Fibrous Mat Coating Thickness Control via Partial Embedding
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Solution Overview
Problem
Existing methods for coating fibrous mats used in wallboard production result in coating layers that are either too thick, leading to fiber protrusion issues and handling difficulties, or too thin, causing adhesion problems and increased costs, with limited control over coating thickness and surface smoothness.
Innovation Solution
A method involving the partial embedding of a fibrous mat in a coating composition, followed by partial hardening, where one major surface remains uncoated, allowing for precise control of coating thickness and surface characteristics, using ultraviolet curable coatings and radiation curing to form a continuous, non-porous layer on the coated surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the mat is saturated with coating composition and a thick coating layer is formed to prevent fiber protrusion, then fiber protrusion is reduced, but the surface becomes too smooth to properly adhere to another coating or material and excess coating weight increases costs
Solution Approach 1:
The patent applies local quality by creating different surface characteristics on different sides of the mat. The first major surface receives a coating layer that is controlled to be thin enough to maintain surface smoothness for adhesion, while the second major surface remains uncoated to allow fiber protrusion for mechanical interlocking with gypsum. This selective coating approach resolves the contradiction by applying coating only where needed to achieve the desired balance between smoothness and adhesion.
2Manufacturing precision
If a thin coating layer is applied to maintain surface smoothness, then adhesion is improved, but fiber protrusion increases making handling difficult
Solution Approach 1:
The patent resolves this contradiction by applying coating locally only to the first major surface of the mat, controlling the coating layer thickness to maintain surface smoothness for adhesion. The second major surface is deliberately left uncoated, allowing fibers to protrude for mechanical interlocking with gypsum. This selective approach ensures smooth surfaces where needed while permitting fiber exposure where beneficial.
3Stability of the object's composition
If the coating composition is applied to both major surfaces of the mat, then uniform coating is achieved, but fiber protrusion control is lost and handling becomes difficult
Solution Approach 1:
The patent applies asymmetry by treating the two major surfaces of the mat differently. The first major surface is coated with a controlled coating layer to achieve uniformity and smoothness, while the second major surface is left uncoated to allow fiber protrusion for handling and installation. This asymmetric coating strategy resolves the contradiction by recognizing that the two surfaces serve different functions and should have different characteristics.
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 approach enables the creation of coated articles with improved surface smoothness, reduced fiber disengagement, enhanced adhesion, and controlled coating thickness, addressing the challenges of fiber protrusion and adhesion issues while minimizing material usage and installation difficulties.
Implementation Method 1
applying radiation to the fibrous mat to at least partially cure the ultraviolet curable coating composition and form a coating layer at the first major surface of the fibrous mat
Data Source
AI summary
A method of forming a coating layer on a fibrous mat to make a coated article includes depositing a coating composition on a carrier material and at least partially embedding a first major surface of a fibrous mat in the coating composition, the fibrous mat including a plurality of mat fibers. The coating composition is at least partially hardened to form a coating layer at the first major surface of the fibrous mat. A second major surface of the fibrous mat opposite the first major surface includes an uncoated portion of the plurality of mat fibers.