System for Electrochemical Treatment and Method Thereof

Abstract

A head unit for electrochemical treatment of a surface including a handle having an output tube and a vacuum tube. The output tube and the vacuum tube configured to couple the handle to a portable cart. The head unit including a body coupled to the handle and an electrode disposed within the body and coupled to the output tube and the vacuum tube. The electrode including a plurality of output channels for outputting an electrochemical solution and a plurality of vacuum channels for vacuuming the electrochemical solution outputted from the plurality of output channels. Each of the plurality of output channels is disposed proximate to at least one of the plurality of vacuum channels and the electrode is fluidly coupled to the output tube to receive the electrochemical solution from the output tube.

Description

TECHNICAL FIELD

The present disclosure generally relates to devices and methods for surface treatment, and specifically in some embodiments, to a portable cart and a head unit for electrochemical treatment of a local area of a surface.

SUMMARY

One embodiment of the present disclosure provides a head unit for electrochemical treatment of a surface, the head unit including a handle including an output tube and a vacuum tube, the output tube and the vacuum tube configured to couple the handle to a portable cart, a body coupled to the handle and an electrode disposed within the body and coupled to the output tube and the vacuum tube, the electrode including a plurality of output channels for outputting an electrochemical solution and a plurality of vacuum channels for vacuuming the electrochemical solution outputted from the plurality of output channels. Each of the plurality of output channels is disposed proximate to at least one of the plurality of vacuum channels. The electrode is fluidly coupled to the output tube to receive the electrochemical solution from the output tube.

In some embodiments, the output tube is coupled to the plurality of output channels and the vacuum tube is coupled to the plurality of vacuum channels. In some embodiments, the output tube and the vacuum tube are each coupled to the electrode and extend from the electrode through the body and the handle.

In some embodiments, the body is integrally formed with the handle.

In some embodiments, the electrode is disposed in the body such that an outer perimeter of the electrode is flush with an inner perimeter the body.

In some embodiments, the plurality of output channels are configured to output the electrochemical solution and the plurality of vacuum channels are configured to vacuum the outputted electrochemical solution.

In some embodiments, the head unit further includes a pad coupled to the electrode such that the pad is disposed within the body, the pad including a plurality of output apertures configured to align with the plurality of output channels.

In some embodiments, the head unit further includes a button disposed on the handle such that activation of the button causes one or more of the electrochemical solution to flow through the plurality of output channels and ceasing flow of the electrochemical solution through the plurality of output channels.

In some embodiments, a distance between one of the plurality of output channels and one of the plurality of vacuum channels is from approximately 0.01 cm to 2 cm.

In some embodiments, the electrode includes an integrated cooling pathway configured to allow for flow of a fluid within the electrode to reduce a temperature of the electrode.

In some embodiments, the head unit further includes one or more sensors configured to determine one or more of an orientation of the head unit, force applied to the head unit, angular rate of the head unit, a pressure between the electrode and the surface, and acceleration of the head unit.

In some embodiments, each of the output tube and the vacuum tube include connectors coupling each of the output tube and the vacuum tube to the head unit, at least one connector having shut off valves.

Another embodiment of the present disclosure provides a head unit for electrochemical treatment of a surface, the head unit including a handle including to an output tube and a vacuum tube, the output tube and vacuum tube configured to couple the handle to a portable cart, a body coupled to the handle and a plurality of electrodes coupled together via one or more connectors, at least one of the plurality of electrodes configured to pivot relative to an adjacent electrode such that each electrode is substantially parallel to the surface. Each of the plurality of electrodes is disposed within the body and each of the plurality of electrodes includes a plurality of output channels for outputting an electrochemical solution and a plurality of vacuum channels for vacuuming the electrochemical solution.

In some embodiments, each of the output tube and the vacuum tube include quick connectors having shut off valves.

In some embodiments, the head unit further includes a pad coupled to the plurality of electrodes such that the pad is configured to conform to a non-flat shape. The pad includes a locking system removably coupling the pad to the head unit.

Another embodiment of the present disclosure provides a system for electrochemical treatment of a surface, the system including a portable cart having a housing including a first container storing a first electrochemical solution and a second container storing a second electrochemical solution, and a solution control system disposed within the housing, the solution control system coupled to each of the first container and the second container, the solution control system having a purging system configured to purge the output tube of one or more of the first electrochemical solution and the second electrochemical solution and a head unit in fluid communication with the solution control system via an output tube, wherein the solution control system is configured to selectively control a flow of the first electrochemical solution from the first container to the head unit via the output tube and a flow of the second electrochemical solution from the second container to the head unit via the output tube.

In some embodiments, the solution control system includes a pump configured to control the flow of the first electrochemical solution from the first container and the flow of the second electrochemical solution from the second container.

Another embodiment of the present disclosure provides a method for electrochemical treatment, the method including storing a first electrochemical solution in a first container and storing a second electrochemical solution in a second container, the first electrochemical solution and the second electrochemical solution configured for electrochemical treatment of a surface, pumping the first electrochemical solution from the first container to a head unit through an output tube, the head unit being in fluid communication with the first container, outputting the first electrochemical solution from the head unit to the surface and simultaneously vacuuming first excess solution into the head unit, the first excess solution being the first electrochemical solution not deposited on the surface, rinsing the output tube with a cleaning solution to purge the first electrochemical solution from the output tube, pumping the second electrochemical solution from the second container to the head unit via the output tube, the head unit being in fluid communication with the second container, and outputting the second electrochemical solution from the head unit to the surface and simultaneously vacuuming second excess solution into the head unit, the second excess solution being the second electrochemical solution not deposited on the surface.

In some embodiments, the method further includes detecting, using a sensor, a characteristic of the first excess solution and the second excess solution and separating the first excess solution and the second excess solution based on the characteristic.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description of embodiments of the systems and methods for electrochemical treatment will be better understood when read in conjunction with the appended drawings of exemplary embodiments. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities shown.

FIG. 1A is a front view of a portable cart in accordance with an exemplary embodiment of the present disclosure;

FIG. 1B is a front perspective view of the portable cart of FIG. 1A;

FIG. 1C is a front view of a control system of the portable cart of FIG. 1A;

FIG. 2 is a first side view of the portable cart of FIG. 1A;

FIG. 3 is a second side view of the portable cart of FIG. 1A;

FIGS. 4A-4C are top perspective views of exemplary compartments of the portable cart of FIG. 1A;

FIG. 5A is a side view a portable cart with a side door closed in accordance with an exemplary embodiment of the present disclosure;

FIG. 5B is a front perspective view the portable cart of FIG. 5A with the side doors opened;

FIG. 6 is a perspective view of a series of portable carts of different sizes in accordance with exemplary embodiments of the present disclosure;

FIG. 7 is a perspective view of a series of portable carts of different sizes with their side doors in the open position in accordance with exemplary embodiments of the present disclosure;

FIG. 8A is a first side view of the portable cart of FIG. 1A;

FIG. 8B is a second side view of the portable cart of FIG. 1A;

FIG. 9 is a top perspective view of a plurality of head units having color coded attachments in according with exemplary embodiments of the present disclosure;

FIG. 10A is a piping and instrumentation diagram of a solution control system of the portable cart of FIG. 1A;

FIG. 10B is a piping and instrumentation diagram of a solution control system of the portable cart of FIG. 1A;

FIG. 10C is a front view of a solution control system of the portable cart of FIG. 1A;

FIG. 11A is a side view of a head unit in accordance with an exemplary embodiment of the present disclosure;

FIG. 11B is a side perspective view of a head unit in accordance with an exemplary embodiment of the present disclosure;

FIG. 12 is a side view of a head unit and a pad in accordance with an exemplary embodiment of the present disclosure;

FIG. 13 is an exploded view of a head unit in accordance with an exemplary embodiment of the present disclosure;

FIG. 14 is cross sectional zoomed in view of a head unit and an electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 15A is a cross sectional view of a head unit in accordance with an exemplary embodiment of the present disclosure;

FIG. 15B is the cross sectional view of the head unit of FIG. 15A with the output tube isolated in accordance with an exemplary embodiment of the present disclosure;

FIG. 16 is cross sectional view of an electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 17 is a top perspective view of a plurality of electrodes in accordance with an exemplary embodiment of the present disclosure;

FIG. 18A is a top perspective view of an electrode decoupled from a front plate in accordance with an exemplary embodiment of the present disclosure;

FIG. 18B is a front view of a plurality of electrodes arranged in a staggered configuration in accordance with an exemplary embodiment of the present disclosure;

FIG. 19 is a top perspective view of a head unit coupled to a power line in accordance with an exemplary embodiment of the present disclosure;

FIG. 20A is a side perspective view of a cart coupled to a head unit via a power line in accordance with an exemplary embodiment of the present disclosure;

FIG. 20B is a side view of the cart of FIG. 2A in use;

FIG. 21 is a front perspective view of the cart of FIG. 20A;

FIG. 22 is a front view of the cart of FIG. 20A with a user interface;

FIG. 23A is a top perspective view of a first electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 23B is a top perspective view of a second electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 24 is a top perspective view of a head unit with a circular electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 25 is a top perspective view of a circular electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 26 is a top perspective view of a plurality of electrodes forming a cross shape in accordance with an exemplary embodiment of the present disclosure;

FIG. 27 is a top perspective view of a plurality of electrodes forming a cross shape in accordance with an exemplary embodiment of the present disclosure;

FIG. 28 is a top view of a cylindrical electrode in accordance with an exemplary embodiment of the present disclosure;

FIG. 29 is a top perspective view of an electrode having a pathway in accordance with an exemplary embodiment of the present disclosure;

FIG. 30A is a top perspective view of a plurality of electrodes coupled via a connector in accordance with an exemplary embodiment of the present disclosure;

FIG. 30B is a bottom perspective view of the plurality of electrodes of FIG. 30A;

FIG. 31A is a plurality of electrodes conforming to a curved exterior surface in accordance with an exemplary embodiment of the present disclosure;

FIG. 31B is a plurality of electrodes conforming to a curved interior surface in accordance with an exemplary embodiment of the present disclosure;

FIG. 32A is a plurality of electrodes coupled via a connector in accordance with an exemplary embodiment of the present disclosure;

FIG. 32B is a plurality of electrodes coupled via a plurality of connectors and forming a curved shape in accordance with an exemplary embodiment of the present disclosure;

FIG. 33 is a top perspective view of a head unit having a button in accordance with an exemplary embodiment of the present disclosure;

FIG. 34A is a top perspective view of a filtration unit coupled to a container in accordance with an exemplary embodiment of the present disclosure;

FIG. 34B is a cross sectional zoomed in view of the filtration unit of FIG. 34A; and

FIG. 35 is a zoomed in view of the filtration unit of 34A.

DETAILED DESCRIPTION

Exemplary embodiments of the present disclosure provide a system for electrochemical treatment. Embodiments of the present disclosure provide exemplary systems for treatment of a surface as shown in FIGS. 1A-35. In use, system for electrochemical treatment (“system”) 100 may be used for electrochemical treatment. In some embodiments, system 100 is used to for the electrochemical treatment of a local area of a surface. For example, system 100 may be used for the electrochemical spot treatment of a surface, such as electroplating. In some embodiments, system 100 is used to electrochemically treat surfaces. For example, system 100 may be used to electroplate a surface. In some embodiments, system 100 is used for treatment of a portion of a surface. However, system 100 may be used to electrochemically treat large surfaces or entire surfaces. The use of the term “electrochemical treatment” herein may include, but not limited to, electroplating, anodizing, passivation, or any other type of treatment that includes application of a chemical substance to a surface.

In some embodiments, system 100 is configured for selective plating. Selective plating allows for the localized treatment of surfaces. For example, selective plating allows for the treatment (e.g., electroplating) of a specific area of a surface. System 100 may be configured to improve the quality of a surface via electrochemical treatment of the surface. For example, system 100 may be configured to improve a surface's resistance to abrasions and/or corrosion. System 100 may be configured to improve various properties of a surface such as, lubricity, reflectivity, electrical conductivity, overall appearance, and/or increasing the thickness of the surface. System 100 may allow for treatment of a surface without having to submerge the surface in a bath of the solution.

In some embodiments, system 100 is easily movable, maneuverable, and transportable. System 100 may allow for selective plating since system 100 is easily transportable. System 100 may be transportable to allow it to move relative to the surface being treated. For example, for multiple spot treatments on a large surface, system 100 may need to be moved and transported relative to the surface. Further, unlike traditional electrochemical and electroplating systems, system 100 does not require the entire surface to submerged in an electrochemical solution. System 100 also allows for treatment of a surface without having to dismantle components. For example, since system 100 is easily transportable, system 100 may be used to treat a specific area of a wing of an airplane without having to dismantle the wing or any other components prior to treatment. System 100 may be used in many industries such as aerospace, automotive, aquatic, military, construction, medical, or any other industry.

Referring to FIGS. 1A-3, system 100 may include cart 102 and head unit 200. In some embodiments, head unit 200 is coupled to cart 102. For example, head unit 200 may be coupled to cart 102 via one or more hoses or tubing. In some embodiments, multiple head units 200 are coupled to cart 102. For example, two or more head units 200 may be coupled to cart 102, each being coupled via their own respective tubing or hose. In some embodiments, each head unit 200 is coupled to cart 102 via a plurality of hoses or tubing.

Cart 102 may include a plurality of compartments 104 configured for storing head unit 200 and other components and/or accessories. Cart 102 may be mobile such that it can be easily transported. For example, cart 102 may include one or more wheels 108 to allow cart 102 to be easily moved. In practice, system 100 may be used to electrochemically treat a large surface. For example, system 100 may be used to treat surfaces having an area greater than 5 cm², 10 cm², 20 cm², 25 cm², 30 cm² 40 cm², 50 cm², 5 dm², 10 dm², 20 dm², or 25 dm². To reduce the amount and length of tubing required, cart 102 may be easily moved as different areas of the surface are being treated.

In some embodiments, head unit 200 is coupled to cart 102. Cart 102 may be configured to house and store one or more solutions (e.g., electrochemical solutions). In some embodiments, the one or more solutions are solutions used for electroplating. For example, the one or more solutions may be electrolyte solutions used for electroplating. The electrochemical solutions may flow from cart 102 to head unit 200 via one or more hoses or tubing. A user may use head unit 200 to apply the solution to a surface for treatment of the surface. In some embodiments, a user uses system 100 to produce a metal coating on a surface via electroplating. For example, head unit 200 of system 100 may include an electrode configured to act as an anode and the surface to be treated may act as a cathode allowing the solution (e.g., the electrochemical solution) to flow from the anode (e.g., electrode of the head unit 200) to the cathode (e.g., surface to be treated). This results in particles, such as metal, in the solution being imbedded into the surface.

In some embodiments, system 100 is configured for electroplating, which results in the depositing of a metal coating on the surface (e.g., surface of a workpiece). In some embodiments, the solution is an electrolyte solution comprising one or more of metal ions, salts, acids, bases, and additives. The solution may be an electrolyte solution that allows for the movement of charged ions to be reduced on the surface of the workpiece forming a metal coating.

Referring to FIGS. 1A-7, system 100 may include cart 102. Cart 102 may include housing 103, which may include one or more doors 105. Doors 105 may be configured to protect the components of cart 102 while allowing a user to access the interior of cart 102. In some embodiments, housing 103 is comprised of metal, a metallic alloy, such as steel, or a combination thereof. However, housing 103 may be comprised of plastic and/or rubber in combination with metal and/or a metallic alloy. In some embodiments, doors 105 are comprised of stainless steel to provide durability and protection to the components stored within housing 103. In some embodiments, housing 103 includes one or more cut-outs or apertures to access and view controls disposed within cart 102.

System 100 may be configured to detect when doors 105 are in the open position. For example, when door 105 is in the open position, system 100 may pause or cease operation to prevent injury to the user or prevent a user from disrupting system 100. In some embodiments, cart 102 includes one or more valves, pumps, and/or manifolds configured to rotate. When door 105 is in the open position, the one or more valves, pumps, and/or manifolds may stop moving (e.g., pause) to prevent a user from getting injured by the rotation valves and pumps. Upon closing of door 105, the one or more valves, pumps, and/or manifolds may continue to operate normally (e.g., continue rotating).

In some embodiments, housing 103 is substantially rectangular in shape. However, housing 103 may be square, circular, or hexagonal. Housing 103 may be coupled to wheels 108, which may allow cart 102 to be movable and transportable. Housing 103 may be coupled to four wheels 108. However, housing 103 may be coupled to any number of wheels 108. In some embodiments, the number of wheels 108 depends on the size of housing 103 and cart 102. one or more wheels 108 may include a brake to secure wheel 108 and cart 102 in place. For example, the brake of wheel 108 may allow for moving and then securing of cart 102 at a specific location. In some embodiments, wheels 108 may be motorized to allow for remote control of cart 102. Wheels 108 may be motorized to assist a user in moving and transporting cart 102 from one location to another.

In some embodiments, system 100 includes remote electronic device 400. Remote electronic device 400 may be a mobile device such as a tablet, cellular phone, laptop, computer, or other type of remote electronic device. Remote electronic device 400 may be configured to wirelessly communicate with cart 102. For example, remote electronic device 400 may be configured to communicate one or more components of cart 102, such as wheels 108 or one or more valves, pumps, and/or manifolds. In some embodiments, a user may control various functions of cart 102 using remote electronic device 400. For example, a user may control wheels 108 with remote electronic device 400 to control the movement of cart 102. In use, a user may keep remote electronic device close to their persons and head unit 200 such that during use of head unit 200, the user can easily control the functions (e.g., movement) of cart 102 without having to go back to cart 102.

In some embodiments, cart 102 is configured to stay within a predetermined distance from remote electronic device 400. For example, a user may activate a follow feature, which causes cart 102 to be within a predetermined distance from remote electronic device. The user may carry remote electronic device 400 and as the user moves cart 102 may be configured to follow the user eliminating the need for the user to manually move cart 102 during use. In some embodiments, during use, cart 102 is configured to stay within a predetermined distance from head unit 200. Cart 102 may be configured to automatically move when head unit 200 moves a predetermined distance. For example, during using of system 100 on a large surface, a user holding head unit 200 may move along the surface. As the user and head unit 200 move along the surface, cart 102 may be configured to follow the user automatically without the user having to pull in the hose or manually move cart 102. This prevents strain on the hose or tubing coupling head unit 200 to cart 102.

Referring to FIGS. 6-7, cart 102 may be any size desired. For example, cart 102 may be substantially compact such that it includes only the essential components (e.g., solutions and head unit 200) to allow cart 102 to be used in small and tight areas. However, cart 102 may be larger and may include additional components (e.g., multiple head units 200, multiple containers 122 for solutions or fluids) when the size of cart 102 is not a concern.

In some embodiments, cart 102 is configured to be in a plurality of sizes (e.g., cart 102a, cart 102b, and cart 102c). For example, cart 102 (e.g., carts 102a, 102b, and 102c) may have a height of 1,000 mm to 1,600 mm, a width of 500 mm to 1,500 mm, and a depth of 500 mm to 1,000 mm. Cart 102a may be substantially similar to cart 102 and may have a height of approximately 1,150 mm, a width of approximately 713 mm and a depth of approximately 865 mm. Cart 102a may be configured to manage up to two different solutions and include up to two tools. Cart 102b may be substantially similar to cart 102 and may have a height of approximately 1,400 mm, a width of approximately 1,238 mm and a depth of approximately 800 mm. Cart 102b may be configured to manage up to seven different solutions and include up to three tools. In some embodiments, cart 102b includes up to two pumps and up to four head units 200.

Cart 102c may be substantially similar to cart 102 and may have a height of approximately 1,700 mm, a width of approximately 1,235 mm and a depth of approximately 800 mm. Cart 102c may be configured to manage up to seven different solutions. In some embodiments, cart 102c is configured to drive up to three tools and includes up to eight pumps and up to eight head units 200. The pumps may be double headed pumps.

In some embodiments, cart 102, such as cart 102c, may include robotic features such as automated control of head unit 200 and may include wheels 108, which may be motorized. Cart 102 may include a battery pack to allow cart 102 to be transported to any location desired. In some embodiments, cart 102 includes an industrial cord reel coupling each head unit 200 to cart 102. The industrial cord reel may be 10 m to 50 m in length. Cart 102 may include one or more splash proof sockets to prevent fluids from entering the socket. In some embodiments, cart 102 is configured to include a thermoregulated process tank.

Referring to FIGS. 1A-5, cart 102 is configured to hold all components of system 100. For example, cart 102 may include a plurality of compartments 104. Compartments 104 may include drawers, cabinets, trays, or any other type of compartment for holding one or more components. Compartments 104 may be disposed throughout cart 102. For example, cart 102 may include one or more compartments to hold head unit 200, containers for solutions, supplies for cleaning system 100, electronics, one or more power supplies, or any other components. In some embodiments, compartments 104 include foam inserts disposed within the interior of compartment 104 to protect the components stored within compartments 104. The foam inserts within compartments 104 may include cutouts sized and shaped to receive and secure specific components, such as one or more head units 200.

Referring to FIGS. 1A-1C, cart 102 may include connection interface panel 110. Connection interface panel 110 may include a plurality of power sockets for coupling to various electronic devices. Connection interface panel 110 may also include hydraulic plugs and leads for coupling to tools. Connection interface panel 110 may be coupled to head unit 200 to allow cart 102 to be coupled to head unit 200. Connection interface panel 110 may include connections or ports for coupling to power supplies, power devices, compressed air devices, or one or more cables. In some embodiments, connection interface panel 110 includes one or more camlocks or quick connect ports for coupling to one or more cables or devices.

Cart 102 may also include control system or control panel 113 for controlling the pumps, the power supply, a rectifier/power pack, and other features of system 100. In some embodiments, control panel 113 includes a plurality of switches, knobs, wires, and/or other physical controls. Alternatively, control panel 113 may include a user interface (e.g., user interface 106) such as a computer, laptop, tablet, mobile device, touchscreen, or other type of user interface. The user interface (e.g., user interface 106) may be configured to control the pumps, the power supply, a rectifier/power pack, and other features of system 100. Control system 113 may include one or more programmable logic controllers (PLC) or microcontrollers configured to control various features and components of system 100, such as valves, pumps, manifolds, tubes, fluid flow, or any other feature or component of system 100.

In some embodiments, the rectifier/power pack disposed within cart 102 is configured to provide electrical current to head unit 200, and other devices, to allow the electrode of head unit 200 to act as an anode. The power supply may be a rechargeable power supply, such as a battery, to allow cart 102 to be mobile and easily transported during use. However, the power supply may be coupled to a wall outlet or other power source. The power supply may be controlled via control system 113. In some embodiments, the power supply is coupled to the rectifier or power pack. The rectifier may be a DC power supply, which may be coupled to the power supply. The rectifier or power pack may be configured to provide an electrical charge to head unit 200 or control the power from the power supply to cart 102.

Control system 113 may be coupled to user interface 106. In some embodiments, user interface 106 is a display, such as touchscreen display, configured to receive inputs from a user. User interface 106 may be a PC based HMI screen that is coupled to control system 113. In some embodiments, control system 113 includes a personal computer (PC) or a human-machine interface (HMI), such as user interface 106. In some embodiments, the user interface 106 is a fanless PC or HMI. In some embodiments, connection interface panel 110 is coupled to control system 113. Connection interface panel 110 may further be coupled to user interface 106, which may be coupled to the control system 113. User interface 106 may be configured to allow a user to control and/or interact with system 100. In some embodiments, user interface 106 is configured to display the current status of system 100.

In some embodiments, control system 113 is coupled to one or more pumps 130, which control the flow of solution from cart 102 to head unit 200. Pumps 130 may be peristaltic pumps configured to control the flow of solution from the cart 102 to head unit 200. In some embodiments, pumps 130 are double headed peristaltic pumps. For example, pumps 130 may include a first head for the inlet flow and a second head for the outlet flow. Pumps 130 having a double-headed configuration may allow for a more efficient pump having a reduced size. Further, a double head pump negates the need for two separate pumps, one for the inlet and one for the outlet. In some embodiments, head unit 200 is coupled to more than one pump 130. For example, head unit 200 may be coupled to two pumps 130. In some embodiments, head unit 200 is either coupled to one two-headed pump or two one headed pumps.

Cart 102 may include button 111. For example, connection interface panel 110 may include button 111. Button 111 may be an emergency stop button configured to cease operation of system 100. For example, a user pressing button 111 may result in system 100 deactivating (e.g., shutting off/ceasing operation). Head unit 200 may include an emergency stop button configured to cease operation of system 100. In some embodiments, remote electronic device 400 includes an emergency stop button configured to cease operation of system 100. Remote electronic device 400 may include an emergency stop button to allow a user to shut off system 100 when the user is not proximate to cart 102 and/or button 111.

Referring to FIGS. 8A-8B, system 100 may include cooling system 112. Cooling system 112 may be disposed within cart 102 and may be configured to regulate the temperature of the components disposed within cart 102. For example, cooling system 112 may be configured to monitor and regulate the temperature of the solution stored within cart 102. Cooling system 112 may include one or more fans configured to prevent the solution from overheating, which may result in degradation of the solution. Cooling system 112 may also be configured to prevent overheating of other components or electronics disposed within cart 102.

In some embodiments, system 100 includes a heated flow system. The heated flow system may be configured to heat solutions stored in the one or more containers 122. For example, a solution flowing from container 122 to head unit 200 may flow through the heated flow system such that the solution is heated prior to being outputted by head unit 200.

Referring to FIGS. 8A-9, system 100 may include a visual management system. In some embodiments, containers 122, 119, and 121 and/or head unit 200 include color coded attachments or portions 157 to indicate to a user the type of solution stored in the container or the type of container. Head unit 200 may include color coded attachments or portions 257 to match the color coded containers 122. For example, system 100 may include multiple head units 200 to be used with multiple containers 122. Each head unit 200 may be color coded to match its respective color coded container 122. Compartments 104 and head units 200 may include color coded indicators corresponding to each other. For example, one compartment 104 and one head unit 200 may have the same corresponding color indicators to indicate that the one head unit 200 is configured to be in fluid communication with the one compartment 104. In some embodiments, each component of system 100 is color coded. For example, each pump, tray, storage, head unit 200, and compartment 104 may have corresponding (e.g., matching) colors to indicate that they work together or utilize the same type of solution. In some embodiments, each color corresponds to a specific type of solution. For example, blue may correspond to caustic solutions, red may correspond to acidic solutions, yellow may correspond to chromic solutions, and green may correspond to cyanide solutions. This prevents mixing of solutions, which can cause the production of harmful or lethal gases and/or cause damage to system 100. In some embodiments, attachment or portion 257 is a protective cover to protect at least a portion (e.g., the perimeter of body 201) of head unit 200. For example, attachment 257 may protect the perimeter of body 201 and may assist in securing electrode 210 within body 201.

Referring to FIGS. 10A-10C, system 100 may include solution control system 120. Solution control system 120 may be disposed within cart 102. Solution control system 120 may be configured to allow system 100 to easily switch between solutions without impacting the performance of head unit 200. For example, solution control system 120 may allow system 100 to switch between various solutions, each stored in their respective container 122. Solution control system 120 may allow for switching between solutions while using the same head unit 200. However, solution control system 120 may be coupled to multiple head units 200 to allow one head unit to be used per solution that is being used for treatment of a surface. In some embodiments, solution control system 120 allows for switching between solutions without resulting in mixing of different solutions or cross contamination between solutions.

Solution control system 120 may include a plurality of valves 124 and a plurality of tubes 126. In some embodiments, valve 124 is a rotating manifold. The rotating manifolds may be configured to be used with one or more carts 102. For example, the rotating manifold may be designed and manufactured such that it is compatible with one or more different carts 102. The rotating manifold may be compatible with a plurality of carts 102 of different sizes.

Solution control system 120 may be configured to be arranged differently depending on the desired use. For example, solution control system 120 may be configured in a specific manner based on the placement of valves 124 and tubes 126. By actuating pumps 130 and opening/activating and closing/deactivating valves 124, solution control system 120 can control the flow of any solution from any of containers 122 to head unit 200.

In some embodiments, solution control system 120 is arranged such that valves 124 and tubes 126 are coupled together to allow solution to flow from many different containers. The arrangement of solution control system 120 may dictate the function desired of solution control system 120. For example, solution control system 120 may be configured for NiW, Cu, Ag, or Au treatment of a surface (FIG. 10A). However, solution control system 120 may be configured for anodization or the passivation step of the Zinc Nickel (FIG. 10B). In some embodiments, multiple configurations of solution control system 120 can be combined, such as combining the configuration for NiW (FIG. 10A) with the configuration for anodization (FIG. 10B) to achieve the desired configuration of solution control system 120.

In some embodiments, solution control system 120 switches between different solutions by using one or more valves or manifolds. Activation of various valves of system 120 may control the flow of fluid (e.g., solution) within solution control system 120. In some embodiments, solution control system 120 is configured to be operated in different configurations. For example, solution control system 120 may be configured to be operated in a semi-automated mode and a fully automated mode. In the semi-automated mode, a user may have to acknowledge each step for the next step to proceed either on cart 102 or via remote electronic device 400. In contrast, in the fully automated mode, a user may actuate a single button on cart 102, head unit 200, or remote electronic device 400 resulting in the rest of the processes no longer needing user intervention. For example, in the fully automated mode, the user may actuate a button resulting in a full sequence of flushing, rinsing, and cleaning steps without substantial user intervention or acknowledgement.

In some embodiments, solution control system 120 includes a plurality of containers 122 configured to store solution (e.g., electrochemical solution, preparatory solutions). For example, containers 122 may be configured to hold preparatory solutions for cleaning, etching, desmutting, and activating a surface of a workpiece during use of system 100. Containers 122 may be configured to hold electrochemical solutions comprising one or more of zinc, nickel, cadmium, silver, gold, tungsten, copper. Containers 122 may also be configured to hold preparatory plating solutions for cleaning and preparing a surface for use or final deposition of a desired solution. Containers 122 may be disposed within cart 102, such as within one or more compartments 104. Cart 102 may include container 122 for each type of solution stored within cart 102. In some embodiments, more than one type of solution is stored within cart 102 resulting in more than one container 122 being stored within cart 102. Each container 122 may be coupled to head unit 200. For example, solution control system 120 may be coupled to head unit 200 to allow flow of solution from each container 122 to head unit 200.

In some embodiments, containers 122 are configured to be easily replaced and interchanged. For example, a user may quickly swap out one container 122 holding a first solution for another container 122 holding a second solution. Containers 122 may be plug-and-play cartridges configured to be easily swapped out and interchanged. In some embodiments, containers 122 are configured to be easily swapped out and interchanged among a plurality of different carts (e.g., carts 102, 102a, 102b, 102c). Each container 122 in cart 102 may contain a different solution. In practice, cart 102 is configured to carry multiple types of electrochemical solutions. The different types of electrochemical solutions may be stored in different containers 122 within cart 102. In some embodiments, a user may easily interchange containers 122 to allow for other types of solutions. System 100 may be configured to allow a user to switch between containers 122 while using the same head unit 200. For example, solution control system 120 may be configured to allow selection from different containers 122. In practice, based on opening and closing of valves 124, pump 130 may cause the solution to flow from a specific container 122 to head unit 200.

Solution control system 120 may allow a user to switch between containers 122 thereby switching between solutions. Switching between containers 122 may result in head unit 200 outputting different solutions. For example, one container 122 may store a solution for Nickel plating (Ni solution) and another container 122 may store a solution for gold plating (Au solution). A user may use head unit 200 for Nickel plating by selecting container 122 holding the Nickel solution. The user may desire to switch to gold plating by using solution control system 120 either on cart 102 or via head unit 200 or remote electronic device 400 to select a different container 122 holding the Au solution and using head unit 200 for gold plating. In some embodiments, the user engages remote electronic device 400, head unit 200, connection interface panel 110 and/or user interface 106 to select the desired solution and the desired step (e.g., cleaning, rinsing, purging, outputting solution, vacuuming solution).

With continued reference to FIGS. 10A-10C, solution control system 120 may include a plurality of valves or manifolds 124 and tubes 126. Valves 124 may be rotating manifolds or solenoid valves. Tubes 126 may be configured to couple valves 124 or pumps 130 to containers 122 and head unit 200. In some embodiments, tubes 126 cause containers 122 to be in fluid communication with head unit 200 via valves 124. In some embodiments, the duration of use of tubes 126 is tracked to determine whether one or more tubes 126 has been used for an extended period. The duration of use of tubes 126 may be tracked using a tube control system. IN some embodiments, use of tubes 126 for extended period of times results in damage or leaks to tube 126. The tube control system may be a programmable logic controller (PLC) configured to notify a user when tube 126 has been used for an extended duration (e.g., greater than 2 hours, greater than 3 hours, greater than 4 hours, greater than 5 hours, or greater than 6 hours). In some embodiments, the PLC notifies a user via remote electronic device 400 or cart 102 (e.g., user interface 106).

Solution control system 120 may include one or more pumps 130. Pump 130 may be a peristaltic pump configured to control the flow of fluid, such as the solution, throughout system 100. For example, pump 130 may be configured to control the flow of solution through solution control system 120, such as from containers 122, through valves 124, to head unit 200. In some embodiments, pump 130 is configured to have a flow rate of 0 l/h to approximately 5500 l/h and a maximum discharge pressure of 0 bar to 25 bar (e.g., 16 bar).

In some embodiments, pump 130 is configured to control the flow of solution to and from head unit 200. For example, pump 130 may be configured to control the flow of solution to head unit 200 and the same pump 130 may be configured to reverse the flow of solution such that the solution flows from head unit 200 to cart 102. However, different pumps 130 may be used for different flow directions of the solution between cart 102 and head unit 200.

In some embodiments, head unit 200 includes one or more vacuum channels configured suck up excess solution. In practice, solution control system 120, via one or more pumps 130, may cause solution to flow from container 122 to head unit 200 for treatment of a surface. Solution control system 120 and head unit 200 may cause excess solution to flow from head unit 200 to container 122. For example, solution control system 120 and head unit 200 may allow for a solution to be recycled from head unit 200 back to one or more containers 122 or waste container 121. In some embodiments, the excess solution flows from head unit 200 to the same container in which the solution is stored. However, the excess solution may flow from head unit 200 to waste container 121. Waste container 121 may be configured to receive and collect the excess solution from head unit 200. Excess solution may be any solution that is outputted by head unit 200 and not deposited on the surface to be treated.

In some embodiments, a user may use connection interface panel 110 to control the flow of the solution within system 100. For example, a user may use connection interface panel 110 to select a specific container 122 holding a specific solution to be used with head unit 200. In some embodiments, the user interacts with user interface 106 or remote electronic device 400 to create, define, modify various configurations, settings, chemical solution listings, or chemical databases of system 100. For example, a user may use user interface 106 or remote electronic device 400 to create or modify an arrangement of solutions to be used by system 100. A user may also use connection interface panel 110 to switch between containers 122 to select different solutions for use with head unit 200. For example, a user may initially select a Nickel solution via connection interface panel 110 or remote electronic device 400 resulting in pumps 130 of solution control system 120 causing the Nickel solution stored in container 122 to flow from container 122 through tubes 126 and valves 124 to head unit 200. A user may then select an Au solution via connection interface panel 110 or remote electronic device 400 resulting in pumps 130 causing the Nickel solution to flow from head unit 200 back to container 122 and then causing the Au solution stored in a different container 122 to flow from the container through tubes 126 and valves 124 to head unit 200. Valves 124 may assist with controlling and regulating the flow of solution through solution control system 120. For example. Valves 124 may prevent mixing and cross contamination of solutions within solution control system 120.

In some embodiments, a user uses the same head unit 200 before and after switching solutions. For example, a user may use head unit 200 with the Nickel solution, then purge/clean tubes 126 coupled to head unit 200, then use the same head unit 200 for Au plating. A user may clear/clean tubes 126 coupling head unit 200 to valves 124 to prevent contamination between solutions. By way of another example, a user may use head unit 200 with the Nickel solution, then purge/clean tubes 126 coupled to head unit 200, then use the same head unit 200 for gold plating, then again purge/clean tubes 126 coupled to head unit 200, then use the same head unit 200 for silver plating.

In some embodiments, solution control system 120 includes purge system 123. Purge system 123 may include purge valve 125, purge line 129, and water container 119. Purge system 123 may be configured to receive waste from tubes 126. For example, using connection interface panel 110, a user may elect to purge system 100 to clean tubes 126. Purging tubes 126 may result in all tubes 126 being flushed with a cleaning solution to prevent mixing and cross contamination between solutions. In practice, a user may select a first solution (e.g., Nickel solution) for use with head unit 200. The user may then stop using the first solution and may switch to the second solution (e.g., Au solution). Prior to using the second solution, the user may use purge system 123 to clean all the tubes coupled to head unit 200 and container 122 storing the second solution to prevent mixing and cross contamination of the second solution with the first solution. In some embodiments, the cleaning solution is water, such as distilled water, which is stored in water container 119. The cleaning solution may be configured to rinse tubes 126. The cleaning solution may be a solution having disinfecting or sterilizing properties. For example, the cleaning solution may be sent through one or more tubes 126 and may be configured to remove any debris, bacteria, liquid, or contaminant remaining in tube 126.

In some embodiments, solution control system 120 includes waste container 121. Waste container 121 may be configured to hold waste collected during use of system 100. In some embodiments, waste container 121 is configured to receive waste vacuumed by head unit 200. For example, head unit 200 may be configured to vacuum waste or excess solution during use and the waste or excess solution may flow to waste container 121. Solution control system 120 may include more than one waste container 121. For example, solution control system 120 may include two, three, four, five, or greater than five waste containers 121. In some embodiments, the cleaning solution is configured to rinse tubes 126 and flow into waster container 121.

Referring to FIGS. 8A and 8B, cart 102 may be configured to hold one or more types of cleaning solution. For example, cart 102 may be configured to hold rinsing water, distilled rinsing water, or an acid/base rinsing solution. The cleaning solution may be configured to clean tubes 126 prior to using the solution for electrochemical treatment of a surface. For example, the cleaning solution may be configured to run through tubes 126 and clean (e.g., sterilize or disinfect) tubes 126 to prevent build-up of particles or contaminants. In some embodiments, cart 102 includes more than one type of cleaning solution. The cleaning solution (e.g., water) may be used for both cleaning/purging of tubes 126 and cleaning of the surface to be treated (e.g., surface of the work piece). The different type of cleaning solutions may be stored in containers 122. The cleaning solution may be used to purge tubes 126 between system 100 using different solutions.

In some embodiments, solution control system 120 includes one or more sensors configured to detect whether a solution is waste or non-waste. For example, tubes 126 may be used for both solution flowing to head unit 200 for treatment of a surface and for waste (e.g., excess solution, waste solution, or rinsing/cleaning solution). A user may use control system 113, user interface 106, or remote electronic device 400 to select and determine which solution is considered waste. For example, a user may interact with user interface 106 to indicate which solutions in a configuration are waste and non-waste. In some embodiments, system 100 is configured to automatically determine which solution is waste or non-waste. In some embodiments, solution flowing from head unit 200 to cart 102 is considered waste by system 100.

Solution control system 120 may include a pH sensor to monitor the pH of the fluid within tubes 126. However, a pH sensor may be disposed within container 122 or any other part of cart 102. In some embodiments, solution control system 120 is configured to separate fluids based on their pH. For example, solution control system 120 may direct the flow of acidic fluids to one container and basic solutions to another container. Solution control system 120 may direct the flow of fluids and solutions using valves 124. For example, the flow path of fluid may be determined by the opening and closing of valves 124 thereby directing the fluid or solution to a specific area or container 122.

In some embodiments, tubes 126 are narrow to allow for easier cleaning of tubes 126 prior to use or prior to using a subsequent solution. For example, tubes 126 may have an internal diameter of 0.5 mm to 70 mm, 1 mm to 60 mm, 2 mm to 50 mm, 2.5 mm to 40 mm, or less than 0.5 mm. Tubes 126 being narrow prevents the buildup of debris, particles, or contaminants. Further, tubes 126 being narrow allows pumps 130 to generate increased pressure more efficiently through tubes 126 resulting in easier cleaning of tubes 126.

Referring to FIGS. 11A and 11B, head unit 200 may be configured to treat surfaces and may be coupled to cart 102. Head unit 200 may be configured to apply a solution (e.g., electrochemical solution), which is stored in cart 102, to a surface for electrochemical treatment (e.g., electroplating) of that surface. Head unit 200 may be coupled to cart 102 via one or more tubes/hoses. Head unit 200 may be comprised of a durable and rigid material. For example, head unit 200 may be comprised of a hard plastic such as acrylic, polycarbonate, high-density polyethylene, or any type of 3D printed resin or material. In some embodiments, head unit 200 includes an outer shell comprised of a polymer. The polymer may be a shock absorbing polymer. In some embodiments, the polymer is a rheoresistant shock absorbing polymer.

In some embodiments, head unit 200 is coupled to one or more pumps disposed within cart 102. Head unit 200 may be coupled to a portion of pump 130, such one or more pump heads. Head unit 200 may include body 201, pad 202, handle 204, and electrode 210. Electrode 210 may be coupled to body 201, which may be coupled to handle 204. Body 201 may be removably coupled to handle 204 or may be integrally formed with handle 204. In some embodiments, handle 204 is integrally formed with body 201 to form a unitary piece. Electrode 210 may be coupled to pad 202 at a distal end and body 201 at a proximal end. In some embodiments, each of handle 204, body 201, and pad 202 are substantially rectangular shaped. However, body 201, pad 202, and handle 204 may be any shape desired.

In some embodiments, pad 202 is coupled to body 201 or electrode 210. Pad 202 may be removably coupled to body 201 or electrode 210 to allow pad 202 to be quickly interchanged or replaced. Pad 202 may be coupled to body 201 or electrode 210 such that pad 202 is flush with body 201. However, pad 202 may be coupled to body 201 or electrode 210 such that pad 202 is not flush with body 201. For example, an outer perimeter of body 201 may be flush with an outer perimeter of pad 202 when pad 202 is disposed within body 201. Pad 202 may be configured to contact the surface to be treated when head unit 200 is in use. For example, a user may contact the surface with pad 202 and solution may flow through electrode 210 into pad 202. Pad 202 may be comprised of a soft material to prevent pad 202 from scratching or damaging the surface to be treated. For example, pad 202 may be comprised of a fabric or cloth-like material that is capable of applying the solution to the surface without damaging or scratching the surface. In some embodiments, pad 202 is comprised of one or more of cotton, polyester, PermaWrap, TuffWrap, or any other fabric or cloth-like material desired.

In some embodiments, electrode 210 is coupled to body 201 at a proximal end and coupled to pad 202 at a distal end. Electrode 210 may be disposed within body 201 such that a distal end of electrode 210 is flush with a distal end of body 201. In some embodiments, an outer perimeter of electrode 210 is adjacent to an inner diameter of body 201. For example, electrode 210 may be disposed within body 201 such that electrode 210 abuts an inner surface of body 201. In some embodiments, electrode 210 is size and shaped to fit within body 201 such there is little to no gap between electrode 210 and body 201.

With continued reference to FIGS. 11A and 11B, electrode 210 may serve as an anode and may include one or more output channels 206. Output channels 206 may be configured to output solution that is stored within cart 102. For example, solution may flow from cart 102 via one or more pumps to head unit 200 for depositing on a surface. Handle 204 may allow a user to easily grip head unit 200 and control the deposition of the solution from head unit 200 to a surface. Handle 204 may be coupled to one or more tubes/hoses thereby coupling head unit 200 to cart 102. The one or more tubes/hoses coupling head unit 200 to cart 102 allow head unit 200 to be in fluid communication with cart 102, such as with one or more containers, pumps, valves, or other tubes disposed within cart 102.

In some embodiments, head unit 200 is comprised of one or more electrodes 210. In some embodiments, electrode 210 is coupled to pad 202. In some embodiments, pad 202 is secured to electrode 210 via a locking system. For example, pad 202 may include an integrated locking system to lock pad 202 to electrode 210. In some embodiments, pad 202 has a surface area substantially equal to the surface area of the one or more electrodes 210 of head unit 200. For example, pad 202 may have a surface area matching the surface of a single electrode 210 or matching the surface area created by multiple electrodes coupled together. Electrode 210 may act as an anode allowing the particles in the solution to flow from electrode 210 to the surface for treatment. The surface being treated may act as a cathode resulting in metal disposed within the solution flowing from electrode 210 (e.g., anode) to the surface being treated (e.g., cathode). In some embodiments, electrode 210 has an anode surface area of 1 cm² to 300 cm², 20 cm² to 250 cm², or 100 cm² to 200 cm². For example, electrode 210 may have an anode surface area of approximately 7 cm² to 100 cm².

Head unit 200 may include one electrode 210 or a plurality of electrodes 210. Electrode 210 may be comprised of a single unitary structure. In some embodiments, electrode 210 is comprised of stainless steel or titanium. Electrode 210 may be platinum plated on surface in contact with pad 202. In some embodiments, electrode 210 is coated with a mixed metal oxide (MMO) coating. Electrode 210 may include one or more output channels 206. Output channels 206 may be configured to output the solution to the surface. For example, output channels 206 may be in fluid communication with a hose or tube coupled to head unit 200. Solution may flow from within cart 102 through head unit 200 and out through output channels 206. In practice, a user may place pad 202 adjacent the surface to be treated. Solution may flow out of output channels 206 onto the surface to be treated.

Referring to FIGS. 11A-16 and 19-22, head unit 200 may be configured to output solution stored within cart 102. Electrode 210 of head unit 200 may include output channels 206 and vacuum channels 208. Electrode 210 may be configured to be electrically charged. For example, electrode 210 may be configured to positively or negatively charged. In some embodiments, cart 102 includes a rectifier or power pack configured to electrically charge electrode 210 via one or more power lines 251.

In some embodiments, electrode 210 is a positively charged anode. For example, electrode 210 may be coupled to a rectifier or power pack disposed within cart 102. The rectifier or power pack may be configured to provide a positive charge to electrode 210. In some embodiments, the power source is disposed within cart 102 and is coupled to electrode 210 via one or more power lines 251. Power line 251 may extend from cart 102 to head unit 200. In some embodiments, power line 215 couples head unit 200 to power port 253 disposed on cart 102. For example, power line 251 may be configured to couple head unit 200 to cart 102 through power port 253. Cart 102 may include one or more power ports 253. For example, cart 102 may include one, two, three, four, five, six, seven, eight, nine, ten, or more than ten power ports 253. In some embodiments, cart 102 includes one or more power ports 253 per head unit 200. In some embodiments, the one or more power ports 253 are camlocks configured to secure one or more cables to cart 102. The one or more power ports 253 may be any type of securing mechanism configured to secure one or more cables to cart 102.

Referring to FIGS. 17-18B, head unit 200 may include a plurality of electrodes 210 coupled together. For example, head unit 200 may include two or more electrodes 210 coupled together to increase the size of head unit 200 (FIG. 17). Head unit 200 being larger in size may allow head unit 200 to treat larger surfaces in a shorter amount of time. In some embodiments, the number of electrodes 210 within head unit 200 can be increased or decreased depending on the size of the surface to be treated. Electrodes 210 may be coupled together via connectors. The connectors may allow electrode 210 to pivot relative to each other. In some embodiments, electrodes 210 are coupled together to form a flat assembly (FIG. 18A) or a planar assembly. However, electrodes 210 may be coupled together to form a staggered assembly (FIG. 18B).

Referring to FIGS. 23A-33, electrode 210 may vary in shape and multiple electrodes 210 may be combined to create various shapes. For example, electrode 210 may be rectangular shaped having different lengths (FIGS. 23A-23B). However, electrode 210 may be any shape, such as circular (FIGS. 24-25), triangular, hexagonal, octagonal, or square. In some embodiments, multiple electrodes 210 are combined together to create different shapes. For example, multiple electrodes 210 may be combined to create a cross-shape (FIGS. 26-27). Electrode 210 may also be cylindrical in shape (FIG. 28) to fit into holes or apertures. For example, electrode 210 may be cylindrical in shape to allow electrode 210 to be inserted into holes or apertures to treat the inner surface of the hole or aperture.

Referring to FIGS. 14-16, electrode 210 includes output channels 206 and vacuum channels 208. Output channels 206 and vacuum channels 208 may extend through a substantial thickness of electrode 210. In some embodiments, output channels 206 and/or vacuum channels 208 are coupled to one or more tubes coupled to cart 102 thereby coupling electrode 210 to cart 102. The tubes coupling electrode 210 to cart 102 may allow output channels 206 and vacuum channels 208 to be in fluid communication with cart 102. In some embodiments, output channels 206 and vacuum channels 208 are in fluid communication with one or more of pumps, valves, manifolds, and/or containers stored within cart 102. For example, output channels 206 and vacuum channels 208 may be in fluid communication with a series of pumps, valves, and tubes such that a solution can flow from containers stored on cart 102 to output channels 206 and from vacuum channels 208 back to the containers.

In some embodiments, vacuum channels 208 are disposed around the perimeter of electrode 210. For example, electrode 210 may be disposed within body 201 such that a portion of body 201 surrounds the perimeter of electrode 210. Vacuum channels 208 may be disposed around a perimeter of electrode 210 such that there is no gap between electrode 210 and body 201. However, vacuum channels 208 may be disposed anywhere on electrode 210. In some embodiments, vacuum channels 208 are disposed around the perimeter of electrode 210 and/or throughout the surface of electrode 210.

Output channels 206 may be disposed proximate vacuum channels 208. For example, an output channel 206 may be located on electrode 210 proximate to a vacuum channel 208 such that an output channel 206 is always proximate a vacuum channel 208. The distance between one output channel 206 and an adjacent vacuum channel 208 may be 0.01 cm to 2 cm, 0.05 cm to 1.75 cm, 0.1 cm to 1.5 cm, or 0.5 cm to 1.0 cm. In some embodiments, output channels 206 and vacuum channels 208 are arranged as a patten on electrode 210. For example, output channels 206 and vacuum channels 208 may be arranged as an array on electrode 210, such as a linear array. For example, output channels 206 may be arranged as a linear array and vacuum channels 208 may be disposed next to output channels 206 resulting in output channels 206 and vacuum channels 208 both being arranged as a linear array on electrode 210. Output channels 206 and vacuum channels 208 may be arranged as an alternating array such that output channels 206 and vacuum channels 208 alternate with each other.

In some embodiments, vacuum channels 208 overlap with each other. For example, one or more vacuum channels 208 may overlap with each other such that one or more vacuum channels 208 share a common tube (e.g., tube 205) from head unit 200 to cart 102. Alternatively, vacuum channels 208 do not overlap with one another. Vacuum channels 208 may be configured to extend through electrode 210 into body 201. In some embodiments, tubes 205 are coupled to vacuum channels 208. For example, one tube 205 may be coupled to one vacuum channel 208 or multiple vacuum channels 208. Tubes 205 may be coupled to vacuum channel 208 at electrode 210 and then combine into larger tubes. For example, tubes with small diameters may be coupled to vacuum channels 208 and may combine to form tubes with larger diameters that extend through body 201 and handle 204. The tubes with larger diameters may also combine into a single tube that extends out of handle 204 and couples head unit 200 to cart 102.

With continued reference to FIGS. 14-16, pad 202 may include one or more apertures configured to align with output channels 206 and/or vacuum channels 208. For example, pad 202 may include output apertures and vacuum apertures configured to align with output channels 206 and vacuum channels 208, respectively. In some embodiments, pad 202 is secured to electrode 210 and/or body 201 via a locking system. For example, pad 202 may include an integrated locking system to lock pad 202 to electrode 210 and/or body 201. Pad 202 may be secured to electrode 210 such that output apertures and vacuum apertures are aligned with each output channels 206 and vacuum channels 208, respectively.

In some embodiments, handle 204 includes vacuum tube 214 configured to couple to vacuum channels 208 and output tube 212 configured to couple to output channels 206. Output tube 212 may extend through handle 204 and join or couple to output channels 206. In some embodiments, output tube 212 may include a terminal end coupled to output channels 206. Output tube 212 may split into one or more smaller tubes, each coupled to one or more output channels 206. Output tube 212 may be coupled to output coupling tube 211. Output coupling tube 211 may couple output tube 212 to cart 102. In some embodiments, handle 204 includes power conduit 255. Power conduit 255 may be an extension of power line 251 or may be coupled to power line 251. Power conduit 255 may allow power line 251 to provide power to electrode 210.

Vacuum tube 214 may also extend through handle 204 and may couple to vacuum channels 208. Vacuum tube 214 may be proximate output tube 212 within handle 204. In some embodiments, vacuum tube 214 may include a terminal end coupled to vacuum channels 208. Vacuum tube 214 may split into one or more smaller tubes, each coupled to one or more vacuum channels 208. In some embodiments, vacuum tube 214 is coupled to vacuum coupling tube 213. Vacuum coupling tube 213 may be configured to couple vacuum tube 214 to cart 102.

In some embodiments, vacuum tube 214 may combine with output tube 212 and extend into cart 102. Vacuum tube 214 and output tube 212 may extend from head unit 200 to one or more pumps (e.g., pumps 130) disposed within cart 102. For example, vacuum tube 214 and output tube 212 may allow head unit 200 to be in fluid communication with one or more peristaltic pumps disposed within cart 102. The peristaltic pump may be configured to control the flow of solution from cart 102 to head unit 200 and from head unit 200 to cart 102.

Referring to FIGS. 12-14, head unit 200 may include shut-off valves 207 and 209. Shut-off valves 207 and 209 may be coupled to output tube 212 and vacuum tube 214, respectively. Shut-off valves 207 and 209 may be quick connectors that allow for quick connection between output tube 212 and vacuum tube 214, and output coupling tube 211 and vacuum coupling tube 213, respectively, which couple head unit 200 to cart 102. In some embodiments, output coupling tube 211 and vacuum coupling tube 213 also include shut-off valves substantially similar to shut-off valves 207 and 209. In some embodiments, shut-off valves 207 and 209 are spring loaded and biased to be in the closed position. Upon pressure, shut-off valves 207 and 209 may open. For example, for shut-off valves 207 and 209 to allow flow of solution from cart 102 to head unit 200, the pressure of solution must exceed a threshold to overcome the biasing of shut-off valves 207 and 209 in the closed position. In some embodiments, valves 207 and 209 allow head unit 200 to be quickly attached and detached to output coupling tube 211 and vacuum coupling tube 213 extending from head unit 200 to cart 102.

In some embodiments, head unit 200 is configured to prevent dripping of the solution that is being applied to the surface. For example, output channels 206 of electrode 210 may output solution to be applied to a surface and vacuum channels 208 may vacuum any excess solution that is not deposited on the surface. Vacuum channel 208 vacuuming the excess solution results in head unit 200 being drip free as any solution not deposited on the surface is sucked up back into head unit 200 preventing excess solution from dripping from the surface and/or head unit 200. In some embodiments, the excess solution that is sucked up into head unit 200 flows back to cart 102. For example, the excess solution may flow from head unit 200, via vacuum channels 208, to cart 102 and may flow into waste container 121 disposed within cart 102 via a pump. In some embodiments, the excess solution flows into the container from which it originated.

In some embodiments, vacuum channels 208 are configured to provide suction during use of head unit 200 to allow pad 202 to be closer to the surface being treated. For example, in use, vacuum channels 208 may provide a negative pressure causing head unit 200 and pad 202 to be pulled closer to the surface being treated. Head unit 200 and pad 202 being closer to the surface reduces the amount of excess solution or the amount of solution that does not deposit on the surface. This prevents dripping of the solution during use. In some embodiments, the suction created between pad 202 and the surface to be treated results in a more efficient application of the solution to the surface resulting in less solution be needed compared to traditional electrochemical treatment systems.

In some embodiments, the vacuuming of excess solution allows system 100 to be a closed loop system thereby preventing contamination of the solution and preventing pollutants to enter solution control system 120. In some embodiments, upon completion of the electrochemical treatment of the desired surface, system 100 may be shut (e.g. power down). Upon powering down of system 100, output channels 206 may cease outputting solution. However, vacuum channels 208 may continue to vacuum excess solution and solution control system 120 may cause the excess solution to flow to one or more containers 122. For example, upon shutting down of system 100, vacuum channels 208 may remain activated for a predetermined amount of time to vacuum and excess solution. The predetermined amount of time may be 1 second to 10 minutes, 10 seconds to 5 minutes, 30 seconds to 3 minutes, or 1 minute to 2 minutes. In some embodiments, the predetermined time is form 3 seconds to 1 minute. The predetermined time may be less than 30 seconds. This allows for the conservation of solution resulting in minimal to no waste of the solution.

Referring to FIG. 29, electrode 210 may include pathway 216. In some embodiments, pathway 216 extends around the perimeter of electrode 210. However, pathway 216 may extend throughout the interior of electrode 210. Pathway 216 may be integrated into electrode 210. Pathway 216 may be configured to allow a fluid, such as water, to flow around electrode 210. In some embodiments, pathway 216 allows a fluid to flow around or throughout electrode 210 to assist in cooling and decreasing the temperature of electrode 210. For example, pathway 216 may be a water cooling loop configured to receive water or another fluid. The fluid within pathway 216 may be configured to absorb heat from electrode 210 to decrease the temperature of electrode 210. In some embodiments, overheating of electrode 210 can damage head unit 200, body 201, electrode 210, vacuum channels 208, and/or output channels 206. Decreasing the temperature of electrode 210 using pathway 216 may prevent damage to electrode 210. In some embodiments, pathway 216 allowing for the flow of fluid around electrode 210 prevent dimensional changes to electrode 210 and/or head unit 200 caused by prolonged use of system 100.

Referring to FIGS. 30A-32B, two or more electrodes 210 may be coupled together via connector 218. In some embodiments, connector 218 allows multiple electrodes 210 to be coupled together and pivot relative to one another. For example, connector 218 may couple a first electrode to an adjacent second electrode such that the first electrode can pivot relative to the second electrode. Connector 218 may allow electrodes 210 to be coupled together and pivot relative to each other such that multiple electrodes 210 can be joined together and conform to the shape of a surface. For example, as illustrated in FIGS. 31A-31B, for non-flat or non-planar surfaces, multiple electrodes 210 may be joined via connector 218 to allow them to pivot and conform to the shape of the non-flat surface. Electrodes 210 may pivot such that each electrode 210 of head unit 200 is substantially parallel to the surface to be treated. Each electrode 210 may form a tangent with the surface or a portion of the surface. In some embodiments, pad 202 may be secured to the multiple electrodes 210 such that conforming of the multiple electrodes 210 results in conforming of pad 202 to the non-flat surface and/or the non-planar surface.

Referring to FIG. 33, head unit 200 may include button 220. Button 220 may be integrated into head unit 200. For example, button 220 may be integrated into handle 204 or body 201. However, button 220 may be removably coupled to head unit 200. Button 220 may be configured to activate pumps within cart 102 to cause output of solution through output channels 206. For example, button 220 may be coupled to or in communication with a power supply disposed in cart 102 and actuation of button 220 may cause solution to flow from cart 102 through output coupling tube 211 to output tube 212 and out through output channels 206. In some embodiments, button 220 only controls output channels 206. However, button 220 may control output channels 206 and vacuum channels 208. Button 220 may be coupled to a transmitter that communicates with a receiver disposed on cart 102 to control valves 124 and/or pumps 130. Button 220 may be configured to require minimal power, no power, or no battery. In some embodiments, button 220 is a piezoelectric such that button 220 does not require a power supply. Button 220 may be a piezoelectric coupled to transmitter such that actuation of button 220 sends a signal to the transmitter to send a signal to cart 102 that button 220 has been actuate.

In some embodiments, actuation of button 220 causes activation of one or more pumps within cart 102, which results in solution flowing from cart 102, out through output channels 206 to the surface being treated. Button 220 may allow a user to easily activate or deactivate the flow of solution from head unit 200 without having to remove their hand from head unit 200. In some embodiments, button 220 is configured to wirelessly communicate with a control system or connection interface panel 110 to activate or deactivate one or more pumps within cart 102. f

In use, activation of a first pump configured to vacuum excess solution into vacuum channels 208 from the surface being treated causes activation of a second pump configured to cause solution to flow out of output channels 206. In some embodiments, the first pump is different than the second pump. However, the first pump may be the same as the second pump. In some embodiments, when output channels 206 are outputting solution onto a surface, vacuum channels 208 is simultaneously vacuuming up excess solution that does not deposit on the surface. For example, a pump may cause vacuum channels 208 to vacuum excess solution from the surface whenever output channels 206 are outputting solution onto the surface. I

In some embodiments, first pump is always activated prior to second pump such that vacuum channels 208 are activated prior to output channels 206 to prevent waste of solution. For example, activation of vacuum channels 208 prior to activation of output channels 206 allows for vacuuming of solution upon output of solution from output channels 206 to prevent unnecessary waste of solution during use. In some embodiments, vacuum channels 208 are configured to always be activated during use of head unit 200. For example, even when solution is not flowing out of output channels 206, vacuum channels 208 may continue to provide a vacuum force.

In some embodiments, head unit 200 includes a pressure sensor. The pressure sensor may be disposed within body 201, electrode 210, and/or pad 202. In some embodiments, the pressure sensor is disposed within body 201 and extends through pad 202 and/or the locking system of pad 202. The pressure sensor may be configured to detect the pressure exerted on pad 202 by the surface being treated. For example, during use, a user may press head unit 200 and pad 202 against the surface for treatment of the surface using a solution outputted by head unit 200 through pad 202. Pressing pad 202 against the surface causes the surface to generate a pressure on pad 202. The pressure sensor within pad 202 and/or head unit 200 may be configured to monitor this pressure and alert the user when the pressure exceeds a predetermined threshold. The pressure sensor may be configured to alert the user when the pressure between pad 202 and the surface exceeds a threshold to prevent a user from pressing head unit 200 too hard against the surface and damaging head unit 200 or the surface.

In some embodiments, the pressure sensor is configured to alert the user when not enough pressure is being exerted between head unit 200 and the surface. For example, the pressure sensor may alert the user to press head unit 200 and pad 202 harder against the surface to ensure that enough solution gets deposited on the surface from head unit 200 for proper treatment of the surface. The pressure sensor may also be configured to educate and train the user so that the ideal pressure is applied to the surface being treated to ensure a perfectly drip free plating sequence.

In some embodiments, head unit 200 includes one or more inertial measurement units (IMUs). The IMUs may be configured to provide the position of head unit 200 relative to a resting position or normal position. The IMU may be configured to communicate with the one or more pumps in cart 102. In some embodiments, the IMU is configured to communicate with one or more pumps to cause the one or more pumps to increase the flow rate or pressure of the solution from output channels 206 and/or increase or decrease the negative pressure/vacuum from vacuum channels 208. The IMU may provide information to the one or more pumps via connection interface panel 110 or the control system. In some embodiments, the IMU provides real-time orientation data of head unit 200 to the one or more pumps to provide real-time adjustment of the pumps based on the orientation data of head unit 200.

In some embodiments, head unit 200 may include a plurality of integrated levels and/or sensors to ensure perfect positioning of head unit 200 during application of a solution to a surface for treatment of the surface. For example, head unit 200 may include one or more levels configured to alert the user when the orientation of head unit 200 is improper thereby resulting in inefficient application of the solution to the surface or an uneven application of the solution to the surface.

Referring to FIGS. 34A-35, system 100 may include filtration unit 300. Filtration unit 300 may be configured to couple to container 122. For example, filtration unit 300 may be configured to couple to an opening of container 122. Filtration unit 300 may include active carbon configured to filter vapors emitted from the opening of container 122. Filtration unit 300 may also include top filter membrane 304 and bottom filter membrane 306. Top filter membrane 304 may be configured to stabilize the active carbon and provide air permeability. Bottom filter membrane 306 may be configured to protect the active carbon and provide optimal flow conditions for solvent vapors emitted from container 122. In some embodiments, filtration unit 300 includes housing 302. Housing 302 may be a fire resistant or fireproof housing. In some embodiments, housing 302 is comprised of partially crystalline polypropylene. Filtration unit 300 may be coupled to container 122 via cap 310. Filtration unit 300 may be coupled to cap 310, which may be coupled to container 122. In some embodiments, filtration unit 300 is inserted into cap 310 and cap 310 is threaded onto an opening of container 122. Cap 310 may be partially or fully comprised of polytetrafluoroethylene. Cap 310 may include a portion that is freely rotatable relative container 122. In some embodiments, filtration unit 300 is coupled to containers 122 or waste container 121.

It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concepts thereof. It is understood, therefore, that this invention is not limited to the exemplary embodiments shown and described, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the claims. For example, specific features of the exemplary embodiments may or may not be part of the claimed invention and various features of the disclosed embodiments may be combined. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”.

It is to be understood that at least some of the figures and descriptions of the invention have been simplified to focus on elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention. However, because such elements are well known in the art, and because they do not necessarily facilitate a better understanding of the invention, a description of such elements is not provided herein.

Further, to the extent that the methods of the present invention do not rely on the particular order of steps set forth herein, the particular order of the steps should not be construed as limitation on the claims. Any claims directed to the methods of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the steps may be varied and still remain within the spirit and scope of the present invention.

Claims

1. A head unit for electrochemical treatment of a surface, the head unit comprising: a handle including an output tube and a vacuum tube, the output tube and the vacuum tube configured to couple the handle to a portable cart;a body coupled to the handle; andan electrode disposed within the body and coupled to the output tube and the vacuum tube, the electrode including a plurality of output channels for outputting an electrochemical solution and a plurality of vacuum channels for vacuuming the electrochemical solution outputted from the plurality of output channels,wherein each of the plurality of output channels is disposed proximate to at least one of the plurality of vacuum channels, andwherein the electrode is fluidly coupled to the output tube to receive the electrochemical solution from the output tube.

2. The head unit of claim 1, wherein the output tube is coupled to the plurality of output channels and the vacuum tube is coupled to the plurality of vacuum channels.

3. The head unit of claim 1, wherein the body is integrally formed with the handle.

4. The head unit of claim 1, wherein the electrode is disposed in the body such that an outer perimeter of the electrode is flush with an inner perimeter the body.

5. The head unit of claim 1, wherein the output tube and the vacuum tube are each coupled to the electrode and extend from the electrode through the body and the handle.

6. The head unit of claim 1, wherein the plurality of output channels are configured to output the electrochemical solution and the plurality of vacuum channels are configured to vacuum the outputted electrochemical solution.

7. The head unit of claim 1 further comprising: a pad coupled to the electrode such that the pad is disposed within the body, the pad including a plurality of output apertures configured to align with the plurality of output channels.

8. The head unit of claim 1 further comprising: a button disposed on the handle such that activation of the button causes one or more of the electrochemical solution to flow through the plurality of output channels and ceasing flow of the electrochemical solution through the plurality of output channels.

9. The head unit of claim 1, wherein a distance between one of the plurality of output channels and one of the plurality of vacuum channels is from approximately 0.01 cm to 2 cm.

10. The head unit of claim 1, wherein the electrode includes an integrated cooling pathway configured to allow for flow of a fluid within the electrode to reduce a temperature of the electrode.

11. The head unit of claim 1 further comprising: one or more sensors configured to determine one or more of an orientation of the head unit, force applied to the head unit, angular rate of the head unit, a pressure between the electrode and the surface, and acceleration of the head unit.

12. The head unit of claim 1, wherein each of the output tube and the vacuum tube include connectors coupling each of the output tube and the vacuum tube to the head unit, at least one connector having shut off valves.

13. A head unit for electrochemical treatment of a surface, the head unit comprising: a handle including to an output tube and a vacuum tube, the output tube and vacuum tube configured to couple the handle to a portable cart;a body coupled to the handle; anda plurality of electrodes coupled together via one or more connectors, at least one of the plurality of electrodes configured to pivot relative to an adjacent electrode such that each electrode is substantially parallel to the surface,wherein each of the plurality of electrodes is disposed within the body and each of the plurality of electrodes includes a plurality of output channels for outputting an electrochemical solution and a plurality of vacuum channels for vacuuming the electrochemical solution.

14. The head unit of claim 13, wherein each of the output tube and the vacuum tube include quick connectors having shut off valves.

15. The head unit of claim 13 further comprising: a pad coupled to the plurality of electrodes such that the pad is configured to conform to a non-flat shape.

16. The head unit of claim 15, wherein the pad includes a locking system removably coupling the pad to the head unit.

17. A system for electrochemical treatment of a surface, the system comprising: a portable cart having a housing including a first container storing a first electrochemical solution and a second container storing a second electrochemical solution, and a solution control system disposed within the housing, the solution control system coupled to each of the first container and the second container, the solution control system having a purging system configured to purge the output tube of one or more of the first electrochemical solution and the second electrochemical solution; anda head unit in fluid communication with the solution control system via an output tube, wherein the solution control system is configured to selectively control a flow of the first electrochemical solution from the first container to the head unit via the output tube and a flow of the second electrochemical solution from the second container to the head unit via the output tube.

18. The portable cart of claim 17, wherein the solution control system includes a pump configured to control the flow of the first electrochemical solution from the first container and the flow of the second electrochemical solution from the second container.

19. A method for electrochemical treatment, the method comprising: storing a first electrochemical solution in a first container and storing a second electrochemical solution in a second container, the first electrochemical solution and the second electrochemical solution configured for electrochemical treatment of a surface;pumping the first electrochemical solution from the first container to a head unit through an output tube, the head unit being in fluid communication with the first container;outputting the first electrochemical solution from the head unit to the surface and simultaneously vacuuming first excess solution into the head unit, the first excess solution being the first electrochemical solution not deposited on the surface;rinsing the output tube with a cleaning solution to purge the first electrochemical solution from the output tube;pumping the second electrochemical solution from the second container to the head unit via the output tube, the head unit being in fluid communication with the second container; andoutputting the second electrochemical solution from the head unit to the surface and simultaneously vacuuming second excess solution into the head unit, the second excess solution being the second electrochemical solution not deposited on the surface.

20. The method of claim 19 further comprising: detecting, using a sensor, a characteristic of the first excess solution and the second excess solution; andseparating the first excess solution and the second excess solution based on the characteristic.