Multilayer Coating Film Formation with Electrostatic Atomization
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Solution Overview
Problem
Existing methods for forming metallic coating films on industrial products, such as automobile exterior panels and home electronics, often result in coatings with insufficient metallic luster and poor water resistance.
Innovation Solution
A multilayer coating film formation method involving a sequence of applying a colored paint, a base paint, an effect pigment dispersion, and a clear paint, using specific pigments and resins, and employing electrostatic rotary atomization coating to achieve excellent metallic luster and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If aqueous base paint is used instead of solvent-based paint, then environmental impact is reduced, but metallic luster and water resistance of the coating film deteriorate
Solution Approach 1:
The patent uses a composite coating system consisting of multiple layers (base coat, clear coat, and effect pigment dispersion) where each layer contributes different properties. The base coat provides adhesion and color, the clear coat provides water resistance and protection, and the effect pigment dispersion provides metallic luster, together achieving both environmental friendliness and high performance
Solution Approach 2:
Different regions of the coating system have different compositions and functions. The effect pigment dispersion layer specifically targets metallic luster with its unique particle distribution and orientation, while the clear coat layer specifically targets water resistance and protection, allowing each component to optimize its local function
2Illumination intensity
If effect pigment concentration is increased to enhance metallic luster, then water resistance of the coating film deteriorates
Solution Approach 1:
The coating system is segmented into functionally distinct layers: the base coat layer contains the effect pigments at high concentration for metallic luster, while the clear coat layer provides water resistance. This segmentation allows high pigment concentration without compromising water resistance, as the protective function is separated into a dedicated clear coat layer
3Productivity
If conventional coating methods are used, then production efficiency is maintained, but coating quality with sufficient metallic luster and water resistance cannot be achieved
Solution Approach 1:
The base coat layer is applied and cured first to establish a stable foundation with proper adhesion and color. Then the effect pigment dispersion is applied to achieve metallic luster, followed by the clear coat for water resistance. This preliminary structuring of layers ensures that each subsequent layer builds upon a stable base, achieving high quality without requiring rework
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 method produces a coating film with enhanced metallic luster and improved water resistance, characterized by high specular reflectance and reduced graininess, while maintaining the appearance and durability of the substrate.
Implementation Method 1
employing electrostatic rotary atomization coating
Data Source
AI summary
Provided is a method for forming a multilayer coating film, comprising simultaneously curing an uncured base coating film, an uncured effect coating film, and an uncured clear coating film. In this method, an effect pigment dispersion (Y) that forms the effect coating film contains water, a surface adjusting agent (A), a flake-effect pigment (B), and a rheology control agent (C), and has a solids content of 0.5 to 10 mass%.