Porous Coating Resin Penetration Measurement Using NIR Spectroscopy
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Solution Overview
Problem
Existing methods for determining resin penetration into porous coating materials like veneers are non-destructive and cannot be monitored in real-time, leading to quality control issues and increased production downtime.
Innovation Solution
A non-destructive method using Near-Infrared (NIR) spectroscopy and multivariate data analysis to determine resin penetration by correlating NIR spectra with mechanical removal data, enabling real-time monitoring and calibration models for resin penetration in porous coating materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical removal methods are used to determine resin penetration, then measurement accuracy is improved, but production downtime increases and the method becomes destructive
Solution Approach 1:
The patent replaces mechanical removal methods with Near-Infrared (NIR) spectroscopy to measure resin penetration. The NIR measuring head non-destructively determines resin content by analyzing spectral characteristics of the pressed product, eliminating the need for time-consuming mechanical sectioning and analysis while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces NIR spectral analysis as an intermediary measurement technique. By correlating NIR spectral data with actual resin penetration depths obtained through mechanical methods, the system creates a predictive model that allows rapid non-destructive measurement without requiring physical sample destruction in production.
2Productivity
If resin penetration is not monitored, then production speed is maintained, but quality control deteriorates
Solution Approach 1:
The patent implements a feedback system where the NIR measuring head continuously monitors resin penetration in the pressed product. The measured values are compared against target ranges, and the pressing process parameters can be automatically adjusted to maintain optimal resin penetration, ensuring consistent quality while maintaining production speed.
Solution Approach 2:
The pressed product itself serves as the measurement sample for NIR analysis. The system measures resin penetration directly on the product without requiring separate destructive testing, enabling continuous quality control that does not slow down production.
3Measurement precision
If pressing parameters are adjusted frequently for quality determination, then measurement accuracy is improved, but production efficiency decreases
Solution Approach 1:
The patent performs preliminary correlation studies between NIR spectral characteristics and actual resin penetration depths using reference samples with known penetration levels. This preliminary calibration creates a model that can be applied during production without requiring frequent adjustments or re-measurements, maintaining both accuracy and efficiency.
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 real-time, non-destructive monitoring of resin penetration, reducing production downtime and improving quality control, allowing for immediate process adjustments.
Implementation Method 1
Recording of at least one NIR spectrum of several reference samples, each having different values for resin penetration into a porous coating material, using at least one NIR measuring head in a wavelength range between 500 nm and 2500 nm
Data Source
AI summary
Provided is a method for determining the resin penetration into at least one porous coating material which is pressed with at least one carrier board and at least one resin layer arranged on the carrier board. During the pressing process the resin penetrates or rises into the at least one porous coating material.