Water-Based Thermosetting Coating for Metal Products Using Residual Heat
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Solution Overview
Problem
Existing methods for coating metal products like wire, wire strand, or tape require reheating after applying thermosetting coatings, consuming additional energy and increasing environmental impact, while failing to ensure effective adhesion and corrosion protection.
Innovation Solution
A method where metal products are cooled with water immediately after high-temperature processes like annealing, followed by applying a water-based thermosetting coating that solidifies through heat transfer from the metal, eliminating the need for separate curing and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting coating is applied to metal product, then corrosion protection and adhesion are improved, but additional reheating is required consuming extra energy
Solution Approach 1:
The metal product is preheated to high temperature (200-1000°C) during annealing, patenting, relaxation, or heating processes before coating application. This preliminary heating eliminates the need for separate post-coating curing, as the coating solidifies using the residual heat from the metal substrate itself.
Solution Approach 2:
The coating application process is merged with the thermal processing process. Instead of treating them as separate operations (heating then cooling, then separately heating again for curing), the patent combines them by applying the thermosetting coating during or immediately after the thermal processing when the metal is already at elevated temperature.
2Manufacturing precision
If separate curing process is used for thermosetting coating, then coating solidification is achieved, but production time and energy consumption increase
Solution Approach 1:
The metal substrate is preheated to the required temperature for coating solidification during the necessary thermal processing operations. This preliminary heating action provides the thermal energy needed for coating curing without requiring a separate heating and holding phase after coating application.
Solution Approach 2:
The thermal processing and coating application are performed in continuous sequence without interrupting the thermal field. The metal product transitions directly from thermal processing to coating application while maintaining elevated temperature, ensuring continuous useful action and eliminating idle time.
3Reliability
If traditional coating method is used, then corrosion protection is provided, but environmental impact increases due to additional heating requirements
Solution Approach 1:
The high temperature required for metal thermal processing, which would normally be followed by cooling and then require additional heating for coating curing, is instead utilized as a benefit. The residual heat from the thermal processing is converted into the curing energy for the thermosetting coating, eliminating the need for additional fossil fuel-based heating.
Solution Approach 2:
The metal product serves its own thermal needs by providing the heat required for coating solidification. The thermal energy stored in the metal substrate during annealing or heating processes is used to cure the coating, making the system self-sufficient and eliminating external energy inputs.
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
This method achieves improved adhesion and corrosion protection with reduced energy use and environmental impact by utilizing heat from the metal itself to solidify the coating, minimizing the need for additional heating sources and chemical pollutants.
Implementation Method 1
a water-based thermosetting coating is applied to the surface of the metal product... which undergoes thermosetting due to heat transfer from the metal product
Implementation Method 2
the metal product is cooled by immersion or spraying with water
Data Source
AI summary
As shown in the drawing (in the form of a block diagram), the developed invention provides a method of applying a coating (2) to the surface of a metal product (1) (which takes the form of a metal wire, wire strand, or metal tape). The coating (2) protects the metal product (1) from corrosion or imparts physical properties ensuring corrosion protection or high flexibility of the applied coating. The metal product (1), shaped in the technological process to the desired dimensions and cross-sectional shape, such as a metal wire, wire strand, or metal tape, is heated to a temperature of 200°C-1000°C using at least one process known from the prior art (for example, annealing, patenting, relaxation, or heating). Next, the metal product (1) is cooled to a temperature of 150°C-500°C. In the described method, water (H2O) serves as the cooling medium - the final cooling is done by immersion in water or spraying with water. After cooling to a temperature of 150°C-500°C, at least one thermosetting, water-dilutable coating (2) is applied to the metal product (1), typically in the form of paint, usually by immersion or spraying.