Spray Coating Apparatus for Uniform Latex Thickness
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Solution Overview
Problem
Existing methods for producing latex products are inefficient, leading to uneven thickness, damage during removal from molds, and difficulty in applying double-sided fiber coatings, especially for complex shapes and thin products.
Innovation Solution
A method involving controlled spraying of liquid material onto a workpiece former with optional fiber coatings and breathable components to achieve uniform or varying thickness and easy removal, using gas flow to create perforations and facilitate detachment without damaging the product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dipping methods are used to produce latex products, then the process is simple and equipment is basic, but the thickness of the product is uneven and difficult to control
Solution Approach 1:
The patent replaces the traditional mechanical dipping process with a spray application system. The spray system applies latex material through aerosol or liquid spray onto the former surface, allowing precise control of material deposition thickness through spray parameters (pressure, distance, duration) rather than relying on complex mechanical dipping movements and timing
Solution Approach 2:
The patent utilizes pneumatic spray mechanisms to deliver latex material onto the former. The spray system uses compressed air or hydraulic pressure to atomize and distribute the latex uniformly across the surface, enabling precise thickness control through pressure regulation and spray pattern adjustment without complex mechanical positioning
2Ease of operation
If liquid and gas jets are used to separate products from molds, then the process is simple, but very thin products are damaged during removal
Solution Approach 1:
The patent incorporates breathable elements with porous structures into the former design. These porous materials allow gas or liquid to pass through uniformly, creating gentle, distributed pressure that separates the product from the former without concentrated force that could damage thin products. The porous structure diffuses the separation force across the entire product surface
Solution Approach 2:
The patent applies a releasing agent to the former surface before applying the latex material. This preliminary action creates a non-stick surface that prevents adhesion between the product and former, eliminating the need for aggressive separation methods like liquid/gas jets that could damage thin products during removal
3Ease of manufacture
If the whole mould is dipped in liquid latex, then the process is simple, but material is wasted on areas that do not require coating
Solution Approach 1:
The patent employs a spray application system that can be directed to coat only specific zones or areas of the former that require product material. The spray mechanism allows selective application based on local requirements, adjusting spray direction, duration, and intensity for different regions, thereby avoiding material waste on areas that do not need coating while maintaining simple operational procedures
4Ease of operation
If multiple layers of latex and adhesive are applied for double-sided fiber coating, then the coating is complete, but the product thickness increases and process becomes complex
Solution Approach 1:
The patent combines the application of latex material and fiber coating into a single integrated spray operation. The spray system simultaneously deposits latex and adheres fibers in one pass, eliminating the need for separate layers of latex and adhesive applied at different times. This merging of operations maintains complete fiber coating while preventing cumulative thickness increase and process complexity
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 the production of products with uniform or varying thickness, efficient double-sided fiber coating, and easy removal from molds, reducing waste and process complexity while maintaining product integrity.
Implementation Method 1
spraying liquid material, e.g. liquid latex, onto the at least partially fibre-coated wall surface to form a product material layer
Implementation Method 2
introducing gas or liquid through the breathable element embedded in the workpiece former under sufficient pressure so as to push the workpiece away from the wall
Implementation Method 3
spraying liquid material onto the at least partially fibre-coated wall surface to form a product material layer
Data Source
AI summary
The invention provides methods and apparatus for producing flexible, stretchable, and/or elastic products comprised principally of material such as natural elastomers and other synthetic polymers. The method and apparatus for producing stretchable products by spraying product material over a workpiece former, and method and apparatus for creating perforated products by spraying product material over a perforated surface or partly breathable surface, The invention also provides methods and apparatus for making double sided fibre coating of the product and, or to at least coating the product surface on the side facing the wall without the need for removing the product from the wall. The method and apparatus also enable easy removal of the product from the former. Workpiece formers are also provided.