Systems and methods for managing sharp transitions for powder coating

Patent metadata

Field	Value
Publication number	US-2022016668-A1
Application number	US-202016933114-A
Country	US
Kind code	A1
Filing date	Jul 20, 2020
Priority date	Jul 20, 2020
Publication date	Jan 20, 2022
Grant date	—

Abstract

An apparatus includes a component having an edge feature that has a radius of curvature. The apparatus includes an underlayer arranged over the edge feature and configured to increase the radius of curvature of the edge feature. The apparatus includes a powder coating arranged over the component and over the underlayer to form a continuous layer. The underlayer is configured to remain under the powder coating. The underlayer helps the powder coating achieve a more uniform thickness over the edge feature. The apparatus is formed by applying an underlayer to a first region of the component to form an underlaid component. The first region includes the edge feature. A powder coating is applied to the underlaid component. A masking layer may be applied to a region other than the first region, and after powder coating, the masking may be removed to expose a surface of the component.

First claim

What is claimed is:

1 . An apparatus comprising:
a component comprising at least one edge feature having a radius of curvature; an underlayer arranged over the at least one edge feature, wherein the underlayer is configured to increase the radius of curvature of the at least one edge feature; and a powder coating arranged over the component and over the underlayer to form a continuous layer, wherein the underlayer is configured to remain under the powder coating.

2 . The apparatus of claim 1 , wherein the component comprises a cooling assembly formed from sheet metal, wherein the at least one edge feature comprises a joint at an edge of the sheet metal.

3 . The apparatus of claim 1 , wherein the component further comprises a region that is exposed, wherein the region does not coincide with the underlayer.

4 . The apparatus of claim 3 , wherein the component comprises a busbar, and wherein the region is configured to be electrically coupled to an electrical circuit.

5 . The apparatus of claim 1 , wherein the underlayer is electrically insulative.

6 . The apparatus of claim 1 , wherein the component comprises one or more recess features, and wherein the underlayer is arranged to cover the one or more recess features.

7 . The apparatus of claim 6 , wherein the component comprises a mounting bracket of a battery module.

8 . The apparatus of claim 1 , wherein the underlayer comprises a tape.

9 . The apparatus of claim 8 , wherein the tape comprises at least one of a thermoset tape, a masking tape, or a heat activated tape.

10 . The apparatus of claim 1 , wherein the underlayer comprises a thickness, and wherein the thickness is selected to provide a predetermined spatial dimension of the apparatus.

11 . The apparatus of claim 1 , wherein the component comprises an electrically conductive material.

12 . An apparatus comprising:
a first component comprising at least one edge feature having a radius of curvature, wherein the first component is electrically conductive; an underlayer arranged over the at least one edge feature, wherein the underlayer is configured to increase the radius of curvature of the at least one edge feature; a second component arranged a distance from the first component, wherein the second component is electrically conductive; and a powder coating arranged over the first component and over the underlayer to form a continuous layer, wherein the underlayer is configured to remain under the powder coating, and wherein the underlayer provides dielectric protection against shorting between the first component and the second component.

13 . A method for coating a component comprising an edge feature, the method comprising:
applying an underlayer to a first region of the component to form an underlaid component, wherein the first region comprises the edge feature, wherein the edge feature comprises a first radius of curvature, and wherein the underlayer comprises a second radius of curvature at the edge feature larger than the first radius of curvature; and applying a powder coating to the underlaid component to form a coated component, wherein the underlayer is configured to remain on the component under the powder coating.

14 . The method of claim 13 , wherein the underlaid component comprises an exterior surface, the method further comprising preparing the exterior surface for the powder coating.

15 . The method of claim 13 , further comprising applying a masking layer to a second region of the component, wherein the first region and the second region do not overlap.

16 . The method of claim 15 , further comprising removing the masking layer after applying the powder coating to expose the second region of the component.

17 . The method of claim 13 , wherein applying the powder coating comprises:
spraying a powder onto the underlaid component; and curing the powder to from the powder coating, wherein curing the powder coating comprises increasing a temperature of the underlaid component to cause the underlayer to adhere more strongly to the component.

18 . The method of claim 13 , wherein applying the underlayer comprises applying a tape to the first region, wherein the tape comprises at least one of a thermoset tape, a masking tape, or a heat activated tape.

19 . The method of claim 13 , further comprising selecting the underlayer based at least in part on a material of the component.

20 . The method of claim 13 , further comprising selecting the underlayer based at least in part on a desired electrical property of the coated component.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Cournoyer Travis
• Wynn Nathaniel

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• B32B3/04

  characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} · CPC title

• B32B2255/06

  on metal layer · CPC title

• B32B2457/10

  Batteries · CPC title

• B32B15/043

  of metal (B32B15/01 takes precedence) · CPC title