Patent Publication Number: US-2021195754-A1

Title: Systems and methods for coating a substrate

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a U.S. National Stage Application of International Patent Application No. PCT/US2018/059995, filed Nov. 9, 2018, which claims the benefit of U.S. Provisional Patent App. No. 62/584,259, filed Nov. 10, 2017, the entire disclosures of both of which are hereby incorporated by reference as if set forth in their entireties herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure generally relates to applying a coating to a substrate and, more particularly, to a modular system for applying a coating to a substrate, curing the coating, and inspecting the substrate. 
     BACKGROUND 
     A variety of coating systems exist for applying a conformal coating to a substrate, such as a printed circuit board (PCB). A conformal coating is a thin layer of dielectric material that is applied to a substrate to provide environmental and mechanical protection to the circuitry on the board. The coating protects the circuitry from moisture and prevents short circuiting and corrosion of the metal conductors and soldered joints. The conformal coating also prevents or minimizes the dendritic growth (electrochemical migration) of metal at the soldered joints that could later result in short circuit. After the coating has been applied, the coating can be heat cured on the substrate using one or more ovens included in the coating system. Further, the coating can be manually inspected by an operator of the coating system or automatically inspected by an inspection station included in the coating system. 
     Conventional coating systems can include a conveyer that extends through each part of the coating system for moving the substrate from the beginning to the end of the coating process. As a result, such conveyers move the substrate along a substantially linear path through the coating system. Due to the size of certain parts of the coating system, particularly the long length of some ovens, conventional coating systems can be very long. These coating systems therefore define large footprints and likewise require a large floor space for operation. 
     As a result, there is a need for a coating system that defines a reduced footprint and therefore conserves floor space in a factory setting. 
     SUMMARY 
     An embodiment of the present disclosure includes a system for applying a coating to a substrate. The system includes a coating station for applying a coating material to the substrate, where the coating station has a bottom portion, and an oven for curing the coating material on the substrate, where the oven is positioned vertically below the bottom portion. The system also includes a first lift for transporting the substrate from the coating station to the oven. 
     Another embodiment of the present disclosure includes a method for applying a coating to a substrate. The method includes applying a coating material to the substrate with a coating station, transporting the substrate from the coating station to an oven in a vertically downward direction, and curing the coating on the substrate within the oven. The method also includes, after curing the coating, transporting the substrate from the oven in a vertically upward direction opposite the downward direction to an inspection station, and inspecting the substrate with the inspection station. 
     Another embodiment of the present disclosure includes a system for applying a coating to a substrate. The system includes a first self-contained module comprising a coating station for applying a coating material to the substrate and a second self-contained module comprising an oven for curing the coating material on the substrate, where the second self-contained module is adjacent to the first self-contained module. The system also includes a third self-contained module comprising a first lift for transporting the substrate from the first self-contained module to the second self-contained module, where the third self-contained module is adjacent to the first and second self-contained modules. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of illustrative embodiments of the present application, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the present application, there is shown in the drawings illustrative embodiments of the disclosure. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. 
         FIG. 1  is a perspective view of a coating system according to an embodiment of the present disclosure; 
         FIG. 2  is a side cross-sectional view of a coating station of the coating system shown in  FIG. 1 ; 
         FIG. 3A  is a schematic diagram of an inspection station of the coating system shown in  FIG. 1 ; 
         FIG. 3B  is a schematic diagram of an inspection station of the coating system shown in  FIG. 1 ; 
         FIG. 4  is a perspective view of the coating system shown in  FIG. 1 , with some elements removed for clarity; 
         FIG. 5  is a schematic diagram of the coating system shown in  FIG. 1 ; 
         FIG. 6A  is a perspective view of a coating system according to an embodiment of the present disclosure; 
         FIG. 6B  is a perspective view of a coating system according to an embodiment of the present disclosure; 
         FIG. 6C  is a perspective view of a coating system according to an embodiment of the present disclosure; 
         FIG. 6D  is a perspective view of a coating system according to an embodiment of the present disclosure; 
         FIG. 7  is a schematic diagram of a control system according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     Described herein is a modular coating system  10  that includes a coating station  24  for applying a coating to a substrate  100  and an oven  34  for curing the coating positioned below the coating station  24 . Certain terminology is used to describe the coating system  10  in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inner” and “outer” refer to directions toward and away from, respectively, the geometric center of the description to describe the coating system  10  and related parts thereof. The words “forward” and “rearward” refer to directions in a lateral direction  4  and a direction opposite the lateral direction  4  along the coating system  10  and related parts thereof. The terminology includes the above-listed words, derivatives thereof, and words of similar import. 
     Unless otherwise specified herein, the terms “vertical” and “lateral” are used to describe the orthogonal directional components of various components of the coating system  10 , as designated by the vertical direction  2  and lateral direction  4 . It should be appreciated that while the vertical and lateral directions  2  and  4  are illustrated as extending along a vertical plane, the plane that encompasses the various directions may differ during use. 
     Referring to  FIGS. 1, 4, and 5 , the coating system  10  is a modular assembly of removable and interchangeable components for applying a coating material to a substrate  100 , curing the coating  102 , and inspecting the substrate  100 . The substrate  100  may be a printed circuit board (PCB), or may comprise any other type of substrate as desired. The coating system  10  includes a loading area  20  for adding an uncoated substrate  100  to the coating system  10  and removing a coated substrate  100  from the coating system  10 . The substrate  100  can be added to and removed from the loading area  20  manually by an operator of the coating system  10 , or automatically from a loading machine. The coating system  10  can include an upper conveyer system  300  for transporting the substrate  100  between various components of the coating system  10  disposed above a first plane P 1 , as will be described below. Specifically, the loading area  20  can include a second section  312  of the upper conveyer system  300  that transports the substrate  100  from the loading area  20  to a coating station  24 , which can be located immediately to the right of the loading area  20  along the lateral direction  4 . In the depicted embodiment, each section of the upper conveyer system  300  is an endless conveyer, though other embodiments of conveyer systems are contemplated. 
     Referring to  FIG. 2 , the coating system  10  can include a coating station  24  for applying a coating to the substrate  100 . The coating station  24  can include a housing  104  and an applicator assembly  106  configured to be disposed within the housing  104 . The bottom portion of the housing  104  defines a plane P 1  that is parallel to the lateral direction  4 . The applicator assembly  106  includes an applicator  108  that is in fluid communication with a material source  116 , and is configured to move coating material (not shown) from the material source  116  to form a coating  102  on the substrate  100 . The coating material can be acrylic, polyurethane, silicone, or other types of materials typically used for coating substrates. The applicator  108  can comprise a jetting dispenser, contact dispenser, air or airless spray applicator, or other type of applicator as desired. The amount of coating material moved through the applicator  108  to the substrate  100  can be monitored by a flow meter  124 . In the depicted embodiment, the flow meter  124  is disposed on a portion of the applicator  108 , such as the applicator tip  115 , so that the flow meter  124  can measure how much coating material passes from the applicator  108  to the substrate  100 . In another embodiment, the flow meter  124  can be disposed at the coating material source  116  or between the material source  116  and the applicator  108 . Alternatively, a plurality of flow meters can be positioned at multiple locations within the applicator assembly  106 . 
     The flow meter  124  can measure one or more parameters of the flow of coating material as it flows from the material source  116 . In some embodiments, the flow meter  124  can measure the volume, velocity, pressure, and/or the duration of the flow. The flow meter can be connected to a controller  402 , where the controller  402  is configured to receive data from the flow meter  124  and perform analysis on the data. The controller  402  can also be configured to analyze other parameters of the flow, such as the type of coating material, the characteristics of the applicator  108 , and/or characteristic of other portions of the coating system  10 . In addition to the flow meter  124 , the applicator assembly  106  can also include other types of sensors for detecting aspects of the coating material, such as a solvent sensor. Though one embodiment of an applicator assembly  106  is described above, it is contemplated that the coating station  24  can include various other types of applicator assemblies  106  as desired, depending on the type of substrate  100  to be coated or the type of coating operation to be performed. Due to the modular nature of the coating system  10 , the particular coating station  24  described above can be easily removed from the coating system  10  and replaced with another coating station with little to no impact on the rest of the coating system  10 . Though described as including an applicator configured for conformal coating, the coating station  24  can alternatively include applicators configured to perform other varieties of dispensing methods. For example, the coating station  24  can include an applicator configured to perform dispensing methods such as underfill, encapsulation, dam and fill, or other operations as desired. 
     Continuing with  FIGS. 1, 4, and 5 , the coating station  24  can also include a third section  316  of the upper conveyer system  300 . The third section  316  is configured to receive the substrate  100  from the loading area  20 , and move the substrate  100  so that it is positioned appropriately for receiving the coating material from the applicator assembly  106 . After the coating station  24  has applied the coating  102  to the substrate  100 , the third section  316  of the upper conveyer system  300  moves the substrate  100  to the first lift  28 , which is configured to transport the substrate  100  downward along the vertical direction  2  to the oven  34 . 
     The first lift  28  is configured to receive the substrate  100  from the coating station  24 , particularly the third section  316  of the upper conveyer system  300 , through a first lift entrance  320  defined by a side of the first lift  28  that faces the coating station  24 . The substrate  100  is received from the coating station  24  by an upper chamber  28   a  of the first lift  28 , which is situated at the top of the first lift  28 . Once the substrate  100  is fully within the upper chamber  28   a , a sensor  29   a  within the upper chamber  28   a  can sense the position of the substrate  100  and notify the controller  402 . The controller  402  then directs the first lift  28  to transport the substrate  100  from the upper chamber  28   a  downward along the vertical direction  2  to a lower chamber  28   b  of the first lift  28 . The lower chamber  28   b  is positioned at the bottom of the first lift  28  opposite the upper chamber  28   a . As a result, the lower chamber  28   b  is positioned entirely below the first plane P 1 , while the upper chamber  28   a  is positioned above the first plane P 1 . Once the substrate  100  is entirely disposed within the lower chamber  28   b , a sensor  29   b  disposed within the lower chamber  28   b  notifies the controller  402 , which instructs the first lift  28  to move the substrate  100  from the lower chamber  28   b  to the oven  34  through the first lift outlet  324 . 
     The oven  34  is entirely disposed below the first plane P 1 , and can be modular and include a plurality of separate ovens  34   a - 34   c . The oven  34  includes a lower conveyer system  304  for moving the substrate  100  from the first lift  28  to the second lift  50  through the oven  34 . In one embodiment, each part of the lower conveyer system  304  can be an endless conveyer, though other types of conveyers are also contemplated. Additionally, each oven of the oven  34  is configured to be heated to a predetermined temperature. As depicted, the oven  34  includes a first oven  34   a  disposed immediately to the left of the first lift  28  along the lateral direction  4 . Additionally, the first oven  34   a  is positioned entirely and immediately below the coating station  24  along the vertical direction  2 . The interior of the first oven  34   a  can be raised to and maintained at a first temperature for heat curing the coating  102  applied to the substrate  100 . For example, the first oven  34   a  can be raised to a temperature that is from about 60 degrees Celsius to about 130 degrees Celsius. The coating system  10  can include a seal  30  disposed between the first lift  28  and the first oven  34   a  for creating a thermal seal between the first lift  28  and the first oven  34   a . The seal  30  can prevent heat from the first oven  34   a  from escaping to the first lift  28 , as well as from the first oven  34   a  to the environment in which the coating system  10  is located. The seal  30  can comprise Viton, silicone, or other materials that can withstand the temperatures encountered in the oven  34 . Alternatively, the seal  30  can be a metal flange. The seal  30  can define part of the first oven  34   a  or the first lift  28 , or can be releasably attached to the first oven  34   a  and the first lift  28 , such that the seal  30  can be used with other configurations of components in the coating system  10 . The first oven  34   a  can include a first section  328  of the lower conveyer system  304  for moving the substrate  100  from the first lift  28  through the first oven  34   a . Once the substrate  100  passes through the first oven  34   a  on the first section  328  of the lower conveyer system  304 , the substrate  100  can enter a second oven  34   b  disposed immediately to the left of the first oven  34   a  along the lateral direction  4 . 
     The second oven  34   b  is disposed immediately to the left of the first oven  34   a  along the lateral direction  4 . Additionally, the second oven  34   b  is positioned entirely and immediately below the loading area  20 . The interior of the second oven  34   b  can be raised to and maintained at a second temperature for further heat curing the coating  102  applied to the substrate  100 . For example, the second oven  34   b  can be raised to a temperature that is from about 60 degrees Celsius to about 130 degrees Celsius. The second temperature of the second oven  34   b  may be the same as or different than the first temperature of the first oven  34   a . The coating system  10  can include a seal  38  disposed between the second oven  34   b  and the first oven  34   a  for creating a thermal seal between the first oven  34   a  and the second oven  34   b . The seal  38  can prevent the heat levels within each of the first and second ovens  34   a  and  34   b  from affecting each other, as well as prevent heat from escaping from the first and second ovens  34   a  and  34   b  to the external environment. The seal  38  can be similarly configured as the seal  30 , or can be different as desired. Further, the seal  38  can define part of the first or second ovens  34   a  and  34   b , or can be releasably attached to the first and second ovens  34   a  and  34   b , such that the seal  38  can be used with other configurations of components in the coating system  10 . The second oven  34   b  can include a second section  332  of the lower conveyer system  304  for moving the substrate  100  from the first oven  34   a  through the second oven  34   b . Once the substrate  100  passes through the second oven  34   b  on the second section  332  of the lower conveyer system  304 , the substrate  100  can enter a third oven  34   c  disposed immediately to the left of the second oven  34   b  along the lateral direction  4 . 
     The third oven  34   c  is disposed immediately to the left of the second oven  34   b  along the lateral direction  4 . Additionally, the third oven  34   c  is positioned entirely and immediately below the inspection station  54 , which will be described further below. The interior of the third oven  34   c  can be raised to and maintained at a third temperature for further heat curing the coating  102  applied to the substrate  100 . For example, the third oven  34   c  can be raised to a temperature that is from about 60 degrees Celsius to about 130 degrees Celsius. The third temperature of the third oven  34   c  can be the same as or different than the first and/or second temperatures. The coating system  10  can include a seal  42  disposed between the third oven  34   c  and the second oven  34   b  for creating a thermal seal between the third oven  34   c  and the second oven  34   b . The seal  42  can prevent heat levels within each of the second and third ovens  34   b  and  34   c  from affecting each other, as well as prevent heat from escaping from the second and third ovens  34   b  and  34   c  to the external environment. The seal  42  can be similarly configured to the seals  30  and/or  38 , or can be different as desired. Further, the seal  42  can define part of the second or third ovens  34   b  and  34   c , or can be releasably attached to the second and third ovens  34   b  and  34   c , such that the seal  42  can be used with other configurations of components in the coating system  10 . The third oven  34   c  can include a third section  336  of the lower conveyer system  304  for moving the substrate  100  from the second oven  34   b  through the third oven  34   c.    
     Though the oven  34  is described as including three ovens  34   a - 34   c , the modular nature of the coating system  10  allows more ovens to be attached to the coating system  10  to accommodate different types of substrates, coating materials, coating operations, etc. without significantly affecting the rest of the coating system  10 . Likewise, any of the ovens  34   a - 34   c  can be removed as desired. For example, the oven  34  can include only one oven. Though described as being capable of raising to a certain temperature, each of the ovens  34   a - 34   c  can internally define multiple temperature zones, such that each of the ovens  34   a - 34   c  can be simultaneously raised to a plurality of temperatures. Each additional oven can be similarly configured as the ovens  34   a - 34   c  already described, or can be alternatively configured as desired. Each additional oven can also include an additional conveyer portion that will comprise part of the lower conveyer system  304 . Regardless of the number of ovens that comprise the oven  34 , the lower surface of any of the ovens of the oven  34  can define a second plane P 2  that is parallel to the lateral direction  4 . The second plane P 2  is spaced from the first plane P 1  along the vertical direction  2 . The lower surfaces of the other ovens of the oven  34  can also be substantially disposed on the second plane P 2 . 
     Once the substrate  100  passes through the third oven  34   c , the substrate  100  can enter the second lift  50  disposed immediately to the left of the third oven  34   c . The second lift  50  is configured to receive the substrate  100  from the oven  34  through a second lift entrance (not shown) and transport the substrate  100  upward along the vertical direction  2  to the inspection station  54 . The substrate  100  passes through the second lift entrance defined by a side of the second lift  50  that faces the oven  34 . The coating system  10  can include a seal  46  disposed between the third oven  34   c  and the second lift  50  for creating a thermal seal between the third oven  34   c  and the second lift  50 . The seal  46  can prevent heat levels within the third oven  34   c  from affecting operation of the second lift  50 , as well as prevent heat from escaping from the third oven  34   c  to the external environment. The seal  46  can be similarly configured to the seals  30 ,  38 , and/or  46 , or can be different as desired. Further, the seal  46  can define part of third oven  34   c  and the second lift  50 , or can be releasably attached to the third oven  34   c  and the second lift  50 , such that the seal  46  can be used with other configurations of components in the coating system  10 . 
     The substrate  100  is received from the oven  34  within a lower chamber  50   b  of the second lift  50 , which is situated at the bottom of the second lift  50 . Once the substrate  100  is fully within the lower chamber  50   b , a sensor  51   b  within the lower chamber  50   b  can sense the position of the substrate  100  and notify the controller  402 . The controller  402  then directs the second lift  50  to transport the substrate  100  from the lower chamber  50   b  upward along the vertical direction  2  to an upper chamber  50   a  of the second lift  50 . The upper chamber  50   a  is positioned at the top of the second lift  50  opposite the lower chamber  50   b . As a result, the upper chamber  50   a  is positioned entirely above the first plane P 1 , while the lower chamber  50   b  is positioned below the first plane P 1 . Once the substrate  100  is entirely disposed within the upper chamber  50   a , a sensor  51   a  disposed within the upper chamber  50   a  notifies the controller  402 , which instructs the second lift  50  to move the substrate  100  from the upper chamber  50   a  to the inspection station  54 . 
     Continuing with  FIGS. 3A-3B , the inspection station  54  includes an inspection system  200 . The inspection system  200  can include a lighting sub-system  204  that has an ultraviolet (UV) light source  208  that directs UV light onto the coating  102 . The coating  102  can include a tracer that fluoresces in the presence of the UV light. The lighting sub-system  204  also can include an optional white light source  212  that directs white light onto the coating  102  of the substrate  100 . The inspection system  200  further includes a camera sub-system  216  that includes a camera  240 . The camera  240  has a lens  244  positioned above the substrate  100  for capturing one or more images of the illuminated substrate  100  when light is emitted onto the substrate  100 . Specifically, the camera  240  can be angled or positioned perpendicular to the confronting surface  100   a  of the substrate  100 . When positioned perpendicular to the confronting surface  100   a , as shown in  FIG. 3B , the inspection system  200  can include an angled mirror  248 . Though depicted in  FIG. 3A  as being situated above the substrate  100  and in  FIG. 3B  as perpendicular to the substrate  100 , the camera  240  can be angled, e.g., at a 45° angle, relative to the confronting surface  100   a  of the substrate  100  so that the lens  244  captures one or more edge images of an outer edge  100   b  of the illuminated substrate  100 . The images from the camera  240  are conveyed to an image-processing computer  224 , which can be the controller  402 , for determining whether the substrate  100  is properly coated. Alternatively, the image-processing computer  224  can be separate from but in electronic communication with the controller  402 . 
     The inspection station  54  can also include a board holder sub-system  228  that comprises the first section  308  of the upper conveyer system  300 . The first section  308  can be configured to hold the substrate  100  about one or more of its edges during inspection. In another embodiment, the board holder sub-system  228  can include support pins (not shown) that holds the substrate  100  during inspection. The first section  308  transports the substrate  100  from the second lift  50  to the loading area  20 , which can be located immediately to the right of the inspection station  54  along the lateral direction  4 . To adjust the position of the camera  216 , the camera  216  can be connected to an X-Y axis motor  220 . The X-Y axis motor  220  is configured to move the camera  216  relative to the substrate  100  upon receiving instructions from a motion controller  232  and/or the image-processing computer  224 . The motion controller  232  can be the controller  402 , or can alternatively be separate from but in electronic communication with the controller  402 . Though one type of inspection device is described, the inspection station  54  can include various other types of inspection devices as desired, such as an optical 3D scanner, 2D laser profiler, or 3D laser profiler. Alternatively, the coating system  10  may not include the inspection station  54 , but can rather include a manual or semi-automatic inspection station (not shown) where the operator of the coating system  10  must verify the coating quality of each substrate  100 . 
     Each of the separate elements of the coating system  10 , including the coating station  24 , first lift  28 , oven  34  (and likewise first, second, and third ovens  34   a - 34   c ), second lift  50 , and inspection station  54  can define self-contained, independently separable modules. As a result, each of these modules can be individually removed from and/or reorganized within the coating system  10  without affecting the configuration of other modules of the coating system  10 . For example, though the coating station  24  is depicted as disposed on top of the first oven  34   a , the coating station  24  or the first oven  34   a  can be removed from the coating system  10  without affecting the other module. Likewise, though the inspection station  54  is depicted as disposed on top of the third oven  34   c , the inspection station  54  of the third oven  34   c  can be removed from the coating system  10  without affecting the other module. Due to this modular construction, the coating system  10  can include other modular stations not already mentioned, such as a vacuum chamber for removing bubbles from a coating material, an atmospheric or vacuum plasma system for substrate surface treatment, or other modules as desired. 
       FIGS. 6A-D  illustrate coating systems  111 ,  112 ,  113 , and  114 , respectively. 
     The coating systems  111 ,  112 ,  113 , and  114  may serve as alternative embodiments or configurations of the coating system  10  shown in  FIGS. 1, 4, and 5 . The coating system  111 ,  112 ,  113 , and  114  demonstrate the modular nature of the coating systems described herein. That is, various coating system components described herein (e.g., a coating station  24 , an oven  34 , an inspection station  54 , a loading area  20 , a lift  28 , etc.) and/or modules may be added (including additional instances of a component/module) or omitted according to particular needs. Further, the various components and/or modules may be configured in various sequential orderings according to particular needs. The coating systems  111 ,  112 ,  113 , and  114  may be similar in some aspects to the coating system  10 . Accordingly, like reference numerals in the figures shall refer to like elements. 
     Referring to  FIG. 6A , the coating system  110  includes a loading area  20  where a substrate is initially loaded prior to processing. The substrate proceeds to a coating station  24  to undergo a coating operation. The coated substrate is subsequently conveyed to a fourth oven  34   d  to begin a curing process of the coated substrate. The fourth oven  34   d  may form a module with a fifth oven  34   e  below. The temperatures of the fourth oven  34   d  and the fifth oven  34   e  may be separately and independently controller. From the fourth oven  34   d , the coated substrate passes to a lift  27 . The lift  27  may be similar in some aspects to the lift  28  of  FIGS. 1, 4, and 5 . The lift  27  comprises an upper section  27   a  configured to initially receive the substrate. The substrate is lowered to a lower section  27   b  of the lift  27 . The lift  27  may be insulated and/or heated to keep the substrate from cooling during transport between the fourth oven  34   d  and the fifth oven  34   e . The upper section  27   a  is located on the upper plane of the coating system  111  and the lower section  27   b  is located on the lower plane of the coating system  111 . From the lower section  27   b  of the lift  27 , the coated substrate passes sequentially through a fifth oven  34   e , a first oven  34   a , a second oven  34   b , and a third oven  34   c  to complete the curing process. The substrate is brought to the upper plane by a lift  50 . The substrate is positioned in an inspection station  54  for inspection, such as inspection of the coating applied to the substrate. The inspected substrate is thereafter unloaded at the loading area  20 . 
     Referring to  FIG. 6B , the coating system  112  comprises a loading area  20  to receive an uncoated substrate. The substrate is passed to a coating station  24  to be coated. The coated substrate is then brought to a fourth oven  34   d , which forms the upper portion of a vertical stack with a lift  28 . The substrate is lowered from the fourth oven  34   d  by the lift to the lower plane of the coating system  112 . The substrate is thereafter passed sequentially through a first oven  34   a , a second oven  34   b , and a third oven  34   c  for completion of the curing process of the coated substrate. The substrate is then moved to another lift  50  to raise the substrate from the lower plane to the upper plane of the coating system  111 . On the upper plane, the substrate is inspected at an inspection station  54  and removed from the coating system at the loading area  20 . 
     Referring to  FIG. 6C , the coating system  113  comprises an initial loading area  20   a  for receiving an uncoated substrate. The received substrate is brought to a coating station  24  to be coated. The coated substrate is lowered from the upper plane of the coating system  113  to the lower plane of the coating system  113  by a lift  28 . The coated substrate is cured while passing sequentially through the a first oven  34   a , a second oven  34   b , a fourth oven  34   d , and a third oven  34   c . The component containing the fourth oven  34   d  is configured with an unloading area  20   b  situated above the fourth oven  34   d . The cured substrate is passed from the third oven  34   c  to a lift  50 , which raises the substrate to the upper plane of the coating system  113 . The substrate is thereafter conveyed to an inspection station  54  for inspection, such as inspection of the coating as applied to the substrate. Following inspection, the substrate is moved to the unloading area  20   b  for unloading, such as by a human operator or a robotic appendage. 
     Referring to  FIG. 6D , the coating system  114  is configured with a loading area  22   a  (similar in some aspects with the loading area  20  of  FIGS. 1, 4, and 5 ) at an end of the linear assembly of the coating system  113 . The substrate initially passes to a coating station  24  to undergo a coating process. The coated substrate is moved over a conveyance area  23  to an inspection station  54 , which may inspect the coating on the substrate before it is cured. Following inspection, the substrate is lowered from the upper plane of the coating system  114  to the lower plane by a lift  28 . On the lower plane, the coating on the substrate is cured by moving the substrate through a first oven  34   a , a second oven  34   b , and a third oven  34   c . After final curing at the third oven  34   c , the substrate is transferred to an unloading area  22   b . The lower unloading area  22   b  is part of the same vertical component as the upper loading area  22   a.    
     Further embodiments (not illustrated) are also contemplated. An embodiment may comprise a coating station  24  and/or an inspection station  54  positioned on the lower plane of a coating system, which may be additional or alternative to a coating station  24  or inspection station  54  positioned on the upper plane of the coating system. For example, an embodiment may be configured similarly to that shown in  FIGS. 1, 4, and 5 , but the third oven  34   c  is replaced with another inspection station  54 . That is, the module comprising the inspection station  54  positioned above the third oven  34   c , as shown in  FIGS. 1, 4, and 5 , may be swapped with a module comprising a first inspection station  54  positioned on the upper plane and above a second inspection  54  on the lower plane. 
     As another example, an embodiment may be configured similarly to the coating system  114  show in  FIG. 6D , but the third oven  34   c  is replaced with another inspection station  54  in addition to the initial inspection station  54  over the first oven  34   a . Thus, the module initially comprising the coating station  24  in  FIG. 6D  may be re-configured to comprise the coating station  24  on the upper plane of the coating system  114  and a second inspection station  54  on the lower plane. A coating system so-configured may allow for an initial inspection of the coating by the first inspection station  54  (above the first oven  34   a ) before it is cured by the first oven  34   a  and the second oven  34   b . The cured coating on the substrate may be then inspected by the second inspection station  54  positioned below the coating station  24 . 
     The coating systems described herein may comprise (e.g., a module may comprise) a drying component and/or a flash-off component. For example, an embodiment may be similar to the coating system  10  shown in  FIGS. 1, 4, and 5 , but the first oven  34   a  may be replaced with a drying component or a flash-off component. As such, a coating initially applied to a substrate by the coating station  24  may be allowed to dry before the coating is cured by the second oven  34   b  and the third oven  34   c . A drying component and/or a flash-off component may be positioned on either of the upper plane or the lower plane of a coating system. 
     Referring to  FIG. 7 , the coating system  10  can be controlled by a control system  400  including a controller  402  and/or an HMI device  408  in communication with the controller  402 . The controller  402  may include one or more controllers and may also be referred to as one or more processors. The controller  402  can include the image-processing computer  224 , or be separate from but in electronic communication with the image-processing computer  224 . As shown in  FIG. 7 , the controller  402  and/or the HMI device  408  can be in wired and/or wireless connection with each aspect of the coating system  10 , such as the loading area  20 , coating station  24 , first lift  28 , oven  34 , second lift  50 , and inspection station  54 , and are configured to transmit instructions to each of these aspects of the coating system  10 , through the wireless and/or wired connection. The controller  402  can also be easily connected to additional modules added to the coating system  10  over time. The controller  402  can be a programmable logic controller (PLC), a microprocessor based controller, a personal computer, or another conventional control device capable of carrying out the functions described herein as understood by a person having ordinary skill in the art. For example, the controller  402  can perform the various methods relating to controlling the coating system  10  based upon user input, as described in detail below. Additionally, the controller  402  can perform the various methods related to controlling the coating system  10  based upon a library of operational cycles or sequences that are stored in a memory unit  404  of the controller  402 . The memory unit  404  may include one or more memory units, and may also be referred to as a storage device. The operational sequences are recalled and placed in a particular control program, as desired, executing on the controller  402 . The operational sequences can be adjusted to accommodate different dispensing operations, different types of substrates, or different types of material, for example through the HMI device  408 . 
     The HMI device  408  is operatively connected to the controller  402  in a known manner. The HMI device  408  may include input devices and controls, such as a keypad, pushbuttons, control knobs, a touch screen, etc., and output devices, such as displays and other visual indicators, that are used by an operator to control the operation of the controller  402  and, thereby, control the operation of the coating system  10 . The HMI device  408  may further include an audio output device, such as a speaker, by which an audio alert may be communicated to an operator. Using the HMI device  408 , an operator can enter parameters such as type of coating material, type of substrate  100 , desired coating pattern, and desired temperature of the oven  34 , etc. Additionally, the controller  402  and/or the HMI device  408  can be in wired and/or wireless communication with an external network (not shown), such that the operator of the coating system  10  can access the controller  402  remotely from a separate system or device. 
     In operation, an operator of the coating system  10  begins a coating operation by placing a substrate  100  on the loading area  20 , particularly the second section  312  of the upper conveyer system  300 . This can be done manually by the operator, or can be performed by a separate robotic or otherwise automated apparatus (not shown), such as a shuttle conveyer. To commence operation of the coating system  10 , the operator actuates a manual button or switch on the body of the coating system  10  or remotely directs the controller  402  to instruct the coating system  10  to being operation, such as through the HMI device  408  of the controller  402 . However, when an automated loading mechanism is used, operation of the coating system  10  can commence automatically. Once the coating system  10  begins operation, the second section  312  of the upper conveyer system  300  moves the substrate  100  in a first direction along the lateral direction  4  to the third section  316  of the upper conveyer system  300 , and likewise into the housing  104  of the coating station  24 . The first direction may be either to the left or the right along the lateral direction  4 , depending on the orientation of the coating system  10 . Once disposed in the coating station  24 , the applicator assembly  106  commences the coating operation, either automatically, upon direction from the operator, or direction from the controller  402 . The various aspects of the coating operation (pattern, direction, etc.) can be pre-selected by the operator through the HMI device  408  or recalled from the memory unit  404  of the controller  402 . After the coating operation is complete, the substrate  100  is moved by the third section  316  of the upper conveyer system  300  in the first direction into the upper chamber  28   a  of the first lift  28 . Once a sensor  29   a  disposed within the upper chamber  28   a  senses that the substrate  100  is completely within the upper chamber  28   a , the first lift  28  will convey the substrate  100  downward along the vertical direction  2  to the lower chamber  28   b  of the first lift  28 . Once the sensor  29   b  disposed within the lower chamber  28   b  senses that the substrate  100  is completely within the lower chamber  28   b , the first lift  28  will convey the substrate  100  to the oven  34 , particularly the first oven  34   a , in a second direction that is opposite the first direction. 
     When the substrate  100  enters the first oven  34   a , the substrate  100  is disposed on a first section  328  of the lower conveyer system  304 , which transports the substrate  100  through the first oven  34   a . The first oven  34   a , which may be located below the coating station  24 , is heated to a first temperature for performing a part of a curing operation on the coating  102  of the substrate  100 . The substrate  100  is maintained in the first oven  34   a  for a first period of time. The first temperature and first period of time can be selected by the operator of the coating system  10  through the HMI device  408 , recalled from the memory unit  404  based upon a particular feature of the coating operation, such as substrate type, coating type, etc., or be default values. After the portion of the curing operation to be performed by the first oven  34   a  is completed, the first section  328  of the lower conveyer system  304  can convey the substrate  100  to a second oven  34   b  of the oven  34  in the second direction. 
     When the substrate  100  enters the second oven  34   b , the substrate  100  is disposed on a second section  332  of the lower conveyer system  304 , which transports the substrate  100  through the second oven  34   b . The second oven  34   b , which may be located below the loading area  20 , is heated to a second temperature for performing a second part of a curing operation on the coating  102  of the substrate  100 . The substrate  100  is maintained in the second oven  34   b  for a second period of time. The second temperature and second period of time can be selected by the operator of the coating system  10  through the HMI device  408 , recalled from the memory unit  404  based upon a particular feature of the coating operation, such as substrate type, coating type, etc., or be default values. The second temperature and second period of time may be the same as the first temperature and period of time, respectively, or can be different as desired. After the portion of the curing operation to be performed by the second oven  34   b  is completed, the second section  332  of the lower conveyer system  304  can convey the substrate  100  to a third oven  34   c  of the oven  34  in the second direction. 
     When the substrate  100  enters the third oven  34   c , the substrate  100  is disposed on a third section  336  of the lower conveyer system  304 , which transports the substrate  100  through the third oven  34   c . The third oven  34   c , which may be located below the inspection station  54 , is heated to a third temperature for performing a third part of a curing operation on the coating  102  of the substrate  100 . The substrate  100  is maintained in the third oven  34   c  for a third period of time. The third temperature and third period of time can be selected by the operator of the coating system  10  through the HMI device  408 , recalled from the memory unit  404  based upon a particular feature of the coating operation, such as substrate type, coating type, etc., or be default values. The third temperature and third period of time may be the same as the first and second temperatures and periods of time, respectively, or can be different as desired. After the portion of the curing operation to be performed by the third oven  34   c  is completed, the third section  336  of the lower conveyer system  304  can convey the substrate  100  to the second lift  50  in the second direction. Though the coating system  10  is described as including an oven  34  that includes three separate ovens  34   a - 34   c , the modular nature of the coating system  10  allows additional ovens to be added or any of the ovens  34   a - 34   c  to be taken away. For example, the second oven  34   b  can be removed from the coating system  10 , such that only the first and third ovens  34   a  and  34   c  remain, and only the second section  332  of the lower conveyer system  304  is disposed below the loading area  20 . Additionally, the first and second ovens  34   a  and  34   b  can be removed from the coating system. Alternatively, the first through third ovens  34   a - 34   c  can be replaced by a singular oven that comprises the entirety of the oven  34 . 
     After the curing operation is complete, the substrate  100  is moved by the third section  336  of the lower conveyer system  304  in the second direction into the lower chamber  50   b  of the second lift  50 . Once a sensor  51   b  disposed within the lower chamber  50   b  senses that the substrate  100  is completely within the lower chamber  50   b , the second lift  50  will convey the substrate  100  upward along the vertical direction  2  to the upper chamber  50   a  of the second lift  50 . Once the sensor  51   a  disposed within the upper chamber  50   a  senses that the substrate  100  is completely within the upper chamber  50   a , the second lift  50  will convey the substrate  100  to the inspection station  54  in the first direction. 
     Once disposed in the inspection station  54 , the applicator assembly  106  commences the inspection operation, either automatically, upon direction from the operator, or direction from the controller  402 . The various aspects of the inspection operation (what parts of the substrate  100  and coating  102  are inspected, type of inspection performed, etc.) can be pre-selected by the operator through the HMI device  408  or recalled from the memory unit  404  of the controller  402 . Though the inspection operation can be performed by the inspection station  54  itself, inspection can also at least partially include visual inspection by the operator of the coating system  10  when the substrate  100  is in the inspection station  54 . If the inspection station  54  detects a feature of the coating  102  of the substrate  100  that does not meet quality standards, the inspection station  54  can send a signal to the controller  402 , which can alert the operator of the coating system  10  through the HMI device  408 . The alert may be in the form of a sound, light, text notification, etc. After the inspection operation is complete, the substrate  100  is moved by the first section  308  of the upper conveyer system  300  in the first direction to the loading area  20 , where the substrate  100  can be removed from the coating system  10 . This can be done manually by the operator, or can be performed by a separate robotic or otherwise automated apparatus, such as a shuttle conveyer (not shown). Optionally, one operator can be situated on one side of the loading area  20  for placing a substrate  100  on the loading area  20 , while another operator is situated on the opposite side of the loading area  20  for removing the substrate  100  from the loading area  20 . 
     While the invention is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method can be implemented in a particular order as desired.