Cyanide-free copper plating process

Claim 2

A process for electrodepositing a grain refined ductile and adherent copper strike on a conductive substrate which comprises the steps of providing an aqueous alkaline cyanide-free electrolyte containing copper ions in an amount sufficient to electrodeposit copper, a complexing agent in an amount sufficient to chelate the copper ions present, said complexing agent comprising a compound selected from the group consisting of 1-hydroxyethylidene-1,1-disphosphonic acid, a mixture of 1-hydroxyethylidene-1,1-disphosphonic acid and aminotri-(methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 50 percent by weight of the mixture; and a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and ethylene diamine tetro (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 30 percent by weight of the mixture, as well as the bath soluble and compatible salts and partial salts thereof, a bath soluble and compatible carbonate compound in an amount sufficient to stabilize the pH of the electrolyte, and hydroxyl ions in an amount to provide a pH of about 7.5 to about 10.5, controlling the temperature of said electrolyte between about 100° to about 160° F., immersing a conductive substrate to be plated as a cathode in said electrolyte, immersing a combination of a copper-base soluble anode and a ferrite insoluble anode in said electrolyte to provide a copper anode to ferrite anode surface area ratio of about 1:2 to about 1:6, and passing current between said anodes and said cathode for a period of time sufficient to deposit copper on said substrate to the desired thickness.

Claim 3

The process as defined in claim 1 in which said copper ions are present in an amount of about 3 to about 50 g/l.

Claim 4

The process as defined in claim 1 in which said copper ions are present in an amount of about 15 to about 50 g/l.

Claim 5

The process as defined in claim 1 in which said copper ions are present in an amount of about 3.5 to about 10 g/l.

Claim 6

The process as defined in claim 1 in which said hydroxyl ions are present in an amount to provide a pH of about 9.5 to about 10.

Claim 7

The process as defined in claim 1 further including a bath soluble and compatible wetting agent present in an amount up to about 0.25 g/l.

Claim 8

The process as defined in claim 1 further including a bath soluble and compatible wetting agent present in an amount of about 0.01 to about 0.1 g/l.

Claim 9

The process as defined in claim 1 in which said carbonate compound is selected from the group consisting of alkali metal and alkaline earth metal carbonate and bicarbonate compounds and mixtures thereof.

Claim 10

The process as defined in claim 1 in which said carbonate compound is selected from the group consisting of alkali metal carbonate and bicarbonate compounds and mixtures thereof.

Claim 11

The process as defined in claim 1 in which said carbonate compound comprises potassium bicarbonate.

Claim 12

The process as defined in claim 1 in which said carbonate compound is present in an amount of about 3 to about 100 g/l calculated on a weight equivalent basis as sodium carbonate.

Claim 13

The process as defined in claim 1 in which said carbonate compound is present in an amount of about 10 to about 20 g/l calculated on a weight equivalent basis as sodium carbonate.

Claim 14

The process as defined in claim 1 in which said complexing agent comprises 1-hydroxyethylidene-1,1-diphosphonic acid present in an amount of about 50 to about 500 g/l.

Claim 15

The process as defined in claim 1 in which said complexing agent comprises a mixture containing 70 percent by weight 1-hydroxyethylidene-1,1-diphosphonic acid and 30 percent by weight aminotri - (methylene phosphonic acid) as well as the bath soluble and compatible salts and partial salts thereof, said mixture present in an amount of about 20 to about 322 g/l.

Claim 16

The process as defined in claim 1 in which said complexing agent comprises a mixture containing about 50 percent by weight 1-hydroxyethylidene-1,1-diphosphonic acid and about 50 percent by weight ethylene diamine tetra (methylene phosphonic acid) as well as the bath soluble and compatible salts and partial salts thereof and mixtures thereof, said mixture present in an amount of about 19 to about 311 g/l.

Claim 17

The process as defined in claim 1 in which the step of controlling the temperature of said electrolyte is performed to provide a temperature of from about 110° F. to about 140° F.

Claim 18

The process as defined in claim 1 in which the step of controlling the temperature of said electrolyte is performed to provide a temperature of about 120° F. to about 140° F.

Claim 19

The process as defined in claim 1 in which the step of passing current between said anodes and said cathode is performed to provide a cathode current density of about 1 to about 80 ASF.

Claim 20

The process as defined in claim 1 in which the step of passing current between said anodes and said cathode is performed to provide a cathode current density of about 5 to about 25 ASF.

Claim 21

The process as defined in claim 1 including the further step of maintaining the pH of said electrolyte within a range of about 9.5 to about 10.

Claim 22

The process as defined in claim 1 including the further step of maintaining the copper anode to ferrite anode surface area ratio between about 1:3 to about 1:5.

Claim 23

The process as defined in claim 1 including the further step of maintaining the copper anode to ferrite anode surface area ratio at about 1:4.

Claim 24

The process as defined in claim 1 in which the step of passing current is controlled to provide a copper deposit on said substrate of an average thickness of about 0.015 to about 5 mils.

Claim 25

The process as defined in claim 1 in which the step of passing current is controlled for a period of time of from about 1 minute to about 1 hour.

Claim 26

The process as defined in claim 1 in which the step of passing current is controlled for a time of from about 2 to about 30 minutes.

Claim 27

The process as defined in claim 1 including the further step of replenishing said complexing agent and said carbonate compound to maintain said bath constituents within the desired operating range.

Claim 28

The process as defined in claim 1 including the further step of controlling the cathode to anode surface area ratio between about 1:2 to about 1:6.

Claim 29

The process as defined in claim 1 including the further step of controlling the cathode to anode surface area ratio between about 1:3 to about 1:5.

Claim 30

The process as defined in claim 1 including the further step of controlling the cathode to anode surface area ratio at about 1:4.

Claim 31

A process for electrodepositing a grain refined ductile and adherent copper strike on a ferrous-base conductive substrate which comprises the steps of providing an aqueous alkaline cyanide-free electrolyte containing copper ions in an amount sufficient to electrodeposite copper, a complexing agent in an amount sufficient to chelate the copper ions present, said complexing agent comprising a compound selected from the group consisting of 1-hydroxyethylidene-1,1-diphosphonic acid, a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and aminotri - (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 50 percent by weight of the mixture; and a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and ethylene diamine tetro (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in amount of at least 30 percent by weight of the mixture, as well as the bath soluble and compatible salts and partial salts thereof, a bath soluble and compatible carbonate compound in an amount sufficient to stabilize the pH of the electrolyte, and hydroxyl ions in an amount to provide a pH of about 7.5 to about 10.5, controlling the copper ion concentration within a range of about 15 to about 50 grams per liter, controlling the temperature of said electrolyte between about 100° to about 160° F., immersing a ferrous-base conductive substrate to be plated as a cathode in said electrolyte, immersing a combination of a copper-base soluble anode and a ferrite insoluble anode in said electrolyte to provide a copper anode to ferrite anode surface area ratio of about 1:2 to about 1:6, and passing current between said anodes and said cathode for a period of time sufficient to deposit copper on said ferrous-base substrate to the desired thickness.

Claim 32

A process for electrodepositing a grain refined ductile and adherent copper strike on a ferrous-base conductive substrate which comprises the steps of providing an aqueous alkaline cyanide-free electrolyte containing copper ions in an amount sufficient to electrodeposite copper, a complexing agent in an amount sufficient to chelate the copper ions present, said complexing agent comprising a compound selected from the group consisting of 1-hydroxyethylidene-1,1-diphosphonic acid, a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and aminotri - (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 50 percent by weight of the mixture; and a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and ethylene diamine tetro (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in amount of at least 30 percent by weight of the mixture, as well as the bath soluble and compatible salts and partial salts thereof, a bath soluble and compatible carbonate compound in an amount sufficient to stabilize the pH of the electrolyte, and hydroxyl ions in an amount to provide a pH of about 7.5 to about 10.5, controlling the copper ion concentration within a range of about 15 to about 50 grams per liter, controlling the temperature of said electrolyte between about 100° to about 160° F., immersing a ferrous-base conductive substrate to be plated as a cathode in said electrolyte, immersing a combination of a copper-base soluble anode and a ferrite insoluble anode in said electrolyte to provide a copper anode to ferrite anode surface area ratio of about 1:2 to about 1:6, and passing current between said anodes and said cathode for a period of time sufficient to deposit copper on said ferrous-base substrate to the desired thickness.

Claim 33

The process as defined in claim 30 including the further step of electrifying said ferrous-base substrate prior to and during the step of immersing said substrate in said electrolyte.

Claim 34

A process for electrodepositing a grain refined ductile and adherent copper strike on a zinc-base conductive substrate which comprises the steps of providing an aqueous alkaline cyanide-free electrolyte containing copper ions in an amount sufficient to electrodeposit copper, a complexing agent in an amount sufficient to chelate the copper ions present, said complexing agent comprising a compound selected from the group consisting of 1-hydroxyethylidene-1,1-diphosphonic acid, a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and aminrotri - (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 50 percent by weight of the mixture; and a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and ethylene diamine tetro (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 30 percent by weight of the mixture, as well as the bath soluble and compatible salts and partial salts thereof, a bath soluble and compatible carbonate compound in an amount sufficient to stabilize the pH of the electrolyte, and hydroxyl ions in an amount to provide a pH of about 7.5 to about 10.5, controlling the copper ion concentration within a range of about 3.5 to about 10 grams per liter, controlling the temperature of said electrolyte between about 100° to about 160° F., cathodically electrifying said conductive zinc-base substrate at a voltage of at least about 3 volts and inmersing the electrified said substrate in said electrolyte, immersing a combination of a copper-base soluble anode and a ferrite insoluble anode in said electrolyte to provide a copper anode to ferrite anode surface area ratio of about 1:2 to about 1:6, and passing current between said anodes and said zinc-base substrate for a period of time sufficient to deposit copper on said substrate to the desired thickness.

Claim 35

A process for electrodepositing a grain refined ductile and adherent copper strike on a zinc-base conductive substrate which comprises the steps of providing an aqueous alkaline cyanide-free electrolyte containing copper ions in an amount sufficient to electrodeposit copper, a complexing agent in an amount sufficient to chelate the copper ions present, said complexing agent comprising a compound selected from the group consisting of 1-hydroxyethylidene-1,1-diphosphonic acid, a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and aminrotri - (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 50 percent by weight of the mixture; and a mixture of 1-hydroxyethylidene-1,1-diphosphonic acid and ethylene diamine tetro (methylene phosphonic acid) in which said 1-hydroxyethylidene-1,1-diphosphonic acid is present in an amount of at least about 30 percent by weight of the mixture, as well as the bath soluble and compatible salts and partial salts thereof, a bath soluble and compatible carbonate compound in an amount sufficient to stabilize the pH of the electrolyte, and hydroxyl ions in an amount to provide a pH of about 7.5 to about 10.5, controlling the copper ion concentration within a range of about 3.5 to about 10 grams per liter, controlling the temperature of said electrolyte between about 100° to about 160° F., cathodically electrifying said conductive zinc-base substrate at a voltage of at least about 3 volts and inmersing the electrified said substrate in said electrolyte, immersing a combination of a copper-base soluble anode and a ferrite insoluble anode in said electrolyte to provide a copper anode to ferrite anode surface area ratio of about 1:2 to about 1:6, and passing current between said anodes and said zinc-base substrate for a period of time sufficient to deposit copper on said substrate to the desired thickness.