BACKGROUND OF THE INVENTION

Field of the Invention

[0001] The present invention relates to a dispense system. In particular, the present invention relates to a dispense system configured for dispensing coating material from a replaceable cartridge configured for use with a coating system.

Description of the Related Art

[0002] With optical articles, such as lenses, one or more surfaces may be subjected to a treatment to enhance the overall performance and function of the optical articles. Examples of such treatments include the formation of one or more coatings on a surface of an optical substrate.

[0003] In order to manufacture a coated optical article from an uncoated optical substrate, a variety of manufacturing techniques have been developed. In some processes, an uncoated optical substrate is first washed and dried, after which a coating is applied on at least one surface of the substrate. With coatings that require curing with ultraviolet light, the coated substrate is passed through a curing device having an ultraviolet radiation source. In large scale operations, optical substrates may be processed on an automated production line. Such a production line may have a plurality of processing stations for performing the various operations, including washing, drying, coating, and curing. Typically, a single coating is selected for producing a batch of optical articles.

[0004] In many coating processes, a precise amount of the coating material must be dispensed onto the surface of the optical surface. It would be desirable to develop a new dispense system configured for dispensing precise amounts of the coating material.

SUMMARY OF THE INVENTION

[0005] In some non-limiting examples or aspects of the present disclosure, provided is a coating dispense system that may include a housing with an inlet having an inlet valve, an outlet having an outlet valve, and a pumping chamber between the inlet valve and the outlet valve; and a piston disposed within the pumping chamber and configured for reciprocal movement within the pumping chamber via a drive member. The inlet valve and the outlet valve may be pneumatically operated, zero displacement slide valves.

[0006] In some non-limiting examples or aspects of the present disclosure, the inlet valve and the outlet valve may be operable independently of each other. The inlet valve and the outlet valve each may include a valve housing having a pneumatic chamber and a valve element slidably disposed within the pneumatic chamber between an open position and a closed position. The valve element of each of the inlet valve and the outlet valve may be slidably movable within the pneumatic chamber in response to a change in pneumatic pressure within the pneumatic chamber. The valve element of each of the inlet valve and the outlet valve may be slidably movable within the pneumatic chamber from the open position toward the closed position in response to an increase in pneumatic pressure within the pneumatic chamber, and/or from the closed position toward the position in response to a decrease in pneumatic pressure within the pneumatic chamber. A pneumatic source may be in fluid communication with the pneumatic chamber of each of the inlet valve and the outlet valve.

[0007] In some non-limiting examples or aspects of the present disclosure, the drive member may include an actuator configured for reciprocally moving the piston. The actuator may be a stepper motor. A controller may be provided for controlling operation of at least one of the actuator, the inlet valve, and the outlet valve.

[0008] In some non-limiting examples or aspects of the present disclosure, the pumping chamber may include a pair of seals spaced apart from each other and configured for sealing against an outer surface of the piston. A reservoir may be provided between the pair of seals and the outer surface of the piston. The reservoir may be filled with a solvent. Alternatively, or in addition, the reservoir may be in fluid communication with a solvent source.

[0009] In some non-limiting examples or aspects of the present disclosure, the piston may have a ceramic coating.

[0010] A coating dispense system may be characterized by one or more of the following aspects.

[0011] In a first aspect, coating dispense system includes a housing with an inlet having an inlet valve, an outlet having an outlet valve, and a pumping chamber between the inlet valve and the outlet valve; and a piston disposed within the pumping chamber and configured for reciprocal movement within the pumping chamber via a drive member, wherein the inlet valve and the outlet valve are pneumatically operated, zero displacement slide valves.

[0012] In a second aspect, in the coating dispense system in accordance with the first aspect, the inlet valve and the outlet valve are operable independently of each other.

[0013] In a third aspect, in the coating dispense system in accordance with the first aspect or the second aspect, the inlet valve and the outlet valve each include a valve housing having a pneumatic chamber and a valve element slidably disposed within the pneumatic chamber between an open position and a closed position.

[0014] In a fourth aspect, in the coating dispense system in accordance with the third aspect, the valve element of each of the inlet valve and the outlet valve is slidably movable within the pneumatic chamber in response to a change in pneumatic pressure within the pneumatic chamber.

[0015] In a fifth aspect, in the coating dispense system in accordance with the third aspect or the fourth aspect, the valve element of each of the inlet valve and the outlet valve is slidably movable within the pneumatic chamber from the open position toward the closed position in response to an increase in pneumatic pressure within the pneumatic chamber.

[0016] In a sixth aspect, in the coating dispense system in accordance with any one of the third aspect to the fifth aspect, the valve element of each of the inlet valve and the outlet valve is slidably movable within the pneumatic chamber from the closed position toward the open position in response to a decrease in pneumatic pressure within the pneumatic chamber.

[0017] In a seventh aspect, in the coating dispense system in accordance with any one of the third aspect to the sixth aspect, further provided is a pneumatic source in fluid communication with the pneumatic chamber of each of the inlet valve and the outlet valve.

[0018] In an eighth aspect, in the coating dispense system in accordance with any one of the first aspect to the seventh aspect, the drive member includes an actuator configured for reciprocally moving the piston.

[0019] In a ninth aspect, in the coating dispense system in accordance with the eighth aspect, the actuator is a stepper motor.

[0020] In a tenth aspect, in the coating dispense system in accordance with the eighth aspect or the ninth aspect, further provided is a controller for controlling operation of at least one of the actuator, the inlet valve, and the outlet valve.

[0021] In an eleventh aspect, in the coating dispense system in accordance with any one of the first aspect to the tenth aspect, the pumping chamber includes a pair of seals spaced apart from each other and configured for sealing against an outer surface of the piston.

[0022] In a twelfth aspect, in the coating dispense system in accordance with the eleventh aspect, further provided is a reservoir between the pair of seals and the outer surface of the piston.

[0023] In a thirteenth aspect, in the coating dispense system in accordance with the twelfth aspect, the reservoir is filled with a solvent. [0024] In a fourteenth aspect, in the coating dispense system in accordance with the twelfth aspect or the thirteenth aspect, the reservoir is in fluid communication with a solvent source.

[0025] In a fifteenth aspect, in the coating dispense system in accordance with any one of the first aspect to the fourteenth aspect, the piston comprises a ceramic coating.

[0026] The features that characterize the present invention are pointed out with particularity in the claims, which are annexed to and form a part of this disclosure. These and other features of the invention, its operating advantages, and the specific objects obtained by its use will be more fully understood from the following detailed description in which non-limiting examples of the invention are illustrated and described.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a representative schematic view of a coating system in accordance with some examples of the present disclosure;

[0028] FIG. 2 is a representative perspective view of an optical article;

[0029] FIG. 3 is a representative schematic view of a coating material storage system for use with a coating system;

[0030] FIG. 4 is a perspective view of a replaceable cartridge configured for use with the coating material storage system of FIG. 3;

[0031] FIG. 5 is a side cross-sectional view of the dispense pump of the replaceable cartridge shown in FIG. 4;

[0032] FIG. 6 is a side cross-sectional view of a slide valves of the dispense pump shown in FIG. 5, with the slide valve shown in an open positon; and

[0033] FIG. 7 is a side cross-sectional view of a slide valves of the dispense pump shown in FIG. 5, with the slide valve shown in a closed positon.

[0034] In FIGS. 1-7, like characters refer to the same components and elements, as the case may be, unless otherwise stated.

DETAILED DESCRIPTION OF THE INVENTION

[0035] As used herein, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0036] Spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, and the like, relate to the invention as shown in the drawing figures and are not to be considered as limiting as the invention can assume various alternative orientations. [0037] All numbers used in the specification and claims are to be understood as being modified in all instances by the term “about”. By “about” is meant plus or minus twenty-five percent of the stated value, such as plus or minus ten percent of the stated value. However, this should not be considered as limiting to any analysis of the values under the doctrine of equivalents.

[0038] Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass the beginning and ending values and any and all subranges or subratios subsumed therein. For example, a stated range or ratio of “1 to 10” should be considered to include any and all subranges or subratios between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges or subratios beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less. The ranges and/or ratios disclosed herein represent the average values over the specified range and/or ratio.

[0039] The terms “first”, “second”, and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

[0040] All documents referred to herein are “incorporated by reference” in their entirety.

[0041] The term “at least” is synonymous with “greater than or equal to”.

[0042] The term “not greater than” is synonymous with “less than or equal to”.

[0043] As used herein, “at least one of’ is synonymous with “one or more of’. For example, the phrase “at least one of A, B, or C” means any one of A, B, or C, or any combination of any two or more of A, B, or C. For example, “at least one of A, B, or C” includes A alone; or B alone; or C alone; or A and B; or A and C; or B and C; or all of A, B, and C.

[0044] The term “adjacent” means proximate to but not in direct contact with.

[0045] The term “includes” is synonymous with “comprises”.

[0046] As used herein, the terms “parallel” or “substantially parallel” mean a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from 0° to 5°, or from 0° to 3°, or from 0° to 2°, or from 0° to 1°, or from 0° to 0.5°, or from 0° to 0.25°, or from 0° to 0.1°, inclusive of the recited values.

[0047] As used herein, the terms “perpendicular” or “substantially perpendicular” mean a relative angle as between two objects at their real or theoretical intersection is from 85° to 90°, or from 87° to 90°, or from 88° to 90°, or from 89° to 90°, or from 89.5° to 90°, or from 89.75° to 90°, or from 89.9° to 90°, inclusive of the recited values. [0048] The term “optical” means pertaining to or associated with light and/or vision. For example, an optical element, article, or device can be chosen from ophthalmic elements, articles, and devices; display elements, articles, and devices; visors; windows; and mirrors.

[0049] The term “ophthalmic” means pertaining to or associated with the eye and vision. Non-limiting examples of ophthalmic articles or elements include corrective and non-corrective lenses, including single vision or multi-vision lenses, which may be either segmented or nonsegmented multi-vision lenses (such as, but not limited to, bifocal lenses, trifocal lenses, and progressive lenses), as well as other elements used to correct, protect, or enhance (cosmetically or otherwise) vision, including without limitation, contact lenses, intra-ocular lenses, magnifying lenses, and protective lenses or visors.

[0050] As used herein, the terms “lens” and “lenses” mean and encompass at least individual lenses, lens pairs, partially formed (or semi-finished) lenses, fully formed (or finished) lenses, and lens blanks.

[0051] As used herein, the term “transparent”, such as used in connection with a substrate, film, material, and/or coating, means that the indicated substrate, film, material, and/or coating has the property of transmitting visible light without appreciable scattering so that objects lying beyond are visibly observable.

[0052] As used herein, the terms “ultraviolet”, “UV”, “ultraviolet light”, or “ultraviolet radiation” mean electromagnetic radiation having a wavelength in the range of 10 nm to 400 nm.

[0053] As used herein, the terms “infrared”, “IR”, “infrared light”, or “infrared radiation” mean electromagnetic radiation having a wavelength in the range of 780 nm to 1 mm.

[0054] As used herein, the term “ultrasonic” refers to one or more sound waves having a frequency higher than approximately 20,000 Hz (20 kHz).

[0055] As used herein, the term “coating” means a supported film derived from a flowable coating material, which can optionally have a uniform thickness, and specifically excludes polymeric sheets. The terms “layer” and “film” each encompass both coatings (such as a coating layer or a coating film) and sheets, and a layer can include a combination of separate layers, including sub-layers and/or over-layers. The verb “coating” means, within appropriate context, the process of applying a coating material (or materials) to the substrate to form a coating (or coating layer).

[0056] As used herein, the terms “cure”, “cured”, and related terms, mean that at least a portion of the polymerizable and/or crosslinkable components that form a curable composition are at least partially polymerized and/or crosslinked. In accordance with some examples, the degree of crosslinking can range from 5% to 100% of complete crosslinking. In accordance with some further examples, the degree of crosslinking can range from 30% to 95%, such as 35% to 95%, or 50% to 95%, or 50% to 85% of complete crosslinking. The degree of crosslinking can range between any combination of these recited lower and upper values, inclusive of the recited values.

[0057] As used herein, the terms “communication” and “communicate” may refer to the reception, receipt, transmission, transfer, provision, and/or the like, of information (e.g., data, signals, messages, instructions, commands, and/or the like).

[0058] As used herein, a “graphical user interface” or “GUI” refers to a generated display with which a user may interact, either directly or indirectly (e.g., through a button, keyboard, mouse, touchscreen etc.).

[0059] The discussion of the invention may describe certain features as being “particularly” or “preferably” within certain limitations (e.g., “preferably”, “more preferably”, or “even more preferably”, within certain limitations). It is to be understood that the invention is not limited to these particular or preferred limitations but encompasses the entire scope of the disclosure.

[0060] The invention comprises, consists of, or consists essentially of the following examples of the invention, in any combination. Various examples of the invention may be discussed separately. However, it is to be understood that this is simply for ease of illustration and discussion. In the practice of the invention, one or more aspects of the invention described in one example can be combined with one or more aspects of the invention described in one or more of the other examples.

[0061] With reference to FIG. 1, a coating system 100 is shown in accordance with some examples or aspects of the present disclosure. The coating system 100, as described herein, and in accordance with some examples, provides a low cost, small scale coating system configured for applying one or more coating materials to an optical article 200. The coating system 100 can include a surface pretreatment station (such as, but not limited to, a plasma pretreatment station), a washing/drying station, one or more coating apparatuses (utilizing one or more of multiple coatings and combinations of coatings), and one or more curing apparatuses (such as UV, IR, and/or thermal curing apparatuses) or combinations thereof. The coating system 100 of the present invention can, with some examples, be operated with the formation of minimal waste streams and/or waste materials. [0062] The coating system 100 of the present disclosure can, with some examples, be used for the production of optical articles 200, which each independently have the same or different coating materials applied thereon. In some examples, the coating system 100 of the present disclosure can be at least partially automated and optionally incorporated into art-recognized product tracking and control systems.

[0063] With reference to FIG. 1, the coating system 100 generally has a plurality of stations, each having an apparatus configured for performing a specified task. For example, the coating system 100 may have a coating station 301 having at least one coating apparatus 300, such as a first coating apparatus 300a and a second coating apparatus 300b, for coating the optical article 200 and a curing station 401 having at least one curing apparatus 400 for curing the coated optical article 200. Optionally, the coating system 100 has a pre-treatment station 501 having at least one pre-treatment apparatus 500, and/or a washing and drying station 601 having at least one washing and drying apparatus 600. A placement arm 900 may be provided for moving the optical article 200 between various stations of the coating system 100. In some examples or aspects, a conveyor belt 950 may be provided for moving the optical articles 200 between different stations of the coating system 100 or within any single station of the coating system 100.

[0064] With continued reference to FIG. 1, the coating system 100 may have a loading station 110 having a plurality of blank optical articles 200 that are to be processed through the coating system 100. The coating system 100 further may include an unloading station 120 configured for storing one or more coated optical articles 200 after the one or more optical articles 200 have been processed through the coating system 100.

[0065] The coating system 100 can, with some examples or aspects, be used to coat a variety of articles, such as, but not limited to, optical articles 200. With reference to FIG. 2, the optical article 200 has a forward or top surface 202, a rearward or bottom surface 204, and a side surface 206 extending between the top surface 202 and the bottom surface 204. When the optical article 200 is an ophthalmic lens, the bottom surface 204 is opposed to the eye of an individual wearing the optical article 200, the side surface 206 typically resides within a supportive frame, and the top surface 202 faces incident light (not shown), at least a portion of which passes through the optical article 200 and into the individual’s eye. With some examples or aspects, at least one of the top surface 202, the bottom surface 204, and the side surface 206 may have various shapes including, but not limited to, round, flat, cylindrical, spherical, planar, substantially planar, plano-concave and/or plano-convex, and curved, including, but not limited to, convex, and/or concave.

[0066] The optical article 200 that is coated with the system and method of the present disclosure can, with some examples, be formed from and correspondingly include organic materials, inorganic materials, or combinations thereof (for example, composite materials).

[0067] Examples of organic materials that can be used as optical articles 200 in accordance with various examples of the present invention, include polymeric materials, such as homopolymers and copolymers, prepared from the monomers and mixtures of monomers disclosed in U.S. Patent No. 5,962,617 and in U.S. Patent No. 5,658,501 from column 15, line 28 to column 16, line 17. For example, such polymeric materials can be thermoplastic or thermoset polymeric materials, can be transparent or optically clear, and can have any refractive index required. Examples of such monomers and polymers include: polyol(allyl carbonate) monomers, e.g., allyl diglycol carbonates such as diethylene glycol bis(allyl carbonate), which monomer is sold under the trademark CR-39 by PPG Industries, Inc.; polyurea-polyurethane (polyurea-urethane) polymers, which are prepared, for example, by the reaction of a polyurethane prepolymer and a diamine curing agent, a composition for one such polymer being sold under the trademark TRIVEX by PPG Industries, Inc.; polyol(meth)acryloyl terminated carbonate monomer; diethylene glycol dimethacrylate monomers; ethoxylated phenol methacrylate monomers; diisopropenyl benzene monomers; ethoxylated trimethylol propane triacrylate monomers; ethylene glycol bismethacrylate monomers; poly(ethylene glycol) bismethacrylate monomers; urethane acrylate monomers; poly(ethoxylated bisphenol A dimethacrylate); poly(vinyl acetate); poly(vinyl alcohol); poly(vinyl chloride); poly(vinylidene chloride); polyethylene; polypropylene; polyurethanes; polythiourethanes; thermoplastic polycarbonates, such as the carbonate-linked resin derived from bisphenol A and phosgene, one such material being sold under the trademark LEXAN; polyesters, such as the material sold under the trademark MYLAR; poly(ethylene terephthalate); polyvinyl butyral; poly(methyl methacrylate), such as the material sold under the trademark PLEXIGLAS, and polymers prepared by reacting polyfunctional isocyanates with polythiols or polyepisulfide monomers, either homopolymerized or co-and/or terpolymerized with polythiols, polyisocyanates, and polyisothiocyanates; and optionally ethylenically unsaturated monomers or halogenated aromatic-containing vinyl monomers. Also contemplated are copolymers of such monomers and blends of the described polymers and copolymers with other polymers, for example, to form block copolymers or interpenetrating network products. [0068] With some examples of the present invention, the optical article 200 can be an ophthalmic article. Examples of organic materials suitable for use in forming ophthalmic articles include art-recognized polymers that are useful as ophthalmic articles, such as organic optical resins that are used to prepare optically clear castings for optical applications, such as ophthalmic lenses.

[0069] Examples of inorganic materials that can be used as optical articles 200 with some examples of the present invention include glasses, minerals, ceramics, and metals. With some examples, the optical article 200 can include glass. In other examples, the optical article 200 can have a reflective surface, for example, a polished ceramic substrate, metal substrate, or mineral substrate. In other examples, a reflective coating or layer (e.g., a metal layer, such as a silver layer) can be deposited or otherwise applied to a surface of an inorganic or an organic substrate to make it reflective or to enhance its reflectivity.

[0070] Optical articles 200 that can be used with the method according to some examples of the present disclosure can also include untinted, tinted, linearly polarizing, circularly polarizing, elliptically polarizing, photochromic, or tinted-photochromic substrates. As used herein with reference to optical articles 200, the term “untinted” means optical articles that are essentially free of coloring agent additions (such as conventional dyes) and have an absorption spectrum for visible radiation that does not vary significantly in response to actinic radiation. Further, with reference to optical articles 200, the term “tinted” means substrates that have a coloring agent addition (such as conventional dyes) and an absorption spectrum for visible radiation that does not vary significantly in response to actinic radiation.

[0071] With reference to FIG. 1, a surface-treated and cleaned optical article 200 can be transferred to the coating apparatus 300 for applying one or more coatings to at least one surface of the optical article 200. The coating apparatus 300 may be a plurality of coating apparatuses 300. The one or more coatings may be applied on at least one surface of the optical article 200 using a number of different techniques. In some examples or aspects, the optical article 200 may be immersed into a liquid coating material. After the optical article is pulled out of the liquid, the liquid coating material forms a coating layer on the immersed surface(s) of the optical article 200. In other examples or aspects, as disclosed herein, a liquid coating material is deposited onto a surface of the optical article 200, which is then rotated at high speed to spread the coating material into a thin film covering the surface of the optical article 200. In further examples or aspects, the coating apparatus 300 may be an inkjet printing apparatus that is configured to apply a coating material in the form of extremely fine droplets on a printing surface, such as one or more surfaces of the optical article 200. In various examples or aspects, the coating apparatus 300 may be configured for applying a uniform coating or a gradient coating on at least one surface of the optical article 200.

[0072] With reference to FIG. 1, each coating apparatus 300 is in fluid communication with a coating material storage system 1000 (hereinafter referred to as “storage system 1000”). The storage system 1000 is configured for containing the coating material and selectively supplying the coating material to each coating apparatus 300 during a coating application process. In some examples or aspects, the storage system 1000 may contain a single coating material that is selectively supplied to each coating apparatus 300 during the coating application process. In other examples or aspects, the storage system 1000 may contain a plurality of different coating materials, each of which can be independently selected and supplied to each coating apparatus 300 during the coating application process. In this manner, a plurality of coating materials may be supplied to each coating apparatus 300 to create a desired mixture of the coating materials.

[0073] The coating material can, with some examples, include a curable resin composition, and optionally, a solvent. The coating material can be in the form of art-recognized liquid coating materials and powder coating materials. The coating material can be thermoplastic, radiation curable such as by ultraviolet radiation or electron beam, or thermosetting coating material. With some examples, the coating materials are selected from curable or thermosetting coating materials. Coating materials can include kinetic enhancing additives, photoinitiators, and thermal initiators. With some examples, coating materials can include a static dye, a photochromic material, or a combination thereof. Alternatively or additionally, the optical article 200 can include a static dye, a photochromic material, or a combination thereof. Various coating materials can be used for applying primer coatings and films; protective coatings and films, including transitional coatings and films and abrasion resistant coatings and films; anti- reflective coatings and films; polarizing coatings and films; and combinations thereof.

[0074] With reference to FIG. 3, the storage system 1000 may have at least one replaceable cartridge 1002. Each replaceable cartridge 1002 of the storage system 1000 may be configured for containing the coating material, recirculating the coating material in a recirculation loop, and selectively dispensing a desired amount of coating material to the coating apparatus 300. In some examples or aspects, a plurality of replaceable cartridges 1002 are provided. Each replaceable cartridge 1002 may contain a different coating material. In some examples or aspects, at least some of the plurality of replaceable cartridges 1002 may contain the same coating material. [0075] With continued reference to FIG. 3, each replaceable cartridge 1002 can be removed from the storage system 1000 for cleaning, refilling, and servicing. For example, the storage system 1000 may have a plurality of bays 1004, each of which is configured to receive a single replaceable cartridge 1002. Each bay 1004 has a first pneumatic connector 1006 and a first electric connector 1008 configured for connecting to the corresponding pneumatic and electric connectors on the replaceable cartridge 1002. In this manner, each replaceable cartridge 1002 can be quickly and easily connected to or disconnected from the respective bay 1004 of the storage system 1000. In some examples or aspects, inserting the replaceable cartridge 1002 into the bay 1004 may automatically establish a pneumatic and electric connection between the replaceable cartridge 1002 and the storage system 1000. In other examples or aspects, pneumatic and electrical connections between the replaceable cartridge 1002 and the bay 1004 can be done separately after inserting the replaceable cartridge 1002 into the bay 1004. Similarly, removing the replaceable cartridge 1002 from the bay 1004 may automatically disconnect the pneumatic and electric connections between the replaceable cartridge 1002 and the storage system 1000. In other examples or aspects, pneumatic and electrical connections between the replaceable cartridge 1002 and the bay 1004 can be disconnected separately prior to or after removal of the replaceable cartridge 1002 from the bay 1004.

[0076] With continued reference to FIG. 3, when connected to the bay 1004 of the storage system 1000, each replaceable cartridge 1002 may be fluidly connected to a delivery line 1010 configured to deliver the coating material from the replaceable cartridge 1002 to the at least one coating apparatus 300. In some examples or aspects, each replaceable cartridge 1002, when connected to the respective bay 1004, may be connected to the at least one coating apparatus 300 via a dedicated delivery line 1010. In other examples or aspects, delivery lines 1010 from each replaceable cartridge 1002 may be connected to a manifold that is then connected to the at least one coating apparatus 300.

[0077] With reference to FIG. 4, the replaceable cartridge 1002 has a frame 1012 configured for supporting various components for containing the coating material, recirculating the coating material in a recirculation loop, and selectively dispensing a desired amount of coating material to the coating apparatus 300. The frame 1012 may be configured to removably or non-removably support the various components. In some examples or aspects, the frame 1012 may be configured for interacting with the bay 1004, such as by having at least one side that is slidably engagable with at least a portion of the bay 1004. The frame 1012 can, in some examples or aspects, be a planar material having a sufficient thickness to support the various components configured for containing the coating material, recirculating the coating material in a recirculation loop, and selectively dispensing a desired amount of coating material to the coating apparatus 300. The frame 1012 can be made from a metal material, a plastic material, or a combination of metal and plastic materials. In some examples or aspects, the frame 1012 may have a handle 1014 for handling the frame 1012 during removal of the frame 1012 from the bay 1004 and/or insertion of the frame 1012 into the bay 1004.

[0078] With continued reference to FIG. 4, the replaceable cartridge 1002 has a reservoir 1016 configured for containing a volume of a coating material. In some examples or aspects, the reservoir 1016 has a storage portion 1018 defining an interior for containing the coating material, and a cap 1020 that is removably connectable to the storage portion 1018 and is configured for enclosing the interior of the storage portion 1018. At least one of the storage portion 1018 and the cap 1020 may be removably connected to the frame 1012. In some examples or aspects, the reservoir 1016 may have a volume of IL to 20L. The coating material inside the reservoir 1016 may be kept at ambient pressure, a vacuum pressure, or a positive pressure.

[0079] In some examples or aspects, the storage portion 1018 may be a conventional coating reservoir that is provided by a manufacturer of the coating material. Such a storage portion 1018 may be removably connectable to cap 1020. In this manner, the storage portion 1018 may be discarded after the coating material is used up and a new storage portion 1018 filled with the coating material can be connected to the cap 1020. In other examples or aspects, the storage portion 1018 may be re-fillable with the coating material after the coating material is used up.

[0080] With continued reference to FIG. 4, the cap 1020 has an outlet 1022 configured for delivering the coating material out of the storage portion 1018 and an inlet 1024 configured for returning the coating material into the storage portion 1018. The outlet 1022 and inlet 1024 are connected to a recirculation loop 1026 that is configured for circulating the coating material from the reservoir 1016 using a recirculation pump 1028. In some examples or aspects, the recirculation loop 1026 comprises tubing 1030 having a first end connected to the outlet 1022 and a second end connected to the inlet 1024. In this manner, the recirculation loop 1026 is in fluid communication with the reservoir 1016. Various additional elements may be disposed inline with the tubing 1030 between the first end and the second end such that these additional elements are in fluid communication with the recirculation loop 1026, as described herein. When additional elements are provided in-line with the tubing 1030, the tubing 1030 may comprise a plurality of tubing segments interconnecting the various elements and being in fluid communication with each other.

[0081] With continued reference to FIG. 4, the replaceable cartridge 1002 has the recirculation pump 1028 in-line with the recirculation loop 1028. The recirculation pump 1028 is connected to the outlet 1022 of the reservoir 1016 via a first tubing segment 1030a. In some embodiments or aspects, the recirculation pump 1028 may be configured to aspirate the coating material from the reservoir 1016 and pump the coating material through the recirculation loop 1026 to be delivered back into the storage portion 1018 via the inlet 1024 or to be delivered to the at least one coating apparatus 300 via a dispense system, as described herein. In some examples or aspects, the recirculation pump 1028 may be configured to continuously circulate the coating material through the recirculation loop 1016 while the replaceable cartridge 1002 is connected to the coating system 100. In this manner, the coating material is continuously mixed to prevent separation of solids and to extend the life of the coating material.

[0082] With continued reference to FIG. 4, the replaceable cartridge 1002 has a filter 1056 positioned in-line and in fluid communication with the recirculation loop 1028. The filter 1056 may be positioned downstream of the recirculation pump 1028 and may be connected to the liquid outlet 1042 of the recirculation pump 1028 via a second tubing segment 1030b. The filter 1056 may be configured for filtering the coating material circulating through the recirculation loop 1026.

[0083] With reference to FIG. 4, the replaceable cartridge 1002 has a de-bubbling system 1058 positioned in-line and in fluid communication with the recirculation loop 1028. The debubbling system 1058 may be positioned downstream of the filter 1056 and may be connected to the filter 1056 via a third tubing segment 1030c. The de-bubbling system 1058 may be configured for removing air bubbles in the coating material circulating through the recirculation loop 1026.

[0084] With continued reference to FIG. 4, the de-bubbling system 1058 has a chamber 1060 configured for receiving the coating material from the filter 1056 via the third tubing segment 1030c. The third tubing segment 1030c may be connected to a first end 1062 of the chamber 1060. A conical separator 1064 is positioned within the chamber 1060 and is configured for attracting any air bubbles in the coating material as the coating material flows down the conical separator 1064. The attracted air bubbles are dislodged from the conical separator 1064 and float toward the first end 1062 of the chamber 1060. A second end 1066 of the chamber 1060 is positioned at an inlet of the dispense pump, as described herein. As the coating material fills the chamber 1060, the level of the coating material in the chamber 1060 rises in a direction from the second end 1066 toward the first end 1062. A chamber outlet 1068 is provided in a sidewall of the chamber 1060 proximate to the first end 1062. The chamber outlet 1068 is in fluid communication with the reservoir 1026 via a fourth tubing segment 130d. In this manner, de-bubbled coating material can be returned from the de-bubbling system 1058 into the reservoir 1026 via the fourth tubing segment 1030d.

[0085] With continued reference to FIG. 4, the replaceable cartridge 1002 has a dispense system 1069 comprising a dispense pump 1070 positioned in-line and in fluid communication with the recirculation loop 1028. The dispense pump 1070 is connected to the second end 1066 of the de-bubbling system 1058 and is configured to, when actuated, aspirate the coating material from the chamber 1060 of the de-bubbling system 1058. In some embodiments or aspects, the dispense pump 1070 is operable to aspirate a select amount of the coating material from the recirculation loop 1026, such as from the de-bubbling system 1058, and delivers the select amount of the coating material to the at least one coating apparatus 300.

[0086] With reference to FIG. 5, the dispense pump 1070 may be a piston pump. In some examples or aspects, the dispense pump 1070 may be any other kind of pump that is configured for aspirating a select amount of the coating material from the recirculation loop 1026 and delivering the coating material to the at least one coating apparatus 300. When embodied as a piston pump, the dispense pump 1070 includes a housing 1072 having an inlet 1074 with an inlet valve 1076, an outlet 1078 having an outlet valve 1080, and a pumping chamber 1082 in fluid communication the inlet valve 1076 and the outlet valve 1080. The inlet valve 1076 is in fluid communication with the recirculation loop 1026, such as via an inlet tube 1077 connected to the de-bubbling system 1058 while the outlet valve 1080 is in fluid communication with the at least one coating apparatus 300 (shown in FIG. 1). The piston pump 1070 further includes a piston 1084 disposed within the pumping chamber 1082 and configured for reciprocal movement within the pumping chamber 1082. The drive member 1086 may be an actuator configured for reciprocally moving the piston 1084. The drive member 1086 may be connected to the piston 1084 via a coupling 1087. In some examples or aspects, the actuator may be a stepper motor. In some examples or aspects, the piston 1084 may have a coating on an outer surface thereof to reduce frictional losses as the piston 1084 is reciprocally moved within the pumping chamber 1082. For example, the piston 1084 may have a ceramic coating on via a drive member 1086. [0087] With reference to FIGS. 6-7, the inlet valve 1076 and the outlet valve 1080 may be pneumatically-operated, zero-displacement slide valves. In some examples or aspects, the inlet valve 1076 and the outlet valve 1080 may be operable independently of each other. The inlet valve 1076 and the outlet valve 1080 each comprise a valve housing 1088 having a pneumatic chamber 1090 and a valve element 1092 slidably disposed within the pneumatic chamber 1090. The valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 may be operable between an open position (shown in FIG. 6) configured to permit a flow of the coating material in a direction from the inlet 1074 to the outlet 1078 and a closed position configured to prevent the flow of the coating material in a direction from the inlet 1074 to the outlet 1078. The valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 may be configured for reciprocal movement within the valve housing 1088.

[0088] In some examples or aspects, the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 may be sealed against a sidewall of the pneumatic chamber 1090 by an O-ring 1094. In this manner, the pneumatic chamber 1090 is divided into two portions by the valve element 1092. Depending on the difference in pressure between the two portions of the pneumatic chamber 1090, the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 is slidably movable within the pneumatic chamber 1090 in response to a change in pneumatic pressure within the pneumatic chamber 1090. For example, the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 is slidably movable within the pneumatic chamber 1090 from the open position (shown in FIG. 6) toward the closed position (shown in FIG. 7) in response to an increase in pneumatic pressure within the pneumatic chamber 1090, such as an increase in pneumatic pressure in a lower portion of the pneumatic chamber 1090 relative to the pneumatic pressure in an upper portion of the pneumatic chamber 1090. Alternatively, the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 is slidably movable within the pneumatic chamber 1090 from the closed position (shown in FIG. 7) toward the open position (shown in FIG. 6) in response to a decrease in pneumatic pressure within the pneumatic chamber 1090, such as a decrease in pneumatic pressure in a lower portion of the pneumatic chamber 1090 relative to the pneumatic pressure in an upper portion of the pneumatic chamber 1090.

[0089] With reference to FIGS. 6-7, the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 has a passage 1098 that is configured to be placed in selective fluid communication with the inlet 1074 and the outlet 1078, depending on a position of the valve element 1092 within the housing 1088. When the valve element 1092 of each of the inlet valve 1076 and the outlet valve 1080 is in the open positon (shown in FIG. 6), the passages 1098 are aligned with the inlet 1074 and the outlet 1078 such that the coating material can flow through the central passage 1096 of the valve housing 1088. When the valve element 1092 of either or both of the inlet valve 1076 and the outlet valve 1080 is in the closed position (shown in FIG. 7), the passages 1098 are misaligned with the inlet 1074 and the outlet 1078 such that the coating material cannot flow through the central passage 1096 of the valve housing 1088.

[0090] With continued reference to FIG. 6-7, a pneumatic source 1099 is in fluid communication with the pneumatic chamber 1090 of each of the inlet valve 1076 and the outlet valve 1080. In some examples or aspects, the pneumatic source 1099 may be a compressed air source.

[0091] With reference to FIG. 5, the pumping chamber 1082 comprises a pair of seals 1097 spaced apart from each other in an axial direction of the piston 1084 and configured for sealing against an outer surface of the piston 1084. A reservoir 1095 is defined between the pair of seals 1097 and the outer surface of the piston 1084. In some examples or aspects, the reservoir 1095 is in fluid communication with a solvent source and/or is filled with a solvent. In this manner, the outer surface of the piston 1084 can be cleaned as the piston 1084 is reciprocally moved between the seals 1097 of the reservoir 1095.

[0092] With reference to FIG. 5, at least one controller 1100 may be configured to control operation of at least one of the drive member 1086, the inlet valve 1076, and the outlet valve 1080 to accurately dispense a select amount of the coating material from the recirculation loop 1026 and deliver the coating material to the at least one coating apparatus 300. In some examples or aspects, the at least one controller 1100 may be a microprocessor controller. The at least one controller 1100 may be configured for pulse width modulated (PWM) operation, wherein analog operation of at least one component of the dispense system 1069, such as at least one of the drive member 1086, the inlet valve 1076, and the outlet valve 1080, can be achieved using digital control signals. In some examples or aspects, the at least one controller 1100 may be configured for continuously modulated control of at least one component of the dispense system 1069, such as at least one of the drive member 1086, the inlet valve 1076, and the outlet valve 1080. The at least one controller 1100 may have memory configured for storing one or more predetermined automated processes. In some examples or aspects, the at least one controller 1100 may be configured for operating on a 110V or a 220V AC power circuit, and/or on battery power. In other examples or aspects, the at least one controller 1100 may be configured for operating on a 12V DC power circuit. [0093] The present invention has been described with reference to specific details of particular examples thereof. It is not intended that such details be regarded as limitations upon the scope of the invention except insofar as and to the extent that they are included in the accompanying claims.