Masking Tray Assemblies for Arc Spray Applications

Abstract

Various tray assemblies for arc spray applications are disclosed. In some embodiments, the assembly may include: a bottom frame including a plurality of recesses, each recess operable to accommodate an electronic device; and a top frame coupled to the bottom frame, wherein the top frame includes a plurality of top frame openings aligned with the plurality of recesses. The assembly may also include a sealing layer between the first main frame and the second main frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings.

Description

Technical Field

[0001] The present disclosure relates generally to the field of surface protection. More specifically, embodiments of the present disclosure relate to a tray assembly for arc spray applications. Background Art

[0002] Typically, masking trays for electronic devices such as metal oxide varistors are made of solid metals such as aluminum or steel. During the arc spraying process, ultra-high temperature, ultra-high speed metal particles are delivered to the electronic device. However, conventional metal masking trays are easily contaminated by the sprayed metal particles, thereby reinforcing and causing unstable spray quality on the surface of the electronic device, while also reducing the service life of the masking tray. In addition, conventional metal trays cannot provide adequate edge sealing for those areas of the electronic device that will remain uncoated, such as along the edges.

[0003] Therefore, there is a need for an improved masking tray assembly for arc spray applications. Summary of the invention

[0004] This Summary is provided to introduce some concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be an aid in determining the scope of the claimed subject matter.

[0005] In one approach, an assembly may include: a bottom frame comprising a plurality of grooves, each groove operable to accommodate an electronic device; a top frame coupled to the bottom frame, wherein the top frame comprises a plurality of top frame openings aligned with the plurality of grooves; and a sealing layer between the top frame and the bottom frame, wherein the sealing layer comprises a plurality of sealing layer openings aligned with the plurality of top frame openings.

[0006] In another approach, a masking tray assembly may include: a bottom frame having a plurality of recesses, each recess operable to receive an electronic device; and a top frame coupled to the bottom frame, wherein the top frame includes an inner surface facing the bottom frame, and wherein the top frame includes a plurality of top frame openings aligned with the plurality of recesses. The masking tray assembly may also include a sealing layer extending along the inner surface of the top frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings.

[0007] In yet another approach, a masking tray assembly may include: a bottom frame including a plurality of recesses, each recess operable to accommodate an electronic device; and a top frame coupled to the bottom frame, wherein the top frame includes an inner surface facing the bottom frame, and wherein the top frame includes a plurality of top frame openings aligned with the plurality of recesses. The masking tray assembly may also include a sealing layer extending along the inner surface of the top frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings, and wherein a flange of the sealing layer is coupled to an engagement member of the top frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings illustrate exemplary methods of the disclosed embodiments hitherto devised for practical application of the principles of the disclosed embodiments, and in which:

[0009] Figure 1 depicts a top perspective view of a bottom frame of an assembly according to an embodiment of the present disclosure;

[0010] Figure 2 Depicts the bottom frame of an assembly according to an embodiment of the present disclosure. Figure 1 A side cross-sectional view taken along the cutting line 2-2;

[0011] Figure 3 depicts a top perspective view of a top frame of an assembly according to an embodiment of the present disclosure;

[0012] Figure 4 Describes an embodiment of the present disclosure Figure 3 A bottom perspective view of the top frame of FIG.

[0013] Figure 5 depicts a perspective view of a cylindrical sealing element according to an embodiment of the present disclosure;

[0014] Figure 6 depicts a side cross-sectional view of an assembly according to an embodiment of the present disclosure;

[0015] Figure 7 depicts a top perspective view of a top frame according to an embodiment of the present disclosure;

[0016] Figure 8 Describes an embodiment of the present disclosure Figure 7 A bottom perspective view of the top frame of FIG.

[0017] Fig. 9 depicts a side cross-sectional view of an assembly according to an embodiment of the present disclosure;

[0018] Fig.10 depicts a top perspective view of a top frame according to an embodiment of the present disclosure;

[0019] Fig.11 Describes an embodiment of the present disclosure Fig.10 A close-up view of the top frame of

[0020] Fig.12 Depicted is a top perspective view of a portion of a top frame according to an embodiment of the present disclosure.

[0021] The drawings are not necessarily to scale. The drawings are merely representations and are not intended to depict specific parameters of the present disclosure. The drawings are intended to depict exemplary embodiments of the present disclosure and are not to be considered limiting of the scope. In the drawings, like numbers represent like elements.

[0022] In addition, for clarity of illustration, some elements in some of the drawings may be omitted or not shown to scale. For clarity of illustration, the cross-sectional views may be in the form of "sliced" or "close-up" cross-sectional views, omitting certain background lines that would otherwise be visible in a "true" cross-sectional view. In addition, for clarity, some reference numerals may be omitted in some of the drawings. DETAILED DESCRIPTION

[0023] Components and methods according to the present disclosure will now be described more fully below with reference to the accompanying drawings, in which embodiments are shown. The components and methods may be embodied in a variety of different forms and are not to be construed as being limited to the embodiments set forth herein. Instead, these embodiments are provided so that the present disclosure will be thorough and complete and will fully convey the scope of the present disclosure to those skilled in the art.

[0024] As will be described in more detail herein, embodiments of the present disclosure provide a novel edge protection method that includes a top frame with an optional masking layer (e.g., facing a spray gun), a bottom frame for accommodating multiple electronic devices (e.g., MOVs), and a sealing layer between the top frame and the bottom frame. In some embodiments, a sealing barrier strip may extend around the perimeter of the top frame and / or the bottom frame. The sealing barrier strip is designed to prevent the ingress of spray particles that might otherwise contaminate the electronic device, such as along a free zone (edge ​​area without coating).

[0025] Although non-limiting, the top frame can be made of metal or other materials with high mechanical strength (e.g., metal alloys, steel, stainless steel, aluminum, aluminum alloys, etc.) to prevent deformation of the components. The masking layer can be a non-sticky or low-sticky material (e.g., polyurethane (PU), PU+silicone compound, silicone, thermoplastic polyurethane (TPU), TPU+25% carbon fiber, TiN, Ti+Cr alloy, diamond, etc.) to minimize or prevent metal particles from being deposited along the outer surface of the top frame.

[0026] In some embodiments, the sealing layer may extend from the inner surface of the top frame. For example, the sealing layer may include a plurality of cylindrical sealing elements (e.g., plugs) extending from the inner surface of the top frame. Each cylindrical sealing element may include a wall defining a sealing layer opening, the sealing layer opening being aligned with a corresponding opening through the top frame. Although non-limiting, the sealing layer may be made of a relatively soft material that provides a seal with the top surface of the electronic device during the arc spraying process. The sealing layer opening and the walls of the cylindrical sealing element may be sized to protect the uncoated area of ​​the MOV disc to prevent contamination.

[0027] It should be appreciated that, through the embodiments of the present disclosure, at least the following advantages are achieved. First, the masking layer along the outer surface of the top frame can provide improved protection in ultra-high temperature and ultra-high speed spray environments. Second, the sealing layer between the top frame and the bottom frame provides an enhanced seal to the free area of ​​the MOV disk. Third, the sealing barrier strip can prevent the ingress of spray particles to avoid equipment contamination. Fourth, the cylindrical sealing element of the sealing layer can be removed and replaced separately.

[0028] Go to Figure 1-2 , a bottom frame 102 of a tray assembly (hereinafter referred to as "assembly") 100 will be described. As shown, the bottom frame 102 may include a central interior area 104, which includes a plurality of recesses 106, each recess 106 operable to accommodate an electronic device 108, which may be one or more MOV disks. The bottom frame 102 may include a raised portion 110 surrounded by a sealing channel 112. As shown, the sealing channel 112 may extend completely around the plurality of recesses 106, wherein the peripheral wall 114 of the bottom frame 102 further defines the sealing channel 112. As will be described in more detail below, a perimeter seal may extend within the sealing channel 112 to block spray particles, thereby avoiding contamination of the electronic device 108. Although a single row of electronic devices 108 is shown, it should be understood that in alternative embodiments, a greater or lesser number of electronic devices 108 may be present within the plurality of recesses 106. The bottom frame 102 may be made of a metal or other material (e.g., a metal alloy, steel, stainless steel, aluminum, aluminum alloy, etc.) having high mechanical strength to prevent deformation of the assembly 100.

[0029] Figure 3-4The top frame 120 of the assembly 100 is shown. In some embodiments, the top frame 120 includes an inner surface 122 opposite to an outer surface 124. The outer surface 124 can face the spray gun (not shown), while the inner surface 122 can face the bottom frame 102. As shown, the top frame 120 can include a plurality of top frame openings (hereinafter referred to as "openings") 128 extending between the outer surface 124 and the inner surface 122. Although non-limiting, the top frame 120 can be made of metal or other materials (e.g., metal alloys, steel, stainless steel, aluminum, aluminum alloys, etc.) with high mechanical strength to prevent deformation of the assembly 100.

[0030] As further shown, the assembly 100 may include a sealing layer 130 coupled between the top frame 120 and the bottom frame 102. In some embodiments, the sealing layer 130 includes a plurality of cylindrical sealing elements 134 extending from the inner surface 122 of the top frame 120, wherein each of the plurality of cylindrical sealing elements 134 includes a wall 136 defining a sealing layer opening 138. As shown, each sealing layer opening 138 is aligned with a corresponding opening 128 of the top frame 120. In some embodiments, a plurality of cylindrical sealing elements 134 are generally adjacent to each other. In other embodiments, a plurality of cylindrical sealing elements 134 may be spaced apart. It should be understood that the number and configuration of a plurality of cylindrical sealing elements 134 may depend on the number and configuration of the opening 128 of the top frame 120. In some embodiments, each of the plurality of cylindrical sealing elements 134 is individually removable. Although non-limiting, the sealing layer 130 may be made of silicone, silicone+polyurethane (PU) compounds, PU or other rubber materials with relatively low hardness.

[0031] like Figure 4 , the perimeter seal 140 may extend from the inner surface 122 of the top frame 120. The perimeter seal 140 is configured to extend within the sealing channel 112 of the bottom frame 102 to block spray particles, thereby preventing contamination of the electronic device 108. As shown, the perimeter seal 140 may extend completely around the plurality of cylindrical sealing elements 134. Although non-limiting, the perimeter seal 140 may be made of silicone, silicone + polyurethane (PU) compound, PU or other rubber materials with relatively low hardness.

[0032] Now go to Figure 5, an example cylindrical sealing element 134 according to an embodiment of the present disclosure will be described in more detail. As shown, the cylindrical sealing element 134 may include a first axial end 141 opposite a second axial end 142. During use, the first axial end 141 may be operable to be in direct physical contact with the top frame 120, and the second axial end 142 may be operable to be in direct physical contact with the electronic device 108. In some embodiments, a first flange 143 may extend radially from the wall 136 at the first axial end 141, and a second flange 144 may extend radially from the wall 136 at the second axial end 142. The outer diameter of the second flange 144 may be greater than the outer diameter of the first flange 143. Between the first flange 143 and the second flange 144 may be a center portion 145 of reduced diameter. The first axial end 141 may include a first end face 146, and the second axial end 142 may include a second end face 147.

[0033] like Figure 6 As shown, when the top frame 102 and the bottom frame 120 are coupled together, the second end surface 147 of the one or more cylindrical sealing elements 134 can be in direct physical contact with the perimeter of the electronic device 108. By setting the inner diameter of the sealing layer opening 138 to be slightly smaller than the diameter of the electronic device 108, the spray particles can be prevented from reaching the uncoated edge area of ​​the electronic device 108. In addition, the top surface 150 of the perimeter seal 140 can be in direct physical contact with the inner surface 122 of the top frame 120. As shown, the perimeter seal 140 is located within the sealing channel 112 of the bottom frame 102.

[0034] In some embodiments, the top frame 120 may include one or more engagement members 152 extending from its inner surface 122. Each engagement member 152 may include a radially extending flange 154 that engages with a central portion 145 of a wall 136 of a pair of cylindrical sealing elements 134. The flange 154 of the engagement member 152 may be sandwiched between a first flange 143 and a second flange 144 of the cylindrical sealing element 134. As further shown, the assembly 100 may include a plurality of posts 156 that couple the top frame 102 and the bottom frame 120 together. Although non-limiting, the posts 156 may include sealing rings 158 to further minimize particle contamination.

[0035] Now go to Figure 7-8, the top frame 220 of the assembly 200 according to another embodiment of the present disclosure will be described. In some embodiments, the top frame 220 includes an inner surface 222 opposite to the outer surface 224. The outer surface 224 may face the spray gun (not shown), while the inner surface 222 may face the bottom frame (not shown). In some embodiments, the top frame 220 may include a plurality of top frame openings (hereinafter referred to as "openings") 228 extending between the outer surface 224 and the inner surface 222. Although non-limiting, the top frame 220 may be made of metal or other materials (e.g., metal alloys, steel, stainless steel, aluminum, aluminum alloys, etc.) with high mechanical strength to prevent deformation of the assembly 200.

[0036] As further shown, the assembly 200 may include a sealing layer 230 coupled to the top frame 220. In the present embodiment, the sealing layer 230 may be in direct physical contact with the inner surface 222. The sealing layer 230 may include a plurality of sealing layer openings 238, which are generally aligned with the openings 228. Although not limiting, the sealing layer 230 may be made of silicone, silicone + polyurethane (PU) compound, PU, ​​or other rubber materials having a relatively low hardness.

[0037] like Figure 8 228. As best shown in FIG. 22, the perimeter seal 240 can extend from the inner surface 222 of the top frame 220. In the present embodiment, the perimeter seal 240 can be integrally formed with the sealing layer 230. The perimeter seal 240 is configured to extend within the sealing channel of the bottom frame to block the spray particles, thereby avoiding contamination of the electronic device. As shown, the perimeter seal 240 can extend completely around the opening 228. Although non-limiting, the perimeter seal 240 can be made of silicone, silicone + polyurethane (PU) compound, PU or other rubber materials with relatively low hardness.

[0038] like Fig. 9As shown, when the top frame 220 is coupled to the bottom frame 202, the sealing layer 230 can be in direct physical contact with the periphery of the electronic device 208. In addition, the top surface 250 of the perimeter seal 240 can be in direct physical contact with the inner surface 222 of the top frame 220. As shown, the perimeter seal 240 is located in the sealing channel 212 of the bottom frame 202. Once the top frame 220 and the bottom frame 202 are coupled together, the sealing layer opening 238 and the opening 228 are aligned on the corresponding groove 206 in the bottom frame 202. By setting the diameter of the sealing layer opening 238 to be slightly smaller than the diameter of the electronic device 208, the spray particles can be prevented from reaching the uncoated edge area of ​​the electronic device 208. As further shown, the assembly 200 may include a plurality of posts 256, which couple the top frame 220 and the bottom frame 202 together. Although non-limiting, the posts 256 can extend through the openings 258 of the sealing layer 230 to further minimize particle contamination.

[0039] Now go to Figure 10-12 , a top frame 320 according to another embodiment of the present disclosure will be described. As shown, the top frame 320 may include a main body 310 having a first main side 312 opposite to a second main side 314. Passing through the main body 310 may be a plurality of top frame openings (hereinafter referred to as "openings") 328 extending between the first main side 312 and the second main side 314, wherein the openings 328 may be defined by side walls 331. A sealing layer 330 may be formed above the main body 310, including along the first main side 312 and the second main side 314. In Fig.11 In embodiments, the sidewall 331 of the opening 328 may not be covered by the sealing layer 330. Although not limiting, the sealing layer 330 may include a first sealing layer 330A extending along the first main side 312 and a second sealing layer 330B extending along the second main side 314. It should be understood that the first sealing layer 330A and the second sealing layer 330B may be the same or different materials. In some embodiments, the sealing layer 330 may be made of silicone, silicone + polyurethane (PU) compound, PU, ​​or other rubber materials with relatively low hardness. Fig.12 In the embodiment of the present invention, the sidewall 331 of the opening 328 may be covered by the sealing layer 330 .

[0040] As used herein, an element or step described in the singular and beginning with the word "a" or "an" is understood to not exclude plural elements or steps, unless such exclusion is explicitly stated. In addition, reference to "one embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also include the described features.

[0041] As used herein, "include," "comprising," or "having" and variations thereof are meant to include the items listed below and their equivalents as well as additional items. Therefore, the terms "include," "comprising," or "having" and variations thereof are open-ended expressions and can be used interchangeably herein.

[0042] As used herein, the phrases "at least one", "one or more", and "and / or" are open-ended expressions and are both conjunctive and disjunctive in operation. For example, the expressions "at least one of A, B, and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C", and "A, B, and / or C" refer to A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0043] All directional references (e.g., proximal, distal, up, down, upward, downward, left, right, lateral, longitudinal, front, rear, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are used for identification purposes only to help the reader understand the present disclosure. Directional references do not create limitations, especially with respect to position, orientation, or use of the present disclosure. Connection references (e.g., attachment, coupling, connection, and combination) should be interpreted broadly and may include intermediate members between sets of elements and relative movement between elements, unless otherwise stated. Thus, connection references do not necessarily infer that two elements are directly connected and are in a fixed relationship to each other.

[0044] Furthermore, identifying references (e.g., primary, secondary, first, second, third, fourth, etc.) is not intended to imply importance or priority, but rather is used to distinguish one feature from another. The drawings are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the drawings attached hereto may vary.

[0045] In addition, the terms "substantially" or "approximately" and the terms "approximately" or "approximately" can be used interchangeably in some embodiments and can be described using any relative measure acceptable to those of ordinary skill in the art. For example, these terms can be used as a comparison to a reference parameter to indicate a deviation from being able to provide the intended function. Although non-limiting, the deviation from the reference parameter can be, for example, within an amount of less than 1%, less than 3%, less than 5%, less than 10%, less than 15%, less than 20%, etc.

[0046] Although specific embodiments of the present disclosure have been described herein, the present disclosure is not limited thereto, as the scope of the present disclosure is within the scope that the art will allow, and the specification can be read similarly. Therefore, the above description should not be interpreted as limiting. On the contrary, the above description is merely an example of a specific embodiment. Those skilled in the art will appreciate other modifications within the scope and spirit of the appended claims.

Claims

1. A component comprising: a bottom frame including a plurality of recesses, each recess being operable to receive an electronic device; a top frame coupled to the bottom frame, wherein the top frame includes a plurality of top frame openings aligned with the plurality of grooves; and A sealing layer is disposed between the top frame and the bottom frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings.

2. The assembly according to claim 1, wherein The sealing layer includes a plurality of cylindrical sealing elements extending from an inner surface of the top frame.

3. The assembly according to claim 2, wherein: Each of the plurality of cylindrical sealing elements includes a wall defining one of the plurality of sealing layer openings.

4. The assembly according to claim 2, wherein: Each of the plurality of cylindrical sealing elements includes a first axial end opposite a second axial end, wherein the first axial end is in direct physical contact with the top frame, and wherein the second axial end is operable to be in direct physical contact with the electronic device.

5. The assembly according to claim 4, wherein: The first axial end includes a flange, and wherein an engagement member extending from an inner surface of the top frame engages with the flange.

6. The assembly of claim 2 further comprising a perimeter seal extending from the top frame, wherein: The perimeter seal surrounds the plurality of top frame openings.

7. The assembly according to claim 6, wherein: The perimeter seal extends within a sealing channel of the bottom frame.

8. The assembly of claim 1, wherein: The sealing layer extends along a side wall of one or more top frame openings of the plurality of top frame openings.

9. The assembly of claim 1, wherein: The sealing layer extends along an outer surface of the top frame.

10. The assembly of claim 1, wherein: The sealing layer is made of at least one of silicone and polyurethane.

11. The assembly according to claim 1, wherein: The sealing layer includes a first sealing layer extending along an inner surface of the top frame and a second sealing layer extending along an outer surface of the top frame.

12. The assembly according to claim 11, wherein The first sealing layer and the second sealing layer are made of different materials.

13. A masking tray assembly comprising: a bottom frame including a plurality of recesses, each recess being operable to receive an electronic device; a top frame coupled to the bottom frame, wherein the top frame includes an inner surface facing the bottom frame, and wherein the top frame includes a plurality of top frame openings aligned with the plurality of grooves; and A sealing layer extends along an inner surface of the top frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings.

14. The masking tray assembly of claim 13, wherein: The sealing layer includes a plurality of cylindrical sealing elements extending from an inner surface of the top frame, wherein each of the plurality of cylindrical sealing elements includes a wall defining one of the plurality of sealing layer openings, and wherein each of the plurality of cylindrical sealing elements includes a first axial end opposite to a second axial end.

15. The masking tray assembly of claim 14, wherein: The first axial end is in direct physical contact with the top frame, and wherein the second axial end is operable to be in direct physical contact with the electronic device.

16. The masking tray assembly of claim 15, wherein: The first axial end includes a flange, and wherein an engagement member extending from an inner surface of the top frame engages with the flange.

17. The masking tray assembly of claim 13, further comprising a perimeter seal extending from an inner surface of the top frame, wherein: The perimeter seal surrounds the plurality of top frame openings, and wherein the perimeter seal extends within a sealing channel of the bottom frame.

18. The masking tray assembly of claim 13, wherein: The sealing layer extends along side walls of one or more top frame openings of the plurality of top frame openings.

19. The masking tray assembly of claim 13, wherein: The sealing layer extends along an outer surface of the top frame.

20. A masking tray assembly comprising: a bottom frame including a plurality of recesses, each recess being operable to receive an electronic device; a top frame coupled to the bottom frame, wherein the top frame includes an inner surface facing the bottom frame, and wherein the top frame includes a plurality of top frame openings aligned with the plurality of grooves; and A sealing layer extends along an inner surface of the top frame, wherein the sealing layer includes a plurality of sealing layer openings aligned with the plurality of top frame openings, and wherein a flange of the sealing layer is coupled to a joining member of the top frame.

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