Abstract: This invention relates to an electroforming device and a process used to electroform a metal layer on an inner surface of a female mandrel. The electrolytic solution flows only through an electrolytic solution passageway that defines the inner surface as the walls of the passageway. The mandrel may include more than one electrolytic solution passageway, or multiple mandrels may be used in a sequential order to mass produce the electroforms.

Abstract: There is disclosed an apparatus for depositing metal on a member comprising: (a) a first electrode comprising a first corrugated side; (b) a second electrode having the same polarity as the first electrode and comprising a second corrugated side, wherein the second corrugated side is disposed opposite the first corrugated side, and spaced therefrom; (c) a channel defined by the first corrugated side and the second corrugated side for movement of the member therebetween, wherein the channel has a plurality of alternating expansive areas and constrictive areas; and (d) a conveyor device for transporting the member through the channel.

Abstract: An electroforming/electrodeposition process and apparatus includes a first electrode, a second electrode spaced from the first electrode, a channel defined by the first and second electrodes and at least one electrically nonconductive or poorly conductive shield disposed adjacent at least one electrode. The shield(s) define(s) a region of the channel wherein the surface of a mandrel placed in that region experiences substantially uniform current density. The apparatus may contain additional electroforming/electrodeposition and/or other steps and may be arranged in a carousel apparatus with one or more mandrels to permit continuous operation of the apparatus.

Abstract: An apparatus for depositing metal which provides a brushless electrical current continuity between a member, such as an electroforming mandrel or an electroplating rack, and a current source, comprising: (a) an electrode; (b) a member, spaced apart from the electrode, wherein the member defines a space that is partially or fully filled with a first conductive liquid in electrical contact with the member; (c) a second conductive liquid electrically isolated from the electrode; and (d) connecting means for electrically connecting the first conductive liquid and the second conductive liquid.

Abstract: An apparatus is disclosed for depositing metal on a mandrel which provides a brushless electrical current continuity between the mandrel and a current source, comprising: (a) a metal deposition vessel; (b) an electrode disposed in the vessel; (c) a mandrel disposed in the vessel, spaced apart from the electrode; (d) an electrically conductive liquid disposed in the vessel; (e) an electrolytic solution disposed in the tank; (f) a layer of a substantially electrically nonconductive material disposed between the electrolytic solution and the conductive liquid; and (g) connecting means for electrically connecting the mandrel and the conductive liquid, coupled to the mandrel.

Abstract: An endless metal belt resistant to failure due to stress induced by bending contains an internal stress gradient of radially outward increasing compressive stress which opposes external stress applied to the belt. The belt can be made by an electroforming process.

Abstract: An endless metal belt resistant to failure due to stress induced by bending contains an internal stress gradient of radially outward increasing compressive stress which opposes external stress applied to the belt. The belt can be made by an electroforming process. While electroforming, at least one operating parameter selected from bath temperature, current density, agitation, and stress reducer concentration is adjusted to cause the internal stress to gradually increase, compressively, from the radially inner surface of the belt to the radially outer surface of the belt. The internal stress preferably increases at a substantially constant rate and may range from about 160,000 psi tensile at the inner surface to about 120,000 psi compressive at the outer surface.

Abstract: Polymer films are formed by electrocodeposition of solutions containing a dispersion of charged particles of a first polymer and charged particles of a second polymer. Microheterogeneous films are obtained having micro-domains of a minor component polymer dispersed in the major component polymer. Processes for preparing dispersions for electrocodeposition are also provided In a first process, two polymers are dissolved in a common solvent and then dispersed as small charged particles in another solvent which is a precipitant for both polymers. In another process, a dispersion of a first polymer is prepared by adding a solution of the first polymer to a dispersant solvent, and then a solution of a second polymer is dispersed in the dispersion of the first polymer. In another process, a solution of the second polymer is added to a dispersion of the first polymer which contains only a single non-solvent for the second polymer.