Abstract:
The present invention relates to a racking fixture for holding components while they are electro-chemically processed. The fixture includes at least one shelf for holding the components and is electrically connected to a bus bar. A motor is mechanically engaged with the shelf and causes it to agitate to remove gasses trapped in components held on the fixture. The fixture also includes localized anodes for positioning adjacent to specific portions of the component.

Description:
This application claims the benefit of U.S. provisional application Ser. No. 60/064,225, filed Nov. 4, 1997. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a fixture for holding components during electro-chemical processing and, more particularly, is directed to a racking fixture designed to ensure uniform electrochemical processing over all surfaces of a component. 
     2. Background Information 
     Metallic components critical to a mechanical operation are often electro-chemically treated to ensure their reliability. For example, components critical to the performance of an aircraft are coated with cadmium to protect the components from corrosion or other related damage caused by exposure to an extreme environment. Another example of electrochemical processing would be copper plating a component to prevent a build-up of carbon which would otherwise occur in a high temperature environment. 
     The electrochemical processing of a component to enhance its reliability is often a complex process. For example, to electroplate components with cadmium, they are first cleaned in an emulsion cleaner, such as Brulan 815 GD, and soap to remove all oil deposits. Then the components are double rinsed and cleaned in an alkaline cleaning solution, such as IsoPrep 44L-ND. The components are then double rinsed and treated with IsoPrep 172, where they undergo a &#34;forward/reverse&#34; treatment in which they are polarized first at one polarity and then in the opposite polarity. The forward/reverse treatment assists in removing any remaining unwanted deposits. The components are then rinsed again and immersed in a solution of hydrochloric acid to activate the metallic portions of the components. The activated metal of the components is then double rinsed again and finally dipped into a tank 200 containing cyanide, as shown in FIG. 1. 
     The tank 200 is typically electrically connected to a main rectifier 202, which produces approximately 1000 amps of current and 3 volts potential within the cyanide solution. The negative terminal of the rectifier 202 is coupled to negative terminal contacts 204a and 204b, while the positive terminal of the rectifier 202 is coupled to positive terminal contacts 206a and 206b. Extension positive buses 208a and 208b are placed lengthwise across the tank 200 to make contact with the respective positive terminal contacts 206a and 206b. Anode baskets 210a-210f are suspended from the positive buses 208a and 208b by conductive metal cables 211a-211f The anode baskets 210a-210f typically contain three or four cadmium balls. 
     A rack 212, including current transmitting support members (i.e. negative buses) 214a-214e, is seated upon the tank 200. The support members 214a-214e are physically, as well as electrically, connected to negative terminal contacts 204a and 204b. Two parallel projections 216a and 216b extend downward into the tank 200 from the support members 214a-214e. Two or more component-holding shelves 218a and 218b are positioned between the parallel projections 216a and 216b and supply a negative electric charge from the main rectifier 202 to each of the components supported within the rack 212. 
     Many of the components processed in this manner, such as component 220 in FIG. 2, have blind holes, i.e., holes which dead-end within the component 220. For example, in the component 220, holes 222a and 222b are both blind holes. Unfortunately, with the above-described process, hydrogen and oxygen gas generated during the electro-chemical treatment form bubbles within the blind holes 222a preventing proper cleaning and deposition of electroplate or anodonic coatings. Further, because of the structure of the blind holes 222a and 222b, they also usually receive insufficient potential for proper electroplating. Consequently, the components 220 need to be further processed within a secondary electroplating device 223, shown in FIG. 3. 
     The secondary electroplating device 223 includes cathode holders 224a-224f, each having holes filled with cyanide solution and coupled to a negative terminal of a rectifier (not shown). Each of the blind major holes 222a of the components 220 are filled by hand with cyanide solution and the components 220 are positioned into a respective one of these cathode holders 224a-224f Then, a series of cadmium anodes 226a-226f, which are held in position by plate 227, are stuck into the holes 222a of the respective components 220. Current is then applied to each of the anodes 226a-226f to deposit the appropriate amount of cadmium into the holes 222a. 
     Unfortunately, the secondary electroplating process performed by the device 223 can only handle a small number of the components 220 at a time. Also, the process potentially exposes a worker to direct contact with a toxic cyanide solution. Thus, the present process requires an extensive number of man hours to perform and may be hazardous as well. 
     Consequently, in the art of electroplating and electrochemical processing, there is a need for a device or racking fixture which can uniformly electroplate a component having blind holes without the use of a secondary process. 
     SUMMARY OF THE INVENTION 
     According to one aspect, the present invention relates to a racking fixture for holding components while they are electro-chemically processed. The fixture includes at least one shelf for holding the components and is electrically connected to a bus bar. A motor is mechanically engaged with the shelf and causes it to agitate to remove gasses trapped in components held on the fixture. The fixture also includes localized anodes for positioning adjacent to specific portions of the component. 
     According to another aspect, the present invention relates to a racking fixture for holding components while they are electro-chemically processed. The fixture includes a plurality of bus bars for supplying electrical current to the components while they are electro-chemically processed, and a shelf for holding the components, which is electrically connected to at least one of the plurality of bus bars. The fixture also includes a drive assembly electrically powered by the plurality of bus bars and mechanically engaged with the shelf to agitate the shelf to remove gases trapped in the components. 
     According to yet another aspect, the present invention relates to a racking fixture for moving components while they are electro-chemically processed to prevent uneven deposits of electroplating material. The fixture includes component support means for engaging the components and applying voltage of a designated polarity to the components, and a drive means imparting a rocking motion to the component support means to remove gases contiguous with any surface of the components. The fixture further includes movable anodes and means for positioning anodes local to a selected portion of one or more of the components. The anode means has a polarity applied to the components by the component support means. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features, aspects, and advantages of the present invention will be better understood with regard to the following description, appended claims, and accompanying drawings. In the accompanying drawings, there is shown a present preferred embodiment of the invention, wherein like-referenced numerals are employed to designate like parts, wherein: 
     FIG. 1 is an isometric view of a prior art chemical treatment tank; 
     FIG. 2 is an isometric view of a component having blind-sided holes; 
     FIG. 3 is an isometric view of a prior art secondary electroplating device used for electroplating the inside of a blind-sided hole; 
     FIG. 4 is an isometric view of a racking fixture for electrochemical processing as a first embodiment of the present invention; 
     FIG. 5a is an isometric view of a first semi-rotatable shelf and two anode racks of the racking fixture; 
     FIG. 5b is a side view of an anode and a component held by the racking fixture; and 
     FIG. 6 is an isometric view of a tank for supporting the racking fixture of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 4 refers to a racking fixture 20 for holding components during an electro-chemical processing of the components in a first embodiment of the present invention. The racking fixture 20 includes a motor 38 powered by current-carrying buses which also support the fixture 20 within a plating bath. The motor 38 imparts an oscillatory motion to the racking fixture 20 when the racking fixture 20 is partially immersed, along with the components it supports, within the plating bath. The oscillatory motion removes any gas bubbles trapped within blind holes of the components that are positioned on the racking fixture 20. 
     The racking fixture 20 is supported upon first and second negatively charged current-carrying parallel buses 22a and 22b, as well as an auxiliary positive current-carrying bus 26, as shown in FIG. 4. Once seated in a tank 100, shown in FIG. 6, both the first parallel bus 22a and the second parallel bus 22b are connected to a main auxiliary rectifier 102, which is capable of producing up to 500 amps. Support cross members 24a-24c keep the first and second current-carrying buses 22a and 22b parallel, while insulating members 28a-28c separate the support cross members 24a-24c from the auxiliary positive current-carrying bus 26. 
     A positive parallel support member 30 is electrically and mechanically coupled to the auxiliary positive current-carrying bus 26 and extends downward at a 90° angle therefrom. A negative parallel support member 32 is electrically and mechanically coupled to the negative current-carrying parallel bus 22b, and extends downward 90° therefrom. The negative support member 32 is positioned parallel to the positive parallel support member 30. A T-shaped platform 34 and a spacing member 36 are mechanically coupled at opposite ends of and between the positive parallel support member 30 and the negative parallel support member 32. The T-shaped platform 34 and the spacing member 36 keep the support members 30 and 32 parallel to one another. The T-shaped platform 34 and the spacing member 36 are each made of a nonconductive, corrosion-resistant plastic, which is capable of withstanding temperatures of up to 400° F. 
     The motor 38, preferably a 3 volt motor, is mechanically fastened to the T-shaped platform 34 and is electrically connected to the negative current-carrying parallel bus 22b and the auxiliary positive carrying current-carrying bus 26 via a circuit breaker 40 and electrical leads 42a and 42b. A drive shaft of the motor 38 is mechanically coupled via a clutch 44 to a cam 43. The clutch 44 may be triggered by a local or remote switch, as is well known in the art. 
     The racking fixture 20 has first and second semi-rotatable shelves 46a and 46b, respectively. However, the present embodiment could easily be modified to accommodate more than two semi-rotatable shelves. The semi-rotatable shelves 46a and 46b have rocking members 48a and 48b, each semi-rotatable about its axis and supported by the positive and negative parallel support members 30 and 32 via bearing braces 50a-50d, respectively, at both ends. One end of each of the rocking members 48a and 48b is also coupled to a respective one of first and second fixed braces 52a and 52b. 
     The cam 43 of the motor 38 is mechanically coupled to one end of a first arm 54 via a cam pin 56. The other end of the first arm 54 is coupled to a distal end of the first fixed brace 52a via pin 58a. A second arm 57 is coupled at one end to the fixed brace 52a and, at the other end, to the fixed brace 52b via pins 58a and 58b, respectively. 
     To ensure that the shelf 46a returns to a neutral position once the clutch 44 is disengaged, the first rocking member 48a is coupled at one end to a central portion of a horizontal stabilizer 60. Each end of the horizontal stabilizer is coupled to a point on the T-shaped platform 34 via springs 61a and 61b. 
     The components 220 to be electroplated and having blind holes 222a and 222b, are supported on first and second part supports 62a and 62b. Each of the part supports 62a and 62b has respective pair of parallel lower notched members 64a, 64b, 64c, and 64d. All metal portions of the racking fixture 20 are coated with a nonconductive fuel cell primer to minimize contact and corrosive effect of the cyanide on the metal, preferably stainless steel, and to minimize electrical losses along the rack except at desired portions. Once such desired portion where the metal is exposed and not covered by the coating are notches 66 in each of the notched members 64a-64d. Each of the notches 66 is stripped clean and designed to make electrical contact with the surface of a respective one of the components 220. 
     The pairs of lower notched parallel members 62a, 62b, 62c, and 64d are slidingly coupled to their respective first and second rocking members 48a and 48b. Further, stands 74a-74d are affixed to an upper portion of the first and second rocking members 48a and 48b to support respective first and second upper notched members 70a and 70b. The upper notched members 70a and 70b are slidably engageable to the respective stands 74a, 74b, 74c, and 74d. Thus, the first and second part supports 62a and 62b can be moved to the appropriate position to hold the component 220 in place and allow firm physical as well as electrical contact with the upper notched members 70a and 70b. The notched members 70a and 70b are electrically coupled to the negatively charged parallel support member 32. 
     The fixed braces 52a and 52b and the bearing supports 50b and 50d are made of an insulating plastic and any electrical contact is only made to the negatively charged parallel supporting member 32 and not to the positively charged positive parallel supporting member 30, including the respective stands 74a, 74b, 74c and 74d. 
     Each of the semi-rotatable shelves 46a and 46b extend from the first and second respective rocking members 48a and 48b. At one end of the stands 74a-74d, a respective first appendage 76a-76d is rotatably coupled at its center to a respective one of the stands 74a-74d. Each end of the first appendages 76a-76d is rotatably coupled to a respective second appendage 78a-78h. First through fourth anode racks 80a-80d are rotatably held between two parallel respective second appendages 78a-78h, as shown in FIG. 4. 
     Each of the anode racks 80a-80d, such as the first anode rack 80a, contains anodes 82a-82f as shown in FIG. 5A. Each of the anodes 82a-82f is slidably removable from the anode racks 80a, so that the anodes 82a-82f may be maneuvered, swapped out, or removed. For example, when the component 220 being copper plated, the copper is in the cyanide solution and not on the anode. Therefore, when switching from cadmium plating to copper plating, each of the anodes 82a-82f is made of stainless steel. However, if the component is to be plated with cadmium, the stainless steel anodes would be replaced by cadmium anodes. 
     As shown in FIGS. 4 and 6, the anode racks 80a-80d are electrically coupled to the positive parallel supporting member 30, which is in turn electrically coupled to the auxiliary rectifier 27. The auxiliary rectifier 27 provides a current of 35-40 amps between each of the anodes 82a and 82h and its respective component 220, i.e. each of the anodes is positioned within the blind hole of the component 220, as shown in FIG. 5B. However, the overall current used to electroplate the outside of the component 220 is approximately 80 to 120 amps. By using two different potentials in this manner, a more uniform electroplating will occur on the component 220. If a higher current were used for the internal anodes 82a-82f when electroplating in the holes of each of the components 220, an excessive buildup of cadmium or copper would occur relative to the surface coating due to the relative proximities of the electrodes. 
     Typically, the anodes 82a-82f are composed of brightened cadmium if the components 220 are under 200 ksi in strength, while the anodes 82a-82f are composed of titanium cadmium if the components 220 are over 200 ksi in strength. 
     In an alternative embodiment, lower notched members 64a-64b can be further divided into a plurality of slidable plates, allowing the fixturing of components having different widths within the same shelf Further flexibility can be obtained by affixing a plurality of stands to the first and second rocking members 48a and 48b used to slideably engage the upper notched members 70a and 70b, allowing them to be subdivided in the same manner as the lower notched members. 
     The racking fixture 20 is operated in the following manner. First, six components 220 are positioned in each of the six notches 66a-66f of the parallel lower notched members 64a-64d. The lower notched members are slidably adjusted so that components 220 are firmly seated in the notches 66a-66f The upper notched members 70a and 70b are then slid down onto the components 220 and when the upper and lower notches are in electrical contact with the exposed negatively charged portion of the notches 66a-66f, the upper notched members 70a and 70b are locked in place on their respective stands 74a-74d. Each of the anodes 82a-82f is slid back and then the respective anode racks 80a-80d are rotated so that the anodes 80a-d may be inserted, or positioned adjacent to each of the holes 222a and 222b of the components 220, as shown in FIG. 5B. 
     Once the above operations are performed for the first semi-rotatable shelf 46a and the second semi-rotatable shelf 46b, the racking fixture 20 is immersed in a series of tanks for pre-treating the components 220. Once the components 220 are ready for electroplating with a substance, such as bright cadmium, the racking fixture 20 is immersed in tank 100 containing cyanide, shown in FIG. 6. The tank 100 includes a 1000-amp main rectifier 102, which is coupled to negative terminal contacts 104a-104d and positive terminal contacts 106a-106d. The auxiliary rectifier 27 is coupled to at least two of the negative terminal contacts 104a-104d and auxiliary positive contacts 107a and 107b. 
     The racking fixture 20 is seated in the tank 100 such that the negative current carrying parallel busses 22a and 22b make physical and electrical contact with the respective negative terminal contacts 104a-104d. After the fixture 20 is seated properly, the auxiliary positive current carrying bus 26 makes physical and electrical contact with the auxiliary positive contacts 107a and 107b, shown in FIG. 6. 
     When properly seated, the racking fixture 20 will totally immerse components 220 in the cyanide solution while the motor 38 and current breaker 40 remain above the solution. 
     Extension rods 108a and 108b holding anode baskets 110a-f containing cadmium balls are positioned on the positive terminal contacts 106a-d. 
     The main rectifier 102 and auxiliary rectifier 27, shown in FIG. 6, are switched on and a potential develops between the components 220 and the anodes 82a-82f, which have been placed in the holes 222a and 222b of the components 220, as shown in FIG. 5B. A potential is also developed between the anode baskets 110a-f and the outer surface of the components 220. Since the auxiliary rectifier 27 produces half the amperage of the cadmium baskets 110a-f, the close proximity of the anodes 82a-82f is compensated for and a controlled migration of cadmium between the anode and the inside surface of the holes of components 220 begins. After some time, cadmium migration from the balls in baskets 110a-f evenly coats the outside surface of components 220. 
     Hydrogen and oxygen bubbles inside the holes of components 220 may impede an even coating within the hole. Therefore, the circuit breaker 40 is switched on, allowing current from the auxiliary bus bar 26 and the negative current carrying bus 22b to flow to motor 38. The clutch 44 is then actuated, allowing the rotation of the cam 43, which in turn moves arms 54 and 57 connected to the fixed braces 52a-52b, which pivot the rocking members 48a and 48b, causing the semi-rotatable shelves 46a and 46b to rock back and forth, effectively &#34;jiggling out&#34; any bubbles and ensuring that the entire inner surfaces of the holes of components 72 are properly plated. 
     Once finished, the clutch is disengaged, causing the springs 61a and 61b to return the horizontal stabilizer 60 to a level position and, in turn, the semi-rotatable shelves 46a and 46b to a horizontal position so that they may be safely lifted up with the racking fixture 20 and removed as finished plated components. 
     Accordingly, the present invention utilizes power supplied by bus bars to drive a motor, which oscillates components held on a fixture to remove hydrogen and oxygen gas generated during electro-chemical processing that has been trapped within blind holes of the components being treated. Further, the present invention provides low powered localized anodes to ensure that the blind holes are evenly plated. 
     While the foregoing has been a discussion of a specific embodiment of the present invention, those skilled in the art will appreciate that numerous modifications to the disclosed embodiment may be made without departing from the spirit and scope of the present invention. Accordingly, the invention is limited only the following claims.