Patent Description:
When applying coatings such as paint on a surface, it is often necessary to mask those areas of the surface that are not intended to be coated. Mask materials, such as masking tape and/or paper may be used to form clean lines and/or shapes on the surface. For example, in the aircraft industry, lines, numbers and decorative features may be painted on the fuselage, wings and/or stabilizers of an aircraft.

In the past, in order to paint lines on the wings of an airplane, strips of masking tape and craft paper have been used to mask off those areas around the lines that are to be painted. The exposed areas of the wing surface between strips of the masking tape were then spray-painted, following which the masking tape was removed, leaving painted lines. This process had a number of disadvantages. Paint creep could occur beneath the masking tape, reducing the sharpness of the edges of the lines. The edge of masked-off paint lines may reduce aerodynamics and increase drag, and therefore fuel costs. Also, the preparation process involving layout and application of the masking tape and craft paper was time-consuming, labor-intensive and added to material costs. Finally, in those cases where the lines were to be painted over a fresh basecoat of paint on the airplane, it was necessary to wait until the basecoat was fully cured before the masking tape could be applied for painting lines, thereby adding to aircraft production time.

Accordingly, there is a need for a device and method for painting features such as lines on a surface that eliminates the need for masking materials and improves the sharpness and smoothness of the edges of the lines. There is also a need for an automated method of painting lines on a surface that obviates the need for manually masking of areas of the surface while also reducing VOC's (volatile organic compounds).

<CIT> states a method and apparatus for performing repetitive cycles of panel coating operations using a programmable manipulator including a manipulator arm movable along a plurality of axes. The apparatus comprises a hand unit carried on the manipulator arm. The hand unit is movable so as to bring the brush held by it into resilient contact with an area of the panel to be coated. A coating material is injected into the brush at a predetermined rate while the brush is held in resilient sliding contact with the panel and while the manipulator arm moves about the panel to coat a preselected area of the panel. After the preselected area of the panel has been coated, the manipulator arm is moved to move the brush out of contact with the panel. Between the coating cycles, the manipulator arm moves the brush into a storage chamber where it is treated to prevent the coating material from caking on the coating brush.

<CIT> states a method of applying a clear glass primer material and then a black glass primer material onto the marginal edge of a vehicular window glass, such as a windshield and/or rear window of an automobile, in which a dispenser is employed to discharge a clear primer material in discrete streams or drops and in which a black primer material is conformally coated onto the clear primer material by another dispenser. The clear and black primer materials are able to be applied to the window glass in a single pass operation.

<CIT> states a small-sized brushing machine, aiming at effectively solving the problems that the existing manual spraying is serious in material waste, is not environment-friendly, and is high in labor intensity of manual brushing and low in efficiency. The technical scheme is as follows: the small-sized brushing machine comprises a stand; the upper surface of the stand is provided with a bottom plate, the left end and right end of the bottom plate extend outside the stand, and the upper surface of the bottom plate is smooth; conveyor belts are respectively arranged at the two outer sides of the bottom plate at intervals, and the transmission sides of the conveyor belts are arranged towards the side of the bottom plate; a woolen row brush inclined towards the transmission direction of the conveyor belts is positioned above the bottom plate; a coating box is arranged above the woolen row brush; a plurality of burettes are arranged on the coating box at intervals along the axial direction of the woolen row brush; the lower ends of the burettes are arranged above the wool part of the woolen row brush; the conveyor belts are driven by a power device. The small-sized brushing machine is novel and unique in structure and simple in structure, is suitable for small-scale production after being regulated for once, and is high in automatic production degree, low in cost, energy-saving, environment-friendly, low in labor intensity and high in efficiency, thus being suitable for small-scale production.

<CIT> states a process for making disposable absorbent articles such as sanitary napkins, panty liners, catamenials, incontinence inserts perspiration pads, and diapers for adults or babies. In particular the present invention relates to a process for the manufacture of disposable absorbent articles comprising two component materials which are adhered to each other which utilizes an improved gravure roll printing process (<NUM>) to provide the adhesive, wherein the adhesive is applied to the gravure print roll (<NUM>) such that the gravures (<NUM>) are only partly filled.

Aspects and features of the present disclosure are defined in the accompanying claims.

The disclosed examples may be employed to paint lines and other features and/or patterns on a surface such as an airplane or other vehicles that may reduce or eliminate the use of masking materials. Lines may be directly applied to the surface without the need for atomizing the paint, thereby eliminating the need for paint application in a paint booth or similar controlled environment. The method allows painting lines that have cleaner and smoother edges. Elimination of the need for masking materials permits lines and features to be painted over underlying basecoats that have not fully cured, thereby reducing wait time and improving production rate. In one variation, the examples may be employed as an end effector on an automated robot, allowing lines and features to be painted under semi-automatic or fully automatic digital control. In another variation, the examples may employ a combination of a line painting system and spray painting system to paint wide strips and/or large area features on a surface.

According to one disclosed example of the invention, an apparatus is provided for applying a patterned coating on a surface. The apparatus comprises a fluid pump adapted to pump a coating fluid, and a line applicator adapted to be brought into contact with the surface for applying a line of the coating fluid on the surface. The apparatus also includes a dispensing tip coupled with the fluid pump and the line applicator for dispensing the coating fluid to the line applicator.

The apparatus further comprises a manipulator having the line applicator and the dispensing tip mounted thereon, and a CNC controller including digital control programs for controlling the manipulator. The apparatus also comprises a coating fluid spray gun mounted on the manipulator and adapted to be coupled with a source of the coating fluid for spraying the coating fluid onto the surface, wherein the coating fluid spray gun is offset from the line applicator.

According to still another disclosed example of the invention, a method, for example a maskless painting method, is provided, comprising delivering paint from a source of paint to a pump, and pumping the paint from the pump to a dispensing tip. The method also includes dispensing the paint from the dispensing tip to line applicator comprising a wick, bringing the wick into contact with a surface, and painting features on the surface by moving the wick over the surface, wherein the dispensing tip is mounted on a manipulator which included a CNC controller including digital control programs for controlling the manipulator. The method may also include spraying coating fluid on to the surface ysing a coating fluid spray gun mounted on the manipulator and offset form the line applicator, wherein the coating fluid spray gun is offset from the line applicator in the direction of travel of the line applicator.

The features, functions, and advantages can be achieved independently in various examples of the present disclosure or may be combined in yet other examples in which further details can be seen with reference to the following description and drawings.

The illustrative embodiments, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:.

The disclosed embodiments provide a method and apparatus for applying coatings such as paint on a surface to form visually decorative or functional features. For example, the embodiments can be employed to carry out maskless painting of decorative lines and patterns on surfaces of vehicles such as aircraft. The embodiments may also be used to apply patterns of functional coatings on a wide range of surfaces and structures, including, for example and without limitation, as coatings used to indicate barely visible impact damage on an aircraft. As used herein, the terms "features" and "patterns" include a wide range of designs, strips, lines, images and the like which may be either decorative or functional. In the exemplary embodiment described below, the method and apparatus are employed to paint lines and strips on an aircraft, however principles of the disclosed embodiments are applicable to painting features and patterns on the surfaces of other structures.

Referring now to <FIG> and <FIG>, an airplane <NUM> comprises a fuselage <NUM> and a pair of wings <NUM> having leading and trailing edges <NUM>, <NUM> respectively. Lines <NUM> are painted on the upper surface <NUM> of the wings <NUM> and extend along the leading and trailing edges <NUM>, <NUM> from the wing root <NUM> to the wing tip <NUM>. Additionally, wide strips <NUM> are painted on the wing surfaces <NUM> which function as visual references to aid a pilot in landing the airplane <NUM>. The wide strips <NUM> are located slightly outboard of the fuselage <NUM> and extend fore and aft between the painted lines <NUM>. The widths <NUM>, <NUM> of the lines <NUM> and wide strips <NUM> respectively, may vary with the application. In one commercial airplane application, for example, the width <NUM> of lines <NUM> may be approximately <NUM> inch, and the width <NUM> of wide strips <NUM> may be approximately <NUM> inches (<NUM> inch equals <NUM>,<NUM>).

<FIG> illustrates apparatus <NUM> for painting the lines <NUM> and wide strips <NUM> on the wing surfaces <NUM> shown in <FIG> and <FIG>. An end effector <NUM> for painting the lines <NUM> and wide strips <NUM> is mounted on a robot <NUM> or similar robotic manipulator that is controlled by a CNC (computer numerical control) controller <NUM>. The CNC controller <NUM> includes one or more memories <NUM> for storing digital control programs <NUM> and digital information <NUM> relating to wing geometry configurations and line/strip information for each of the wing geometry configurations. As will be discussed below in more detail, under automatic control by the CNC controller <NUM>, the robot <NUM> moves the end effector <NUM> over the wing surfaces <NUM> and paints the lines <NUM> and wide strips <NUM> without the need for masking materials.

<FIG> illustrates one arrangement for painting lines <NUM>, wide strips <NUM> or other features on the surface <NUM> of a wing <NUM> or other area of an airplane <NUM>. In this example, the apparatus <NUM> comprises a pair of the robots <NUM> mounted for linear movement along tracks <NUM> within a controlled environment, such as a paint booth <NUM>. A pair of end effectors <NUM> are mounted on articulated arms 60a of the two robots <NUM>. The CNC controllers <NUM> may be mounted outside of the paint booth <NUM> to isolate electrical components of the CNC controllers <NUM> from volatiles within the paint booth <NUM>. In this example, the robots <NUM> are moved along the tracks <NUM> to traverse the length of the wing <NUM>, and their operation is coordinated such that, in combination, the end effectors <NUM> are moved to various locations over the surface <NUM> of the wing <NUM> to paint desired features, such as without limitation, the lines <NUM> and wide strips <NUM>.

Attention is now directed to <FIG>, <FIG> and <FIG> which illustrate additional details of the end effector <NUM>. The end effector <NUM> includes head <NUM> that serves as a structural frame on which various components discussed below are be mounted. The head <NUM> is supported on and is releasably connected to the robot <NUM> by a quick-change adapter <NUM>. A line painting system <NUM> and a spray painting system <NUM> are mounted on the head <NUM> and, as will be discussed below, may be operated independently or in combination to paint features on a surface <NUM>, such as the lines <NUM> and wide strips <NUM> shown in <FIG> and <FIG>. In the illustrated embodiment, a compressed air tank <NUM> is mounted on the head <NUM> and acts as a source of pressurized air for operating various pneumatic powered components of the two painting systems <NUM>, <NUM>. In other embodiments, however, the supply of compressed air may be remotely located, off-board the end effector <NUM> and coupled with the painting systems <NUM>, <NUM> by pneumatic lines (not shown).

The line painting system <NUM> may be provided with an onboard, non-pressurized fluid container <NUM> for holding a quantity of paint or other coating fluid that is to be painted as lines <NUM> onto the wing surface <NUM>. In other embodiments, however the coating fluid may be drawn from a bulk fluid supply (not shown) located off-board the end effector <NUM>. A fluid pump <NUM> draws fluid from the fluid container <NUM> and pumps it through a shut off valve <NUM> and dispensing tube <NUM> to a dispensing tip <NUM>. The fluid pump <NUM> comprise a pneumatically powered motor driven positive displacement pump such as a peristaltic pump that is provided with a motor muffler <NUM> for reducing motor exhaust noise.

The shut off valve <NUM> may comprise a pneumatically controlled solenoid valve that is selectively opened and closed to control the flow of fluid to the dispensing tip <NUM>. The dispensing tip <NUM> includes an outlet (not shown) at the distal end (<FIG>) thereof which dispenses the fluid onto a line applicator <NUM> which, in the exemplary embodiment, comprises a wick 90a. The wick 90a becomes saturated with the fluid dispensed from the dispensing tip <NUM>, and as will be discussed below, is capable of flowing the fluid onto the surface <NUM>. The wick 90a is removably attached to a wick holder <NUM> (<FIG> and <FIG>) at the end of a pair of support arms <NUM> extending forwardly from and connected to the head <NUM>. The shut off valve <NUM> is also mounted on the outer end of the support arms <NUM>.

The spray painting system <NUM> includes a pressurized fluid container <NUM>, a fluid regulator <NUM> and a coating fluid spray gun <NUM> having a nozzle <NUM> from which paint or other coating fluid may be sprayed onto the wing surface <NUM>. In the illustrated embodiment, the pressurized fluid container <NUM> is mounted on the head <NUM>, however in other embodiments the pressurized fluid container may comprise a bulk fluid tank (not shown) located off-board the end effector <NUM>. The fluid pressure regulator <NUM> may include controls to regulate the pressure and flow of the fluid to the spray gun <NUM>. A pressure gauge <NUM> may be coupled with the fluid regulator to display the fluid pressure. As best seen in <FIG>, the spray gun <NUM> is supported on an arm <NUM> that is attached to the head <NUM>. The spray gun <NUM> is mounted on the forward end of the end effector <NUM>, and the nozzle <NUM> is oriented to spray fluid downwardly from the spray gun <NUM>. The wick 90a along with the dispensing tip <NUM> is mounted on the rear or trailing end of the end effector <NUM>. The spray gun <NUM> and line applicator <NUM> may be mounted in other locations on the head <NUM>, depending upon the application. In some embodiments, the end effector <NUM> may include more than one line painting system <NUM> and more than one spray tanning system <NUM>, depending on the application, and/or the size and shapes of the features to be painted.

<FIG> illustrate additional details of the applicator wick 90a and dispensing tip <NUM>. The applicator wick 90a may comprise any suitable flexible and compliant material capable of being saturated with and holding paint or other coating fluid, and flowing the fluid onto the surface to be coated, such as the wing surface <NUM>. In the illustrated example, the applicator wick 90a comprises a woven or knitted flexible gauze <NUM> having openings <NUM> that are capable of being saturated with and holding the fluid, and flowing it onto a surface <NUM>. However, a variety of other materials and material arrangements may be employed as the line applicator <NUM> including, without limitation, one or more brushes (not shown). The illustrated wick 90a has straight, parallel edges <NUM> and a width <NUM> corresponding to the width of the line e.g. lines <NUM> (<FIG> and <FIG>). However, the wick may have other geometries, depending on the type of line being painted. For example and without limitation, the wick 90a may have a tapered geometry, in which case, lines <NUM> with varying widths may be painted by using the robot <NUM> to change the elevation of the head <NUM> above the surface <NUM> being painted.

The flexible and compliant nature of the wick 90a allows it to conform varying surface geometries. For example, referring to <FIG>, the applicator wick 90a remains in contact with the surface <NUM> when the head <NUM> undergoes minor changes in elevation, such as a displacement from a height H<NUM> shown in <FIG> to a lower height H<NUM> shown in <FIG>. Similarly, as shown in <FIG>, the applicator wick 90a remains in contact with undulating surfaces <NUM> that may have minor peaks 50a and valleys 50b, as the head <NUM> moves <NUM> along the surface <NUM> at a constant elevation. The robot <NUM> may move the end effector <NUM> along any desired path in three dimensions. For example, referring to <FIG>, the line painting system <NUM> may be moved along a curved path to paint lines 36a having one or more complex curves rather non-linear geometries.

Attention is now directed to <FIG> which illustrate a method of painting strips on a surface, such as the wide strips <NUM> on the wing surface <NUM> shown in <FIG> and <FIG>. As shown in <FIG>, wide strip <NUM> intended to be painted has a predetermined width <NUM> and sharp outer edges 46a. In one variation of the method, the end effector <NUM> is moved over the surface <NUM> along a desired path and the spray painting system <NUM> is used to spray paint a centrally located section 46b of the wide strip <NUM> between the outer edges 46a of the wide strip <NUM>. Then, in one or more subsequent passes of the end effector <NUM>, the line painting system <NUM> is used to paint outer lines 46c on opposite sides of the centrally located section 46b. The outer lines 46c may be contiguous to or overlie the centrally located section 46b and are substantially aligned with the outer edges 46a of the wide strips <NUM>. In another embodiment of the method, the outer lines 46c may be painted, following which the centrally located section 46b is spray-painted.

As previously mentioned, in some embodiments, the end effector <NUM> may be provided with more than one line painting system <NUM> and spray painting system <NUM>. For example, <FIG> illustrates an alternate embodiment of the end effector <NUM> that carries <NUM> line painting systems <NUM> that are positioned on opposite sides of a centrally located spray painting system <NUM>. In this example, the fluid, such as paint, is supplied to the line painting system <NUM> and spray painting system <NUM> from one or more off-board bulk paint supplies <NUM>. The embodiment of <FIG> is well-suited to paint wide paint strips, such as the wide strips <NUM> on the airplane wings <NUM> shown in <FIG> and <FIG>. In a single pass of the end effector <NUM> over a surface <NUM>, the line painting systems <NUM> respectively paint the outer lines 46c (<FIG>), while the spray painting system <NUM> paints the centrally located section 46b. Although not shown in the Figures, the spray painting system <NUM> is offset or staggered from the line painting systems <NUM> in the direction of travel of the end effector <NUM>. In other examples useful for understanding the background of the invention. the spray painting system may be laterally aligned with the line painting systems <NUM>, in which case the outer lines 46c and centrally located section 46b are painted at substantially the same time in a single pass of the end effector <NUM> over surface <NUM>.

<FIG> broadly illustrates the overall steps of a method of painting strips on a surface <NUM>. Beginning at <NUM>, a robotic end effector <NUM> is moved over the surface <NUM>, and at <NUM> the end effector <NUM> is used to paint lines <NUM> on the surface <NUM>. The lines <NUM> may be painted using a line applicator <NUM> such as a wick 90a forming part of the line painting system <NUM> carried on at the end effector <NUM>. The painted lines <NUM> maybe spaced apart from each other, as shown in <FIG>. At <NUM>, the robotic end effector <NUM> is used to spray paint onto the surface <NUM>. A central area between two painted lines <NUM> maybe spray-painted using the spray painting system <NUM> on the end effector <NUM>.

Attention is now directed to <FIG> which broadly illustrates the overall steps of a maskless painting method. At <NUM>, paint is delivered a paint source <NUM> to a fluid pump <NUM> which, as previously mentioned may comprise a pneumatically driven peristaltic pump. At <NUM>, paint is pumped to a dispensing tip <NUM>. At <NUM>, the paint is dispensed from the dispensing tip <NUM> to a wick 90a or similar line applicator <NUM>, causing the wick 90a to be saturated with paint. At <NUM>, the wick 90a is brought into contact with a surface <NUM> on which one or more features are to be painted. At <NUM>, the features are painted on the surface <NUM> by moving the wick 90a over the surface <NUM>. As the wick 90a moves over the surface <NUM>, the paint flows from the wick 90a onto the surface <NUM>.

Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive applications and other application where it is necessary to apply coatings such as paint and desired patterns. Thus, referring now to <FIG>, embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method <NUM> as shown in <FIG> and an aircraft <NUM> as shown in <FIG>. Aircraft applications of the disclosed embodiments may include, for example, without limitation, applying patterned coatings on surfaces and painting lines and patterns on wings, stabilizers and fuselages. During pre-production, exemplary method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component and subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, the aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may also include modification, reconfiguration, refurbishment, and so on.

As shown in <FIG>, the aircraft <NUM> produced by exemplary method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. The disclosed method and apparatus may be employed to paint lines and other features on the aircraft's skin forming part of the airframe <NUM>. Examples of high-level systems <NUM> include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM> and an environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the marine and automotive industries.

Systems and methods embodied herein may be employed during any one or more of the stages of the production and service method <NUM>. For example, components or subassemblies corresponding to production process <NUM> may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft <NUM> is in service <NUM>. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages <NUM> and <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft <NUM> is in service, for example and without limitation, to maintenance and service <NUM>.

As used herein, the phrase "at least one of", when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, "at least one of item A, item B, and item C" may include, without limitation, item A, item A and item B, or item B. The item may be a particular object, thing, or a category. In other words, at least one of means any combination items and number of items may be used from the list but not all of the items in the list are required.

Claim 1:
An apparatus for painting a line on an airplane surface, the apparatus comprising:
a fluid pump (<NUM>) adapted to pump a coating fluid;
a line applicator (<NUM>) adapted to be brought into contact with the surface for applying a line of the coating fluid on the surface;
a dispensing tip (<NUM>) coupled with the fluid pump and the line applicator for dispensing the coating fluid to the line applicator;
a manipulator (<NUM>) having the line applicator and the dispensing tip mounted thereon;
a CNC controller (<NUM>) including digital control programs for controlling the manipulator; and
a coating fluid spray gun (<NUM>) mounted on the manipulator and adapted to be coupled with a source of the coating fluid for spraying the coating fluid onto the surface, wherein the coating fluid spray gun is offset from the line applicator.