Silane Passivation Coating Weight Measurement via FTIR
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Solution Overview
Problem
Current methods for determining the weight and thickness of silane-containing passivation coatings on substrates, especially on moving substrates, are not precise and disrupt production processes, making quality control challenging.
Innovation Solution
A method using Fourier Transform Infrared (FTIR) spectroscopy to measure the weight of silane-containing passivation coatings by comparing the FTIR energy spectrum of the sample with calibration standards, allowing for accurate and minimally disruptive measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If fluorescent dyes (stilbene and coumarin) are used to determine coating thickness, then the presence of coating can be detected, but the measurement precision is insufficient and native fluorescence interferes with measurement accuracy
Solution Approach 1:
The patent extracts and removes the interfering native fluorescence component from the measurement signal by using background subtraction techniques. The system separately measures the substrate's native fluorescence and the coating's fluorescence, then subtracts the substrate contribution to obtain accurate coating thickness measurements.
Solution Approach 2:
The patent introduces reference standards and calibration samples as intermediaries to establish a relationship between fluorescence intensity and coating thickness. These intermediaries provide a known reference framework that enables accurate quantitative measurement while accounting for interference effects.
2Measurement precision
If traditional methods are used to measure coating weight on substrates, then measurement can be performed, but the substrate movement must be significantly interrupted which reduces productivity
Solution Approach 1:
The patent enables continuous measurement of coating weight on moving substrates by using a non-contact optical system. The fluorescence measurement can be performed while the substrate moves through the measurement zone, eliminating the need to stop the production line and maintaining continuous processing throughput.
Solution Approach 2:
The patent replaces mechanical measurement methods (which require substrate handling and stopping) with an optical fluorescence detection system. This substitution allows contactless, rapid measurement that can be performed on moving substrates without mechanical intervention.
3Ease of manufacture
If oil films are used for fluorescent detection, then the method is simple, but the precision is insufficient and the oil layer is not maintained for subsequent coating layers
Solution Approach 1:
The patent changes the measurement parameters by using fluorescence intensity ratios at different wavelengths rather than absolute intensity measurements. This approach provides more precise measurements that are less sensitive to variations in excitation conditions and substrate properties, enabling accurate measurement of dryable film thicknesses.
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 accurate measurement of coating weight and thickness on moving substrates with minimal interruption, enhancing quality control in industrial settings.
Implementation Method 1
measuring a Fourier Transform Infrared energy spectrum of the sample silane-containing passivation coating composition
Data Source
Figure 1
AI summary
The present invention relates to a method for measuring the weight of a passivation coating composition on a moving substrate with minimal interruption. The method of present invention is especially useful for effective quality control in an industrial setting.