US20050072682A1 - Process and apparatus for coating components of a shopping cart and a product - Google Patents
Process and apparatus for coating components of a shopping cart and a product Download PDFInfo
- Publication number
- US20050072682A1 US20050072682A1 US10/679,436 US67943603A US2005072682A1 US 20050072682 A1 US20050072682 A1 US 20050072682A1 US 67943603 A US67943603 A US 67943603A US 2005072682 A1 US2005072682 A1 US 2005072682A1
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- US
- United States
- Prior art keywords
- nickel
- component
- chromium
- plated
- plating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 62
- 238000000576 coating method Methods 0.000 title claims abstract description 30
- 239000011248 coating agent Substances 0.000 title claims abstract description 26
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 54
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 27
- 238000004140 cleaning Methods 0.000 claims abstract description 27
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 27
- 239000000843 powder Substances 0.000 claims abstract description 27
- 239000011651 chromium Substances 0.000 claims abstract description 26
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 26
- 239000000126 substance Substances 0.000 claims abstract description 12
- 238000005260 corrosion Methods 0.000 claims abstract description 10
- 230000007797 corrosion Effects 0.000 claims abstract description 10
- 239000002253 acid Substances 0.000 claims abstract description 7
- 229910052751 metal Inorganic materials 0.000 claims abstract description 6
- 239000002184 metal Substances 0.000 claims abstract description 6
- 229910018487 Ni—Cr Inorganic materials 0.000 claims description 43
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 claims description 43
- 238000007747 plating Methods 0.000 claims description 39
- 238000001035 drying Methods 0.000 claims description 19
- 238000007598 dipping method Methods 0.000 claims description 15
- 238000001816 cooling Methods 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 9
- 238000007654 immersion Methods 0.000 claims description 9
- 238000005507 spraying Methods 0.000 claims description 8
- 238000005299 abrasion Methods 0.000 claims description 7
- 239000003518 caustics Substances 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 6
- 238000007590 electrostatic spraying Methods 0.000 claims description 3
- 238000003618 dip coating Methods 0.000 abstract 1
- 239000000565 sealant Substances 0.000 abstract 1
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 9
- 239000000243 solution Substances 0.000 description 9
- 238000010586 diagram Methods 0.000 description 6
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 238000007730 finishing process Methods 0.000 description 2
- -1 for example Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000000080 wetting agent Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000003929 acidic solution Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 239000002318 adhesion promoter Substances 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000032258 transport Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/48—After-treatment of electroplated surfaces
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
Definitions
- the present invention generally relates to a process for coating metal articles and more particularly, a process for applying abrasion and corrosion resistance substances to components of a shopping cart, an apparatus for applying such coatings and to shopping cart components having such components.
- protective final finishes e.g., paint or resin type finishes
- paint or resin type finishes are currently applied using a wide range of known techniques such as, for example, electrostatic spray. These finishes may involve a wide range of materials including resins, polymers, organic paint, and the like.
- electrostatic spray e.g., electrostatic spray.
- these finishes may involve a wide range of materials including resins, polymers, organic paint, and the like.
- these processes by themselves, do not provide a high level of abrasion and corrosion resistance.
- a layering process is needed that provides exceptionally high corrosion resistance and exceptionally strong durability against abrasion that utilizes a low cost layering technique and is adaptable to a wide range of article shape, strength, and size.
- the process should also be suitable for use on a wide range of base metal substrates and provide for application of various final finishes.
- An aspect of the present invention includes a process for plating a component for a shopping cart.
- the process includes cleaning the component by immersion in a cleaning solution then rinsing the component at least one time to remove the cleaning solution.
- the process further includes dipping the component into a nickel bath to produce a nickel-plating having a thickness of approximately 0.35-2 mil-inch.
- the nickel-plated component is rinsed at least one time and electrostatically sprayed with a powder coating, wherein the nickel-plated component produces a substantially corrosion resistant component. Chromium plating may be applied directly to the nickel, in an embodiment.
- Another aspect of the present invention includes a process for plating a component including cleaning the component by immersion in a cleaning solution, rinsing the component at least one time and dipping the component into a nickel bath to produce a nickel-plated component having a nickel plating substantially 0.35-2 mil-inch thick.
- the component may be dipped in a chromium bath to produce a nickel-chromium plated component having a chromium plating substantially 0.0002-0.1 mil-inch thick.
- Another aspect of the present invention provides for a means for dipping the component into a nickel bath to produce a nickel-plated component and a means for rinsing the nickel-plated component at least one time.
- a means is also provided for dipping the nickel-plated component in a chromium bath to produce a nickel-chromium plated component having a chromium plating substantially 0.0002-0.1 mil-inch.
- a means for rinsing the nickel-chromium plated component at least one time and a means for sealing the nickel-chromium plated component with a chemical sealer and a means for rinsing the sealed nickel-chromium plated component at least one time is provided.
- a means for drying the nickel-chromium plated component by heating and a means for applying a powder coating to the nickel-chromium plated component to provide a finish and a means for curing the nickel-chromium plated and powder coated component is also provided.
- a shopping cart having one or more components having one or more components.
- the one or more components of the shopping cart have a metal like structure with a nickel chromium plating and an electrostatic sprayed powder coating applied over the nickel chromium plating.
- the nickel plating has a thickness in range of approximately 0.35-2 mil-inch
- the chromium plating has a thickness in a range of approximately 0.0002-0.1 mil-inch
- the powder coating has a thickness in a range of approximately 2-6 mil-inch.
- FIGS. 1A-1C are block diagrams showing components and stages of the process according to the present invention.
- FIG. 2 is a block diagram showing components and stages of drying and finishing process according to the present invention.
- the process of providing coatings to articles according to the present invention involves a multi-step process, in an embodiment, for layering protective metallic layers onto the article, such as components for a shopping cart or other mobile carrier, followed by an application of a finishing layer of powder coat.
- the layering of an article according to this invention provides particularly durable properties against corrosion and abrasion and is accomplished in a low cost and practical manner.
- the present invention will be discussed with reference to components of a shopping cart as an illustrative example implementing the process of the present invention. It should be understood, however, by those of ordinary skill that the present invention is not limited to components of shopping carts and may equally be used with other suitable articles capable of undergoing the processes of the present invention.
- FIGS. 1A, 1B , and 1 C are block diagrams showing components and stages of the plating process and plating machine according to the present invention, as generally shown as reference numeral 5 .
- FIGS. 1A-1C may also represent high level flow diagrams representative of the process steps according to the present invention.
- the illustrative embodiment portrays a shopping cart frame as an article 10 for coating; however, any suitable article of manufacture may be coated using the process of the present invention.
- These articles may be made from any suitable metal such as, for example, steel, alloys, or the like (generally metal-like).
- the temperatures, layering thickness of any plating and time period discussed throughout the process of the present invention each have, in an embodiment, an associated tolerance of +/ ⁇ 20%.
- FIGS. 1A-1C each are representative of a component to be dipped in an appropriate solution and then removed therefrom.
- the processes of the invention include stages of cleaning and rinsing the article in preparation of receiving coatings of nickel, and optionally, chromium.
- the article 10 is loaded onto a plating machine 5 via conveyor 15 , which successively moves the article through various stages of the process.
- These stages include the dipping stages as well as, in an embodiment, spraying stages.
- the dipping and spraying stages may be interchangeable, in instances.
- the article is immersed in a caustic soak cleaner and comprises sodium hydroxide, having a concentration range 8 to 14 percent by volume, and surfactants and solvents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit.
- This cleaner solution removes any foreign substances and generally cleans the article.
- This caustic soak typically lasts approximately 6-8 minutes. It is noted that, as stated above, all temperature, concentrations, voltage, current, time and thickness ranges contemplated by the invention may vary approximately +/ ⁇ 20% from the stated ranges.
- the article is at a rinse stage for removing the caustic soak and typically lasts approximately 0.5-2 minutes for the rinse.
- the rinse typically is typically flowing fresh water, but may be other rinse agents, and minimizes carry-over of cleaner solution to the next process tank.
- the rinse is shown as a dip, however, other methods may be used in all the rinse steps such as, for example, a spray rinse.
- the article moves along to an electro cleaner stage 30 for immersion and further preparation for layering of the nickel or chromium plating.
- the electro cleaner may include such cleaners as, for example, a caustic cleaning solution comprising sodium hydroxide, having a concentration range of 6 to 15 percent by volume, and surfactants and chromium reducing agents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit.
- the part is subjected to an anodic electrolytic cleaning process at an impressed voltage of approximately 5 to 12 volts resulting in a current density of approximately 40 to 60 amperes per square foot of part surface area.
- This immersion typically lasts approximately 3-4 minutes and is followed by another rinse stage 35 with a suitable rinse agent, such as water, to remove the electro cleaner.
- a suitable rinse agent such as water
- This rinse stage lasts approximately 1-2 minutes.
- a second rinse at stage 40 may also be provided, in an embodiment, after stage 35 and may last approximately 1-2 minutes to insure complete removal of the electro cleaner.
- stage 45 is an electro acid immersion stage.
- the electro acid may include, for example, sulfuric acid having a concentration range of 9 to 14 percent by volume, fluoride agents having an active fluoride of 0 to 6 percent by volume, and wetting agents, operating at a temperature range of 150 to 190 degrees Fahrenheit.
- the part is subjected to an cathodic electrolytic cleaning process at an impressed voltage of 4 to 12 volts resulting in a current density of approximately 5 to 30 amperes per square foot of part surface area.
- This stage further advances the cleaning of the article's surface typically removing any oxide scales present from the processing of the metal and is followed by another rinse stage 50 that lasts approximately 0.5-2 minutes.
- another electro cleaner immersion stage 55 may be provided, in an embodiment, for approximately 1-4 minutes.
- the electro cleaner may include such cleaners as, for example, a caustic cleaning solution comprising sodium hydroxide, having a concentration range of 6 to 15 percent by volume, and surfactants and chromium reducing agents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit.
- the part is subjected to an anodic electrolytic cleaning process at an impressed voltage of approximately 5 to 12 volts resulting in a current density of approximately 40 to 60 amperes per square foot of part surface area.
- stage 25 Two rinse stages 60 and 65 , similar to stage 25 , are then provided to remove any electro cleaner.
- the stages 60 and 65 each last approximately 0.5-2 minutes.
- the article moves along the plating machine 5 to an acid dip stage 70 wherein the article is dipped in an acid bath for approximately 1-3 minutes.
- the acid may include an acidic cleaning solution comprising hydrochloric acid, having a concentration of 15 to 40 percent by volume, fluoride agents having an active fluoride of 0 to 6 percent by volume, and wetting agents, operating at a temperature range of 70 to 150 degrees Fahrenheit.
- the part is subjected to an anodic electrolytic cleaning process at an impressed voltage of 5 to 12 volts resulting in a current density of 40 to 60 amperes per square foot of part surface area.
- a rinse stage 75 similar too stage 25 , follows for approximately 0.5-2 minutes.
- the conveyor 15 then transports the article 10 to a nickel plating stage 80 .
- the article is dipped in an electrolytic nickel bath for approximately 19-24 minutes to provide a thickness in the range of 0.35-2 mil-inch. This provides a nickel-plated coating to the article.
- the nickel plate is then rinsed by four or more successive rinse stages 85 , 90 , 95 , and 100 , each of which is approximately 0.5-2 minutes.
- the article 10 may optionally enter another sequence for coating with chromium to produce a nickel-chromium layered article, or alternatively, continue directly with the rinse stage 110 . In an embodiment, the additional rinse steps may be eliminated if there is no chromium layering.
- the nickel coated article 10 proceeds to a chromium dipping stage 105 .
- the nickel-coated article 10 is immersed in a chromium bath for approximately 2-4 minutes that produces a chromium plating in the range of 0.0002 to 0.1 mil-inch.
- the chromium plating includes chromium metal plating derived from tri-valent or hexavalent electrolytic process.
- the nickel-plated, or alternatively, the nickel-chromium plated article 10 is rinsed for approximately 0.5-2 minutes, followed by a second rinse stage 115 for about another 0.5-2 minutes, both similar to stage 25 .
- a chemical sealer is applied at stage 120 , which lasts for about 0.5-2 minutes.
- the chemical sealer may include an acidic solution and other adhesion promoters. The sealer passivates unplated surfaces and enhances subsequent metal-to-plastic adhesion.
- the chemical sealer stage 120 is followed by two rinse stages 125 and 130 , similar to stage 25 . If necessary, the article 10 may be removed from the plating machine 5 at this point and transferred to a drying and finishing sequence, or if the sequence is continuous, the article 10 proceeds directly to the drying and finishing sequence.
- FIG. 2 is a block diagram showing components and stages of the drying and finishing process according to the present invention.
- FIG. 2 may also represent high level flow diagrams representative of the process steps according to the present invention.
- the plated article 10 proceeds to the drying and finishing sequence, generally shown as reference numeral 145 , beginning with a drying stage 150 .
- the drying stage the nickel coating or nickel-chromium coatings are dried in an oven.
- the oven temperature is nominally 325 degrees Fahrenheit.
- the heating time is approximately 5-10 minutes (+/ ⁇ 20%) with a cooling time of approximately 5-10 minutes (+/ ⁇ 20%).
- the cooling time may be greater.
- all temperatures, drying and cooling times, etc. may vary according to the present invention by approximately +/ ⁇ 20%, or in another embodiment, more or less ranges are also contemplated for use by the invention.
- the article 10 is then conveyed to the powder coating stage 160 .
- a powder coating finish is applied to the article 10 , typically by an electrostatic spraying process, although other means may be employed by the present invention.
- the powder coating finish may be one of many types including plastic, resins, polymers, or the like, and may be of various colors.
- the thickness is typically 3-5 mil-inch with time in the spraying booth of approximately 1-2 minutes.
- the powder coated article 10 then enters a curing stage 170 , at which time, the article is heated in an oven to a temperature of approximately 425 degrees Fahrenheit for approximately 15-20 minutes.
- the article 10 is then cooled for approximately 5-10 minutes producing a finished article 10 of substantial corrosion resistance and high durability.
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Abstract
Description
- 1. Field of the Invention
- The present invention generally relates to a process for coating metal articles and more particularly, a process for applying abrasion and corrosion resistance substances to components of a shopping cart, an apparatus for applying such coatings and to shopping cart components having such components.
- 2. Background Description
- Various types of articles, such as for example, shopping carts, require protective coatings to withstand corrosion and abrasion while presenting an attractive appearance. Several techniques are known for coating metallic articles that may involve electrostatic applications of compounds onto the articles. Additionally, certain types of dipping processes are known for specific types of layering. However, individually these techniques typically do not provide high abrasion resistance and impart high strength characteristics.
- In addition, protective final finishes (e.g., paint or resin type finishes) are currently applied using a wide range of known techniques such as, for example, electrostatic spray. These finishes may involve a wide range of materials including resins, polymers, organic paint, and the like. However, these processes, by themselves, do not provide a high level of abrasion and corrosion resistance.
- A layering process is needed that provides exceptionally high corrosion resistance and exceptionally strong durability against abrasion that utilizes a low cost layering technique and is adaptable to a wide range of article shape, strength, and size. The process should also be suitable for use on a wide range of base metal substrates and provide for application of various final finishes.
- An aspect of the present invention includes a process for plating a component for a shopping cart. The process includes cleaning the component by immersion in a cleaning solution then rinsing the component at least one time to remove the cleaning solution. The process further includes dipping the component into a nickel bath to produce a nickel-plating having a thickness of approximately 0.35-2 mil-inch. The nickel-plated component is rinsed at least one time and electrostatically sprayed with a powder coating, wherein the nickel-plated component produces a substantially corrosion resistant component. Chromium plating may be applied directly to the nickel, in an embodiment.
- Another aspect of the present invention includes a process for plating a component including cleaning the component by immersion in a cleaning solution, rinsing the component at least one time and dipping the component into a nickel bath to produce a nickel-plated component having a nickel plating substantially 0.35-2 mil-inch thick. The component may be dipped in a chromium bath to produce a nickel-chromium plated component having a chromium plating substantially 0.0002-0.1 mil-inch thick.
- Another aspect of the present invention provides for a means for dipping the component into a nickel bath to produce a nickel-plated component and a means for rinsing the nickel-plated component at least one time. A means is also provided for dipping the nickel-plated component in a chromium bath to produce a nickel-chromium plated component having a chromium plating substantially 0.0002-0.1 mil-inch. Also, a means for rinsing the nickel-chromium plated component at least one time and a means for sealing the nickel-chromium plated component with a chemical sealer and a means for rinsing the sealed nickel-chromium plated component at least one time is provided. A means for drying the nickel-chromium plated component by heating and a means for applying a powder coating to the nickel-chromium plated component to provide a finish and a means for curing the nickel-chromium plated and powder coated component is also provided.
- In another aspect of the invention, a shopping cart having one or more components is provided. The one or more components of the shopping cart have a metal like structure with a nickel chromium plating and an electrostatic sprayed powder coating applied over the nickel chromium plating. The nickel plating has a thickness in range of approximately 0.35-2 mil-inch, the chromium plating has a thickness in a range of approximately 0.0002-0.1 mil-inch, and the powder coating has a thickness in a range of approximately 2-6 mil-inch.
- The foregoing and other objects, aspects and advantages will be better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
-
FIGS. 1A-1C are block diagrams showing components and stages of the process according to the present invention; and -
FIG. 2 is a block diagram showing components and stages of drying and finishing process according to the present invention. - The process of providing coatings to articles according to the present invention involves a multi-step process, in an embodiment, for layering protective metallic layers onto the article, such as components for a shopping cart or other mobile carrier, followed by an application of a finishing layer of powder coat. The layering of an article according to this invention provides particularly durable properties against corrosion and abrasion and is accomplished in a low cost and practical manner. The present invention will be discussed with reference to components of a shopping cart as an illustrative example implementing the process of the present invention. It should be understood, however, by those of ordinary skill that the present invention is not limited to components of shopping carts and may equally be used with other suitable articles capable of undergoing the processes of the present invention.
-
FIGS. 1A, 1B , and 1C are block diagrams showing components and stages of the plating process and plating machine according to the present invention, as generally shown asreference numeral 5.FIGS. 1A-1C may also represent high level flow diagrams representative of the process steps according to the present invention. The illustrative embodiment portrays a shopping cart frame as anarticle 10 for coating; however, any suitable article of manufacture may be coated using the process of the present invention. These articles may be made from any suitable metal such as, for example, steel, alloys, or the like (generally metal-like). The temperatures, layering thickness of any plating and time period discussed throughout the process of the present invention each have, in an embodiment, an associated tolerance of +/−20%. It should also be understood thatFIGS. 1A-1C , each are representative of a component to be dipped in an appropriate solution and then removed therefrom. - To begin, the processes of the invention include stages of cleaning and rinsing the article in preparation of receiving coatings of nickel, and optionally, chromium. In operation, the
article 10 is loaded onto aplating machine 5 viaconveyor 15, which successively moves the article through various stages of the process. These stages include the dipping stages as well as, in an embodiment, spraying stages. However, as discussed, the dipping and spraying stages may be interchangeable, in instances. - At
stage 20, the article is immersed in a caustic soak cleaner and comprises sodium hydroxide, having a concentration range 8 to 14 percent by volume, and surfactants and solvents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit. This cleaner solution removes any foreign substances and generally cleans the article. - This caustic soak typically lasts approximately 6-8 minutes. It is noted that, as stated above, all temperature, concentrations, voltage, current, time and thickness ranges contemplated by the invention may vary approximately +/−20% from the stated ranges.
- At
stage 25, the article is at a rinse stage for removing the caustic soak and typically lasts approximately 0.5-2 minutes for the rinse. The rinse typically is typically flowing fresh water, but may be other rinse agents, and minimizes carry-over of cleaner solution to the next process tank. - The rinse is shown as a dip, however, other methods may be used in all the rinse steps such as, for example, a spray rinse. The article moves along to an
electro cleaner stage 30 for immersion and further preparation for layering of the nickel or chromium plating. The electro cleaner may include such cleaners as, for example, a caustic cleaning solution comprising sodium hydroxide, having a concentration range of 6 to 15 percent by volume, and surfactants and chromium reducing agents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit. The part is subjected to an anodic electrolytic cleaning process at an impressed voltage of approximately 5 to 12 volts resulting in a current density of approximately 40 to 60 amperes per square foot of part surface area. - This immersion typically lasts approximately 3-4 minutes and is followed by another
rinse stage 35 with a suitable rinse agent, such as water, to remove the electro cleaner. This rinse stage lasts approximately 1-2 minutes. A second rinse atstage 40 may also be provided, in an embodiment, afterstage 35 and may last approximately 1-2 minutes to insure complete removal of the electro cleaner. - Still referring to
FIGS. 1A-1C , the article proceeds to stage 45, which is an electro acid immersion stage. This immersion stage lasts approximately 3-4 minutes. The electro acid may include, for example, sulfuric acid having a concentration range of 9 to 14 percent by volume, fluoride agents having an active fluoride of 0 to 6 percent by volume, and wetting agents, operating at a temperature range of 150 to 190 degrees Fahrenheit. The part is subjected to an cathodic electrolytic cleaning process at an impressed voltage of 4 to 12 volts resulting in a current density of approximately 5 to 30 amperes per square foot of part surface area. - This stage further advances the cleaning of the article's surface typically removing any oxide scales present from the processing of the metal and is followed by another rinse
stage 50 that lasts approximately 0.5-2 minutes. Atstage 50, another electrocleaner immersion stage 55 may be provided, in an embodiment, for approximately 1-4 minutes. The electro cleaner may include such cleaners as, for example, a caustic cleaning solution comprising sodium hydroxide, having a concentration range of 6 to 15 percent by volume, and surfactants and chromium reducing agents at a combined concentration of 2 to 8 percent by volume, operating at a temperature range of 150 to 190 degrees Fahrenheit. The part is subjected to an anodic electrolytic cleaning process at an impressed voltage of approximately 5 to 12 volts resulting in a current density of approximately 40 to 60 amperes per square foot of part surface area. - Two rinse
stages stage 25, are then provided to remove any electro cleaner. Thestages - The article moves along the plating
machine 5 to anacid dip stage 70 wherein the article is dipped in an acid bath for approximately 1-3 minutes. The acid may include an acidic cleaning solution comprising hydrochloric acid, having a concentration of 15 to 40 percent by volume, fluoride agents having an active fluoride of 0 to 6 percent by volume, and wetting agents, operating at a temperature range of 70 to 150 degrees Fahrenheit. The part is subjected to an anodic electrolytic cleaning process at an impressed voltage of 5 to 12 volts resulting in a current density of 40 to 60 amperes per square foot of part surface area. A rinsestage 75, similar toostage 25, follows for approximately 0.5-2 minutes. - The
conveyor 15 then transports thearticle 10 to anickel plating stage 80. At this stage, the article is dipped in an electrolytic nickel bath for approximately 19-24 minutes to provide a thickness in the range of 0.35-2 mil-inch. This provides a nickel-plated coating to the article. The nickel plate is then rinsed by four or more successive rinsestages - The
article 10 may optionally enter another sequence for coating with chromium to produce a nickel-chromium layered article, or alternatively, continue directly with the rinsestage 110. In an embodiment, the additional rinse steps may be eliminated if there is no chromium layering. Continuing with chromium plating, the nickel coatedarticle 10 proceeds to a chromium dipping stage 105. The nickel-coatedarticle 10 is immersed in a chromium bath for approximately 2-4 minutes that produces a chromium plating in the range of 0.0002 to 0.1 mil-inch. The chromium plating includes chromium metal plating derived from tri-valent or hexavalent electrolytic process. - At
stage 110, the nickel-plated, or alternatively, the nickel-chromium platedarticle 10 is rinsed for approximately 0.5-2 minutes, followed by a second rinsestage 115 for about another 0.5-2 minutes, both similar tostage 25. A chemical sealer is applied atstage 120, which lasts for about 0.5-2 minutes. The chemical sealer may include an acidic solution and other adhesion promoters. The sealer passivates unplated surfaces and enhances subsequent metal-to-plastic adhesion. Thechemical sealer stage 120 is followed by two rinsestages stage 25. If necessary, thearticle 10 may be removed from the platingmachine 5 at this point and transferred to a drying and finishing sequence, or if the sequence is continuous, thearticle 10 proceeds directly to the drying and finishing sequence. -
FIG. 2 is a block diagram showing components and stages of the drying and finishing process according to the present invention.FIG. 2 may also represent high level flow diagrams representative of the process steps according to the present invention. In this sequence, the platedarticle 10 proceeds to the drying and finishing sequence, generally shown asreference numeral 145, beginning with a dryingstage 150. In the drying stage, the nickel coating or nickel-chromium coatings are dried in an oven. The oven temperature is nominally 325 degrees Fahrenheit. The heating time is approximately 5-10 minutes (+/−20%) with a cooling time of approximately 5-10 minutes (+/−20%). Of course, the cooling time may be greater. Again, it is noted that all temperatures, drying and cooling times, etc. may vary according to the present invention by approximately +/−20%, or in another embodiment, more or less ranges are also contemplated for use by the invention. - The
article 10 is then conveyed to thepowder coating stage 160. At this stage, a powder coating finish is applied to thearticle 10, typically by an electrostatic spraying process, although other means may be employed by the present invention. The powder coating finish may be one of many types including plastic, resins, polymers, or the like, and may be of various colors. The thickness is typically 3-5 mil-inch with time in the spraying booth of approximately 1-2 minutes. The powder coatedarticle 10 then enters acuring stage 170, at which time, the article is heated in an oven to a temperature of approximately 425 degrees Fahrenheit for approximately 15-20 minutes. Thearticle 10 is then cooled for approximately 5-10 minutes producing afinished article 10 of substantial corrosion resistance and high durability. - While the invention has been described in terms of embodiments, those skilled in the art will recognize that the invention can be practiced with modifications and in the spirit and scope of the appended claims.
Claims (26)
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060283716A1 (en) * | 2003-07-08 | 2006-12-21 | Hooman Hafezi | Method of direct plating of copper on a ruthenium alloy |
US20070125657A1 (en) * | 2003-07-08 | 2007-06-07 | Zhi-Wen Sun | Method of direct plating of copper on a substrate structure |
US20090120799A1 (en) * | 2003-07-08 | 2009-05-14 | Zhi-Wen Sun | Multiple-step electrodeposition process for direct copper plating on barrier metals |
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