Spray Coating Pressure Control for Uniform Viscosity Handling
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Solution Overview
Problem
Existing methods for applying coating agents to resin-based materials face limitations, particularly with the inkjet method, where increased viscosity prevents ejection, and the spray method struggles with forming uniform coating layers with desired thickness.
Innovation Solution
A manufacturing system and coating device that utilize a spray method with a nozzle, incorporating a host control device to create application data and a pressure adjustment mechanism to maintain consistent spray amounts, and a temperature sensor to regulate viscosity, ensuring uniform coating layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the inkjet method is used to apply the coating agent, then the coating agent can be applied with precise control, but the coating agent cannot be ejected when its viscosity increases
Solution Approach 1:
The patent replaces the inkjet ejection mechanism with a spray method using a nozzle. Instead of relying on inkjet ejection which fails at high viscosity, the system uses a spray nozzle that can atomize and deposit coating agents with varying viscosities, thus maintaining adaptability while achieving uniform coating application.
Solution Approach 2:
The patent introduces a viscosity adjustment mechanism that modifies the coating agent's viscosity parameters before application. By controlling viscosity within an optimal range through adjustment mechanisms, the system enables both inkjet and spray methods to effectively apply coating agents regardless of their initial viscosity state.
2Adaptability or versatility
If the spray method is used to apply the coating agent, then coating agents with various viscosities can be applied, but the coating layer thickness becomes uneven
Solution Approach 1:
The patent incorporates a feedback control system with sensors that monitor coating layer thickness in real-time during the spray application process. The system adjusts spray parameters based on feedback signals to maintain uniform coating thickness, resolving the unevenness issue while preserving the ability to handle various viscosity coating agents.
Solution Approach 2:
The patent introduces a movable nozzle mechanism that dynamically adjusts the nozzle position, angle, and distance from the base material during the spraying process. This dynamic adjustment ensures uniform coating thickness across the surface while accommodating coating agents with different viscosity characteristics.
3Stability of the object's composition
If the viscosity of the coating agent is increased, then the coating agent can maintain its shape better, but the coating agent cannot be ejected from the inkjet head
Solution Approach 1:
The patent replaces the inkjet ejection system with a spray nozzle system that does not rely on high-pressure ejection through small nozzles. The spray mechanism can handle high-viscosity coating agents by atomizing them through different physical mechanisms, thus maintaining shape stability while enabling successful application.
Solution Approach 2:
The patent applies a heating treatment to the coating agent before spraying to temporarily reduce its viscosity, making it easier to spray. After application, the coating agent retains its shape stability due to the base material's properties and the coating agent's composition, thus achieving both ease of manufacture and shape stability.
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 simplifies data creation for product manufacturing and achieves uniform coating layers with desired thickness, overcoming viscosity variations and uneven thickness issues.
Implementation Method 1
a temperature sensor to regulate viscosity
Implementation Method 2
a pressure adjustment mechanism to maintain consistent spray amounts
Implementation Method 3
a nozzle that sprays the coating agent onto a base material
Data Source
AI summary
A coating device includes a nozzle that sprays a coating agent toward a base material, a coating agent storing part that stores the coating agent to be supplied to the nozzle, a temperature sensor that detects a temperature of the coating agent to be supplied to the nozzle from the coating agent storing part, a pressure adjustment mechanism that adjusts a supplying pressure of the coating agent to be supplied to the nozzle from the coating agent storing part, and a controller that receives an output signal of the temperature sensor and controls the pressure adjustment mechanism.