HIGH SURFACE AREA ANODE AND METHOD OF MANUFACTURING
The invention described herein shows a high surface area anode. The high surface area anode contains a flat surface on one side and a ribbed surface on the opposite side. On the ribbed surface there is a first edge-lip on its first-end and a second edge-lip on its second-end. Both the first edge-lip and the second edge-lip run parallel to each other. The high surface area anode further contains a plurality of ribs and groves between the first edge-lip and the second edge-lip also running parallel to each other. The high surface area anode is manufactured using a continuous casting method that includes the following steps; dissolving the anode metal into the holding furnace shaping the anode metal using a high surface area graphite mold; solidifying the anode metal using a liquid while extruding the anode metal through the high surface area mold; solidifying the anode metal by using a secondary cooling source; and extracting the now solidified and shaped high surface anode metal.
The present invention is directed to a high surface area anode and a method of manufacturing the high surface area anode to electroplate the surface of various products.
Description of the Related ArtThe electroplating process consists of the immersion of an object to be coated in a bath containing an anode. The object itself functions as the cathode. The bath is usually a solution of salts of the metal to be deposited. An electrolytic cell is produced when voltage is applied to the anode. The cathode being negative. Metal ions formed in the solution are attracted to the cathode where they gain electrons and deposit out of the solution onto the cathode surface as pure metal.
Electroplating is widely used in various industries for coating metal objects with a thin layer of a different metal. The layer of metal deposited has some desired property, which the metal of the object lacks. For example, chromium plating is done on many objects such as car parts, bath taps, kitchen gas burners, wheel rims and many others for the fact that chromium is very corrosion resistant, and thus prolongs the life of the parts. Electroplating has wide usage in industries, including in the making of inexpensive jewelry. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.
Silver anodes are used to plate the surface of various products from jewelry to precision military and aerospace parts. Electroplating uses electric current to reduce dissolved metal cations so that they form a coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate, as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes.
The process used in electroplating is called electrodeposition. It is analogous to a galvanic cell acting in reverse. The part to be plated is the cathode of the circuit. In one technique, the anode is made of the metal to be plated on the part. Both components are immersed in a solution called an electrolyte containing one or more dissolved metal salts as well as other ions that permit the flow of electricity. A power supply supplies a direct current to the anode, oxidizing the metal atoms that it comprises and allowing them to dissolve in the solution. At the cathode, the dissolved metal ions in the electrolyte solution are reduced at the interface between the solution and the cathode, such that they “plate out” onto the cathode. The rate at which the anode is dissolved is equal to the rate at which the cathode is plated, vis-a-vis the current through the circuit. In this manner, the ions in the electrolyte bath are continuously replenished by the anode.
There are many kinds of anodes. Typical bar anodes when spent form a “sword” shape which for many reasons are a disadvantage, as described in prior art U.S. Pat. No. 2,802,702.
Unfortunately, plating with the aforementioned variable surface area anode “sword” design, dissolves the anode unevenly and there is a lot of waste of metal. Moreover, when the anode is dissolved unevenly, it makes the electrodeposition of the metal also uneven thus creating an irregular coating.
One way to solve the aforementioned issues is to make the current distribution uniform, so if the current distribution is uniform, the plating thickness will be uniform. But to even out the thickness when geometry favors higher or lower current density to certain areas, three “mechanical” techniques are shielding (the use of plastic shields to block off the shortest path), thieving (the use of conductive wires as cathodes to steal some of the current away from high current areas, and auxiliary anodes (anode material in close proximity to the work in the areas which need more current). These techniques are antiquated when performing high volume plaiting and it also consumes time and money.
What is needed in the industry is an anode that consumes from the front surface closest to the plated part to the back surface furthest from the plated part, reduces or eliminates the need for the addition of additional salts in solution, maintains an even current density throughout the life of the anode, results in a more uniform plating or coating, and at the same time causes less waste of the anode metal. Available art does not provide an anode with the aforementioned properties. Therefore, a need exists to overcome the problems with the prior art as discussed above.
SUMMARYThe invention provides a High Surface Area Anode and Method of Manufacturing that overcomes the previously mentioned disadvantages of the heretofore-known devices and methods of this general type.
The anode described herein includes a method of manufacturing; wherein the anode created generates superior electrodeposited coatings. Furthermore, the design of the anode allows the electrolyte to dissolve it more uniformly and it doesn't have the diminishing effects of the prior art sword.
Specifically, the invention includes a high surface area anode including, at least one flat surface and at least one ribbed surface on its short end; the ribbed surface further comprising at least one edge lip on the long end. The ribbed surface further comprises a plurality of ribs and groves and at least one edge lip is larger in height and width than one of the ribs. The at least one edge lip contains more material by volume than one of the ribs, wherein the plurality of ribs and groves define the width of the high surface area anode.
The invention also describes a high surface area anode including a flat surface on one side and a ribbed surface on its opposite side; the ribbed surface further including a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other. The ribbed surface further comprises a plurality of ribs and groves and the first edge lip and second edge lip are larger in height and with than one of the ribs. The first edge lip and second edge lip contain more material by volume than one of the ribs, and the first edge lip and second edge lip contain more material by volume than the plurality of ribs. The plurality of ribs and groves define the width of the high surface area anode.
The invention al so includes a method of manufacturing, the method of manufacturing a high surface area anode includes the steps of; 1) dissolving the anode metal into the holding furnace; 2) shaping the anode metal 801 using a high surface area graphite mold; 3) solidifying the anode metal using a liquid while extruding the anode metal through the high surface area mold; 4) solidifying the anode metal by using a secondary cooling source, and 5) extracting the now solidified and shaped high surface anode metal. The shape of the high surface area anode further includes a flat surface on one side and a ribbed surface on its opposite side, and the ribbed surface further including a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other.
Other features that are considered as characteristic for the invention are set forth in the appended embodiments. As required, detailed embodiments of the present invention are disclosed; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defusing the features of the invention regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward. The figures of the drawings are not drawn to scale.
Before the present invention is disclosed and described, the terminology used is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.
As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
Current density is defined as current in amperes per unit area of the electrode. It is a very important variable in electroplating operations. It affects the character of the deposit and its distribution. Current distribution (depicted in
There are three types of electrolytic metal deposition processes: direct current electrodeposition, pulse plating, and laser-induced metal deposition. In the direct current (DC) electrodeposition, the current source is a power source in the form of a battery or rectifier (which converts alternating current electricity to regulated low-voltage DC current) provides the necessary current. Electroplating is performed in a plating unit. Electrodes, immersed in the electroplating bath (electrolyte), are connected to the output of a DC current source. The workpiece (depicted in
When an anode (such as the one depicted in numerals 201 and 500) is charged with power, it becomes similar to the positive end of a magnet, emitting a force field. The workpiece, being connected to the negative side of the power supply, becomes negatively charged and attracts the positive charge from the anode.
The “positively charged” anode dissolves gradually into the solution as it is attracted to the negative workpiece. The dissolved metal is attracted to the workpiece along the lines of force within a force field. An edge creates multiple force fields, hence concentrated at the edge and emitting more metal from that edge. When an object is placed into the force it effects the lines of force, the workpiece diverts the force fields emitted by the anode depending on its shape. Metallic objects, depending on its shape, attracts the force fields a specially at the corners, this concentration of force field produce more plating in these areas. Other reasons why more material concentration is because force field are attracted to edges that we nearest to the anode.
By creating the ribbed surface in the middle with larger first edge-lip on its first-end, and a second larger edge-lip on its second-end, the force fields are made to radiate equally towards all surfaces to be coated. The increase in material at the edge of the high surface area anode compensates for the increase in force fields at the edges, hence transferring more material to the part to be coated. The invention herein contains more material at the edges of the anode, this allow for the force field concertation to transfer material at a larger rate at the edges than in the middle. Since the edges contain more material, it has more to give and therefore the entire high surface area anode part is consumed evenly.
As explained above, the anode has a superior design because 1) it makes the force fields radiate evenly; and 2) the anode is dissolved more uniformly and stays intact as it is consumed until the very end. One of the many advantages of this technology is that it wears more evenly from the front surface than from the edges. Therefore, there is very little dimensional change to the anode as it is dissolved allowing for a more even distribution of the coating layer.
Ribbed surface 112 comprises a multitude of ribs and groves, but it could also be created with “V” shaped typed indentations, that could be stamped or milled. Similarly, edge lips, could be created of multiple dimensions and of different geometries both round or squared, as long as the volume of material is larger 106 that of the ribs 103 inside the ribbed surface 107. The high surface anode can be made of many types of materials, such as: Gold, Silver, Copper, Nickel, Tin, Solder (tin-lead alloy), Brass, Cadmium, Palladium, Zinc, and Chrome.
Having a better more uniform metal coating is advantage because the silver (or any other precious metal) is electrolytically plated onto surfaces of parts creating a surface that does not need re-work thus reducing significantly the cost of manufacturing. A more uniform deposition and plating are achieved because the current density 603 and 604, of the anode of
The continuous casting method 920 of
The process 920 described in
The volume of the edge lips 1402 and 1404 depend how large the anode 1401 is, but as a rule of thumb, the height of the lip is approximately 4 times that of a single rib (previously shown in
A high surface area anode, and method of manufacturing has been disclosed. The manufacturing method and mold creates an anode where the ends of the anode are rounded, and thicker which help ensure the anode dissolves and electroplates evenly. Also, there are multiple center ribs and groves in the high surface area anode that helps ensure there is a more uniform current density in the plating solution. One of the many advantages of this technology is that the high surface area anode is continuously casted which helps control a tight tolerance of silver grain sizes. Furthermore, the high surface area anode allows for a more uniform plating process, which helps reduce the use of silver and provide a better finish with fewer imperfections.
Claims
1. A high surface area anode comprising,
- a. At least one flat surface and at least one ribbed surface on its short end; i. the ribbed surface further comprising at least one edge lip on the long end.
2. The high surface area anode, wherein
- a. the ribbed surface further comprises a plurality of ribs and groves.
3. The high surface area anode, wherein
- a. the at least one edge lip is larger in height and width than one of the ribs.
4. The high surface area anode, wherein
- a. the at least one edge lip contains more material by volume than one of the ribs.
5. The high surface area anode, wherein
- a. the plurality of ribs and groves define the width of the high surface area anode.
6. A high surface area anode comprising,
- a. a flat surface on one side and a ribbed surface on its opposite side; i. the ribbed surface further comprising a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other.
7. The high surface area anode, wherein
- a. the ribbed surface further comprises a plurality of ribs and groves.
8. The high surface area anode, wherein
- a. the first edge lip and second edge lip are larger in height and with than one of the ribs.
9. The high surface area anode, wherein
- a. the first edge lip and second edge lip contain more material by volume than one of the ribs.
10. The high surface area anode, wherein
- a. the first edge lip and second edge lip contain more material by volume than the plurality of ribs.
11. The high surface area anode, wherein
- a. the plurality of ribs and groves define the width of the high surface area anode.
12. A method of manufacturing a high surface area anode comprising the steps of,
- a. dissolving the anode metal into the holding furnace;
- b. shaping the anode metal using a high surface area graphite mold;
- c. solidifying the anode metal using a liquid while extruding the anode metal through the high surface area mold;
- d. solidifying the anode metal by using a secondary cooling source, and
- e. extracting the now solidified and shaped high surface anode metal,
- f. wherein the shape of the high surface area anode further comprises a flat surface on one side and a ribbed surface on its opposite side; i. the ribbed surface further comprising a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other.
Type: Application
Filed: Oct 1, 2018
Publication Date: Apr 22, 2021
Inventor: Randy Frank Klein (Eagieville, PA)
Application Number: 16/148,966