Electroforming System Segmented Anode Cathode Tanks

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Solution Overview

Problem

Conventional electroforming processes face issues with non-uniform metal layer deposition due to soluble anode dissolution and particulate contamination, leading to variations in layer thickness and quality.

Innovation Solution

The system employs a sacrificial anode setup with separate anode and cathode tanks, using a recirculation circuit and conformable non-sacrificial anodes to maintain electrolyte quality and control metal layer thickness, along with adjustable flow rates and apertures to direct the electrolyte solution effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional electroforming process uses a soluble anode in the same tank as the cathode, then the process is simple and continuous, but particulate contamination occurs and metal layer uniformity deteriorates

Engineering Contradiction:

Improvecontinuous operationVSAvoidmetal layer uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The electroforming system is divided into separate anode and cathode tanks, with the anode tank containing the soluble anode and the cathode tank containing the workpiece. This segmentation prevents particulate contamination from the dissolving anode from reaching the cathode, thereby maintaining metal layer uniformity while allowing continuous operation through electrolyte recirculation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A recirculation circuit acts as an intermediary between the anode tank and cathode tank, transporting electrolyte from the anode tank to the cathode tank and back. This intermediary system enables continuous electrolyte flow that maintains deposition uniformity while preventing direct contact between particulate contaminants and the workpiece

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If a soluble anode is used to generate electrolytes, then the process is simple, but particulate contamination and non-uniform deposition occur

Engineering Contradiction:

Improveprocess simplicityVSAvoidparticulate contamination

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

By segmenting the system into separate anode and cathode tanks, the harmful particulate byproducts of anode dissolution are confined to the anode tank and prevented from contaminating the cathode tank, thereby eliminating particulate contamination while maintaining the simplicity of using a soluble anode

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The harmful function of particulate generation from the soluble anode is extracted and isolated in the anode tank, while the useful function of electrolyte generation is retained and transferred to the cathode tank through the recirculation circuit, thereby eliminating contamination while preserving process simplicity

Inventive Principle:

Principle #2Taking out (Extraction)

3Device complexity

If the anode and cathode are in the same tank, then the device complexity is low, but deposition uniformity and quality control are poor

Engineering Contradiction:

Improvetank configurationVSAvoiddeposition uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The single tank is segmented into two separate tanks (anode tank and cathode tank) connected by a recirculation circuit. This segmentation increases device complexity slightly but enables precise control of deposition uniformity by preventing particulate contamination and allowing independent optimization of each tank's conditions

Inventive Principle:

Principle #1Segmentation

4Productivity

If conventional electroforming is used, then production efficiency is moderate, but mass production with tailored properties is not achieved

Engineering Contradiction:

Improveproduction efficiencyVSAvoidcustomization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system incorporates adjustable flow rates for the recirculation circuit and variable aperture sizes in the anode tank, allowing dynamic control of electrolyte flow and metal ion distribution. This enables mass production while tailoring deposition properties such as thickness uniformity and metal layer composition to specific application requirements

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in improved uniformity and customization of metal layer thickness, reduced particulate contamination, and increased production efficiency, enabling mass production of electroformed components with tailored properties.

Implementation Method 1

supplying electrical power to an anode within the at least one anode chamber to generate additional electrolytes in the electrolyte solution

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Implementation Method 2

depositing, via the enriched electrolyte solution, a metal layer onto the workpiece to define an electroformed component

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Data Source

PatentUS11174564B2Electroforming system and method

Publication Date: 2021.11.16 UNISON INDUSTRIES LLC

AI summary

An electroforming system and method for electroforming a component includes an electroforming reservoir with a housing with at least one inlet and at least one outlet, and at least one anode chamber within the housing and fluidly coupled to the at least one inlet. An anode can be located within the at least one anode chamber.