High-Viscosity Coating Applicator for Uniform Air-Free Deposition
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods struggle to apply high viscosity materials over large surface areas with uniform thickness and minimal air entrapment, leading to inadequate control of thickness and uniformity, and often require solvents that increase environmental and health risks.
Innovation Solution
Extrusion applicators with a diverging transition section and converging nozzle design, combined with a flow and pressure control system, facilitate the application of high viscosity materials with minimal air entrapment and controlled thickness, using shear thinning and laminar flow to achieve uniform coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spraying or atomizing is used to apply low-viscosity materials, then coating efficiency and coverage area are improved, but high viscosity materials cannot be atomized effectively resulting in air entrapment and poor thickness control
Solution Approach 1:
The patent changes the physical state and flow parameters of the high viscosity material through controlled shear thinning in the transition section, transforming it from a non-sprayable viscous state to a sprayable lower-viscosity state, enabling effective atomization and thickness control
Solution Approach 2:
The patent replaces the conventional spray nozzle with a specialized applicator system incorporating a transition section that uses controlled mechanical shear and pressure differential to prepare the material for application, substituting direct mechanical spray with a multi-stage flow control mechanism
2Ease of operation
If solvents or rheological agents are added to reduce viscosity, then ease of application is improved, but volatile organic content increases causing environmental and health risks
Solution Approach 1:
The patent converts the harmful high viscosity property into a beneficial feature by using the material's thixotropic characteristics - the material remains highly viscous for storage and handling (preventing solvent addition) but undergoes controlled shear thinning during application through the transition section, enabling easy application without solvents
Solution Approach 2:
The transition section acts as an intermediary device between the material reservoir and application point, providing controlled shear and pressure differential that temporarily reduces viscosity during application without requiring chemical solvents, thus mediating between high viscosity and ease of application
3Productivity
If high speed application is used to increase productivity, then output is improved, but air entrapment increases adversely affecting cured sealant properties
Solution Approach 1:
The patent maintains continuous, controlled material flow through the applicator system with optimized channel geometries that prevent turbulence and air mixing, ensuring steady laminar flow even at high application speeds, thus maintaining sealant quality while increasing productivity
Solution Approach 2:
The patent uses pressure differential control and fluid dynamics principles to manage material flow through the applicator, using controlled pressure gradients to maintain smooth, air-free flow of high viscosity material at high application speeds
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 high-speed application of high viscosity materials with minimal air entrapment and uniform thickness, reducing environmental impact and health risks associated with solvent use.
Implementation Method 1
The applicators facilitate the application of high viscosity materials... using shear thinning and laminar flow to achieve uniform coatings
Implementation Method 2
using shear thinning and laminar flow to achieve uniform coatings
Data Source
AI summary
Coating applicators for applying high viscosity coatings to large area surfaces are disclosed. The coating applicators facilitate the ability to apply high viscosity materials over large areas at high speed with minimal air entrapment to provide coatings having a controlled thickness.