Segmented Gas Catalytic IR Curing for Wet Coating Uniformity

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Solution Overview

Problem

Existing gas catalyst infrared radiation systems face challenges in effectively curing films of wet coatings applied to substrates, particularly wood substrates, due to uneven absorption of infrared radiation and potential damage from high temperatures.

Innovation Solution

A system and process utilizing a curing room divided into upstream and downstream sections with gas catalytic infrared heating systems producing varying radiation intensities, combined with a conveyor assembly for vertical and transverse substrate displacement, ensuring even absorption and controlled curing of wet coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If gas catalytic infrared radiation is used to cure wet coating, then curing speed is improved, but uneven absorption of infrared radiation causes non-uniform curing

Engineering Contradiction:

Improvecuring speedVSAvoidcuring uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The curing system is segmented into multiple independent infrared radiation sources positioned at different locations and angles. Each radiation source targets specific zones of the coating, allowing independent control of radiation intensity and distribution to achieve uniform curing across the entire substrate surface while maintaining high curing speed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the coating receive tailored infrared radiation intensities based on their specific curing requirements. The system adjusts radiation parameters locally to account for variations in coating thickness, substrate material properties, and desired cure characteristics, ensuring uniform curing quality across the entire surface.

Inventive Principle:

Principle #3Local quality

2Productivity

If high temperature infrared radiation is used to accelerate curing, then curing efficiency is improved, but substrate damage occurs

Engineering Contradiction:

Improvecuring efficiencyVSAvoidsubstrate damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The infrared radiation system employs dynamic temperature control where the radiation intensity and substrate exposure time are continuously adjusted during the curing process. This allows the system to maintain optimal curing temperatures that accelerate the curing reaction while preventing excessive heat accumulation that could damage the substrate.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The curing process uses periodic infrared radiation pulses rather than continuous high-temperature exposure. This pulsed approach allows the coating to absorb radiation energy for curing while having brief intervals for heat dissipation, preventing thermal damage to the substrate while maintaining high overall curing efficiency.

Inventive Principle:

Principle #19Periodic action

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

The system achieves uniform curing of wet coatings on wood substrates by evenly absorbing infrared radiation, expelling moisture, and reducing the risk of substrate damage, resulting in a fully cured film with minimal defects.

Implementation Method 1

Gas catalytic infrared (IR) systems can deliver medium to long wave radiation so as to cure wet coatings applied to substrate

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Implementation Method 2

catalytic combustion occurs when a combustible gas (e.g., a gaseous hydrocarbon such as natural gas, propane, butane, etc.), in the presence of an oxidizer gas (e.g., oxygen), produces carbon dioxide, water, and heat

Methodology Applied

Scientific EffectCatalytic combustion: Catalysis

Implementation Method 3

infrared energy can be absorbed directly by the coating or powder

Methodology Applied

Scientific EffectInfrared absorption: Absorption (EM radiation)

Implementation Method 4

expelling moisture

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250296115A1System and process for curing a wet coating applied to a substrate

Publication Date: 2025.09.25 9063-8974 QUÉBEC INC

AI summary

The present disclosure concerns a system for curing a wet coating of a coated substrate, the system comprising: a curing room having a curing room inlet and a curing room outlet, the curing room being configured to receive the coated substrate being introduced at the curing room inlet thereof along a first displacement axis, the system comprising a conveyor assembly for conveying the coated substrate through the curing room along a second displacement axis transverse to the first displacement axis, wherein the system further comprises a gas catalytic IR system, provided in the curing room, for producing an infrared radiation to partially cure the wet coating while the coated substrate is in the curing room. The disclosure concerns also a corresponding process.