Electrodeposition applicator

Abstract

An electrodeposition applicator including a body, an electrodeposition tip, a spring action release valve, an internal power source and at least two electrodes. The body has a chamber for holding a coating that will be applied upon a workpiece, while the electrodeposition tip is attached to the body. The spring action release valve is within the body communicating with the chamber and the electrodeposition tip such that when pressure is applied to the electrodeposition tip, the spring action release valve causes the electrodeposition tip to saturate with the coating, allowing for application of the coating on the workpiece. The internal power source has one or more batteries, depending on the desired power, and at least one electrode is cathodic and one is anodic, one end of each electrode connected to corresponding battery terminals.

Description

Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et alElectrodeposition ApplicatorSTATEMENT OF GOVERNMENT INTEREST

[0001] The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without payment of any royalties thereon or therefore.BACKGROUND

[0002] Electrodeposition devices hold significant importance in various industries and scientific disciplines, making them indispensable. These devices are specifically designed to achieve precise deposition of thin metal or other material layers onto diverse surfaces through an electrochemical process. The ability to meticulously control the thickness, composition, and morphology of these coatings makes electrodeposition devices vital in sectors such as electronics, automotive, and aerospace, which all are making active efforts to mitigate the effects and damages from bare metals entirely. Electrodeposition devices enable the production of corrosion-resistant coatings, decorative finishes, and conductive layers, and enhance the durability, aesthetics, and functionality of a wide range of products. As such, electrodeposition devices play a pivotal role in technological advancements, product performance improvement, and driving innovation across multiple industries. With that being said, the development of an all-encompassing and easy-to-use electrodeposition device is crucial.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al

[0003] There are currently two main methods for applying an electrolytic coating using a portable hand-held tool. The first is the brush plating method, which uses a power supply that is connected to an external power source and a wand utilizing a carbon electrode wrapped in cloth. This cloth is soaked in the desired electrolyte, and with the power turned on, the wand is rubbed over the desired area, with more solution being added via a squirt bottle. This process has several drawbacks, including difficulty in repairing small defects, the need for more than one person to execute the method, excess amounts of hazardous electrolyte discharged from the squirt bottle, and a required connection to a fixed (nonportable) power source. Furthermore, while one electrode is built into the electrodeposition tip, the second must be clipped onto an area near the coating application site, thereby, requiring an attachable conductive region near the coating application area to effectively coat the substrate, which is neither guaranteed nor convenient.

[0004] The second main method is a variant of brush plating, which uses a tool called the Dalistick®. The process uses a wand, an electrodeposition shaft, and a pump to circulate the desired solution with a power supply connected to an external electrical network. This tool has difficulties in repairing small defects due to the wand and electrodeposition shaft being bulky and offered in only one relatively large size. The smallest Dalistick® tip is approximately 1 .5 inches wide and the wand is approximately 8 inches long, which attaches to several feet of tubing. This method also has a cumbersome setup and has only one integrated electrode in the tip. This limits the ability of the device for efficacious and efficient electrodeposition. Due to the limitations of the size of the Dalistick®, the traditional method of coating is sometimes still used instead. This is not ideal since current-drive applications arePatent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al substantially more effective. The described invention remedies the previously discussed issues with a self-contained (internal battery power supply), manually -controlled, spring-loaded electrolyte dispenser, and a variety of electrodeposition tip shapes and sizes that enable precise application per the shape of the surface to be coated. These innovations expand the usability of touch-up applicators by avoiding common limitations and obstacles, making this a more universal design option for many applications.SUMMARY

[0005] The present invention is directed to an electrodeposition applicator that meets the needs enumerated above and below.

[0006] The present invention is directed to an electrodeposition applicator with a body with a chamber, the chamber for holding a coating that will be applied upon a workpiece; an electrodeposition tip attached to the body; a spring action release valve within the body communicating with the chamber and the electrodeposition tip such that when pressure is applied to the electrodeposition tip, the spring action release valve causes the electrodeposition tip to saturate with the coating, allowing for application of the coating on the workpiece; an internal power source comprised of one or more batteries, depending on the desired power; and at least two electrodes, at least one electrode being cathodic and one electrode being anodic, with the electrodes connected to corresponding ends of the battery.

[0007] The present invention is directed to an electrodeposition device that is handheld and self-contained; the device can be configured in two ways: contactless (shown in Figure 1) and with contact (shown in Figure 2) where the circuit of the working and counter electrodes is completed within the device itself and where the counter electrode is in direct contact with thePatent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al targeted substrate, respectively. In both configurations, the device has a spring-action electrodeposition tip with a release valve that exchanges the desired solution from the main body-chamber to the electrodeposition tip until a constant, yet controlled, flow of solution is maintained. The circuitry is designed with an internal power source having one or more batteries-depending on the desired power, at least two electrodes-one electrode being cathodic and one electrode being anodic. For the contactless configuration, the circuit of the electrodes is satisfied by way of the conductive solution pathway in the electrodeposition tip, and for the contact configuration, one electrode is directly attached to the substrate being coated.

[0008] It is a feature of the present invention to provide an electrodeposition applicator that is compact, handheld, and wireless, utilized effectively in any location, as its wiring and power supply are internal to the device and do not require any external power sources (e.g. electric grids, large portable batteries, etc.).

[0009] It is a feature of the present invention to provide an electrodeposition applicator whereby the electrodeposition tip is compatible with numerous substrates, comes various shapes and thicknesses, and can be interchanged easily.

[0010] It is a feature of the present invention to provide an electrodeposition applicator that can effectively apply a desired electrolyte onto a metal surface with an induced current and deposit a coating with increased coating weight and durability.

[0011] It is a feature of the present invention to provide an electrodeposition applicator that is compact, handheld, wireless, can be utilized in any environment, and does not require any external power sources.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al

[0012] It is a feature of the present invention to provide an electrodeposition applicator that can be held and operated with one hand, while contemporary products either require a robotic apparatus or several people to monitor the electrical density and apply the coating.

[0013] It is a feature of the present invention to provide an electrodeposition applicator that electrolytically deposits coatings via a felt tip that allows charge to carry from the electrolytic coating to the area of interest.

[0014] It is a feature of the present invention to provide an electrodeposition applicator that includes an internal reservoir for the solution, enhancing the portability and reliability of the device.

[0015] It is a feature of the present invention to provide a versatile electrodeposition that is adept at electroplating surfaces with unique geometries that have previously been otherwise unachievable due to the interchangeable felt tip.

[0016] It is a feature of the present invention to provide solution chemistries and deposition methods which produce coated articles that are highly resistant to corrosion.DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims, and accompanying drawings wherein:Figure 1 shows an embodiment of the electrodeposition applicator in the contactless configuration;Figure 2 shows an embodiment of the electrodeposition applicator in the contact configuration;Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et alFigure 3 shows close up images of coatings produced by the conversion coating methods and control and exposed to neutral salt fog for over four weeks;Figure 4 shows full panel scans of the workpieces utilizing the conversion coating methods and control over four weeks of neutral salt fog exposure;Figure 5 is an embodiment of the electrodeposition applicator wherein the working electrode is adjacent and flush to the applicator tip; and,Figure 6 is an embodiment the electrodeposition applicator wherein the working electrode is embedded within applicator tip. Counter electrode is not shown.DESCRIPTION

[0018] The preferred embodiments of the present invention are illustrated by way of example below and in Figures 1- 6. As shown in Figure 1, the electrodeposition applicator 10 includes a body 100, an electrodeposition tip 200, a spring release action valve 300, an internal power source 400, and electrodes 500. The body 100 has a solution chamber 105 for holding a coating 50 that will be applied upon a workpiece 75. The electrodeposition tip 200 is attached to the body 100, while the spring action release valve 300 is disposed within the body 100 communicating with the chamber 105 and the electrodeposition tip 200 such that when pressure is applied to the electrodeposition tip 200, the spring action release valve 300 causes the electrodeposition tip 200 to saturate with the coating 50, allowing for application of the coating 50 on the workpiece 75. The internal power source 400 may include one or more coin-cell batteries, depending on the desired power, or may be any type of power source practicable. One electrode 500 is cathodic 505 and the other is anodic 510, one end of each electrode 500 is connected to the negative and positive ends of the power source or battery 400.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al

[0019] In the description of the present invention, the invention will be discussed in a military environment; however, this invention can be utilized for any type of application that utilizes an electrodeposition applicator with an electrolytic solution.

[0020] In an alternate embodiment, the chamber 105 may have a 20mL capacity — enough to fully coat several small blemishes. In operation, the spring action release valve 300 communicates with the chamber 105 and the electrodeposition tip 200 such that when pressure is applied to the electrodeposition tip 200, the spring action release valve 300 causes the electrodeposition tip 200 to saturate with the coating 50, allowing for the application of the coating 50 on the workpiece 75. Once the electrodeposition tip 200 is fully saturated, the release of the coating 50 is slowed, preventing flooding. Additionally, the spring action release valve 300 is internal and closed unless depressed into the applicator position, preventing leakage when not in use.

[0021] As shown in Figure 1, in an embodiment of the invention that allows for electrodeposition that is entirely contained within the electrodeposition applicator 10 (herein referred to as the contactless method), a working electrode wire 515 is placed adjacent to the electrodeposition tip 200 and a counter electrode wire 520 is placed on the opposite side of the electrodeposition tip 200, such that a circuit can be completed through the electrolytic solution or coating 50 in the electrodeposition tip 200 and is electrified by the power source 400, allowing for the application of the coating 50 on the workpiece 75.

[0022] As shown in Figure 2, in an embodiment of the invention that allows for electrodeposition with an external connection to the workpiece 75 (herein referred to as the contact method), a wire 515 is placed adjacent to the electrodeposition tip 200 and the counter electrode wire 520 is directly attached to a conductive site on the workpiece 75. The wire 515 orPatent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al electrode 500 communicates with an external anode wire 525 such that a circuit can be completed via a power source 400, and through the electrodeposition applicator 10, allowing for the application of the coating 50 on the workpiece 75.

[0023] The coating 50 may be, but without limitation, any anodizing coating, or any type of coating practicable. The applicator tip electrodeposition tip 200 may be any felt tip, or any type of tip practicable. In the preferred embodiment, the device is designed for a 15mm tip, but is not limited to any specific shape, and can be sized adjusted if needed.

[0024] In another embodiment of the invention, the electrodeposition applicator 10 further includes a conductive metal 525 and a power source 400. The conductive metal 525 communicates with and is disposed within the electrodeposition tip 200, the spring action release valve 300, and the electrodeposition tip 200, such that a circuit can be completed via the power source 400 throughout the electrodeposition applicator 10, allowing for application of the coating 50 on the workpiece 75.

[0025] In another embodiment of the invention, as shown in Figure 5, a wire 515 is disposed adjacent to or juxtapositioned next to the electrodeposition tip 200. The wire 515 communicates with the spring action release valve 300 and the coating 50 within the chamber 105, such that a circuit can be completed via a power source 400, and through the electrodeposition applicator 10 allowing for the application of the coating 50 on the workpiece 75.

[0026] Figure 3 shows the efficacy of the electrodeposition device with standard corrosion testing in a neutral salt fog chamber with a 4-week testing duration. Electrochemical conversion coatings were applied with three methods: the non-current method (referred to as the “contemporary state of the art” method where an applicator pen is used but is not connected to aPatent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al power source), the contact method, and the contactless method. In the “Week 1 - non-current” image, pitting spots can already be seen. By week 2 in a neutral salt fog chamber, the non-current panel was drastically worse than the contactless and contact method panels. By week 4, a corrosion band covered the non-current panel almost completely across its width, whereas the contact panel remained effectively pristine without any signs of pitting. The contactless panel did not develop pitting until week 4, demonstrating superior performance protecting a metal surface compared to the non-current method. Maximum protection was provided by the contact method as there were no signs of corrosion throughout the duration of testing.

[0027] In operation, a saturated material (such as, but without limitation, cotton, nylon, synthetic blend) is saturated with the conversion coating 50. Two electrodes 500 are present, one acts as the cathode 505 the other as the anode 510. The working part may be either one. The circuit, which may include, but without limitation, diodes, resistors, inductors, capacitors or transistors, has a direct current flow that is either voltage or amperage-driven. The saturated material or liquid emanating from the material is in contact with the working part for about 1-60 minutes with a voltage of about -15-+15 volts or an amperage of about -2 A-+2A. The electrodeposition tip 200 may move during application.

[0028] In one embodiment, the conversion coating composition is comprised of about 1.2 grams per liter chromium sulfate basic, about 1.6 grams sodium hexafluorozirconate, and about 0.02 grams per liter sodium tetrafluoroborate. The coating was applied for about 10 minutes and allowed to dry in the laboratory overnight before testing.

[0029] As shown in Table 1 below, the electrodeposition applicator 10 can effectively apply a desired electrolyte onto a metal surface with an induced current and deposit a coating 50 with increased coating weight and durability. The electrodeposition applicator 10 is capablePatent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al of applying a myriad of coatings 50 with a variety of methods. Most ionically conductive solutions with a low enough viscosity to flow through the applicator tip can be used with this device. Additionally, the electrodeposition applicator 10 can be used for processes such as, but without limitation, anodization, electrodeposition, etc., because the electrode and supplied current density may be switched and changed as the user desires. The table below gives examples of coating weights yielded with the electrodeposition applicator 10, showing consummate coverage onto a variety of metallic substrates.

[0030] The electrodeposition applicator 10 can be utilized in a process for coating a metal surface by using and passing an electric current through a trivalent chromium conversion-coating electrolyte at the cathodic or anodic metal. The current has a density of about 0.001 to about 5.0 amperes per square foot for a duration of about less than 20 minutes, wherein the trivalent chromium conversion-coating electrolyte includes chromium sulfate, metal hexafluorozirconate and metal tertrafluoroborate. The metal, but without limitation, can be a metal selected from the group consisting of aluminum, aluminum alloy, titanium, titanium alloy, magnesium, and magnesium alloy. The process for coating a metal surface can use the electrodeposition applicator by passing an electric current through a sulfuric acid electrolyte at the anodic metal.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et alThe metal, which can be aluminum, an aluminum alloy, or any metal practicable, may have a density of about 10 amperes per square foot for a duration of about 5 to about 20 minutes. Alternatively, the process for coating a metal surface by using an electrodeposition applicator can be accomplished by passing an electric current through a nickel electroplating electrolyte at the cathodic metal. The current may have a density of about 10-40 amperes per square foot for a duration of about 5 to about 20 minutes, wherein the nickel electroplating electrolyte consists of nickel metal cations, surface active agents and an acid(s) or a base(s) to appropriately adjust the pH of electrolyte for the desired electroplating parameters.

[0031] When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles "a," "an," "the," and "said" are intended to mean there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0032] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the claims should not be limited to the description of the preferred embodiment(s) contained herein.

Claims

Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et alWhat is claimed is:

1. An electrodeposition applicator comprising: a body with a chamber, the chamber for holding a coating that will be applied upon a workpiece; an electrodeposition tip attached to the body; a spring action release valve within the body communicating with the chamber and the electrodeposition tip such that when pressure is applied to the electrodeposition tip, the spring action release valve causes the electrodeposition tip to saturate with the coating, allowing for application of the coating on the workpiece; an internal power source comprised of at least one battery; and, at least two electrodes, at least one electrode being cathodic and one electrode being anodic, one end of each electrode connected to corresponding battery terminals.

2. The electrodeposition applicator of claim 1, wherein the electrodeposition applicator further includes a conductive metal, the conductive metal communicates with and is disposed within the body, the spring action release valve, and the electrodeposition tip such that a circuit can be completed via the power source throughout the electrodeposition applicator allowing for easier application of the coating on the workpiece.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al3. The electrodeposition applicator of claim 2, wherein a wire is disposed adjacent to the electrodeposition tip and communicates with the spring action release valve and the coating within the chamber such that a circuit can be completed via the power source and through the electrodeposition applicator allowing for application of the coating on the workpiece.

4. The electrodeposition applicator of claim 2, wherein an electrode wire is embedded in the electrodeposition tip and communicates with the spring action release valve and the coating within the chamber such that a circuit can be completed via the power source and through the electrodeposition applicator allowing for application of the coating on the workpiece.

5. The electrodeposition applicator of claim 4, wherein the desired substrate is connected by a working electrode from the power source of the device.

6. A process for coating a metal surface by using an electrodeposition applicator of claim 1 and passing an electric current through a trivalent chromium conversion-coating electrolyte at the cathodic or anodic metal, the current having a density of about 0.001 to about 5.0 amperes per square foot for a duration of less than 20 minutes, wherein the trivalent chromium conversioncoating electrolyte includes chromium sulfate, metal hexafluorozirconate and metal tertrafluorob orate .

7. The process of claim 6, wherein the metal is a metal selected from the group consisting of aluminum, aluminum alloy, titanium, titanium alloy, magnesium, and magnesium alloy.Patent Application Navy Case: PAX 390Electrodeposition Applicator Inventor: Westbrook et al8. A process for coating a metal surface by using an electrodeposition applicator of claim 1 and passing an electric current through a sulfuric acid electrolyte at the anodic metal, said current having a density of about 10 amperes per square foot for a duration of about 5 to about 20 minutes.

9. The process of claim 8, wherein the metal is aluminum or aluminum alloy.

10. A process for coating a metal surface by using an electrodeposition applicator of claim 1 and passing an electric current through a nickel electroplating electrolyte at the cathodic metal, said current having a density of about 10-40 amperes per square foot for a duration of about 5 to about 20 minutes, wherein the nickel electroplating electrolyte consists of nickel metal cations, surface active agents and acid or base to appropriately adjust the pH of electrolyte for the desired electroplating parameters.

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