Stain Preventing Cover for Electrostatic Coating Machines

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Solution Overview

Problem

In electrostatic coating processes, the frequent attachment of atomized coating particles to the cover of coating machines leads to reduced productivity due to the need for frequent cover exchanges, caused by disturbances in the electric potential distribution on the machine's surface.

Innovation Solution

A stain preventing cover is developed using a composite sheet with a 3-layer laminate structure, comprising a first sheet with a low dielectric constant, a second sheet with a higher dielectric constant or semiconductivity, and a third sheet with a lower dielectric constant, which alleviates the disturbance in electric potential distribution, making it homogeneous and reducing particle attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a cover made of insulating resin is used to suppress the attaching of atomized coating particles, then the insulation performance is improved, but the cover becomes heterogeneous in electric potential distribution causing partial attaching of particles and frequent cover exchanges

Engineering Contradiction:
Improveinsulation performanceVSAvoidcover exchange frequency
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies composite materials by combining three different sheet materials with distinct dielectric properties in a laminated structure. The first sheet material (low dielectric constant) provides base insulation, the second sheet material (high dielectric constant or semiconductive) equalizes potential distribution, and the third sheet material (low dielectric constant) provides additional insulation layer. This composite structure resolves the contradiction by maintaining overall insulation performance while eliminating heterogeneous potential distribution that causes particle attachment.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent changes the dielectric constant parameter through the laminated structure of different sheet materials. By varying the dielectric constant across different layers (low-high-low), the electric potential distribution on the cover surface is normalized, transforming from heterogeneous to homogeneous distribution. This parameter change prevents the partial attaching of coating particles while maintaining insulation performance.

Inventive Principle:
Principle #35Parameter changes

2Manufacturing precision

If the coating machine is stopped for cleaning the stain, then the coating quality is maintained, but the productivity is sacrificed

Engineering Contradiction:
Improvecoating qualityVSAvoidcoating continuity
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by using the stain preventing cover to prevent particle attachment before it becomes a problem. The homogeneous potential distribution achieved through the laminated structure prevents coating particles from attaching to the cover in the first place, eliminating the need for periodic cleaning operations and maintaining continuous productivity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The cover structure performs self-service by automatically preventing particle attachment through its homogeneous potential distribution property. The laminated structure with varying dielectric constants inherently equalizes potential differences, making the cover self-maintaining without requiring external cleaning intervention or production interruption.

Inventive Principle:
Principle #25Self-service

3Ease of manufacture

If a single-layer insulating resin cover is used, then the manufacturing is simple, but the electric potential distribution becomes heterogeneous causing partial attaching of particles

Engineering Contradiction:
Improvecover manufacturing simplicityVSAvoidpotential distribution uniformity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent uses composite materials with different dielectric properties arranged in a laminated structure to achieve homogeneous potential distribution. The combination of three sheet materials with varying dielectric constants (low-high-low) creates an inherent potential equalizing effect that prevents particle attachment, improving reliability while maintaining manufacturability through standard lamination processes.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by assigning different dielectric constant properties to different layers of the cover structure. Each layer has a specific dielectric characteristic optimized for its function: the first and third layers provide insulation with low dielectric constant, while the second layer provides potential equalization with high dielectric constant or semiconductivity. This localized property assignment achieves uniform potential distribution throughout the cover.

Inventive Principle:
Principle #3Local quality

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 solution effectively suppresses the attachment of atomized coating particles to the cover, reducing the frequency of cover exchanges and enhancing productivity by ensuring a more uniform electric potential distribution.

Implementation Method 1

a first sheet material having a low dielectric constant and having insulation performance, a second sheet material having a dielectric constant higher than that of the first sheet material or having semiconductivity and a third sheet material having a dielectric constant lower than that of the second sheet material and having insulation performance

Methodology Applied
Scientific EffectDielectric constant variation: Dielectric

Implementation Method 2

a disturbance of the electric potential distribution on the surface of the coating machine influences on the cover and the potential difference on the surface of the cover becomes heterogeneous

Methodology Applied
Scientific EffectElectric potential distribution: Electric Field

Implementation Method 3

by applying a high voltage to a rotating atomizer head of a coating machine to charge negatively atomized coating particles and by causing an object to adsorb onto the coating particles through electrostatic force

Methodology Applied
Scientific EffectElectrostatic force: Electrostatics

Data Source

PatentUS8261689B2Stain preventing cover for coating machine
Publication Date: 2012.09.11 TOYOTA JIDOSHA KK
  • US8261689B2 patent drawing
  • US8261689B2 patent drawing
  • US8261689B2 patent drawing

AI summary

The stain preventing cover is formed from a composite sheet 24 having a three layer structure as a raw material which is produced by laminating a first sheet material 21 having a low dielectric constant and having insulation performance, a second sheet material 22 having a dielectric constant higher than that of the first sheet material 21 or having semiconductivity and a third sheet material 23 having a dielectric constant lower than that of the second sheet material 22 and having insulation performance, in which an end of the second sheet material 22 is positioned together with an end of the first and third sheet materials 21 and 23 adjacent to a electrostatic high voltage part 10 of a coating machine and another end thereof is positioned distant from an earth part 11 of the coating machine to be electrically insulated. The influence of the disturbance of the electric potential distribution on the surface of a coating machine main body 5 is alleviated by the first and second sheet materials 21 and 22 to cause the electric potential distribution on the surface of the third sheet material 23 to be homogeneous to thereby preventing the attaching of atomized coating particles to the surface.