U.S. patent application number 11/726631 was filed with the patent office on 2007-10-11 for electrophoretic deposition system.
This patent application is currently assigned to Knapheide Maunfacturing Co.. Invention is credited to Lucas Creasy, Dick Wicker.
Application Number | 20070235334 11/726631 |
Document ID | / |
Family ID | 38574008 |
Filed Date | 2007-10-11 |
United States Patent
Application |
20070235334 |
Kind Code |
A1 |
Wicker; Dick ; et
al. |
October 11, 2007 |
Electrophoretic deposition system
Abstract
An electrophoretic disposition system for simultaneously coating
the exterior and interior of metal parts having an exterior portion
and an interior portion comprising an emersion tank having four
side walls and a bottom, at least one vertical anode for conducting
current through the paint positioned along one of the walls, and at
least one retractable remote anode positioned adjacent the at least
one vertical anode. Once a part to be coated is submerged into the
emersion tank, the at least one remote anode is extended into the
interior of the part. Once in place, a current is passed through
both the anodes. The at least one vertical anode creates a current
path on the exterior of the part and the at least one horizontal
anode creates a current path on the interior of the part.
Inventors: |
Wicker; Dick; (Quincy,
IL) ; Creasy; Lucas; (Payson, IL) |
Correspondence
Address: |
ROBERT L. KNECHTEL, M.D., J.D.
10 S. LASALLE ST.
SUITE 3300
CHICAGO
IL
60603
US
|
Assignee: |
Knapheide Maunfacturing Co.
|
Family ID: |
38574008 |
Appl. No.: |
11/726631 |
Filed: |
March 22, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60787916 |
Mar 31, 2006 |
|
|
|
Current U.S.
Class: |
204/471 ;
204/622 |
Current CPC
Class: |
C25D 13/22 20130101 |
Class at
Publication: |
204/471 ;
204/622 |
International
Class: |
C25B 7/00 20060101
C25B007/00; C25D 1/12 20060101 C25D001/12 |
Claims
1) A system for the electrophoretic disposition of the exterior and
interior of parts comprising: An emersion tank having a first wall,
a second wall, a third wall, a fourth wall, and a bottom; At least
one vertical anode positioned along the first wall of the emersion
tank; At least one retractable remote anode positioned adjacent the
at least one vertical anode; and, An electrical current supply for
providing current to the anodes.
2) The system for the electrophoretic disposition of the exterior
and interior of parts of claim 1 wherein the at least one
retractable remote anode further comprises an outer generally
cylindrical sheath having a tank end and a distal end, a generally
cylindrical anode of a diameter smaller than the sheath and having
a current end and a piston end housed within the sheath at the tank
end, a piston positioned at the piston end of the anode, an inlet
valve for supplying piston extension force, and an outlet valve for
supplying piston retraction force.
3) A system for system for simultaneously applying a coating to the
exterior and interior of a metal surface comprising: An emersion
tank having a first wall, a second wall, a third wall, a fourth
wall, and a bottom; At least one vertical anode positioned along
the first wall of the emersion tank; At least one retractable
remote anode positioned adjacent the at least one vertical anode,
the at least one retractable remote anode further comprises an
outer generally cylindrical sheath having a tank end and a distal
end, a generally cylindrical anode of a diameter smaller than the
sheath and having a current end and a piston end housed within the
sheath at the tank end, a piston positioned at the piston end of
the anode, an inlet valve for supplying piston extension force, and
an outlet valve for supplying piston retraction force.
4) The system for simultaneously applying a coating to the exterior
and interior of a metal surface of claim 3 further comprising a
hydraulic system for extending and retracting the remote anode.
5) A method for simultaneously applying a coating to the exterior
and interior of a metal part through electrophoretic disposition
comprising the steps of: submerging a metal part into a solution
found within an emersion tank, the emersion tank having a first
wall, a second wall, a third wall, a fourth wall, and a bottom, at
least one vertical anode positioned along the first wall of the
emersion tank, and at least one retractable remote anode positioned
adjacent the at least one vertical anode, the at least one
retractable remote anode further comprises an outer generally
cylindrical sheath having a tank end and a distal end, a generally
cylindrical anode of a diameter smaller than the sheath and having
a current end and a piston end housed within the sheath at the tank
end, a piston positioned at the piston end of the anode, an inlet
valve for supplying piston extension force, and an outlet valve for
supplying piston retraction force; applying force to the piston,
thereby activating the piston which in turn extends the at least
one remote anode into the tank and into the interior of the metal
part; applying a current to the solution through the at least one
vertical anode and the at least one remote anode, thereby drawing
the solution to the metal part.
6) The method of claim 5 comprising the further step of applying
retraction force to the piston, thereby withdrawing the at least
one remote anode from the interior of the metal part and from the
tank once the metal part is adequately coated.
Description
RELATED UNITED STATES PROVISIONAL PATENT APPLICATION
[0001] This application claims the priority of provisional patent
application Ser. No. 60/787,916, filed Mar. 31, 2006.
I. TECHNICAL FIELD
[0002] The present invention relates to electrophoretic disposition
systems and, more particularly, to an electrophoretic disposition
system which evenly and simultaneously coats the interior and
exterior surfaces of hollow apparatus.
II. BACKGROUND OF THE INVENTION AND PRIOR ART
[0003] Electrophoretic deposition (EPD) covers a broad range of
material coating processes which have as a characteristic feature
colloidal particles suspended in a liquid medium that migrate under
the influence of an electric field (electrophoresis) and are
deposited onto an electrode. Non-limiting examples of EPD processes
include electrocoating, electrophoretic coating, and
electrophoretic painting.
[0004] In general, any colloidal particle that can be used to form
a stable suspension and that can carry a charge can be used in
electrophoretic deposition. Non-limiting examples of suitable
materials include polymers, pigments, dyes, ceramics and
metals.
[0005] EPD is useful for applying materials to any electrically
conductive surface and is used industrially for applying coatings
to metal fabricated products. It has been widely used to coat
automobile bodies and parts, tractors and heavy equipment,
electrical switch gear, appliances, metal furniture, beverage
containers, fasteners, and many other industrial products.
[0006] During the EPD process itself, direct current is applied to
a solution of polymers with ionizable groups or a colloidal
suspension of polymers with ionizable groups which may also
incorporate solid materials such a pigments and fillers. The
ionizable groups incorporated into the polymer are formed by the
reaction of an acid and a base to form a salt. The particular
charge, positive or negative, which is imparted to the polymer
depends on the chemical nature of the ionizable group. If the
ionizable groups on the polymer are acids, the polymer will carry a
negative charge when salted with a base. If the ionizable groups on
the polymer are bases, the polymer will carry a positive charge
when salted with an acid.
[0007] There are two types of EPD processes, anodic and cathodic.
In the anodic process, negatively charged material is deposited on
the positively charged electrode, or anode. In the cathodic
process, positively charged material is deposited on the negatively
charged electrode, or cathode.
[0008] When an electric field is applied, all of the charged
species migrate by the process of electrophoresis towards the
electrode with the opposite charge. In anodic deposition, the
material being deposited will have salts of an acid as the charge
bearing group. These negatively charged anions react with the
positively charged hydrogen ions (protons) which are being produced
at the anode by the electrolysis of water to reform the original
acid. The fully protonated acid carries no charge (charge
destruction) and is less soluble in water, and may precipitate out
of the water onto the anode.
[0009] The analogous situation occurs in cathodic deposition except
that the material being deposited will have salts of a base as the
charge bearing group. If the salt of the base has been formed by
protonation of the base, the protonated base will react with the
hydroxyl ions being formed by electrolysis of water to yield the
neutral charged base (again charge destruction) and water. The
uncharged polymer is less soluble in water than it was when was
charged, and precipation onto the cathode occurs.
[0010] The cathodic process results in considerably more gas being
trapped within the film than the anodic process. Since the gas has
a higher electrical resistance than either depositing film or the
bath itself, the amount of gas has a significant effect on the
current at a given applied voltage. This is why cathodic processes
are often able to be operated at significantly higher voltages than
the corresponding anodic processes.
[0011] The ability for the EPD coating to coat interior recesses of
a part is called the "throwpower." In many applications, it is
desirable to use coating materials with a high throwpower. The
throwpower of a coating is dependent on a number of variables, but
generally speaking the higher the coating voltage, the further a
given coating will "throw" into recesses. High throwpower
electrophoretic paints typically use application voltages in excess
of 300 volts DC.
[0012] However, prior art systems often fail in the complete
coating of interior surfaces as the ability to completely coat the
interior surface of a part using EPD is limited. This can occur for
many reasons, including but not limited to the to-be-coated-part
size, insufficient voltage capibilities, colloid insufficiency,
insufficient coating time, and systems directed at a general
coating scheme as opposed to site specific coatring. This is a
significant shortcoming when working in environments in which it is
important that all surfaces of the treated object are coated,
leaving no uncovered areas such as a truck bed or utility box.
Uncoated areas require hand coating. This, in turn, results in
increased cost due to having to have an employees inspect and coat
the uncoated surfaces, increased production time in having to do
the hand work, and the increased probability that the part may be
ruined to inadequate hand coating work.
[0013] There is need, therefore, for a system to coat parts having
an interior surface that must be completely coated, leaving no
uncovered areas. The present invention provides such a
solution.
III. OBJECTS AND ADVANTAGES OF THE PRESENT INVENTION
[0014] It is an object of the present invention to provide an
electrophoretic disposition system which evenly coats the exterior
and interior surfaces of a part.
[0015] It is a further object of the present invention to provide
an electrophoretic disposition system which coats the exterior and
interior surfaces of a part in a continuous process.
[0016] It is yet a further object of the present invention to
provide an electrophoretic disposition system which decreases
manufacturing time.
[0017] It is yet a further object of the present invention to
provide an electrophoretic disposition system which decreases
manufacturing cost.
[0018] The advantages offered by the present invention include but
are not limited to providing parts having an interior surface being
less susceptible to corrosion, and to further decrease the time and
cost involved in manufacturing the coated parts.
IV. SUMMARY OF THE INVENTION
[0019] The present invention comprises an emersion tank having four
side walls and a bottom, at least one vertical anode for conducting
current through the paint positioned along one of the walls, and at
least one retractable remote anode positioned adjacent the at least
one vertical anode.
[0020] Once a part to be coated is submerged into the emersion
tank, which contains a material to be applied to the part, the at
least one remote anode is extended into the interior of the part.
Once in place, a current is passed through both the at least one
vertical anode and the remote anode. The at least one vertical
anode creates a current path on the exterior of the part and the at
least one horizontal anode creates a current path on the interior
of the part. The current, in turn, results in both the exterior of
the part and the interior of the part to be coated in a single
continuous process which results in a coating of the exterior and
interior surfaces.
[0021] There has been outlined, rather broadly, the more important
features of the invention in order that the detailed description
thereof that follows may be better understood, and in order that
the present contribution to the art may be better appreciated.
There are, of course, additional features of the invention that
will be described hereinafter and that will form the subject matter
of the invention.
[0022] As such, those skilled in the art will appreciate that the
conception, upon which this disclosure is based, may readily be
utilized as a basis for designing of other structures, methods, and
systems for carrying out the several purposes of the present
invention. It is important, therefore, that the claims be regarded
as including such equivalent constructions in so far as they do not
depart from the spirit and scope of the present invention.
[0023] Further, the purpose of the abstract is to enable the US
patent and trademark office and the public generally, and
especially the scientists, engineers and practitioners in the art
who are not familiar with the patent or legal terms or phraseology,
to determine quickly from what cursory inspection the nature and
essence of the technical disclosure of the application. The
abstract is neither intended to define the invention of the
application, which is measured by the claims, nor is it intended to
be limiting as to the scope of the present invention in any
way.
[0024] These together with other objects of the present invention,
along with the various features of novelty which characterize the
present invention, are pointed out with particularity in the claims
annexed to and forming a part of this disclosure. For a better
understanding of the present invention, its operating advantages
and the specific objects attained by its uses, reference should be
had to the accompanying drawings and descriptive matter in which
there is illustrated a preferred embodiment of the present
invention.
[0025] Before explaining the preferred embodiment of the present
invention in detail, it is to be understood that the present
invention is not limited in its application to the details of
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
present invention is capable of other embodiments and of being
practiced and carried out in various ways. Also, it is to be
understood that the phraseology and terminology employed herein are
for the purpose of description and should not be regarded as
limiting.
IV. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 depicts a top perspective view of the inventive
device from the anode end of the emersion tank.
[0027] FIG. 2 depicts a top perspective view of the inventive
device from the rectifier end.
[0028] FIG. 3 depicts a cross section perspective view of the
remote anode.
[0029] FIG. 4 depicts a side cross sectional view of the remote
anode.
V. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Before explaining the preferred embodiment of the present
invention in detail, it is to be understood that the present
invention is not limited in its application to the details of
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
present invention is capable of other embodiments and of being
practiced and carried out in various ways. Also, it is to be
understood that the phraseology and terminology employed herein are
for the purpose of description and should not be regarded as
limiting.
[0031] Turning to FIG. 1, electrophoretic disposition system 20 is
seen. Emersion tank 22 comprises four walls, A, B, C, and D and a
bottom. Emersion tank 20 holds the solution which is to be coated
to metal part E. For non-limiting example, emersion tank 20 can
hold paint for coating a metal part E, such as a utility truck bed
as depicted in FIGS. 1 and 2. Emersion tank 22 can be constructed
of any suitable material. The inventors have found that a steel
construction with the interior of the tank coated in fiberglass
works best.
[0032] Attached to the interior of at least one of the walls, are
vertical anodes 24 (FIG. 2). There may a single vertical anode or a
plurality of vertical anodes. The number only depends on the needs
of the user and the type and size of the part to be coated. In this
non-limiting example, there are a plurality of anodes surrounding
the interior of the emersion tank 22 and affixed adjacent to Wall
A, B, C, and D. Vertical anodes 24 comprise stainless steel rod
connected in electrical series via wire F and conduct current
through the emersion tank to coat the exterior of the metal
part.
[0033] Returning to FIG. 1, affixed to and extending through, in
this example, Wall C is remote anode 26. Remote anode 26 further
extends generally perpendicular to wall C and horizontal to the
bottom of emersion tank 22. Remote anode 26 is placed generally
adjacent to vertical anode 22, however, as those skilled in the
arts will quickly understand, the placement of remote anode 26 is
flexible and limited only by the configuration of the system
20.
[0034] Turning to FIG. 3, it is seen that remote anode 26 further
comprises and external sheath which affixes to and extends through
wall C at point F. Housed within sheath 28 is found anode 30 and
piston 32. Anode 30 is sized lightly smaller than sheath and
designed to move freely within sheath 28.
[0035] Located on the exterior of sheath 28 and extending through
it are found extension valve 34 and retraction valve 36. Return to
FIG. 1, connected to Extension valve 34 is first fluid line 38
which in turn is connected to first hydraulic tank 40. Connected to
retraction valve 36 is second fluid line 42 which in turn is
connected to second hydraulic tank 44. First fluid line 38 supply
deionized water to the piston end of remote anode 26 and second
fluid line 42 supply deionized water to the anode end of remote
anode 26 to retract anode 30. The deionized water entering the
piston end and anode end of sheath 28 are kept separated by divider
46 (FIG. 3).
[0036] System 20 is used simultaneously coat the exterior and
interior of a metal part having an interior portion. In use, a
metal part E is submerged into a solution found within emersion
tank 22. Force is supplied to first hydraulic tank 40 which pushes
deionized water through first line 38, through extension valve 34,
causing piston 32 to move forward, thereby causing anode 30 to move
within sheath 28 and extend into emersion tank 22 and into part E
(FIG. 2).
[0037] Power is then applied to system 20 via rectifier 50.
Rectifier 50 can be any suitable power source capable of supplying
sufficient current to the anodes. The inventors have found that an
800 amp rectifier works best. Current is then passed through the
anodes, both vertical and remote, causing the electrophoretic
disposition of both the exterior of the part E via the vertical
anodes and the interior of part E via the remote anode.
[0038] Applying a current to the solution through the at least one
vertical anode and the at least one remote anode draws the solution
to the metal part.
[0039] Once the electrophoretic disposition process is complete,
force is applied to second tank 44, thereby pushing fluid through
second fluid line 42, thereby causing anode 30 to retract into
sheath 28. Remote anode 26 can include a safety solenoid which
enables power to be supplied to anode 30 only when anode 30 is
extended. Applying retraction force to the piston withdraws the at
least one remote anode from the interior of the metal part and from
the tank once the metal part is sufficiently coated.
[0040] It is to be understood, however, that even though numerous
characteristics and advantages of the preferred and alternative
embodiments have been set forth in the foregoing description,
together with details of the structure and function of the
embodiments, the disclosure is illustrative only.
[0041] Such variations should be considered to be within the scope
and spirit of the invention which is meant to cover an
electrophoretic disposition system for simultaneously coating the
exterior and interior of parts having an interior portion. Changes
may be made in detail, especially in matters of shape, size and
arrangement of parts within the principles of the invention to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
* * * * *