# US 12,214,377 B2 · Conformal coating process with thickness control

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- Number: US 12,214,377 B2
- Document ID: US12214377B2
- Status: Granted
- Kind: B2
- Application number: 17/497,318
- Filed: 2021-10-08
- Published: 2022-06-02
- Granted: 2025-02-04
- Earliest claimed: 2020-12-02
- Assignees: Precision Valve & Automation, Inc.
- Applicants: Precision Valve & Automation, Inc.
- Inventors: Jason Schoen; Jonathan Neal Urquhart; Frank Hart
- Web page: https://patentgrep.com/patent/US12214377B2

## CPC

- B05D 1/02: performed by spraying
- B05B 12/084: {responsive to condition of liquid or other fluent material already sprayed on the target, e.g. coating thickness, weight or pattern}
- B05D 1/00: Processes for applying liquids or other fluent materials (B05D5/00, B05D7/00 take precedence)
- G05B 19/042: using digital processors (G05B19/05 takes precedence)
- G01B 11/0683: {measurement during deposition or removal of the layer}
- G05B 2219/45013: Spraying, coating, painting
- G05B 2219/45065: Sealing, painting robot
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- G01B: MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS

## Abstract

A method for controlling a dispensing system is provided, including the steps of dispensing, by a dispensing device, a coating material onto a substrate according to a first dispensing operation, inspecting, by an inspection device integrated with the dispensing device, the coating material applied to the first substrate, and altering the first dispensing operation based on the inspecting so that the coating material is dispensed onto a subsequent substrate according to a second dispensing operation. An associated coating machine is also provided.

## Claims

### Claim 1

A method for controlling a dispensing system comprising:
first dispensing, by a dispensing device, a coating material onto a first substrate of a sequence of substrates according to a first dispensing operation;
first inspecting, by an inspection device physically attached to the dispensing device, the coating material applied to the first substrate, wherein movement of the dispensing device results in movement of the inspection device, wherein the first inspecting includes measuring a thickness of the coating material and comparing the thickness to a preset tolerance surrounding a desired thickness of coating material;
altering the first dispensing operation based on determining that the thickness exceeds the preset tolerance so that the coating material is dispensed onto a second substrate according to a second dispensing operation, wherein the second substrate immediately follows the first substrate in the sequence;
ejecting the first substrate from the dispensing system;
second dispensing the coating material on the second substrate according to the second dispensing operation;
second inspecting, by the inspection device, the coating material applied to the second substrate, wherein the second inspecting includes measuring a thickness of the coating material applied to the second substrate and comparing the thickness to the preset tolerance; and
altering the second dispensing operation if the thickness of the coating material applied to the second substrate exceeds the preset tolerance so that the coating material is dispensed onto a third substrate according to a third dispensing operation, wherein the third substrate immediately follows the second substrate in the sequence, or dispensing the coating material on the third substrate according to the second dispensing operation;
wherein the first dispensing operation, the second dispensing operation, and the third dispensing operations are different from each other.

### Claim 2 (depends on 1)

The method of claim 1, wherein the first dispensing operation includes dispensing the coating material at a first flow rate, and the second dispensing operation includes dispensing the coating material at a second flow rate which is different than the first flow rate.

### Claim 3 (depends on 1)

The method of claim 1, wherein the first inspecting and the second inspecting includes detecting a placement of the coating material in one or more target areas of the substrate.

### Claim 4 (depends on 1)

The method of claim 1, wherein altering the first dispensing operation includes adjusting at least one parameter of the dispensing device.

### Claim 5 (depends on 1)

The method of claim 1, wherein the at least one parameter of the dispensing device includes a pump speed, a fluid pressure, an orifice opening, a valve stroke, a travel speed, and a coating position.

### Claim 6 (depends on 1)

The method of claim 1, wherein the first inspecting occurs prior to the first substrate exiting the dispensing system, and the second inspecting occurs after the first substrate exits the dispensing system and before the second substrate exits the dispensing system.

### Claim 7 (depends on 1)

The method of claim 1, wherein the first inspecting occurs while the first substate is in a same position within the dispensing system, after the first dispensing.

### Claim 8 (depends on 1)

The method of claim 1, wherein the inspection device and the dispensing device are both located within a same housing of the dispensing system.

### Claim 9

A method for controlling a dispensing system comprising:
dispensing a coating material onto a first substrate received by the dispensing system;
measuring a thickness of the coating material applied to the first substrate with a sensor physically attached to a dispensing device within the dispensing system, wherein movement of the dispensing device results in movement of the inspection device;
determining an error in the thickness of the coating material, wherein determining the error includes comparing the thickness measured by the sensor to a preset tolerance and determining that the thickness measured by the sensor exceeds a preset tolerance surrounding a desired thickness of coating material;
adjusting at least one parameter of the dispensing system to correct the error;
performing a corrective action, in response to the adjusting;
ejecting the first substrate to receive a second substrate in a sequence of substrates, and in response to the ejecting, dispensing the coating material onto the second substrate and measuring a thickness of the coating material applied to the second substrate;
wherein, for each substrate of the sequence of substrates to enter the dispensing system, a measuring step is performed to determine whether an adjustment to the at least one parameter is required, until a last substrate in the sequence.

### Claim 10 (depends on 9)

The method of claim 9, wherein the corrective action includes dispensing additional coating material onto the first substrate.