High Transfer Efficiency Applicator for Automotive Coating
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Solution Overview
Problem
Current automotive painting techniques require multiple time-consuming and labor-intensive steps for applying multiple colors, leading to overspray waste, uneven coatings, and increased costs due to the wide droplet size distribution and bleeding of paints during the spray atomization process.
Innovation Solution
A method using high transfer efficiency applicators to apply first and second coating compositions with precise control, forming a continuous layer across gaps less than 2 mm, with each applicator applying a uniform wet film thickness of 5 to 150 microns, ensuring minimal solvent evaporation and high contact efficiency, and utilizing non-Newtonian fluid behavior for improved coating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pneumatic spray or rotary equipment is used to apply coating, then a uniform high-quality coating is produced, but the droplet size distribution is wide causing significant overspray waste
Solution Approach 1:
The coating application process is segmented into discrete droplet delivery using a multi-nozzle applicator head, where each nozzle delivers controlled droplets to specific target areas on the substrate, replacing the continuous spray approach that causes overspray
Solution Approach 2:
The applicator delivers coating material with precise spatial control, applying coating only to specific target areas defined by the nozzle pattern, thereby eliminating unnecessary coating application in non-target regions and reducing overspray waste
2Adaptability or versatility
If multiple colors are applied using conventional spray painting, then the vehicle body can be painted with different colors, but masking and multiple spray operations are required which is time-consuming and labor-intensive
Solution Approach 1:
The applicator head is segmented into multiple independently controllable nozzles that can be selectively activated to apply different colors to different zones of the substrate in a single pass, enabling multi-color painting without masking
Solution Approach 2:
The system uses sequential or simultaneous periodic activation of different nozzle groups to apply multiple colors in controlled sequences, allowing complex multi-color patterns to be created through time-sequential deposition rather than requiring separate painting operations
3Ease of manufacture
If paint is applied using spray atomization, then coating can be applied to the substrate, but bleeding and uneven lines occur at adjacent color boundaries
Solution Approach 1:
The applicator divides the coating application into discrete, controllable droplet streams from separate nozzles positioned at defined intervals, allowing precise control over where each color is applied and preventing the blending that occurs with continuous spray atomization at color boundaries
Solution Approach 2:
The system replaces the mechanical spray atomization process with a controlled droplet ejection mechanism that delivers discrete coating material, eliminating the uncontrolled atomization that causes bleeding and uneven transitions at adjacent color regions
4Area of stationary object
If a wide jet of paint droplets is sprayed, then coating can cover the vehicle body, but many droplets do not land on the vehicle due to overspray or insufficient momentum
Solution Approach 1:
The applicator employs localized droplet delivery through individually positioned nozzles that target specific areas on the substrate, ensuring coating material is applied only where needed and improving transfer efficiency by eliminating droplets that would otherwise miss the substrate or land in unwanted locations
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 reduces overspray, minimizes waste, achieves sharp color interfaces, and enhances coating uniformity and durability, thereby reducing time, labor, and costs while improving the physical and long-term durability of automotive coatings.
Implementation Method 1
The drops can be jetted onto the substrate by a variety of inkjet application methods including continuous and drop-on-demand printing. In drop-on-demand printing the energy to eject a drop of ink can be from a thermal resistor, a piezoelectric crystal, acoustic or a solenoid valve.
Implementation Method 2
Each of the first and second high transfer efficiency applicators independently applies the first and second coating compositions respectively to the substrate without atomization such that at least about 99.9% of the applied coating compositions contact the respective first and second target areas.
Implementation Method 3
utilizing non-Newtonian fluid behavior for improved coating properties
Data Source
AI summary
This disclosure provides a method of applying a first coating composition and a second coating composition to a substrate. The method includes providing the substrate defining a first target area and a second target area which define a gap there between of less than about 2 mm; applying the first coating composition via a first high transfer efficiency applicator to the first target area at a wet film thickness of from about 5 to about 150 microns; and applying the second coating composition via a second high transfer efficiency applicator to the second target area at a wet film thickness of from about 5 to about 150 microns to form a continuous layer of a combination of the first and second coating compositions that extends across the gap and also extends across at least an additional portion of the substrate.