DESC:TECHNICAL FIELD
The present disclosure relates to the field of automotive components, specifically to ball joints used in various automotive applications. More particularly, the present disclosure pertains to a surface protection coating that prevents the formation of rust and ensures the long-lasting performance of ball joints.
BACKGROUND
In the automotive components industry, ball joints are essential for maintaining the performance and safety of various automotive systems. To protect the surface of ball joints and ensure their long-lasting functionality and aesthetics, different surface protection methods are employed. However, the use of paint as a protective coating during the assembly process presents specific challenges and drawbacks.
One significant issue encountered when using paint for surface protection is the impact on the assembly room environment. To avoid dust particles sticking, the assembly room is typically a controlled atmosphere where workers carry out the assembly process. The application of paint inside the assembly room can lead to the release of volatile organic compounds (VOCs) and other potentially harmful substances. This can result in suffocation and health hazards for workers, compromising their well-being and safety.
To address this suffocation issue, an alternative approach is to perform the painting process in a separate area away from the assembly room. However, this solution introduces another challenge related to traceability. When the painting process is conducted separately, it often becomes a batch process, where multiple ball joints are painted simultaneously. This can make it difficult to track and trace specific ball joints to their respective coating processes, leading to potential issues in quality control, batch identification, and overall traceability.
While the current practice of using paint for surface protection in the roll-over area of the outer ball joint after assembly offers some benefits, such as corrosion resistance, it is necessary to consider these drawbacks. The suffocation risk to workers and the traceability issues associated with a separate painting area pose challenges to the efficiency, safety, and quality control of the ball joint manufacturing process.
Therefore, there is a need for an improved surface protection system that addresses these concerns while ensuring the longevity, performance, and aesthetics of ball joints. Such a system should provide effective surface protection without compromising the health and safety of assembly room workers. Additionally, it should enable accurate traceability of individual ball joints to their respective coating processes, ensuring quality control and efficient production.
SUMMARY
One or more of the problems of the conventional prior art may be overcome by various embodiments of the present disclosure.
In one aspect of the present disclosure, there's a process comprising: cleaning and activating the surface of a target material via a plasma treatment within a time frame of 10-50 seconds; applying a vinyl primer on the activated target surface within a time frame of 10-30 seconds; applying a vinyl composition on the primer applied target surface within a time frame of 100-220 seconds; inspecting the applied vinyl composition on the target surface; and packing the inspected vinyl composition.
In another aspect of the present disclosure, the cumulative process time involving the cleaning, activation, primer application, and vinyl composition application of the process as claimed before is between 200-300 seconds.
In another aspect of the present disclosure, the target material for the process as claimed before can be a ball joint.
In another aspect of the present disclosure, the vinyl composition used in the process provides surface protection against environmental factors and rust formation as per the preceding claims.
In another aspect of the present disclosure, the adhesion of the vinyl composition is enhanced due to plasma treatment and primer coating as claimed in any preceding claim.
In another aspect of the present disclosure, the process further comprises the step of evaluating peel strength of the vinyl coating under various use case scenarios.
In yet another aspect of the present disclosure, the vinyl composition serves as an eco-friendly alternative to conventional surface protection methods as claimed in any preceding claim.
In another aspect of the present disclosure, the primer for coating used in the process contains Cyclohexane, Xylene, Ethylbenzene, Ethanol, Ethyl acetate, Acrylate Polymer, Chlorinated Polyolefin, Toluene, Acetone, Propan-2-ol, Epoxy Resin, Methanol, 4-Methylpentan-2-one, Cumene, Chlorobenzene, Maleic anhydride, or Naphthalene or any combination thereof as per the preceding claims.
In another aspect of the present disclosure, the application of the process results in benefits such as enhanced traceability, reduced cycle time, lower operational expenses, and improved line balancing in the manufacturing process.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawing,
Figure 1 illustrates a flowchart that depicts a method of application of vinyl composition, in accordance with an aspect of the present disclosure; and
Figure 2 illustrates a picture depicting ball joint having the vinyl composition, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and, such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.
Figure 1 illustrates a flowchart that depicts method (100) of application of the vinyl composition on a target, in accordance with an aspect of the present disclosure.
At step 102, cleaning and activating surface of target of a material by way of a plasma treatment associated with a time interval of 10-50 seconds.
At step 104, applying a vinyl primer on the target surface associated with a time interval of 10-30 seconds.
At step 106, applying the vinyl composition on the vinyl primer applied target surface associated with a time interval of 100-220 seconds. In some aspects of the present disclosure, process time associated with step 102, step 104, and 106 is 200-300 seconds. In some aspects of the present disclosure, process time associated with step 102, step 104, and 106 is 240 seconds.
At step 108, inspecting the applied vinyl composition on the target surface.
At step 110, packing the inspected vinyl composition.
In some aspects of the present disclosure, the primer for coating ball joint may include Cyclohexane, Xylene, Ethylbenzene, Ethanol, Ethyl acetate, Acrylate Polymer, Chlorinated Polyolefin, Toluene, Acetone, Propan-2-ol, Epoxy Resin, Methanol, 4-Methylpentan-2-one, Cumene, Chlorobenzene, Maleic anhydride, and Naphthalene alone or in combination thereof.
In some aspects of the present disclosure, the vinyl primer is a primer 94.
In some aspects of the present disclosure vinyl composition may be applied to a surface of a ball joint. In some aspects of the present disclosure, the vinyl composition may provide effective surface protection against rust formation and environmental factors. In some aspects of the present disclosure, the vinyl composition may ensure bonding due to surface energy treatment.
In some aspects of the present disclosure, a validation method was performed to evaluate peel strength of the vinyl coating under different use case scenarios, including water wash and water splash on roads.
In some aspects of the present disclosure, the application of the vinyl coating allows for its usage inside the assembly room, eliminating suffocation concerns associated with traditional painting methods.
In some aspects of the present disclosure, the application of the vinyl coating can be carried out in the same assembly line as single-piece flow, ensuring traceability of individual products and eliminating the need for batch processing.
In some aspects of the present disclosure, the application of the vinyl coating reduces the process cycle time requirements significantly compared to traditional spray paints and powder coatings, eliminating the need for complex conveyorized online heating systems for drying and facilitating line balancing.
In some aspects of the present disclosure, the use of surface energy treatment, such as plasma treatment in combination with a primer coating, enhances the adhesion of the protective vinyl coating, enabling it to withstand the water jet testing procedure and ensuring reliable surface protection.
In some aspects of the present disclosure, the implementation of the unique process offers benefits such as enhanced traceability, reduced cycle time, lower operational costs, and improved line balancing in the manufacturing of ball joints.
In some aspects of the present disclosure, the use of the vinyl film as a surface protection coating provides an eco-friendly alternative to conventional methods such as painting, plating, or coating.
In some aspects of the present disclosure, the implementation of single-piece flow facilitates better traceability, reduces process costs, and enables immediate progression to subsequent processes after the completion of the surface protection process.
Example 1: application of vinyl composition on a ball joint
The ball point with surface energy less than 38 dyne was cleaned with a plasma treatment for 10 seconds and the facilitated improvement to 60 level. The vinyl primer was applied on the plasma treated ball joint applying a vinyl primer on the target surface associated with a time interval of 100 seconds. The vinyl composition was applied on the vinyl primer applied target surface associated with a time interval of 130 seconds.
Example 2: application of vinyl composition on a ball joint
The ball point with surface energy less than 38 dyne was cleaned with a plasma treatment for 25 seconds and the facilitated improvement to 60 level. The vinyl primer was applied on the plasma treated ball joint applying a vinyl primer on the target surface associated with a time interval of 15 seconds. The vinyl composition was applied on the vinyl primer applied target surface associated with a time interval of 200 seconds.
Example 3: Water jet testing
The target part was clamped in a special fixture on a rotating table with four nozzles for spraying water, each positioned 30 degrees apart. The water was sprayed at a pressure of 85 bar, with the temperature maintained at 80 degrees Celsius and a flow rate of 16 liters per minute. The width of the spray was directed vertically at a 30-degree angle and horizontally at an 8mm distance. The rotating table, which held the target, rotated at an angular speed of 5 rotations per minute. The test resulted as passed which indicates the present disclosure withstand the water jet testing.
Example 4: Validation
The plasma treatment with 0.5bar pressure on 5501-Black sample with 3M-94 primer failed in validation on testing by resulting peeling of coating. The plasma treatment with 1 bar pressure on 5501-Black sample with 3M-94 primer failed in validation on testing by resulting peeling of coating.
The plasma treatment with 0.5 bar pressure on 900 series-Black sample with 3M-94 primer failed in validation on testing by resulting peeling of coating. The plasma treatment with 1 bar pressure on 900 series-Black sample with 3M-94 primer failed in validation on testing by resulting peeling of coating.
The plasma treatment with 0.5bar pressure on 180LSE sample with 3M-94 primer failed in validation on testing by resulting peeling of coating. The plasma treatment with 1 bar pressure on 180LSE sample with 3M-94 primer failed in validation on testing by resulting peeling of coating.
The plasma treatment with 0.5bar pressure on permanent black sample with 3M-94 primer passed in validation on testing by resulting non-peeling of coating. The plasma treatment with 1 bar pressure on permanent black sample with 3M-94 primer passed in validation on testing by resulting non-peeling of coating.
The plasma treatment with 0.5bar pressure on 180 LSE with lamination sample with 3M-94 primer passed in validation on testing by resulting non-peeling of coating. The plasma treatment with 1 bar pressure on 180 LSE with lamination sample with 3M-94 passed in validation on testing by resulting non-peeling of coating.
Example 5: Validation
A ball joint was coated with Supplier-1 long term removable film over the surface and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with Supplier-1 permanent film over the surface and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with Supplier-1 long term removable film over the surface with primer and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with Supplier-1 permanent film over the surface with primer and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with 3M LSE film over the surface with primer and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with 3M permanent black film over the surface with primer and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with Supplier-1 long term removable film over the surface with plasma treatment and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with Supplier-1 permanent film over the surface with plasma treatment and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with 3M LSE film over the surface with plasma treatment and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface. A ball joint was coated with 3M permanent black film over the surface with plasma treatment and taken for water jet testing. The film peeled off from the surface during testing and failed to remain on the surface.
Example 6: Validation
The surface was treated with plasma with 0.5 bar pressure and at a distance 3 to 5mm and primer at a temperature of 30 degree Celsius and the strength obtained was 34.079kg/cm2. The surface was treated with plasma with 0.5 bar pressure and at a distance 3 to 5mm and without primer at a temperature of 30 degree Celsius and the strength obtained was 27.42/cm2. The surface was treated with plasma with 1 bar pressure and at a distance 1 to 3mm and primer at a temperature of 30 degree Celsius and the strength obtained was 34.38kg/cm2. The surface was treated with plasma with 1 bar pressure and at a distance 1 to 3mm and without primer at a temperature of 30 degree Celsius and the strength obtained was 28.20kg/cm2. The surface treated without plasma and with primer at a temperature of 30 degree Celsius and the strength obtained was 28.20kg/cm2. The surface treated without plasma and without primer at a temperature of 30 degree Celsius and the strength obtained was 21.94kg/cm2.
The target with primer and plasma exhibits 34.079kg/cm2and 34.38kg/cm2 passed the water jet testing.
Example 6: Dyne testing (Surface energy testing)
The target with plasma treatment exhibited surface energy of 52dyne. The target without plasma treatment exhibited surface energy of less than 32dyne.
The implementation set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detain above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementation described can be directed to various combinations and sub combinations of the disclosed features and/or combinations and sub combinations of the several further features disclosed above. In addition, the logic flows depicted in the accompany figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. Other implementations may be within the scope of the following claims.
,CLAIMS:1. A method (100) of application of the vinyl composition on a target comprising:
cleaning and activating (102) the surface of a target material via a plasma treatment within a time frame of 10-50 seconds;
applying (104) a vinyl primer on the activated target surface within a time frame of 10-30 seconds;
applying (106) a vinyl composition on the primer applied target surface within a time frame of 100-210 seconds with an ambient temperature of 15-35 degree C and relative humidity of 75-85; and
inspecting (108) the applied vinyl composition on the target surface.

2. The method (100) as claimed in claim 1, where the cumulative process time involving the cleaning, activation, primer application, and vinyl composition application is between 200-300 seconds.
3. The method (100) as claimed in claim 1, where the target material is a ball joint.
4. The method (100) as claimed in claim 1, where the vinyl composition provides surface protection against environmental factors and rust formation.
5. The method (100) as claimed in claim 1, where the adhesion of the vinyl composition is enhanced due to plasma treatment and primer coating.
6. The method (100) as claimed in claim 1, further comprising the step of evaluating peel strength of the vinyl coating under various use case scenarios.
7. The method (100) as claimed in claim 1, wherein the vinyl composition serves as an eco-friendly alternative to conventional surface protection methods.
8. The method (100) as claimed in claim 1, where the primer for coating contains Cyclohexane, Xylene, Ethylbenzene, Ethanol, Ethyl acetate, Acrylate Polymer, Chlorinated Polyolefin, Toluene, Acetone, Propan-2-ol, Epoxy Resin, Methanol, 4-Methylpentan-2-one, Cumene, Chlorobenzene, Maleic anhydride, or Naphthalene or any combination thereof.