Multi-layer Coating Joint Curing Process
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Solution Overview
Problem
Current multi-layer coating processes for metallic substrates, particularly in the automotive industry, face challenges in simplifying the manufacturing process while maintaining excellent application technology and aesthetic properties, often resulting in issues like pinholes, needle sticks, and inadequate adhesion due to the absence of a separate curing step for the coating layer applied directly to the electrocoating layer.
Innovation Solution
A method involving the production of a hardened electrophoretic paint layer on a metallic substrate, followed by the direct application of one or multiple basecoat layers and a clearcoat layer, with the basecoat layer comprising an aqueous dispersion polymerized from specific olefinically unsaturated monomer mixtures, and joint curing of all layers together, eliminating the need for a separate curing step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate curing step is performed for the coating layer applied directly to the electrocoating layer, then adhesion and defect prevention are improved, but process complexity and energy consumption increase
Solution Approach 1:
The patent combines the curing of the basecoat layer and clearcoat layer into a single joint curing step performed after all coating layers are applied. This eliminates the separate curing step for the basecoat layer, simplifying the manufacturing process while maintaining adhesion quality and preventing defects through the specific polymer composition formulated for joint curing.
2Reliability
If a separate curing step is performed for the coating layer applied directly to the electrocoating layer, then adhesion and defect prevention are improved, but energy consumption increases
Solution Approach 1:
The patent combines the curing of the basecoat layer and clearcoat layer into a single joint curing step performed after all coating layers are applied. This eliminates the separate curing step for the basecoat layer, simplifying the manufacturing process while maintaining adhesion quality and preventing defects through the specific polymer composition formulated for joint curing.
3Manufacturing precision
If the basecoat layer is cured separately before applying the clearcoat layer, then pinholes and needle sticks are prevented, but process time increases
Solution Approach 1:
The patent combines the curing of the basecoat layer and clearcoat layer into a single joint curing step performed after all coating layers are applied. This eliminates the separate curing step for the basecoat layer, simplifying the manufacturing process while maintaining adhesion quality and preventing defects through the specific polymer composition formulated for joint curing.
4Manufacturing precision
If the basecoat layer is cured separately before applying the clearcoat layer, then pinholes and needle sticks are prevented, but productivity decreases
Solution Approach 1:
The patent combines the curing of the basecoat layer and clearcoat layer into a single joint curing step performed after all coating layers are applied. This eliminates the separate curing step for the basecoat layer, simplifying the manufacturing process while maintaining adhesion quality and preventing defects through the specific polymer composition formulated for joint curing.
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 produces multi-layer coatings with excellent application technology and aesthetic properties, preventing defects like pinholes and ensuring sufficient adhesion without the need for a separate curing step, thereby simplifying the process and reducing energy consumption.
Implementation Method 1
an electrophoretic paint, in particular a cathodic electrophoretic paint, is first applied or deposited electrophoretically on the metallic substrate
Implementation Method 2
the successive radical polymerization of three mixtures (A), (B) and (C) of olefinically unsaturated monomers
Data Source
Figure 1~3
AI summary
The present invention relates to a method for producing a multi-layered coating on a metallic substrate, wherein a base coat layer or a plurality of directly consecutive base coat layers are produced directly on a metallic substrate coated with a hardened electrophoretic dip coating, a clear coat layer being produced directly on the one or on the uppermost of the plurality of base coat layers, and the one or the plurality of base coat layers and the clear coat layer subsequently being hardened together. The method is characterised in that at least one base coat employed in the production of the base coat layers contains at least one aqueous dispersion (wD) that contains a polymer the production of which involves the successive radical emulsion polymerisation of three mixtures (A), (B) and (C) of olefinically-unsaturated monomers.