Epoxy Powder Coating for Coil Ends With Stable Flow and Uniform Coverage
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Solution Overview
Problem
Existing powder coating materials for coil ends lack sufficient storage stability, leading to issues such as uneven coating and voids during application.
Innovation Solution
A powder coating material comprising a particulate thermosetting resin composition with specific particle size and flow rate characteristics, including an epoxy resin, curing agent, and inorganic filler, is used to coat coil ends by immersing them in a fluidized chamber and adhering the melt to exposed portions, ensuring stable flow and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing powder coating materials are used for coil ends, then coating application is possible, but storage stability is insufficient leading to uneven coating and voids
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution of the thermosetting resin composition (d50: 40-80 μm, d90: 150-250 μm) and adjusting the flow rate parameters (X(0): 10-50%, X(15): 10-50%, R: -20% to 20%). These parameter optimizations ensure the powder maintains stable flow characteristics during storage while achieving uniform coating application, directly resolving the contradiction between storage stability and coating uniformity
Solution Approach 2:
The patent uses a composite material system consisting of thermosetting resin composition mixed with specific inorganic fillers (such as alumina or silica with particle sizes of 5-50 μm). This composite structure improves both the storage stability through enhanced powder flow control and the coating uniformity through the synergistic effect of the resin and filler particles, eliminating the problematic voids and unevenness
2Reliability
If powder coating material flows during storage, then storage stability deteriorates, but coating application requires adequate flow
Solution Approach 1:
The patent applies dynamics by creating a flow rate model that accounts for temporal changes during storage. The flow rate parameters X(0) before storage and X(15) after 15 days of storage, along with the change index R, allow the material to adapt its flow characteristics over time while maintaining operability. This dynamic approach ensures the powder remains stable during storage but retains adequate flow properties when needed for coating application
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 material provides excellent storage stability and uniform coating, suppressing unevenness and voids, thereby enhancing the strength of connection and welded portions.
Implementation Method 1
immersing a coil end of a coil in a fluidized chamber in which a powder coating material flows
Implementation Method 2
adhering a melt of the powder coating material to an outside of the exposed portion
Data Source
AI summary
A powder coating material used for a powder coating method including a step of immersing a coil end of a coil, which includes a conductor portion coated with an insulating coating and an exposed portion where the conductor portion is exposed from the insulating coating, in a fluidized chamber in which a powder coating material flows, and adhering a melt of the powder coating material to an outside of the exposed portion, the powder coating material containing a particulate thermosetting resin composition. The thermosetting resin composition contains an epoxy resin, and a curing agent.