Flexible Edge Coating Applicator for Uniform Curved Surface Coverage

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing applicators are unsuitable for applying edge protection coatings uniformly and continuously to highly curved surfaces such as rotor blades, wings, or hydrofoils, which are prone to erosion, thereby impairing aerodynamic properties.

Innovation Solution

A device comprising a flexible base plate with a toothed surface, channel, and sealing lip is used to apply coating materials uniformly and continuously, adapting to the contours of the component, ensuring a uniform layer thickness without interrupting the application process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a rigid applicator is used to apply coating material to highly curved surfaces, then the application process is simple, but the coating cannot adapt to the contours of the surface resulting in non-uniform layer thickness

Engineering Contradiction:

Improveuniformity of layer thicknessVSAvoidcomplexity of applicator structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The applicator employs a flexible base plate that can conform to highly curved surfaces such as rotor blade edges. This flexibility allows the coating material to be applied uniformly across contoured surfaces while maintaining a relatively simple overall device structure.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The applicator incorporates a doctor blade that can move relative to the flexible base plate, allowing dynamic adjustment during the coating process. This enables continuous application of uniform coating material while adapting to surface contours.

Inventive Principle:

Principle #15Dynamics

2Productivity

If coating material is applied manually to rotor blade edges, then the process can be performed with simple equipment, but the application is time-consuming and cannot maintain continuous uniform coating

Engineering Contradiction:

Improvespeed of coating applicationVSAvoiduniformity of layer thickness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The applicator is designed to apply coating material continuously along the rotor blade edge in a single pass. The doctor blade mechanism ensures continuous material supply and distribution, eliminating interruptions and maintaining uniform layer thickness throughout the coating process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The applicator divides the coating material distribution into multiple outlets along the doctor blade, allowing simultaneous coating of different sections of the rotor blade edge. This segmentation enables faster, continuous application while maintaining uniformity across the entire surface.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If excess coating material is applied to level out erosion damage, then the aerodynamic properties are maintained, but the shape of the blade is impaired

Engineering Contradiction:

Improvesurface flatness for aerodynamicsVSAvoidoriginal blade contour

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The applicator applies coating material with precise local control, targeting only the eroded areas on the rotor blade edge. The flexible base plate conforms to the existing surface topology, allowing material to be deposited exactly where needed to level depressions without adding excess material that would alter the overall blade shape.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The applicator uses controlled partial action by applying coating material only to the extent necessary to level erosion damage. The doctor blade mechanism regulates material flow to provide just enough coating to fill depressions and restore surface flatness, avoiding over-application that would change the blade's aerodynamic shape.

Inventive Principle:

Principle #16Partial or excessive action

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 protective coatings with precise adaptation to curved surfaces, maintaining aerodynamic integrity by providing consistent layer thicknesses on edges, thus enhancing erosion protection.

Implementation Method 1

The device has a base plate made of a flexible material

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The teeth are designed so that they project beyond the base plate

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 3

a channel (4) which is mounted on the flexible base plate (2) and through which a liquid or a pasty coating material can be conducted

Methodology Applied

Scientific EffectFluid Flow:

Implementation Method 4

A sealing lip is arranged on the side of the channel facing away from the toothed side, the sealing lip preventing an undesired escape of the material or coating material

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS12589409B2Device and methods for producing edge protection coatings, the device having a flexible base plate, a channel, and a sealing lip

Publication Date: 2026.03.31 MANKIEWICZ GEBR & CO GMBH & CO KG

AI summary

A device for applying at least one coating material to a substrate surface. The device includes a flexible base plate having a toothing which is mounted on at least one side of the flexible base plate as a toothed side, a channel which is arranged parallel to the toothed side, and at least one sealing lip which is arranged on a side of the channel which faces away from the toothed side.