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  Method and apparatus for the bulk coating of componentsUSPTO Application #: 20060011479Title: Method and apparatus for the bulk coating of components Abstract: A method and apparatus for the electrocoating of relatively small components is disclosed. The apparatus includes a coating process unit, which is comprised of three component parts, which are defined as the process tank, the transfer system, and the electrode system. Each of the three component parts is integrated with a support structure. The process tank is a fluid-tight, open-top receptacle that holds the coating solution through which the parts are passed. The transfer system generally includes a conveyor chain and transfer media connected with the conveyor chain. The conveyor chain may be electrically insulated. The transfer media connects to the conveyor chain to form the continuous moving support surface onto which the parts are loaded, coated and are unloaded. The transfer media includes a support surface and electrical contact. The electrode system includes both an electrode and an electrode contact of opposite polarity. (end of abstract) Agent: Thomas T. Moga Butzel Long - Bloomfield Hills, MI, US Inventors: Leo L. Case, Michael R. Morin, James G. Weslosky, Michael A. Weslosky USPTO Applicaton #: 20060011479 - Class: 204512000 (USPTO) Related Patent Categories: Chemistry: Electrical And Wave Energy, Non-distilling Bottoms Treatment, Electrophoresis Or Electro-osmosis Processes And Electrolyte Compositions Therefor When Not Provided For Elsewhere, Coating Or Forming Of Object, Continuous Movement Of Substrate Through Bath The Patent Description & Claims data below is from USPTO Patent Application 20060011479. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation-in-part of prior U.S. patent application Ser. No. 09/952,132, filed Sep. 14, 2001. 1. Technical field [0002] The present invention relates generally to the coating of components. More particularly, the present invention relates to a method and apparatus for the bulk electrocoating of relatively small components. The method generally includes: the preparation of the components to be coated, the placement of the components on transfer media in the form of a movable conveyor, the movement of the transfer media and its accompanying components through a coating-filled process tank, the subject of the uncoated parts to an electrically charged coating solution wherein the parts are coated, and the conveyed removal of the coated parts to a curing/post treatment/polymerization means. 2. SUMMARY OF RELATED ART [0003] Electrocoating or electrodeposition is a process undertaken by the use of opposite polarity electrodes disposed in a spaced-apart array in a tank having a coating bath. The coating process is actually the application of coating by electrolysis and the charged particles, in this case the paint or coating solids, are attracted to the substrate forming an even and uniform deposit of coating thereupon. [0004] Because conductivity is a requirement for electrocoating, the coated article must be conductive or at least must bear an electrically conductive surface. Accordingly, articles to be coated include those manufactured from steel, iron, zinc die-cast, aluminum, copper, brass, or composite materials. This type of coating is particularly valuable where the parts are of complex shapes having recesses and other difficult-to-coat surfaces. This method of coating is also valuable where many like parts must be coated with an identical coating on a volume basis. Accordingly, electrocoating has particular utility in the coating of appliances, metal furniture and in the automotive industry. [0005] Many examples of the electrocoating processes are known in the industry. Some of these include rack and drum coating, the latter being represented by U.S. Pat. No. 5,433,834, issued to Belz et al. on Jul. 18, 1995. Another popular arrangement for electrocoating is characterized in the suspension or dipping system, whereby a plurality of parts are hung from an overhead conveyor and are pulled through an electrocoating bath. Examples of this approach include U.S. Pat. No. 4,263,122, issued to Urquhart on Apr. 21, 1981, U.S. Pat. No. 4,668,358, issued to Ball on May 26, 1987, U.S. Pat. No. 4,844,783, issued to Takahashi et al. on Jul. 4, 1989, and U.S. Pat. No. 6,139,708, issued to Nonomura et al. on Oct. 31, 2000. [0006] However, attention has been recently directed to the use of conveyor systems upon which are loaded parts. The parts are then carried through and out of an electrocoating tank. An example of this approach includes U.S. Pat. No. 5,810,987, issued to Opitz on Sep. 22, 1998. [0007] While the above-noted approaches represent improvements in the state of the art, there still remains room for improved electrocoating techniques. SUMMARY OF THE PRESENT INVENTION [0008] The present invention discloses a method and apparatus for the electrocoating of relatively small components. The apparatus may be generally defined as a coating process unit. The coating process unit is comprised of three component parts, which are defined as the process tank, the transfer system, and the electrode system. Each of the three component parts is integrated with a support structure. The process tank is a fluid-tight, open-top receptacle that holds the coating solution through which the parts are passed. The transfer system generally includes a conveyor chain and transfer media connected to the conveyor chain. The conveyor chain may be electrically insulated. The transfer media connects to the conveyor chain to form the continuing moving support surface on which the parts are loaded, coated and unloaded. The transfer media includes a support surface and electrical contact. The electrode system includes both an electrode and an electrode contact of opposite polarity. [0009] The method of the invention generally includes the preparation of the parts to be coated (by cleaning and, preferably, by phosphating), the introduction of the components onto the transfer media (the conveyor), the movement of the transfer media and its accompanying parts to be coated through the coating-filled process tank, the subjecting of the prepared parts to an electrically charged coating solution while in the process tank, and the conveyed removal of the parts to a post treatment and/or curing area as required. During the coating operation, the conductive portions of the transfer media are coated simultaneously with the parts. Accordingly, following the unloading of the coated parts, the top surface of the transfer media is cleaned to remove the deposited but uncured coating. This step helps to provide positive electrical contact of the parts and, thus, optimal coating results. [0010] The present invention finds broad utility in a variety of painting and coating applications, particularly where small parts are presently being manually fixtured for coating. For example, the present invention would be desirable in painting small parts, i.e. fasteners, clamps, brackets, etc. The coating apparatus of the present invention finds particular application in the painting of small parts, which require a uniform film of highly corrosion resistant coating applied over irregularly-shaped items. BRIEF DESCRIPTION OF THE DRAWINGS [0011] The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout the views, and in which: [0012] FIG. 1 is an elevational side view of the present invention, illustrated in partial shadow lines, and showing the primary components of the bulk electrocoating apparatus; [0013] FIG. 2 is a top plan view of the present invention, illustrated in partial shadow lines; and [0014] FIG. 3 is an elevational end view of the input end of the present invention, illustrated in partial shadow lines. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0015] The drawings disclose the preferred embodiment of the present invention. While the configurations according to the illustrated embodiment are preferred, it is envisioned that alternate configurations of the present invention may be adopted without deviating from the invention as portrayed. The preferred embodiment is discussed hereafter. [0016] Referring primarily to FIG. 1, a side elevational view of the present coating apparatus, generally illustrated as 9, is shown. The apparatus 9 includes a parts input end 10, an output end 11, a support portion 12 and a coating portion 14. The support portion 12 may be defined by a frame arrangement (as shown) or may be of any other supportive configuration (a cast cement base, for example). [0017] The coating portion 14 includes a coating or process tank 16, a transfer system, generally illustrated as 18, an electrode 20, and an opposite polarity electrode contact 21. The electrode 20, and the electrode contact 21, are supplied D.C. power by a rectifier 25 or other appropriate external D.C. power source. [0018] The electrode network composed of the electrodes 20 and 21 forms a plane that is substantially parallel to both the opposing electrode and the transfer media 26. These electrodes 20 and 21 may be a single unit or multiple units. The use of multiple units will allow the use of multiple D.C. sources for multiple voltage potentials or differently sized electrodes for multiple current densities. The electrodes are mounted in an easily removed assembly, which includes an insulating grid 23 below the electrode to prevent accidental short circuits should parts stack excessively on the transfer media 26. This design allows very close proximity of the electrode to the parts which reduces the required voltage and improves the overall coating efficiency. As illustrated in FIG. 2, the electrodes are shown as bare conductive plates, although it is to be understood that other electrode configurations, such as tubular flushable electrodes, may be used. Continue reading... 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