Patent ID: 12209323

DETAILED DESCRIPTION OF EMBODIMENTS

The following embodiments describe an electroplating shield device and methods of fabricating the electroplating shield device for improving electroplating processes, in accordance with one or more aspects of the present disclosure.

As described above, there is a need in the electroplating technology field to efficiently and uniformly electroplate, for example, machinery parts. For example, electroplating a large machinery part (e.g., a mud motor rotor) having irregular shapes may require at least 4 inches of space between a surface of the large machinery part and one or more electroplating electrodes (e.g., anode electrode(s)). That is, a relatively large electrode spacing may be required in order to produce a suitable electroplate coating layer on the large machinery part. However, such electrode spacing generally requires a large volume of electroplating solution, especially for large machinery parts (e.g., a mud motor rotor) that could extend beyond 30 feet. Minimizing the electrode spacing, in an attempt to reduce the amount of electroplating solution, may result in uneven electroplate coating layers formed on various areas of the large machinery part. Accordingly, the following embodiments describe an electroplating shield device that facilitates application of uniform electroplate coating layers on machinery parts of any shape and/or size.

According to certain aspects of the present disclosure, the electroplating shield device may include a plurality of first openings and a plurality of second openings on the sidewall of the electroplating shield device. The plurality of first openings and the plurality of second openings may be arranged to align with particular areas of a machinery part. For example, the plurality of first openings may be aligned with the minor regions (e.g., concave surfaces of a mud motor rotor) of the machinery part, and the plurality of second openings may be aligned with the major regions (e.g., convex surfaces of a mud motor rotor) of the machinery part. The size of each of the plurality of first openings may be larger than the size of each of the plurality of second openings. The electric field applied between the machinery part and the electroplating electrode may vary based on the size of each of the plurality of first openings and the plurality of second openings. Additionally, the rate of flow of the electroplating solution through the plurality of first openings and the plurality of second openings may also vary based on the size of each of the plurality of first openings and the plurality of second openings. Thus, the amount and/or thickness of electroplate coating layers on the major regions and the minor regions of the machinery part may be controlled and/or applied as desired. Accordingly, a uniform electroplate coating layer may be achieved on machinery parts with any shape and/or size by utilizing the electroplating shield device of the present disclosure.

The subject matter of the present description will now be described more fully hereinafter with reference to the accompanying drawings, which form a part thereof, and which show, by way of illustration, specific exemplary embodiments. An embodiment or implementation described herein as “exemplary” is not to be construed as preferred or advantageous, for example, over other embodiments or implementations; rather, it is intended to reflect or indicate that the embodiment(s) is/are “example” embodiment(s). Subject matter can be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any exemplary embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, subject matter may be embodied as methods, devices, components, or systems. Accordingly, embodiments may, for example, take the form of hardware, software, firmware, or any combination thereof (other than software per se). The following detailed description is, therefore, not intended to be taken in a limiting sense.

Throughout the specification and claims, terms may have nuanced meanings suggested or implied in context beyond an explicitly stated meaning. Likewise, the phrase “in one embodiment” as used herein does not necessarily refer to the same embodiment and the phrase “in another embodiment” as used herein does not necessarily refer to a different embodiment. It is intended, for example, that claimed subject matter include combinations of exemplary embodiments in whole or in part.

The terminology used below may be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the present disclosure. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section. Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed.

In this disclosure, the term “based on” means “based at least in part on.” The singular forms “a,” “an,” and “the” include plural referents unless the context dictates otherwise. The term “exemplary” is used in the sense of “example” rather than “ideal.” The term “or” is meant to be inclusive and means either, any, several, or all of the listed items. The terms “comprises,” “comprising,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, or product that comprises a list of elements does not necessarily include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. Relative terms, such as, “substantially” and “generally,” are used to indicate a possible variation of ±10% of a stated or understood value.

Referring now to the appended drawings,FIG.1shows an exemplary electroplating shield device100, according to one or more aspects of the present disclosure. In one embodiment, the electroplating shield device100may include a cylindrical tube (or a conduit)106. The cylindrical tube106may be hollow and substantially straight, extending vertically from a proximal end102to a distal end104. The electroplating shield device100may also include a plurality of first openings108(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) that penetrate through the sidewall of the cylindrical tube106. The plurality of first openings108may be arranged in a first section110on the sidewall of the cylindrical tube106. The first section110of the cylindrical tube106may be a continuous, spiral-shaped (or helical) surface that extends vertically from the proximal end102to the distal end104. Additionally, the electroplating shield device100may include a plurality of second openings112(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) that penetrate through the sidewall of the cylindrical tube106. The plurality of second openings112may be arranged in a second section114on the side wall of the cylindrical tube106. The second section114of the cylindrical tube106may be a continuous, spiral-shaped (or helical) surface that extends vertically from the proximal end102to the distal end104. The second section114may be arranged adjacent to and in between the first section110. In other words, the continuous, spiral-shaped (or helical) surface of the second section114may be arranged adjacent to and alternately in between the continuous, spiral-shaped (or helical) surface of the first section110, as shown inFIG.1.

In one embodiment, the size of each of the plurality of first openings108may be equal. The size of each of the plurality of second openings112may also be equal. In some embodiments, the size of each of the plurality of first openings108may be greater than the size of each of the plurality of second openings112. However, the shape and size of each of the plurality of first openings108and the plurality of second openings112, individually or in groups, may vary based on the shape and dimensions of one or more parts or work pieces (e.g., a shaft, rod, beam, cylinder, bar, etc.) being electroplated. Further, the density and/or number of openings of the plurality of first openings108and the plurality of second openings112in the first section110and the second section114may vary based on the shape and dimensions of one or more parts or work pieces. Conventionally, achieving a uniform electroplate coating layer thickness on large machinery parts (e.g., mud motor rotors) with irregular shapes has been difficult. That is, a mud motor rotor, for example, may include major regions (e.g., high/convex regions) that may be coated with electroplating deposits many times thicker than those of minor regions (e.g., low/concave regions). The ratio of electroplating deposit thickness difference between the major regions and the minor regions may be 8:1 or higher depending on the geometry of the mud motor rotor. As such, the difference in the electroplating deposit thicknesses may leave the minor regions with a thinner-than-desired electroplate deposit thickness, which may result in reduced wear and corrosion resistance. Accordingly, the shape and size of each of the plurality of first openings108and the plurality of second openings112may be varied based on the desired thickness of electroplating deposits on various regions of one or more parts or work pieces. Further, the density of the plurality of first openings108and the plurality of second openings112in the first section110and the second section114may also be varied based on the desired thickness of electroplating deposits on various regions of one or more parts or work pieces.

In one embodiment, the cylindrical tube106may be made from a material including, for example, titanium or any other suitable materials that have a linear coefficient of thermal expansion (CTE) value (e.g., about 8.4 ppm/° Celsius) substantially similar to the CTE value of a 17-4 Precipitation Hardening grade (17-4PH) alloy or a 4140 alloy. The following table shows a list of suitable metals that may be used to fabricate the cylindrical tube106.

CTECTE TemperatureMetal(ppm/° C.)Range (° C.)Titanium8.420-6817-4ph Stainless10.821-93Hatelloy c276 Superalloy11.224-100Inconel 718 Superalloy12.821-93304 Stainless17.320 C.440C Stainless10.10-1004140 Steel12.20-100
For example, a suitable metal for fabricating the cylindrical tube106may be selected based at least on one or more the following attributes: light weight; high strength; corrosion resistance; matching coefficient of thermal expansion to the one or more parts or work pieces (e.g., mud motor rotors); cost; and ease or difficulty of fabrication.

Plastic electroplating shields (e.g., polyethylene (PE), chlorinated polyvinyl chloride (CPVC), polyvinyl chloride (PVC), etc.), for example, may have a CTE value (e.g., about 79 ppm/° Celsius) that is 7 times or higher than the CTE value of a 17-4PH alloy. As such, plastic electroplating shields may undergo dimensional distortions in hot (e.g., about 70° Celsius or greater) electroplating baths, particularly for plastic shields for large, long machinery parts such as mud motor rotors. However, the cylindrical tube106made from high strength titanium, or any other suitable materials described above, may yield a thin and lightweight construction for the electroplating shield device100that undergoes relatively low dimensional distortions (e.g., about 0.029 inches of relative growth per 20 feet length over about 50° Celsius temperature range) in hot electroplating baths. The cylindrical tube106made from titanium or other suitable materials having a lightweight construction improves mobility and efficiency during electroplating processes, especially for electroplating large machinery parts (e.g., length greater than 20 feet) such as mud motor rotors. Further, the thin sidewall of the cylindrical tube106may displace less electroplating solution and promote efficient electroplating solution movement as compared to thicker plastic shields. Accordingly, the cylindrical tube106made of titanium or other suitable materials may allow tighter electrode spacing, for example, in relatively smaller, enclosed electroplating chambers. The thin sidewalls of the cylindrical tube106may also yield openings (the plurality of first openings108and the plurality of second openings112) with low aspect ratios, which may facilitate improved electroplating solution movement through the electroplating shield device100. In one embodiment, masks may be applied to the cylindrical tube106to improve corrosion resistance. The masks may include, for example, PVC, epoxy, and fluoropolymers (e.g., polytetrafluoroethylene (PTFE), ethlyne tetrafluoroethylene (ETFE), fluorinated ethylene propylene (FEP), perfluoroalkoxy alkane (PFA), etc.).

FIG.2depicts an example electroplating system200, according to one or more aspects of the present disclosure. The electroplating system200may include an electroplating chamber208. The electroplating chamber208may be an open electroplating chamber (or bath) or an enclosed electroplating chamber that is configured to receive and store one or more parts202(e.g., a shaft, rod, beam, cylinder, bar, etc.). An enclosed electroplating chamber may receive the one or more parts202via one or more openings on the enclosed electroplating chamber. An enclosed chamber may include one or more covers that are configured to open and close the one or more openings of the enclosed electroplating chamber. The electroplating chamber208may contain one or more electroplating solutions210, one or more anode electrodes212and one or more cathode electrodes (only anode electrode212shown inFIG.2for clarity). The one or more anode electrodes212and the cathode electrodes may to apply electric current and electric fields in the electroplating chamber208to facilitate the application of electroplating coating layers on the one or more parts202.

In one embodiment, the electroplating chamber208may be configured to receive and store the part202and the electroplating shield device100. The length of the electroplating chamber208may be greater than the part202and the electroplating shield device100. The electroplating chamber208may be greater than 20 feet, for example, to receive and store large machinery parts (e.g., a rotor of positive-displacement motors, progressive cavity pumps, etc.). However, of course, the electroplating chamber208may be designed to be any length suitable for various other applications. Further, the electroplating chamber208may be configured to receive the one or more electroplating solutions210from a reservoir system via one or more conduits (not shown in the figures), in order to facilitate the electroplating process of the present disclosure. Additionally, the electroplating chamber208may be connected a controller system. The controller system may automatically or manually facilitate the electroplating processes of the present disclosure by providing the electroplating solutions210and electric current to the electroplating chamber208via pumps, actuators, electrodes, and/or valves that are coupled to the electroplating chamber208and the reservoir system.

Still referring toFIG.2, the part202may be greater than 30 feet, for example, and may include major regions204and minor regions206. The major regions204may include one or more protruding, spiral-shaped lobes (or convex surface) that vertically extend from one end to the opposite end of the part202. The minor regions206may include spiral-shaped depressions (or concave surface) that vertically extend from one end to the opposite end of the part202. The minor regions206may be arranged adjacent to and in between the major regions204. In other words, the continuous, spiral-shaped depressions of the minor regions206may be arranged adjacent to and alternately in between the continuous, spiral-shaped lobes of the major regions204, as shown inFIG.2.

In one embodiment, the part202may be placed into the electroplating chamber208, and the electroplating shield device100may be placed in between the part202and the anode electrode212. In this embodiment, the length of the electroplating shield device100may be equal to or greater than the length of the part202, so as to arrange or place the entire piece of the part202within the electroplating shield device100. Further, the electroplating shield device100may be arranged or placed relative to the part202, so as to align the first section110of the electroplating shield device100with the minor regions206of the part202and the second section114of the electroplating shield device100with the major regions204of the part202. In one embodiment, the size of the plurality of first openings108arranged in the first section110may be greater than the size of the plurality of second openings112arranged in the second section114. As such, during an electroplating process of the present disclosure, one or more electroplating solutions may flow through the plurality of first openings108at a greater rate than through the plurality of second openings112. Further, a greater electric field may be applied to the minor regions206through the plurality of first openings108than the major regions204through the plurality of second openings112. Accordingly, despite the minor regions206of the part202being located at a greater distance from the anode electrode212than the major regions204, an electroplate coating layer may be deposited on both the minor regions206and the major regions204of the part202with a uniform thickness. The size of each, and the density the openings, of the plurality of first openings108and the plurality of second openings112may be varied depending on the shape, size, and/or dimensions of the part202. Further, the size of each, and the density of the openings, of the plurality of first opening108and the plurality of second openings112may be varied based on the distance between the anode electrode212and the surfaces of different regions (e.g., major regions204and minor regions206) of the part202. In one embodiment, the electrode spacing between the anode electrode212and the part202may be 1 inch or less.

FIG.3shows another example electroplating shield device300, according to one or more aspects of the present disclosure. In one embodiment, the electroplating shield device300may include a cylindrical tube306. The cylindrical tube306may be hollow and substantially straight, extending vertically from a proximal end302to a distal end304. The electroplating shield device300may include a plurality of first openings308(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) that penetrate through the sidewall of the cylindrical tube306. The plurality of first openings308may be arranged in a first section310of the cylindrical tube306. The first section310of the cylindrical tube306may be a continuous, spiral-shaped (or helical) surface that extends vertically from the proximal end302to the distal end304. Additionally, the electroplating shield device300may include a plurality of second openings312(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) that penetrate through the sidewall of the cylindrical tube306. The plurality of second openings312may be arranged in a second section314of the cylindrical tube306. The second section314of the cylindrical tube306may be a continuous, spiral-shaped (or helical) surface that extends vertically from the proximal end302to the distal end304. The second section314may be arranged adjacent to and in between the first section310. In other words, the continuous, spiral-shaped (or helical) surface of the second section314may be arranged adjacent to and alternately in between the continuous, spiral-shaped (or helical) surface of the first section310, as shown inFIG.3.

Still referring toFIG.3, the electroplating shield device300may include a first zone316and a second zone318on the cylindrical tube306. The first zone316may include a continuous, cylindrical surface between the proximal end302and the plurality of first openings308and the plurality of second openings312. The first zone316may include a solid surface that may not include any openings (e.g., a non-perforated zone). The second zone318may include a continuous, cylindrical surface between the distal end304and the plurality of first openings308and the plurality of second openings312. The second zone318may also include a solid surface that may not include any openings (e.g., a non-perforated zone).

In some embodiments, the opposing ends of the part202(i.e., the proximal end302and the distal end304) may experience a higher electroplating rate compared to the rest of the part202. For example, about 6 inches in vertical length at each end of the part202may gain a thicker growth of electroplate coating layer compared to the rest of the part202. Accordingly, the electroplating shield device300may include the first zone316and the second zone318with a vertical length that may be equal to or greater than about 6 inches. In some embodiments, the size and length of the first zone316and the second zone318may be varied based on the amount of electroplate coating layer growth on each end of one or more parts being electroplated. Further, the electroplating shield device300may be arranged or placed within the an electroplating chamber (e.g., the electroplating chamber208) in the manner to cover at least about 6 inches of each end of the part202with the first zone316and the second zone318. Accordingly, a uniform electroplate coating layer may be formed on the part202by utilizing the electroplating shield device300, in accordance with one or more aspects of the present disclosure.

FIG.4shows an exemplary process400for fabricating an electroplating shield device401, according to one or more aspects of the present disclosure. In one embodiment, a strip402having a plurality of first openings404(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) and a plurality of second openings406(e.g., apertures, holes, slots, slits, ovals, perforations, etc.) may be provided. In one embodiment, the plurality of first openings404may be provided on a first half of the strip402, and the plurality of the second openings406may be provided on a second half of the strip402, as shown inFIG.4. The plurality of first openings404and the plurality of second openings406may be machined, punched, drilled, photoetched and/or laser cut by utilizing a suitable manual or automated equipment/device. The strip402may be made from, for example, titanium or other suitable materials that have a coefficient of thermal expansion (CTE) substantially similar to the CTE of a 17-4 Precipitation Hardening grade (17-4PH) alloy or a 4140 alloy.

Still referring toFIG.4, the strip402may be formed into a cylindrical-shaped tube403by helically winding the strip402around a mandrel408(e.g., a column, a rod, a cylinder, a pillar, etc.). The strip402may be wound around the mandrel408to align the plurality of first openings404and the plurality of the second openings406with the minor regions206and the major regions204of the part202. In one embodiment, the strip402may be welded at a continuous, helical gap (or seam)410. In one embodiment, the electroplating shield device401may be tack welded at various sections of the continuous, helical gap410to confine and hold the dimensions of the electroplating shield device401. Any suitable welding device (or equipment) may be used to manually or automatically weld the continuous, helical gap410.

FIG.5shows another exemplary process500for fabricating an electroplating shield device512, according to one or more aspects of the present disclosure. In one embodiment, a strip502having a plurality of first openings504(e.g., apertures, holes, slots, perforations, etc.) and a plurality of second openings506(e.g., apertures, holes, slots, perforations, etc.) may be provided. In one embodiment, the plurality of first openings504and the plurality of second openings506may be provided diagonally, extending from a proximal end501to a distal end503. The first plurality of openings504and the second plurality of openings506may be provided alternately in different diagonal sections of the strip502, as shown inFIG.5. The plurality of first openings404and the plurality of second openings406may be machined, punched, drilled, photoetched and/or laser cut by utilizing suitable automated equipment. The strip402may be made from, for example, titanium or other suitable materials that have a coefficient of thermal expansion (CTE) substantially similar the CTE of a 17-4 Precipitation Hardening grade (17-4PH) alloy or a 4140 alloy.

Still referring toFIG.5, the strip502may be formed into a cylindrical-shaped tube505by rolling the strip502into a cylindrical shape by vertically joining a first section508with a second section510. The plurality of first openings504and the plurality of the second openings506may be provided on the strip502such that the plurality of the first openings504and the plurality of second openings506, once the strip502has been rolled into the cylindrical shape, are provided as alternating continuous, helical sections extending vertically from one end to the other end of the cylindrical-shaped tube505, as shown inFIG.5. The strip502may then be welded at a third section514, where the first section508and the second section510meet to form the cylindrical-shaped tube505. In one embodiment, the electroplating shield device512may be tack welded at various locations of the third section514to confine and hold the dimensions of the electroplating shield device512. Any suitable welding device (or equipment) may be used to manually or automatically weld the third section514where the first section508and the second section510meet. Alternatively or additionally, the strip502may include a first solid surface zone adjacent to the proximal end501and a second solid surface zone adjacent to the distal end503. The first and second solid surface zones may not include the plurality of first openings504and the plurality of second openings506. In one embodiment, the first and second solid surface zones may be at least 6 inches in vertical length. The first and second solid surface zones may be provided on the strip502such that when the strip502is rolled into a cylindrical shape by vertically joining the first section508with the second section510, the electroplating shield device512may include the first solid surface zone and the second solid surface zone similarly to the first zone316and the second zone318on the cylindrical tube306, as shown inFIG.3.

FIG.6depicts a flowchart of an exemplary method600for fabricating an electroplating shield device, in accordance with one or more aspects of the present disclosure. At step602, a fabrication system of the present disclosure may form a first set of apertures having a first size on a first region of a strip. The strip may be formed of titanium. Additionally or alternatively, the strip may be formed of a material having a linear coefficient of thermal expansion lower than 79.0 ppm/° C.

At step604, the fabrication system may form a second set of apertures having a second size on a second region of the strip adjacent the first region of the strip. In one embodiment, the first size of each of the first set of apertures and the second size of each of the second set of apertures may be different. The first set of apertures and the second set of apertures may be formed with at least one of a drill, a punch device, a photoetching device, a laser device, and/or a computer numerical control device.

Still referring toFIG.6, at step606, the fabrication system may form a conduit with the strip. The conduit may comprise a first helical section having the first set of apertures and a second helical section having the second set of apertures. In one embodiment, the conduit may be formed by helically winding the strip around a pillar as described above in reference toFIG.4. The fabrication system may then weld a continuous gap formed between the first helical section and the second helical section. In another embodiment, the conduit may be formed by rolling the strip and bringing a first vertical side of the strip to a second vertical side of the strip as described above in reference toFIG.5. The fabrication system may then weld a continuous gap formed between the first vertical side of the strip and the second vertical side of the strip. Further, the strip may comprise a first section proximate to a first end (e.g., a proximal end302inFIG.3), and a second section proximate a second end (e.g., a distal end304inFIG.3). The first section and the second section may each comprise a solid surface without apertures as described above in reference toFIG.3.

It should be appreciated that in the above description of exemplary embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed embodiment requires more features than are expressly recited in each claim. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the disclosure, and form different embodiments, as would be understood by those skilled in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Thus, while certain embodiments have been described, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the disclosure, and it is intended to claim all such changes and modifications as falling within the scope of the disclosure. For example, functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present disclosure.

The above disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other implementations, which fall within the true spirit and scope of the present disclosure. Thus, to the maximum extent allowed by law, the scope of the present disclosure is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the foregoing detailed description. While various implementations of the disclosure have been described, it will be apparent to those of ordinary skill in the art that many more implementations and implementations are possible within the scope of the disclosure. Accordingly, the disclosure is not to be restricted.