PRECISION POWDER COATING BATCH SYSTEM

Abstract

A multi-tiered precision powder coating batch system configured to enable simultaneous preparation of a first and second batch of powder coatings. The multi-tiered precision powder coating batch system including a plurality of storage bins configured to store a corresponding plurality of raw materials for preparation of batches of powder coatings, each of the storage bins including an automated dispenser configured to dispense a desired quantity of raw material within the storage bins into a corresponding first raw material container located on a first tier, and a second raw material container located on a second tier, and a robotic arm configured to sequence a transfer of the raw material contents of the first tier raw material containers into a first tier mixing container for preparation of a first batch of a powder coating, and to sequence a transfer of the raw material contents of the second tier raw material containers into a second tier mixing container for a simultaneous preparation of a second batch of a powder coating.

Claims

1-20. (canceled)

21-40. (canceled)

41. A method of producing batches of powder coating materials, the method comprising: dispensing a selected amount of a first raw material from a first storage bin into a first raw material container; dispensing a selected amount of a second raw material from a second storage bin into a second raw material container; transferring the first raw material from the first raw material container into a mixing container; and transferring the second raw material from the second raw material container into the mixing container; wherein the first raw material and the second raw material are transferred into the mixing container in a transfer sequence selected to promote production of a homogeneous mixture comprising the first raw material and the second raw material in the mixing container.

42. The method of claim 41, wherein the first raw material is transferred into the mixing container such that the first raw material comprises a layer of the first raw material having a substantially uniform thickness in the mixing container.

43. The method of claim 41, wherein the second raw material is transferred into the mixing container such that the second raw material comprises a layer of the second raw material in the form of a cone.

44. The method of claim 43, wherein a center of the layer of the second raw material in the form of a cone comprises a thickness greater than the thickness of the layer of the second raw material at an edge of the layer proximate a wall of the mixing container.

45. The method of claim 41, wherein the first raw material is transferred into the mixing container such that the first raw material comprises a layer of the first raw material having a substantially uniform thickness in the mixing container, and wherein the second raw material is transferred into the mixing container such that the second raw material comprises a layer of the second raw material in the form of a cone.

46. The method of claim 45, wherein a center of the layer of the second raw material in the form of a cone comprises a thickness greater than the thickness of the layer of the second raw material at an edge of the layer proximate a wall of the mixing container.

47. The method of claim 41, wherein the method comprises: dispensing a selected amount of a third raw material from a third storage bin into a third raw material container; transferring the third raw material from the third raw material container into a mixing container before transferring the first raw material and the second raw material to promote production of a homogeneous mixture comprising the first raw material, the second raw material, and the third raw material in the mixing container.

48. The method of claim 47, wherein the third raw material is transferred into the mixing container such that the third raw material comprises a layer of the third raw material having a flat surface.

49. The method of claim 48, wherein the first raw material is transferred into the mixing container after the third raw material, and wherein the first raw material comprises a layer of the first raw material on the flat surface of the layer of the third raw material, the layer of the first raw material having a substantially uniform thickness above the third raw material in the mixing container, and wherein the second raw material is transferred into the mixing container such that the second raw material comprises a layer of the second raw material in the form of a cone.

50. The method of claim 49, wherein a center of the layer of the second raw material in the form of a cone comprises a thickness greater than the thickness of the layer of the second raw material at an edge of the layer proximate a wall of the mixing container.

51. The method of claim 47, wherein the third raw material is transferred into the mixing container before the first raw material such that the first raw material comprises a layer of the first raw material on the third raw material, and wherein the second raw material is transferred into the mixing container after the first raw material such that the second raw material comprises a layer of the second raw material on the first raw material in the form of a cone comprising a center having a thickness greater than a thickness of the layer of the second raw material at an edge of the layer proximate a wall of the mixing container.

52. The method of claim 51, wherein the layer of first raw material comprises a layer of the first raw material having a substantially uniform thickness in the mixing container.

53. An automated precision powder coating batch system, comprising: a plurality of raw material containers; a plurality of storage bins configured to store a corresponding plurality of raw materials for preparation of a batch of powder coating, each storage bin of the plurality of storage bins including a dispenser configured to dispense the raw material within the storage bin; a robot configured to transfer raw material in the selected raw material container into a mixing container; and a central processor operably connected to each dispenser of the plurality of storage bins, the mass sensor, and the robot, wherein the central processor is configured to: receive instructions to initiate preparation of a batch of powder coating comprising two or more different raw materials of the plurality of raw materials; operate the dispensers to dispense a first desired quantity of the raw material in a first storage bin of the plurality of storage bins into a first raw material container of the plurality of raw material containers by measuring the weight of the first raw material container, and to dispense a second desired quantity of the raw material in a second storage bin of the plurality of storage bins into a second raw material container of the plurality of raw material containers by measuring the weight of the second raw material container; and operate the robot to transfer the raw material contents of first raw material container and the second raw material container to a mixing container.

54. The automated precision powder coating batch system of claim 53, wherein the central processor is configured to operate the robot to transfer the raw material contents of first raw material container and the second raw material to the mixing container in a transfer sequence selected to promote production of a homogeneous mixture comprising the raw materials from the first raw material container and the second raw material container.

55. The automated precision powder coating batch system of claim 53, wherein the central processor is configured to operate the robot to transfer the raw material contents of first raw material container and the second raw material to the mixing container in a transfer sequence selected to reduce mixing time needed to achieve a desired degree of homogeneity in a batch of powder coating comprising the raw materials from the first raw material container and the second raw material container.

56. The automated precision powder coating batch system of claim 53, wherein the first storage bin includes a low-level sensor configured to send a notification via a user interface when a quantity of raw material within the first storage bin falls below a defined threshold.

57. The automated precision powder coating batch system of claim 53, wherein the central processor is configured to operate the robot to transfer the raw material contents of first raw material container and the second raw material to the mixing container in a transfer sequence based on an expected dispensation time of each of the raw materials from the first storage bin and the second storage bin.

58. The automated precision powder coating batch system of claim 41, each raw material container of the plurality of raw material containers is specific to a selected storage bin of the plurality of storage bins to reduce contamination between batches of powder coatings.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The disclosure can be more completely understood in consideration of the following detailed description of various embodiments of the disclosure, in connection with the accompanying drawings, in which:

[0019] FIG. 1 is a diagram depicting a precision powder coating batch system configured to autonomously measure and sequence the transfer of desired quantities of raw material into a mixing container for the preparation of one or more batches of powder coating, in accordance with an embodiment of the disclosure.

[0020] FIG. 2 is a perspective view depicting storage bins of a precision powder coating batch system, in accordance with an embodiment of the disclosure.

[0021] FIG. 3 is a perspective view depicting a robotic arm of a precision powder coating batch system, in accordance with an embodiment of the disclosure.

[0022] FIG. 4 is a partial, cutaway view depicting layers of raw material within a mixing container of a precision powder coating batch system, in accordance with an embodiment of the disclosure.

[0023] FIG. 5 is a schematic view depicting scanning of a QR code to initiate a batch script for preparation of a batch of powder coating by a precision powder coating batch system, in accordance with an embodiment of the disclosure.

[0024] FIG. 6 is an architectural diagram depicting a mobile, automated precision powder coating batch system, in accordance with an embodiment of the disclosure.

[0025] FIG. 7 is an architectural diagram depicting a precision powder coating batch system having two banks of storage bins, in accordance with an embodiment of the disclosure.

[0026] FIG. 8 is an elevation diagram depicting a multi-tiered structure of the precision powder coating batch system of FIG. 7 taken along line A-A in FIG. 7.

[0027] While embodiments of the disclosure are amenable to various modifications and alternative forms, specifics thereof shown by way of example in the drawings will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

[0028] Referring to FIG. 1, a precision powder coating batch system 100 configured to simultaneously measure and autonomously sequence the transfer of desired quantities of raw material into a mixing container for the preparation of a batch of one or more batches of powder coating is depicted in accordance with an embodiment of the disclosure. In some embodiments, the precision powder coating batch system 100 can be configured to execute the batch preparation according to a defined batch script, which can be initiated by entering a batch script number into a user interface, scanning a batch script code, or the like. Accordingly, in some embodiments, the precision powder coating batch system 100 can be configured to automate the process of powder coating batch preparation from a variety of suppliers, including SHERWIN-WILLIAMS, PPG, AKZO NOBEL, BEHR, NIPPON PAINT, and CLARIENT, just to name a few. Moreover, the precision powder coating batch system 100 can be configured to simultaneously prepare multiple batches of powder coatings in a precise, repeatable manner, while isolating the precisely measured raw materials from one another until they are emptied into the mixing chamber in a specific order, thereby both reducing the amount of labor necessary to produce each batch, as well as improving quality control and reducing material usage losses.

[0029] In some embodiments, the precision powder coating batch system 100 can include a plurality of raw material storage bins 102 configured to store a quantity of raw ingredients for use in preparation of powder coatings, which can include resins, curing agents, pigments, additives, fillers, and the like. With additional reference to FIG. 2, a perspective view of a raw material storage bin 102 is depicted in accordance with an embodiment of the disclosure.

[0030] As depicted in FIG. 2, in some embodiments, the raw material storage bins 102 can be configured as a hopper having a funnel portion configured to naturally urge the raw materials therein towards an automated dispenser 104 under the force of gravity; although the use of other bin configurations, including both stationary and portable storage bins 102 is contemplated. In some embodiments, the automated dispenser 104 can be in the form of an automated rotary valve, volumetric screw feeder, vibratory or oscillating feeder, or the like, configured to dispense precise quantities of raw materials from the storage bin 102.

[0031] Each of the storage bins 102 can further include an inlet 106 configured to enable raw materials to be added to fill or replenish the storage bins 102 as needed. In some embodiments, the storage bins 102 can include a low-level sensor 108 configured to notify users when the quantity of raw material within a given storage bin 102 falls below a defined threshold.

[0032] Raw materials dispensed from the raw material storage bins 102 can be collected in a raw material container 110, which can be positioned on a load cell or other mass sensor 112. The sensors 112, which can be configured to monitor a weight of the raw material containers 110, can be in communication with the automated dispensers 104 to limit dispensation of raw materials from the storage bins 102 as an aid in ensuring that a desired quantity of raw material is dispensed into the raw material container 110. For example, in one embodiment, each of the mass sensors 112 can be configured to determine a tare weight of the raw material container 110 positioned on it. Thereafter, increases in weight, as detected by the mass sensor 112, can be associated with dispensed raw material.

[0033] In some embodiments, each of the raw material containers 110 can be specific to each raw material storage bin 102, such that only raw materials dispensed from a particular storage bin 102 contact the raw material container 110, thereby minimizing inadvertent contamination of powder coatings. In some embodiments, precise measurement of each of the raw materials of a batch of powder coating can be initiated by entering a batch script number into a user interface, scanning a code (e.g., QR code, barcode, etc.), or the like. Thereafter, the respective automated dispensers 104 of the raw material storage bins 102 can simultaneously begin dispensing precise quantities of each of the raw materials called for in the batch script.

[0034] With continued reference to FIG. 1, in some embodiments, a robotic arm 114 can be configured to autonomously sequence a transfer of the raw materials from the raw material containers 110 into a mixing container 116. With additional reference to FIG. 3, a perspective view of a robotic arm 114 is depicted in accordance with an embodiment of the disclosure. In some embodiments, the robotic arm 114 can include a pivotable base 118 configured to enable the robotic arm 114 to rotate relative to a horizontal plane. In some embodiments, the base 118 of the robotic arm 114 can be operably coupled to a rail system 120 configured to translate, shift or move the robotic arm 114 relative to the horizontal plane. The use of other robotic arm mobility mechanisms to translate, shift or move the robotic arm 114 relative to the horizontal plane, such as an automated guided vehicle, are also contemplated. In other embodiments, for example in compact or portable precision powder coating batch systems, the robotic arm 114 can be mounted to a stationary platform, such that the base 118 of the robotic arm 114 is fixed within the precision powder coating batch system 100.

[0035] In some embodiments, the robotic arm 114 can include a first member 122, second member 124, third member 126, and gripping portion 128. In one embodiment, a first pivot 130 configured to rotate the second member 124 relative to the first member 122 within a given plane, can be positioned between the first member 122 and the second member 124. In one embodiment, a second pivot 132 configured to rotate the third member 126 relative to the second member 124 within a given plane, can be positioned between the second member 124 and the third member 126. In one embodiment, a third pivot 134 configured to rotate the gripping portion 128 about a longitudinal axis relative to the third member 126, can be positioned between the third member 126 and the gripping portion 128. In some embodiments, the gripping portion 128 can be a clamp, suction device, or other mechanism configured to selectively grip the raw material containers 110.

[0036] Accordingly, in some embodiments, the robotic arm 114 can be configured to autonomously sequence a transfer of precise measured quantities of raw materials from the respective storage bins 102 to the mixing container 116. In some embodiments, the transfer sequence of raw materials can be based on an expected dispensation time of each of the raw materials from the storage bins 102, with the first raw material to be fully dispensed into a raw material container 110 transferred first, and the last raw material to be fully dispensed into a raw material container 110 transferred last. Accordingly, in some embodiments, the transfer sequence can be designed to minimize the overall amount of time necessary to complete the preparation of any given batch of powder coating.

[0037] In other embodiments, the transfer sequence can be completed according to a prescribed batch script, particularly where it has been found that adding the raw materials to the mixing container 116 is a specific order achieves a more desirable outcome (e.g., a more homogeneous mixture of the final powder coating, reduced mixing time to achieve the same results, etc.). Referring to FIG. 4, a mixing container 116 containing a sequenced layer of raw materials 136A-C according to a prescribed batch script is depicted in accordance with an embodiment of the disclosure. In some embodiments, the raw materials 136 can be dispensed into the mixing container 116 in a layer having a substantially uniform thickness (such as that of raw material 136B). In some embodiments, the raw materials 136 can be dispensed into the mixing container 116 in the form of a cone, wherein a center of the raw material distribution has a greater thickness than the edges (such as that of raw material 136C). Other distributions of raw materials 136, such as an inverted cone, distribution of raw material 136 into a particular area of the mixing container 116, and the like, are also contemplated. In some embodiments, the transfer sequence of raw materials 136 can be determined according to one or more statistical approaches (e.g. a design of experiment), as an aid in optimizing the final powder coating mixture.

[0038] With additional reference to FIG. 5, in some embodiments, the precision powder coating batch system 100 can be configured to initiate powder coating batch preparation by scanning a code 138 (e.g., QR code, barcode, etc.), which in some embodiments can be operably coupled to the mixing container 116. Other methods of initiating powder coating batch preparation, such as entering a batch script number into a user interface, or the like are also contemplated.

[0039] Accordingly, in some embodiments, the precision powder coating batch system 100 can include a central processor 140, database 142, optional scanner 144, and optional user interface 146. In some embodiments, one or more peripheral computing devices 148 can be configured to communicate with the central processor 140, through either a wired or wireless connection. For example, in some embodiments, the one or more peripheral computing devices 148 can be a mobile computing platform, such as a cellular telephone (as depicted in FIG. 5), tablet, laptop computer (as depicted in FIG. 1), or the like. Accordingly, in some embodiments, the one or more peripheral computing devices 148 can optionally serve as a user interface for configuration and manipulation of the precision powder coating batch system 100.

[0040] As depicted in FIG. 5, in some embodiments, the scanner 144 can be configured to scan a code 138 (e.g., QR code, barcode, etc.), thereby initiating the powder coating batch preparation procedure. For example, in some embodiments, a code 138 can be coupled to a cleaned mixing container 116, or a mixing container 116 designated for a particular powder coating mixture. Thereafter, the mixing container 116 can be positioned at a mixing station 150 (as depicted in FIG. 1), which in some embodiments can be configured to detect the presence of a mixing container 116. In some embodiments, upon detecting the presence of a mixing container 116, the scanner 144 can automatically scan the code 138, thereby initiating the powder coating batch preparation procedure. In other embodiments, the user can enter instructions into a user interface 146, 148, thereby initiating the powder coating batch preparation procedure.

[0041] Upon receipt of instructions to initiate the powder coating batch preparation procedure, the central processor 140/database 142 can look up the specific raw materials called for in the batch script and begin dispensing precise measured quantities of the raw materials into the respective raw material containers 110. For powder coating batch recipes calling for an unusual or not frequently used raw material or ingredient (e.g., not stored in one of the storage bins 102), the central processor 140 can be configured to prompt a user (e.g., via a user interface 146, 148) to manually add the desired quantity of raw material to the mixing container 116.

[0042] With continued reference to FIG. 1, once all of the raw materials have been added to the mixing container 116A, the raw materials can be mixed according to the batch script. In some embodiments, mixing of the raw materials can take place at the mixing station 150. Thereafter, the mixing container 116A can be transported to an extruder (not depicted) for further processing. In some embodiments, while the mixing of raw materials within a first mixing container 116A is occurring, the precision powder coating batch system 100 can be configured to scan a code 138 (depicted in FIG. 5) on a second mixing container 116B, thereby initiating a subsequent powder coating batch preparation procedure. Accordingly, in some embodiments, the precision powder coating batch system 100 can be configured to begin dispensing the raw materials for a second batch of powder coating, while a first batch of a powder coating is being mixed.

[0043] To facilitate transfer of mixing containers 116A-B to and from the mixing station 150, in some embodiments, the precision powder coating batch system 100 can include a conveyor assembly 152 configured to transport the mixing containers 116 from a loading station 154, through the mixing station 150, and onto a delivery station 156 for further processing. In some embodiments, the conveyor assembly 152 can be configured to direct the mixing containers 116A-B to a plurality of extruders (not depicted), thereby enabling simultaneous processing of multiple batches of powder coating. In smaller, more compact, and potentially systems 100 (such as that depicted in FIG. 6), the precision powder coating batch system 100 need not include a conveyor assembly 152. Rather, the mixing containers 116 can be manually positioned on the mixing station 150.

[0044] In some embodiments, the precision powder coating batch system 100 can be horizontally scalable to include a greater or lesser number of storage bins 102. For example, as depicted in FIG. 6, in one embodiment, the precision powder coating batch system 100 can be configured to fit within the confines of a standard sized shipping container 158 for ease in transport. Accordingly, in some embodiments, the precision powder coating batch system 100 can have an architectural footprint measuring less than about 8 feet wide by about 40 feet long; other architectural footprint dimensions are also contemplated. In such embodiments, the self-contained, mobile precision powder coating batch system 100 can be wheeled into and out of a standard sized shipping container 158, for example with the aid of a forklift, thereby enabling easy in deployment of such systems 100 to a variety of locations.

[0045] With reference to FIG. 7, in other embodiments, the precision powder coating batch system 100 can be configured as a large industrial application, with two or more banks 160A/B of storage bins 102. In some embodiments, the precision powder coating batch system 100 can include two banks 160A/B, which are mirror images of one another, thereby enabling the simultaneous preparation of at least two batches of powder coating. In other embodiments, the banks 160A/B can complement each other to include a more complete stock of raw materials. Accordingly, in some embodiments, raw materials from multiple banks 160 of storage bins 102 can be delivered to the mixing container 116 in the preparation of a single batch of powder coating.

[0046] In some embodiments, one or more dust collectors 162 can be configured to collect airborne particulate matter within the banks 160A/B or in proximity to the outlets 104 of the storage bins 102, thereby promoting housekeeping improvement within the precision powder coating batch system 100 as a further aid in reducing the likelihood of contamination of any given batch of powder coating being prepared. In some embodiments, a variety of environmental factors (e.g., temperature, humidity, etc.) can be controlled within each bank 160A/B of storage bins 102, thereby inhibiting caking of the raw materials, and ensuring desirable flow dispensing characteristics and accuracy in determined weights of the dispensed raw materials.

[0047] With additional reference to FIG. 8, in some embodiments, the precision powder coating batch system 100 can be vertically scalable as a multi-tiered system. For example, in one embodiment, the precision powder coating batch system 100 can include a first tier 164A and a second tier 164B; although the inclusion of additional tiers is also contemplated. In some embodiments, the first tier 164A can be configured to measure and sequence the transfer of desired quantities of raw material for the preparation of a first batch of powder coating, while a second tier 164B simultaneously measures and sequences the transfer of desired quantities of raw material for the preparation of a second batch of powder coating. Accordingly, in some embodiments, the precision powder coating batch system 100 is configured to simultaneously prepare multiple (potentially different) batches of powder coatings from a single bank 160 of storage bins 102, and within a given architectural footprint. In some embodiments, one tier 164A can be adapted to prepare small batches of powder coatings (e.g., less than about 50 pounds) using first tier storage bins 102A dispensing raw material into first tier raw material containers 110A, while the second tier 164B can be adapted to prepare larger batches of powder coatings (e.g., about 50 pounds or greater) using second tier storage bins 102B dispensing raw material into second tier raw material containers 110B.

[0048] In one or more embodiments, the storage bins 102A and raw material containers 110A on the first (lower) tier 164A may be located directly below the storage bins 102B and raw material containers 110B as seen in, e.g., FIGS. 7-8 (although that is not required). Also, although the larger storage bins 102B and raw material containers 110B are located above the smaller storage bins 102A and raw material containers 110A in the embodiment depicted in FIG. 8, one or more alternative embodiments may provide the larger storage bins and raw material containers on the lower tier 164A and smaller storage bins and raw material containers on the upper tier 164B. In one or more other alternative embodiments, the storage bins 102A on the first tier 164A and the storage bins 102B on the second tier 164B may have the same size (regardless of the size of the raw material containers into which the storage bins dispense raw material). In one or more other alternative embodiments, the raw material containers 110A on the first tier 164A and the raw material containers 110B on the second tier 164B may have the same size (regardless of the size of the storage bins dispensing raw material into the raw material containers).

[0049] Accordingly, in some embodiments, the use of a multi-tiered precision powder coating batch system 100 can be configured to promote a more economic preparation of smaller quantities of powder coatings, with lower labor requirements and fewer quality control issues.

[0050] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0051] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0052] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0053] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0054] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. ? 112(f) are not to be invoked unless the specific terms means for or step for are recited in a claim.