ZHANG, Jun (Cal-comp Technology Pte Ltd, 32 Marsiling Lane, Singapore 1, 73915, SG)
LI, Yan Ling (Cal-comp Technology Pte Ltd, 32 Marsiling Lane, Singapore 1, 73915, SG)
CHAN, Say Leong (Cal-comp Technology Pte Ltd, 32 Marsiling Lane, Singapore 1, 73915, SG)
ZHANG, Jun (Cal-comp Technology Pte Ltd, 32 Marsiling Lane, Singapore 1, 73915, SG)
LI, Yan Ling (Cal-comp Technology Pte Ltd, 32 Marsiling Lane, Singapore 1, 73915, SG)
| Claims A dipping apparatus for dipping components into a liquid, the dipping apparatus comprising: an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θ0) offset from a horizontal plane; and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9L) offset from the horizontal plane; wherein the upper and lower frame angles (6o,9L) of said support frames are configured to orient said components such that any excess, liquid on the components drips from a single point. A dipping apparatus as claimed in claim 1, wherein the upper and lower support frames are configured such that any excess liquid on the dipping apparatus drips from distinct single points. A dipping apparatus as claimed in claims 1 or 2, wherein the ends of the upper and lower support frames are respectively connected to a pair of side panels. A dipping apparatus as claimed in any of claims 1 to 3, wherein the upper frame angle (θυ) is different from the lower frame angle (9L) . 5. A dipping apparatus as claimed in any of claims 1 to 4, wherein the upper frame angle (θ0) is less than the lower frame angle (9L) . 6. A dipping apparatus as claimed in any of claims 1 to 5, wherein the upper frame angle (θ0) is more than 0° to less than 90°. 7. A dipping apparatus as claimed in claim 6, wherein (θυ) is about 5°. 8. A dipping apparatus as claimed in any of claims 1 to 7, wherein the lower frame angle (9L) is more than 0° to less than 90°. 9. A dipping apparatus as claimed in claim 8, wherein (9L) is about 10°. 10. A dipping apparatus as claimed in claim 3, wherein the lower frame comprises: a pair of arms respectively coupled to said side panels and below the upper frame, wherein both arms are inclined at an arm angle (ΘΑ) offset from a horizontal plane. 11. A dipping apparatus as claimed in claim 10, wherein the arms are inclined in opposite directions from each other. 12. A dipping apparatus as claimed in claim 10, wherein the inclined arms are positioned at different vertical heights with reference to a horizontal plane. · 13. A dipping apparatus as claimed in any of claims 10 to 12, wherein the lower frame further comprises a plurality of cross-beams connecting the pair of arms throughout the length of the arms. 14. A dipping apparatus as claimed in claim 13, wherein the cross-beams are disposed at cross-beam angles (9C) offset from a horizontal plane. A dipping apparatus as claimed in claim 14, wherein the cross-beam angle (9C) of each cross beam varies along the length of the pair of arms. A dipping apparatus as claimed in claim 15, wherein, the pair of arms and the cross-beams form a non-planar surface. A dipping apparatus as claimed in any of claims 1 to 16, wherein the upper and lower support frames are coated with a low friction coating. A dipping apparatus as claimed in claim 17, wherein the low friction coating is a nanoparticle coating . A dipping apparatus as claimed in any of claims 1 to 18, wherein the dipping apparatus is a dip coating apparatus for coating hard disk components . A dipping apparatus as claimed in any of claims 1 to 18, wherein the dipping apparatus is a dip washing apparatus for washing coated hard disk components. A dipping apparatus as claimed in any of claims 1 to 20, further comprising a hopper for containing a coating liquid therein, and being disposed relative to the upper and lower support frames for allowing said frames to dip into said coating liquid. A dipping apparatus as claimed in any of claims 1 to 20, further comprising a hopper for containing a washing liquid therein, and being disposed relative to the upper and lower support frames for allowing said frames to dip into said washing liquid. A system for coating components with coating liquid, the system comprising: a coating bath containing coating liquid for coating components; a dip coating apparatus for containing said components comprising an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θυ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9L) offset from the horizontal plane, and wherein said dip coating apparatus is disposed at a position above said coating bath; movement means configured to move said dip coating apparatus into and out of said coating bath to be coated with said coating liquid; and wherein upon said movement out of said dip coating apparatus, said upper frame angle (θσ) and said lower frame angle (θυ) are configured to allow any excess coating liquid on the components to drip from a single point. A system as claimed in claim 23, wherein upon said movement out of said dip coating apparatus, said upper frame angle (9D) and said lower frame angle (θ0) are configured to allow any excess coating liquid on the dip coating apparatus to drip from distinct single points. A system as claimed in claim 23 wherein said components are hard disk components. A system as claimed in any of claims 23 to 25, wherein the ends of the upper and lower support frames of said dip coating apparatus are respectively connected to a pair of side panels. A system as claimed in claim "26, wherein said pair of side panels further comprise at least one pair of coupling means for coupling said dip coating apparatus to said movement means. A system as claimed in any of claims 23 to 27, further comprising a means for applying a jet of gas towards part of the coated components to at least partly remove coating therefrom. A system for washing coated components with washing liquid, the system comprising: a washing bath containing washing liquid for washing coated components; a dip washing apparatus for containing said coated components comprising an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θο) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9L) offset from the horizontal plane, and wherein said dip washing apparatus is disposed at a position above said washing bath; movement means configured to move said dip washing apparatus into and out of said washing bath to be washed with said washing liquid; and wherein upon said movement out of said dip washing apparatus, said upper frame angle (θ0) and said lower frame angle (θυ) are configured to allow any excess washing liquid on the components to drip from a single point. A system as claimed in claim 29, wherein upon said movement out of said dip washing apparatus, said upper frame angle (θ0) and said lower frame angle (θο) are configured to allow any excess washing liquid on the dip washing apparatus to drip from distinct single points. |
Technical Field
The present invention generally relates to a dipping apparatus for dipping components into a liquid. The present invention also relates to a dip coating apparatus for the application of a coating to hard disk components with exposed surfaces. Background
Thin film coatings with precise uniformity and zero particle contamination are crucial precursors affecting the life-span and operation of hard disk drive components. As such, a number of different techniques for coating hard disk drive components have been developed in an attempt to discover an effective coating process. One coating technique for hard disk drive components is a thin film deposition technique, which involves the immersing of hard disk drive components into a tank containing coating material, removing the component from the tank, and allowing it to drain. The coated component can then be washed, rinsed and dried by force-drying or baking.
The hard disk components to be coated are usually loaded onto a dip coating apparatus, which is then immersed in a curable . coating bath. After the hard disk components are coated, the dip coating apparatus loaded with the hard disk components is removed from the curable coating bath. In a conventional dip coating process, the excess coating on the hard disk component is allowed to drip from any point. This not only creates a non-uniform coating, but accumulation and coagulation of the coating may occur, resulting in lumps on the coating. Furthermore, conventional dip coating processes are limited by improper control of the withdrawal speed and method. The drag force on the coated hard disk component is not uniform across the surface of the hard disk component, which inadvertently affects the uniformity of the film. . Due to the uneven drag force, the film thicknesses at the edge and corners of the hard disk components are normally larger than that the centre of the hard disk components. Thus, even though conventional dip coating processes are more efficient than spray coating, many people find that dip coating processes are not practical, due to the excess and uneven coating of the hard disk components.
Another disadvantage is that upon removal from the coating bath, the excess coating present on the dip coating apparatus is allowed to drip from any point on the dip coating apparatus. This often results in the formation of drip marks throughout the dip coating apparatus. Formation of drip marks on the coating apparatus is undesirable because it results in higher costs in maintaining the dip coating apparatus. Furthermore, when the coating material dries and hardens, it can be very difficult to remove the coating from the dip coating apparatus. The dried and hardened coating is usually only removable by surface treatment, which is relatively costly and time consuming. On the other hand, if the coating material is allowed to accumulate on the coating apparatus, it will eventually become unsuitable for use in the coating process and will have to be replaced. As such, conventional dip coating apparatuses usually have a very short lifespan.
Before the hard disk drive components have been coated, they are usually immersed in a water bath to remove any oil, dirt or other particles present on the hard disk components. In addition, the hard disk drive components are also immersed in a water bath after they have been coated. Similarly, upon removal from the water bath, the excess water present on the apparatus is allowed to drip from any point on the apparatus. If the same apparatus is to be used for a subsequent dip coating process, all the excess water on the apparatus must first be dried off to prevent any possible contamination of the coating liquid in the coating bath. However, since the excess water is allowed to drip from any point, the time taken to dry the apparatus can be relatively long.
Given the disadvantages of using a conventional dip coating apparatus in a dip coating process, there is a need to provide a coating apparatus that overcomes or at least ameliorates one or more of the disadvantages described above.
Summary of invention
According to a first aspect, there is provided a dipping apparatus for dipping components into a liquid, the dipping apparatus comprising:
an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θυ) offset from a horizontal plane; and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane;
wherein the upper and lower frame angles (9 0 ,9 L ) of said support frames are configured to orient said component such that any excess liquid on the components drips from a single point.
In one embodiment, there is disclosed a dip coating apparatus for coating hard disk components with coating liquid, the dip coating apparatus comprising:
an upper support frame configured to support an upper part of said hard disk components and being disposed at an upper frame angle (θυ) offset from a horizontal plane; and
a lower support frame disposed below the upper support frame and configured to support a lower part of said hard disk components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane;
wherein the upper and lower frame angles (9 U( 9 L ) of said support frames are configured to orient said hard disk components such that any excess coating liquid on the hard disk components drips from a single point.
Advantageously, a uniform coating can be obtained by adjusting the orientation of the component to allow excess coating to drip therefrom and produce a relatively thin film coating. More advantageously, the excess coating liquid drips from a single point, ensuring that the coating will be uniform through the edges, corners and crevices of the hard disk component. Advantageously, the orientation of the upper and lower support frame allows residual coating material present of the coating apparatus to be removed from distinct points on the coating apparatus. This ensures that minimal drip marks form on the coating apparatus, and also ensures that no coagulation of the coating material occurs. Even more advantageously, the excess coating material can be recycled for further use, thus reducing material cost.
In a second aspect, there is provided a system for coating components with coating liquid, the system comprising:
a coating bath containing coating liquid for coating components;
a dip coating apparatus for containing said components comprising an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θυ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, and wherein said dip coating apparatus is disposed at a position above said coating bath;
movement means configured to move said dip coating apparatus into and out of said coating bath to be coated with said coating liquid;
and wherein upon said removal of said dip coating apparatus, said upper frame angle (θ 0 ) and said lower frame angle (9 D ) are configured to allow any excess coating liquid on the components to drip from a single point.
In one embodiment, there is disclosed a system for coating hard disk components with coating liquid, the system comprising:
a coating bath containing coating liquid for coating hard disk components ;
a dip coating apparatus for containing said hard disk components comprising an upper support frame configured to support an upper part of said hard disk components and being disposed at an upper frame angle (θυ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of said hard disk components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, and wherein said dip coating apparatus is disposed at a position above said coating bath;
movement means configured to move said dip coating apparatus into and out of said coating bath to be coated with said coating liquid;
and wherein upon said removal of said dip coating apparatus, said upper frame angle (θ υ ) and said lower frame angle (θυ) are configured to allow any excess coating liquid on the hard disk components to drip from a single point.
Advantageously, the system disclosed herein produces coated hard disk components with substantially uniform thickness profiles. More advantageously, the absence of coagulated lumps on the coated component surfaces allows the components to undergo rapid drying, thereby shortening the overall process time.
In a third aspect, there is provided a system for washing coated components with washing liquid, the system comprising:
a washing bath containing washing liquid for washing coated components;
a dip washing apparatus for containing said components comprising an upper support frame configured to support an upper part of said components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of said components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, and wherein said dip washing apparatus is disposed at a position above said washing bath;
movement means configured to move said dip washing apparatus into and out of said washing bath to be washed with said washing liquid;
and wherein upon said movement out of said dip washing apparatus, said upper frame angle (θ 0 ) and said lower frame angle (θ 0 ) are configured to allow any excess washing liquid on the components to drip from a single point.
Definitions
The following words and terms used herein shall have the meaning indicated:
Unless specified otherwise, the terms "comprising" and "comprise", and grammatical variants thereof, are 00146 intended to represent "open" or "inclusive" language such that they include recited elements but also permit inclusion of additional, unrecited elements.
As " used herein, the term "about", typically means +/- 5% of the stated value, more typically +/- 4% of the stated value, more typically +/- 3% of the stated value, more typically, +/- 2% of the stated value, even more typically +/- 1% of the stated value, and even more typically +/- 0.5% of the stated value.
Throughout this disclosure, certain embodiments may be disclosed in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosed ranges. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 · etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
Disclosure of Optional Embodiments
Exemplary, non-limiting embodiments of a dip coating apparatus will now be disclosed.
In one embodiment, there is disclosed a dipping apparatus for dipping components into a liquid. The dipping apparatus comprises an upper support frame configured to support an upper part of the components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane, a lower support frame disposed below the upper support frame and configured to support a lower part of the components, the lower support frame being disposed at a lower frame angle (6 L ) offset from the horizontal plane, wherein the upper and lower frame angles (θ α , 9 L ) of the support frames are configured to orient the components such that any excess liquid on the components drips from a single point. Advantageously, there is minimal wastage of the liquid.
The upper and lower support frames are also configured such that any excess liquid on the dipping apparatus drips from distinct single points. Advantageously, this minimizes, or even eliminates the formation of drip marks on the dipping apparatus and allows for recycling of the excess liquid.
The components may be any suitable components for dip coating or dip washing. Exemplary components include hard disk components, vehicle parts and components, household tools and appliances, outdoor furniture and fitness equipment.
In one embodiment, there is disclosed a dip coating apparatus for coating hard disk components with coating liquid. The dip coating apparatus comprises an upper support frame configured to support an upper part of the hard disk components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane, a lower support frame disposed below the upper support frame and configured to support a lower part of the hard disk components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, wherein the upper and lower frame angles (θυ,e L ) of the support frames are configured to orient the hard disk components such that any excess coating liquid on the hard disk components drips from a single point.
The upper and lower support frame may be manufactured from any suitable material and may have any suitable dimensions and shape. Exemplary materials include stainless steel, plastic, copper, aluminum, aluminum alloy and titanium. The upper support frame may further comprise a plurality of hooks or any other suitable means for supporting an upper part of the hard disk components or any other components. The plurality of hooks or any other suitable securing means may also serve to secure an upper part of the hard disk components to the upper support frame.
In one embodiment, the ends of the upper and lower support frames are respectively connected to a pair of side panels. The side panels may be of any suitable dimension and shape. In one embodiment, the side panels are arched to reduce the cost of material. The side panels may further comprise suitable handles and notches. Advantageously, the side panels may assist in the removal and movement of the coating apparatus from the coating bath. The edges of the side panels may also be inclined with respect to the horizontal plane, so as to allow any liquid, such as the coating liquid, to easily flow therefrom.
The hard disk components may be dipped into a curable coating bath. The curable coating bath may be a thermal or ultraviolet (UV) curable coating bath. The thermal or UV curable coating bath may be a sol-gel composition comprising silane-based compounds such as a tetraalkoxysilane, for example, tetraethoxysilane; an alkylsilane, for example,, tetraethyl orthosilane; or an alkylalkoxysilane, for example, dimethyldiethoxysilane or methyltrimethoxysilane .
The curable coating bath may further comprise a pH adjusting compound such as an acid or an alkali to adjust the pH of the curable coating bath as appropriate. The silane-based compounds may be provided in an alcoholic solvent such as ethanol, propanol, isopropanol, butanol or pentanol; or may be provided in an aqueous medium. The curable coating bath may comprise a resin material to form a matrix.
The curable coating bath may comprise additives that confer a selected property to the coating. Exemplary types of additives that may be added include hardening agents such as zinc particles and stabilizing agents such as polyvinylpyrrolidone.
In one embodiment, the upper frame angle (9 0 ) is different from the lower frame angle (9 L ) . The upper frame angle (9 0 ) may be selected from the group consisting of more than about 0° to less than about 90°, more than about 1° to less than about 70°, more than about 2° to less than about 50°, more than about 3° to less than about 30° and more than about 4° to less than about 10°. In one embodiment, the upper frame angle (9u) is about 5°. The lower frame angle (9 L ) may be selected from the group consisting of more than about 0° to less than about 90°, more than about 1° to less than about 75°, more than about 2° to less than about 60°, more than about 3° to less than about 45°, more than about 4° to less than about 30° and more than about 5° to less than about 15°. In one embodiment, the lower frame angle (9 L ) is about 10°.
If the lower frame angle (9 L ) and the upper frame angle (θ α ) are too large, the resulting size of the dipping apparatus may be too large. However, if the lower frame angle (9 L ) and the upper frame angle (θυ) are too small, the liquid may take a longer time to flow off the dipping apparatus. Thus, the optimum upper and lower frame angles (θ 0 ) and (6 L ) may be selected based on the desired length and width of the dipping apparatus.
In one embodiment, the lower frame of the dipping apparatus comprises a pair of arms respectively coupled to the side panels and below the upper frame, wherein both arms are inclined at an arm angle (Θ Α ) offset from a horizontal plane.
The arm angle (Θ Α ) may be selected from the group consisting of more than about 0° to less than about 90°, more than about 1° to less than about 70°, more than about 2° to less than about 50°, more than about 3° to less than about 30° and more than about 4° to less than about 10°. In one embodiment, the arm angle (Θ Α ) is about 10° .
The arms of the dipping apparatus may be inclined in the same direction, or inclined in opposite directions from each other. The inclined arms may also be positioned at different vertical heights with reference to a horizontal plane. The arms have a uniform cross section throughout their length. In one embodiment, the arms are longitudinal rods. The pair of arms may further comprise a plurality of cross-beams connecting the pair of arms throughout the length of the arms. In one embodiment, the cross-beams are in the form of rungs. The cross-beams may also be inclined at an angle relative to the horizontal plane. Advantageously, the cross-beams are orientated such that any residual coating liquid present on the cross-beams upon removal from the coating bath, drips from a single point of the cross-beams. In this way drip marks do not form throughout the length of the cross-beams, reducing the maintenance cost of the coating apparatus. The crossbeams are advantageously resiliently flexible to conform with the shape of the hard disk drive components being supported thereon. In one embodiment, the pair of arms and the cross beams form a non-planar surface.
In one embodiment, the cross-beams of the dip coating apparatus are disposed at cross-beam angles (9 C ) offset from a horizontal plane. The cross-beam angles (9 C ) may be selected from the group consisting of more than about 0° to about 45°, about 5° to about 40°, about 10° to about 35, and about 15° to about 25°. In one embodiment, the cross-beam angle (9 C ) is about 20°. The cross beam angles (9 C ) may also vary along the length of the pair of arms.
The upper and lower support frames may be coated with a low friction coating. Exemplary low friction coatings include fluoropolymer compositions, silicone compositions, epoxy compositions or a nanoparticle coating .
In one embodiment, the upper and lower support frames are coated with a nanoparticle coating. Advantageously, the nanoparticle coating serves to ensure that there is no metal to metal contact between the coating apparatus and the hard disk components. Metal to metal contact between the hard disk components and the support frame is undesirable because metal particle will be generated, which will cause contamination to the coating.
In one embodiment, the dipping apparatus is a dip coating apparatus for coating hard disk components. In another embodiment, the dipping apparatus is a dip washing apparatus for washing hard disk components both before and after the coating process. The dipping apparatus may also function as both a dip coating and dip washing apparatus, at different stages of a coating process. The dipping apparatus may also be in the form of a jig or a basket.
The dipping apparatus may further comprise a. hopper for containing a coating liquid therein. The hopper may be disposed relative to the upper and lower support frames for allowing the frames to dip into the coating liquid. In one embodiment, the hopper is a coating bath. Advantageously, the upper and lower support frames may be loaded with the hard disk components and subsequently lowered into the coating bath to be coated by the coating liquid.
The dipping apparatus may also further comprise a hopper for containing a washing liquid therein. The hopper may be disposed relative to the upper and lower support frames for allowing the frames to dip into the washing liquid. Advantageously, the upper and lower support frames may be loaded with the coated hard disk components and subsequently lowered into the hopper to be washed by the washing liquid. In one embodiment, the washing liquid is water.
There is also disclosed a system for coating components with coating liquid. The system comprises a coating _ bath containing coating liquid for coating components, a dip coating apparatus for containing the components comprising an upper support frame configured to support an upper part of the components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of the components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, wherein the dip coating apparatus is disposed at a position above the coating bath. The system also comprises movement means configured to lower the dip coating apparatus into the coating bath to be coated with the coating liquid, and raise the dip coating apparatus from the coating bath after the " components are coated with the coating liquid, and wherein upon the removal of the dip coating apparatus, any excess coating liquid on the components drips from a single point. Upon removal of the dip coating apparatus from the coating bath, the upper frame angle (θ 0 ) and the lower frame angle (9 D ) are also configured to allow any excess coating liquid on the dip coating apparatus to drip from ' distinct single, points .
The system as disclosed above may be used for coating any suitable component. In one embodiment, the components are hard disk components and there is disclosed a system for coating hard disk components with coating liquid. The system comprises a coating bath containing coating liquid for coating hard disk components, a dip coating apparatus for containing the hard disk components comprising an upper support frame configured to support an upper part of said hard disk components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of the hard disk components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, wherein the dip coating apparatus is disposed at a position above the coating bath. The system also comprises movement means configured to lower the dip coating apparatus into the coating bath to be coated with the coating liquid, and raise the dip coating apparatus from the coating bath after the hard disk components are coated with the coating liquid, and wherein upon the removal of the dip coating apparatus, any excess coating liquid on the hard disk components drips from a single point .
The end of the upper and lower support frames of the dip coating apparatus are respectively connected to a pair of side panels. The side panels may further comprise at least one pair of coupling means for coupling said dip coating apparatus to the movement means. In one embodiment, the movement means are coupled to the dip coating apparatus via the coupling means, and serve to raise and lower the dip coating apparatus during the dip coating process. The coupling means may be of any form suitable for coupling the dip coating apparatus to the movement means. In one embodiment, the coupling means are in the form a pair of outwardly extending knobs situated on the outer surface of the respective side panels. The outwardly, extending knobs may rest on corresponding inward notches or recesses on the movement means, thereby coupling the dip coating apparatus to the movement means.
The movement means may be in any suitable form for moving the dip coating apparatus in the vertical direction, as well as the horizontal direction. In one embodiment, the movement means may comprise of a mechanical grip for lifting and lowering the dip coating apparatus .
The system may further comprise a means for applying a jet of gas toward parts of the coated component to at least partly removing coating therefrom. The jet of gas may also serve to dry the coated hard disk component. In one embodiment, the movement means may further comprise a conveyor belt system, for moving the dip coating apparatus from the coating bath where the hard disk components are coated, to the supply of gas where the coated hard disk components are dried.
There is also disclosed a system for washing coated components with washing liquid. The system comprises a washing bath containing washing liquid for washing coated components, a dip washing apparatus for containing the coated components comprising an upper support frame configured to support an upper part of the components and being disposed at an upper frame angle (θ 0 ) offset from a horizontal plane and a lower support frame disposed below the upper support frame and configured to support a lower part of the components, the lower support frame being disposed at a lower frame angle (9 L ) offset from the horizontal plane, wherein the dip washing apparatus is disposed at a position above the washing bath. The system also comprises movement means configured to lower the dip washing apparatus into the washing bath to be washed with the washing liquid, and raise the dip washing apparatus from the washing bath after the components are washed with the washing liquid, and wherein upon the removal of the dip washing apparatus, any excess washing liquid on the components drips from a single point
Upon removal of the dip washing apparatus from the washiing bath, the upper frame angle (θ 0 ) and the lower frame angle (θυ) are also configured to allow any excess washing liquid on the dip washing apparatus to drip from distinct single points.
If the dip washing apparatus is to be used for a subsequent dip coating process, all the excess washing liquid will have to be dried off from the apparatus so as to prevent contamination of the coating liquid. Advantageously, as the excess washing liquid is allowed to drip from distinct single points, the time taken for all the excess washing liquid to be removed from the apparatus is significantly reduced.
The time taken to remove all the excess washing liquid from the apparatus may be less than about 40 minutes, less than about 30 minutes, less than about 20 minutes, less than about 10 minutes, less than about 5 minutes, less than about 3 minutes. In one embodiment, the time taken to remove all the excess washing liquid is about 3 to 5 minutes.
There is also disclosed a process for dipping a component contained within a dipping apparatus into a liquid bath, wherein upon removal of the component and the dipping apparatus from the liquid bath, any excess liquid on the component and the dipping . apparatus drips from distinct single points.
The process, may be a dip coating process where the liquid bath a coating bath comprising a coating liquid. The process may also be a dip washing process where the liquid bath is a washing bath comprising a washing liquid such as water. Brief Description Of Drawings
The accompanying drawings illustrate a disclosed embodiment and serves to explain the principles of the disclosed embodiment. It is to be understood, however, that the drawings are designed for purposes of illustration only, and not as a definition of the limits of the invention.
Fig. 1 shows one embodiment of a coating apparatus of the present invention.
Fig. 2 shows the side view of the coating apparatus of Fig. 1.
Fig. 3 shows the front view of the coating apparatus of Fig. ' 1.
Fig. 4 shows a second embodiment of a coating apparatus of the present invention. Fig. 5 shows the side view of the coating apparatus of Fig. 4.
Fig. 6 shows the front view of the coating apparatus of Fig. 4.
Fig. 7 shows a third embodiment of a coating apparatus of the present invention. The coating apparatus is in the form of a jig.
Fig. 8 shows the front view of the coating apparatus of Fig. 7.
Fig. 9 shows the side view of the coating apparatus of Fig. 7.
Detailed Description
Referring to Fig. 1, there is shown a dipping apparatus 100 for dipping hard disk components into a coating liquid. The dipping apparatus 100 comprises two side panels 102 and 104, disposed opposite each other and connected by a central upper support 106. The lower surface of the central upper support 106 contains a plurality of hooks 108 for hanging hard disk components therefrom. The two side panels 102 and 104 are also connected by a lower support frame 110, which is disposed below the central upper support 106. The lower support frame 110 comprises a pair of arms 112 and 114 which are coupled at each end to the side panels 102 and 104. The arms 112 and 114 are connected throughout their lengths by a plurality of cross beams 116. The cross beams 116 are positioned along the length of the arms 112 and 114 such that the hard disk components handing from the hooks 108 are capable of being supported by the cross beams 116.
The outer surface of the side panels 102 and 104 each contain a pair of protruding knobs 118 and 120 (on side panel 102), and 122 and 124 (on side panel 104). These protruding knobs 118, 120, 122 and 124 allow the dipping apparatus to be carried and moved.
Referring now to Fig. .2, it can be seen that the central upper support 106, the lower support frame 110 and the arms 112 and 114 are all tilted with respect to the horizontal plane.. The central upper support 106 is disposed at an upper frame angle (θ 0 ) offset from the horizontal plane. The lower support frame is disposed at a lower frame angle (9 L ) offset from the horizontal plane. The arms 112 and 114 are also disposed at an arm angle (Θ Α ) offset from the horizontal plane.
Referring now to Fig. 2 and Fig. 3, it can be seen that the cross beams 116 are also tilted with respect to the horizontal plane. The cross beams 116 are disposed at a cross beam angle (6 C ) offset from the horizontal plane.
In use, the hard disk component (not shown) is loaded onto the dipping apparatus 100 by hanging the upper end of the hard disk component f om the plurality of hooks 108, and supporting the lower portion of the hard disk component on the cross beams 116. The dipping apparatus 100 is then immersed into a coating bath containing coating liquid (not shown) , which is disposed at a position below the dipping apparatus 100.
When the dipping apparatus 100 is dipped into a coating liquid in a coating bath (not shown) , the inclined central upper support 106, lower support frame 110, arms 112 and 114 and cross beams 116, allow the dipping apparatus 100 to enter the coating liquid with ease.
When the dipping apparatus 100 is removed from the coating bath, the orientation of the central upper support 106 and the lower support frame 110 allow any excess coating liquid on the hard disk components to drip from a single point. Also, as the upper support 106, the lower support frame 110, the arms 112 and 114, and the cross beams 116 are all tilted with respect to the horizontal axis, any excess coating liquid on the dipping apparatus 100 is allowed to drip off from distinct single points.
Referring now to Fig. 4, Fig. 5 and Fig. 6, there is shown a second embodiment of the dipping apparatus 100' . The dipping apparatus 100' comprises of the same features as the dipping apparatus 100 and the same numerals are repeated except that they have the prime symbol (').
The difference between the dipping apparatus 100 and the dipping apparatus 100' is that the two side panels 102' and 104' of dipping apparatus 100' are arched shaped. The two bases of the arched side panel 102' contain notches 126' and 128' and the two bases of the arched side panel 104' contain notches 130' and 132'.
These notches 126', 128', 130' and 132' allow the dipping apparatus 100' to be securely positioned on the protruding knobs of another dipping apparatus.
Referring now to Fig. 7, there is shown a jig 210 for use in the process of dip coating hard disk components. The jig 210 comprises an inner basket 212 stacked over an outer " basket 214. The outer basket 214 comprises two arched side panels 216 and 218, situated opposite each other and substantially parallel to each other. The two side panels 216 and 218 are connected by two pairs of parallel rods 220a and 220b (upper rods), and 222a and 222b (lower rods). The two bases of the arched side panels 216 contain notches 224a and 224b respectively. Similar notches 226a and 226b are made in side panel 218. These notches · 224a, 224b, 226a, 226b, allow the outer basket 214 to be securely positioned on corresponding knobs (not shown) during the dip coating process. The outer surfaces of the side panels 216 and 218 each contain a pair of outwardly protruding knobs 228a and 228b (on panel 216) and 230a and 230b (on panel 218, shown in Fig. 9) . These outwardly protruding knobs 228a, 228b, 230a, 230b allow the outer basket 214 to be carried or moved. The inner surfaces of the side panels 216 and 128 each also contain a pair of inwardly protruding knobs 232a and 232b (on panel 216, shown in Fig. 9) and 234a and 234b (on panel 218) . These inwardly protruding knobs 232a, 232b, 234a, 234b allow the inner basket 212 to be stacked on the outer basket 214.
The inner basket 212 comprises two arched side panels 236 and 238, situated opposite each other and connected by a central upper support 240. The lower surface of the central upper support 240 contains a plurality of hooks (not shown) for hanging the hard disk components. The two side panels 236 and 238 are also connected by two pairs of parallel rods 242a and 242b (upper rods) , and 244a and 244b (lower rods) . The parallel rods 242a and 244a are situated on one side of the inner basket 212 and the parallel rods 242b and 244b are situated on the opposite side. The upper rods 242a and 242b are connected throughout their lengths by a plurality of rungs 246. The rungs 246 are positioned along the length of the rods 242a and 242b such that the hard disk components hanging from the hooks, are capable of being supported by the rungs 246.
The outer surfaces of the side panels 236 and 238 each contain a pair of protruding knobs 248a and 248b (on panel 236) and 250a and 250b (on panel 238). These protruding knobs 248a, 248b, 250a, 250b allow the inner basket 212 to be carried, allowing for the placement and removal of the inner basket 212 on the outer basket 214. The two bases of the arched side panels 236 contain notches 252a and 252b respectively (not shown) . Similar notches 254a and 254b are made in side panel 238. These notches 252a, 252b, 254a, 254b, allow the inner basket 212 to be securely positioned on the corresponding inwardly protruding knobs 232a, 232b, 234a, 234b of the outer basket 214.
Referring now to Fig. 8 and Fig. 9, it can be seen that the central upper support 240, the parallel rods 220a, 220b, 222a, 222b, 242a, 242b, 244a, 244b and the rungs 246 are all tilted with respect to the horizontal plane. As shown in Fig. 9, the left end of the central upper support 240 is connected to the side panel 236 at a lower vertical position with respect to the right end of the central upper support 240, which is connected to the side panel 238. As such, the central upper support 240 is tilted and makes an angle (θυ'') with the horizontal plane. The tilted central upper support 240 allows for any liquid left on the central upper support 40 after the dip coating process, to flow to the lower end (left side) and to drip from a single point.
Similarly, the left ends of the parallel rods 242a and 244a are connected to the side panel 236 at a lower vertical position with respect to the right ends of the parallel rods 242a and 244a, which are connected to the side panel 238. Also, the left ends of the parallel rods 220a and 222a are connected to the side panel 216 at a lower vertical position with respect to the right ends of the. parallel rods 220a and 222a which are connected to the side panel 218. As such, the parallel rods 220a, 222a, 242a, 244a are tilted, making an angle (e L " ) with the horizontal plane. As a result, any liquid left on the parallel rods 220a, 222a, 242a, 244a after the dip coating process, flows to the lower end (left side) and drips from a single point.
On the opposite side of the jig 210, the left ends of the parallel rods 242b and 244b are connected to the side panel 236 at a higher vertical position with respect to the right ends of the parallel rods 242b and 244ab which are connected to the side panel 238. Also, the left ends of the parallel rods 220b and 222b are connected to the side panel 216 at a higher vertical position with respect to the right ends of the parallel rods 220b and 222b which are connected to the side panel 218. The tilted parallel rods 220b, 222b, 242b, 244b make an angle (Θ Α '') with the horizontal plane. As a result, any liquid left on the parallel rods 220b, 222b, 242b, 244b after the dip coating process, flows to the lower end (right side) and drips from a single point.
The upper rods 242a and 242b which are connected along their lengths by the rungs 246 are tilted in opposite directions. This results in the rungs -246, also being tilted with respect to the horizontal plane. As the rungs 246 also make an angle with the horizontal plane, any liquid left on the rungs 246 after the dip coating process will also flow to their respective lower ends and drip from a single point.
Applications
It should be appreciated that the coating apparatus disclosed herein is a simple yet effective apparatus for use in a dip coating process for hard disk components.
Advantageously, the support frames of the dip coating apparatus are configured to orient the hard disk components such that any excess coating liquid on the hard disk components drips from a single point. More advantageously, the frame components of the coating apparatus are tilted in an orientation that allows for excess coating material from each frame component to drip from a single point. Even more advantageously, the excess coating material on the coating apparatus only drip from distinct single points of the frame components.
Advantageously, the formation of drip marks on the coating apparatus is significantly reduced. More advantageously, drip marks do ' not form throughout the length of the frame components, but are confined to the corners of each component. Advantageously, the cost and frequency of maintaining the coating apparatus is reduced. More- advantageously, the lifespan of the coating apparatus is extended.
While reasonable efforts have been employed to describe equivalent embodiments of the present invention, it will be apparent to the person skilled- in the art after reading the foregoing disclosure, that various other modifications and adaptations of the invention may be made therein without departing from the spirit and scope of the invention and it is intended that all such modifications and adaptations come within the scope of the appended claims.