Apparatus and process for producing coatings

Abstract

An apparatus is disclosed for applying a coating to a desired object including a rotatable container having at least one container wall. An electrolyte can be retained within the container, the at least one container wall made of a material that does not allow the electrolyte to pass through the at least one container wall of the container. An anode can be positioned within the container. The apparatus can include a mount for securing the desired object such that a surface of the desired object is exposed to the electrolyte. A controller can be in electrical communication with the anode and the mount, wherein when power is supplied from the controller to the anode and the mount, particles in the electrolyte are deposited on the desired object forming a composite coating.

What is claimed is: 
     
         1 . An apparatus for applying a coating to a desired object comprising:
 a rotatable container having at least one container wall;   an electrolyte retained within the container, the at least one container wall made of a material that does not allow the electrolyte to pass through the at least one container wall of the container;   an anode positioned within the container;   a mount for securing the desired object such that a surface of the desired object is exposed to the electrolyte; and   a controller in electrical communication with the anode and the mount;   wherein when the desired object is secured to the mount and power is supplied from the controller to the anode and the mount, particles in the electrolyte are deposited on the desired object forming a composite coating.   
     
     
         2 . The apparatus of  claim 1 , wherein the apparatus further comprises:
 a frame;   a motor mounted to the frame and coupled to the container, the motor selectively operable by the controller to rotate the container.   
     
     
         3 . The apparatus of  claim 2 , wherein:
 the container further comprises a cap;   the motor is coupled to the cap such that the container is rotated by the motor via the cap; and   the mount is positioned on the cap such that the container and the mount rotate at the same rotational speed.   
     
     
         4 . The apparatus of  claim 2 , further comprising a gear system coupled between the motor and the container, wherein the container is rotated by the motor via the gear system. 
     
     
         5 . The apparatus of  claim 1 , wherein:
 the container has a central axis of rotation;   the mount is located along the central axis of the container; and   the anode is a hollow member positioned within the container and at least partially about the desired object when the desired object is mounted to the mount.   
     
     
         6 . The apparatus of  claim 1 , further comprising:
 a first electrically conductive wire electrically connected between the mount and the controller; and   a second electrically conductive wire connected between the controller and the anode.   
     
     
         7 . The apparatus of  claim 1 , wherein:
 the container further comprises a trunnion, the anode in electrical communication with the trunnion; and   the apparatus further comprises a slip ring disposed on the trunnion and electrically communicated with the controller, the slip ring oriented to maintain electrical contact between the trunnion and the slip ring while the slip ring remains stationary and the container and trunnion rotate such that the trunnion and thus the anode are in electrical communication with the controller via the slip ring.   
     
     
         8 . The apparatus of  claim 1 , further comprising a heating element positioned on an exterior of the container, wherein the electrolyte is heated as the heating element heats the container. 
     
     
         9 . The apparatus of  claim 8 , further comprising a temperature sensor extending through the container and into the electrolyte, the temperature sensor operable to monitor a temperature of the electrolyte. 
     
     
         10 . The apparatus of  claim 9 , wherein:
 the container further comprises a trunnion, the anode, the heating element, and the temperature sensor are in electrical communication with the trunnion; and   the apparatus further comprises a slip ring mounted on the trunnion and electrically communicated with the controller, the slip ring oriented to maintain electrical contact between the trunnion and the slip ring while the slip ring remains stationary and the container and trunnion rotate such that the trunnion, the anode, the heating element, and the temperature sensor are in electrical communication with the controller via the slip ring.   
     
     
         11 . The apparatus of  claim 1 , wherein the container is a hollow object and is the desired object to be coated, the container being removably connectable to the mount with an inner surface of the container exposed to the electrolyte, and the anode is positioned within the container. 
     
     
         12 . The apparatus of  claim 11 , wherein the container has a first end and a second end, the mount being removably connected to the first end of the container and the apparatus further comprises:
 a trunnion removably connected to the second end of the container, the anode in electrical communication with the trunnion; and   a slip ring disposed on the trunnion and electrically communicated with the controller, the slip ring oriented to maintain electrical contact between the trunnion and the slip ring while the slip ring remains stationary and the container and trunnion rotate such that the trunnion and thus the anode are in electrical communication with the controller via the slip ring.   
     
     
         13 . The apparatus of  claim 1 , wherein the particles in the electrolyte include micron-, submicron- or nano-sized particles, and the container wall does not allow the particles from the anode to pass through the at least one container wall. 
     
     
         14 . The apparatus of  claim 1 , further comprising one or more baffles or paddles positioned within the container and extending into the electrolyte. 
     
     
         15 . An apparatus for applying a coating to a desired object comprising:
 a frame;   a container rotatably disposed on the frame, the container having at least one container wall;   a motor connected to the frame and coupled to the container, the motor selectively operable to rotate the container,   a plating solution retained within the container, the plating solution containing micron-, submicron- or nano-sized particles for coating the desired object, the at least one container wall made of a material that does not allow the plating solution or the particles contained therein to pass through the at least one container wall of the container;   a mount for securing the desired object such that a surface of the desired object is exposed to the plating solution; and   wherein when the desired object is connected to the mount and the container is rotated via the motor, particles from the plating solution are deposited on the desired object as a coating.   
     
     
         16 . The apparatus of  claim 15 , further comprising:
 the plating solution being an electrolyte;   an anode positioned in the container; and   a controller in electrical communication with the anode and the mount;   wherein when the controller provides power to the anode and the mount when the desired object is connected to the mount, the particles in the electrolyte are deposited on the desired object.   
     
     
         17 . The apparatus of  claim 16 , wherein the anode is a hollow cylindrical member that is positioned to surround the desired object when the desired object is mounted to the mount. 
     
     
         18 . An apparatus for applying a coating to an object, the apparatus comprising:
 a frame;   a hollow desired object rotatably disposed on the frame, the desired object having at least one wall;   a motor connected to the frame and coupled to the desired object, the motor selectively operable to rotate the desired object,   an electrolyte retained within the desired object, the at least one wall of the desired object made of a material that does not allow the electrolyte to pass through the at least one wall of the desired object;   an anode positioned within the desired object and the electrolyte; and   a controller in electrical communication with the anode and the desired object;   wherein when power is supplied from the controller to the anode and the desired object, particles in the electrolyte are deposited on the desired object forming a composite coating.   
     
     
         19 . The apparatus of  claim 18 , wherein the apparatus further comprises:
 a cap rotatably connected to the frame, the desired object removably connectable to the cap;   a trunnion removably connected to the desired object opposite the mount, wherein the electrolyte is retained between the desired object, the cap, and the trunnion.