Coating Three-Dimensional Structural Strands in Fluidized Beds
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Solution Overview
Problem
Existing methods for coating three-dimensional structural strands composed of different materials with varying structures are inadequate for achieving comprehensive, high-quality, and long-term stable coatings.
Innovation Solution
A method involving guiding the strand through a fluidized bed chamber or powder cloud, where swirled powder particles react chemically and physically with the strand and structural bodies, allowing for bonding and application of coatings to either the structural bodies, the basic strand, or both, using a cord or tube with structural bodies threaded onto it, and incorporating pretreatment and post-treatment processes to stabilize the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used on three-dimensional structural strands with different materials, then the coating process is simple, but the coating quality is poor and not comprehensive
Solution Approach 1:
The coating process is divided into multiple sequential stages: pretreatment stage (cleaning, priming), fluidized bed coating stage (powder application), and post-treatment stage (curing, stabilization). This segmentation allows each stage to optimize for its specific function, achieving comprehensive coating quality on complex three-dimensional structures with different materials.
Solution Approach 2:
A primer layer is introduced as an intermediary between the base strand/structural bodies and the coating powder particles. The primer enhances adhesion between dissimilar materials and the coating, enabling comprehensive and stable coating on strands with different base materials and surface properties.
2Reliability
If coating is applied to all surfaces of the strand, then comprehensive coverage is achieved, but coating stability on different materials is poor
Solution Approach 1:
The strand structure is designed with a base strand and separate structural bodies that can be selectively coated. The coating process allows different coating materials, thicknesses, and treatment conditions to be applied to different components based on their specific material properties and functional requirements, achieving both comprehensive coverage and material-appropriate coating stability.
Solution Approach 2:
Different physical and chemical parameters (temperature, humidity, coating material composition, fluidization intensity) are optimized for different material types within the strand. This allows each material component to receive coating conditions tailored to its specific properties, ensuring both comprehensive coverage and optimal stability for each material type.
3Manufacturing precision
If fluidized bed coating is used, then coating adherence improves, but process complexity increases
Solution Approach 1:
Pretreatment steps (cleaning, priming, surface preparation) are performed before the fluidized bed coating process to ensure optimal surface conditions. This preliminary action enhances coating adherence by preparing the surface to better receive and bond with the coating powder, reducing the complexity demands on the fluidized bed process itself.
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 the application of a wide variety of coatings to enhance the refinement and functionalization of the structural strand, resulting in a stable and long-lasting coating on three-dimensional strands with diverse components.
Implementation Method 1
the strand is guided through a fluidized bed chamber or a powder cloud in which swirled powder particles of at least one coating material are applied to the strand and adhere to it
Implementation Method 2
the powder particles in the fluidized bed chamber or the powder cloud react chemically and/or physically with the main strand and/or the structural bodies
Implementation Method 3
the powder particles in the fluidized bed chamber or the powder cloud react chemically and/or physically with the main strand and/or the structural bodies
Implementation Method 4
are thermally bound in or to the surface of the structural bodies and/or the primer
Data Source
Figure 1~2
Figure 3~7
AI summary
The present invention relates to a method for forming a three-dimensional strand, wherein the strand is guided through a fluidized bed chamber or a powder cloud in which swirled powder particles of at least one coating material are applied to the strand and adhere to it, forming a coating.According to the invention, the method uses a structural strand comprising spaced-apart structural bodies arranged on or in a base strand, which is a cord or a tube with structural bodies threaded onto it and/or inserted therein, wherein the base strand and the structural bodies are made of different materials, the powder particles in the fluidized bed chamber react chemically with the base strand and/or the structural bodies and/or with a primer applied to the base strand and/or the structural bodies and/or are thermally bound in or to the surface of the structural bodies and/or the primer.