Application: Evenly coat displays and high-quality visible surfaces
What this application is about
In practice, solutions range from flexible manual workstations to indexed, robot-assisted series-production systems. The spray equipment, material supply and movement sequence must be suited to the coating material and the workpiece.
Requirements for visually high-quality exposed surfaces
The application mainly concerns glass, transparent and high-gloss plastics, painted metal surfaces and composite components. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
Typical requirements for the spraying process
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- highest requirements for uniformity and cleanliness
- visible errors already with very small shift deviations
- small application quantities and fine atomisation
- Avoiding particles, spray mist and edge construction
- Reproducible wetting of large or curved surfaces
- Adaptation to sensitive substrates and coating materials
Optical uniformity on sensitive surfaces
Displays, apertures and high-quality viewing areas show dust, clouds, overlaps and smallest runs particularly clearly. Pre-treatment, component cleanliness and controlled environment are therefore just as important as atomisation. In the case of transparent or translucent layers, the amount of material must be very constant over the entire surface.
Masks protect contacts, windows and functional areas. The spray webs shall be arranged in such a way that no visible points are created.
- fine and homogeneous atomisation
- low variation of the wet layer
- clean surface and controlled dust exposure
- defined masquerade and edge areas
- coordinated ventilation and curing
Krautzberger solutions for spray application and material supply
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on finely atomizing hand or automatic spray guns, precise XLINE nozzle combinations, stable material pressure control as well as clean material containers and pipes. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Components, industries and fields of application
The application is used in different industries and component groups. Typical examples are:
- Touchscreens and control panels
- Cover lenses and display elements
- Piano-black and high gloss surfaces
- Fittings and interior components
- Household and electrical appliances
- high-quality design and consumer goods
Manual, partially automated or fully automatic
Manual coating is suitable for samples and small series. In series plants, component cleaning, spraying web, overlap, cabin air and drying are closely coordinated.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Result for quality and economy
- even, high-quality visual surfaces
- less scrap due to stable process parameters
- controlled application of thin functional layers
- reduced material consumption
- Flexible application on glass and plastic
- scalable up to automated series production
Tests with original material and sample components
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
In the test, spray pattern and optical quality are evaluated under appropriate illumination; in addition, wetting, drying and surface function shall be tested.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Trials at the Krautzberger technical centre
At the Krautzberger technical centre, the process can be tested with the original medium and representative sample components. Conveyability, spray pattern, application quantity, material pressure, distance, movement and cleaning are coordinated during these trials.
The trials provide a reliable basis for selecting the spray gun, nozzle, material supply and degree of automation. Final functional and process approval is issued by the operator together with the material manufacturer.
Related products
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Contact for your application
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
A small irregularity in the layer is already noticeable on displays and other viewing surfaces. An even application is therefore important, so that optics, haptics and cleanability fit the respective product.
