Polymer Coating Polymerization Determination via Spectroscopy

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Solution Overview

Problem

Existing methods for determining the quality and reliability of polymer coatings on wires are destructive, time-consuming, and offline, lacking a fast and non-destructive in-line assessment method.

Innovation Solution

A spectroscopic method using a reflection-type probe with chemometric analysis to correlate acquired spectra with coating parameters, enabling real-time, non-destructive determination of polymerization and other coating properties, with a feedback loop for automatic process control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If destructive testing methods (Loss Angle Tangent Test, voltage burn test) are used to assess coating quality, then reliable insulation property evaluation is achieved, but the testing process becomes time-consuming (10 minutes to several hours per sample) and offline

Engineering Contradiction:

Improveinsulation property evaluationVSAvoidtesting duration

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces mechanical/thermal destructive testing methods with optical spectroscopic measurement. A probe measures coating properties through light interaction (reflectance, absorbance) without physical contact or damage to the coating, achieving instantaneous results compared to the 10 minutes to several hours required by traditional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates an optical copy or spectral fingerprint of the coating's molecular structure. By analyzing the spectral characteristics (absorption peaks, reflectance patterns), the system determines coating quality parameters without destroying the original coating, enabling non-destructive quality assessment

Inventive Principle:

Principle #26Copying

2Reliability

If destructive testing methods are used to determine coating quality, then accurate insulation assessment is achieved, but the testing process requires sample destruction and offline processing

Engineering Contradiction:

Improvecoating quality assessmentVSAvoidonline measurement capability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent substitutes contact-based destructive testing with contactless optical measurement. The spectroscopic probe measures coating properties through electromagnetic radiation interaction, eliminating the need to destroy samples and enabling continuous online monitoring during the coating process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The coating process itself provides the measurement opportunity. The coating being applied serves as both the process object and the measurement target, allowing real-time feedback without interrupting or destroying the coating process

Inventive Principle:

Principle #25Self-service

3Ease of operation

If traditional spectroscopic measurement is used without proper probe positioning, then measurement can be performed, but signal attenuation by external sources increases and signal-to-noise ratio decreases

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidsignal-to-noise ratio

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent positions the probe to interact with a specific local region of the coating on the wire. By controlling the measurement location and geometry (probe-to-coating distance, angle of incidence), the system optimizes signal quality and minimizes interference from external sources

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses the coating itself as an intermediary between the probe and the wire substrate. The spectral measurements are taken through or of the coating layer, allowing quality assessment of the coating while the coating acts as the measurement interface

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Provides a fast, efficient, and non-destructive method for determining polymer coating quality, allowing for real-time adjustments to ensure high-quality coating application.

Implementation Method 1

a reflection type probe. A reflection probe carries out transmission and detection of the signal which enables the signal to be acquired from the sample

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

using spectroscopic techniques to determine the properties of a coating materials

Methodology Applied

Scientific EffectAbsorption Spectroscopy: Absorption Spectroscopy

Data Source

PatentEP3602015B1Coating determination

Publication Date: 2025.10.08 TAU ACT GMBH

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AI summary

There is disclosed a method performed in a coating testing system for automatically determining the polymerisation of coating material, the method comprising: positioning a spectrometer probe adjacent to an object, the object comprising a polymer coating; acquiring spectra of the polymer coating using the probe; and performing chemometric analysis on the acquired spectra in order to measure the polymerisation of the polymer coating.