Xerox Corporation

Henry G Grey

William G Herbert

Ronald E Jansen

Robert P Altavela

Peter J Schmitt

John H Lennon

Patricia Bischoping

Lawrence Kotowicz

Andrew R Melnyk

Joseph C Mammino

Donald S Sypula

Bruce C Reynolds

This invention relates to an electroforming device and a process used to electroform a metal layer on an inner surface of a female mandrel. The electrolytic solution flows only through an electrolytic solution passageway that defines the inner surface as the walls of the passageway. The mandrel may include more than one electrolytic solution passageway, or multiple mandrels may be used in a sequential order to mass produce the electroforms.

Electroforming process

There is disclosed an apparatus for depositing metal on a member comprising: (a) a first electrode comprising a first corrugated side; (b) a second electrode having the same polarity as the first electrode and comprising a second corrugated side, wherein the second corrugated side is disposed opposite the first corrugated side, and spaced therefrom; (c) a channel defined by the first corrugated side and the second corrugated side for movement of the member therebetween, wherein the channel has a plurality of alternating expansive areas and constrictive areas; and (d) a conveyor device for transporting the member through the channel.

Apparatus for electrodeposition

An electroforming/electrodeposition process and apparatus includes a first electrode, a second electrode spaced from the first electrode, a channel defined by the first and second electrodes and at least one electrically nonconductive or poorly conductive shield disposed adjacent at least one electrode. The shield(s) define(s) a region of the channel wherein the surface of a mandrel placed in that region experiences substantially uniform current density. The apparatus may contain additional electroforming/electrodeposition and/or other steps and may be arranged in a carousel apparatus with one or more mandrels to permit continuous operation of the apparatus.

Electroforming semi-step carousel, and process for using the same

An apparatus for depositing metal which provides a brushless electrical current continuity between a member, such as an electroforming mandrel or an electroplating rack, and a current source, comprising: (a) an electrode; (b) a member, spaced apart from the electrode, wherein the member defines a space that is partially or fully filled with a first conductive liquid in electrical contact with the member; (c) a second conductive liquid electrically isolated from the electrode; and (d) connecting means for electrically connecting the first conductive liquid and the second conductive liquid.

Brushless electrodeposition apparatus

An apparatus is disclosed for depositing metal on a mandrel which provides a brushless electrical current continuity between the mandrel and a current source, comprising: (a) a metal deposition vessel; (b) an electrode disposed in the vessel; (c) a mandrel disposed in the vessel, spaced apart from the electrode; (d) an electrically conductive liquid disposed in the vessel; (e) an electrolytic solution disposed in the tank; (f) a layer of a substantially electrically nonconductive material disposed between the electrolytic solution and the conductive liquid; and (g) connecting means for electrically connecting the mandrel and the conductive liquid, coupled to the mandrel.

Brushless electroforming apparatus

An electroforming process is used to prepare an electroformed metal layer on the inside surface of a female mandrel to form an electroform with a hollow interior. A device may be positioned within the hollow interior of the electroform, and the interior is filled with a filling material. The electroform may then be separated from the mandrel by a force applied to the device positioned within the filling material.

Electroforms with high dimensional stability

A process for preparing a multilayered belt includes providing a mandrel having an outer electroforming surface or an inner electroforming surface; and sequentially electrodepositing both a polymer layer and a conductive layer on the electroforming surface of the mandrel to form a multilayered belt.

Multilayer belts formed by electrodeposition

A composite metal article is disclosed comprising at least a first elongated electroformed hollow member and a second electroformed elongated hollow member, each of the hollow members comprising at least a first sleeve and a second sleeve, one sleeve of each of the hollow members having a perimeter larger than the perimeter of the other sleeve of the same member, at least a segment of the outer surface of one sleeve of the second elongated hollow member being adjacent to and substantially surrounded by the inner surface of one sleeve of the first elongated hollow member. This composite hollow member may be formed by electroforming the hollow members on two appropriately shaped mandrels, removing the hollow members from the mandrels, and inserting at least a segment of the hollow member from one mandrel inside at least a segment of the hollow member from the other mandrel whereby the inner surface of at least a segment of the hollow member from one mandrel substantially surrounds at least a segment of the outer surface of the hollow member from the other mandrel.

Electroforming process and product

An electroforming process is described comprising providing an elongated electroforming mandrel core, applying a substantially uniform coating of a molten, inert, inorganic, homogeneous, electrically conductive metal or metal alloy to the mandrel core, the metal or metal alloy having a melting point and a surface tension less than the melting point and surface tension of the mandrel core, immersing the mandrel core bearing the coating in an electroforming bath having a surface tension less than the surface tension of the metal or metal alloy, depositing an electroformed metal layer on the coating, the electroformed metal layer having a melting point greater than the metal or metal alloy, melting the metal or metal alloy, and removing the electroformed metal layer from the mandrel core.

Growing community of inventors

Las Vegas, NV, United States of America

Henry G Grey