DESC:FIELD OF THE DISCLOSURE
The present disclosure relates to a painting process, and more specifically, to a process for painting of glass fiber-reinforced polymer materials.
BACKGROUND
Glass Fiber-Reinforced Polymer, also known as GFRP, was first developed in the mid 1930s. Since their development, glass fiber-reinforced plastic has become a staple in the construction industry. GFRP can be used for interior as well as exterior fixtures in a variety of shapes, styles, and textures. GFRP is used in new buildings and restorative projects as well. GFRP is preferred in construction because of their high strength, light weight, low maintenance, good durability, and high resistance towards salt, water, chemicals, and the environment. GFRP also exhibits good ability to mold into complex shapes, which is a desired property in a construction material. They are widely used around the world in construction of domes, fountains, columns, balustrade, planters, panels, sculpture, entryways, moldings, facades, cornice, porticos, cupolas, signs, and roofs.
Further, Gloss refers to the shine or polish on a smooth surface. In the realm of paints, Glossy and flat (or matte) are typical extreme levels of glossiness of a finish. Glossy paints are shiny and reflect most light in the specular (mirror-like) direction, while most of the light diffuses in a range of angles on flat paints. Between those extremes, there are a number of intermediate gloss levels. Their common names, from the dullest to the shiniest, include: matte, eggshell, satin, silk, semi-gloss, and high gloss. These terms are not standardized and therefore, are not used by manufacturers.
A gloss value is a critical indicator of aesthetic appearance of the final constructed materials. The requirement of the gloss value to make the final constructed glass fiber-reinforced polymers to be aesthetically appealing to the human eye and of world class quality requirement is from 55 to 75. However, achieving the gloss value within this specified range is often a challenge.
Therefore, there is a need of a painting method for glass fiber-reinforced polymers that is, accurate, easy to handle and operate, cost-effective, and has a wide range of applications. Further, there is a need for a painting process that can provide materials constructed from GFRP with gloss value within the desired range.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified format that is further described in the detailed description of the present disclosure. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter. In accordance with the purposes of the disclosure, the present disclosure as embodied and broadly described herein, describes a process for painting of glass fiber-reinforced polymer materials.
In accordance with some embodiments of the present disclosure, a method of painting a panel formed of glass fiber-reinforced polymer is disclosed. The method includes cleaning the panel with acetone, smoothening the cleaned panel with a first sandpaper, and applying putty to the smoothened panel. The first sandpaper includes a sandpaper of a first grade. After the putty has dried, the method includes polishing the panel with the first sandpaper and then spraying a first coat of primer on the panel. Further, the primer is formed by mixing epoxy paint, hardener, and thinner in a predefined ratio. The method further includes applying the putty on the panel after the drying of the first coat, and smoothening the panel with a second sandpaper after the drying of the putty. The grade of the second sandpaper is higher than the first grade. Further, the method includes spraying a second coat of the primer on the panel, and applying the putty on the panel after drying of the second coat. The method further includes smoothening the panel with a third sandpaper after the putty has dried. Also, the grade of the third sandpaper is higher than the grade of the second sandpaper. Then, the method includes spraying a third coat of the primer on the panel and spraying a paint mixture on the triple primer-coated panel. The paint mixture is formed by mixing the paint with hardener.
The primary object of the present disclosure is to provide a painting process for glass fiber-reinforced polymers. Another objective of the present disclosure is to provide a painting process for glass fiber-reinforced polymers to obtain a desired gloss value. Yet another objective of the present disclosure is to provide a painting process for panels made of glass fiber-reinforced polymers. It is also an objective the present disclosure to provide a painting process for panels made of glass fiber-reinforced polymers to obtain a desired gloss value. The further objective of the present disclosure is achievement of gloss value at par with international standard using indigenized technology.
These aspects and advantages will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF FIGURES
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Figure 1 illustrates a flow chart depicting a method of painting a panel formed of glass fiber-reinforced polymer, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates another flow chart depicting a method of painting a panel formed of glass fiber-reinforced polymer, in accordance with another embodiment of the present disclosure; and
Figure 3 illustrates a cube plot depicting various combinations of variable parameters of the painting process for the glass fiber-reinforced polymer, in accordance with an embodiment of the present disclosure.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
DETAILED DESCRIPTION
It should be understood at the outset that although illustrative implementations of the embodiments of the present disclosure are illustrated below, the present invention may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary design and implementation illustrated and described herein.
The terminology and structure employed herein is for describing, teaching and illuminating some embodiments and their specific features and elements and does not limit, restrict or reduce the spirit and scope of the invention.
More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do not specify an exact limitation or restriction and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “must comprise” or “needs to include.”
Whether or not a certain feature or element was limited to being used only once, either way, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language such as “there needs to be one or more . . . ” or “one or more element is required.”
Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by one having an ordinary skill in the art.
Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the invention fulfill the requirements of uniqueness, utility, and non-obviousness.
Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
Figure 1 illustrates a flow chart depicting a method 100 of painting a panel formed of glass fiber-reinforced polymer, in accordance with an embodiment of the present disclosure. At step 102, the method 100 includes cleaning of the panel with acetone. The method 100 branches to step 104, wherein the cleaned panel is smoothened with a first sandpaper. At step 106, the method includes applying putty to the smoothened panel. At step 108, the method 100 includes polishing the panel with the first sandpaper after the putty has dried. Further, at step 110, the method 100 includes spraying a first coat of primer on the panel. The method 100 then branches to step 112, wherein the putty is applied on the panel after the first coat of the primer has dried. At step 114, the panel is smoothened with a second sandpaper. At step 116, the method 100 includes spraying a second coat of the primer on the panel. At step 118, the method 100 includes applying the putty on the panel after the second coat of the primer has dried. At step 120, the method 100 includes smoothening the panel with a third sandpaper. At step 122, the method 100 includes spraying a third coat of the primer on the panel. Further, at step 124, the method 100 includes spraying a paint mixture on the triple primer-coated panel.
In an embodiment of the present disclosure, at step 102, the panel is cleaned with the acetone with the help of a cotton cloth. Then, at step 104, the cleaned panel is smoothened with a sanding machine with the first sandpaper. At step 106, putty is applied with a putty blade to the smoothened panel. At step 108, the panel is polished with the help of the sanding machine with appropriate sand paper. A paint booth and a spray gun are used for spraying a first coat of primer on the panel as depicted at step 110. Further, at step 112, again the putty blade is used for applying the putty. At step 114, the sanding machine is again used for smoothening the dried panel. Further, at step 116, the spray gun is used for spraying the second coat of the primer. Then, the putty blade is used for drying the second coat of primer applied on the panel, as depicted at step 118. Further, the sanding machine is again used at step 120 for smoothening the panel. Further, the spray gun is used for spraying the paint mixture on the triple primer-coated panel.
The method 100 of painting the panel formed of the glass fiber-reinforced polymer is further explained in detail in the description of Figure 2.
Figure 2 illustrates another flow chart depicting a method 200 of painting a panel formed of glass fiber-reinforced polymer, in accordance with another embodiment of the present disclosure. For the sake of brevity, constructional and operational features of the process that are already explained in the description of Figure 1 are not explained in detail in the description of Figure 2.
In one embodiment the present disclosure, the method 200 for painting panels made of glass fiber-reinforced polymers is described. Firstly, at step 202, the raw material i.e. glass fiber-reinforced polymer material is taken, checked for damage and thoroughly cleaned with acetone. At step 204, the surface of the cleaned raw material is smoothened with a 120 grade sandpaper. The method 200 branches to step 206, wherein putty is applied to the smoothened material and then, the smoothened material is allowed for natural air drying for 4 hours. At step 208, the obtained dried putty covered material is again polished with the sandpaper. Further, at step 210, a primer composition is prepared which ensures better adhesion of paint to the surface, increases paint durability, and provides additional protection for the material being painted. The primer composition is prepared by mixing epoxy paint and hardener in a ratio of 3:1. Further, thinner is added to the primer composition to achieve a viscosity of 24 to 28 seconds.
At step 212, a spray gun with a 1.5 mm clean nozzle is taken. The smoothened putty covered material is kept in a spray paint booth with compressed air pressure of 5-6 bars as depicted at step 214. At step 216, first coat of primer is sprayed on the smoothened putty covered material. Afterwards, the primer coated material is dried in an oven as depicted at step 218. The method 200 further branches to step 220, wherein the obtained dried material is inspected and if the obtained dried material fails the inspection the process right from the step 204 is repeated. But if the results are found to be satisfactory, the method 200 branches to step 222, wherein the steps of applying putty and drying the applied putty in an oven is done. At step 224, the method 200 includes smoothening the surface with sandpaper of grade 180. Then, at step 226, the method 200 further includes applying a second coat of primer followed by oven drying as depicted in Figure 2. At step 228, the method 200 includes applying putty and drying the applied putty in an oven on the obtained dried double primer coated material. At step 230, the method 200 includes smoothening the surface with sandpaper of grade 220 to obtain a triple primer coated material.
In yet another embodiment of the present application, the paint for application is prepared as shown at step 232. Paint and hardener are mixed in a ratio of 4:1 to obtain a paint hardener mixture with a viscosity in the range of 20-24 (units). The obtained paint hardener mixture is then stirred and filtered. Further, at step 234, steps 212, 214 and 218 are repeated and the prepared paint is sprayed onto the triple primer coated material in a spray paint booth. Then, finish coat paint spraying is repeated again for a double coating of paint. At step 236, the final painted material obtained is inspected. If the final painted material fails the inspection tests the process right from the step 204 is repeated. But, if the results are found to be satisfactory, the final painted material is moved to the assay tests.
In an embodiment of the present disclosure, a stirrer and a filter are used for stirring and filtering the paint mixture. A measuring jar is used to mix the epoxy paint with the hardener in a ratio of 3:1. For measuring the viscosity of the primer, a ford viscosity cup can be used. Also, an air compressor fitted with pressure gauge and a spray gun fitted with a nozzle is used for measuring the compressed air pressure. Further, an oven may be used for heating ad drying purposes.
Figure 3 illustrates various combinations of variable parameters of the painting process for the glass fiber-reinforced polymer, in accordance with an embodiment of the present disclosure. In an embodiment of the present disclosure, to improve the process and to understand the effect of certain parameters on gloss value, a total of 64 experiments were conducted. Hardener mixing ratio, heating temperature, heating time, spraying viscosity and surface preparation were chosen as the variable experimental factors. Paint source, nozzle size, spraying pressure, and painter were the control factors in the experiment. The compressor’s supply line, ambient conditions (temperature, humidity, etc.), operator fatigue were the noise factors of this experiment. The experiments were full factorial experiments with five factors each with two levels and were replicated twice. The experiments were randomized in order to reduce the effect of undesired variables.
The total 64 experiments were conducted and data was collected for hardener mixing ratio, surface preparation, spraying viscosity, heating time and heating temperature. Large effects were determined using pareto chart and normal plot. The cube plot of figure 3 depicts the various combinations of variables that were done to get the desired gloss value. From figure 3, the painting process parameters to get the optimum gloss value were concluded. Significant factors are found to be hardener mixing ratio, heating temperature, spraying viscosity and drying time. Surface preparation had no effect on gloss value.
In one embodiment of the present disclosure, the hardener mixing ratio is in a desired ratio. Preferably, the hardener mixing ratio is about 8:1. In another embodiment of the present disclosure, the heating temperature is in the desired range. Preferably, the heating temperature is about 80°C. In yet another embodiment of the present disclosure, the drying time is in the desired range. Preferably, the drying time is about 60 minutes. In yet another embodiment of the present disclosure, the spraying viscosity is in the desired range. Preferably, the spraying viscosity is about 16 seconds. In one embodiment of the present disclosure, the main effect plot was plotted and it was found that there is a significant change in gloss value when hardener mixing ratio is changed from 4:1 to 8:1. In one embodiment of the present disclosure, interaction plot was also plotted for gloss value determination using all five variables; however no interaction was found between the variables.
EXAMPLES
The following examples are set forth below to illustrate the methods and results according to the disclosed subject matter. These examples are not intended to be inclusive of all aspects of the subject matter disclosed herein, but rather to illustrate representative methods, compositions, and results. These examples are not intended to exclude equivalents and variations of the present disclosure, which are apparent to one skilled in the art.
A total of 64 experiments, varying the various painting process parameters, were conducted in order to obtain the desired gloss value (Table 1).
Table 1: Indicating 64 experiment results
Sr No Std Order Run Order Centre
Point(s) Blocks Hardener Mixing Ratio Heating Temperature Drying Time Surface
Preparation Spraying Viscosity Gloss
1 46 1 1 1 8:1 60 60 400 16 63.8
2 35 2 1 1 4:1 80 30 220 16 75.5
3 41 3 1 1 4:1 60 30 400 16 78.2
4 62 4 1 1 8:1 60 60 400 25 69.8
5 44 5 1 1 8:1 80 30 400 16 66.7
6 49 6 1 1 4:1 60 30 220 25 79.7
7 16 7 1 1 8:1 80 60 400 16 65.3
8 17 8 1 1 4:1 60 30 220 25 80.4
9 2 9 1 1 8:1 60 30 220 16 72.7
10 22 10 1 1 8:1 60 60 220 25 69.5
11 51 11 1 1 4:1 80 30 220 25 79.3
12 57 12 1 1 4:1 60 30 400 25 81.8
13 30 13 1 1 8:1 60 60 400 25 71
14 12 14 1 1 8:1 80 30 400 16 66.6
15 27 15 1 1 4:1 80 30 400 25 80.3
16 23 16 1 1 4:1 80 60 220 25 75
17 56 17 1 1 8:1 80 60 220 25 66
18 55 18 1 1 4:1 80 60 220 25 74.9
19 42 19 1 1 8:1 60 30 400 16 73.9
20 58 20 1 1 8:1 60 30 400 25 77.2
21 20 21 1 1 8:1 80 30 220 25 69.1
22 50 22 1 1 8:1 60 30 220 25 73.3
23 48 23 1 1 8:1 80 60 400 16 65.8
24 63 24 1 1 4:1 80 60 400 25 75.5
25 3 25 1 1 4:1 80 30 220 16 72.3
26 29 26 1 1 4:1 60 60 400 25 81.8
27 9 27 1 1 4:1 60 30 400 16 78.1
28 37 28 1 1 4:1 60 60 220 16 74.8
29 18 29 1 1 8:1 60 30 220 25 77.2
30 52 30 1 1 8:1 80 30 220 25 68
31 64 31 1 1 8:1 80 60 400 25 66.2
32 1 32 1 1 4:1 60 30 220 16 78.3
33 47 33 1 1 4:1 80 60 400 16 74.2
34 45 34 1 1 4:1 60 60 400 16 74.7
35 53 35 1 1 4:1 60 60 220 25 77.3
36 26 36 1 1 8:1 60 30 400 25 76.7
37 61 37 1 1 4:1 60 60 400 25 81.9
38 15 38 1 1 4:1 80 60 400 16 73.6
39 14 39 1 1 8:1 60 60 400 16 65.1
40 33 40 1 1 4:1 60 30 220 16 78
41 60 41 1 1 8:1 80 30 400 25 68.8
42 25 42 1 1 4:1 60 30 400 25 82.5
43 40 43 1 1 8:1 80 60 220 16 67.2
44 59 44 1 1 4:1 80 30 400 25 79.1
45 7 45 1 1 4:1 80 60 220 16 74.6
46 13 46 1 1 4:1 60 60 400 16 73.9
47 24 47 1 1 8:1 80 60 220 25 65.6
48 39 48 1 1 4:1 80 60 220 16 73.1
49 4 49 1 1 8:1 80 30 220 16 66.6
50 5 50 1 1 4:1 60 60 220 16 74.5
51 11 51 1 1 4:1 80 30 400 16 74.2
52 32 52 1 1 8:1 80 60 400 25 66.9
53 31 53 1 1 4:1 80 60 400 25 75.5
54 28 54 1 1 8:1 80 30 400 25 68.4
55 36 55 1 1 8:1 80 30 220 16 67.6
56 21 56 1 1 4:1 60 60 220 25 79.7
57 38 57 1 1 8:1 60 60 220 16 66.1
58 8 58 1 1 8:1 80 60 220 16 65.9
59 10 59 1 1 8:1 60 30 400 16 69.9
60 6 60 1 1 8:1 60 60 220 16 67.5
61 43 61 1 1 4:1 80 30 400 16 74.1
62 34 62 1 1 8:1 60 30 220 16 72.4
63 19 63 1 1 4:1 80 30 220 25 78.9
64 54 64 1 1 8:1 60 60 220 25 70.3

As would be gathered, the present disclosure relates to a painting process for a panel made of glass fiber-reinforced polymers which can be used in different industries. In one embodiment of the present disclosure, the present disclosure relates to a painting process for glass fiber-reinforced polymers panels used to construct rolling stock furnishing and automobiles. In a preferred embodiment of the present disclosure, the present disclosure relates to a painting process for glass fiber-reinforced polymers used to construct interior panels of metro cars. In yet another embodiment of the present disclosure, the present disclosure relates to establishment of panel painting process parameters for painting glass fiber-reinforced polymers to obtain a desired gloss value. Also, the steps of the painting process are made simple and easy in order to obtain the gloss value of the final painted material within the desired range. A primer composition is prepared which ensures better adhesion of paint to the surface and hence, increases paint durability and provides additional protection for the material being painted. Further, thinner is added to the primer composition to achieve a viscosity of 24 to 28 seconds. Therefore, the painting process of the present disclosure is accurate, easy to handle and operate, cost-effective, and has a wide range of applications.
While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. Clearly, the present disclosure may be otherwise variously embodied, and practiced within the scope of the following claims.
,CLAIMS:WE CLAIM:

1. A method (100) of painting a panel formed of glass fiber-reinforced polymer, the method comprising:
cleaning the panel with acetone;
smoothening the cleaned panel with a first sandpaper, wherein the first sandpaper comprises of a sandpaper of a first grade;
applying putty to the smoothened panel;
polishing, after the putty has dried, the panel with the first sandpaper;
spraying a first coat of primer on the panel, wherein the primer is formed by mixing epoxy paint, hardener, and thinner in a predefined ratio;
applying, after the drying of the first coat, the putty on the panel;
smoothening, after the drying of the putty, the panel with a second sandpaper, wherein a grade of the second sandpaper is higher than the first grade;
spraying a second coat of the primer on the panel;
applying, after the drying of the second coat, the putty on the panel;
smoothening, after the drying of the putty, the panel with a third sandpaper, wherein a grade of the third sandpaper is higher than the grade of the second sandpaper;
spraying a third coat of the primer on the panel; and
spraying a paint mixture on the triple primer-coated panel, wherein the paint mixture is formed by mixing the paint with hardener.

2. The method (100) as claimed in claim 1, comprising:
stirring and filtering the paint mixture; and
spraying the paint mixture on the triple primer-coated panel.

3. The method (100) as claimed in claim 1, wherein the grade of the first sandpaper, the second sandpaper, and the third sandpaper is 120, 180, and 220, respectively.

4. The method (100) as claimed in claim 1, comprising forming the primer by:
mixing the epoxy paint with the hardener in a ratio of 3:1; and
adding the thinner to achieve a viscosity of 24 seconds to 28 seconds for the formed primer.

5. The method (100) as claimed in claim 1, comprising spraying the coats of the primer through a nozzle at a compressed air pressure of 5 bars to 6 bars.

6. The method (100) as claimed in claim 1, comprising forming the paint mixture by mixing the paint with the hardener in a ratio of 4:1 to achieve a viscosity of 20 seconds to 24 seconds.

7. The method (100) as claimed in claim 1, wherein a hardener mixing ratio is 8:1.

8. The method (100) as claimed in claim 1, wherein a heating temperature is 80°C.

9. The method (100) as claimed in claim 1, wherein a drying time is 60 minutes.

10. The method (100) as claimed in claim 1, wherein a spraying viscosity is 16 seconds.