Lamp Black Electrodeposition Coatings for Homogeneous Film Build
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrodeposition coating materials struggle to achieve a homogeneous film build on various metallic substrates with different surface properties, requiring costly and labor-intensive post-treatment processes to address film build height variations and maintain corrosion protection.
Innovation Solution
An aqueous cathodically depositable electrodeposition coating composition containing a lamp black pigment with a specific particle size range of 50 nm to 200 nm, along with a cathodically depositable polymer, ensures a uniform film build and enhanced corrosion protection, independent of substrate material and pretreatment methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrodeposition coating materials are applied to metallic substrates with different surface properties, then corrosion protection is provided, but film build height varies and requires additional post-treatment
Solution Approach 1:
The patent changes the particle size parameter of the carbon black pigment to a specific range (50-200 nm) to optimize film build homogeneity. This parameter modification allows the coating to achieve uniform film thickness across substrates with different surface properties, eliminating the need for post-treatment while maintaining corrosion protection.
Solution Approach 2:
The patent uses a composite coating material comprising cathodically depositable polymer and carbon black pigment with specific particle size characteristics. This composite formulation improves both film build homogeneity and corrosion protection, resolving the contradiction between manufacturing precision and reliability.
2Reliability
If conventional carbon black pigments are used in electrodeposition coating, then corrosion protection is achieved, but film build homogeneity deteriorates due to substrate surface property variations
Solution Approach 1:
The patent modifies the particle size parameter of carbon black pigment to 50-200 nm, which fundamentally changes the coating behavior. This parameter change enables the coating to achieve uniform film build on substrates with varying surface properties, directly resolving the ease of operation issue while preserving corrosion protection.
3Manufacturing precision
If manual post-treatment is applied to level film build variations, then surface homogeneity is improved, but production cost and time increase
Solution Approach 1:
The patent enables the coating material to self-adjust and achieve homogeneous film build without requiring manual post-treatment. The specific carbon black pigment formulation allows the coating to automatically level on substrates with different surface properties, eliminating the need for additional manual operations and improving productivity.
Solution Approach 2:
The patent incorporates the film build homogeneity improvement directly into the electrodeposition coating step itself, performing the leveling action during the primary coating process rather than requiring subsequent post-treatment. This preliminary action approach eliminates additional production steps and improves overall efficiency.
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
The composition provides a homogeneous film build and improved corrosion protection without additional post-treatment, maintaining film quality and reducing substrate surface roughness variations.
Implementation Method 1
In cathodic electrodeposition coating, the substrates to be coated are immersed into an electrocoating bath and connected as the cathode. The particles of the electrocoating material are stabilized with positive charge and deposit on the cathode to form a coating film.
Implementation Method 2
The particles of the electrocoating material are stabilized with positive charge and deposit on the cathode to form a coating film.
Data Source
AI summary
Described herein is an aqueous cathodically depositable electrodeposition coating material composition including at least one cathodically depositable polymer (a) and at least one carbon black pigment (b), where the at least one carbon black pigment (b) is a lamp black pigment having a number-based median primary particle size (dN,50%) of at least 50 nm and at most 200 nm. Also described herein is a method for at least partially coating an electrically conductive substrate by cathodic electrodeposition coating including immersing the substrate at least partially into an electrodeposition coating bath, which includes the electrodeposition coating material composition. Also described herein is an electrically conductive substrate, which is at least partially coated with a baked electrodeposition coating material composition and/or which is obtainable by the method. Further, described herein is a method of using the carbon black pigment (b) for improving corrosion protection and/or homogeneity of the film build.