Custom Powder Coating via Dynamic Monochromic Blending

Solution Overview

Problem

Powder coating manufacturers and applicators face challenges in rapidly creating small batches of custom colors, as the traditional twin-screw extrusion process is time-consuming and costly, limiting their ability to offer precise color matching and leading to substandard dry blended options.

Innovation Solution

Combining additive manufacturing with 3D printing technology and color measurement systems to rapidly produce small batches of custom color powder coating compositions by combining single-color polymer filaments, allowing for precise color matching and reduced inventory needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the traditional twin-screw extrusion process is used to produce custom color powder coatings, then color matching precision is improved, but production time and cost increase significantly

Engineering Contradiction:

Improvecolor matching precisionVSAvoidproduction time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The powder coating formulation is segmented into multiple monochromic powder components, each containing a specific pigment concentration. These pre-formulated monochromic powders are stored in separate hoppers and dynamically blended during application to create custom colors, eliminating the need for traditional extrusion-based color mixing while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses dynamic blending of monochromic powder components during the coating application process. The ratios of different monochromic powders are adjusted in real-time based on the desired custom color specifications, allowing rapid production of small batches without reconfiguration of extrusion equipment.

Inventive Principle:

Principle #15Dynamics

2Measurement precision

If the traditional twin-screw extrusion process is used to produce custom color powder coatings, then color matching precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecolor matching precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The powder coating formulation is segmented into multiple monochromic powder components, each containing a specific pigment concentration. These pre-formulated monochromic powders are stored in separate hoppers and dynamically blended during application to create custom colors, eliminating the need for traditional extrusion-based color mixing while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the fundamental parameter of color creation from extrusion-based melting and mixing to powder-based dynamic blending. This parameter change allows for more economical production of small batches since it avoids the minimum purchase requirements and high setup costs associated with traditional extrusion processes.

Inventive Principle:

Principle #35Parameter changes

3Loss of time

If dry blending process is used to create custom colors, then production time is reduced, but mixing homogeneity and color precision deteriorate

Engineering Contradiction:

Improveproduction timeVSAvoidmixing homogeneity

Core Design Contradiction:

Loss of timeVSManufacturing precision

Solution Approach 1:

The powder coating formulation is segmented into multiple monochromic powder components, each containing a specific pigment concentration. These pre-formulated monochromic powders are stored in separate hoppers and dynamically blended during application to create custom colors, eliminating the need for traditional extrusion-based color mixing while maintaining precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates color measurement and control mechanisms that provide feedback on the blended powder composition. This allows real-time adjustment of the monochromic powder ratios to achieve the desired color specifications, ensuring both speed and precision in custom color production.

Inventive Principle:

Principle #23Feedback

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 rapid and economical production of custom color powders, reducing inventory costs and increasing production capabilities while ensuring precise color matching and quality control.

Implementation Method 1

combine a plurality of single-color polymer filaments that are solid at an average room temperature to rapidly produce a small batch of polymer powder coating composition

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11904505B2Powder coating composition system and process

Publication Date: 2024.02.20 ANDREWS SCOTT

AI summary

A system and process for producing a homogenous extrudate powder coating composition having predetermined properties, the system comprising a color library database that is configured to store one or more input formulation data objects capable of use in controlling the inputs and operation of an electronically controlled homogenous extrudate mixer.