Mechanical Entrapment Structures for Additive-Manufactured Coating Adhesion

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Solution Overview

Problem

Existing methods for coating additively manufactured objects face challenges in achieving effective adhesion, particularly with coatings like silicone or fluoropolymers, often requiring additional processing steps and primers that may not be sufficiently effective.

Innovation Solution

The method involves applying a coating composition to a surface with entrapment structures, which are configured to entrap the coating within their void spaces, enhancing adhesion by providing additional surface area and structural support, potentially eliminating the need for additional primers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coating methods are used on additively manufactured objects, then the coating process is simple, but adhesion is poor and additional primers are required

Engineering Contradiction:

Improvecoating adhesionVSAvoidprocessing steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The entrapment structures are incorporated into the base object during the additive manufacturing process itself, creating pre-formed anchoring features before coating application. This preliminary structuring eliminates the need for separate surface preparation steps like priming, as the entrapment structures are already in place to mechanically anchor the coating upon application.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The entrapment structures function as a porous or void-containing surface feature that allows the coating material to penetrate and become mechanically interlocked with the base object. The void spaces within the entrapment structures provide anchoring points that enhance coating adhesion through mechanical interlocking rather than relying on chemical primers.

Inventive Principle:

Principle #31Porous materials

2Reliability

If primers are used to improve coating adhesion, then adhesion improves, but additional processing steps and cost increase

Engineering Contradiction:

Improvecoating adhesionVSAvoidprocessing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The entrapment structures are created during the base object manufacturing process, serving as pre-prepared anchoring features that eliminate the need for separate primer application steps. This integration of surface preparation into the manufacturing process reduces total processing time while maintaining or improving adhesion.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The function of a primer (surface preparation and adhesion promotion) is extracted from the coating process and integrated directly into the base object structure through entrapment features. This eliminates the need for the primer material and its associated application step, reducing both time and material requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

3Shape

If the coating surface is made smooth, then appearance is improved, but adhesion may be reduced

Engineering Contradiction:

Improvesurface smoothnessVSAvoidcoating adhesion

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The entrapment structures segment the surface into distinct functional zones: the void spaces provide mechanical anchoring for adhesion, while the outer surface can be finished smoothly for appearance. This segmentation allows different surface regions to serve different functions simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the surface have different properties: the entrapment structure void spaces provide rough, anchoring surfaces for adhesion, while the external surface can be finished smooth for aesthetic purposes. This local differentiation of surface quality allows both adhesion and appearance requirements to be met simultaneously.

Inventive Principle:

Principle #3Local quality

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 entrapment structures improve the adherence of the coating to the base object, resulting in a smooth outer surface without bumps or protrusions, and can enhance the bonding strength between surfaces.

Implementation Method 1

The entrapment structures are configured to entrap the coating within their void spaces, enhancing adhesion by providing additional surface area and structural support

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Force

Implementation Method 2

curing and/or solidifying the coating composition to form the coated object

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS20250221803A1Mechanical entrapment structures and methods of coating additively manufactured objects using the same

Publication Date: 2025.07.10 CARBON INC

AI summary

Provided herein are methods of making a coated object that include applying a coating composition to a surface of an object that comprises a plurality of entrapment structures thereon, wherein the coating composition is on at least a portion of the plurality of entrapment structures; and curing and/or solidifying the coating composition to form the coated object. Also provided are coated objects formed by such methods. Additionally, provided herein are methods of bonding a first surface to a second surface wherein the first surface and/or the second surface comprises a plurality of entrapment structures thereon. Composite articles are also provided herein.