Profile Member Coating via Pre-Coated Foil Intermediary
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Solution Overview
Problem
Existing methods for coating profile members, such as those used in window and door construction, are inefficient due to high overspray rates and labor-intensive masking processes, leading to increased costs and environmental waste.
Innovation Solution
Applying a thermosetting resin coating with polymeric powder to a foil wider than the profile member's surface, cutting the foil into strips, and attaching them to the surface, which reduces overspray and eliminates the need for masking, using a hard PVC foil with a suitable thickness and coating properties to ensure adhesion and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray coating is used to apply coating to profile members, then a relatively thick coating layer can be applied with polymeric powder to obtain grained surface structure, but significant overspray occurs (at least 40 wt% of total coating) leading to material waste and environmental pollution
Solution Approach 1:
The patent introduces a foil as an intermediary carrier between the spray coating system and the profile member. The foil captures the sprayed coating material, allowing 90-95% of the coating to be deposited on the foil instead of being wasted as overspray. The foil then transfers the coating to the profile member surface, eliminating direct spray exposure and reducing material loss to the environment.
Solution Approach 2:
The patent segments the coating process into two distinct stages: first applying coating to the foil carrier, then transferring it to the profile member. This segmentation allows precise control of coating deposition on the foil (where 90-95% capture efficiency is achieved) and subsequent controlled transfer to the final surface, separating the spraying operation from the substrate exposure.
2Manufacturing precision
If manual masking, degreasing and spray coating are used for profile members, then coating can be applied to specific surfaces, but the process is very labour-intensive, time-consuming and creates high amounts of waste from masking materials
Solution Approach 1:
The foil acts as a pre-coated intermediary that can be selectively positioned and attached only to those profile member surfaces requiring coating. This eliminates the need for manual masking of non-coated surfaces, as the foil itself defines the coated areas. The process transforms a complex multi-step manual operation into a simpler attachment operation, significantly improving productivity.
Solution Approach 2:
The coating is applied to the foil in advance before the foil is attached to the profile member. This preliminary coating action allows the coating to be applied under optimized conditions (with 90-95% capture efficiency) and then transferred as a complete unit to the profile member, eliminating the need for on-site masking, degreasing, and multi-layer spraying operations.
3Manufacturing precision
If spray coating is used on profile members, then coating can be applied to surfaces, but masking of surfaces not to be coloured is required, followed by manual degreasing and multi-layer spraying
Solution Approach 1:
The coating is applied to the foil in advance under controlled conditions, allowing for single or double layer application with 90-95% material capture efficiency. This preliminary action consolidates multiple spraying operations into one or two efficient coating passes on the foil, which is then transferred as a complete coated unit to the profile member, eliminating subsequent drying and re-coating steps.
Solution Approach 2:
The foil intermediary enables the coating to be applied once or twice on the foil with high efficiency, then transferred directly to the profile member. This eliminates the need for multiple manual spraying passes, intermediate drying steps, and repeated handling, significantly reducing the total process time from masking through multi-layer spraying to final coating completion.
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
Significantly reduces coating material usage and waste, enhances productivity by minimizing manual labor, and achieves a matte finish without the need for additional masking or surface treatments.
Implementation Method 1
the coating comprising a thermosetting resin and a polymeric powder dispersed in said resin. The polymeric powder is dispersed in the resin to give the coating a grained structure, thus avoiding a glossy appearance.
Data Source
Figure 1
AI summary
The invention relates to a method for providing a profile member and in particular a window profile with a coating, at least over a first part of its surface with a width W, the coating comprising a thermosetting resin and a polymeric powder dispersed in said resin, wherein: a) the coating is applied to a foil with a width of at least 2 x W; b) the foil is cut in at least two parts with a width W; c) the parts are attached to the first part of the surfaces of the profile members. The invention further relates to a profile member, covered over at least a first part of its surface with a foil comprising a wherein the coating comprises a thermosetting resin and a polymeric powder dispersed in said resin and the coating has an elongation at break of at least 40 % and to a construction e.g. a window comprising such profile.