Powder Resin Flow Inspection via Viscosity Bulk Density Correlation

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Solution Overview

Problem

The challenge in powder coating is the increased bulk density of powder resin due to heat conduction, leading to reduced flowability and difficulty in forming a uniform coating, as particles stick together, affecting the efficiency and quality of the coating process.

Innovation Solution

A powder resin flow inspection method and apparatus that measures the viscosity of the resin to estimate bulk density, using a correlation between viscosity and bulk density, allowing for efficient inspection without direct measurement of bulk density, and adjusts air supply to maintain optimal flowability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If air is supplied to the housing portion to make powder resin flow, then the powder resin can be made to flow and form coating, but the bulk density increases and flowability decreases

Engineering Contradiction:

Improvecoating formation efficiencyVSAvoidflowability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by measuring the viscosity of powder resin before it becomes problematic. The inspection apparatus detects changes in viscosity that indicate increasing bulk density and declining flowability, allowing operators to take corrective action (such as adjusting air supply or replacing powder) before coating quality deteriorates. This preventive measurement approach addresses the contradiction by enabling early intervention.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If viscosity measurement is performed to estimate bulk density, then inspection efficiency is improved, but measurement precision is required

Engineering Contradiction:

Improveinspection efficiencyVSAvoidviscosity measurement accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent replaces direct bulk density measurement (which would require complex mechanical systems for sampling and weighing) with viscosity measurement. The inspection apparatus uses rotational viscosity measurement to indirectly assess bulk density through the established correlation. This substitution maintains inspection efficiency while achieving sufficient measurement precision through the reliable viscosity-density relationship.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the housing portion is vibrated to improve powder flow, then flowability is enhanced, but the complexity of the device increases

Engineering Contradiction:

ImproveflowabilityVSAvoidvibration mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements feedback by using viscosity measurement results to monitor and assess powder resin flowability conditions. The inspection apparatus provides continuous feedback on powder state, enabling operators to adjust operating parameters (such as air supply rate or vibration intensity) to maintain optimal flowability. This feedback mechanism addresses the contradiction by enabling dynamic optimization without permanently increasing device complexity.

Inventive Principle:

Principle #23Feedback

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

Enables easy and efficient inspection of powder resin flow, ensuring bulk density remains within permissible limits, thereby maintaining flowability and coating quality by preventing particle sticking and ensuring uniform coverage.

Implementation Method 1

supplying air to an inside of the housing portion through pores of a porous plate provided in a bottom of the housing portion

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

a viscosity measurement step of measuring a viscosity of the powder resin flowing in the housing portion

Methodology Applied

Scientific EffectViscosity:

Implementation Method 3

a judgment step of judging whether or not the powder resin is in a state in which an estimate of a bulk density of the powder resin flowing in the housing portion is less than or equal to a bulk density permissible value, the estimate being obtainable from a correlation, calculated in advance, between the bulk density and a viscosity of the powder resin flowing in the housing portion

Methodology Applied

Scientific EffectCorrelation between bulk density and viscosity:

Data Source

PatentUS11480507B2Powder resin flow inspection method and powder resin flow inspection apparatus

Publication Date: 2022.10.25 HONDA MOTOR CO LTD

AI summary

A flow inspection method includes: a flow step of making powder resin flow in a housing portion of a flow tank; a viscosity measurement step of measuring a viscosity of the powder resin flowing in the housing portion; and a judgment step of judging whether or not an estimate of a bulk density of the powder resin flowing in the housing portion is less than or equal to a bulk density permissible value, the estimate being obtainable from a correlation, calculated in advance, between the bulk density and a viscosity of the powder resin flowing in the housing portion, and a measured value of the viscosity obtained in the viscosity measurement step.