System and method for coating a substrate

Abstract

The invention relates to a system and a method for coating a substrate. A system and method for applying a coating to a substrate is disclosed. The system comprises: a coating station for applying a coating material to a substrate, where the coating station has a bottom portion; an oven for curing the coating material on the substrate, where the oven is vertically positioned below the bottom portion; and a first lift table for transferring the substrate from the coating table to the oven. The system may also include an inspection station for inspecting the substrate. Each individual element of the coating system, including the coating console, the first lift table, the oven, and the inspection console, may define an individual kit of modules.

Description

[0001] Divisional Application Description

[0002] This application is a divisional application of a Chinese patent application with application number 201880079671.8, filing date November 9, 2018, and invention title "Systems and Methods for Coating Substrates".

[0003] Cross - Reference to Related Patent Applications

[0004] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 584,259, filed November 10, 2017, the disclosure of which is hereby incorporated by reference herein. Technical Field

[0005] The present disclosure generally relates to applying a coating to a substrate, and more particularly, to a modular system for applying a coating to a substrate, curing the coating, and inspecting the substrate. Background Art

[0006] There are various coating systems for applying conformal coatings to substrates such as printed circuit boards (PCBs). A conformal coating is a thin layer of dielectric material that is applied to a substrate to provide environmental and mechanical protection to the circuits on the board. The coating protects the circuits from moisture and prevents short - circuits and corrosion of metal conductors and solder joints. The conformal coating also prevents or minimizes dendritic growth (electrochemical migration) of metal at solder joints, which can subsequently lead to short - circuits. After the coating has been applied, the coating can be thermally cured on the substrate using one or more ovens included in the coating system. Additionally, the coating can be manually inspected by an operator of the coating system or automatically inspected by an inspection console included in the coating system.

[0007] Conventional coating systems can include a conveyor that extends through each part of the coating system to move the substrate from the start to the end of the coating process. Thus, such a conveyor moves the substrate along a substantially linear path through the coating system. Due to the size of some parts of the coating system, particularly the long lengths of some ovens, conventional coating systems can be very long. Thus, these coating systems define a large footprint and likewise require a relatively large floor area for operation.

[0008] Accordingly, there is a need for a coating system that defines a reduced footprint and thus saves floor space in a factory environment. Summary of the Invention

[0009] Embodiments of the present disclosure include a system for applying a coating to a substrate. The system includes: a coating operation table for applying a coating material to the substrate, wherein the coating operation table has a bottom portion; and an oven for curing the coating material on the substrate, wherein the oven is vertically positioned below the bottom portion. The system further includes a first lift table for transferring the substrate from the coating operation table to the oven.

[0010] Another embodiment of the present disclosure includes a method for applying a coating to a substrate. The method includes applying a coating material to the substrate using a coating operation table, transferring the substrate from the coating operation table in a vertically downward direction to an oven, and curing the coating on the substrate within the oven. The method further includes: after curing the coating, transferring the substrate from the oven in a vertically upward direction opposite to the downward direction to an inspection operation table; and inspecting the substrate using the inspection operation table.

[0011] Another embodiment of the present disclosure includes a system for applying a coating to a substrate. The system includes a first self - contained module and a second self - contained module. The first self - contained module includes a coating operation table for applying a coating material to the substrate, and the second self - contained module includes an oven for curing the coating material on the substrate, wherein the second self - contained module is adjacent to the first self - contained module. The system further includes a third self - contained module, which includes a first lift table for transferring the substrate from the first self - contained module to the second self - contained module, wherein the third self - contained module is adjacent to the first self - contained module and the second self - contained module. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The above - described summary of the invention and the following detailed description of the illustrative embodiments of the present application will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the present application, illustrative embodiments of the present disclosure are shown in the drawings. However, it should be understood that the present application is not limited to the precise arrangements and instrumentalities shown.

[0013] Figure 1 is a perspective view of a coating system according to an embodiment of the present disclosure;

[0014] Figure 2 is Figure 1 a side cross - sectional view of the coating operation table of the coating system shown;

[0015] Figure 3A is Figure 1 a schematic view of the inspection operation table of the coating system shown;

[0016] Figure 3B is Figure 1 a schematic view of the inspection operation table of the coating system shown;

[0017] Figure 4For Figure 1 Perspective view of the coating system shown, with some components removed for clarity;

[0018] Figure 5 is Figure 1 Schematic view of the coating system shown;

[0019] Figure 6A Perspective view of a coating system according to an embodiment of the present disclosure;

[0020] Figure 6B Perspective view of a coating system according to an embodiment of the present disclosure;

[0021] Figure 6C Perspective view of a coating system according to an embodiment of the present disclosure;

[0022] Figure 6D Perspective view of a coating system according to an embodiment of the present disclosure;

[0023] Figure 7 Schematic view of a control system according to an embodiment of the present disclosure. Detailed Description

[0024] A modular coating system 10 is described herein, which includes a coating operation table 24 for applying a coating to a substrate 100 and an oven 34 for curing the coating positioned below the coating operation table 24. In the following description, certain terms are used for convenience only to describe the coating system 10 and are not restrictive. The words "right", "left", "down", and "up" represent the directions as reference in the drawings. The words "inner" and "outer" respectively refer to the directions towards and away from the geometric center of the described content, for describing the coating system 10 and its related parts. The words "forward" and "backward" refer to the direction along the transverse direction 4 and the direction opposite to the transverse direction 4 of the coating system 10 and its related parts. Terms include the words listed above, their derivatives, and words with similar meanings.

[0025] Unless otherwise specified herein, the terms "vertical" and "transverse" are used to describe the orthogonal direction components of the various components of the coating system 10, as represented by the vertical direction 2 and the transverse direction 4. It should be understood that although the vertical direction 2 and the transverse direction 4 are shown as extending along a vertical plane, during use, the planes including the respective directions can be different.

[0026] See Figure 1 、 Figure 4 and Figure 5, the coating system 10 is a modular assembly of removable and interchangeable components for applying a coating material to a substrate 100, curing the coating 102, and inspecting the substrate 100. The substrate 100 can be a printed circuit board (PCB) or can include any other type of substrate as needed. The coating system 10 includes a loading area 20 for adding the uncoated substrate 100 to the coating system 10 and removing the coated substrate 100 from the coating system 10. The substrate 100 can be manually or automatically added to and removed from the loading area 20 by an operator of the coating system 10 from a loading machine. The coating system 10 can include an upper conveyor system 300 for transporting the substrate 100 between various components of the coating system 10 disposed in a first plane P1, as will be described below. Specifically, the loading area 20 can include a second section 312 of the upper conveyor system 300 that transports the substrate 100 from the loading area 20 to a coating operation table 24, which can be adjacent to the right side of the loading area 20 along a lateral direction 4. In the depicted embodiment, each section of the upper conveyor system 300 is an endless conveyor, but other embodiments of the conveyor system are also contemplated.

[0027] See Figure 2 , the coating system 10 can include a coating operation table 24 for applying a coating to the substrate 100. The coating operation table 24 can include a housing 104 and a coater assembly 106 configured to be disposed within the housing 104. A bottom portion of the housing 104 defines a plane P1 parallel to the lateral direction 4. The coater assembly 106 includes a coater 108 that is in fluid communication with a material source 116 and is configured to move a coating material (not shown) from the material source 116 to form a coating 102 on the substrate 100. The coating material can be acrylic, polyurethane, silicone, or other types of materials commonly used for coating substrates. As needed, the coater 108 can include a jet dispenser, a contact dispenser, an air or airless spray coater, or other types of coaters. The amount of coating material moved to the substrate 100 by the coater 108 can be monitored by a flow meter 124. In the depicted embodiment, the flow meter 124 is disposed on a portion of the coater 108 such as a coater tip 115 so that the flow meter 124 can measure how much coating material is transferred from the coater 10 to the substrate 100. In another embodiment, the flow meter 124 can be disposed at the coating material source 116 or between the material source 116 and the coater 108. Alternatively, multiple flow meters can be positioned at multiple locations within the coater assembly 106.

[0028] Flowmeter 124 can measure one or more parameters of the flow of coating material as it exits material source 116. In some embodiments, flowmeter 124 can measure the volume, velocity, pressure, and / or duration of the flow. The flowmeter can be connected to controller 402, where controller 402 is configured to receive data from flowmeter 124 and perform analysis on the data. The controller 402 can also be configured to analyze other parameters of the flow, such as the type of coating material, the characteristics of coater 108, and / or the characteristics of other parts of coating system 10. In addition to flowmeter 124, coater assembly 106 can also include other types of sensors for detecting aspects of the coating material, such as a solvent sensor. Although one embodiment of coater assembly 106 has been described above, it is contemplated that coating station 24 can include various other types of coater assemblies 106 as needed, depending on the type of substrate 100 to be coated or the type of coating operation to be performed. Due to the modular nature of coating system 10, the above-described particular coating station 24 can be easily removed from coating system 10 and replaced with another coating station with little impact on the remainder of coating system 10. Although described as including a coater configured for conformal coating, coating station 24 can alternatively include a coater configured to perform other kinds of dispensing methods. For example, coating station 24 can include a coater configured to perform dispensing methods such as underfill, encapsulation, dam and fill, or other operations as needed.

[0029] Continuing to refer to Figure 1 、 Figure 4 and Figure 5 , coating station 24 can also include a third section 316 of upper conveyor system 300. The third section 316 is configured to receive substrate 100 from loading area 20 and move substrate 100 such that substrate 100 is properly positioned to receive coating material from coater assembly 106. After coating station 24 has applied coating 102 to substrate 100, the third section 316 of upper conveyor system 300 moves substrate 100 to first lift table 28, which is configured to convey substrate 100 downward in the vertical direction 2 to oven 34.

[0030] The first lifting table 28 is configured to receive the substrate 100 from the coating operation table 24 (in particular, the third section 316 of the upper conveyor system 300) through a first lifting table entrance 320 defined by a side of the first lifting table 28 facing the coating operation table 24. The substrate 100 is received by an upper chamber 28a of the first lifting table 28 from the coating operation table 24, and the upper chamber 28a is located at the top of the first lifting table 28. Once the substrate 100 is completely within the upper chamber 28a, a sensor 29a within the upper chamber 28a can sense the position of the substrate 100 and notify the controller 402. Then, the controller 402 guides the first lifting table 28 to transfer the substrate 100 from the upper chamber 28a downward along the vertical direction 2 to a lower chamber 28b of the first lifting table 28. The lower chamber 28b is positioned at the bottom of the first lifting table 28 opposite to the upper chamber 28a. Accordingly, the lower chamber 28b is completely positioned below the first plane P1, while the upper chamber 28a is positioned above the first plane P1. Once the substrate 100 is completely disposed within the lower chamber 28b, a sensor 29b disposed within the lower chamber 28b notifies the controller 402, and the controller instructs the first lifting table 28 to move the substrate 100 from the lower chamber 28b to the oven 34 through a first lifting table exit 324.

[0031] The oven 34 is entirely disposed below the first plane P1 and can be modular and include a plurality of independent ovens 34a - 34c. The oven 34 includes a lower conveyor system 304 for moving the substrate 100 from the first lift table 28 through the oven 34 to the second lift table 50. In one embodiment, each section of the lower conveyor system 304 can be an endless conveyor, although other types of conveyors are also contemplated. Additionally, each oven of the oven 34 is configured to be heated to a predetermined temperature. As shown, the oven 34 includes a first oven 34a disposed along the lateral direction 4 immediately to the left of the first lift table 28. Additionally, the first oven 34a is fully positioned directly below the coating operation table 24 along the vertical direction 2. The interior of the first oven 34a can be raised to and maintained at a first temperature for thermally curing the coating 102 applied to the substrate 100. For example, the first oven 34a can be raised to a temperature of about 60 degrees Celsius to about 130 degrees Celsius. The coating system 10 can include a seal 30 disposed between the first lift table 28 and the first oven 34a for forming a thermal seal between the first lift table 28 and the first oven 34a. The seal 30 can prevent heat from escaping from the first oven 34a to the first lift table 28 and from the first oven 34a to the environment in which the coating system 10 is located. The seal 30 can comprise fluororubber, silicone, or other materials capable of withstanding the temperatures encountered in the oven 34. Alternatively, the seal 30 can be a metal flange. The seal 30 can define a part of the first oven 34a or the first lift table 28, or can be releasably attached to the first oven 34a and the first lift table 28 such that the seal 30 can be used with other configurations of components in the coating system 10. The first oven 34a can include a first section 328 of the lower conveyor system 304 for moving the substrate 100 through the first oven 34a from the first lift table 28. Once the substrate 100 passes through the first oven 34a on the first section 328 of the lower conveyor system 304, the substrate 100 can enter a second oven 34b disposed along the lateral direction 4 immediately to the left of the first oven 34a.

[0032] The second oven 34b is disposed along the transverse direction 4 immediately to the left of the first oven 34a. Additionally, the second oven 34b is fully positioned directly below the loading area 20. The interior of the second oven 34b can be raised to and maintained at a second temperature to further thermally cure the coating 102 applied to the substrate 100. For example, the second oven 34b can be raised to a temperature of about 60 degrees Celsius to about 130 degrees Celsius. The second temperature of the second oven 34b can be the same as or different from the first temperature of the first oven 34a. The coating system 10 can include a seal 38 disposed between the second oven 34b and the first oven 34a for forming a thermal seal between the first oven 34a and the second oven 34b. The seal 38 can prevent the heat levels within each of the first oven 34a and the second oven 34b from affecting each other and prevent heat from escaping from the first oven 34a and the second oven 34b to the external environment. The seal 38 can be similarly configured as the seal 30 or can be different as needed. Additionally, the seal 38 can define a portion of the first oven 34a or the second oven 34b or can be releasably attachable to the first oven 34a and the second oven 34b such that the seal 38 can be used with other configurations of components in the coating system 10. The second oven 34b can include a second section 332 of the lower conveyor system 304 for moving the substrate 100 from the first oven 34a through the second oven 34b. Once the substrate 100 passes through the second oven 34b on the second section 332 of the lower conveyor system 304, the substrate 100 can enter a third oven 34c disposed along the transverse direction 4 immediately to the left of the second oven 34b.

[0033] The third oven 34c is disposed adjacent to the left side of the second oven 34b along the transverse direction 4. Additionally, the third oven 34c is fully positioned directly below the inspection operation table 54, which will be further described below. The interior of the third oven 34c can be raised to and maintained at a third temperature to further thermally cure the coating 102 applied to the substrate 100. For example, the third oven 34c can be raised to a temperature of about 60 degrees Celsius to about 130 degrees Celsius. The third temperature of the third oven 34c can be the same as or different from the first temperature and / or the second temperature. The coating system 10 can include a seal 42 disposed between the third oven 34c and the second oven 34b for forming a thermal seal between the third oven 34c and the second oven 34b. The seal 42 can prevent the heat levels in each of the second oven 34b and the third oven 34c from affecting each other and prevent heat from escaping from the second oven 34b and the third oven 34c to the external environment. The seal 42 can be similarly constructed to the seals 30 and / or 38, or can be different as needed. Additionally, the seal 42 can define a part of the second oven 34b or the third oven 34c, or can be releasably attached to the second oven 34b and the third oven 34c such that the seal 42 can be used with other configurations of components in the coating system 10. The third oven 34c can include a third section 336 of the lower conveyor system 304 for moving the substrate 100 from the second oven 34b through the third oven 34c.

[0034] Although the oven 34 is described as including three ovens 34a - 34c, the modular nature of the coating system 10 allows additional ovens to be attached to the coating system 10 to accommodate different types of substrates, coating materials, coating operations, etc. without significantly affecting the remainder of the coating system 10. Similarly, any one of the ovens 34a - 34c can be removed as needed. For example, the oven 34 can include only one oven. Although each of the ovens 34a - 34c is described as being capable of being raised to a certain temperature, they can define multiple temperature zones internally such that each of the ovens 34a - 34c can be raised to multiple temperatures simultaneously. Each additional oven can be similarly constructed to the ovens 34a - 34c that have been described, or can be alternatively constructed as needed. Each additional oven can also include an additional conveyor portion that will include a part of the lower conveyor system 304. Regardless of the number of ovens included in the oven 34, the lower surface of any oven of the oven 34 can define a second plane P2 parallel to the transverse direction 4. This second plane P2 is spaced apart from the first plane P1 along the vertical direction 2. The lower surfaces of the other ovens of the oven 34 can also be substantially disposed on the second plane P2.

[0035] Once the substrate 100 passes through the third oven 34c, the substrate 100 can enter the second lift table 50 disposed to the left of the third oven 34c. The second lift table 50 is configured to receive the substrate 100 from the oven 34 through a second lift table inlet (not shown) and convey the substrate 100 vertically upward along the vertical direction 2 to the inspection operation table 54. The substrate 100 passes through the second lift table inlet defined by the side of the second lift table 50 facing the oven 34. The coating system 10 may include a seal 46 disposed between the third oven 34c and the second lift table 50 for forming a thermal seal between the third oven 34c and the second lift table 50. The seal 46 can prevent the heat level in the third oven 34c from affecting the operation of the second lift table 50 and prevent heat from escaping from the third oven 34c to the external environment. The seal 46 can be constructed similarly to the seals 30, 38, and / or 46, or can be different as needed. Additionally, the seal 46 can define a part of the third oven 34c and the second lift table 50, or can be releasably attached to the third oven 34c and the second lift table 50 such that the seal 46 can be used with other configurations of components in the coating system 10.

[0036] The substrate 100 is received from the oven 34 within the lower chamber 50b of the second lift table 50, and the lower chamber 50b is located at the bottom of the second lift table 50. Once the substrate 100 is fully within the lower chamber 50b, the sensor 51b within the lower chamber 50b can sense the position of the substrate 100 and notify the controller 402. Then, the controller 402 guides the second lift table 50 to convey the substrate 100 vertically upward from the lower chamber 50b to the upper chamber 50a of the second lift table 50. The upper chamber 50a is positioned at the top of the second lift table 50 opposite the lower chamber 50b. Thus, the upper chamber 50a is fully positioned above the first plane P1, while the lower chamber 50b is positioned below the first plane P1. Once the substrate 100 is fully disposed within the upper chamber 50a, the sensor 51a disposed within the upper chamber 50a notifies the controller 402, and the controller instructs the second lift table 50 to move the substrate 100 from the upper chamber 50a to the inspection operation table 54.

[0037] Continue Figures 3A to 3B, the inspection console 54 includes an inspection system 200. The inspection system 200 may include an illumination subsystem 204 having an ultraviolet (UV) light source 208 that directs UV light onto the coating 102. The coating 102 may include a tracer that fluoresces in the presence of UV light. The illumination subsystem 204 may also optionally include a white light source 212 that directs white light onto the coating 102 of the substrate 100. The inspection system 200 further includes a camera subsystem 216 that includes a camera 240. The camera 240 has a lens 244 positioned above the substrate 100 for capturing one or more images of the illuminated substrate 100 when light is emitted onto the substrate 100. Specifically, the camera 240 may be positioned at an angle or perpendicular to the opposing surface 100a of the substrate 100. When positioned perpendicular to the opposing surface 100a, as Figure 3B shown, the inspection system 200 may include an angled mirror 248. Although depicted in Figure 3A as being located above the substrate 100 and in Figure 3B as being perpendicular to the substrate 100, the camera 240 may be at an angle, such as 45°, relative to the opposing surface 100a of the substrate 100 such that the lens 244 captures one or more edge images of the outer edge 100b of the illuminated substrate 100. Images from the camera 240 are transmitted to an image processing computer 224, which may be the controller 402, for determining whether the substrate 100 is properly coated. Alternatively, the image processing computer 224 may be separate from, but in electronic communication with, the controller 402.

[0038] The inspection operation table 54 may further include a wafer gripper subsystem 228, which includes a first section 308 of the upper conveyor system 300. The first section 308 may be configured to hold the substrate 100 around one or more of its edges during inspection. In another embodiment, the wafer gripper subsystem 228 may include support pins (not shown) that hold the substrate 100 during inspection. The first section 308 transfers the substrate 100 from the second lift table 50 to the loading area 20, which may be positioned along the lateral direction 4 adjacent to the right side of the inspection operation table 54. To adjust the position of the camera 216, the camera 216 may be connected to an X-Y axis motor 220. The X-Y axis motor 220 is configured to move the camera 216 relative to the substrate 100 when receiving instructions from the motion controller 232 and / or the image processing computer 224. The motion controller 232 may be the controller 402, or alternatively may be separate from but in electronic communication with the controller 402. Although one type of inspection device is described, the inspection operation table 54 may include various other types of inspection devices as needed, such as an optical 3D scanner, a 2D laser profiler, or a 3D laser profiler. Alternatively, the coating system 10 may not include the inspection operation table 54, but may include a manual or semi-automatic inspection operation table (not shown), where the operator of the coating system 10 must verify the coating quality of each substrate 100.

[0039] Each individual element of the coating system 10, including the coating operation table 24, the first lift table 28, the ovens 34 (and likewise the first oven 34a, the second oven 34b, and the third oven 34c), the second lift table 50, and the inspection operation table 54, may define a separate and independently separable module. Thus, each of these modules can be individually removed from the coating system 10 and / or reorganized within the coating system 10 without affecting the construction of the other modules of the coating system 10. For example, although the coating operation table 24 is depicted as being disposed on top of the first oven 34a, the coating operation table 24 or the first oven 34a can be removed from the coating system 10 without affecting the other modules. Similarly, although the inspection operation table 54 is depicted as being disposed on top of the third oven 34c, the inspection operation table 54 of the third oven 34c can be removed from the coating system 10 without affecting the other modules. Due to this modular construction, the coating system 10 may include other modular operation tables not yet mentioned, such as a vacuum chamber for removing bubbles from the coating material, an atmospheric or vacuum plasma system for substrate surface treatment, or other modules as needed.

[0040] Figures 6A to 6D Coating systems 111, 112, 113, and 114 are respectively shown. The coating systems 111, 112, 113, and 114 can be used as Figure 1 , Figure 4 and Figure 5An alternative embodiment or configuration of the coating system 10 shown in the figure. The coating systems 111, 112, 113, and 114 demonstrate the modular nature of the coating systems described herein. That is, the various coating system components (e.g., coating operation table 24, oven 34, inspection operation table 54, loading area 20, lift table 28, etc.) and / or modules described herein can be added (including additional instances of components / modules) or omitted according to specific needs. In addition, the various components and / or modules can be configured in various sequential orders according to specific needs. In some aspects, the coating systems 111, 112, 113, and 114 can be similar to the coating system 10. Therefore, like reference numerals in the drawings should refer to like elements.

[0041] See Figure 6A , the coating system 110 includes a loading area 20 where the substrate is initially loaded before processing. The substrate advances to the coating operation table 24 for coating operations. Subsequently, the coated substrate is transferred to the fourth oven 34d to initiate the curing process of the coated substrate. The fourth oven 34d can form a module with the fifth oven 34e described below. The temperatures of the fourth oven 34d and the fifth oven 34e can be controlled by separate and independent controllers. The coated substrate is transferred from the fourth oven 34d to the lift table 27. The lift table 27 can be similar to the lift table 28 in some aspects. Figure 1 , Figure 4 and Figure 5 . The lift table 27 includes an upper section 27a configured to initially receive the substrate. The substrate is lowered to the lower section 27b of the lift table 27. The lift table 27 can be insulated and / or heated to prevent the substrate from cooling during transfer between the fourth oven 34d and the fifth oven 34e. The upper section 27a is located on the upper plane of the coating system 111, and the lower section 27b is located on the lower plane of the coating system 111. Starting from the lower section 27b of the lift table 27, the coated substrate sequentially passes through the fifth oven 34e, the first oven 34a, the second oven 34b, and the third oven 34c to complete the curing process. The substrate is brought to the upper plane by the lift table 50. The substrate is positioned in the inspection operation table 54 for inspection, such as inspecting the coating applied to the substrate. Subsequently, the inspected substrate is unloaded at the loading area 20.

[0042] See Figure 6B, the coating system 112 includes a loading area 20 for receiving an uncoated substrate. The substrate is transferred to a coating operation table 24 for coating. Then the coated substrate is brought to a fourth oven 34d, which forms the upper part of a vertical stack having a lift table 28. The substrate is lowered from the fourth oven 34d to the lower plane of the coating system 112 by the lift table. Then the substrate is sequentially passed through a first oven 34a, a second oven 34b, and a third oven 34c to complete the curing process of the coated substrate. Then the substrate is moved to another lift table 50 to raise the substrate from the lower plane to the upper plane of the coating system 111. On the upper plane, the substrate is inspected at an inspection operation table 54 and removed from the coating system at the loading area 20.

[0043] See Figure 6C , the coating system 113 includes an initial loading area 20a for receiving an uncoated substrate. The received substrate is brought to a coating operation table 24 for coating. The coated substrate is lowered from the upper plane to the lower plane of the coating system 113 by the lift table 28. The coated substrate is cured while sequentially passing through a first oven 34a, a second oven 34b, a fourth oven 34d, and a third oven 34c. The component including the fourth oven 34d is configured to have an unloading area 20b located above the fourth oven 34d. The cured substrate is transferred from the third oven 34c to the lift table 50, which raises the substrate to the upper plane of the coating system 113. Then the substrate is transferred to an inspection operation table 54 for inspection, such as inspecting the coating applied to the substrate. After inspection, the substrate is moved to the unloading area 20b for unloading, such as performed by a human operator or a robotic attachment.

[0044] See Figure 6D , the coating system 114 is configured to have a loading area 22a (similar in some aspects to Figure 1 , Figure 4 and Figure 5 's loading area 20) at the end of the linear component of the coating system 114. The substrate is initially transferred to a coating operation table 24 for the coating process. The coated substrate is moved on a conveying area 23 to an inspection operation table 54, which can inspect the coating on the substrate before curing. After inspection, the substrate is lowered from the upper plane to the lower plane of the coating system 114 by the lift table 28. On the lower plane, the coating on the substrate is cured by moving the substrate through a first oven 34a, a second oven 34b, and a third oven 34c. After final curing at the third oven 34c, the substrate is transferred to an unloading area 22b. The lower unloading area 22b is part of the same vertical component as the upper loading area 22a.

[0045] Additional embodiments (not shown) can also be envisioned. One embodiment may include a coating operation table 24 and / or an inspection operation table 54 positioned on the lower plane of the coating system, which can be a supplement or alternative to the coating operation table 24 or the inspection operation table 54 positioned on the upper plane of the coating system. For example, the embodiment can be configured similar to Figure 1 、 Figure 4 and Figure 5 the shown embodiment, but the third oven 34c is replaced with another inspection operation table 54. That is, as Figure 1 、 Figure 4 and Figure 5 shown, the module including the inspection operation table 54 positioned above the third oven 34c can be exchanged with the module including the first inspection operation table 54 positioned on the upper plane and the second inspection operation table 54 positioned above the second inspection operation table 54 on the lower plane.

[0046] Again, for example, the embodiment can be configured similar to the coating system 114 shown in Figure 6D , but in addition to the initial inspection operation table 54 above the first oven 34a, the third oven 34c is also replaced with another inspection operation table 54. Therefore, the module initially including the coating operation table 24 in Figure 6D can be reconfigured to include the coating operation table 24 on the upper plane of the coating system 114 and the second inspection operation table 54 on the lower plane. The coating system configured in this way can allow the coating to be initially inspected by the first inspection operation table 54 (above the first oven 34a) before the coating is cured by the first oven 34a and the second oven 34b. Then the cured coating on the substrate can be inspected by the second inspection operation table 54 positioned below the coating operation table 24.

[0047] The coating system described herein can include (for example, the module can include) a drying component and / or a flash component. For example, one embodiment can be similar to the coating system 10 shown in Figure 1 、 Figure 4 and Figure 5 , but the first oven 34a can be replaced with a drying component or a flash component. Therefore, before the coating is cured by the second oven 34b and the third oven 34c, the coating initially applied to the substrate through the coating operation table 24 can be allowed to dry. The drying component and / or the flash component can be positioned on either the upper plane or the lower plane of the coating system.

[0048] See Figure 7, the coating system 10 can be controlled by a control system 400, which includes a controller 402 and / or an HMI device 408 that communicates with the controller 402. The controller 402 can include one or more controllers and can also be referred to as one or more processors. The controller 402 can include an image processing computer 224 or be separate from but in electronic communication with the image processing computer 224. As Figure 7 shown, the controller 402 and / or the HMI device 408 can be wired and / or wirelessly connected to each aspect of the coating system 10, such as the loading area 20, the coating operation table 24, the first lifting table 28, the oven 34, the second lifting table 50, and the inspection operation table 54, and is configured to transmit instructions to each of these aspects of the coating system 10 via wireless and / or wired connections. Over time, the controller 402 can also be easily connected to additional modules added to the coating system 10. The controller 402 can be a programmable logic controller (PLC), a microprocessor-based controller, a personal computer, or another conventional control device capable of performing the functions described herein as understood by a person of ordinary skill in the art. For example, the controller 402 can execute various methods related to controlling the coating system 10 based on user input, as detailed below. Additionally, the controller 402 can execute various methods related to controlling the coating system 10 based on a library of operating cycles or sequences stored in the memory unit 404 of the controller 402. The memory unit 404 can include one or more memory units and can also be referred to as a storage device. Call an operating sequence and place it in a specific control program executed on the controller 402 as needed. The operating sequence can be adjusted, for example, via the HMI device 408 to accommodate different dispensing operations, different types of substrates, or different types of materials.

[0049] The HMI device 408 is operably connected to the controller 402 in a known manner. The HMI device 408 can include input devices and controls, such as a keypad, buttons, control knobs, a touch screen, etc., and output devices, such as a display and other visual indicators, which are used by an operator to control the operation of the controller 402 and thus the operation of the coating system 10. The HMI device 408 can also include an audio output device, such as a speaker, through which audio alerts can be sent to the operator. The operator can use the HMI device 408 to input parameters, such as the type of coating material, the type of substrate 100, the desired coating pattern, and the desired temperature of the oven 34, etc. Additionally, the controller 402 and / or the HMI device 408 can communicate with an external network (not shown) via wire and / or wirelessly, such that an operator of the coating system 10 can remotely access the controller 402 from a separate system or device.

[0050] In operation, an operator of the coating system 10 begins the coating operation by placing the substrate 100 on the loading area 20, specifically on the second section 312 of the upper conveyor system 300. This can be done manually by the operator or can be performed by a separate robot or other automated device (not shown) such as a shuttle conveyor. To start the operation of the coating system 10, the operator actuates a manual button or switch on the body of the coating system 10 or remotely instructs the controller 402 to indicate that the coating system 10 is in operation, such as through the HMI device 408 of the controller 402. However, when an automatic loading mechanism is used, the operation of the coating system 10 can start automatically. Once the coating system 10 starts operating, the second section 312 of the upper conveyor system 300 moves the substrate 100 in a first direction along the lateral direction 4 to the third section 316 of the upper conveyor system 300 and similarly into the housing 104 of the coating operation table 24. The first direction can be to the left or right along the lateral direction 4, depending on the orientation of the coating system 10. Once set in the coating operation table 24, the coater assembly 106 starts the coating operation automatically, at the operator's instruction, or at the instruction of the controller 402. Various aspects of the coating operation (pattern, direction, etc.) can be preselected by the operator through the HMI device 408 or called from the memory unit 404 of the controller 402. After the coating operation is completed, the third section 316 of the upper conveyor system 300 moves the substrate 100 in the first direction into the upper chamber 28a of the first lift table 28. Once the sensor 29a within the upper chamber 28a senses that the substrate 100 is fully within the upper chamber 28a, the first lift table 28 transfers the substrate 100 downward along the vertical direction 2 to the lower chamber 28b of the first lift table 28. Once the sensor 29b within the lower chamber 28b senses that the substrate 100 is fully located within the lower chamber 28b, the first lift table 28 transfers the substrate 100 in a second direction opposite to the first direction to the oven 34, specifically the first oven 34a.

[0051] When the substrate 100 enters the first oven 34a, the substrate 100 is disposed on the first section 328 of the lower conveyor system 304, which conveys the substrate 100 through the first oven 34a. The first oven 34a, which may be located below the coating operation table 24, is heated to a first temperature for performing a part of the curing operation on the coating 102 of the substrate 100. The substrate 100 is maintained in the first oven 34a for a first period of time. The first temperature and the first period of time may be selected by an operator of the coating system 10 through the HMI device 408, called from the memory unit 404 based on specific characteristics of the coating operation (such as substrate type, coating type, etc.), or be default values. After completion of the part of the curing operation to be performed by the first oven 34a, the first section 328 of the lower conveyor system 304 may convey the substrate 100 in a second direction to the second oven 34b of the oven 34.

[0052] When the substrate 100 enters the second oven 34b, the substrate 100 is disposed on the second section 332 of the lower conveyor system 304, which conveys the substrate 100 through the second oven 34b. The second oven 34b, which may be located below the loading area 20, is heated to a second temperature for performing a second part of the curing operation on the coating 102 of the substrate 100. The substrate 100 is maintained in the second oven 34b for a second period of time. The second temperature and the second period of time may be selected by an operator of the coating system 10 through the HMI device 408, called from the memory unit 404 based on specific characteristics of the coating operation (such as substrate type, coating type, etc.), or be default values. The second temperature and the second period of time may be the same as the first temperature and the period of time respectively, or may be different as required. After completion of the part of the curing operation to be performed by the second oven 34b, the second section 332 of the lower conveyor system 304 may convey the substrate 100 in a second direction to the third oven 34c of the oven 34.

[0053] When the substrate 100 enters the third oven 34c, the substrate 100 is disposed on the third section 336 of the lower conveyor system 304, and the lower conveyor system conveys the substrate 100 through the third oven 34c. The third oven 34c, which may be located below the inspection operation table 54, is heated to a third temperature for performing the third part of the curing operation on the coating 102 of the substrate 100. The substrate 100 is held in the third oven 34c for a third time period. The third temperature and the third time period can be selected by the operator of the coating system 10 through the HMI device 408, called from the memory unit 404 based on specific characteristics of the coating operation (such as substrate type, coating type, etc.), or be default values. The third temperature and the third time period can be the same as the first temperature and the second temperature and the first time period and the second time period respectively, or can be different as required. After completing the part of the curing operation to be performed by the third oven 34c, the third section 336 of the lower conveyor system 304 can convey the substrate 100 in a second direction to the second lift table 50. Although the coating system 10 is described as including the oven 34 having three separate ovens 34a - 34c, the modular nature of the coating system 10 allows for the addition of additional ovens or the removal of any of the ovens 34a - 34c. For example, the second oven 34b can be removed from the coating system 10 so that only the first oven 34a and the third oven 34c remain, and only the second section 332 of the lower conveyor system 304 is disposed below the loading area 20. Additionally, the first oven 34a and the second oven 34b can be removed from the coating system. Alternatively, the first to third ovens 34a - 34c can be replaced with a single oven including the entire oven 34.

[0054] After the curing operation is completed, the third section 336 of the lower conveyor system 304 moves the substrate 100 in a second direction into the lower chamber 50b of the second lift table 50. Once the sensor 51b disposed within the lower chamber 50b senses that the substrate 100 is fully within the lower chamber 50b, the second lift table 50 conveys the substrate 100 upward in the vertical direction 2 to the upper chamber 50a of the second lift table 50. Once the sensor 51a disposed within the upper chamber 50a senses that the substrate 100 is fully within the upper chamber 50a, the second lift table 50 conveys the substrate 100 in a first direction to the inspection operation table 54.

[0055] Once set in the inspection console 54, the applicator assembly 106 begins the inspection operation automatically, under the guidance of the operator, or under the guidance of the controller 402. Various aspects of the inspection operation (which parts of the substrate 100 and the coating 102 are inspected, the type of inspection performed, etc.) can be preselected by the operator via the HMI device 408 or called from the memory unit 404 of the controller 402. Although the inspection operation can be performed by the inspection console 54 itself, when the substrate 100 is in the inspection console 54, the inspection can also at least partially include a visual inspection by the operator of the coating system 10. If the inspection console 54 detects a feature of the coating 102 of the substrate 100 that does not meet the quality standard, the inspection console 54 can send a signal to the controller 402, which can alert the operator of the coating system 10 via the HMI device 408. The alert can be in the form of a sound, light, text notification, etc. After the detection operation is completed, the first section 308 of the upper conveyor system 300 moves the substrate 100 in a first direction to the loading area 20, where the substrate 100 can be removed from the coating system 10. This can be done manually by the operator or can be performed by a separate robot or other automated device such as a shuttle conveyor (not shown). Optionally, one operator can be located on one side of the loading area 20 for placing the substrate 100 on the loading area 20, while another operator is located on the opposite side of the loading area 20 for removing the substrate 100 from the loading area 20.

[0056] Although the present invention has been described using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the present invention as otherwise described and claimed herein. The exact arrangement of the various elements described herein and the order of steps of the articles and methods should not be regarded as restrictive. For example, although the steps of a method are described with reference to the progression of reference symbols and blocks in a sequential series in the drawings, the method can be implemented in a specific order as needed.

Claims

1. A system for applying a coating to a substrate, the system comprising: A coating operation table for applying a coating material to the substrate, wherein the coating operation table has a bottom portion; A first oven for curing the coating material on the substrate, wherein the first oven is vertically and closely positioned below the bottom portion; A first lifting table for transferring the substrate from the coating operation table to the first oven, whereby the first lifting table is configured to transfer the substrate vertically downward to the first oven; An inspection operation table for inspecting the substrate; A loading area provided between the inspection operation table and the coating operation table, wherein the loading area includes a conveyor extending from the inspection operation table to the coating operation table; A second oven vertically positioned below the conveyor, such that the second oven is also vertically positioned below the bottom portion of the coating operation table; A third oven vertically positioned below the inspection operation table, such that the third oven is also positioned below the bottom portion; and A second lifting table for transferring the substrate from the third oven to the inspection operation table, wherein the second oven is adjacent to the first oven, the second oven is arranged closely to the first oven along a first direction transverse to the vertical direction, and the second oven is vertically positioned directly below the loading area, and wherein each of the coating operation table, the inspection operation table, the first oven, the second oven, the third oven, the first lifting table and the second lifting table can be separated independently of each other and each defines an independent and separable module.

2. The system according to claim 1, wherein The second oven operates at a temperature different from that of the first oven.

3. The system according to claim 1, wherein The first oven is all vertically positioned below the bottom portion.

4. The system according to claim 1, wherein The first oven can be raised to a temperature of about 60 degrees Celsius to about 130 degrees Celsius.

5. A system for applying a coating to a substrate, the system comprising: A coating operation table for applying a coating material to the substrate, wherein the coating operation table has a bottom portion; A first oven for curing the coating material on the substrate, wherein the first oven is vertically and closely positioned below the bottom portion; A first lifting table for transferring the substrate from the coating operation table to the first oven, whereby the first lifting table is configured to transfer the substrate vertically downward to the first oven; An inspection operation table for inspecting the substrate; A loading area provided between the inspection operation table and the coating operation table, wherein the loading area includes a conveyor extending from the inspection operation table to the coating operation table; A second oven vertically positioned below the conveyor, such that the second oven is also vertically positioned below the bottom portion of the coating operation table; A third oven, the third oven being vertically positioned below the inspection operation table such that the third oven is also positioned below the bottom portion; and A second lift table for transferring the substrate from the third oven to the inspection operation table, wherein the third oven is spaced apart from the first oven, wherein the third oven is disposed adjacent to the second oven along a first direction transverse to the vertical direction, and the third oven is vertically positioned directly below the inspection operation table, and wherein each of the coating operation table, the inspection operation table, the first oven, the second oven, the third oven, the first lift table, and the second lift table can be separated independently of each other and each defines an independent set of separable modules.

6. The system according to claim 1, wherein, The third oven is spaced apart from the first oven, wherein the third oven is disposed adjacent to the second oven along a first direction transverse to the vertical direction, and the third oven is vertically positioned directly below the inspection operation table.

7. The system according to claim 5, wherein The third oven operates at a different temperature from the first oven.

8. The system according to claim 1, wherein, The inspection operation table includes a camera for capturing an image of the substrate.

9. The system according to claim 1, wherein The coating operation table includes a jet dispenser for applying a coating material to the substrate.

10. The system according to claim 1, further comprising a vacuum chamber for removing air bubbles from the coating material.

11. The system according to claim 1, further comprising a plasma system for processing the substrate.

12. A method for applying a coating to a substrate, the method comprising: Applying a coating material to the substrate with a coating operation table, wherein a loading area is provided between the inspection operation table and the coating operation table, and wherein the loading area includes a conveyor extending from the inspection operation table to the coating operation table; Transferring the substrate in a vertically downward direction from the coating operation table to a first oven with a first lift table; Curing the coating on the substrate in the first oven, wherein a second oven is vertically positioned below the conveyor such that the second oven is also vertically positioned below the bottom portion of the coating operation table, wherein the second oven is adjacent to the first oven, the second oven is disposed adjacent to the first oven along a first direction transverse to the vertically downward direction, and the second oven is vertically positioned directly below the loading area, and wherein a third oven is vertically positioned below the inspection operation table such that the third oven is also positioned below the bottom portion; After curing the coating, transferring the substrate in a vertically upward direction opposite to the vertically downward direction from the third oven to the inspection operation table with a second lift table; and Inspecting the substrate with the inspection operation table, wherein each of the coating operation table, the inspection operation table, the first oven, the second oven, the third oven, the first lift table, and the second lift table can be separated independently of each other and each defines an independent set of separable modules.

13. The method according to claim 12, wherein, Applying the coating includes moving the substrate through the coating operation station in a second direction opposite to the first direction.

14. The method according to claim 13, wherein, Inspecting the coating includes moving the substrate through the inspection operation station in the second direction.

15. The method according to claim 13, wherein, Curing the coating includes moving the substrate through the first oven in the first direction, wherein a lower conveyor system moves the substrate from the lifting table through the first oven in the first direction, and wherein the lifting table transfers the substrate from the coating operation station to the first oven in a vertically downward direction.

16. The method according to claim 15, wherein, The second oven is adjacent to the first oven, and wherein once the substrate passes through the first oven on the first section of the lower conveyor system, the substrate enters the second oven in the first direction.

17. The method according to claim 16, wherein, The third oven is adjacent to the second oven, and after curing of the coating is completed, the substrate is transferred from the third oven to the inspection operation station in a vertically upward direction.

18. The method according to claim 12, wherein, Transferring the substrate from the coating operation station includes moving the substrate from above the bottom portion of the coating operation station to below the bottom portion in the vertically downward direction.

19. The method according to claim 17, wherein, Transferring the substrate from the third oven includes moving the substrate from below the bottom portion of the coating operation station to above the bottom portion in a vertically upward direction.

20. The method according to claim 12, wherein, The first oven can be raised to a temperature of about 60 degrees Celsius to about 130 degrees Celsius.

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