such that the component (16) can be irradiated by the light (28) from the light source (24) and that the surface (14) can be protected by the shield (38) against direct light irradiation (26). Furthermore, the invention relates to a method for evaluating the quality of a coating (12) on a surface (14) of a component (16) with such a device.