Thermal Spray Coating for Industrial Fabrics

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Solution Overview

Problem

Industrial fabrics and belts used in papermaking and other processes face challenges such as thermal degradation, abrasion, and wear due to exposure to high temperatures and harsh environments, leading to reduced lifespan and performance.

Innovation Solution

Applying a coating or layer to the fabrics or belts using thermal spray processes, such as flame spray or plasma spray, to enhance properties like thermal resistance, abrasion resistance, and chemical resistance, which can include thermoplastic or thermoset resins and inorganic particles to improve durability and functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fabrics and belts are used in high temperature environments without protective coating, then they can maintain their base functional properties, but they suffer from thermal degradation and reduced lifespan

Engineering Contradiction:

Improveresistance to thermal degradationVSAvoidlifespan of fabric

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies a multi-layer composite coating structure consisting of a primer layer and a topcoat layer with different functional properties. The primer layer provides adhesion and corrosion resistance, while the topcoat layer provides thermal and abrasion resistance. This composite structure resolves the contradiction by combining materials with complementary properties to simultaneously achieve reliability and extended lifespan.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of the fabric surface through thermal spray coating application. The coating process changes the surface temperature resistance, hardness, and chemical composition parameters, transforming the fabric from being susceptible to thermal degradation to having enhanced thermal stability and extended service life.

Inventive Principle:

Principle #35Parameter changes

2Strength

If fabrics and belts are exposed to harsh environments without protective coating, then they can maintain their original structure, but they experience increased abrasion and wear

Engineering Contradiction:

Improveabrasion resistanceVSAvoidlifespan of fabric

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent applies a thin film protective coating through thermal spray process that forms a flexible yet durable layer on the fabric surface. This thin film provides abrasion and wear resistance while maintaining the fabric's flexibility and base functional properties, thereby resolving the contradiction between strength and lifespan.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The coating system uses composite materials including thermoplastic or thermoset resins combined with inorganic particles to create a coating that provides both abrasion resistance and flexibility. This composite approach allows the coating to protect against wear while adhering to the fabric substrate, extending its operational life.

Inventive Principle:

Principle #40Composite materials

3Reliability

If a protective coating is applied using thermal spray process, then resistance to thermal degradation and abrasion is improved, but the complexity of the manufacturing process increases

Engineering Contradiction:

Improveresistance to thermal degradationVSAvoidcomplexity of coating application process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces conventional coating methods with a thermal spray process that uses thermal energy to deposit and fuse coating materials onto the fabric surface. This substitution of the coating application mechanism enables efficient, uniform coating application with controlled thickness, resolving the contradiction between improved reliability and process complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The thermal spray process allows for precise control of coating parameters such as temperature, deposition rate, and coating thickness. By optimizing these parameters, the process achieves reliable protective coating application while minimizing unnecessary process complexity through efficient material utilization and reduced processing steps.

Inventive Principle:

Principle #35Parameter changes

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 thermal spray process effectively enhances the functional characteristics of fabrics and belts, improving their resistance to thermal degradation, abrasion, and wear, thereby extending their lifespan and maintaining performance in demanding environments.

Implementation Method 1

The coating or layer is applied by a thermal spray process such as a flame spray process, an electric wire arc spray process, a plasma spray process, a detonation gun deposition process, a cold spray process or a high velocity oxygen fuel combustion spray process

Methodology Applied

Scientific EffectThermal spray:

Implementation Method 2

The coating or layer is applied by a thermal spray process such as a flame spray process

Methodology Applied

Scientific EffectFlame spray:

Implementation Method 3

The coating or layer is applied by a thermal spray process such as a plasma spray process

Methodology Applied

Scientific EffectPlasma spray: Plasma Spray

Implementation Method 4

a thermal spray process such as a flame spray process, an electric wire arc spray process, a plasma spray process

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS8058188B2Thermally sprayed protective coating for industrial and engineered fabrics

Publication Date: 2011.11.15 ALBANY INT CORP

AI summary

A fabric or belt and a method for forming such a fabric or belt, including a base support structure and at least one coating with the coating being applied by a thermal spray process.