Automated Thermal Spray Masking with UV-Cured Paste Beads
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Solution Overview
Problem
Current masking methods for thermal spraying lack automation and precision, especially for critical mask boundaries, leading to inefficiencies and inaccuracies in the masking process.
Innovation Solution
A method using a temperature-controlled dispensing of a paste with specific viscosity to create precise sealing beads along critical mask boundaries, which can be cured using UV radiation, combined with a low-viscosity paste for non-critical areas, allowing for automated and precise masking with a high degree of accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual masking methods are used, then flexibility in handling complex geometries is maintained, but automation degree and productivity remain very low
Solution Approach 1:
The patent changes the physical parameters of the masking material by using a two-component system that transitions from a fluid state (easy to apply) to a solid state (precise and stable). This parameter change enables automation while maintaining the ability to handle complex geometries, as the material can be dispensed precisely and then locked into position.
Solution Approach 2:
The invention uses a composite masking system consisting of two different paste materials with complementary properties: one material provides easy application and coverage, while the other provides precision and stability. This composite approach allows automated dispensing to achieve both productivity and precision without requiring overly complex positioning systems.
2Manufacturing precision
If high-precision masking is applied to all areas, then critical mask boundaries are accurate, but application time and productivity increase significantly
Solution Approach 1:
The patent applies different quality levels of masking to different areas: high-precision dispensing is used only for critical mask boundaries where accuracy is essential, while less critical areas receive standard masking treatment. This local differentiation maintains precision where needed while significantly improving overall productivity.
Solution Approach 2:
The masking task is segmented into two distinct operations: precise boundary definition using automated dispensing of the second paste material, and area coverage using the first paste material. This segmentation allows the high-precision step to be limited to only the necessary critical boundaries, improving overall efficiency.
3Productivity
If low-viscosity paste is used for quick application, then large areas can be covered quickly, but precision and stability of the sealing bead decrease
Solution Approach 1:
The first paste material with lower viscosity is applied first to cover large areas quickly, preparing the base layer. Then the second paste material with higher viscosity is applied to define precise boundaries. This preliminary action allows the precision-critical step to focus only on boundary definition rather than entire area coverage.
Solution Approach 2:
The invention changes the viscosity parameter of the masking material by using two different materials: the first material has lower viscosity for easy flow and quick coverage, while the second material has higher viscosity for stable, precise bead formation. This parameter differentiation resolves the contradiction between speed and precision.
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 high-precision, automated masking of critical areas with quick application of large areas, preventing the thermal sprayed layer from extending beyond the mask boundaries, ensuring accurate and efficient coating processes.
Implementation Method 1
curing is at least partially achieved by crosslinking, particularly preferably by photoinduced crosslinking
Implementation Method 2
Thermal spraying is a coating process in which a material, for example in powder form, is continuously melted. The resulting droplets are propelled onto the surface to be coated
Data Source
Figure 1
AI summary
The invention relates to a method for coating components by means of thermal spraying methods, wherein not the entire surface of the component is intended to be coated and the parts of the surface that are not intended to be coated are covered by means of a masking before the coating, characterized in that, at least in the regions of critical mask boundaries, the covering is performed by means of paste methods, i.e., by means of a paste discharged from at least one nozzle.