Extruded Profile Coating Using Powder Suspension
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Solution Overview
Problem
Existing methods for coating extruded profiles with elastomer materials, such as windscreen wiper rubbers, face challenges in applying a uniform monolayer of powder material without risk of dust explosions and limited ability to add additives, while ensuring the powder does not form a closed film or coagulate.
Innovation Solution
A method involving the application of a suspension containing the powder material in a solvent to the extruded profile, followed by solvent removal and vulcanization, using polyphenylene ether as the powder material, which prevents the formation of a closed layer and allows for smaller particle sizes, reducing the risk of dust explosions and enabling the addition of additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dry powder coating process is used, then the coating can be applied to the extruded profile, but there is a risk of dust explosions and the powder may form a closed film or coagulate
Solution Approach 1:
The patent uses a suspension as an intermediary medium to carry the friction-reducing particles. Instead of applying dry powder directly, the particles are dispersed in a liquid suspension that is applied to the extruded profile. This eliminates dust explosion risks while maintaining the friction-reducing function, as the particles are delivered in a controlled liquid state rather than as airborne dust.
2Ease of manufacture
If a dry powder coating process is used, then the coating can be applied, but it is not possible to add additional additives to influence product properties
Solution Approach 1:
The suspension serves multiple functions: it acts as a carrier for the friction-reducing particles, provides a safe application medium that eliminates dust explosion risks, and serves as a vehicle for incorporating additional additives. The liquid suspension matrix can accommodate various additives that would influence product properties, making the coating process versatile and adaptable to different performance requirements.
3Manufacturing precision
If powder coating is applied to form a monolayer, then uniform coating is achieved, but the process requires difficult conditions and the powder may coagulate
Solution Approach 1:
The patent changes the physical state parameter of the coating material from solid powder to liquid suspension. This parameter change fundamentally simplifies the application process, allowing for easy and uniform coating application without requiring difficult process conditions. The liquid suspension naturally flows and distributes evenly, forming a uniform monolayer when dried, while eliminating coagulation issues associated with dry powder handling.
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
This method allows for a stable, uniform monolayer of powder material on the elastomer, reducing friction and improving the operational performance of the extruded profiles, such as windscreen wiper rubbers, by enhancing sliding properties and preventing sticking issues in window and door applications.
Implementation Method 1
applying a suspension containing the powder material in a solvent to the extruded profile
Implementation Method 2
removing the solvent
Implementation Method 3
vulcanizing the extruded profile
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for coating an extruded section (3) made of an elastomeric material (23) with a monolayer comprising a powdered material (21), wherein an extruded section (3) is extruded from the elastomeric material (23). A suspension containing the powdered material (21) in a solvent is applied to the extruded section (3). The solvent is removed and the extruded section (3) is vulcanized, wherein the application of the suspension to the extruded section (3) and the removal of the solvent can be carried out before or after vulcanizing the extruded section (3).