Abstract: An improved implantable hearing aid apparatus and related method of manufacture are disclosed. The inventive apparatus and method utilize electrodeposition techniques to yield enhanced sealing of implanted componentry. In one embodiment an inventive apparatus comprises at least first and second implantable hearing aid component housing members having at least one electrodeposited layer overlapping adjacent portions of the housing members to provide a hermetic seal therebetween. In another embodiment an inventive apparatus comprises an implantable hearing aid component housing member formed via electrodeposition having a plurality of electrodeposited layers, wherein at least two adjacent ones of the layers comprise differing materials (e.g. to yield enhanced functional characteristics). By way of primary example, a hollow bellows of any implantable middle ear actuator may be formed via the sequential electrodeposition of multiple layers on a shaped mandrel which is then selectively removed (e.g.

Abstract: An optical mounting for an optical component includes an inner, preferably multi-part, portion that abuts the optical component and an outer frame, which are connected together by a plurality of spring hinge beams. The spring hinge beams and other portions of the optical mounting are produced galvanoplastically.

Abstract: The present invention's device and method of manufacturing metal ferrules used as connector elements for optical fibers is characterized such that, by growth-guidance of an internal-diameter formation member whose external diameter is the same as the internal diameter of the metal ferrule to be manufactured, an electroformed layer having a cylindrical internal hole is grown on the cathode side of a electroforming cistern and said cylindrical electroformed layer is grown to a prescribed external diameter in the process of lifting such electroformed layer from the aforementioned electroforming cistern, and such that said cylindrical electroformed layer, when outside the aforementioned electroforming cistern, is cut to prescribed dimensions.

Abstract: In the method of manufacturing a ferrule, electrocasting is carried out using at least one wire 9 such as of a metal or a plastic as a mother die, and then the wire 9 is removed from the resulting electrocast product, wherein the electrocasting treatment is carried out under rotation of the wire while it is maintained static in the longitudinal direction. According to this method, neither biased thickening nor bending occurs in the electrocast products, and they are almost free from decentering of holes. Intermediate rod products obtained after the electrocasting treatment have perfectly circular cross sections. In addition, variation in the diameter of the rod products can be reduced. Besides, agitation of the electrocasting solution can be facilitated by employing a method in which agitation is achieved by forced circulation of the liquid, and further deterioration of the electrocasting working environment can be prevented.

Abstract: Electroforming is performed in an electroforming bath with a cathode of a metal wire member immersed in an electroforming solution to electrodeposit nickel around the aluminum alloy wire member. The aluminum alloy wire member is removed by dissolution with an alkaline solution from an obtained nickel electroformed product. Accordingly, a nickel cylinder is obtained, which has a through-hole formed corresponding to the wire member. The cylinder is cut into those having a predetermined length. The outer circumference is subjected to cutting based on the through-hole to obtain a ferrule. The inner diameter accuracy of the through-hole of the ferrule is determined by the outer diameter accuracy of the wire member.

Abstract: It is disclosed a process for preparing a removable sleeve to be photoengraved, for use in printing presses, which sleeve is obtained by immersion of a cylinder in a copper-electroplating tank to generate the sleeve itself, and separation of the cylinder is obtained either by an extraction tooling or with use of a metal ring for closure of the holes for air admission, which are designed to create an air cushion enabling easy removal.

Abstract: A process of producing a slit-formed cylindrical sleeve connector for press-fitting and joining thin wires or thin rods, rigid or elastic, together in close or contacting relationship using an electroforming process that includes providing a thin conductive electroforming mandrel having an external surface finished to a specified grade of surface finish, forming a given pattern of nonconductive layer so as to define at least one cylindrical but circumferentially discontinuous electrodeposition cell on the electroforming mandrel electrodepositing an electroformed metal layer in the electrodeposition cell on the electroforming mandrel by an electroforming process, and removing the electroformed metal layer from the electroforming mandrel, thereby providing a cylindrical metal tube formed with a longitudinal slit as a slit-formed cylindrical sleeve connector having an internal wall with the same grade of surface finish as the external surface of the mandrel.

Abstract: A method of electroforming a non-ferromagnetic substrate for use in an electrostatographic imaging member includes electroforming a non-ferromagnetic substrate of nickel and one of phosphorus, tin and copper. The substrate can be cylindrical shaped and have a substantially constant inner diameter and outer diameter along a length of the substrate. The substrates can be used in various electrostatographic imaging members including electrographic and electrophotographic imaging members. The methods of this invention can provide seamless imaging members such as photoreceptors that can be used in apparatus that include magnetic developer systems, without adversely interacting with magnetic brushes and magnetic toners.

Abstract: A water soluble core of an aluminum or magnesium alloy is used for the production of an object with a hollow space. The aluminum or magnesium alloy is rendered water-soluble by flame spraying or by sintering to produce a high oxide content.

Abstract: A mandrel for forming an inkjet printer nozzle plate having a non-wetting surface of uniform thickness and an orifice wall of tapered contour, and method of making the mandrel. A metal masking layer is deposited on a glass substrate, the masking layer having an opening therethrough for passage of light only through the opening. Next, a negative photoresist layer is deposited on the masking layer, the negative photoresist layer being capable of photochemically reacting with the light. A light source passes light through the substrate, so that the light also passes only through the opening in the form of a tapered light cone. This tapered light cone will define the tapered contour of a nozzle plate orifice wall to be formed. The negative photoresist layer photochemically reacts with the light only in the light cone to define a light-exposed region of hardened negative photoresist.

Abstract: Manufacturing couplers for optical fibers having thin precision dimensions for precision alignment and low-loss coupling of optical fiber segments are disclosed. The couplers can be formed by depositing material on a precision mandrel, removing the mandrel, and then further machining the couplers if necessary. Design variations include simple sleeves and sleeves having ends that are flanged outward so that the ends taper to the correct diameter.

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: A method of forming a hollow metallic article, comprising the following steps: (a) applying a layer of base metal to a fusible alloy mandrel; (b) applying a layer of precious metal to the layer of base metal; (c) applying a third layer of a non-metallic protective coating to the layer of precious metal; and (d) melting out the fusible alloy mandrel. Hollow articles formed by this method are also disclosed.

Abstract: The present invention is directed to methods for preparing devices having hollow metallic microchannels on a surface of a planar substrate. More specifically, the present invention is directed to methods for preparing devices having surface metallic microchannels with a range of widths and heights selected to provide efficient flow characteristics and having thick and, thus, strong and durable channel walls. In addition, the methods of the present invention are compatible with standard integrated circuit fabrication techniques and, because the microchannels are formed upon the surface of the substrate without degrading the surface planarity, these techniques can be used to incorporate electronic circuitry into the microchannel-containing devices. For purposes of this application, the term "microchannel" refers to enclosed or partially enclosed channels having heights within the range from about 2 to about 200 micrometers (.mu.m) and widths within the range of about 10 micrometers to about 2 millimeters.

Abstract: The present invention is directed to methods for preparing devices having hollow metallic microchannels on a surface of a planar substrate. More specifically, the present invention is directed to methods for preparing devices having surface metallic microchannels with a range of widths and heights selected to provide efficient flow characteristics and having thick and, thus, strong and durable channel walls. In addition, the methods of the present invention are compatible with standard integrated circuit fabrication techniques and, because the microchannels are formed upon the surface of the substrate without degrading the surface planarity, these techniques can be used to incorporate electronic circuitry into the microchannel-containing devices. For purposes of this application, the term "microchannel" refers to enclosed or partially enclosed channels having heights within the range from about 2 to about 200 micrometers (.mu.m) and widths within the range of about 10 micrometers to about 2 millimeters.

Abstract: A method of producing a hollow electroformed product of precious metal includes the steps of forming a hollow soluble metal electroformed layer soluble in an inorganic acid on the outer surface of a master model formed of a low melting point material or a chemically soluble material soluble in a chemical, melting or dissolving and removing the master model from inside the soluble metal electroformed layer, coating the outer surface of the remaining soluble metal electroformed layer with a masking layer, forming a precious metal electroformed layer on the inner surface of the soluble metal electroformed layer, stripping the masking layer, and dissolving the soluble metal electroformed layer with inorganic acid.

Abstract: A method of separating an electroformed metal substrate from a mandrel includes establishing a parting gap between the electroformed metal substrate and the mandrel, attaching the electroformed metal substrate at a parabolic end of the mandrel to a parting fixture, and introducing a fluid through the parting fixture into an opening of the mandrel to effect separation of the electroformed metal substrate from the mandrel. The parting fixture includes a parabolically shaped outer cup with a fluid inlet tube extending through the bottom thereof. The parting fixture also preferably includes an inner cup for containing the fluid introduced through the fluid inlet tube and a vacuum device to effect attachment of the electroformed metal substrate to the parting fixture.

Abstract: An implantable medical device such as an intraluminal prosthetic device is formed by an improved manufacturing process. A generally cylindrical mandrel is provided. A reverse image of the prosthesis is engraved into a portion of the mandrel. The reverse image of the prosthesis defines voids and raised surface areas in the mandrel portion. A prosthesis-forming metallic medium is electrochemically deposited into the reverse image of the mandrel. The metallic medium may be a metal, metal alloy or a metal compound. The mandrel including the prosthesis-forming medium thereon is further processed to separate the prosthesis formed by the prosthesis-forming medium from the mandrel by dissolving the mandrel. The process provides greater design freedom in the formation of flexible expandable stents.

Abstract: There is disclosed a method for parting an electroformed article from a mandrel including: (a) solidifying a liquid that is disposed between a parting device and the article, thereby joining the parting device to the article via the solidified liquid; and (b) moving the parting device in a direction of separation of the article from the mandrel while the parting device is joined to the article via the solidified liquid to assist in separation of the article from the mandrel.

Abstract: There is disclosed a method for separating an electroformed article from a mandrel wherein the article is more attracted to a magnetic force than the mandrel comprising employing the magnetic force on the article in separating the article and the mandrel.

Abstract: A titanium ring for an electrodeposition drum has an attractive, uniform surface without patterns comprising bright and dark spots which are formed during surface polishing. The ring has a thickness of 4-30 mm and a surface hardness when it has been polished to an average surface roughness Ra of at most 0.3 .mu.m such that the difference between the maximum and minimum Vickers hardness measured with a load of at most 1 kg at 10 or more points disposed at a pitch of 0.3-1 mm along a line in an arbitrary direction along the surface is at most 10. The ring can be manufactured by welding of a rolled plate or by ring rolling of a tube. When the temperature of the material forming the ring is heated to at least its .beta. transformation point, cooling past the .beta. transformation point is carried out at a rate of at least 1000.degree. C. per hour. Subsequent working or heat treatment is carried out below the .beta. transformation point.

Abstract: An electroforming process and apparatus for forming an electroform with a roughened surface. The present invention roughens the surface of the mandrel using a sandblasting device in the center region of the mandrel allowing the two end regions to remain smooth. The intersection of the roughened center region and each of the two end regions form a step. This step on either side of the roughened center region facilitates sealing while the roughened center region enables toner distribution. The electroform created using the step roughened mandrel surface is separated from the mandrel without destroying the mandrel. The step roughened mandrel can then be reused to create another electroform with a roughened surface.

Abstract: Disclosed is a method of manufacturing a porous alumina tube with numerous pores having a uniform shape and a uniform diameter of 5 to 200 nm and extending linearly in the vertical direction to the outer peripheral surface thereof, which comprises the steps of forming an anodized layer by anodizing the outer peripheral surface of an aluminum tube, and removing the aluminum tube after the anodized layer is formed.

Abstract: The invention is a metal tube such as a heat exchanger tube which has been treated by in situ electrodeposition to repair one or more degraded sections. The repaired metal tube section has an electroformed structural layer which has an ultrafine grain microstructure of sufficient thickness to restore the degraded section at least to its original mechanical specifications.

Abstract: The invention relates to platinum electroforming and platinum electroplating capable of preparing a deposited platinum material having high hardness and increased thickness and size utilizing an electrolyte bath comprising at least one compound selected from the group consisting of chloroplatinic acid, chloroplatinates of alkali metals, hydrogen hexahydroxoplatinate, and hexahydroxoplatinates of alkali metals, 2-100 g/l as platinum; a hydroxylated alkali metal, 20-100 g/l; and a soluble carboxylate.

Abstract: A process for repairing degraded sections of metal tubes, such as heat exchanger tubes, by in situ electroforming utilizes a probe containing an electrode. The probe is movable through the tube to the site of degradation and is sealed in place, thereby creating an electrochemical cell. Electrolyte flows from a reservoir through the cell and a structural layer of metal is deposited on the tube using a pulsed direct current and a duty cycle of 10-60%. The metal layer so formed possesses an ultrafine grain size preferably with a highly twinned microcrystalline structure giving the layer excellent mechanical properties.

Abstract: A method is disclosed for heating a portion of an article comprised of nickel, formed by electrodeposition, and possessing an internal stress sufficient to shrink the outer cross-sectional dimension upon application of heat, thereby shrinking the outer cross-sectional dimension of the heated portion. The method may be used to couple the article to other members such as end flanges without the use of an adhesive.

Abstract: A process for repairing degraded sections of metal tubes, such as heat exchanger tubes, by in situ electroforming utilized a flexible probe containing an electrode. The probe is movable through the tube to the site of degradation and is sealed in place, thereby creating an electrochemical cell. Electrolyte flows from a reservoir through the cell and a structural layer of metal is deposited on the tube using a pulsed direct current and a duty cycle of 10-40%. The metal layer so formed possesses an ultrafine grain size preferably with a highly twinned microcrystalline structure giving the layer excellent mechanical properties.

Abstract: An electroforming process and apparatus for bowing the imaging surface to provide "steering" for moving the electroformed imaging surfaces over rollers or like devices. One embodiment of the present invention is to bow or crown the electroformed imaging surface by using a bimetallic mandrel. The outer material of the mandrel has a greater coefficient of expansion than the inner material. Thus, when the mandrel is heated the outer material expands more than the inner material creating the bowed or crown effect. The electroform takes on the bowed shape during plating and maintains that shape when removed from the mandrel. Another embodiment of the present invention involves mechanically or hydraulically bowing the mandrel and then plating the electroform on the bowed surface. This electroform also maintains the bowed shape when removed from the mandrel.

Abstract: A method of fabricating a needle useful in the dispensing of plastic fasteners and a needle fabricated by the method. In a preferred embodiment, the method involves electroplating a nickel alloy onto a master, the master being made of a meltable material and being appropriately shaped to produce an unfinished shank portion of a needle. The master is then melted away from the electroplated metal, leaving behind an unfinished shank portion. The unfinished shank portion is then finished by machining, and a plastic base portion is insert-molded around the end thereof.

Abstract: Apparatus and process are disclosed for fabricating an endless metal belt comprising a center region between a first end region and a second end region, wherein a portion of the first end region is at least 1.5 times thicker than the center region, thereby resulting in a thickened end portion.

Abstract: An at least partially hollow electroforming mandrel containing therein means for adjustably altering the diameter of the mandrel. The mandrel assists in creating a parting gap between the mandrel and the electroformed article, thereby facilitating separation of the two components.

Abstract: A method of electroforming gold jewelry articles utilizes a first gold/silver electroforming bath which is effective for depositing a relatively soft, ductile gold alloy, and a second gold/silver electroforming bath which is effective for depositing a hard, brittle gold alloy. Prior to the electroforming steps, the method includes the preliminary steps of forming a wax mandrel in a desired configuration, inserting a copper wire into the mandrel and applying a conductive lacquer onto the mandrel. The electroforming method includes the steps of alternately immersing the mandrel into the first and second electroforming baths and electroforming alternating layers of the soft and hard gold alloys over each other to form a laminated gold shell. After the last layer has been electroformed, the wax mandrel is melted and removed from the laminated gold shell thereby forming a hollow jewelry article.

Abstract: Methods and apparatus for separating a mandrel having a tapered end portion from an article formed thereon comprising: (a) providing the mandrel having an opening in the tapered end portion; (b) plugging at least a substantial portion of the opening with a member which presents a deposition surface for the formation of the article; (c) forming the article having a tapered end portion on the mandrel, including on the deposition surface of the member; and (d) pushing the member against the inside surface of the tapered end portion of the article to move the article away from the mandrel, thereby forming a gap between the article and the mandrel.

Abstract: A method is disclosed for parting an electrodeposited article comprised of a first surface region and a second surface region from a mandrel, wherein the method comprises: (a) positioning the article and the mandrel in a metal deposition solution; (b) forming a plurality of metal dendrites on the second surface region wherein the first surface region is free of metal dendrites; and (c) separating the article and the mandrel.

Abstract: The present invention relates to a process for making copper foil from copper-bearing material comprising:(A) contacting said copper-bearing material with an effective amount of at least one aqueous leaching solution to dissolve copper ions into said leaching solution and form a copper-rich aqueous leaching solution;(B) contacting said copper-rich aqueous leaching solution with an effective amount of at least one water-insoluble extractant to transfer copper ions from said copper-rich aqueous leaching solution to said extractant to form a copper-rich extractant and a copper-depleted aqueous leaching solution;(C) separating said copper-rich extractant from said copper-depleted aqueous leaching solution;(D) contacting said copper-rich extractant with an effective amount of at least one aqueous stripping solution to transfer copper ions from said extractant to said stripping solution to form a copper-rich stripping solution and a copper-depleted extractant;(E) separating said copper-rich stripping solution from

Abstract: A method of making a perforated tubular member by supporting a thin stainless tube (10) on a mandrel; machine engraving funnel-shaped holes ( 12 ) through the tube ( 10 ) and removing the machine-engraved tube from the mandrel. An alternate embodiment applies an intermediate layer (22) of aluminum to a core roll (20); applies a plurality of metallic layers (24) to the intermediate layer (22); machine engraves funnel-shaped holes (12) through the metallic layers (24); etches away the intermediate layers (22) and removes the machine-engraved tube. A third embodiment applies a separating-chemical layer (32) to a core roll (30); electro plates a plurality of metallic layers (34); machine engraves funnel-shaped holes (12); into the metallic layers ( 34 ); releases the resulting tube from the separating layer (32); and removes the resulting tube from the core roll.

Abstract: The invention relates to a method for producing a heatable and refrigerable element (12) for a system handling small amounts of liquid and to an element manufactured by the method. The element comprises flow channels (11) and one or more liquid spaces (8) communicating with them, the channels being provided with valves (10) connected to a refrigerator (25) and a heater (18), for blocking the channels by freezing the liquid in them. The element (12) is produced by using a removable mould which serves as a substrate for deposition and by depositing one or more metallic materials by electroformation or an equivalent procedure in such a way that the deposited metal forms a shell (5, 7) by removing the mould from inside the shell by dissolving or smelting, and by connecting the shell at the spot of the valves to a refrigerator (25) and a heater (18). The deposition is carried out so that there is a higher thermal conductivity at the spot of the valves (10) than in the adjacent shell areas.

Abstract: The invention relates to platinum electroforming and platinum electroplating capable of preparing a deposited platinum material having high hardness and increased thickness and size. The platinum electroforming or electroplating bath comprises at least one compound selected from the group consisting of chloroplatinic acid, chloroplatinates of alkali metals, hydrogen hexahydroxoplatinate, and hexahydroxoplatinates of alkali metals, 2-100 g/l as platinum and a hydroxylated alkali metal, 20-100 g/l.

Abstract: A method of fabricating a hollow jewelry object in which an electrically conductive coating is applied to part (18) of a non-conductive mandrel or mould (10), the coated mandrel being presented for a first dip into an electrolyte containing ions of a precious metal e.g. gold so that the parts of the mandrel are coated with an initial deposit; the mandrel is then removed from the electrolyte and the previously uncoated portions (24) coated before the mould is again dipped in the or a different electrolyte to form an outer shell integral with the internal ribs or points formed during the first dip. Thus the hollow jewelry object is internally strengthened by the ribs; though in an alternative embodiment the ribs can be replaced by individual upstanding projections in bas relief if these conform to the external profile required for the jewelry object. The invention also includes a hollow jewelry object formed by the method according to the invention.

Abstract: In a multilayer endless metal belt assembly, adjacent opposing belt surfaces have different hardnesses so that they may be lubricous and less subject to galling.

Abstract: A layered photosensitive imaging member is modified to reduce the effects of interference within the member caused by reflections from coherent light incident on a base ground plane. The modification described is to form the ground plane surface with a rough surface morphology by an electroforming process which leaves the surface with a matte-like finish. Light reflected from the ground plane formed with the matte finish is diffused through the bulk of the photosensitive layer breaking up the interference fringe patterns which are otherwise later manifested as a plywood pattern on output prints made from the exposed sensitive medium.

Abstract: A pressure switch for use in a device for alarming the reduction of pneumatic pressure of vehicle tire is disclosed. The switch comprises a base board, a bellofram secured to the base board and having conductive coating of one electric contact applied to the inner surface and the outer surface thereof and having both bellows and diaphragm characteristics, a housing provided to enclose the bellofram and for defining a hermetic chamber, and a conductor provided at inner portion and outer portion of the bellofram near the center of the diaphragm portion thereof and for forming another electric contact. A back pressure is applied to the inner portion or outer portion of the bellofram against the pneumatic pressure of a vehicle tire.

Abstract: A sheet member and a method for constructing the sheet member. The sheet member includes a plurality of elongated, enclosed channels formed by electrodeposition.