AU2017204328B2

AU2017204328B2 - Tip Brush - New Electrochemical Electrode

Info

Publication number: AU2017204328B2
Application number: AU2017204328A
Authority: AU
Inventors: Dean Klower
Original assignee: Metal Science Technologies Pty Ltd
Current assignee: Metal Science Technologies Pty Ltd
Priority date: 2016-05-09
Filing date: 2017-06-26
Publication date: 2023-03-02
Anticipated expiration: 2037-05-09
Also published as: AU2017204328A1

Abstract

This invention relates to the electro chemical processes and its applications in metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or 5 welding. In particular the use of carbon fibre as the electrode tool in the form of a brush where the majority of the brush is rigid and only the contact tip is soft. With the use of a standard dielectric solution or conductive solution the new electrode design can focus the action in the desired area with maximum control and without arc damage to the microstructure of the piece being treated. Using 10 this new system the solution can be controlled much easier and economically and as the electrode wears the soft tip will relocate automatically up the rigid carbon fibre only remaining soft at the electrode tip even if the electrode is one quarter its original size due to wear. ill 1/1 aL. c 0 n co C : CC .o Or .. c, DI D0 D

Description

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[001] The present invention generally relates to a tip brush electrochemical electrode comprising carbon fibre. The invention relates to an electrode for electrochemical processes and its application in metal cleaning, polishing including electropolishing, etching, Electro-Discharge Machining (EDM) or welding and it will be convenient to hereinafter disclose the invention in relation to that exemplary application.

SUMMARY OF THE INVENTION

[002] The present invention provides an electrode for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding that is made primarily from carbon fibre. In particular, the electrode is a tip brush electrode formed from carbon fibre.

[003] A first aspect of the present invention provides a tip brush electrode configured for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding, wherein the electrode is in the form of a brush and is made primarily from carbon fibre, and wherein the electrode comprises an elongate rod formed from resin or polymer coated carbon fibre which is partially carbonised which includes a contact tip comprising a brush section of the electrode which comprises soft carbon fibres.

[004] The present invention therefore relates to the use of carbon fibre as the electrode tool of a metal cleaning, polishing (including electropolishing), etching, Electro-Discharge Machining (EDM) or welding apparatus. The carbon fibre is used as the electrode tool in the form of a brush where the majority of the brush is rigid and only the contact tip is soft. In embodiments, the contact tip comprises a 10 mm breakdown brush area formed of soft carbon fibres.

[005] In embodiments, the electrode comprises an elongate cylindrical rod having a soft tip at one end forming the soft brush and a holding lug at the other end. The electrode is preferably conductive from contact tip to its opposite end (top).

[006] The carbon fibre in the electrode is typically coated with a resin or polymer coating. The resin or polymer coating is partially carbonised (i.e. has undergone a partial carbonisation process). In some embodiments, the resin or polymer coating comprises polyurethane.

[007] Additionally, as the electrode wears the soft top will relocate automatically up the rigid carbon fibre only remaining soft at the electrode tip even if the electrode is one quarter of its original size due to wear.

[008] The present invention provides an electrode for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding that is made primarily from carbon fibre. The electrode can be shaped or bent to any direction. The electrode can include a solution feed to the process that can be fed internal of the tool or external from single or multiple points. The electrode will allow the use of conductive or non-conductive solutions for the use of metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding.

[009] With the use of a standard dielectric solution or conductive solution, the new electrode design can focus the action in the desired area with maximum control and without arc discharge to the microstructure of the piece being treated. Using this new system, the solution can be controlled much easier and economically.

[010] The present invention additionally provides an electrode and extension for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding that can connect to a portable or fixed power source. The electrode can therefore further include an extension that can connect to a portable or fixed power source.

[011] The present invention also provides a hand-held tool made primarily from carbon fibre for use in metal cleaning, polishing, etching, Electro-Discharge

Machining (EDM) or welding. The hand-held tool preferably comprises an electrode according to the first aspect of the present invention.

[012] A second aspect of the present invention provides a method of forming an tip brush electrode for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding that is made primarily from carbon fibre, the method comprising: A. forming carbon fibre into an electrode body having a desired electrode shape, density and thickness; B. treating the carbon fibre of the electrode body with a resin or polymer coating; C. curing the resin or polymer coated carbon fibre electrode body; D. placing the cured electrode in a furnace of kiln for partial carbonisation; E. cooling the partially carbonised electrode to room temperature to produce a rigid and conductive electrode body that is rigid and conductive from top to tip; and F. forming the soft tip of the electrode into a brush configuration using a mechanical method or a localized burning method.

[013] In embodiments, the resin or polymer coating comprises a polyurethane coating.

[014] In embodiments, the cured electrode is partially carbonised in a furnace for 40 minutes at 400 degrees Celsius.

[015] In embodiments, the partially carbonised polyurethane carbon fibre electrode is cooled at approximately 60 degrees Celsius per hour until it reaches room temperature.

[016] In embodiments, the mechanical method comprises a crushing means.

BRIEF DESCRIPTION OF THE DRAWINGS

[017] The present invention will now be described with reference to the figures of the accompanying drawings, which illustrate particular preferred embodiments of the present invention, wherein:

[018] Figure 1 is a diagram of a tip brush according to an embodiment of the present invention.

DETAILED DESCRIPTION

[019] The invention relates to electrochemical processes and its application in metal cleaning, polishing (including electropolishing), etching, Electro-Discharge Machining (EDM) or welding.

[020] The present invention provides an electrode for metal cleaning, polishing (including electropolishing), etching, Electro-Discharge Machining (EDM) or welding that is made primarily from carbon fibre. One embodiment of the electrode of the present invention is illustrated in Figure 1.

[021] The illustrated electrode 100 comprises a brush formed from carbon fibre encased in a polymer or resin. The electrode 100 comprises an elongate cylindrical rod 110 formed of rigid carbon fibre having a soft tip 120 at one end forming the soft brush and a holding lug 130 at the other end. The holding lug 130 includes a threaded adaptor for connecting the brush to an extension, typically an extension which connects the electrode 100 to to a portable or fixed power source. As shown in Figure 1, the majority of the brush is rigid and only the contact tip is soft.

[022] To build the Tip Brush electrode 100 illustrated in Figure 1, the following steps are used:

1. Firstly, form the carbon fibre (for example DAKEX type, as shown in the illustrated example in Figure 1) into the desired electrode shape, density and thickness before treating the carbon fibre with a coating.

2. Treating the carbon fibre with a resin or polymer coating. Many resins or polymer coatings will work effectively depending on the final application.

As an illustrative example, a carbon fibre brush used in electropolishing was constructed in the configuration illustrated in Figure 1. For this application, the inventor chose a polyurethane coating as its properties are suited to the characteristics of this material, in particular the decomposition temperatures of the material. After application of the polyurethane over the carbon fibre shaped body, the polyurethane is left to cure.

3. Following the curing of the electrode, the electrode is placed in a furnace or kiln for partial carbonisation process.

In the illustrative example, the cured polyurethane carbon fibre shaped body is partially carbonised in a furnace for 40 minutes at 400 degrees Celsius dependent on the polyurethane used.

4. Cooling the partially carbonised electrode to room temperature to produce a rigid and conductive electrode body that is rigid and conductive from top to tip.

In the illustrative example, the partially carbonised polyurethane carbon fibre electrode is cooled at approximately 60 degrees Celsius per hour until it reaches room temperature.

5. The next step is to form the soft tip of the electrode into a brush configuration using a mechanical or localized burning method.

In the illustrative example, the very tip of the brush is crushed with crushing means such as grips no further than 10 mm from the tip. While holding the electrode 15 mm from the tip, the tip is rubbed vigorously against a coarse rasp file. This breaks all of the excessive carbon from the tip making the tip very soft. This forms a 10 mm breakdown brush area formed of soft carbon fibres. It is also possible to soften the tip through localized burning, although for the described application the mechanical method is more appropriate.

[023] The breakdown of the carbon 10 mm from the tip during use is due to heat and movement of the electrode. This soft tip will move up the length of the electrode shaft as the electrode wears. For example, if the electrode starts out 70 mm long and wears down during use to 30 mm in length, the soft tip will remain only 10 mm from the tip of the electrode throughout the life of the electrode.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A tip brush electrode configured for metal cleaning, polishing, etching, Electro Discharge Machining (EDM) or welding, wherein the electrode is in the form of a brush and is made primarily from carbon fibre, and wherein the electrode comprises an elongate rod formed from resin or polymer coated carbon fibre which is partially carbonised which includes a contact tip comprising a brush section of the electrode which comprises soft carbon fibres.

2. A tip brush electrode according to claim 1, wherein the majority of the brush is rigid and only the contact tip is soft.

3. A tip brush electrode according to claim 1 or 2, wherein the contact tip comprises a 10 mm breakdown brush area formed of soft carbon fibres.

4. A tip brush electrode according to any one of claims 1 to 3, wherein the elongate rod comprises an elongate cylindrical rod having a soft tip at one end forming the brush section and a holding lug at the other end.

5. A tip brush electrode according to any preceding claim, wherein the resin or polymer coating comprises polyurethane.

6. A tip brush electrode according to any preceding claim, wherein the electrode is conductive from contact tip to its opposite end.

7. A tip brush electrode according to any preceding claim, wherein the electrode is configured to be shaped or bent to any direction.

8. A tip brush electrode according to any preceding claim, further comprising a solution feed that is fed internal of the electrode or external of the electrode from single or multiple points.

9. A tip brush electrode according to claim 8, wherein the solution feed comprises a conductive or a non-conductive solution for use in metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding.

10. A hand-held tool comprising the tip brush electrode according to any one of the preceding claims.

11. An electrode according to any preceding claim, further including an extension connected to a portable or fixed power source.

12. A method of forming an tip brush electrode for metal cleaning, polishing, etching, Electro-Discharge Machining (EDM) or welding that is made primarily from carbon fibre, the method comprising: A. forming carbon fibre into an electrode body having a desired electrode shape, density and thickness; B. treating the carbon fibre of the electrode body with a resin or polymer coating; C. curing the resin or polymer coated carbon fibre electrode body; D. placing the cured electrode in a furnace or kiln for partial carbonisation; E. cooling the partially carbonised electrode to room temperature to produce a rigid and conductive electrode body that is rigid and conductive from top to tip; and F. forming a soft tip of the electrode into a brush configuration using a mechanical method or a localized burning method.

13. A method according to claim 12, wherein the resin or polymer coating comprises a polyurethane coating.

14. A method according to claim 12 or 13, wherein the cured electrode is partially carbonised in a furnace for 40 minutes at 400 degrees Celsius.

15. A method according to claim 12, 13 or 14, wherein the partially carbonised polyurethane carbon fibre electrode is cooled at approximately 60 degrees Celsius per hour until it reaches room temperature.

16. A method according to any one of claims 12 to 15, wherein the mechanical method comprises a crushing means.

EDITORIAL NOTE THERE IS ONLY ONE PAGE OF DRAWING

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