Electrochemical treatment device

Abstract

The invention relates to an apparatus comprising an apparatus housing and a first flexible contact and a second flexible contact extending from the housing, the first flexible contact and the second flexible contact each comprising a mounting means and a flexible applicator portion extending from the mounting means, wherein the first flexible contact and the second flexible contact are each adapted to receive an electrically conductive fluid and subsequently apply the electrically conductive fluid to a surface, and one of the first flexible contact and the second flexible contact is positively charged relative to the other and the other is negatively charged relative to the other.

Description

[0001] Priority details

[0002] This application claims priority to AU 2021902996, filed on 17 September 2021 in Australia, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates generally to the field of treating conductive surfaces, and more specifically to the field of apparatus for electrochemically treating conductive surfaces. Background Technology

[0004] Electrochemical reactions are used in various processes on metal surfaces, such as cleaning solder coloring after assembly, electropolishing surfaces, depositing or plating material onto surfaces, or electrochemically etching templated designs into surfaces. This process requires the circuit to be completed in the presence of a conductive fluid, meaning the conductive surface must be electrically connected to two opposite terminals of a power source. These connections are typically made using a pair of opposing electrodes—for convenience, these electrodes will be referred to below as the “working” electrode and the “return” electrode, indicating that the electrodes are connected to opposite power source terminals. Electrochemical processes require the working electrode to be positively or negatively charged relative to the conductive surface and the return electrode. The specific charge on the working electrode will depend on the properties of the conductive surface, the desired electrochemical process, and the conductive fluid.

[0005] It is well known that if a conductive fluid is present at both the working electrode and the return electrode, then opposing electrochemical reactions will occur near both electrodes—one desirable and the other potentially undesirable. However, if it is desired that only one of these electrochemical reactions occurs, then only the working electrode should be conductive via the conductive fluid; the return electrode should be a "direct return electrode" because it is directly connected to a conductive surface.

[0006] Typical prior art electrochemical cleaning / etching / marking tools include a contact tool that serves as both a working electrode (sometimes called a "bar") and a conductive fluid applicator, and a grounding clamp that is directly attached to a conductive surface to provide a direct return electrode. The contact tool and grounding clamp are connected to opposite terminals of a power source. As long as the grounding clamp is connected, the contact tool, along with the conductive fluid, contacts the conductive surface, allowing the circuit to complete and initiating the desired electrochemical reaction.

[0007] Some alternative existing technology arrangements can utilize a direct return electrode that relies on pressure and springs from the user to maintain a return connection to the workpiece, while other arrangements can rely on a conductive stage to act as a direct return electrode and maintain an electrical connection with the workpiece.

[0008] Technicians will understand that, generally, applying or “plating” material onto a conductive surface requires the working electrode to be positive relative to the conductive surface, while removing material (such as during cleaning or polishing processes) typically requires the working electrode to be negative relative to the conductive surface. However, technicians will understand that the electrochemical principle remains the same, regardless of the effect the user is seeking—the circuit must still be established, and the conductive fluid must still be applied.

[0009] Existing electrochemical cleaning / etching / marking tools vary in the size, shape, and arrangement of their working electrodes, and may carry different advantages or disadvantages. However, every electrochemical cleaning / etching / marking tool requires the presence of a grounding clamp or other form of direct return electrode. Unfortunately, the various existing direct return electrode designs each impose significant limitations on the user. For example, using a grounding clamp restricts user mobility—the clamp is tethered to the electrochemical cleaning / etching tool's power source via a cable, and to move beyond the cable's reach, the user must remove and reattach the clamp at a new location. Furthermore, not all surfaces provide easily accessible protrusions to which the grounding clamp can be properly attached for operation; for example, large, smooth metal surfaces (such as the interior of hoppers or water tanks) may lack suitable protrusions for receiving the grounding clamp. In a similar context, spring-loaded direct return electrodes require constant user attention to maintain the necessary pressure. Finally, existing electrochemical cleaning / etching / marking tools that rely on conductive stages limit the user, as they can only work on items placed directly on the stage—these existing tools are essentially completely stationary.

[0010] Therefore, there is a need for an electrochemical cleaning / etching device that offers improvements in its mobility and / or portability, or at least overcomes some of the disadvantages of the prior art. Specifically, the object of the present invention is to provide an electrochemical cleaning / etching device that does not require a separate grounding clamp or other form of separate device that restrains the user to a specific area or otherwise restricts their direct return electrode. Summary of the Invention

[0011] In a first aspect, the present invention relates to an apparatus comprising an apparatus housing and a first flexible contact and a second flexible contact extending from the housing, each of the first and second flexible contacts comprising a mounting device and a flexible applicator portion extending from the mounting device, wherein the first and second flexible contacts are each adapted to receive a conductive fluid and subsequently apply the conductive fluid to a surface, and one of the first and second flexible contacts is positively charged relative to each other, and the other is negatively charged relative to each other.

[0012] In an embodiment, the power received from the power source by the first flexible contact and the second flexible contact may be alternating current (AC) power, such that the first flexible contact alternates between being positively charged and negatively charged, and the second flexible contact alternates between being negatively charged and positively charged, with the alternation of each of the first and second flexible contacts occurring simultaneously and in opposite directions.

[0013] In this embodiment, the power source may be an alternating current (AC) power source.

[0014] In an alternative embodiment, the power supply may be a direct current (DC) power supply, and the device may further include a switching unit located between the power supply and the first and second flexible contacts, the switching unit being electrically connected to a voltage output terminal and a ground terminal, the first and second flexible contacts, a switching controller being connected to the switching unit and having a charge polarity period, the switching unit having a first configuration and a second configuration, in the first configuration the first flexible contacts are positively charged relative to each other and the second flexible contacts are negatively charged relative to each other, in the second configuration the first flexible contacts are negatively charged relative to each other and the second flexible contacts are positively charged relative to each other, and the switching controller being configured to periodically switch the switching unit between the first and second configurations at a rate determined by the switching period.

[0015] In an embodiment, the device may further include a DC-DC converter electrically connected to a power supply and a switching unit, with a voltage output terminal and a ground terminal being corresponding terminals of the DC-DC converter, and the DC-DC converter configured to: receive a constant voltage input from the power supply, convert the constant voltage input into a pulsed voltage output, and provide the pulsed voltage output to the switching unit via the voltage output terminal. Further, the pulsed voltage output includes a voltage waveform having a repeating pattern formed by alternating maximum and minimum voltages and having a pulse period, and the charge polarity period is approximately an integer multiple of the pulse period. In an embodiment, the charge polarity period may be approximately an odd integer multiple of the pulse period.

[0016] In one embodiment, the pulsed voltage output may include a voltage waveform having an asymptotic slope at its minimum voltage and a non-asymptotic slope elsewhere, and the timing of the switching unit switched by the switching controller is approximately aligned with the minimum voltage. In another embodiment, the voltage waveform may be a rectified full-wave sine wave.

[0017] In an embodiment, the switching unit may include an array of switches, the array including: a first switch forming a closable circuit segment between a voltage output terminal and a first flexible contact; a second switch forming a closable circuit segment between a voltage output terminal and a second flexible contact; a third switch forming a closable circuit segment between a ground terminal and the first flexible contact; and a fourth switch forming a closable circuit segment between a ground terminal and a second flexible contact. Further, switching the switching unit to a first configuration includes closing the first and fourth switches and opening the second and third switches, and switching the switching unit to a second configuration includes opening the first and fourth switches and closing the second and third switches.

[0018] In an alternative embodiment, where the power source is a direct current (DC) power source, the first flexible contact may include a contact area much smaller than that of the second flexible contact. In this embodiment, the contact area of ​​the first flexible contact may be at least twice as small as that of the second flexible contact.

[0019] In this embodiment, the DC power source may be a storage battery, a power battery, a fuel cell, or other independent DC power source.

[0020] In an embodiment, at least one of the first flexible contact and the second flexible contact may include a roller having a roller support and a rolling element formed of absorbent material mounted on the roller support, the rolling element being adapted to receive a conductive fluid and subsequently apply the conductive fluid to the surface.

[0021] In an embodiment, the roller can be a separate roller having a first rolling element portion and a second rolling element portion, the first rolling element portion being arranged to form a first electrode and the second rolling element portion being arranged to form a second electrode, the separate roller being electrically connected to a power source, and the first rolling element portion and the second rolling element portion being electrically isolated from each other.

[0022] In an embodiment, at least one of the first flexible contact and the second flexible contact may include an absorbent pad adapted to receive conductive fluid and subsequently apply the conductive fluid to the surface.

[0023] In one embodiment, at least one of the first flexible contact and the second flexible contact may include a brush. In another embodiment, the brush may include conductive filaments.

[0024] In one embodiment, the device may further include a separating element formed of a non-conductive material, arranged to prevent the first or second flexible contact from directly contacting the other flexible contact. In another embodiment, the separating element may include a shield extending at least partially around at least one of the first and second flexible contacts.

[0025] In one embodiment, the power source may be an on-board power source contained within or mounted to the device housing. In another embodiment, the on-board power source may be housed within a power supply housing that is detachably mounted to the device housing.

[0026] In an alternative embodiment, the power supply may be located in a power supply housing that is spaced apart from and electrically connected to the device housing.

[0027] In one embodiment, the device may further include a fluid conduit arranged to provide conductive fluid from a fluid source to each of the first flexible contact and the second flexible contact. In another embodiment, the fluid source may be a fluid reservoir housed within or mounted to the device housing. In yet another embodiment, the fluid reservoir may be detachable from the device housing. In a further embodiment, where the power source is located in a power supply housing removably mounted to the device housing, the fluid reservoir may be located within the power supply housing.

[0028] Embodiments of the device are used for electrolytically cleaning and passivating solder in conductive articles. Embodiments of the device are also used for electrochemically etching designs, patterns, or other forms of markings onto the surface of conductive articles.

[0029] Further embodiments or variations of the invention may be disclosed herein, or may otherwise become apparent to those skilled in the art from the following disclosure. These and other embodiments are considered to fall within the scope of the invention. Attached Figure Description

[0030] Embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0031] Figure 1A and Figure 1B Embodiments of the present invention are described;

[0032] Figure 2 The desired and undesired responses are described;

[0033] Figures 3-5 This is a circuit diagram of an alternative embodiment of the present invention;

[0034] Figures 6A-6C This is a voltage waveform diagram of an embodiment of the present invention;

[0035] Figure 7 and Figure 8 This is a circuit diagram of an embodiment of the present invention including a switching unit;

[0036] Figures 9A-10C This is a voltage waveform diagram of an embodiment of the present invention including a switching unit;

[0037] Figure 11A and Figure 11B Alternative embodiments of the invention are described; and

[0038] Figures 12-16 Different embodiments of the first flexible contact and / or the second flexible contact are depicted. Detailed Implementation

[0039] In a first aspect, the present invention relates to an apparatus for applying a conductive fluid to a conductive surface for cleaning, passivating, etching or otherwise treating the conductive surface. Figure 1A and Figure 1B Embodiments of the present invention are described, wherein Figure 1A It is its visual depiction and Figure 1B This is its circuit diagram. An embodiment of the depicted device includes a device housing 10 and a first flexible contact 14 and a second flexible contact 16 extending from the device housing. The first flexible contact 14 and the second flexible contact 16 are electrically connected to opposite terminals of a power supply 12 (the electrical connection is in...). Figure 1A (Depicted by dashed lines), such that one of the flexible contacts will be positively charged relative to each other and the other will be negatively charged relative to each other, and the first and second flexible contacts are each configured to carry conductive fluid in some way. The first flexible contact 14 and the second flexible contact 16 may include mounting devices for securing the flexible contacts to the device housing 10 and flexible applicator portions configured to carry conductive fluid.

[0040] As used herein, the term "charge polarity" refers to whether an element is positively or negatively charged. As used herein and unless otherwise specified, the identification of the charge polarity of any flexible contact 14, 16 shall be interpreted relative to the identification of the other flexible contact. For example, if the first flexible contact is positively charged and the second flexible contact is grounded, then the second flexible contact is "negatively charged" relative to the first flexible contact.

[0041] like Figure 1BAs shown in the circuit diagram, there is no direct electrical connection between the first flexible contact 14 and the second flexible contact 16. When a conductive fluid is applied to the conductive surface 18 having the first flexible contact 14 and the second flexible contact 16, the circuit is completed through the conductive surface, such that the voltage generated by the power source 12 causes current to flow through the conductive surface 18 (and any conductive fluid that may be present) between the first and second flexible contacts. The power source 12 can be any specific power source capable of providing sufficient voltage. The power source 12 in… Figure 1A It is described as a portable battery pack, but this is only an example.

[0042] As those skilled in the art will understand, electrochemical processes (such as weld cleaning, surface passivation, and electrochemical etching or marking) all require the presence of a specific conductive fluid and the formation of a circuit to allow current to flow, thereby driving an electrochemical reaction between ions dissolved in the conductive fluid and the conductive surface 18. Since the device includes a first flexible contact 14 and a second flexible contact 16 with opposite charges, both adapted to carry the conductive fluid, either flexible contact can serve as both a “working electrode” and a “return electrode” depending on the desired electrochemical reaction and the relative charges of the flexible contacts. This contrasts with prior art arrangements using grounding clamps or spring mechanisms, which cannot act as a “working electrode” because they cannot carry or apply the conductive fluid and are directly connected to the conductive surface 18, thus limiting the flow of current through any conductive fluid that may be present in its vicinity.

[0043] In at least one embodiment of the present invention, a plurality of first flexible contacts 14 and / or a plurality of second flexible contacts 16 arranged in parallel with each other may be present. These embodiments are not considered to depart from the scope of the present invention, and any reference to a first flexible contact 14 or a second flexible contact 16 should be considered to apply equally to a plurality of first flexible contacts or second flexible contacts, unless otherwise specified.

[0044] Embodiments of the present invention are believed to enable users to electrolytically clean and passivate solder, electrochemically etch designs, patterns, or other forms of markings on conductive surfaces of articles, without the need for grounding clamps, grounding spring mechanisms, or conductive workbenches. This allows users to utilize a device with substantially improved mobility and flexibility compared to prior art tools that require grounding clamps and are therefore tethered in place. Users may also be able to use embodiments of the device on ladders, in harnesses, or in other hard-to-reach or restricted situations without the risk of grounding clamps and cables hindering their movement.

[0045] Those skilled in the art will understand that electrochemical processes require specific voltage potentials to occur at a useful rate. In at least one embodiment, power source 12 may be a power source capable of providing at least 12 volts. In another embodiment, power source 12 may provide at least 18 volts.

[0046] Expected and Unexpected Responses

[0047] refer to Figure 2 This illustration depicts a portion of an embodiment of the invention arranged for cleaning or polishing conductive surfaces. A first flexible contact 14 and a second flexible contact 16, a conductive surface 18, and a conductive fluid 20 are shown. The conductive surface 18 comprises a bulk material 18A and a surface layer 18B on top. In some embodiments, the surface layer 18B may be an oxide material, solder coloring, or other deposition on the conductive surface 18 and thus covering the bulk material 18A. In other embodiments (not depicted), the surface layer 18B may be an upper layer of the conductive surface 18, which is removed, for example by an etching process, to expose the underlying bulk material 18A. Although not depicted, those skilled in the art will recognize that the flexible contacts carry opposite charges relative to each other, and the appropriate charge polarity for the desired reaction will depend on the nature of the conductive surface, the specific electrochemical process applied to the conductive surface, and the type of conductive fluid employed. For simplicity, the flexible contacts 14, 16, appropriately charged to facilitate the desired reaction 22, may be referred to herein as “activated flexible contacts.”

[0048] Since both the first flexible contact 14 and the second flexible contact 16 are in contact with the conductive fluid, reaction processes 22 and 24 occur at each flexible contact. The reaction processes occurring at each flexible contact depend on its charge polarity relative to the conductive surface and other flexible contacts, properties well known in the art. Positively charged ions in the solution within the conductive fluid will migrate away from the positively charged flexible contacts, through the conductive fluid, and toward the conductive surface and the negatively charged flexible contacts. Similarly, negatively charged ions in the solution will migrate away from the negatively charged flexible contacts and toward the positively charged flexible contacts and the conductive surface.

[0049] Typically, only one of these processes will be the desired process 22—which, in the example Figure 2The process is depicted as surface layer 18B entering the solution within conductive fluid 20, migrating toward the properly charged first flexible contact 14, and ultimately depositing thereon. Charge balancing process 24 may include other non-harmful reactions such as gas or water release, but may also include the reverse of the desired process 22. For example, as depicted by the curved arrow, charge balancing process 24 may also include, undesirably, the re-deposition of material drawn from surface layer 18B into the solution back onto conductive surface 18. Undesirable forms of charge balancing process 24 may also include the dissolution of material deposited on the second flexible contact 16, the migration of these ions toward conductive surface 18, and subsequent deposition thereon.

[0050] Those skilled in the art will recognize that the properties of the conductive surface 18 (including the properties of the bulk material 18A and the surface layer 18B), the conductive fluid 20, and the properties of the desired process 22 and the undesired process 24 can vary between applications of embodiments of the invention. Those skilled in the art will further recognize that these different properties are generally well known in the art.

[0051] Expected process to promote / not expect process improvement

[0052] The time required for an electrochemical reaction to occur at the corresponding reaction site depends on the ion migration rate in solution and the length of the path the ions need to travel. Ion velocity depends on the ion properties, solution concentration, temperature, and applied potential gradient. Further reference Figure 2 Furthermore, without limiting the scope of the invention by theory, it is considered that when the desired process 22 includes the dissolution of surface materials (such as by etching, cleaning and / or polishing), the “path length” of the desired process 22 is the distance between the first flexible contact 14 and the surface layer 18B immediately adjacent to the first flexible contact 14.

[0053] Conversely, one form of the undesirable process (represented by the curved arrow in charge balancing process 24) requires dissolved ions of surface layer 18B to first migrate through conductive fluid 20 toward the second flexible contact 16 before they can subsequently migrate to conductive surface 18 for deposition, because the dissolved ions must first escape the influence of the first flexible contact 14. An alternative form of the undesirable process (dissolution of material on the second flexible contact 16 and subsequent deposition on conductive surface 18) requires three steps: dissolution, migration, and deposition. It has been found that, in general, the undesirable process takes longer to complete than the desired process 22. In some embodiments, the undesirable process may require at least twice the length of the desired process.

[0054] In the desired process 22, which involves marking the conductive surface by depositing or plating material (not depicted), ions already dissolved in the conductive fluid 20 are drawn away from the properly charged flexible contact and toward the conductive surface 18 and other flexible contacts of opposite polarity. Deposition of ions onto another flexible contact, or drawing material deposited on the conductive surface 18 into the solution, is generally an undesirable process. As in the previously discussed examples, it is envisioned that completing the undesirable process (the movement of ions from, for example, the first flexible contact 14 or the conductive surface 18, to the second flexible contact 16 and subsequently depositing thereon) would take longer than completing the desired process 22.

[0055] Based on the above, a specific electrochemical process (i.e., the desired process 22 and its associated charge balance and / or undesirable process 24) applied to a conductive surface 18 with specific properties and using a specific conductive fluid 20 and an applied voltage will have a specific desired process completion time (T) that follows the equation below. C ):

[0056] T D,min ≤T C <T U

[0057] Among them, T D,min It is the minimum time required to perform the desired process 22, while T U This is the time required to perform the undesirable process 24. Technicians will recognize that T C It is in T D,min With T U The range of time values ​​between.

[0058] In an embodiment, the desired reaction 22 can be promoted and the charge balancing reaction 24 restricted by rapidly switching the charge polarity of the first flexible contact 14 and the second flexible contact 16, such that they alternate between being positively or negatively charged relative to each other. Without limiting the scope of the invention theoretically, it is conceivable that by switching the charge polarity of the first flexible contact 14 and the second flexible contact 16 such that each undisconnected time period spent under a particular charge polarity is greater than the minimum time required for the desired process but less than the time required for the undesired process, the desired process 22 can be selectively promoted over the undesired process, thereby reducing, eliminating, or at least improving the need for a direct return electrode such as a grounding clamp.

[0059] Regarding the cleaning, etching, or polishing arrangement, for ease of explanation, it will be described according to one arrangement in which the surface layer 18B dissolves to form positively charged ions—such as when the surface layer being removed comprises metal. The device is powered such that the first flexible contact 14 is negatively charged and the second flexible contact 16 is positively charged. The surface layer 18B is drawn into the solution and its ions migrate toward the first flexible contact 14, some of which migrate over the conductive fluid 20, detaching from the influence of the first flexible contact 14 and subsequently becoming influenced by the positively charged second flexible contact. However, before these ions can be redeposited, the charge polarity of the power source 12 is reversed, such that the first flexible contact 14 is now positively charged and the second flexible contact 16 is negatively charged.

[0060] Regarding the marking or plating arrangement, as an illustrative example, the device can be powered such that the first flexible contact 14 is positively charged and the second flexible contact 16 is negatively charged. Positively charged ions already dissolved in the conductive fluid 20 are propelled by the positively charged first flexible contact 14 to deposit on the conductive surface 18 and migrate from the first flexible contact towards the second flexible contact 16. However, by reversing the charge polarity of the flexible contacts 14, 16 before the ions can be plated thereon, the plating or deposition of dissolved material on the now positively charged second flexible contact 16 is reduced, suppressed, or at least improved.

[0061] Although the above examples have been described with reference to positively charged ions drawn into or deposited from a solution, those skilled in the art will recognize that these are merely exemplary and that adapting the device for drawing negatively charged ions into or depositing them from a solution is within the scope of the invention as disclosed herein.

[0062] In a further embodiment, the device may be configured such that the voltage at the first flexible contact 14 when the first flexible contact is positively charged and the voltage at the second flexible contact 16 when the second flexible contact is positively charged are substantially similar in magnitude. In an alternative embodiment, the device may be configured such that the voltage at the first flexible contact 14 when the first flexible contact is negatively charged and the voltage at the second flexible contact 16 when the second flexible contact is negatively charged are substantially similar in magnitude. In either embodiment, the device may be further configured such that each of the flexible contacts 14, 16 takes substantially similar times to be positively or negatively charged in order to suppress or at least mitigate any possible "DC bias".

[0063] The complete time period taken to charge to a specific charge polarity can be referred to in this paper as the "charge polarity time period" (T). P — That is, the time period during which the charge polarity switches between flexible contacts 14 and 16. In an ideal embodiment, the charge polarity period TP Equal to the expected process completion time T C .

[0064] In an alternative embodiment, the first flexible contact 14 may be configured to facilitate the desired reaction 22 by including a reduced contact area compared to the second flexible contact 16. As those skilled in the art will recognize, while the overall reaction rate of each of the desired reaction 22 and the charge balance reaction 24 depends at least in part on the total current flowing through the completed circuit, the rate per unit area of ​​either the desired reaction 22 or the charge balance reaction 24 depends on the current density. Thus, by reducing the contact area of ​​the first flexible contact 14 to be substantially smaller than that of the second flexible contact 16, the current density adjacent to the first flexible contact 14 increases relative to the current density adjacent to the second flexible contact 16, thereby increasing the rate of the desired reaction 22 per unit area. Conversely, any products of the charge balance reaction 24 will be dispersed over a relatively large surface area without increasing the amount produced, allowing any undesirable deposits to be gradually thinned and substantially removed. In another embodiment, the contact area of ​​the first flexible contact 14 may be at least twice the contact area of ​​the second flexible contact 16. Those skilled in the art will recognize that the ratio between the contact areas of the first flexible contact 14 and the second flexible contact 16 may also depend on various factors, such as the reaction rate per unit area of ​​the desired reaction 22 and the undesired reaction 24.

[0065] power supply

[0066] In one embodiment and see Figure 3 The switching of charge polarity between the first flexible contact 14 and the second flexible contact 16 can be enabled by using an alternating current (AC) power supply 12A. An AC power supply is considered beneficial because it facilitates the desired response 22 via charge polarity switching without requiring complex circuitry. As those skilled in the art will recognize, the AC power supply 12A will have an associated power output frequency, the reciprocal of which will be the power output cycle (T). 输出 The power output cycle is equal to the time it takes for a specific flexible contact 14, 16 to completely cycle through the charge polarity, for example, the time from being positively charged to being negatively charged and then back again. Therefore, the power output cycle T is... 输出 It is the charging cycle T P Twice that. Therefore, in another embodiment, the AC power supply 12A can be selected or configured such that its power output has a frequency (f) that conforms to the following criteria:

[0067]

[0068] AC power is not always practical, especially when portability is required. Thus, in alternative embodiments of the invention and see... Figure 4 The power source 12 can be a direct current (DC) power source 12B. The use of a DC power source 12B can be particularly advantageous in providing embodiments of a portable device. In some embodiments, the DC power source 12B can be one or more of a fuel cell, a storage battery, a power battery, or an alternative to a standalone DC power source.

[0069] An embodiment of the present invention utilizing DC power supply 12B can be configured to promote the desired response 22 by reducing the contact area of ​​the first flexible contact 14.

[0070] Using the charging polarity switching of DC power supply

[0071] DC power supply 12B itself cannot facilitate the desired reaction 22 through charge polarity switching. Therefore, in order to achieve this functionality without sacrificing the potential portability provided by DC power supply 18B (such as a fuel cell or battery pack), alternative embodiments are described, and see also [link to other embodiments]. Figure 5 The device may further include a switching unit 26 between the DC power supply 12B and the flexible contacts 14, 16, and a switching controller 28 connected to the switching unit. The switching unit may be electrically connected to a voltage output terminal 30, a ground terminal 32, and the first flexible contact 14 and the second flexible contact 16. In such an embodiment, the switching unit 26 may have a first configuration and a second configuration, in which the first flexible contact 14 is positively charged and the second flexible contact 16 is negatively charged, and in the second configuration, the first flexible contact is negatively charged and the second flexible contact is positively charged. The switching controller 28 may be configured to operate according to a charge polarity period T. P The switching unit 26 is periodically switched between the first configuration and the second configuration, so that T P =T C .

[0072] In some embodiments, the switch controller 28 may switch the switch unit 26 by periodically transmitting a single “switching” signal. In this embodiment, the charge polarity period may be equal to the “clock period” of the switch controller 28, i.e., the time period between signal pulses. In some alternative embodiments, the switch controller 28 may switch the switch unit 26 by alternately transmitting two different signals, namely a “switch from first configuration to second configuration” signal and a “switch from second configuration to first configuration” signal. As those skilled in the art will recognize, in this embodiment, the “clock period” of the switch controller will be the time period between two consecutive instances of the same signal (e.g., two consecutive instances of transmitting the “switch from first configuration to second configuration” signal) and therefore will be twice the length of the charge polarity period.

[0073] In embodiments of the invention including a switching unit 26 and a switching controller 28, the first flexible contact 14 and the second flexible contact 16 may have corresponding contact areas that are substantially similar in size, in order to mitigate or otherwise prevent induced DC voltage bias during use of the device. Figure 5 In the depicted embodiment, voltage output terminal 30 and ground terminal 32 are depicted as corresponding terminals of DC power supply 12B; however, those skilled in the art will recognize that other circuit components may be located between DC power supply 12B and switching unit 26. As used herein, the terms voltage output terminal 30 and / or ground terminal 32 may refer to the respective terminals of switching unit 26 immediately adjacent to “upstream” or “downstream” (depending on whether other circuit components provide voltage output terminal 30 and / or ground terminal 32).

[0074] Figure 6a depicts the electrode potential at the first flexible contact 14, while Figure 6b depicts the electrode potential at the second flexible contact 16 of the 18-volt DC power supply 12B when the switching unit 26 is implemented, assuming no losses. Finally, Figure 6c depicts the voltage across the two flexible contacts 14, 16. Although the overall voltage waveform is presented such that the first flexible contact 14 is the default "positive" terminal, those skilled in the art will recognize that this is merely customary and does not limit the scope of the invention. As those skilled in the art will appreciate, the "peak-to-peak" voltage across the two contacts is 36 volts, twice the voltage of the 18-volt DC power supply 12B.

[0075] In the embodiments and see Figure 7The switching unit 26 may include a switch array having at least a first switch 26A, a second switch 26B, a third switch 26C, and a fourth switch 26D. The first switch 26A may form a closable circuit segment between the voltage output terminal 30 and the first flexible contact 14; the second switch 26B may form a closable circuit segment between the voltage output terminal 30 and the second flexible contact 16; the third switch 26C may form a closable circuit segment between the first flexible contact and the ground terminal 32; and the fourth switch 26D may form a closable circuit segment between the second flexible contact and the ground terminal. In this embodiment, the switch controller 28 may be configured such that switching the switching unit 26 to a first configuration includes closing the first switch 26A and the fourth switch 26D and opening the second switch 26B and the third switch 26C; and switching the switching unit to a second configuration includes opening the first switch 26A and the fourth switch 26D and closing the second switch 26B and the third switch 26C, wherein closing the switches allows current to flow, and opening the switches prevents current from flowing.

[0076] One or more of switches 26A-26D may include transistors. One or more of switches 26A-26D may include thyristors and diodes connected in parallel. In an embodiment, switching unit 26 may include a full-bridge inverter switch.

[0077] Interference suppression

[0078] In at least one embodiment of the invention including the switching unit 26, the electrode potential at each of the first flexible contact 14 and the second flexible contact 16 can be a square waveform. Examples of each waveform are shown in Figures 6a and 6b, wherein the switching controller 28 is activated every two milliseconds (i.e., T...). P =2ms) Switching unit 26 between the first configuration and the second configuration. Those skilled in the art will recognize that the voltage and charge polarity periods are arbitrarily selected, and are merely for illustrative purposes. When switching at high frequencies, the rapid spikes or drops in voltage at the edges of each “square” in the waveforms described in Figures 6a-6c can cause high levels of electromagnetic interference in nearby circuitry and other electronic devices, wherein the amount of electromagnetic interference generated is at least partially proportional to the instantaneous rate of change of voltage. While the generation of electromagnetic interference may be suitable in certain circumstances according to embodiments of the invention, it may be insufficient when the device is used, for example, in areas with sensitive electronic devices.

[0079] To improve this, embodiments of the device can be configured to reduce the voltage across the first flexible contact and the second flexible contact when the switching unit 26 is to be switched, such that the instantaneous rate of change of the voltage across the first flexible contact 14 and the second flexible contact 16 caused by the switching of the switching unit 26 is reduced, thereby reducing or improving the amount of electromagnetic interference generated.

[0080] In the embodiments and see Figure 8 The device may further include a DC-DC converter 34 between the DC power supply 12B and the switching unit 26. At least in this embodiment, the voltage output terminal 30 and the ground terminal 32, electrically connected to the switching unit 26, are corresponding terminals of the DC-DC converter. In at least this embodiment, the DC-DC converter 34 may be configured to receive a constant voltage input from the DC power supply 12B, convert the constant DC voltage input into a pulsed DC voltage output, and provide the pulsed DC voltage output to the switching unit 26 via the voltage output terminal 30. Those skilled in the art will recognize that the DC-DC converter 34 does not produce an AC output.

[0081] In a further preferred embodiment, the pulse voltage output includes a voltage waveform having a repeating pattern formed by alternating maximum and minimum voltages and having a pulse period (T). 脉冲 As used herein, the term "pulse period" refers to the time period during which a pulse voltage output is repeated, such as the length of time between two consecutive maximum voltages or two consecutive minimum voltages.

[0082] In a further preferred embodiment, the pulse voltage output may include a voltage waveform having an asymptotic slope at a minimum voltage and, otherwise having a non-asymptotic slope, such that the voltage waveform is generally curved at non-minimum values ​​of the voltage. Figure 9A Examples of waveforms with an asymptotic slope at minimum voltage and those with a non-asymptotic slope in other ways are depicted, wherein the pulse period T of the depicted waveforms is... 脉冲 It's 2ms. Although Figure 9A The voltage waveforms depicted include a minimum voltage of 0V, but this is chosen for illustrative purposes only. The minimum voltage can be chosen to be a value higher than 0V, such as... Figure 9B The voltage waveform of the alternative embodiment of the pulse voltage output is shown. Those skilled in the art will recognize that... Figure 9A and Figure 9B The voltages and pulse periods depicted are for illustrative purposes only.

[0083] In this embodiment, the charge polarity period T of the switch controller 28 P Configured to be approximately equal to the pulse period T 脉冲In a further embodiment, the integer multiple of the pulse period is an odd integer multiple. In a further embodiment, the odd integer multiple of the pulse period can be 1, that is, the charge polarity period T. P It can be roughly equal to the pulse period T 脉冲 .

[0084] In one embodiment, the timing of switching unit 26 by switch controller 28 can be approximately aligned with a minimum voltage to reduce the level of generated electromagnetic interference. As the voltage across the first flexible contact 14 and the second flexible contact 16 decreases approximately, the instantaneous rate of change of voltage will be significantly reduced when the charge polarity of the flexible contacts reverses. In a further embodiment, the minimum voltage is at or near zero to substantially completely mitigate the generation of electromagnetic interference.

[0085] Figure 10A and Figure 10B The voltage waveforms of the first flexible contact 14 and the second flexible contact 16 are depicted, wherein the potential is measured as the voltage between the corresponding flexible contacts 14, 16 and the conductive surface 18. Figure 10C The voltage waveform of a device based on an input of an exemplary 18-volt DC power supply 12B, spanning flexible contacts 14 and 16, is depicted. Figure 10C In the present total voltage waveform, the first flexible contact 14 is the default "positive" terminal, but those skilled in the art will recognize that this is merely conventional and does not limit the scope of the invention.

[0086] and Figures 6C to 10C In contrast, those skilled in the art will recognize that the instantaneous rate of change of voltage is substantially reduced in each instance of switching, and as a result, the generation of electromagnetic interference is substantially improved. The transition is smoothed into a sinusoidal shape, rather than a sudden change in voltage across the first flexible contact 14 and the second flexible contact 16. This can be achieved in addition to the reduction in generated electromagnetic interference by immediately reducing the voltage across the first flexible contact 14 and the second flexible contact 16 before switching the charge polarity of the first flexible contact 14 and the second flexible contact 16.

[0087] As a technician will recognize, the peak voltage values ​​in Figures 10a and 10b are approximately the same as the voltage output of DC power supply 12B, resulting in a peak-to-peak voltage (based on an 18-volt DC power supply 12B input) of 36 volts. With the voltage waveform roughly sine wave, the "useful" voltage (RMS voltage) will be approximately 12.6 volts. It is believed that embodiments of the device can therefore be compatible with or usable with typical 18V power tool battery packs, while still generating sufficiently high voltage and current to drive the desired electrochemical reaction at a useful rate.

[0088] Power and fluid source design

[0089] In the embodiments and see Figure 11A The power supply 12 can be an onboard power supply 36. In such an embodiment, the device can be a completely portable device. In a further embodiment, the onboard power supply 36 can be housed within a power supply housing 38, which is detachable from the handle portion 40 of the device, with the first flexible contact 14 and the second flexible contact 16 extending from the handle portion 40.

[0090] In alternative embodiments and reference Figure 11B The power supply 12 can be housed in a power supply housing 38, which is spaced apart from and electrically connected to the handle portion 40 of the device. A first flexible contact 14 and a second flexible contact 16 extend from the handle portion 40. The power supply housing 38 can be electrically connected to the handle portion of the device via one or more flexible cables. This embodiment allows the device to be used over extended periods of time.

[0091] In an embodiment, the device may further include a fluid conduit 42 arranged to deliver conductive fluid from a fluid source 44 to at least one of the first flexible contact 14 and the second flexible contact 16. This allows the conductive fluid to flow at least partially continuously to the first flexible contact 14 and the second flexible contact 16, thereby eliminating or at least improving the need to immerse the first and second flexible contacts in a container of the conductive fluid. The delivery of the conductive fluid through the fluid conduit 42 may be manual (e.g., actuated by a user-operated button or switch) or automatic. Delivery may be pressure-driven, such as by one or more pump units. In a further embodiment, the fluid source may be a fluid reservoir 46, which is housed within or mounted to the device housing 10 and in fluid communication with the fluid conduit 42. In another embodiment (not shown) where the device also includes a power supply 12 within a power supply housing 38, the fluid reservoir 46 may be located within the power supply housing.

[0092] Flexible contact design

[0093] Overall and see also Figure 12The first and second flexible contacts each include: a mounting device 48 for mounting to the device housing 10 and receiving current from the power source 12; and a flexible applicator portion 50 extending therefrom, adapted to apply conductive fluid to the conductive surface 18. The first and second flexible contacts 14 and 16 are further adapted such that current can flow from the power source 12 through the corresponding flexible contact and into the conductive fluid. In some embodiments, this can be achieved by a conductive element that contacts or protrudes into the flexible applicator portion 50 and thus contacts the conductive fluid carried therein. In alternative embodiments, the flexible applicator portion 50 may be made of a conductive material, allowing current to travel along the flexible applicator portion, either together with or in lieu of current traveling through the loaded conductive fluid. In some embodiments, the mounting device 48 may be adapted to receive conductive fluid through a fluid conduit 46.

[0094] Further reference Figure 12 In one embodiment, the flexible applicator portion 50 may include an absorbent pad 50A located at the end of the mounting device 48. This embodiment may also include a conductive element 52. The absorbent material serves as a fluid-carrying device, carrying conductive fluid and allowing it to be applied to a conductive surface (not shown).

[0095] In the embodiments and reference Figure 13 The flexible applicator portion 50 of at least one of the first flexible contact 14 and the second flexible contact 16 may be a roller element comprising absorbent material and mounted on the mounting device 48. Similar to the embodiment including absorbent pad 50A, the absorbent material of the roller element 50B is used to carry conductive fluid. In a further embodiment and referring to… Figure 14 Each of the first flexible contact 14 and the second flexible contact 16 may be provided in the form of separate rollers, each roller having a first roller element 50B-1 and a first mounting device 48-1 arranged to form the first flexible contact 14, and a second roller element 50B-2 and a second roller device 48-2 arranged to form the second flexible contact 16. In an embodiment, the separate rollers may include one or more central portions 54 to provide some structural rigidity. In such an embodiment, the central portions 54 are non-conductive to ensure that the first roller element 50B-1 and the second roller element 50B-2 are electrically isolated from each other.

[0096] In the embodiments and see Figure 15The flexible applicator portion 50 of at least one of the first flexible contact 14 and the second flexible contact 16 may be a brush. In a further embodiment, the flexible applicator portion 50 of the brush may include conductive filaments 50C. In a further embodiment, the brush may be extendable and / or retractable. Its extension and / or retraction may be manual or alternatively motor-driven. Extension and / or retraction may be performed automatically by a switch controller based on sensor input to sense the degree of wear of the brush due to use.

[0097] As those skilled in the art will recognize, the flexible applicator portions 50 of the first flexible contact 14 and the second flexible contact 16 are flexible. This helps to facilitate sufficient and proper contact between the two contacts 14, 16 and the conductive surface 18, which is necessary to ensure circuit completion. However, depending on the size, type, and arrangement of the first flexible contact 14 and the second flexible contact 16, the flexible contacts may have the risk of flexing, bending, or otherwise deforming toward each other. If they are in direct contact with each other, the circuit may complete prematurely and could result in a short circuit. See also the embodiments and references. Figure 16 The device may further include a separating element 56 formed of a non-conductive material, which is arranged to prevent the first flexible contact 14 or the second flexible contact 16 from directly contacting the other flexible contact. In a further embodiment and referring back to [reference needed] Figure 15 The separating element 56 may include a shield that extends at least partially around at least one of the first flexible contact 14 and the second flexible contact 16. In some embodiments, the shield may be extendable and / or retractable. Figure 15 The dividing element 56 depicted in the image is shown with a cutout, but this is only for illustrative and clarity purposes.

[0098] While the invention has been described with reference to the preferred embodiments above, those skilled in the art will understand that the invention is not limited to these embodiments, but can be embodied in many other forms, variations, and modifications besides those specifically described. The invention includes all such variations and modifications. The invention also includes all steps, features, components, and / or devices individually or collectively mentioned or indicated in this specification, as well as any and all combinations or any two or more of steps or features.

[0099] In this specification, unless the context clearly indicates otherwise, the word "comprising" is not intended to have the exclusive meaning of the word, such as "consisting of only," but rather a non-exclusive meaning of "at least including." This also applies to other forms of the word such as "comprise," with corresponding grammatical changes.

[0100] Other definitions of the selected terms used herein can be found in the detailed description of the invention and apply throughout. Unless otherwise defined, all other scientific and technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0101] Any commitments made in this document should be understood to relate to some embodiments of the invention and are not intended to be commitments regarding the invention in all embodiments. Where commitments exist that are considered applicable to all embodiments of the invention, the applicant / patentee reserves the right to subsequently remove them from the description, and they are not dependent on such commitments being accepted or subsequently patented in any country.

Claims

1. A portable, handheld electrochemical treatment device, comprising: Device casing; as well as A first flexible contact and a second flexible contact, the first flexible contact and the second flexible contact extending from the housing, each of the first flexible contact and the second flexible contact including a mounting device and a flexible applicator portion extending from the mounting device, and each of the first flexible contact and the second flexible contact being electrically connected to a power source. The first flexible contact and the second flexible contact are each adapted to receive conductive fluid and then apply the conductive fluid to the surface; The first flexible contact and the second flexible contact receive electricity with periodically changing voltage; as well as The first flexible contact alternates between being positively charged and negatively charged relative to the second flexible contact, and the second flexible contact alternates between being negatively charged and positively charged relative to the first flexible contact; The alternation of each of the first flexible contact and the second flexible contact occurs simultaneously and in opposite directions.

2. The apparatus according to claim 1, wherein, The power source is an alternating current (AC) power source.

3. The apparatus according to claim 1, wherein, The power source is a direct current (DC) power source; The device further includes: A switching unit, located between the power supply and the first flexible contact and the second flexible contact, is electrically connected to an output voltage terminal, a ground terminal, and the first and second flexible contacts; and A switch controller, connected to the switch unit and having a charge polarity period; The switching unit has a first configuration and a second configuration. In the first configuration, the first flexible contact is positively charged relative to the second flexible contact, and the second flexible contact is negatively charged relative to the first flexible contact. In the second configuration, the first flexible contact is negatively charged relative to the second flexible contact, and the second flexible contact is positively charged relative to the first flexible contact. The switch controller is configured to periodically switch the switch unit between the first configuration and the second configuration at a rate determined by the charge polarity period.

4. The apparatus according to claim 3, wherein, The device further includes a DC-DC converter electrically connected to the power supply and the switching unit; The output voltage terminal and the ground terminal are corresponding terminals of the DC-DC converter; and The DC-DC converter is configured to: (i) Receive a constant voltage input from the power source; (ii) Convert the constant voltage input into a pulse voltage output; as well as (iii) The pulse voltage output is provided to the switching unit via the output voltage terminal; Furthermore, the pulse voltage output includes a voltage waveform having a repeating pattern formed by alternating maximum and minimum voltages and having a pulse period; as well as The charge polarity period is an integer multiple of the pulse period.

5. The apparatus according to claim 4, wherein, The charge polarity period is equal to an odd integer multiple of the pulse period.

6. The apparatus according to claim 4, wherein, The pulse voltage output includes a voltage waveform that has an asymptotic slope at the minimum voltage of the pulse voltage output and otherwise has a non-asymptotic slope. as well as The timing of switching the switching unit by the switch controller is aligned with the time when the minimum voltage occurs.

7. The apparatus according to claim 4, wherein, The voltage waveform is a rectified full-wave sine wave.

8. The apparatus according to claim 3, wherein, The switching unit includes an array of switches, the array comprising: A first switch forms a closable circuit segment between the output voltage terminal and the first flexible contact. The second switch forms a closable circuit section between the output voltage terminal and the second flexible contact. A third switch, which forms a closable circuit segment between the grounding terminal and the first flexible contact; and A fourth switch, which forms a closable circuit section between the grounding terminal and the second flexible contact; Further, switching the switching unit to the first configuration includes: closing the first switch and the fourth switch and opening the second switch and the third switch; and Switching the switching unit to the second configuration includes: disconnecting the first switch and the fourth switch and closing the second switch and the third switch.

9. The apparatus according to claim 3, wherein, The charge polarity period is equal to the desired process completion time; Furthermore, the expected process completion time (T) C The definition is as follows: T D,min ≤T C ＜T U T D,min It is the minimum time required to perform the desired process; and T U It is the time required to carry out the undesirable process.

10. The apparatus according to claim 3, wherein, The DC power source is a storage battery, a power battery, a fuel cell, or other independent DC power source.

11. The apparatus according to claim 1, wherein, The flexible applicator portion of at least one of the first flexible contact and the second flexible contact includes a roller element comprising an absorbent material.

12. The apparatus according to claim 1, wherein, The flexible applicator portion of at least one of the first flexible contact and the second flexible contact includes an absorbent pad located at the end of the mounting device.

13. The apparatus according to claim 1, wherein, The flexible applicator portion of at least one of the first flexible contact and the second flexible contact includes a brush.

14. The apparatus according to claim 13, wherein, The brush comprises conductive filaments.

15. The apparatus of claim 1, further comprising a separating element formed of a non-conductive material, the separating element being arranged to prevent the first flexible contact or the second flexible contact from directly contacting the other flexible contact.

16. The apparatus according to claim 15, wherein, The separating element includes a shield that extends at least partially around at least one of the first flexible contact and the second flexible contact.

17. The apparatus according to claim 1, wherein, The power source is an onboard power source housed within the device housing or mounted to the device housing.

18. The apparatus according to claim 17, wherein, The onboard power supply is housed in a power housing that can be detachably mounted to the device housing.

19. The apparatus according to claim 1, wherein, The power source is located in a power housing that is spaced apart from the device housing and is electrically connected to the flexible contact.

20. The apparatus of claim 1, further comprising a fluid conduit arranged to supply the conductive fluid from a fluid source to each of the first flexible contact and the second flexible contact.

21. The apparatus according to claim 20, wherein, The fluid source is a fluid reservoir housed within or installed to the housing of the device.

22. The apparatus according to claim 21, wherein, The fluid reservoir is detachable from the device housing.

23. The apparatus according to claim 21, wherein, The power supply is housed in a power supply housing that is detachably mounted to the housing of the device; and The fluid storage device is located inside the power supply housing.

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