U.S. patent application number 11/509451 was filed with the patent office on 2006-12-21 for gravity-fed in-line continuous processing system and method.
Invention is credited to Michael Asbas, Donald G. Parent, Dean Plaisted.
Application Number | 20060283391 11/509451 |
Document ID | / |
Family ID | 28791905 |
Filed Date | 2006-12-21 |
United States Patent
Application |
20060283391 |
Kind Code |
A1 |
Parent; Donald G. ; et
al. |
December 21, 2006 |
Gravity-fed in-line continuous processing system and method
Abstract
A gravity-fed in-line continuous processing system includes at
least one processing chamber disposed between a first load lock and
a second load lock. The second load lock is disposed lower than the
first load lock. A first device isolates the processing chamber
from the first load lock. A second device isolates the processing
chamber from the second load lock. There is at least one track
through the processing chamber and the first and second load locks.
The track is structured and arranged such that an article slides
thereon under the force of gravity.
Inventors: |
Parent; Donald G.; (Windham,
ME) ; Plaisted; Dean; (Kennebunk, ME) ; Asbas;
Michael; (Alfred, ME) |
Correspondence
Address: |
IANDIORIO & TESKA;INTELLECTUAL PROPERTY LAW ATTORNEYS
260 BEAR HILL ROAD
WALTHAM
MA
02451-1018
US
|
Family ID: |
28791905 |
Appl. No.: |
11/509451 |
Filed: |
August 24, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10400775 |
Mar 27, 2003 |
|
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11509451 |
Aug 24, 2006 |
|
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60368818 |
Mar 29, 2002 |
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Current U.S.
Class: |
118/719 ;
118/733 |
Current CPC
Class: |
C23C 14/566 20130101;
C23C 14/56 20130101; Y10T 137/86751 20150401; Y10T 137/86622
20150401; C23C 4/00 20130101 |
Class at
Publication: |
118/719 ;
118/733 |
International
Class: |
C23C 16/00 20060101
C23C016/00 |
Claims
1. A gravity-fed in-line continuous processing system comprising:
at least one processing chamber disposed between a first load lock
and a second load lock, the second load lock disposed lower than
the first load lock; a first device including a body for isolating
the processing chamber from the first load lock; a second device
for isolating the processing chamber from the second load lock; at
least one track through the processing chamber and the first and
second load locks, the track structured and arranged such that an
article slides thereon under the force of gravity; and at least one
passage through the body defining an inlet and an outlet, a first
actuator for rotating the body, a second actuator for translating
the body, and a sealing portion on the body for sealing the body
with respect to an opening into a chamber adjacent the body.
2. A gravity-fed in-line continuous processing system comprising:
at least one processing chamber disposed between a first load lock
and a second load lock, the second load lock disposed lower than
the first load lock; a first device including a body for isolating
the processing chamber from the first load lock; a second device
for isolating the processing chamber from the second load lock; at
least one track through the processing chamber and the first and
second load locks, the track structured and arranged such that an
article slides thereon under the force of gravity; and a plurality
of passages through the body defining a plurality of inlets and
outlets, a first actuator for rotating the body, a second actuator
for translating the body, and a plurality of sealing portions on
the body, the plurality of sealing portions corresponding to each
of the passages for sealing the body with respect to openings into
a chamber adjacent the body.
Description
RELATED APPLICATIONS
[0001] This application is a Continuation of prior U.S. patent
application Ser. No. 10/400,775 filed Mar. 27, 2003 which claims
priority of and is related to U.S. Provisional Patent Application
Serial No. 60/368,818, filed Mar. 29, 2002. This application is
also related to the U.S. patent application entitled ROTARY BARREL
GATE VALVE, filed on even date herewith and hereby incorporated by
reference herein, and which also claims priority to U.S.
Provisional Patent Application Serial No. 60/368,818 filed Mar. 29,
2002.
FIELD OF THE INVENTION
[0002] This invention relates to a gravity-fed in-line processing
system useful for, inter alia, rapidly coating plastic substrates
such as plastic flatware and cellular telephone housings.
BACKGROUND OF THE INVENTION
[0003] Conventional systems and methods of applying coatings to
substrates such as metallizing insulative substrates include
electroplating, electroless plating, painting, arc-spray,
evaporative vacuum metallization, and sputter vacuum metallization.
These systems and processes are usually batch oriented. Typical
batch oriented systems require parts or substrates to be placed on
racks for insertion into a batch chamber. The batch chamber door is
opened, a rack of parts is inserted into the chamber, and the door
is then closed and sealed. Thereafter, coating takes place, and
after coating, the batch chamber door is again opened, and the rack
of parts is removed manually and unloaded.
[0004] One disadvantage of batch oriented production systems is
that during the coating process, other operations cease, creating
down time. Also, the cycle time is long, and large production run
volumes are required for the system to be cost effective. Batch
oriented systems result in large work-in-process inventories and a
large number of at-risk parts before process quality can be
assessed.
[0005] Some of these disadvantages and limitations may be overcome
by so-called "in-line" systems that integrate vacuum metallization
"in-line" with a parts molding machine. However, conventional
systems are often expensive and complex. Moreover, such systems
often include conveyors, robot arms within the system, and/or gates
with valves and seals that utilize up and down and/or sliding
motion which are subject to excess wear, malfunction and
necessitate frequent replacement of parts over the life of the
system. The conveyors, and robot arms within the system, can also
contaminate the highly sensitive vacuum chambers.
BRIEF SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide an
improved system for applying coatings to substrates and
particularly for metallizing plastic parts.
[0007] It is a further object of this invention to provide a truly
in-line metallizing system that may be physically located adjacent
a parts molding machine.
[0008] It is a further object of this invention to provide such a
system that is rapid, automated, and continuous, with reduced cycle
time and reduced down time.
[0009] It is a further object of this invention to provide such a
system which eliminates the need for a conveyor or a robot arm
within the system.
[0010] It is a further object of this invention to provide such a
system with improved and more robust gates or valves.
[0011] This invention results from the realization that an
improved, faster, more robust, higher quality and more reliable
in-line metallization processing system can be achieved with a
system that utilizes gravity instead of mechanical conveyors, or
robot arms within, and which utilizes rotary barrel gate valves in
place of conventional gates and valves, and which may be located
adjacent a molding machine.
[0012] This invention features a gravity-fed in-line continuous
processing system including at least one processing chamber
disposed between a first load lock and a second load lock, with the
second load lock disposed lower than the first load lock. The
system may include a first device for isolating the processing
chamber from the first load lock, a second device for isolating the
processing chamber from the second load lock, and at least one
track through the processing chamber and the first and second load
locks, with the track structured and arranged such that an article
slides thereon under the force of gravity.
[0013] In one embodiment, the processing chamber, the first load
lock and the second load lock may all be angled with respect to the
horizontal, or the track may be angled with respect to the
horizontal. The track, the processing chamber, the first load lock
and the second load lock, or any combination thereof, may be angled
with respect to the horizontal. The angle with respect to the
horizontal may be greater than 33.degree. but less than 43.degree..
The angle with respect to the horizontal may be about 40.degree..
The first load lock may be an input load lock, and the second load
lock may be an output load lock. The first device may be structured
and arranged to prevent the article from sliding under the force of
gravity when the first device is closed. The second device may be
structured and arranged to prevent the article from sliding under
the force of gravity when the second device is closed. The first
device may be structured and arranged to allow the article to slide
on the track from the first load lock to the processing chamber
when the first device is open. The second device may be structured
and arranged to allow the article to slide on the track from the
processing chamber to the second load lock when the second device
is open.
[0014] The first device may be a first rotary barrel gate valve and
the second device may be a second rotary barrel gate valve. The
system may include a plurality of tracks through the processing
chamber and the first and second load locks, and all tracks may be
angled with respect to the horizontal. The plurality of tracks may
be structured and arranged such that articles in each of the
plurality of tracks slide thereon under the force of gravity for
simultaneously processing a plurality of articles. The plurality of
tracks are typically parallel to one another and the parallel
tracks of the first load lock, the tracks of the processing
chamber, and the tracks of the second load lock are aligned with
one another.
[0015] The system may include an input tray disposed adjacent the
first load lock. An output tray may be disposed adjacent the output
load lock. The processing chamber may be a vacuum sputtering
chamber. The first load lock and the second load lock may be
structured and arranged for venting from a first pressure to a
second pressure. The first pressure may be a vacuum and the second
pressure may be atmospheric pressure. The first load lock and the
second load lock may be structured and arranged for evacuating from
a first pressure to a second pressure. The first pressure may be
atmospheric pressure and the second pressure may be a vacuum. The
system may include a third device between the first load lock and
atmosphere and a fourth device between the second load lock and
atmosphere. The third device may be a third rotary barrel gate
valve and the fourth device may be a fourth rotary barrel gate
valve. The article to be processed may be any sputterable part such
as plastic, polystyrene, and in particular it may be polystyrene
plastic cutlery. The system may further include a take-out robot
for transferring articles from an injection molding machine to the
input tray. The first load lock, the second load lock, the first
device, the second device and the processing chamber may be
sequenced such that sets of articles may be processed
simultaneously. Each of the processing chamber, the first and
second load locks and the first and second devices may be angled
with respect to the horizontal. The first device may include a
body, at least one passage through the body defining an inlet and
an outlet, a first actuator for rotating the body, a second
actuator for translating the body, and a sealing portion on the
body for sealing the body with respect to an opening into a chamber
adjacent the body.
[0016] This invention further features a gravity-fed in-line
continuous processing system including at least one processing
chamber disposed between a first load lock and a second load lock,
the second load lock disposed lower than the first load lock, a
first device for isolating the processing chamber from the first
load lock and a second device for isolating the processing chamber
from the second load lock. The processing chamber, the first load
lock, the second load lock, the first device and the second device
may all be angled with respect to the horizontal, each having a
plurality of tracks with the plurality of tracks structured and
arranged such that a plurality of articles slide thereon under the
force of gravity from the first load lock, through the processing
chamber, and to the second load lock.
[0017] This invention further features a gravity-fed in-line
continuous processing system including at least one vacuum
sputtering chamber disposed between a first load lock and a second
load lock, the second load lock disposed lower than the first load
lock. A first rotary barrel gate valve for isolating the vacuum
sputtering chamber from the first load lock may be included, the
first rotary barrel gate valve structured and arranged to prevent
an article from sliding under the force of gravity when the first
rotary barrel gate valve is closed and to allow the article to
slide therethrough under the force of gravity when the first rotary
barrel gate valve is open. A second rotary barrel gate valve for
isolating the vacuum sputtering chamber from the second load lock
may be included, the second rotary barrel rotary barrel gate valve
structured and arranged to prevent an article from sliding under
the force of gravity when the second rotary barrel gate valve is
closed and to allow the article to slide therethrough under the
force of gravity when the second rotary barrel gate valve is
open.
[0018] This invention also features a gravity-fed in-line
continuous processing system including at least one processing
chamber disposed between a first load lock and a second load lock,
the second load lock disposed lower than the first load lock. There
may be included a first rotary barrel gate valve for isolating the
processing chamber from the first load lock, the first rotary gate
valve structured and arranged to prevent an article from sliding
under the force of gravity when the first rotary gate valve is
closed and to allow the article to slide therethrough under the
force of gravity when the first rotary gate valve is open. There
may be included a a second rotary barrel gate valve for isolating
the processing chamber from the second load lock, the second rotary
gate valve structured and arranged to prevent the article from
sliding under the force of gravity when the second rotary gate
valve is closed and to allow the article to slide therethrough
under the force of gravity when the second rotary gate valve is
open. There may further be included a third rotary barrel gate
valve for isolating the first load lock from atmosphere, the third
rotary gate valve structured and arranged to prevent the article
from sliding under the force of gravity when the third rotary gate
valve is closed and to allow the article to slide therethrough
under the force of gravity when the third rotary gate valve is
open. An input tray may terminate at the third rotary barrel gate
valve. A fourth rotary barrel gate valve may be included for
isolating the second load lock from atmosphere, the fourth rotary
gate valve structured and arranged to prevent the article from
sliding under the force of gravity when the fourth rotary gate
valve is closed and to allow the article to slide therethrough
under the force of gravity when the fourth rotary gate valve is
open. An output tray may be adjacent the fourth rotary barrel gate
valve, and a plurality of tracks may be angled through the first
load lock, the processing chamber, and the second load lock
interconnecting the input tray and the output tray to urge, under
the force of gravity, articles through the first load lock, the
processing chamber, and the second load lock.
[0019] This invention also features a gravity-fed in-line
continuous processing system including at least one processing
chamber module disposed between a first load lock module and a
second load lock module, the second load lock module disposed lower
than the first load lock module. A first device may be included for
isolating the processing chamber module from the first load lock
module, a second device may be included for isolating the
processing chamber module from the second load lock module, and
there may be at least one track through the processing chamber
module and the first and second load lock modules, the track
structured and arranged such that an article slides thereon under
the force of gravity.
[0020] This invention further features a gravity-fed in-line
continuous processing system including at least one processing
chamber including at least one track therethrough, with the track
structured and arranged such that an article slides thereon under
the force of gravity. The processing chamber may be angled with
respect to the horizontal and the at least one track may be angled
with respect to the horizontal.
[0021] This invention further features a gravity-fed in-line
continuous processing system including means for processing
disposed between a first means for alternating between a first
pressure and a second pressure, and a second means for alternating
between a first pressure and a second pressure. The first pressure
may be atmospheric pressure and the second pressure may be a
vacuum. Alternatively, the first pressure may be a vacuum and the
second pressure may be atmospheric pressure. The second means for
alternating may be disposed lower than the first means for
alternating. There may be a first means for isolating the means for
processing from the first means for alternating and a second means
for isolating the means for processing from the second means for
alternating. The system may further include at least one track
through the means for processing and the first and second means for
alternating. The track may be structured and arranged such that an
article slides thereon under the force of gravity.
[0022] This invention further features a gravity-fed in-line
continuous processing system including at least one means for
processing disposed between a first means for alternating between a
first pressure and a second pressure, and a second means for
alternating between a first pressure and a second pressure. The
first pressure may be atmospheric pressure and the second pressure
a vacuum. The second means for alternating may be disposed lower
than the first means for alternating. There may be a first means
for isolating the means for processing from the first means for
alternating. The first means for isolating may be structured and
arranged to prevent an article from sliding under the force of
gravity when the first means for isolating is closed, and to allow
the article to slide therethrough under the force of gravity when
the first means for isolating is open. There may also be a second
means for isolating the means for processing from the second means
for alternating. The second means for isolating may be structured
and arranged to prevent the article from sliding under the force of
gravity when the second means for isolating is closed and to allow
the article to slide therethrough under the force of gravity when
the means for isolating is open. There may be a third means for
isolating the first means for alternating from atmosphere. The
third means for isolating may be structured and arranged to prevent
the article from sliding under the force of gravity when the third
means for isolating is closed, and to allow the article to slide
therethrough under the force of gravity when the third means for
isolating is open. An input tray may terminate at the third means
for isolating. A fourth means for isolating may isolate the second
means for alternating from atmosphere. The fourth means for
isolating may be structured and arranged to prevent the article
from sliding under the force of gravity when the fourth means for
isolating is closed, and to allow the article to slide therethrough
under the force of gravity when the fourth means for isolating is
open. An output tray may be adjacent the fourth means for
isolating. A plurality of tracks may be angled through the means
for alternating, the means for processing, and the second means for
alternating interconnecting the input tray and the output tray to
urge, under the force of gravity, articles through the first means
for alternating, the means for processing, and the second means for
alternating.
[0023] This invention also features a gravity-fed in-line
continuous processing system including at least one processing
chamber isolatable with respect to first and second chambers and
means for urging an article from the first chamber, through the
processing chamber, and to the second chamber under the force of
gravity.
[0024] This invention further features a method for coating
substrates, the method comprising providing at least one processing
chamber and disposing the processing chamber between a first load
lock and a second load lock. The second load lock may be disposed
lower than the first load lock. The method further includes
isolating the processing chamber from the first load lock with a
first device, isolating the processing chamber from the second load
lock with a second device, and providing at least one track through
the processing chamber and the first and second load locks and
structuring and arranging the track such that an article slides
thereon under the force of gravity. The method may further include
the step of angling the processing chamber, the first load lock and
the second load lock with respect to the horizontal. The angle with
respect to the horizontal may be greater than 330 but less than
43.degree.. The angle with respect to the horizontal may be about
40.degree.. The method may further include angling the at least one
track with respect to the horizontal. The first load lock may be an
input load lock and the second load lock may be an output load
lock. The step of isolating the processing chamber from the first
load lock may be carried out by a first device, and the step of
isolating the processing chamber from the second load lock may be
carried out by a second device. The first and second devices may be
rotary barrel gate valves.
[0025] The method may further include structuring and arranging the
first device and the second device to prevent the article from
sliding under the force of gravity when the first device is closed.
The method of this invention may further include structuring and
arranging the first and second devices to allow the article to
slide on the track from the first load lock to the processing
chamber when the first device is open. The first device may be a
first rotary barrel gate valve and the second device may be a
second rotary barrel gate valve. The method may further include the
steps of providing a plurality of tracks through the processing
chamber and the first and second load locks, angling all tracks
with respect to the horizontal, and structuring and arranging each
of the plurality of tracks such that articles in each of the
plurality of tracks slide thereon under the force of gravity for
simultaneously processing a plurality of articles. The plurality of
tracks may be parallel to one another. The method may further
include the steps of aligning the parallel tracks of the first load
lock, the tracks of the processing chamber, and the tracks of the
second load lock with one another, disposing an input tray adjacent
the first load lock, and disposing an output tray adjacent the
output load lock. The method may further include structuring and
arranging the first load lock and the second load lock for
alternating between a first pressure and a second pressure. The
first pressure may be a vacuum and the second pressure may be
atmospheric pressure. The method may also include providing a third
device between the first load lock and atmosphere and a fourth
device between the second load lock and atmosphere, where the third
device is a third rotary barrel gate valve and the fourth device is
a fourth rotary barrel gate valve. The method further include
sequencing the first load lock, the second load lock, the first
device, the second device and the processing chamber such that sets
of articles may be processed simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Other objects, features and advantages will occur to those
skilled in the art from the following description of a preferred
embodiment and the accompanying drawings, in which:
[0027] FIG. 1 is a schematic side view of one preferred embodiment
of the gravity-fed in-line continuous processing system of this
invention;
[0028] FIG. 2 is a schematic cross-sectional side view of the load
locks and processing chamber of the system shown in FIG. 1;
[0029] FIG. 3 is a schematic cross-sectional side view of rotary
barrel gate valves useful in connection with the gravity-fed
in-line continuous processing system of this invention;
[0030] FIG. 4 is a schematic top view of a gravity-fed in-line
continuous processing system in accordance with the present
invention showing the tracks of each section;
[0031] FIG. 5 is a three-dimensional view of tracks useful in
accordance with the present invention;
[0032] FIG. 6 is a schematic side view of the gravity-fed in-line
continuous processing system shown in FIG. 1 in conjunction with an
injection molding machine and a take-out robot;
[0033] FIGS. 7A and 7B are a sequencing chart showing cycle times
and sequencing for the system shown FIG. 6;
[0034] FIG. 8 is a schematic three-dimensional front view of a
gravity-fed in-line continuous processing system of this
invention;
[0035] FIG. 9 is a schematic cross-sectional side view of one
embodiment of a rotary barrel gate valve for use with the system of
this invention;
[0036] FIG. 10 is a schematic side view of one portion of the
rotary barrel gate valve of FIG. 9;
[0037] FIG. 11 is a schematic cross-sectional view of the rotary
barrel gate valve of FIG. 9 shown in the open position;
[0038] FIG. 12 is a schematic cross-sectional view of a rotary
barrel gate valve of FIG. 9 shown in the closed position;
[0039] FIG. 13 is an enlarged schematic cross-sectional side view
of the sealing portion of the rotary barrel gate valve;
[0040] FIG. 14 is a schematic cross-sectional view of an actuator
for translating the rotary barrel gate valve; and
[0041] FIG. 15 is a schematic cross-sectional view of an actuator
for rotating the rotary barrel gate valve.
DISCLOSURE OF THE PREFERRED EMBODIMENT
[0042] Aside from the preferred embodiment or embodiments disclosed
below, this invention is capable of other embodiments and of being
practiced or being carried out in various ways. Thus, it is to be
understood that the invention is not limited in its application to
the details of construction and the arrangements of components set
forth in the following description or illustrated in the
drawings.
[0043] One gravity-fed in-line continuous processing system in
accordance with the present invention is shown in FIG. 1. The
system is comprised of modules, for example, a first load lock with
gate valves module, a processing chamber module, and a second load
lock with gate valves module. Parts for processing proceed from one
module to another module by gravity, with the parts guided
individually in tracks or chutes. Load-locks with rotary barrel
gate valves preferably function as sealing mechanisms and as part
escapements, controlling the flow of parts from one machine module
to the next.
[0044] One embodiment of this invention system 10, FIG. 1 includes
at least one means for processing, such as processing chamber or
module 12. Processing chamber 12 is disposed between first means
for alternating between a first and a second pressure, such as
first load lock or module 14, and second means for alternating
between a first and a second pressure, such as second load lock or
module 16, with second load lock 16 disposed lower than first load
lock 14. In accordance with a preferred embodiment of this
invention, first load lock 14 is an input load lock, and second
load lock 16 is an output load lock, as shown in FIGS. 1 and 2. As
it is known in the art, load lock pressure alternates from high
pressure to low pressure and vice versa, depending on the stage in
a process.
[0045] Any combination of processing chamber modules and a load
lock modules may be used with the system of the subject invention,
thus providing flexibility for the system user. For example, the
system may include a series of load locks and processing chambers
in order to end up with a thicker part coating than could be
achieved with only one processing chamber and using conventional
coating methods.
[0046] System 10, FIG. 1 further includes first means for
isolating, such as first device 18, for isolating processing
chamber 12 from first load lock 14, and second means for isolating,
such as second device 20, for isolating processing chamber 12 from
second load lock 16. First load lock 14 and second load lock 16 are
structured and arranged for venting or evacuating from a first to a
second pressure by venting or evacuating load locks 14 and 16, from
a vacuum to ambient atmospheric pressure and vice versa in one
example, using known methods. For example, when article 24 is in
first load lock 14 at ambient atmosphere, before article 24 can
enter into processing chamber 12, first load lock 14 is evacuated.
Then later, before first load lock can be opened to allow in the
next article, load lock 14 must be vented.
[0047] System 10 includes at least one track or chute 22 through at
least one of processing chamber 12 and first and second load locks
14 and 16, with track 22 structured and arranged such that article
or part 24 slides on track 22 under the force of gravity. Track 22
is shown in phantom cross-section and in exemplary fashion in first
load lock 14 of FIG. 1. At least one of processing chamber 12,
first load lock 14, second load lock 16, first device 18 and second
device 20, is angled with respect to horizontal 19. Alternatively
or additionally, track 22 may be angled with respect to horizontal
19. In one embodiment system 10 is designed for coating plastic
flatware or cutlery, and angle 26 is greater than about 32.degree.
but less than about 44.degree.. In one embodiment for coating
plastic flatware, angle 26 is about 40.degree.. Optimum angles for
various coating processes, such as coating phone carriers, or for
tracks or chutes that include bearings, are possible with system
10. It can be seen that a combination of angling track 22 and
modules 12, 14 and/or 16 with respect to the horizontal can achieve
a desired angle for the system. Track or chute 22 is structured and
arranged so that part 24 will slide under its own weight,
eliminating the need for complex conveyors and robotic arms within
the system, thus improving overall system mechanical and
operational reliability. There is typically one part 24 per chute
22 within any particular module, although there may be many chutes
within any particular module, as well as sets of articles passing
through the system at one time as described below with respect to
sequencing of the system.
[0048] In one embodiment, processing chamber 12 is a vacuum
sputtering chamber including a cathode and shield assembly for
metallization on at least one side of article 24 as is known to
those skilled in the art, although the processing chamber 12 of
this invention is not limited to a vacuum sputtering chamber or to
a particular coating or to coating on one side only. Article 24 to
be coated may be any sputterable part, such as plastic or
polystyrene. The present invention has been successfully used to
coat or metallize polysterene plastic cutlery, such as spoons,
knives and forks, with stainless steel. The system of the present
invention may further include input tray 40 and output tray 42 as
shown in FIG. 1.
[0049] When first device 18 is closed, FIG. 3, first device 18 is
structured and arranged to prevent article 24(1) from sliding under
the force of gravity. Similarly, when second device 20 is closed,
second device 20 is structured and arranged to prevent article
24(2) from sliding under the force of gravity (not shown).
Conversely, when second device 20 is open, second device 20 is
structured and arranged to allow article 24(2) to slide under the
force of gravity on track 22 through second device 20 and into the
next chamber or to atmosphere. Similarly, when first device 18 is
open, first device 18 is structured and arranged to allow article
24(1) to slide on track 22 through first device 18 and into the
next chamber or to atmosphere (not shown). Part gate 29, FIG. 2
keeps article 24 from sliding within processing chamber 12. Part
gate 29 may be used at any point or in any module of the system,
even in addition to the article stopping function of first and
second devices 18 and 20.
[0050] In one preferred embodiment, first and second devices 18 and
20 are rotary barrel gate valves as shown in FIGS. 2 and 3. First
and second devices 18 and 20, i.e. rotary barrel gate valves 18 and
20, are used to open and close first and second load locks 14 and
16 to either the atmosphere or to processing chamber 12. For
example, a mechanical roughing pump may be used to evacuate first
load lock 14 from a first pressure, typically atmosphere, prior to
transferring part 24 from first load lock 14 into processing
chamber 12 which is at a second pressure, typically a vacuum.
[0051] First and second devices 18 and 20 (i.e. rotary barrel gate
valves) operate with long durability and with high reliability.
Each gate valve is interlocked or sequenced to detect full closure,
minimizing the risk of direct passing of atmosphere into processing
chamber 12, for example, should part 24 become lodged in a gate
valve. If part 24 does get lodged in this manner, system 10 halts
and an error condition is reported indicating the reason for the
error.
[0052] In accordance with one embodiment of the present invention,
system 10 may include third device 18', FIGS. 1 and 2 between first
load lock 14 and atmosphere, and fourth device 20' between second
load lock 16 and atmosphere, where atmosphere is atmospheric
pressure. Third and fourth devices 18' and 20' may be rotary barrel
gate valves similar to first and second devices 18 and 20.
[0053] Each of processing chamber 12, first and second load locks
14, 16, and first and second devices 18, 20 may include at least
one track 22. Each of processing chamber 12, first and second load
locks 14 and 16, and first and second devices 18 and 20 may include
a plurality of tracks 22a,22b . . . 22n, FIG. 4. In one example,
plurality of tracks 22a, 22b . . . 22n are angled with the
horizontal in like manner as single track 22 in FIG. 1. The
plurality of tracks 22a, 22b . . . 22n are structured and arranged
such that articles 24a, 24b . . . 24n in each of plurality of
tracks 22a, 22b . . . 22n slide therein under the force of gravity
for simultaneous processing.
[0054] Tracks 22a, 22b . . . 22n of first load lock 14,
corresponding tracks, i.e. 22a', 22b' . . . 22n' of processing
chamber 12 and corresponding tracks i.e. 22a'', 22b''. . . 22n'' of
second load lock 16 are aligned with one another. Each of tracks
22a, 22b . . . 22n, are parallel to one another, as are each of
tracks 22a', 22b' . . . 22n' and each of tracks 22a'', 22b'' . . .
22n''. The parallel layout of the tracks permits more tracks to be
added by adding width to system 10, and by adding length to the
first and second devices 18, 20 (and third and fourth devices 18',
20') where, as noted above, both first and second devices 18, 20
also include tracks, i.e. 22a'''', 22b'''' . . . 22n'''' (not
shown) corresponding to and aligned with tracks of adjacent load
locks or processing chamber.
[0055] Tracks 22a, 22b . . . 22n are arranged in groups 70, 72, 74,
76. . . with members 80, 82, 84 . . . 84n installed between groups
to provide structural support, as exemplified by FIG. 5 showing the
tracks of input tray 40. In one embodiment, members 80 and tracks
22a, 22b . . . 22n are machined from one solid sheet of aluminum.
Input tray 40 includes tracks, i.e. 22a''', 22b''' . . . 22n'''
corresponding to the tracks 22a, 22b . . . 22n . . . of input load
lock 14, tracks 22a', 22b' . . . 22n' of processing chamber 12,
tracks 22a'', 22b'' . . . 22n'' of output load lock 16 as shown in
FIG. 4, and so on with respect to the tracks of first and second
devices 18, 20 and output tray 42 (not shown).
[0056] Those skilled in the art will recognize that a system in
accordance with the present invention may be comprised of
processing chamber 12 alone including at least one track, if
contamination during processing is not a concern. In such a case,
processing chamber 12 may be angled with respect to the horizontal,
or track 22 may be angled with respect to the horizontal, or both
processing chamber 12 and track 22 may be angled with the
horizontal.
[0057] Gravity-fed in-line continuous processing system 10 of this
invention, FIG. 6 may be used stand-alone, or it may include
interface 50 with injection molding machine 52, with interface 50
being an electrical handshake scheme as is known in the art. The
system may further include take-out robot 54 for transferring parts
or articles 24a, 24b . . . 24n, FIG. 4 from injection molding
machine 52 to input tray 40, FIG. 6. Parts 24a, 24b . . . 24n are
loaded onto input tray 40 by take out robot 54. Input tray 40 may
accept parts from take out robot 54 and laterally shift parts 24 to
align them to tracks 22a, 22b . . . 22n. Optical systems can be
used to determine if the tray is full.
[0058] Applying a metal coating to a clear polystyrene cutlery, for
example, by metallization, can be accomplished in a vastly improved
manner utilizing this invention. The invention assures high
quality, high adhesion, and an overall more robust process.
[0059] The operation of system 10 and method of the invention is
described as follows. Freshly molded parts or articles 24a, 24b . .
. 24n (not shown) are placed on input tray 40 by takeout robot 54,
FIG. 6. In one example of this invention, forty parts (e.g. 24a,
24b . . . 24n where part 24n is the fortieth part 24.sub.40) are
transferred at one time from input tray 40 into first or input load
lock 14 through rotary barrel gate valve 18'. Thereafter air is
evacuated from input load lock 14. From input load lock 14 parts
24a, 24b . . . . 24n are transferred through rotary barrel gate
valve 18 into processing or sputtering chamber 12 where they are
sputtered or coated. In this example, parts 24a, 24b . . . 24n are
thereafter transferred through rotary barrel gate valve 20 into
second or output load lock 16. Output load lock 16 is then vented
to atmospheric pressure, and parts 24a, 24b . . . 24n are
thereafter transferred through rotary barrel gate valve 20' to
output tray 42 where parts 24a, 24b . . . 24n may be transferred
into boxes 60 for shipping. The entire machine cycle may take place
in seconds, in contrast to current systems which take much longer.
The subject invention thus results in an improved, more rapid,
gravity-fed in-line continuous processing system.
[0060] Notably, in accordance with the present invention, all
portions of system 10, namely rotary barrel gate valve 18', input
load lock 14, rotary barrel gate valve 18, processing chamber 12,
rotary barrel gate valve 20, output load lock 16, and rotary barrel
gate valve 20' are interlocked or sequenced such that sets of
articles may be processed simultaneously. This makes the system
more efficient and continuous.
[0061] Particularly, one sequence for use in system 10 is shown in
FIGS. 7A and 7B, where "A" is rotary barrel gate valve 18' of FIG.
6, "B" is rotary barrel gate valve 18, "C" is rotary barrel gate
valve 20, and "D" is rotary barrel gate valve 20'. One "day" in
FIGS. 7A and 7B is equivalent to 100 milliseconds. Input load lock
14 and output load lock 16 are signified by "ILL" and "OLL" in
FIGS. 7A and 7B. In FIGS. 7A and 7B, reference numerals 300a . . .
300n each represent one set of parts or articles 24a, 24b . . . 24n
through system 10. First set 300a represents the first set of parts
or articles to go through the system, and 300b represents a second
set of parts to go through the system. The start of second set of
parts 300b is determined by the existence of proper conditions
downstream in system 10. For example, opening of rotary barrel gate
valve 18' for second set of parts 300b is determined by proper
completion of the load lock cycle for first set of parts 300a.
Controller 90, FIG. 6 controls the sequencing of the system using
standard customizable software, such as Ladder Logic, which is
standard for use with automatic Programmable Logic Controllers
(PLCs).
[0062] In one example, the opening of rotary barrel gate valve 18',
FIG. 6 for the start of a second cycle 302, FIGS. 7A and 7B of
parts begins when first set of parts 300a are being processed or
sputtered 304 in processing chamber 12, FIG. 6. As shown in FIGS.
6, 7A and 7B, at that point in time, rotary barrel gate valve 18'
is opened (unsealed) to allow second set of parts 300b to slide
through into input load lock 14. Input load lock 14 is sealed by
closing rotary barrel gate valve 18'. Input load lock 14 is
evacuated from atmospheric pressure of approximately 760 Torr to
vacuum pressure of approximately 250 milliTorr. Rotary barrel gate
valve 18 is opened and first set of parts 300a slides into chamber
12. Rotary barrel gate valve 18 is then closed, input load lock 14
is vented to atmospheric pressure, and first set of parts 300a is
sputtered. During this time, rotary barrel gate valve 18' opens
again and second set of parts 300b enters input load lock 14.
Rotary barrel gate valve 18' closes and seals, and rotary barrel
gate valve 20 is opened while input load lock 14 (with second set
of parts 300b) is being evacuated. First set of parts 300a slide
from processing chamber 12 to output load lock 16. When input load
lock 14 is evacuated, output load lock 16 is vented to atmosphere.
Second set of parts 300b thereafter slides from input load lock 14
into processing chamber 12 after rotary barrel gate valve 18 opens.
First set of parts 300a slides from output load lock 16 to an
optional output tray after rotary barrel gate valve 20' opens. This
sequence continues and repeats itself for any number of desired
cycles or sets of parts 300a . . . 300n. In one embodiment, the
direction of sealing of rotary gate valves 18 and 20, FIG. 6 is
such that the sealing of chamber 12 occurs at points 80, 82, 84, 86
in order to take advantage of pressure assisted sealing. Pressure
assisted sealing is desirable for longer rotary barrel gate valves
18', 18, 20, 20' where there is deflection of the rotary barrel
gate valves due to their length. Sealing points 80, 82, 84 and 86
result in load locks 14 and 16 having larger volumes. In other
embodiments where pressure assisted sealing is less important or
not desired, such as embodiments with short rotary barrel gate
valves 18', 18, 20, 20', sealing of chamber 12 could occur at
points 85 and 87 instead of or in addition to points 82 and 84, for
example. This would result in load locks 14 and 16 having smaller
volumes, which may be desirable in some applications of system
10.
[0063] The sequence just described is for system 10, FIG. 6 using a
thin coating metallizer for processing chamber 12 and using only
one vacuum pump for both first and second load locks 14 and 16. It
will be apparent to one skilled in the art that the sequencing may
be adjusted to accommodate various processing times, any number of
chambers and load locks, and for any number of vacuum pumps used
with the system.
[0064] A schematic three-dimensional representation of system 10 of
this invention, without take out robot or output tray, is shown in
FIG. 8.
[0065] For system 10 of this invention, it is useful to use first,
second, third and fourth devices 18, 18', 20', 20, FIG. 6 which are
rotary barrel gate valves, represented as rotary barrel gate valve
100 in FIGS. 9-13.
[0066] Rotary barrel gate valve 100 includes body 102, FIGS. 9 and
10 and at least one passage 104 through body 102 defining inlet 106
and outlet 108. Means for rotating body 102, such as actuator 110,
rotates body 102 about its axis 105, i.e. in the directions of
arrow 111. Means for translating or moving body 102, such as
actuator 112, translates or moves body 102 approximately linearly,
i.e. in the directions of arrow 113. Means for sealing, such as
sealing portion 116 on body 102, FIG. 10 is for sealing body 102
with respect to an opening into a chamber adjacent body 102
(adjacent chamber not shown). In one example, body 102 is
cylindrical and solid, and passage 104 through body 102 has an
circular shape. If rotary barrel gate valve 100 is adjacent a
vacuum chamber, body 102 is typically surrounded by housing 129 as
shown in FIG. 9. Body 102, however, could be hollow and passage 104
could be in the form of a track interconnecting an inlet and an
outlet as shown in FIG. 10.
[0067] Passage 104 includes at least one track or chute 120. In one
embodiment, a plurality of passages 104, 104a . . . 104n define a
plurality of inlets 106, 106a . . . 106n and outlets 108, 108a . .
. 108n. Each of the plurality of passages 104, 104a . . . 104n
includes at least one track or chute 120 therein, and each passage
104, 104a . . . 104n includes a plurality of tracks or chutes 120,
120.sub.a . . . 120.sub.n, 120a.sub.a, 120a.sub.b . . . 120a.sub.n,
. . . 120n.sub.a, 120n.sub.b . . . 120n.sub.n. Such an embodiment
also includes a plurality of sealing portions 116, 116a . . . 116n,
FIG. 10. By adding length and additional passages, rotary barrel
gate valve 100 of this invention is scalable. This results in
decreased cost to add to system capacity, because adding length and
increasing the number of passages 104 to body 102 does not require
any significant changes to actuator 110 or 112.
[0068] In one embodiment, sealing portion 116, FIG. 10 which may be
anywhere on body 102, is O-ring 130 disposed in groove 132 formed
on surface 138 of body 102. In one preferred embodiment, body 102
will have passage 104 corresponding to sealing portion 116 such
that when body 102 is rotated as indicated by arrow 111, passage
104 and sealing portion 116 will alternately be aligned with an
opening into a chamber adjacent the body (not shown). In other
embodiments, O-ring 130 may instead be located about the opening
into an adjacent chamber (not shown). In either embodiment, the
O-ring pushes on and off the sealing surface, maximizing the life
of the surface of the O-ring.
[0069] When rotary barrel gate valve 100 is open, FIG. 11 inlet 106
in passage 104 of body 102 is aligned with opening 140 of chamber
12, allowing article 24, for example, to move from chamber 12 to
output load lock 16. Controller 300 may be included for
interlocking or sequencing each gate valve 100 with any other gate
valves in accordance with system 10 to detect full closure and to
allow for processing of a plurality of articles simultaneously in
one track. Thus, for instance, the risk of direct passing of
atmosphere into a processing chamber 12 is minimized should an
article become lodged in any gate valve. In such an event, system
10 halts and an error condition is reported. Also, sequencing of
multiple rotary barrel gate valves increases productivity.
[0070] Rotary barrel gate valve 100 is moved from closed, FIG. 12,
to open, FIG. 11, and vice versa, by actuators 110 and 112, FIG. 9.
When rotary barrel gate valve 100 is open as in FIG. 11, inlet 106
is aligned with opening 140 into chamber 12. Passage 104 now
provides access through rotary barrel gate valve 100 out of chamber
12. To close rotary barrel gate valve 100, actuator 110, FIG. 9
rotates body 102 in the direction of arrow 150, FIG. 11 to align
sealing portion 116 with opening 140. Now, passage 104, FIG. 12 is
not aligned with opening 140. Immediately thereafter, actuator 112,
FIG. 9 moves or translates sealing portion 116 in the direction of
arrow 152 and against opening 140. Then, to open rotary barrel gate
valve 100, actuator 112 moves sealing portion 116 in the direction
of arrow 154 and immediately thereafter actuator 110 rotates body
102 in the direction of arrow 156 to once again align inlet 106
with opening 140 into chamber 12.
[0071] When rotary barrel gate valve 100 is closed, FIG. 13 groove
132 is located in opposing flats 134, 136 formed on surface 138 of
body 102. In one embodiment, portion or nose piece 142 of body 102
projects between opposing flats 134, 136 and may have a curvature
to form article stopping surface or escapement 144 for stopping
article 24, for example, from output load lock 16 to atmosphere.
Conversely, when rotary barrel gate valve 100 is open, portion 142
of body 102 no longer forms article stopping surface 144. In one
embodiment of system 10, article stopping surface 144 formed by
portion 142 is used only in rotary barrel gate valve 20', FIG. 1,
with backs 60, 62, and 64 of rotary barrel gate valves 18, 18' and
20 serving to stop article 24. Whether by article stopping surface
144 or by backs 60, 62, 64, rotary barrel gate valves 18', 18, 20,
20' are structured and arranged to prevent article 24 from sliding
under the force of gravity when closed.
[0072] As described herein, a "chamber" could be an input load lock
or an output load lock or atmosphere, and the term "chamber" as
used herein is not necessarily limited to a processing chamber. For
example, in FIG. 12, rotary barrel gate valve 100 seals chamber 12,
e.g. a processing chamber, with respect to output load lock 16.
However, in another example, rotary barrel gate valve 18', FIG. 1
seals input load lock "chamber" 14 from atmosphere.
[0073] For use with rotary barrel gate valve 100 actuator 110, FIG.
14 may be a pneumatic rotary actuator or a cam rotary actuator. In
one embodiment, actuator 110 is a servo motor connected to body 102
for rotating body 102. Actuator 110 alternately rotates body 102 to
align sealing portion 116, FIGS. 12 and 13 with, for example,
opening 140 into chamber 12, and to align passage 104 with opening
140 into chamber 12. Actuator 112, FIG. 15 is typically a pneumatic
cylinder 200. When activated, pneumatic cylinder 200 of actuator
112 projects (or retracts) push pin 202 which causes body 102 to
pivot around pivot point 204 in the directions of arrow 206, thus
urging or translating body 102 approximately linearly, for example,
toward and away from chamber 12, as shown in FIGS. 12 and 13. In
this embodiment, body 102 moves approximately linearly but in a
very slight arc. Actuator 112 may utilize a lead screw or other
mechanical device for linear translation (not shown). The servo
motor and the short stroke of actuator 112 permit very fast gate
valve opening and closing times.
[0074] As noted, the number of chambers or modules of system 10 in
accordance with this invention may be increased or decreased and
articles other than plastic cutlery may be coated. Other types of
processing chambers may be used or added to the system. Also, other
types of load and unload locks may be used.
[0075] Although specific features of the invention are shown in
some drawings and not in others, this is for convenience only as
each feature may be combined with any or all of the other features
in accordance with the invention. The words "including",
"comprising", "having", and "with" as used herein are to be
interpreted broadly and comprehensively and are not limited to any
physical interconnection. Moreover, any embodiments disclosed in
the subject application are not to be taken as the only possible
embodiments.
[0076] Other embodiments will occur to those skilled in the art and
are within the following claims:
* * * * *