Patent ID: 12221717

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and/or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on” something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on.” Like numbers refer to like elements throughout.

A matte finish on a chrome-plated surface may be created using various techniques. For example, a matte finish may be by chemical etching of a chrome-plated surface or by applying a mechanical treatment (e.g., sandblasting) to chrome-plated surface.

A matte finish may be formed on a chrome-plated surface through pulse plating. During pulse plating, instead of supplying a constant direct current to a chromium bath during chromium plating, direct current is supplied as a series of pulses. Chromium deposited during pulse plating may have a matte appearance. Pulse plating; however, can be difficult to implement, particularly in an industrial setting. For example, the pulsed direct current used during pulse plating forms a strong magnetic field that can damage nearby equipment.

Another technique for creating a matte finish is to print a matrix of very small chemically resistant ink dots on a chrome-plated surface and then etching the chrome-plated surface. A frequency modulated raster may be used to define the density/concentration of such dots. By changing the frequency (i.e., density or concentration) of the chemically resistant ink dots, the degree of matte finish can be controlled.

Yet another technique for creating a chrome-plated surface with a matte finish is to depart from the typical current densities and/or chromium bath temperatures used to deposit hard chrome. In this regard, depositing hard chrome on a surface typically requires that the chromium bath temperature and the current density used during deposition be maintained within known ranges. That said, if the chromium bath temperature is lowered to be below the temperatures used for depositing hard chrome, or if the current density is increased to be above the current densities used for depositing hard chrome, then the chromium deposited has a matte/dull appearance, rather than the typical glossy appearance of deposited hard chrome. However, this technique (i.e., lowering the temperature or increasing the current density) is undesirable as the chromium deposited is brittle and soft.

That said, a need exists for an improved method of creating a chromium-plated surface having a matte finish.

Therefore, in one aspect, the present invention embraces a method for creating a chromium-plated surface having a matte finish. In this regard, a substrate is placed in a chromium bath after cleaning and activation. The substrate is typically connected to a cathode bus bar thereby forming a cathode in the chromium bath. One or more electric terminals, typically anodes, are also placed in the chromium bath. The anode(s) and cathode are connected to a power source such that electric current flows from the anode(s) to the cathode through the chromium bath. This current flow causes chromium in the chromium bath to be deposited as chromium metal on the surface of the substrate. Following formation of the chromium layer on the plate via chromium plating, a layer of chromium oxide forms on the outer surface of the chromium layer due to the outer surface of the deposited chromium layer chemically reacting with chrome oxide in the bath. In order to cause the chromium plated surface to have a matte finish, the outer chromium layer of the substrate (e.g., the outer chromium oxide layer and possibly the chromium metal underneath) is then etched or otherwise disrupted. Although this etching does not cause the etched chromium layer to have a matte appearance, after this etching, subsequently deposited layers of chromium have a matte appearance instead of a glossy appearance. This etching is typically performed by causing chromic acid in the chromium bath to attack the outer chromium layer (e.g., the deposited chromium metal and chromium oxide). In this regard, it is important to note that due to the distribution of charged particles in the chromium bath and the chromium plated substrate, a voltage exists between the anode(s) and cathode. Because this voltage arises from the distribution of charged particles, this voltage remains even when the power source is turned off. Moreover, this voltage has the effect of protecting the deposited chromium (e.g., chromium metal and chromium oxide) from being attacked by chromic acid in the chromium bath. Therefore, in order to cause the chromic acid to attack the outer chromium layer of the substrate, this voltage is reduced. This voltage is typically reduced by turning the power source off and, while the power source is off, temporarily engaging a current bridge (e.g., a short) between the anode(s) and cathode. Due to the voltage that exists between the anode(s) and cathode, when the current bridge is engaged and the power source is off, current flows between the anode(s) and cathode and in the opposite direction of current flow during chromium deposition. This current flow causes the voltage between the cathode and the anodes to breakdown (i.e., decrease). Once the voltages sufficiently breaks down, the chromic acid in the chromium bath attacks the outer chromium layer of the substrate, thereby etching the outer chromium oxide layer formed on the surface of the chromium layer and possibly etching the chromium metal underneath the chromium oxide layer. In particular, this etching typically forms a microstructure in the outer chromium layer (e.g., in the outer surface of the outer chromium layer). As noted, after this etching, subsequently deposited layers of chromium metal have a matte appearance, instead of a glossy appearance. In particular, it is thought that depositing a layer of chromium on the microstructure formed on the previously etched chromium layer causes the later deposited chromium to have a matte appearance. By depositing chromium with a matte appearance in this manner, it is possible to achieve a chromium-plated surface with a matte appearance, rather than a glossy appearance, without employing subsequent chemical or mechanical processing (e.g., chemical etching or sandblasting) after the substrate has been chromium plated.

FIGS.1A and1Bdepict an apparatus100for chromium plating a substrate in accordance with one embodiment of the present invention. The apparatus100typically includes a chromium plating tank105. The chromium plating tank105is typically configured to be filled with a chromium plating solution. Chromium plating solutions typically include chromic acid and one or more catalysts, such as a sulfate and/or fluoride catalysts. In typical embodiments, the chromium plating solutions includes two catalysts, such as sulfuric acid and methanesulfonic acid (or any derivative of methanesulfonic acid). An exemplary chromium plating solution is HEEFR® 25, which includes chromic acid and two sulfate catalysts, namely sulfuric acid and methanesulfonic acid, which is available from Atotech USA Inc. The chromium plating tank105is typically formed from or lined with a material that is both nonconductive and nonreactive (or minimally reactive) to the chromium plating solution. For example, the chromium plating tank105may be lined with polyvinyl chloride (PVC). That said, the chromium plating tank105may be formed from any other suitable material.

The apparatus100typically includes a cathode bus bar110from which a substrate115to be chromium plated may be suspended. The cathode bus bar110is typically connected to a negative terminal of a power source120(e.g., a direct current (DC) power source, such as a rectifier) and formed from a conductive material (e.g., copper). As depicted inFIGS.1A-1B, opposing ends of the cathode bus bar110may each be connected to the negative terminal of the power source120. The substrate115to be plated is, in this embodiment, connected to the cathode bus bar. In addition to being mechanically suspended from the cathode bus bar110, the substrate115(which is typically formed from a conductive material) is electrically connected to the cathode bus bar110so that the substrate115forms a cathode during chromium plating. In this regard, the substrate115may be suspended from the cathode bus bar110via conductive hangers. The cathode bus bar110is typically configured to be vertically movable relative to the chromium plating tank105so that the substrate115may be placed in or removed from the chromium plating solution in the chromium plating tank105. In some embodiments, the cathode bus bar110may be connected to a hydraulic, pneumatic, or mechanical actuator (not depicted) to provide this vertical movement.

The substrate115is typically a metallic substrate, such as a metallic press plate. In a particular embodiment, the press plate is made from stainless steel (e.g., 410- or 630-grade hardened stainless steel). The press plate may be a textured press plate. In this regard, U.S. Pat. No. 8,778,202, which is hereby incorporated by reference in its entirety, describes a method of creating a textured press plate. That said, the substrate115may be any other material that is suitable to be chromium plated. In some instances, the substrate115may have been previously chromium plated. For example, the substrate115may have an outer chromium layer with a glossy appearance.

The apparatus100typically includes one or more terminals positioned in the chromium plating tank105. These terminals are typically connected to a positive terminal of the power source120, and soFIGS.1A and1Bdepict these terminals as one or more anodes130. The one or more anodes130are typically formed from a material that is conductive, but does not react (or minimally reacts) with the chromium plating solution. For example, the one or more anodes130may be formed from a lead alloy (e.g., a lead and tin alloy or a lead and antimony alloy). To facilitate uniform deposition of chromium metal on the surface of the substrate115, each of the anodes130is typically positioned an equal distance d from the substrate115. In some embodiments, the position of the one or more anodes130is fixed. For example, the one or more anodes130may be attached to the inner sidewalls of the chromium plating tank105as depicted inFIG.1B. In alternative embodiments, the position of the one or more anodes130may be adjustable. For example, the anodes130may be suspended from one or more anode bus bars (not depicted). Such anode bus bars may be laterally moveable relative to the position of the substrate115so that the distance d between the anodes130and the substrate115may be increased or decreased to thereby alter the plating process.

It may be desirable to heat the chromium plating solution above room temperature. Accordingly, one or more heaters140may be positioned in the chromium plating tank105.

The apparatus100typically includes one or more current bridges150between the anodes130and the cathode bus bar110. Each current bridge150typically includes a switch155that may be opened or closed. Each current bridge150typically has a relatively low resistance when the switch155is closed. As depicted inFIGS.1A-1B, in some embodiments the current bridge150may include one or more resistors156(e.g., variable resistors). In other embodiments, the current bridge150does not include a resistor. One or more controllers160may be used to control the operation of the switch(es)155. The one or more controllers160may also be configured to control other aspects of the apparatus100(e.g., controlling delivery of current from the power source120). In this regard, each controller160is typically a computing device or computing system that is configured to control the operation and/or other aspects of the apparatus100, such as controlling the operation of the switch(es)155.

During chromium plating, the anodes130and the cathode bus bar110are electrically connected to the power source120such that current flows from the power source120to the anodes130and from the cathode bus bar110to the power source120. When the power source120is on during chromium plating, the switch155of each current bridge150typically remains in an open position, and, thus, substantially no current flows through the current bridge(s).

In order to facilitate etching of the surface of the layer of chrome plating on the substrate115, the power source120is typically turned off. Even though the power source120is off, a voltage exists between the cathode (the substrate115) and the anodes130. This voltage between the cathode (the substrate115) and the anodes130is typically about 1.3 volts. When the power source120is turned off (or does not otherwise supply current to the cathode and anodes130), and the switch155is open, typically substantially no current flows between the cathode (the substrate115) and the anodes130. That said, once, the power source120is turned off, the current bridge(s)150may be engaged by closing the switch(es)155. Once the current bridge(s)150are engaged by closing the switch(es)155, the current bridge(s)150close the circuit or “current bridge circuit” between the cathode (the substrate115) and the anodes130, thus allowing current to flow between the cathode and the anodes130. The current bridge circuit includes the current bridge150(including any resistors156), the cathode (the substrate115), the anodes130, and the chromium bath. The current flow through the current bridge circuit, when the current bridge circuit is closed, is typically in the opposite direction of the current flow when the power source120is supplying current. In other words, when current is supplied from the power source120, current flows from the positive terminal of the power source120to the anodes130, from the anodes130to the substrate115through the chromium bath, from the substrate115to the cathode bus bar110, and from the cathode bus bar110to the negative terminal of the power source120. Whereas, when the one or more current bridges150are engaged, current flows from the cathode (the substrate115) to the anodes130through the chromium bath, and from the anodes130back to the cathode (the substrate115) via the current bridge150and the cathode bus bar110. This current flow from the substrate to the anodes etches or otherwise disrupts the chromium oxide formed on the chromium layer on the substrate115and may etch the chromium metal underneath the chromium oxide.

FIG.2depicts a general process flow200for creating a chromium-plated surface with a matte finish on a substrate (e.g., the substrate115) in accordance with one embodiment of the present invention. As previously noted, the substrate115may be a textured press plate. Accordingly, prior to the process described herein for creating a chromium-plated surface with a matte finish, the substrate115may be have previously processed to be textured (e.g., to have various ridges and/or valleys on its surface that formed a desired textured pattern on the substrate115). For example, if the substrate115is intended to be used as a press plate for forming textured decorative laminates that resemble real wood paneling, a textured pattern formed on the surface of the substrate115may include depressions and/or protrusions that simulates the grains and knots of real wood boards. To form a textured pattern on the substrate115, a selected texture design (e.g., mask) may be printed onto the substrate115to guide a subsequent etching process. In this regard, U.S. Pat. No. 8,778,202 describes a method of applying a chemically resistant ink to the surface of a press plate. In some embodiments, this chemically resistant ink is a hot-melt ink. Once the design is properly printed, various surface portions (e.g., exposed surface portion) of the substrate115may be etched based on the printed design to create a three-dimensional surface thereon. These steps of printing a mask on the substrate115followed by corresponding etching of the exposed (e.g., not covered by a mask) portions of the substrate115may be repeated until the desired textured pattern is achieved.

The described process for creating a chromium-plated surface with a matte finish may be used to provide a gloss-level (e.g., a matte appearance) to either the entire surface of the substrate115or, as described in more detail below with respect toFIG.5, to portions of the surface of the substrate115. Accordingly, prior to depositing chromium in the below-described process, a mask may be applied to (e.g., printed on) the substrate115such that the chromium is only deposited on portions of the substrate115not covered by such mask.

Before the substrate115is chromium plated, the surface of the substrate115is typically cleaned and activated. In this regard, at step205, the surface of the substrate115(e.g., a textured stainless steel press plate) is rinsed to remove contaminants. Next, at step210, the surface of the substrate115is degreased (e.g., by applying a suitable solvent or employing electrolytic degreasing) to remove any oil and grease and subsequently rinsed. At step220, the surface of the press plate115is activated. Activating the surface of the substrate115may improve the adhesion of chromium metal to the substrate115and may remove any oxides remaining on the substrate115. To activate the surface of the substrate115, the substrate may be exposed to sulfuric acid or a reverse etch bath having a chromic acid solution with no sulfate. Thereafter, the substrate115may be rinsed again. Alternatively, the surface of the substrate115may be activated by pickling, namely by exposing the surface to a strong acid. This pickling facilitates the removal of rust and scale from the substrate115.

Once the substrate115has been cleaned and activated (e.g., using the process described with respect to steps205-220), the substrate115may be chromium plated. In this regard, at step225, the substrate115is placed in a chromium bath. For example, the substrate115may be attached (e.g., mechanically and electrically connected) to the cathode bus bar110and lowered into the chromium plating tank105so that at least most of the substrate115is submerged in the chromium plating solution. At this time, the switch155of each current bridge150typically remains in the open position, and, thus, no current is flowing through the current bridge(s). Moreover, the switch155of each current bridge150typically remains in the open position so that no current flows through the current bridge(s) whenever the power source120is supplying current.

At step230, a strike is deposited on the surface of the substrate115by supplying current from the power source120to the one or more anodes130and the cathode (e.g., by turning on the power source120). A strike is a thin plating (in this instance of chromium) on the surface of the substrate115that is of high quality and adheres well to the substrate115. The current supplied by the power source causes chemical reactions to occur in the chromium bath that result in chromium from the chromium plating solution being deposited on the substrate115. In order to deposit the strike on the substrate115, a higher current density is typically employed as compared to the current density employed for subsequent chromium plating. For example, a current density of 16 A/dm2may be employed to deposit the strike on the substrate, whereas a current density of 10 A/dm2may be employed during subsequent chromium plating. As used herein, the current density is the amperage provided by the power source120divided by the surface area of the substrate115. To deposit the strike, the substrate115may be subjected to this current density for between about two to six minutes (e.g., about four minutes). In some embodiments, the current density is increased for a period of time before the current density for depositing the strike is reached. For example, the current density may linearly increase (e.g., from a current density of 0 A/dm2to a current density of 16 A/dm2) for a period of about two minutes and then remain steady for a period of about four minutes (e.g., at a current density of 16 A/dm2) while the strike is deposited.

After the strike has been deposited on the surface of the substrate115, at step235, an initial chromium layer (e.g., of a desired thickness) is deposited on the substrate115(i.e., on the previously deposited strike) by supplying current from the power source120to the one or more anodes130and the cathode. In this regard, the current supplied by the power source120causes chemical reactions to occur in the chromium bath that result in chromium from the chromium plating solution being deposited on the substrate115. As noted above, a lower current density is typically employed to perform this chromium plating as compared to the current density employed to deposit the strike on the substrate115. In some embodiments, the current density provided by the power source120is typically reduced (e.g., from 16 A/dm2to 10 A/dm2) once the strike has been deposited in order to initiate this chromium plating step.

The thickness of the chromium layer deposited as a result of this chromium plating step is typically based, among other things, on the length of time of this chromium plating step. Because etching is subsequently performed, it is typically desirable to ensure that this chromium layer is of sufficient thickness so that subsequent etching does not etch entirely through the chromium layer to the substrate115. Accordingly, this initial chromium plating step is typically performed for a sufficient period of time (e.g., between about 20-40 minutes) so that this deposited chromium layer has a sufficient thickness to ensure subsequent etching does not etch through this initial chromium layer to the substrate115.

Once this chromium plating step is complete, the power source120is typically turned off (or otherwise does not supply current to the cathode (the substrate115) and the anodes130). At this point, the outer surface of the initial chromium layer will typically oxidize with chrome oxide in the chromium bath, such that the initial chromium layer has a thin chromium oxide layer on its outer surface with chromium metal underneath.

As noted, even though current is no longer being supplied to the cathode and anodes130from the power source120, a voltage (e.g., of about 1.3 volts) exists between the cathode and the anodes130. This voltage exists because of the distribution of charged particles in the chromium bath and the chromium deposited on the substrate115. As a byproduct, this voltage protects the chromium oxide and chromium metal deposited on the substrate115from being attacked by the chromic acid in the chromium plating solution.

Typically, the chemical reaction that takes place during chromium plating causes the formation of hydrogen gas in the chromium plating solution. In some embodiments, the chromium plating solution is allowed to settle while current is no longer being supplied to the cathode and anodes130before the next step of engaging the current bridge. This settling period allows the hydrogen gas to leave the chromium plating solution. The settling period may be between about 10 seconds and 60 seconds, such as about 20 seconds.

Next, the initial chromium layer is etched. As described above, although this etching typically does not result in the initial chromium layer having a matte appearance, this etching does help to cause subsequently deposited chromium layers to have a matte appearance. In order to facilitate etching of the initial chromium layer, at step240, the one or more current bridges150are engaged by closing each current bridge's switch155. As noted, before the one or more current bridges150are engaged, no current flows between the anodes130and the cathode (the substrate115), because the power source120is not supplying current and there is an open circuit between the anodes130and the cathode. However, by engaging the one or more current bridges150, the current bridge circuit that includes the anodes130and the cathode is completed, thus allowing current to flow between the cathode and the anodes130. This current flow is typically in the opposite direction of the current flow when the power source120is on. The amount of this current depends on the voltage between the cathode and the anodes130(e.g., about 1.3 volts), the electrical resistance of the chromium plating solution (e.g., about 8 milliohms), and the electrical resistance of the resistor(s)156, if any, of the current bridges150, as well as any other resistance included within the current bridge circuit (e.g., any nominal resistance of the cathode bus bar110, substrate115, and anodes130). This current flows causes the voltage between the cathode and the anodes130to breakdown (i.e., decrease). As this voltage decreases, this voltage becomes less able to protect the chromium oxide and chromium metal deposited on the substrate115from being attacked by the chromic acid in the chromium plating solution. Once the voltages sufficiently breaks down, the chromic acid in the chromium plating solution attacks the initial chromium layer. In particular, the chromic acid typically etches the thin outer layer of chromium oxide and may etch the chromium metal underneath the chromium oxide. As noted, the initial chromium layer is typically of sufficient thickness to prevent the substrate115itself from being etched. This etching typically causes the surface of the initial chromium layer deposited in step235to have a microstructure. Although the initial chromium layer now has a microstructure, if the chromium plated substrate were removed from the chromium bath immediately after the etching in step240, the chromium plated substrate would typically have a glossy rather than matte appearance. Accordingly, as described in more detail below, additional chromium plating and etching steps are performed.

The one or more current bridges150typically remain engaged for a relatively short period of time, typically between about 5-30 seconds, more typically between about 10-20 seconds (e.g., 12 seconds). As noted, during this period of time, flowing current causes the voltage between the cathode and the anodes130to breakdown, thereby allowing the chromic acid in the chromium plating solution to etch the initial chromium layer. After this period of time, the one or more current bridges150are typically disengaged (e.g., by opening each current bridge's switch155), thereby ceasing this current flow and the etching of the initial chromium layer.

After the one or more current bridges150are disengaged, at step245, power is again supplied by the power source120, and a second chromium layer is deposited on the substrate. In other words, the second chromium layer is deposited on the etched initial chromium layer. The current density provided by the power source120during this deposition step is typically the same current density used to deposit the initial chromium layer (e.g., about 10 A/dm2). Typically, the thickness of the second chromium layer is less than the thickness of the initial chromium layer. In this regard, this step245of chromium plating to achieve the second chromium layer may occur for a period of between about two minutes and ten minutes (e.g., about five minutes). In some embodiments, the current density may linearly increase (e.g., from a current density of 0 A/dm2to a current density of 10 A/dm2) for a period of about one minute and then remain steady for a period of about five minutes (e.g., at a current density of 10 A/dm2) while the second chromium layer is deposited.

As noted, the second chromium layer is deposited on the etched initial chromium layer. In other words, the second chromium layer is typically deposited on the microstructure formed by etching the initial chromium layer. Applicant has found that this second chromium layer has a matte appearance. It is thought that depositing the second chromium layer on the microstructure of the etched initial chromium layer causes the second chromium layer to have a matte appearance. Applicant, however, has further found that this matte appearance typically lacks uniformity. That said, Applicant has further found that by employing multiple iterations of etching the most recently deposited chromium layer by engaging the one or more current bridges150followed by a subsequent step of chromium plating, it is possible to achieve chromium plating with a substantially uniform matte appearance.

Therefore, at step250, the second chromium layer is etched by engaging the one or more current bridges150a second time (e.g., by closing each current bridge's switch155). Typically, the power source120is turned off (or otherwise disconnected from the cathode (the substrate115) and the anodes130), and the chromium plating solution is allowed to settle (e.g., for a period of between about 10 seconds and 60 seconds, such as about 20 seconds), prior to engaging the one or more current bridges150. When the power source120is turned off, the outer surface of the second chromium layer will typically oxidize with chrome oxide in the chromium bath, such that the second chromium layer has a thin chromium oxide layer on its outer surface with chromium metal underneath. The one or more current bridges150typically remain engaged for a relatively short period of time, such as between about 5-20 seconds (e.g., 12 seconds). Similar to the process described in step240, engaging the one or more current bridges150typically causes the chromic acid in the chromium plating solution to etch the thin outer layer of chromium oxide of the second chromium layer and may etch the chromium metal underneath the chromium oxide, thus forming a microstructure in the second chromium layer.

At step255, the one or more current bridges155are disengaged, power is again supplied by the power source120, and chromium plating of the surface of the substrate115is continued by depositing a third chromium layer. In other words, the third chromium layer is typically deposited on the microstructure formed by etching the second chromium layer. The current density provided by the power source120during this deposition step is typically the same current density used to deposit the initial chromium layer (e.g., about 10 A/dm2). Typically, the thickness of the third chromium layer is less than the thickness of the initial chromium layer. In this regard, this step255of chromium plating to achieve the third chromium layer may occur for a period of between about two minutes and ten minutes (e.g., about five minutes). In some embodiments, the current density may linearly increase (e.g., from a current density of 0 A/dm2to a current density of 10 A/dm2) for a period of about one minute and then remain steady for a period of about five minutes (e.g., at a current density of 10 A/dm2) while the third chromium layer is deposited. This third chromium layer typically has matte appearance. Although this matte appearance is typically more uniform than the matte appearance after step245, this matte appearance may have visual imperfections.

Therefore, at step260, the third chromium layer is etched by engaging the one or more current bridges150a third time (e.g., by closing each current bridge's switch155). Typically, the power source is turned off (or otherwise disconnected from the cathode (the substrate115) and the anodes130), and the chromium plating solution is allowed to settle (e.g., for a period of between about 10 seconds and 60 seconds, such as about 20 seconds), prior to engaging the one or more current bridges150. When the power source120is turned off, the outer surface of the third chromium layer will typically oxidize with chrome oxide in the chromium bath, such that the third chromium layer has a thin chromium oxide layer on its outer surface with chromium metal underneath. The one or more current bridges150typically remain engaged for a relatively short period of time, such as between about 5-20 seconds (e.g., 12 seconds). Similar to that described in step240, engaging the one or more current bridges150typically causes the chromic acid in the chromium plating solution to etch the thin outer layer of chromium oxide of the third chromium layer and may etch the chromium metal underneath the chromium oxide, thus forming a microstructure in the third chromium layer.

At step265, the one or more current bridges155are disengaged, power is again supplied by the power source120, and chromium plating of the surface of the substrate115is continued by depositing a fourth chromium layer. In other words, the fourth chromium layer is deposited on the microstructure created by etching the third chromium layer. The current density provided by the power source120during this deposition step is typically the same current density used to deposit the initial chromium layer (e.g., about 10 A/dm2). This fourth chromium layer is typically the final chromium layer applied to the substrate115. In addition, this fourth chromium plating typically constitutes the main chromium plating of the substrate155. In other words the majority (or plurality) of chromium to be deposited on the substrate115is typically deposited during this fourth chromium plating step (i.e., step265). Accordingly, this fourth chromium plating is typically performed for a significantly longer period that the previous chromium plating steps. For example, the intermediate chromium plating steps (steps245and255) that occur after the initial chromium plating step (step235), but before the final chromium plating step (step265), may be performed for approximately 1-10 minutes (e.g., 5 minutes), whereas the final chromium plating step may be performed for approximately 80-120 minutes (e.g., 100 minutes). In some embodiments, the current density may linearly increase (e.g., from a current density of 0 A/dm2to a current density of 10 A/dm2) for a period of about one minute and then remain steady for a period of about 100 minutes (e.g., at a current density of 10 A/dm2) while the fourth chromium layer is deposited.

Once the final chromium plating step has been completed, the substrate115may be removed from the chromium bath (e.g., by lifting the substrate115out of the chromium plating tank105). Typically, the power source is turned off (or otherwise disconnected from the cathode (the substrate115) and the anodes130), and the chromium plating solution is allowed to settle (e.g., for a period of between about 10 seconds and 60 seconds, such as about 20 seconds), prior to removing the substrate from the chromium bath.

The chromium deposited during this process is typically hard chrome. Therefore, the temperature of the chromium bath and the current density used during deposition are typically selected and/or controlled to ensure that hard chrome is deposited.

FIGS.3A-3Hdepict layers of chromium being deposited and etched on the substrate115in accordance with the general process flow200.FIG.3Adepicts the substrate115before chromium has been deposited.FIG.3Bdepicts the substrate115after an initial chromium layer304is deposited in step235. This initial chromium layer304typically includes a chromium oxide layer306on its outer surface with chromium metal underneath.FIG.3Cdepicts the substrate115after the initial chromium layer304is etched in step240. As noted, this etching causes the outer surface of the initial chromium layer304to have a microstructure.FIG.3Ddepicts the substrate115after a second chromium layer308is deposited in step245. This second chromium layer308typically includes a chromium oxide layer310on its outer surface with chromium metal underneath. As depicted inFIG.3D, because this second chromium layer308is deposited on the microstructure of the initial chromium layer304, the second chromium layer308typically has a rough outer surface after being deposited.FIG.3Edepicts the substrate115after the second chromium layer308is etched in step250. As noted, this etching causes the outer surface of the second chromium layer308to have a microstructure.FIG.3Fdepicts the substrate115after a third chromium layer312is deposited in step255. This third chromium layer312typically includes a chromium oxide layer314on its outer surface with chromium metal underneath. As depicted inFIG.3F, because this third chromium layer312is deposited on the microstructure (and rough surface) of the second chromium layer308, the third chromium layer312typically has a rough outer surface after being deposited.FIG.3Gdepicts the substrate115after the third chromium layer312is etched in step260. As noted, this etching causes the outer surface of the third chromium layer312to have a microstructure.FIG.3Hdepicts the substrate115after a final chromium layer316is deposited in step265. This final chromium layer316typically includes a chromium oxide layer318on its outer surface with chromium metal underneath. As depicted inFIG.3H, because this final chromium layer316is deposited on the microstructure (and rough surface) of the third chromium layer312, the final chromium layer316typically has a rough outer surface after being deposited. This rough outer surface of final chromium layer316helps to provide a matte appearance.

The above-described alternating steps of chromium plating and etching (i.e., by engaging the one or more current bridges150) typically cause the chromium deposited on the substrate115to have a matte finish. For example, the deposited chromium may have a gloss level of between about 1 and 60 (e.g., between about 30 and 40) as measured at 60° using ASTM D523-14, Standard Test Method for Specular Gloss (2014). In this regard, the etching caused by engaging the current bridge causes deposited chromium to have a microstructure. In addition, by depositing further chromium on this microstructure it is possible to achieve a matte appearance. This matte appearance is provided without subsequent chemical or mechanical processing (e.g., chemical etching or sandblasting) of the chromium deposited on the substrate115. By performing multiple alternating deposition and etching steps it is possible to achieve a substantially uniform matte appearance. In this regard, although the general process flow200is described as having two intermediate chromium plating steps (steps245and255), it is within the scope of the present invention to increase or decrease the number of intermediate chromium plating steps that occur between the initial chromium plating step (step235) and the final chromium plating step (step265). For example, it is within the scope of the present invention to include a single intermediate chromium plating step. In other words, the process of the present invention may include: (1) depositing an initial chromium layer, (2) etching the initial chromium layer, (3) depositing an intermediate chromium layer, (4) etching the intermediate chromium layer, and (5) depositing a final/main chromium layer. Alternatively, the process of the present invention may include three or more intermediate chromium plating steps (e.g., by repeating steps255and260one or more times). Notwithstanding the foregoing, it is also within the scope of present invention for the process described herein to include no intermediate chromium plating steps (e.g., such that steps245-260are omitted).

As noted, the deposited chromium may have a gloss level of between about 1 and 60 as measured at 60° using ASTM D523-14, Standard Test Method for Specular Gloss (2014). In particular, and depending on the desired degree of the matte appearance, the deposited chromium may have a gloss level of (i) less than 1, (ii) 2-5, (iii) 5-10, (iv) 10-15, (v) 15-22, (vi) 23-30, (vii) 30-40, or (viii) 40-60 as measured at 60° using ASTM D523-14, Standard Test Method for Specular Gloss (2014). In this regard, the desired degree of the matte appearance of the chromium plating on substrate may be achieved by adjusting the parameters of the foregoing steps. In particular, Applicant has found that reducing the etching that occurs when the one or more current bridges are engaged has the effect of increasing the degree of matte appearance. Applicant has further observed that increasing the etching that occurs when the one or more current bridges are engaged has the effect of reducing the degree of matte appearance. As previously noted, the voltage between the cathode (the substrate115) and the anodes130protects the deposited chromium from being attacked (i.e., etched) by the chromic acid in the chromium plating solution. By increasing the resistance of the chromium plating solution and/or the resistance of the one or more current bridges (e.g., provided by the one or more resistors156), this voltages breaks down more slowly when the one or more current bridges150are engaged, thereby reducing the degree of etching. Moreover, by decreasing the resistance of the this circuit (i.e., the current bridge circuit), such as the combined resistance of the chromium plating solution and the resistance of the one or more current bridges, this voltages breaks down more quickly when the one or more current bridges150are engaged, thereby increasing the degree of etching. Therefore, the gloss level of the chromium plating may be decreased (i.e., the matte appearance may be increased) by: (1) increasing the distance d between the anodes130and the substrate115, which increases the resistance of the chromium plating solution, (2) reducing the temperature of the chromium plating solution, which increases the resistance of the chromium plating solution, and/or (3) increasing the resistance along the one or more current bridges when the bridges are engaged. The gloss level of the chromium plating may be increased (i.e., the matte appearance may be reduced) by: (1) decreasing the distance d between the anodes130and the substrate115, which decreases the resistance of the chromium plating solution, (2) increasing the temperature of the chromium plating solution, which decreases the resistance of the chromium plating solution, and/or (3) decreasing the resistance along the one or more current bridges when the bridges are engaged. It has also been found that the gloss level may be reduced by decreasing the thickness of the final chromium layer (e.g., by decreasing the length of time of the final chromium plating step). Therefore, the gloss level also may be increased by increasing the thickness of the final chromium layer (e.g., by increasing the length of time of the final chromium plating step).

Accordingly, in typical embodiments, the process flow200includes controlling the resistance of the current bridge circuit formed by the current bridges150, the anodes130, the substrate115, and the chromium bath (e.g., in order to obtain a desired gloss level of the chromium plating). As noted, the gloss level of the chromium plating is a function of the resistance of the current bridge circuit when such current bridge circuit is closed by the engagement of the current bridges150. Thus, the gloss level of the chromium plating may be controlled by adjusting a parameter that changes the resistance of the current bridge circuit, such as by (1) controlling the distance d between the anodes130and the substrate115, which affects the resistance of the chromium plating solution, (2) controlling the temperature of the chromium plating solution, which affects the resistance of the chromium plating solution, and/or (3) controlling the resistance (e.g., by adding or removing resistors of a defined resistance or adjusting the resistance of a variable resistor) along the one or more current bridges. These parameters may also be controlled based on other aspects of the chromium plating process. For example, depending on the current density used for chromium plating, the temperature of the chromium bath may be controlled to ensure that hard chrome is deposited.

In some embodiments, one or more of the steps of the general process flow200may be performed by the one or more controllers160. For example, the one or more controllers160may perform steps230-265. By way of further example, the one or more controllers may be configured to control the resistance of the current bridge circuit (e.g., by changing the resistance of the chromium bath, adjusting a variable resistor of a current bridge, or operating an actuator to change the distance d between the anodes130and the substrate115). In addition, the one or more controllers may be able to control inserting the substrate115into the chromium plating solution and removing the substrate115from the chromium plating solution (e.g., by controlling one or more actuators connected to the cathode bus bar110that provide this movement).

Exemplary Process for Chromium Plating a Textured Press Plate

Below is an exemplary process for chromium plating a textured press plate. The steps of this process may be performed manually and/or by a controller.

Initially, a textured stainless steel press plate is provided. The press plate is typically formed from 410- or 630-grade hardened stainless steel having a base surface finish of 7 or higher. The surface of the press plate is rinsed, degreased by electrolytic degreasing (e.g., by cathodic and/or anodic degreasing) and activated.

A chromium bath is prepared. HEEFR® 25, which is available from Atotech USA Inc, is employed as the chromium plating solution in this exemplary process. The chromium bath is heated to a temperature of 37° C. Anodes in the chromium bath are configured to be positioned approximately 250 mm from the press plate when the press plate is placed in the chromium bath. The press plate forms a cathode when placed in the chromium bath. In this exemplary process a current bridge is attached to each end of the cathode bus bar from which the press plate is suspended. In this exemplary process, the current bridges do not include a resistor.

Once the press plate has been cleaned and activated, and the chromium bath has been prepared, the press plate is placed in the chromium bath, and the following steps are performed:1. 2 minutes—rise time to strike (i.e., the power source is turned on and the current density is increased to the current density used in the next step)2. 4 minutes—deposit a strike on the press plate using a current density of 16 A/dm23. 30 minutes—initial chromium plating using a current density of 10 A/dm24. 20 seconds—power source off, settling time5. 12 seconds—engage current bridge between the anodes and cathode6. 1 minute—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)7. 5 minutes—intermediate chromium plating using a current density of 10 A/dm28. 20 seconds—power source off, settling time9. 12 seconds—engage current bridge between the anodes and cathode10. 1 minute—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)11. 5 minutes—intermediate chromium plating using a current density of 10 A/dm212. 20 seconds—power source off, settling time13. 12 seconds—engage current bridge between the anodes and cathode14. 1 minute—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)15. 5 minutes—intermediate chromium plating using a current density of 10 A/dm216. 20 seconds—power source off, settling time17. 12 seconds—engage current bridge between the anodes and cathode18. 1 minute—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)19. 100 minutes—main chromium plating using a current density of 10 A/dm220. 20 seconds-power source off, settling time

The resulting chromium plated press plate is expected to have a gloss level of approximately 30-40 as measured at 60° using the Gardner gloss meter, which complies with ASTM D523-14, Standard Test Method for Specular Gloss (2014).

FIG.4depicts an exemplary apparatus400for chromium plating a press plate. The apparatus400typically includes a chromium plating tank402. During chromium plating a chromium plating solution406is placed in the chromium plating tank402. A first plurality of anodes418A are typically positioned along one interior wall of the chromium plating tank402. In addition, a second plurality of anodes418B are typically positioned along an opposing interior wall of the chromium plating tank402. The first and second plurality of anodes418A and418B are typically electrically connected to a positive terminal of a power source (not depicted inFIG.4). The apparatus400typically includes cathode connectors410that are electrically connected to a negative terminal of a power source. The cathode connectors410are typically configured to hold a cathode bus bar412. The cathode connectors410are also typically configured to provide an electrical connection between the power source and the cathode bus bar412. The cathode bus bar412typically includes one or more connectors414for mechanically holding a substrate416(e.g., a press plate) as well as for electrically connecting the substrate416to the cathode bus bar412. Although not depicted inFIG.4, one or more current bridge typically connect the cathode bus bar412and the first and second plurality of anodes418A and418B is order to provide etching of deposited chromium layers as described herein.

Creating a Chromium-Plated Surface Having Multiple Degrees of Gloss

In another aspect, the present invention embraces a method for creating a chromium-plated surface having multiple degrees of gloss, in which at least a portion of the surface has a matte-chrome finish as described herein. In some instances, rather than creating a surface with a substantially uniform degree of gloss, it may be desirable to create a surface having differing degrees of gloss. In this regard, different gloss-adjusting steps (e.g., polishing or matting) may be employed to form differing degrees of gloss on different portion of a press plate or other substrate. In this aspect of the present invention, instead of employing conventional processes for creating a matte finish (e.g., by chemical etching or sandblasting), the process described herein for created a matte-chrome finish may be applied to a portion of a substrate so that such portion of the substrate has a matte appearance. For example, if the substrate115is a textured press plate with a wood-like pattern, chromium with a matte appearance might only be deposited on depressions (e.g., valleys) in the wood-like pattern in order to differentiate such depressions from surrounding portions (e.g., ridges or protrusions) of the wood-like pattern that may have a higher gloss level. Accordingly, in some embodiments, chromium (e.g., chromium with a high-gloss appearance) may have been previously deposited on the substrate115prior to the below-described process for creating a chromium-plated surface with a matte finish. In other embodiments, chromium (e.g., chromium with a high-gloss appearance) may be deposited on the substrate115after to the below-described process for creating a chromium-plated surface with a matte finish has been completed.

In this regard,FIG.5depicts a general process flow500for creating a chromium-plate surface with a matte finish on a portion of the substrate in accordance with an embodiment of the present invention. Except as specifically described herein, the steps of the general process flow500are substantially the same as the steps of the general process flow200described above.

At block501, a mask is typically applied to (e.g., printed on) the substrate115such that the chromium is subsequently deposited (e.g., printed) on only portions of the substrate115not covered by such mask. For example, if the substrate115is a textured press plate with a wood-like pattern, chromium with a matte appearance might only be deposited on depressions (e.g., valleys) in the wood-like pattern in order to differentiate such depressions from surrounding portions (e.g., ridges or protrusions) of the wood-like pattern that may have a higher gloss level. In some embodiments, chromium (e.g., chromium with a high-gloss appearance) may have been previously deposited on the substrate115prior to the process flow500for creating a chromium-plated surface with a matte finish. The mask may be formed from a chemically resistant ink (e.g., a hot-melt ink) or other material.

At step505, the surface of the substrate115(e.g., a textured stainless steel press plate) is rinsed to remove contaminants. Next, at step510, the surface of the substrate115is degreased (e.g., by manually applying a suitable solvent) to remove any oil and grease and subsequently rinsed. At step520, the surface of the press plate is activated, such as by exposing the substrate115to sulfuric acid or a reverse etch bath having a chromic acid solution with no sulfate. Thereafter, the substrate115may be rinsed again. Alternatively, the surface of the substrate115may be activated by pickling, namely by exposing the surface to a strong acid.

Once the substrate115has been cleaned and activated (e.g., using the process described with respect to steps505-520), the substrate115may be chromium plated. In this regard, at step525, the substrate115is placed in a chromium bath. At step530, a strike is deposited on the surface of the substrate115by supplying current from the power source120to the one or more anodes130and the cathode (e.g., by turning on the power source120).

After the strike has been deposited on the surface of the substrate115, at step535, an initial chromium layer (e.g., of a desired thickness) is deposited on the substrate115(i.e., on the previously deposited strike) by supplying current from the power source120to the one or more anodes130and the cathode. The thickness of the chromium layer deposited as a result of this chromium plating step is typically based, among other things, on the length of time of this chromium plating step. Because etching is subsequently performed, it is typically desirable to ensure that this chromium layer is of sufficient thickness so that subsequent etching does not etch entirely through the chromium layer to the substrate115. That said, it is also desirable to ensure that chrome plating solution does not undesirably degrade the mask (e.g., such that portions of the mark are undesirably etched away so as to expose the substrate underneath). Accordingly, this initial chromium plating step is typically performed for a period of time (e.g., between about 2-10 minutes, such as about 2-5 minutes) that is not too long so as to expose the mask to undesirable degradation but of sufficient length so that this deposited chromium layer has a sufficient thickness to ensure subsequent etching does not etch through this initial chromium layer to the substrate115. That said, in some embodiments, a layer of chromium is deposited on the substrate115prior to initiating process flow500, thereby reducing the likelihood of etching through to the substrate115. Once this chromium plating step is complete, the power source120is typically turned off (or otherwise does not supply current to the cathode (the substrate115) and the anodes130).

Next, at block540, the initial chromium layer is etched by engaging the one or more current bridges150by closing each current bridge's switch155. The one or more current bridges150typically remain engaged for a relatively short period of time, typically between about 5-30 seconds, more typically between about 10-20 seconds (e.g., 12 seconds). As noted, during this period of time, flowing current causes the voltage between the cathode and the anodes130to breakdown, thereby allowing the chromic acid in the chromium plating solution to etch the initial chromium layer. After this period of time, the one or more current bridges150are typically disengaged (e.g., by opening each current bridge's switch155), thereby ceasing this current flow and the etching of the initial chromium layer.

After the one or more current bridges150are disengaged, at step545, power is again supplied by the power source120, and a second chromium layer is deposited on the etched initial chromium layer. The thickness of the second chromium layer may be similar to the thickness of the initial chromium layer. In this regard, this step545of chromium plating to achieve the second chromium layer may occur for a period of between about two minutes and ten minutes (e.g., about five minutes).

At step550, the second chromium layer is etched by engaging the one or more current bridges150a second time (e.g., by closing each current bridge's switch155). At step555, the one or more current bridges155are disengaged, power is again supplied by the power source120, and chromium plating of the surface of the substrate115is continued by depositing a third chromium layer. The thickness of the third chromium layer may be similar to the thickness of the initial chromium layer. In this regard, this step555of chromium plating to achieve the third chromium layer may occur for a period of between about two minutes and ten minutes (e.g., about five minutes).

At step560, the third chromium layer is etched by engaging the one or more current bridges150a third time (e.g., by closing each current bridge's switch155).

At step565, the one or more current bridges155are disengaged, power is again supplied by the power source120, and chromium plating of the surface of the substrate115is continued by depositing a fourth chromium layer. Typically, the mask is removed prior to the deposition of the fourth chromium layer. Once the mask is removed, those areas of the substrate115not covered by the mask would be plated with matte chrome (i.e., chromium having a matte appearance), whereas the portions of the substrate115previously covered by the mask would typically not be plated with matte chrome. If the mask has been removed, then the fourth chromium layer may be substantially thicker than the previous chromium layers. Accordingly, this fourth chromium plating is typically performed for a significantly longer period that the previous chromium plating steps. That said, if the mask has not yet been removed, then the fourth chromium layer would typically have a thickness that is similar to the thickness of the previous chromium layers. If the mask has not been removed prior to the deposition of the fourth chromium layer, then, following deposition of the fourth chromium layer, the mask may be removed and a further layer of chromium may be applied to the entire surface of the substrate115. For example, chromium with a high-gloss appearance may be deposited on the substrate115after the mask has been removed.

The chromium deposited during this process is typically hard chrome. Therefore, the temperature of the chromium bath and the current density used during deposition are typically selected and/or controlled to ensure that hard chrome is deposited.

As with the general process flow200described above, although the general process flow500is described as having two intermediate chromium plating steps (steps545and555), it is within the scope of the present invention to increase or decrease the number of intermediate chromium plating steps that occur between the initial chromium plating step (step535) and the final chromium plating step (step565). Also like the general process flow200described above, the general process flow500may include controlling the resistance of the current bridge circuit formed by the current bridges150, the anodes130, the substrate115, and the chromium bath (e.g., in order to obtain a desired gloss level of the chromium plating). In some embodiments, one or more of the steps of the general process flow500may be performed by the one or more controllers160. For example, the one or more controllers160may perform steps530-565. By way of further example, the one or more controllers may be configured to control the resistance of the current bridge circuit. In addition, the one or more controllers may be able to control inserting the substrate115into the chromium plating solution and removing the substrate115from the chromium plating solution.

Exemplary Process for Chromium Plating a Portion of a Textured Press Plate

Below is an exemplary process for chromium plating a portion of a textured press plate. The steps of this process may be performed manually and/or by a controller.

Initially, a textured stainless steel press plate is provided. The press plate is typically formed from 410- or 630-grade hardened stainless steel having a base surface finish of 7 or higher. The surface of the press plate is rinsed, degreased, and activated.

A chromium bath is prepared. HEEFR® 25, which is available from Atotech USA Inc, is employed as the chromium plating solution in this exemplary process. The chromium bath is heated to a temperature of 37° C. Anodes in the chromium bath are configured to be positioned approximately 250 mm from the press plate when the press plate is placed in the chromium bath. The press plate forms a cathode when placed in the chromium bath. In this exemplary process a current bridge is attached to each end of the cathode bus bar from which the press plate is suspended. In this exemplary process, the current bridges do not include a resistor.

A mask is applied to the press plate, and then press plate is cleaned and activated. Once the press plate has been cleaned and activated, and the chromium bath has been prepared, the press plate is placed in the chromium bath, and the following steps are performed:1. 3 minutes—rise time to strike (i.e., the power source is turned on and the current density is increased to the current density used in the next step)2. 2 minutes—deposit a strike on the press plate using a current density of 16 A/dm23. 4 minutes—initial chromium plating using a current density of 10 A/dm24. 15 seconds—power source off, settling time5. 12 seconds—engage current bridge between the anodes and cathode6. 30 seconds—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)7. 3 minutes—intermediate chromium plating using a current density of 10 A/dm28. 15 seconds—power source off, settling time9. 12 seconds—engage current bridge between the anodes and cathode10. 30 seconds—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)11. 3 minutes—intermediate chromium plating using a current density of 10 A/dm212. 15 seconds—power source off, settling time13. 12 seconds—engage current bridge between the anodes and cathode14. 30 seconds—rise time for intermediate chromium plating (i.e., the power source is turned on and the current density is increased to the current density used in the next step)15. 3 minutes—intermediate chromium plating using a current density of 10 A/dm2

The portions of the resulting chromium plated press plate not covered by the mask are expected to have a gloss level of no more than about 5 as measured at 60° using the Gardner gloss meter, which complies with ASTM D523-14, Standard Test Method for Specular Gloss (2014).

Thereafter, the mask is typically removed and the entire surface of the press plate is chromium plated (including portions of the press plate previously covered by the mask and portions of press plate having matte chrome) by performing the following steps: (i) 3 minutes-rise time to strike, (ii) 2 minutes—deposit a strike on the press plate using a current density of 16 A/dm2, (iii) 30 minutes-chromium plating using a current density of 10 A/dm2. The portions of the resulting chromium plated press plate not previously covered by the mask are expected to have a gloss level of approximately 11-13 as measured at 60° using the Gardner gloss meter, which complies with ASTM D523-14, Standard Test Method for Specular Gloss (2014).

As will be appreciated by one of skill in the art, the present invention may be embodied as a method (including, for example, a computer-implemented process, a business process, and/or any other process), apparatus (including, for example, a system, machine, device, computer program product, and/or the like), or a combination of the foregoing. Accordingly, embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, and the like), or an embodiment combining software and hardware aspects that may generally be referred to herein as a “system.” Furthermore, embodiments of the present invention may take the form of a computer program product on a computer-readable medium having computer-executable program code embodied in the medium.

Any suitable transitory or non-transitory computer readable medium may be utilized. The computer readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device. More specific examples of the computer readable medium include, but are not limited to, the following: an electrical connection having one or more wires; a tangible storage medium such as a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a compact disc read-only memory (CD-ROM), or other optical or magnetic storage device.

In the context of this document, a computer readable medium may be any medium that can contain, store, communicate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer usable program code may be transmitted using any appropriate medium, including but not limited to the Internet, wireline, optical fiber cable, radio frequency (RF) signals, or other mediums.

Computer-executable program code for carrying out operations of embodiments of the present invention may be written in an object oriented, scripted or unscripted programming language. However, the computer program code for carrying out operations of embodiments of the present invention may also be written in conventional procedural programming languages, such as the “C” programming language or similar programming languages.

Embodiments of the present invention are described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products. It will be understood that each block of the flowchart illustrations and/or block diagrams, and/or combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer-executable program code portions. These computer-executable program code portions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a particular machine, such that the code portions, which execute via the processor of the computer or other programmable data processing apparatus, create mechanisms for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.

These computer-executable program code portions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the code portions stored in the computer readable memory produce an article of manufacture including instruction mechanisms which implement the function/act specified in the flowchart and/or block diagram block(s).

The computer-executable program code may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the code portions which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block(s). Alternatively, computer program implemented steps or acts may be combined with operator or human implemented steps or acts in order to carry out an embodiment of the invention.

As the phrase is used herein, a processor (or other device) may be “configured to” perform a certain function in a variety of ways, including, for example, by having one or more general-purpose circuits perform the function by executing particular computer-executable program code embodied in computer-readable medium, and/or by having one or more application-specific circuits perform the function.

Embodiments of the present invention are described above with reference to flowcharts and/or block diagrams. It will be understood that steps of the processes described herein may be performed in orders different than those illustrated in the flowcharts. In other words, the processes represented by the blocks of a flowchart may, in some embodiments, be in performed in an order other that the order illustrated, may be combined or divided, or may be performed simultaneously. It will also be understood that the blocks of the block diagrams illustrated, in some embodiments, merely conceptual delineations between systems and one or more of the systems illustrated by a block in the block diagrams may be combined or share hardware and/or software with another one or more of the systems illustrated by a block in the block diagrams. Likewise, a device, system, apparatus, and/or the like may be made up of one or more devices, systems, apparatuses, and/or the like. For example, where a processor is illustrated or described herein, the processor may be made up of a plurality of microprocessors or other processing devices which may or may not be coupled to one another. Likewise, where a memory is illustrated or described herein, the memory may be made up of a plurality of memory devices which may or may not be coupled to one another.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.