Source: http://patents.com/us-9809878.html
Timestamp: 2019-04-21 20:44:38
Document Index: 83071929

Matched Legal Cases: ['Application No. 13847184', 'Application No. 61', 'arts 55', 'arts 56', 'arts 55', 'arts 55', 'arts 56', 'arts 55', 'arts 55', 'arts 57', 'arts 56', 'arts 56', 'arts 55', 'arts 56', 'arts 55', 'arts 55', 'arts 56', 'arts 55', 'arts 55', 'arts 55', 'art 55', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'art 55', 'art 55', 'art 55', 'arts 55', 'arts 55', 'art 55', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'arts 56', 'arts 56', 'arts 55', 'arts 56', 'arts 56', 'arts 55', 'arts 56', 'arts 57', 'arts 56', 'arts 55', 'arts 56', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 57', 'arts 55', 'arts 55', 'arts 55', 'arts 55', 'arts 56', 'arts 55', 'arts 55', 'arts 55', 'arts 55']

US Patent # 9,809,878. In-line metallizer assemblies and part-coating conveyor systems incorporating the same - Patents.com
United States Patent 9,809,878
Black , et al. November 7, 2017
In-line metallizer assemblies and part-coating conveyor systems incorporating the same
In-line metallizer assemblies can include an external rotating actuator exchange that can be operable to exchange one or more parts between a conveyor system and a vacuum chamber, and an internal rotating actuator exchange within the vacuum chamber that can be operable to receive the one or more parts from the external rotating actuator exchange, transition the one or more parts to a sputter coater integrated with the vacuum chamber for metallizing, and return metallized one or more parts to the external rotating actuator exchange such that the external rotating actuator exchange can return the metallized one or more parts to the conveyor system.
Black; Jeffrey J. (Biddeford, ME), Brooks; Stanton A. (Peaks Island, ME)
Marca Machinery, LLC
Marca Machinery, LLC (Gorham, ME)
Family ID: 1000002934155
14/701,611
US 20150252468 A1 Sep 10, 2015
13655912 Oct 19, 2012 9051650
12688482 Jan 15, 2010
61205200 Jan 16, 2009
Current CPC Class: C23C 14/56 (20130101); C23C 14/205 (20130101); C23C 14/185 (20130101); B65G 47/04 (20130101)
Current International Class: C23C 14/00 (20060101); C23C 14/20 (20060101); C23C 14/18 (20060101); C23C 14/56 (20060101); B65G 47/04 (20060101)
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International Search Report & Written Opinion relating to PCT/US2013/065632 filed Oct. 18, 2013; dated Jan. 7, 2014. cited by applicant .
International Preliminary Report on Patentability relating to PCT/US2013/065632 filed Oct. 18, 2013; dated Apr. 30, 2015. cited by applicant .
European Search Report pertaining to Application No. 13847184.2 dated Feb. 16, 2016. cited by applicant.
Primary Examiner: Brayton; John
This patent application is a division of U.S. patent application Ser. No. 13/655,912 filed Oct. 19, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 12/688,482 filed Jan. 15, 2010, which claims priority to Provisional Patent Application No. 61/205,200 filed Jan. 16, 2009, each of which is hereby incorporated by reference in its entirety.
1. An in-line metallizer assembly comprising: a conveyor system for conveying parts towards and away from a vacuum chamber; an external rotating actuator exchange operable to exchange one or more parts between the conveyor system and the vacuum chamber; a pressurized enclosure maintained at a pressure above ambient pressure throughout the exchange of the one or more parts between the conveyor system and the vacuum chamber, the pressurized enclosure at least partially surrounding the external rotating actuator exchange and comprising an endwall having an opening, wherein at least a portion of the external rotating actuator exchange is operable to selectively extend through the opening of the endwall; one or more external door clasps configured to selectively form a temporary seal with the endwall of the pressurized enclosure; and a pressurized gas delivery system fluidly coupled to the pressurized enclosure and providing pressurized buffer gas to the pressurized enclosure at a rate greater than environmental gas enters the vacuum chamber during the exchange of one or more parts between the conveyor system and the vacuum chamber.
2. The in-line metallizer assembly of claim 1, wherein the external rotating actuator exchange comprises one or more actuating arms connected to a rotating pivot, wherein one of the one or more external door clasps is connected to each of the one or more actuating arms and the external door clasp is operable to releasably engage a part carrier conveyed along the conveyor system.
3. The in-line metallizer assembly of claim 2, wherein the external door clasp selectively forms a vacuum seal with the vacuum chamber.
4. The in-line metallizer assembly of claim 1, further comprising a gas knife positioned within the pressurized enclosure directing pressurized buffer gas onto pre-metallized parts.
5. The in-line metallizer assembly of claim 4, wherein the gas knife directs the pressurized buffer gas in a generally planar orientation.
6. The in-line metallizer assembly of claim 1, wherein the one or more external door clasps are operable to simultaneously provide a first conveying part to the vacuum chamber and provide a second conveying part to the conveyor system.
7. The in-line metallizer assembly of claim 1, wherein the pressurized gas delivery system comprises a desiccation device to reduce the humidity of gas passing through the pressurized gas delivery system into the pressurized enclosure.
8. The in-line metallizer assembly of claim 1, wherein the pressurized gas delivery system comprises a temperature conditioning device to adjust the temperature of the pressurized buffer gas provided to the pressurized enclosure.
9. The in-line metallizer assembly of claim 1, wherein the pressurized gas delivery system comprises a filtration device to capture particles from the pressurized buffer gas before the pressurized buffer gas is provided to the pressurized enclosure.
10. An in-line metallizer assembly comprising: a conveyor system for conveying parts towards and away from a vacuum chamber; an external rotating actuator exchange operable to exchange one or more parts between the conveyor system and the vacuum chamber; a pressurized enclosure maintained at a pressure above ambient pressure throughout the exchange of one or more parts between the conveyor system and the vacuum chamber, the pressurized enclosure at least partially surrounding the external rotating actuator exchange and comprising an endwall having an opening, wherein at least a portion of the external rotating actuator exchange is operable to selectively extend through the opening of the endwall; one or more external door clasps configured to selectively form a temporary seal with the endwall of the pressurized enclosure; a pressurized gas delivery system fluidly coupled to the pressurized enclosure for and providing pressurized buffer gas to the pressurized enclosure at a rate greater than environmental gas enters the vacuum chamber during the exchange of one or more parts between the conveyor system and the vacuum chamber; and a gas knife positioned within the pressurized enclosure and proximate to an opening in the pressurized enclosure through which the external rotating actuator exchanges the one or more parts, the gas knife directing pressurized buffer gas onto pre-metallized parts.
11. The in-line metallizer assembly of claim 10, wherein the gas knife directs the pressurized buffer gas in a generally planar orientation.
12. The in-line metallizer assembly of claim 11, wherein the pressurized gas delivery system comprises a desiccation device to reduce the humidity of gas passing through the pressurized gas delivery system into the pressurized enclosure.
13. The in-line metallizer assembly of claim 12, wherein the pressurized gas delivery system further comprises a temperature conditioning device to adjust the temperature of the pressurized buffer gas provided to the pressurized enclosure.
14. The in-line metallizer assembly of claim 10, wherein the external rotating actuator exchange comprises one or more actuating arms connected to a rotating pivot, wherein one of the one or more external door clasps is connected to each of the one or more actuating arms and the external door clasp is operable to releasably engage a part carrier conveyed along the conveyor system.
15. The in-line metallizer assembly of claim 14, wherein the one or more external door clasps comprise one of a robotic grip operable to open and close about the part carrier or one or more pins or protrusions operable to engage a receiving hole in the part carrier conveyed along the conveyor system.
16. An in-line metallizer assembly comprising: a conveyor system for conveying parts towards and away from a vacuum chamber; an external rotating actuator exchange comprising: one or more actuating arms connected to a rotating pivot operable to exchange one or more parts between the conveyor system and the vacuum chamber; and an external door clasp coupled to each of the one or more actuating arms; a pressurized enclosure maintained at a pressure above ambient pressure throughout the exchange of one or more parts between the conveyor system, the pressurized enclosure at least partially surrounding the external rotating actuator exchange and comprising an endwall having an opening, wherein: at least a portion of the external rotating actuator exchange is operable to selectively extend through the opening of the endwall; and the external door clasp is configured to selectively form a temporary seal with the endwall of the pressurized enclosure; and a pressurized gas delivery system fluidly coupled to the pressurized enclosure and providing pressurized buffer gas to the pressurized enclosure at a rate greater than environmental gas enters the vacuum chamber during the exchange of one or more parts between the conveyor system and the vacuum chamber.
17. The in-line metallizer assembly of claim 16, wherein the pressurized gas delivery system comprises a desiccation device to reduce the humidity of gas passing through the pressurized gas delivery system into the pressurized enclosure.
18. The in-line metallizer assembly of claim 17, wherein the pressurized gas delivery system further comprises a temperature conditioning device to adjust the temperature of the pressurized buffer gas provided to the pressurized enclosure.
19. The in-line metallizer assembly of claim 16, wherein the conveyor system is operable to traverse in a first conveyor direction and a second conveyor direction opposite the first conveyor direction.
Plastic and glass parts are often painted and coated with different materials to change their visual appearance. For instance, plastic parts may first receive one or more basecoats of paint or primer. Basecoats can fill in defects left over from manufacturing and handling as well as provide a more durable and adhesive surface for subsequent coatings. A topcoat may also be applied to protect the basecoat or to otherwise alter the appearance of the part. Both basecoats and topcoats can be applied to parts as they travel about a conveyor line. It can also be desirable to produce a reflective or metallic appearance by applying a reflective metal coating. The metal coating can be applied between the basecoat and the topcoat, on top of a basecoat without a topcoat, below a topcoat without a basecoat, or in any other combination of basecoats and/or topcoats. For example, a thin layer of metal can be deposited onto the surface of the part using an evaporation process such as that available with a batch metallizer. However, batch metallizers and other conventional assemblies can require the collecting and racking of large quantities of parts which can, in turn, create high cycle times for the metallizing process.
In one embodiment, an in-line metallizer assembly includes an external rotating actuator exchange operable to exchange one or more parts between a conveyor system and a vacuum chamber, and, an internal rotating actuator exchange within the vacuum chamber operable to receive the one or more parts from the external rotating actuator exchange, transition the one or more parts to a sputter coater integrated with the vacuum chamber for metallizing, and return metallized one or more parts to the external rotating actuator exchange such that the external rotating actuator exchange can return the metallized one or more parts to the conveyor.
In yet another embodiment, a part-coating conveyor system includes one or more paint stations, an in-line metallizer assembly including an external rotating actuator exchange and an internal rotating actuator exchange, the internal rotating actuator exchange being housed within a vacuum chamber integrated with a sputter coater, wherein the in-line metallizer assembly can be operable to continuously metallize a plurality of parts within the part-coating conveyor system, a track connecting the in-line metallizer assembly with the one or more paint stations, and one or more pallets operable to advance along the track between the one or more paint stations and the in-line metallizer assembly.
FIG. 9 depicts a side view of components of a sputter coater having a repositionable cathode according to one or more embodiments shown and described herein;
Embodiments described herein generally relate to in-line metallizer assemblies and part-coating conveyor systems incorporating in-line metallizer assemblies. In-line metallizer assemblies generally comprise an external rotating actuator exchange and a vacuum chamber integrated with a sputter coater. The external rotating actuator exchange may be operable to exchange one or more parts from an adjacent conveyor system with one or more parts from the vacuum chamber. The vacuum chamber may also comprise an internal rotating actuator exchange operable to transition one or more parts between the external rotating actuator exchange and the sputter coater. Thus, parts traveling along the conveyor system can be removed from the conveyor system, metallized (i.e., coated with a metal film), and returned to the conveyor system for further processing. The external rotating actuator exchange and internal rotating actuator exchange can act in cooperation to allow for the metallization of parts within the sputter coater while previously metallized parts are simultaneously exchanged with non-metallized parts outside of the vacuum chamber. Such cooperation may allow for the continuous in-line metallization of parts along a conveyor system. Part-coating conveyor systems may also incorporate an in-line metallizer assembly such that a base coat, metal coat and top coat can be independently applied to parts using a single conveyor system, such as an asynchronous conveyor system. Various embodiments of the in-line metallizer assemblies and part-coating conveyor systems will be described in more detail herein.
Referring now to FIGS. 1 and 2, an exemplary in-line metallizer assembly 10 is depicted in cooperation with a conveyor system 50 as part of an exemplary part-coating conveyor system 100. As illustrated, and as will be discussed more fully herein, the conveyor system 50 transports parts adjacent the in-line metallizer assembly 10. Pre-metallized parts 55 are transported towards the in-line metallizer assembly 10 while metallized parts 56 are transported away from the in-line metallizer assembly 10. An external rotating actuator exchange 20 will extend and receive (i.e., pick-up) pre-metallized parts 55 from the conveyor system via its actuating arms 22,23 and external door clasp 26. The external rotating actuator exchange 20 will then retract and rotate to transport the pre-metallized parts 55 to a vacuum chamber 30. As seen in FIG. 2, this rotation may also allow for the external rotating actuator exchange 20 to simultaneously provide (i.e., drop-off) metallized parts 56 back to the conveyor system 50. Referring to FIG. 1, an internal rotating actuator exchange 35 disposed within the vacuum chamber 30 may then receive pre-metallized parts 55' when extended (as illustrated) within the vacuum chamber 30. The internal rotating actuator exchange 35 can also retract and rotate to transition pre-metallized parts 55' within the vacuum chamber 30 to a sputter coater 40. The sputter coater can then be activated such that parts 57 facing the metallizer 40 can undergo the metallizing process. As illustrated in FIG. 2, once the parts 56' facing the sputter coater 40 are fully metallized, the internal rotating actuator exchange 35 can retract and rotate to transition the metallized parts 56' back towards the external rotating actuator exchange 20. The internal rotating actuator exchange 35 can simultaneously transition new pre-metallized parts 55' within the vacuum chamber 30 to the sputter coater 40. The external rotating actuator exchange 20 may then receive and transition the metallized parts 56 back onto the conveyor system 50 to complete the metallizer cycle for a given group of parts.
The conveyor system 50 may comprise any conveyor system operable to facilitate the movement of objects (such as pallets 52, part carriers 53,54 and/or one or more parts 55,56 as will become further appreciated herein). For example, as depicted in FIGS. 1-4, the conveyor system 50 may comprise one or more conveyor belts 51 that are each operable to transport a plurality of objects simultaneously. In another embodiment, the conveyor system 50 may comprise a plurality of rollers that allow for objects to pass over the series of rollers with reduced friction. In yet another embodiment, the conveyor system 50 may comprise a guide path in which objects can drive along the guide path independent of one another. It should be appreciated that the conveyor system 50 may comprise any alternative system, or combinations thereof, such that it facilitates the movement of objects. In one specific embodiment, such as that depicted in FIGS. 1-3, the conveyor system 50 may comprise a plurality of pallets 52 operable to be transported along the conveyor belt 51. Each pallet 52 may be operable to hold a part carrier 53,54 which itself may be operable to hold one or more parts 55,56. As illustrated, part carriers carrying metallized parts 56 are identified as element 54. Part carriers carrying pre-metallized parts 55 are identified as element 53. Pallets 52 may comprise any structure operable to hold one or more part carriers 53,54 and/or one or more parts 55,56. For example, each pallet may comprise any type of tray, plate, bin, basket, container, or other type of receptacle.
One or more parts 55,56 may thereby be transported via each pallet 52 either directly or through a part carrier 53,54. Each pre-metallized part 55 may comprise any object that that can be metallized in a sputter coater 40 of the in-line metallizer assembly 10 as will become appreciated herein. For example, pre-metallized parts 55 may comprise plastic parts, glass parts or any other part in which a more metallic or reflective appearance is desired. In one specific embodiment, pre-metallized parts 55 may comprise injection molded plastic parts. Pre-metallized parts 55 may independently comprise any size, shape and configuration that allows for them to enter the vacuum chamber 30 of the in-line metallizer assembly 10. Part carriers 53,54 may comprise any apparatus operable to support one or more parts 55,56 throughout the metallizing process. For example, part carriers may comprise a plurality of vertical pins in which each individual part 55,56 may be supported by an individual pin. In another embodiment, part carriers 53,54 may alternatively or additional comprise any other support structure such as support stands, seats, platforms or stages. In one specific embodiment, part carriers 53,54 may be operable to rotate each individual part 55,56. For example where a part 55,56 on a part carrier 53,54 passes by one or more fixed spray guns (such as those that apply paint or other coating to the part), the part carrier 53,54 may rotate the parts 55,56 such that paint may be applied to all areas of the parts 55,56 by a single gun. Such an embodiment may also allow for the metallizing of the entire part 55,56 when the part is placed in front of a sputter coater 40 as will become appreciated herein. The part carriers 53,54 and their operation in the in-line metallizer assembly 10 will be described in greater detail below.
Still referring to the external rotating actuator exchange 20 of the in-line metallizer assembly 10 illustrated in FIGS. 1 and 2, an external door clasp may be connected to each of the one or more actuating arms 22,23,24 distal the rotating pivot 21. For example, as seen in FIG. 1, a first external door clasp 26 and a second external door clasp 27 may be connected to the actuating arms 22,23,24 distal the rotating pivot 21. The first external door clasp 26 and second external door clasp 27 may comprise any device operable to both releasably engage one or more part carriers 53,54 (and/or individual parts 55,56) from the conveyor system 50 as well as provide a temporary vacuum seal around the entry port 25 of the vacuum chamber 30. As used herein "vacuum seal" refers to a seal that allows for an enclosed area to maintain a pressure lower than the pressure outside of the enclosed area. In one embodiment, the first external door clasp 26 and second external door clasp 27 may comprise a door with robotic grips operable to open and close about the one or more part carriers 53,54 and/or parts 55,56. In such an embodiment, the robotic grips may maintain sufficient pressure when closed to facilitate transportation of the one or more part carriers 53,54 and/or parts 55,56. In another embodiment, the first external door clasp 26 and second external door clasp 27 may comprise a flat plate (such as aluminum, iron or steel) with one or more pins or protrusions operable to engage receiving holes in the part carriers 53,54 and/or parts 55,56. In such an embodiment, the first external door clasp and second external door clasp may enter the receiving holes about the part carriers 53,54 and/or parts 55,56 when the actuating arms 22,23,24 are extended from the rotating pivot 21. Likewise, the first external door clasp and second external door clasp may exit the receiving holes about the part carriers 53,54 and/or parts 55,56 when the actuating arms 22,23,24 are retracted towards the rotating pivot 21. The first external door clasp 26 and the second external door clasp 27 may comprise the same type of device, or may each comprise a unique type of device.
The vacuum chamber 30 of the in-line metallizer assembly 10 may be disposed adjacent the external rotating actuator exchange 10 and may comprise any enclosure operable to maintain vacuum pressure and house an internal rotating actuator exchange 35. As used herein "vacuum pressure" refers to any pressure internal an enclosure that is lower than the pressure external the enclosure. The vacuum chamber 30 can therefore, for example, comprise one or more vacuum pumps 34 connected to one or more vacuum chamber walls 36. The vacuum pump(s) 34 may be able to pump air out from the enclosure formed by the vacuum chamber walls 36 such that the enclosure possesses a vacuum pressure. The vacuum pressure may comprise any pressure less than that outside of the vacuum chamber 30 and sufficient to enable the metallizing of parts within the sputter coater 40. For example, in one embodiment the vacuum pump(s) 34 may be able to lower the pressure in the sputter coater 40 to a pressure from about 5 torr to about 10 torr (i.e., about 6.7 millibar to about 13.3 millibar) or to a pressure as low as about 0.008 torr (i.e., about 0.01 millibar).
The internal rotating actuator exchange 35 may comprise any apparatus operable to receive one or more parts from the external rotating actuator exchange 20, transition the one or more parts to the sputter coater 40 for metallizing, and transition the metallized one or more parts back to the external rotating actuator exchange 35. The internal rotating actuator exchange 35 may comprise an overall structure similar to the external rotating actuator exchange. Specifically, the internal rotating actuator exchange may comprise an internal rotating pivot 31 and internal actuating arms 32,32 connected (either directly or indirectly) to the internal rotating pivot 31. The internal rotating pivot 31 may comprise any device operable to rotate the internal rotating actuator exchange 35 in an internal rotating direction 39. The internal rotating direction 39 can comprise a clockwise direction, a counterclockwise direction or a combination of both (such as where the internal rotating actuator exchange 35 first rotates in a clockwise direction before retracing its path in a counterclockwise direction). In one embodiment, the internal rotating pivot 31 may comprise a swivel or rod connected to an internal rotational drive source. The internal rotational drive source may be operable to turn the internal rotating pivot 31 to facilitate the rotation of the internal rotating actuator exchange 35 in the internal rotating direction 39. The internal rotational drive source may comprise any type of motor, engine, pneumatic apparatus and/or alternative source for power that is operable to rotate the internal rotating actuator exchange 35 when the internal rotating actuator exchange 35 is supporting one or more part carriers 53,54 and/or parts 55,56 as received from the external rotating actuator exchange 20.
Still referring to FIGS. 1 and 2, a sputter coater 40 may further be integrated with the vacuum chamber 30. The sputter coater 40 may comprise any device operable for applying a metal coating to parts within the vacuum chamber 30. For example, as illustrated in FIGS. 1-3 the sputter coater 40 may comprise one or more cathodes 42 comprising the source material (and more specifically the metal) to be deposited onto the parts. When in operation, the sputtered metal 45 will form a film about the parts 56 such that the parts 56 are metallized and therefore possess a metallic or reflective finish. The sputtered metal can comprise any material operable to be sputtered onto the surface of the parts such as pure metals, alloys or other materials. The sputter coater can be completely disposed within the vacuum chamber 30, or, as illustrated in FIGS. 1-3, the sputter coater walls 41 of the sputter coater 40 may abut against the vacuum chamber walls 36 of the vacuum chamber 30 such that a vacuum pressure is present in the sputter coater 40 as maintained by the vacuum pump(s) 34. In one embodiment, the pressure in the sputter coater 40 may be greater than the pressure in the vacuum chamber 30 such that a pressure gradient exists between the two causing air to flow from the sputter coater 40 to the vacuum chamber 30. Such an embodiment may allow for any gas injected by (or otherwise present in) the sputter coater 40 to flow from the sputter coater 40 to the vacuum chamber 30. Such gases may comprise argon or other inert gases (for example, when the sputter coater 40 injects argon during the sputtering process), water vapor, air or any other injected or residual gas. In another embodiment, a plurality of sputter coaters 40 may be integrated with the vacuum chamber 30 such that a plurality of parts can be metallized in different sputter coaters 40 simultaneously, sequentially or in any other order or combination.
The in-line metallizer will now be explained through an exemplary method of operation. With reference to FIGS. 1 and 2, a plurality of parts (pre-metallized parts are identified as 55 and metallized parts are identified as 56) may be carried by part carriers (part carriers carrying pre-metallized parts 55 are identified as 53 and part carriers carrying metallized parts 56 are identified as 54). Each part carrier 53 is initially loaded onto its own pallet 52 and transported along the conveyor system 50 in the first conveyor direction 59. Once the pallet 52 reaches the in-line metallizer assembly 10, one or more actuating arms 22,24 of the external rotating actuator exchange 10 extend such that the part carrier 53 is received (e.g., picked up) from the pallet 52 by the first door clasp 26. Once the part carrier 53 is secured by the first external door clasp 26, the actuating arms 22,24 retract and the rotating pivot 21 rotates the external rotating actuator exchange 20 in the external rotating direction 29 such that the part carrier 53 held by the first door clasp 26 now faces the entry port 25 of the vacuum chamber 30.
Within the vacuum chamber 30, the first internal door clasp 38 is already against the vacuum chamber walls 36 so that the vacuum chamber does not experience an increase in pressure from the outside air. The actuating arms 22,24 supporting the first external door clasp 26 are extended so that the first external door clasp 26 is pushed against the vacuum chamber walls 36 and the part carrier 53 is passed off to the first internal door clasp 37 of the internal rotating actuator exchange 35. While the first external door clasp 26 remains against the vacuum chamber walls (to ensure vacuum pressure is maintained inside the vacuum chamber 30), the internal actuating arms 32,33 of the internal rotating actuator exchange 35 retract so that the first internal door clasp 37 (and second internal door clasp 38) can be rotated via the internal rotating pivot 31. Specifically, the first internal door clasp 37 is rotated such that the part carrier 53 is now facing the sputter coater 40, and part carrier 54 carrying just metallized parts 56 faces the first external door clasp 26 of the external rotating actuator exchange 20. The internal actuating arms 32,34 are then extended so that the part carrier 53 with pre-metallized parts 55 is pushed towards the sputter coater 40 for metallizing. Likewise, second internal door clasp 38 now holding the part carrier 54 with metallized parts 56 is pushed against the vacuum chamber walls 36 around the entry port 25 such that it faces the first external door clasp 26 of the external rotating actuator exchange 20. While the parts 57 are being metallized via the sputter coater 40, the second internal door clasp 38 remains against the vacuum chamber walls 36 while the first external door clasp 26 (of the external rotating actuator exchange 20) receives the part carrier 54 from the second internal door clasp 38, retracts its actuating arms 22,23,24 with the part carrier 54, rotates via its rotating pivot 21, extends its actuating arms 22,23,24 and provides the now metallized parts 56 on the part carrier 54 to a waiting pallet 52.
The external rotating actuator multi-exchange 70 may comprise an external rotating pivot 71 and a plurality of external actuating arms 72 each having an external door clasp 76 attached thereto. The external rotating actuator multi-exchange 70 may be operable to rotate in a rotating direction 77 to transition between receiving pre-metallized parts 55 from the conveyor 350 and providing metallized parts 56 back onto the conveyor 350. The external rotating actuator multi-exchange 70 may specifically be operable to simultaneously receive a new part carrier 53 from the conveyor 350, receive or provide a part carrier 53,54 to or from the vacuum chamber 30, and provide part carriers 54 to the conveyor 350. Such an embodiment may accommodate faster cycle times by the sputter coater 40 by simultaneously picking up and dropping off part carriers 53,54 on the conveyor 350 as opposed to sequentially providing (i.e., dropping into the pallet 52) part carriers 54 and then receiving new part carriers 53.
Referring now to FIG. 5, the in-line metallizer assembly 10 (comprising an external rotating actuator exchange 20, vacuum chamber 30 and integrated sputter coater 40) can be utilized along a part-coating conveyor system 1000. The part-coating conveyor system 1000 can comprise a single system operable to apply a basecoat, metallized coat and topcoat using asynchronous pallets. Specifically, the part-coating conveyor system 1000 can comprise a track 500, a basecoat station 600, an in-line metallizer assembly 10, a topcoat station 700 and one or more process stations. Process stations can comprise any other station operable to assist in the application of coatings to the surface of parts. For example, process stations can include a surface treatment station 550, a flash oven station 800 and/or a cure station 900. The track 500 may comprise any type of conveyor system operable to transport a plurality of pallets 521. For example, the track can comprise a plurality of tracks with transitions and guides there between, a path for motorized pallets to travel across, or any alternative system. In one embodiment, such as that illustrated in FIG. 5, the track 500 may specifically comprise a main track 510 and a supplemental track 511. The supplemental track 511 may combine with the main track 510 to allow for two possible paths to arrive at the same destination. By providing two different paths, pallets may be directed down particular path based on the stations the pallet has already visited. In another embodiment, the track 500 may comprise a single continuous track operable to transition pallets sequentially from station to station. It should be appreciated that any other configuration may be employed to allow pallets to travel between stations.
In one embodiment, the part-coating system 1000 can further comprise a part molder operable to create the original parts. The part molder can comprise any machine operable to produce plastic parts, such as, for example, an injection molding machine. In such an embodiment, the part molder may be integrated with the track 500 such that parts produced from the part molder can directly travel along the track 500 to the basecoat station 600, the metallizer assembly 10, the topcoat station and/or any process station. Such an embodiment may allow for parts to forgo receiving basecoats by reducing the waiting time before being metallized or receiving a topcoat (and thereby reducing the chances the surface of the parts are scratched or otherwise damaged).
Still referring to FIG. 5, the track 500 can further comprise pallets 521 staged in asynchronous groups. Asynchronous groups 520 can comprise a single pallet 521 (such that each group is just a single pallet 521), a set number of pallets 521 (such that each asynchronous group 520 comprises the same set number of pallets 521), or any independent number of pallets 521 (such that each asynchronous group 520 can comprise any number of pallets 521 independent from one another). Asynchronous groups are groups that can travel along the track 500 independent of one another. For example, as opposed to a "chain-on-edge conveyor" (i.e., a conveyor in which all parts are transported by a continuous chain such that each part starts and stops in synch), asynchronous pallets on the track 500 can start and stop independent of one another. In such an embodiment, the movement and direction of each asynchronous group 520 of pallets 521 can be achieved through the use of RFID tags, scanners, flags, electrical signals, machine logic part mapping or any other alternative method for tracking the status of parts to direct them to subsequent stations.
In operation, one or more parts are loaded into pallets 521 on the track 500 via one or more loaders 540. The one or more loaders 540 can comprise any combination of manual or automatic loaders operable to load and unload parts, part carriers and/or pallets onto the track 500. The pallets 521 are arranged in asynchronous groups 520 where each pallet 521 in the asynchronous group 520 holds parts that are at a common stage (such as no paint, base coat only, base coat and metallized coat or all coats). An asynchronous group 520 of pallets 521 with newly molded parts (i.e., no paint coatings) may first be directed to the surface treatment station 550 to blow off unwanted debris left over from initial manufacturing, or otherwise be treated to improve adhesion such as through the use of flames, corona or other type of plasma. The asynchronous group 520 of pallets 521 is then directed through the basecoat station 600 where an initial base coat (e.g., a primer coat) is applied. The base coat can help fill in surface defects left over from manufacturing as well as provide durability and color. After the asynchronous group 520 of pallets 521 passes through the basecoat station 600, it is directed to the flash oven station 800 and/or cure station 900 so that the basecoat can set. It should be noted that where the basecoat station 600 and topcoat station 700 are two separate stations in the same track line (as illustrated in FIG. 5), the asynchronous group 520 of pallets 521 could pass through the topcoat station without actually stopping to receive the topcoat application. Depending on the desired treatment, the asynchronous group 520 of pallets 521 can return to the basecoat station 600 to receive additional basecoats such that the parts are coated with a plurality of basecoats (such as a primer coat and a first coat of base paint). In the alternative, asynchronous group 520 of pallets 521 may independently bypass the basecoat station 600 such as where parts are freshly manufactured and have not acquired surface abrasions, scratches or other defects.
After completion and setting of the basecoat, the asynchronous group 520 of pallets 521 would then be directed to the in-line metallizer assembly 10. The external rotating actuator exchange 20 of the in-line metallizer assembly 10 may thereby continuously pickup the parts from the pallets 521 (either individually or via part carriers) for metallizing while also returning the metallized parts to pallets 521. The in-line metallizer assembly 10 can thereby alleviate the need to collect and remove large batches of parts to be metallized when employing a batch metallizer. Once the parts of the asynchronous group 520 of pallets 521 are all metallized, the asynchronous group 520 of pallets 521 is directed to the topcoat station 700 (potentially via passing through the basecoat station 600 without actually receiving a basecoat). After receiving a topcoat from the topcoat station 700, the asynchronous group 520 of pallets 521 is directed to the flash oven station 800 and cure station 900. Finally, the completed products in the asynchronous group 520 of pallets 521 may be removed from the track 500 by the manual or automatic loaders 540.
Referring now to FIG. 8, the in-line metallizer 10 also includes a drive shaft 628 that extends through the sputter coater wall 41 of the sputter coater 40. The drive shaft 628 is coupled to one of the first drive gear 624 or the second drive gear 626 of the rotation mechanism 620. Rotation of the drive shaft 628, therefore, directly controls rotation of one of the first drive gear 624 or the second drive gear 626 and controls translation of the continuous drive element 622 around the first and second drive gears 624, 626. The in-line metallizer 10 also includes a rotary feed-through 630 which is coupled to the sputter coater wall 41 of the sputter coater 40. The rotary feed-through 630 allows the drive shaft 628 to pass through the sputter coater wall 41, while maintaining a fluid-tight seal between the sputter coater wall 41 and the drive shaft 628 such that at least a partial vacuum can be pulled inside the sputter coater 40.
Still referring to FIG. 8, the part carriers 54 are shown in greater detail. In the embodiment depicted in FIG. 8, the part carrier 54 includes a support frame 542 and a lifting body 544. The support frame 542 includes a plurality of rotatable pin fixtures 58 which are positioned spaced apart from one another along the support frame 542. The rotatable pin fixtures 58 include a support shaft 549 that extends through openings in the support frame 542, and a fixture gear 548 rotationally coupled to the support shaft 549. The fixture gear 548 and the support shaft 549 rotate together with respect to the support frame 542 of the part carrier 54. In some embodiments, the part carrier 54 may include a plurality of bearing elements (not shown) which position the support shafts 549 relative to the support frame 542 and minimize friction between the support shafts 549 and the support frame 542.
Referring again to FIG. 6, the individual parts 57 are introduced to the sputter coater 40 and positioned proximate to the cathodes 42 for completion of the metallizing operation. In some embodiments of the in-line metallizer assembly 10, the rotation mechanism 620 causes the rotatable pin fixtures 58, and therefore the individual parts 57, to rotate continuously during the metallizing operation such that the fixed-position cathodes 42 metallize all of the surfaces of the individual parts 57 having line-of-sight access to the cathodes 42. By rotating the individual parts 57 during the metallizing operation, a continuous metallized layer can be applied to the individual parts 57. In other embodiments of the in-line metallizing assembly 10, the rotation mechanism 620 limits rotation of the rotatable pin fixtures 58, and therefore the individual parts 57, during the metallizing operation such that only those limited surfaces of the individual parts 57 with line-of sight-access to the cathodes 42 are metallized. Such embodiments of the in-line metallizer assembly 10 may incorporate a servo motor or a stepper motor as the rotation device 640 such that rotation of the rotatable pin fixtures 58 can be minimized and/or eliminated. Orientation of the individual parts 57 relative to the cathodes 42 allow for complete or partial metallization of the individual parts 57, as dictated by a particular design.
Referring now to FIG. 9, components of another embodiment of the in-line metallizing assembly 10 are depicted. In this embodiment, components positioned within the sputter coater 40 are depicted. In this embodiment, the cathode 42 that metallizes the individual components 57 is repositionable in a vertical direction 710 and a horizontal direction 712, and is tiltable in a vertical orientation 714 as well as a horizontal orientation 716. In the embodiment depicted in FIG. 9, the cathode 42 is coupled to a cathode frame 720 positioned within the sputter coater 40. The cathode frame 720 depicted in FIG. 9 allows the cathode 42 to be adjusted in the directions of freedom of movement (i.e., the vertical direction 710, the horizontal direction 712, the vertical orientation 714, and the horizontal orientation 716) independently of one another, such that the cathode 42 can be positioned to provide the desired line-of-sight access to the individual parts 57. In the embodiment depicted in FIG. 9, the in-line metallizer assembly 10 further includes cathode drive mechanisms 722 that modifies the position of the cathode 42 along the cathode frame 720 or the orientation of the cathode 42 relative to the cathode frame 720.
In some embodiments of the in-line metallizing assembly 10, the cathode drive mechanisms 722 may be linear-acting servo motors that directly translate the cathode 42 in the vertical direction 710 or the horizontal direction 712. Similarly, the cathode drive mechanisms 722 may be rotary-acting servo motors that tilt the cathode 42 in the vertical orientation 714 or the horizontal orientation 716. Alternatively or in addition, the cathode drive mechanism 722 may include a remote tracking apparatus (not shown) similar to rotation mechanism 620 described above and depicted in FIGS. 6-8. Incorporation of a remote tracking apparatus with the cathode frame 720 may allow for the cathode drive mechanisms 722 to be positioned remotely from the sputter coater 40.
Pressurized buffer gas is delivered to the enclosure 742 such that buffer gas generally fills the enclosure 742. Because the pressurized buffer gas is maintained at a pressure above ambient within the enclosure 742, the buffer gas flows out into the surrounding environment and limits ingestion of untreated environmental air into the enclosure 742. Introduction of contaminants such as dust and moisture to the vacuum chamber 30 and the sputter coater 40 may negatively impact the metallizing process on pre-metallized parts 55 by the sputter coater 40. Reducing ingestion of untreated environmental air that carries such contaminants into the enclosure 742, reduced the likelihood of ingestion of untreated environmental air into the vacuum chamber 30 and the sputter coater 40 as the part carriers 54 are moved for sputter coating the pre-metallized parts 55, as discussed hereinabove. In particular, pressurized buffer gas may be introduced to the enclosure 742 at a rate greater than gas enters the vacuum chamber 30 during the exchange of part holders 54 and parts 55 by the external rotating actuator exchange 20.
Because of the short cycle time in which the parts 55 are metallized, the vacuum pumps 34 that evacuate gas from the vacuum chamber 30 and the sputter coater 40 may have difficulty in removing gas that is introduced to the vacuum chamber 30 and the sputter coater 40 during the part carrier 54 exchanges within one cycle of operation of the sputter coater 40. Further, any condensation that is introduced to the vacuum chamber 30 and the sputter coater 40 may tend to collect along surfaces of the vacuum chamber 30 and the sputter coater 40, increasing the difficulty of removing the moisture from the vacuum chamber 30 and the sputter coater 40. Therefore, by flooding the enclosure 742 with pressurized buffer gas from the pressurized gas delivery system 750, ingestion of contaminants into the enclosure 742, and therefore the vacuum chamber 30 and the sputter coater 40, may be reduced. Accordingly, in-line metallizer assembly 10 that incorporate a buffer gas system 740 may increase the yield of metallized parts 56 produced.
As depicted in FIG. 10, the gas knife 746 is positioned within the enclosure 742 proximate to the opening through which the external rotating actuator exchange 20 exchanges parts along the conveyor system 50. As discussed hereinabove, the gas knife 746 is provided with pressurized buffer gas that is ejected from the gas knife 746 in a generally planar orientation, such that the gas knife 746 forms a "gas curtain." The gas knife 746 may include a flow tube that is perforated with a plurality of holes or slots that direct passage of pressurized buffer gas. By positioning the gas knife 746 such that the pre-metallized parts 55 pass through the gas curtain as the part carriers 54 are exchanged, the gas knife 746 may direct pressurized buffer gas onto the pre-metallized parts 55 as to dislodge any contaminants and/or dry any moisture from the pre-metallized parts 55 before the pre-metallized parts 55 are exchanged into the vacuum chamber 30 and the sputter coater 40. Thus, the gas knife 746 further reduces the likelihood of ingestion of contaminants into the vacuum chamber 30.
It should now be appreciated that in-line metallizer assemblies may continuously metallize parts off of a conveyor belt without the need for batch loading/unloading. In-line metallizer can continuously pick up parts from a conveyor belt and swap them with recently metallized parts. The newly picked-up parts may be transferred to a vacuum chamber where they can be metallized and returned. While parts are being metallized inside the vacuum chamber, a new set of pre-metallized parts is picked up and exchanged with the most recently metallized parts. This in-line metallizer assembly may further be combined with an asynchronous part-coating conveyor system to efficiently apply a basecoat, metallized coat and topcoat to a part. The asynchronous grouping of pallets can help ensure partially completed pallets receive their next coats before an undesirable amount of time passes.
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