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.

1 . A method for the bulk painting of components includes the steps of: 
 forming a bulk coating paint process unit including a substantially fluid-tight process tank for holding paint, a transfer system comprising a conveyor having replaceable, non-insulated segmented media for conveying the components through the process tank, and electrodes and a support structure for substantially supporting said tank, system and electrodes, said electrodes including at least one electrode contact disposed below said conveyer such that at least some of said segmented media are in contact with said electrode contact at all times as said segmented media pass thereover;    placing a quantity of conductive paint into said process tank;    electrically charging said conductive paint with said at least one electrode contact disposed below said conveyer;    surface treating a selected plurality of unpainted components to be painted, said plurality of unpainted components being selected from the group consisting of like parts and different parts, said unpainted components being selected from the group consisting of an electrically conductive component or a component having an electrically conductive surface;    placing said selected plurality of unpainted components randomly on said segmented conveyor in a single layer or in plural layers;    conducting said conveyor with said carried unpainted components into said process tank and through said quantity of conductive paint;    sliding at least some of said segmented media along said electrode contact;    subjecting said unpainted components to said electrically-charged conductive paint while in said process tank so that said conductive paint is coated on said components through a process of electrodeposition;    conducting said conveyor with the carried painted components out of said process tank;    unloading said now-painted components from said conveyor; and    brushing at least a portion of the top surface of said segmented conveyor to remove residual uncured paint.    
     
     
         2 . The method for the bulk painting of components according to  claim 1 , wherein the bulk painting of said components is done in a substantially continuous manner.  
     
     
         3 . The method for the bulk painting of components according to  claim 1 , wherein said placement of said quantity of components on said segmented conveyor is done in a single layer.  
     
     
         4 . The method of the bulk painting of components according to  claim 1 , wherein the segmenting of said segmented conveyor allows said components to be placed in lots on each of said segments for lot grouping.  
     
     
         5 . The method of the bulk painting of components according to  claim 1 , wherein said electrodes include an upper set of electrodes in addition to said electrode contact, each of said upper set of electrodes and said electrode contact being represented by a plurality of individual adjacent sections, such that each section of said plurality of individual sections is given a charge that is different from an adjacent section for adjusting the paint coating.  
     
     
         6 . The method of the bulk painting of components according to  claim 1 , wherein said bulk coating paint process unit further includes a spray assembly for spraying a cleaning solution on said segmented conveyor in a substantially continuous manner for improving electrical conductivity between said segmented conveyor and said components.  
     
     
         7 . The method of the bulk painting of components according to  claim 1 , wherein said transfer system further includes a conveyor chain assembly, said segmented conveyor being attached to said conveyor chain assembly.  
     
     
         8 . The method of the bulk painting of components according to  claim 7 , wherein said bulk coating paint process unit further includes a pan having a quantity of permeate provided therein, said segmented conveyor and said conveyor chain assembly being passed through said permeate in said pan for cleaning.  
     
     
         9 . The method of the bulk painting of components according to  claim 7 , wherein said bulk coating paint process unit further includes a plurality of conveyor isolating connectors connecting said conveyor chain assembly and said segmented conveyor for isolating said conveyor chain assembly from said segmented conveyor such that the material from which said conveyor segments is composed is broadly varied.  
     
     
         10 . The method of the bulk painting of components according to  claim 7 , wherein said conveyor chain assembly forms a structural foundation, said conveyor segments being attached to said structural foundation, thereby directing the drive forces to and through the conveyor chain assembly, thus relieving tension from said conveyor segments.  
     
     
         11 . The method of the bulk painting of components according to  claim 1 , wherein electrical contact between said segmented conveyor and at least some of said electrodes is made while said segmented conveyor is submerged in said conductive paint.  
     
     
         12 . The method of the bulk painting of components according to  claim 1 , wherein said bulk coating paint process unit is either an anodic or a cathodic arrangement.  
     
     
         13 . The method of the bulk painting of components according to  claim 1 , wherein transfer system comprises a plurality of side-by-side transfer systems that share said fluid-tight process tank.  
     
     
         14 . The method of the bulk painting of components according to  claim 1 , wherein said transfer system comprises a plurality of substantially independent transfer system segments that are aligned to operate as a single conveyor system.