US4898647A
Expired / Lapsed
US
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Process and apparatus for electroplating copper foil
Assignee: Gould Electronics Inc
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Filing: 1988-12-22
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Granted: 1990-02-06
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Expires: 2008-12-22
Abstract
Abstract The present invention involves a process and associated apparatus for producing surface treated metal foil, comprising: providing an electrolytic cell having an electrolyte and a cathodic surface immersed in the electrolyte, the electrolyte containing a concentration of matel ions; applying a first current density in a frist zone for plating a relatively smooth metal foil deposit on the cathodic surface; and applying a pulsed second current density having a magnitude greater than the limiting current density in a subsequent second zone, the pulsed second current density forming a plurality of self adhering nodules on the base metal deposit.
Inventors
- 👤 Betty M. Luce
- 👤 Betty L. Berdan
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 06:22
CPC Classifications
C; C25; C25D; C25D1/00; C25D1/04; H; H05; H05K; H05K3/00; H05K3/38; H05K3/382; H05K3/384; H05K2201/00; H05K2201/03; H05K2201/0332; H05K2201/0335; H05K2201/0355; H05K2203/00; H05K2203/03; H05K2203/0307; H05K2203/07; H05K2203/0703; H05K2203/0723; H05K3/22; H05K3/24; H05K3/241
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
93 words
A process for producing surface treated metal foil, said process comprising: providing an electrolytic cell having an electrolyte and a cathodic surface immersed in said electrolyte, said electrolyte containing a concentration of metal ions; applying a first current density in a first zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, applying a continuous series of pulses of a second current density having a magnitude greater than the limiting current density in a second zone, said second current density forming a plurality of nodules on said metal deposit.
Claim 2
Dependent Claim
93 words
A process for producing surface treated metal foil, said process comprising: providing an electrolytic cell having an electrolyte and a cathodic surface immersed in said electrolyte, said electrolyte containing a concentration of metal ions; applying a first current density in a first zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, applying a continuous series of pulses of a second current density having a magnitude greater than the limiting current density in a second zone, said second current density forming a plurality of nodules on said metal deposit.
Claim 3
Dependent Claim
41 words
The process of claim 1 further comprising: providing at least one insoluble primary anode in said cell; at least one treatment anode in said cell positioned posterior to said primary anode and applying said second current to each said treatment anode.
Claim 4
Dependent Claim
16 words
The process of claim 2 further comprising: agitating said electrolyte in said first and second zones.
Claim 5
Dependent Claim
40 words
The process of claim 2 wherein said second current density consists of pulses of current having a duty cycle of from about 0.05 to about 50 milliseconds followed by an off cycle of from about 0.05 to about 50 milliseconds.
Claim 6
Dependent Claim
40 words
The process of claim 2 wherein said second current density consists of pulses of current having an duty cycle of from about 0.10 to about 10 milliseconds followed by an off cycle of from about 0.10 to about 10 milliseconds.
Claim 7
Dependent Claim
80 words
The process of claim 3 further comprising: providing at least two primary anodes in said cell; spacing said primary anodes from said cathodic surface and from each other so as to form a space between each said primary anode and said cathodic surface and at least one fluid passageway; and, said agitating step comprising flowing said electrolyte at a desired rate through said at least one fluid passageway and said space between each said primary anode and said cathodic surface.
Claim 8
Dependent Claim
80 words
The process of claim 4 further comprising: providing at least two primary anodes in said cell; spacing said primary anodes from said cathodic surface and from each other so as to form a space between each said primary anode and said cathodic surface and at least one fluid passageway; and, said agitating step comprising flowing said electrolyte at a desired rate through said at least one fluid passageway and said space between each said primary anode and said cathodic surface.
Claim 9
Dependent Claim
80 words
The process of claim 5 further comprising: providing at least two primary anodes in said cell; spacing said primary anodes from said cathodic surface and from each other so as to form a space between each said primary anode and said cathodic surface and at least one fluid passageway; and, said agitating step comprising flowing said electrolyte at a desired rate through said at least one fluid passageway and said space between each said primary anode and said cathodic surface.
Claim 10
Dependent Claim
61 words
The process of claim 2 further comprising: said electrolyte comprising a copper sulfate-sulfuric acid solution; said first current density applying step comprising applying a first current density in the range of about 0.4 A/cm 2 to about 2 A/cm 2 ; and applying said second current density in the range of about 1.1 A/cm 2 to abut 6 A/cm 2 .
Claim 11
Dependent Claim
46 words
The process of claim 9 further comprising: said first current density being in the range of about 0.75 A/cm 2 to about 1.5 A/cm 2 ; and said second current density being in the range of abut 2 A/cm 2 to about 3 A/cm 2 .
Claim 12
Independent Claim
124 words
An apparatus for producing surface treated metal foil, said apparatus comprising: an electrolytic cell containing an electrolyte having a concentration of metal ions; a cathodic surface at least partially immersed in said electrolyte; first anode means for applying a first current density in a first zone for plating a relatively smooth metal deposit on said cathodic surface; and second anode means for applying a continuous series of pulses of a second current density having a magnitude greater than the limiting current density over said first current density in a second zone, said second current density means forming a plurality of nodules on said metal deposit firmly adhering to said metal foil without the need for a still further metal deposit on said metal foil.
Claim 13
Independent Claim
124 words
An apparatus for producing surface treated metal foil, said apparatus comprising: an electrolytic cell containing an electrolyte having a concentration of metal ions; a cathodic surface at least partially immersed in said electrolyte; first anode means for applying a first current density in a first zone for plating a relatively smooth metal deposit on said cathodic surface; and second anode means for applying a continuous series of pulses of a second current density having a magnitude greater than the limiting current density over said first current density in a second zone, said second current density means forming a plurality of nodules on said metal deposit firmly adhering to said metal foil without the need for a still further metal deposit on said metal foil.
Claim 14
Dependent Claim
76 words
The apparatus of claim 11 further comprising: said first current density applying means comprising at least one insoluble primary anode in said cell and means for applying a first current to each said primary anode; and said second anode means comprising at least one treatment anode positioned in said cell posterior to said first anode means and means for applying a continuous series of pulses of a second current to said at least one treatment anode.
Claim 15
Dependent Claim
12 words
The apparatus of claim 12 further comprising: a plurality of treatment anodes.
Claim 16
Dependent Claim
18 words
The apparatus of claim 13 further comprising: means for agitating said electrolyte in said first and second zones.
Claim 17
Dependent Claim
68 words
The apparatus of claim 14 further comprising: at least two primary anodes in said cell, said primary anodes being spaced from said cathodic surface and from each other so as to form at least one fluid passageway; and said agitating means comprising means for causing said electrolyte to flow at a desired rate through said passageway and said space between each said primary anode and said cathodic surface.
Claim 18
Dependent Claim
48 words
The apparatus of claim 13 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having a duty cycle of from about 0.05 to about 50 milliseconds followed by an off cycle of from about 0.05 to about 50 milliseconds.
Claim 19
Dependent Claim
48 words
The apparatus of claim 14 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having a duty cycle of from about 0.05 to about 50 milliseconds followed by an off cycle of from about 0.05 to about 50 milliseconds.
Claim 20
Dependent Claim
48 words
The apparatus of claim 15 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having an duty cycle of from about 0.05 to about 50 milliseconds followed by an off cycle of from about 0.05 to about 50 milliseconds.
Claim 21
Dependent Claim
48 words
The apparatus of claim 13 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having a duty cycle of from about 0.10 to about 10 milliseconds followed by an off cycle of from about 0.10 to about 10 milliseconds.
Claim 22
Dependent Claim
48 words
The apparatus of claim 14 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having an duty cycle of from about 0.10 to about 10 milliseconds followed by an off cycle of from about 0.10 to about 10 milliseconds.
Claim 23
Dependent Claim
48 words
The apparatus of claim 15 further comprising means to provide each said treatment anode with a current density consisting of pulses of current having an duty cycle of from about 0.10 to about 10 milliseconds followed by an off cycle of from about 0.10 to about 10 milliseconds.
Claim 24
Dependent Claim
124 words
A process for producing surface treated metal foil, said process comprising: providing an electrolytic cell having an electrolyte and a cathodic surface immersed in said electrolye, said electrolyte containing a concentration of metal ions; applying a continuous series of pulses of a first high current density in a first zone for producing nucleation sites on said cathodic surface; applying a low current density below the limiting current density in a second zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, applying a continuous series of pulses of a second high current density having a magnitude greater than the limiting current density in a third zone, said second high current density forming a plurality of nodules on said metal depost.
Claim 25
Dependent Claim
124 words
A process for producing surface treated metal foil, said process comprising: providing an electrolytic cell having an electrolyte and a cathodic surface immersed in said electrolye, said electrolyte containing a concentration of metal ions; applying a continuous series of pulses of a first high current density in a first zone for producing nucleation sites on said cathodic surface; applying a low current density below the limiting current density in a second zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, applying a continuous series of pulses of a second high current density having a magnitude greater than the limiting current density in a third zone, said second high current density forming a plurality of nodules on said metal depost.
Claim 26
Dependent Claim
80 words
The process of claim 22 further comprising: providing at leat two primary anodes in said cell, spacing said primary anodes from said cathodic surface and from each other so as to form a space between each said primary anode and said cathodic surface and at least one fluid passageway; and, an agitating step comprising flowing said electrolyte at a desired rate through said at least one fluid passageway and said space between each said primary anode and said cathodic surface.
Claim 27
Dependent Claim
19 words
The process of claim 23 further comprising: said flow rate being from about 0.1 m/sec. to about 4 m/sec.
Claim 28
Dependent Claim
61 words
The process of claim 22 further comprising: said electrolyte comprising a copper sulfate-sulfuric acid solution, said second current density applying step comprising applying a current density in the range of about 0.2 A/cm 2 to about 2 A/cm 2 ; and said pulses comprising a current density in the range of about 0.5 A/cm 2 to about 6 A/cm 2 .
Claim 29
Independent Claim
124 words
An apparatus for producing surface treated metal foil, said apparatus comprising: an electrolytic cell containing an electrolyte having a concentration of metal ions; a cathodic surface at least partially immersed in said electrolyte; means for applying a continuous series of pulses of a high current density in a first zone for creating nucleation sites on said cathode surfaces; means for applying a second, low, current density in a second zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, means for applying a continuous series of pulses of a second high current density having a magnitude greater than the limiting current density in a third zone, said second high current density forming a plurality of nodules on said metal deposit.
Claim 30
Independent Claim
124 words
An apparatus for producing surface treated metal foil, said apparatus comprising: an electrolytic cell containing an electrolyte having a concentration of metal ions; a cathodic surface at least partially immersed in said electrolyte; means for applying a continuous series of pulses of a high current density in a first zone for creating nucleation sites on said cathode surfaces; means for applying a second, low, current density in a second zone for plating a relatively smooth metal foil deposit on said cathodic surface; and, means for applying a continuous series of pulses of a second high current density having a magnitude greater than the limiting current density in a third zone, said second high current density forming a plurality of nodules on said metal deposit.
Claim 31
Dependent Claim
52 words
The apparatus of claim 26 further comprising: said first current density applying means comprising at leat on insoluble primary anode in said cell and means for applying a first current to each said primary anode; and, second high current density means comprising at least one treatment anode posterior to said primary anode.
Claim 32
Dependent Claim
15 words
The apparatus of claim 26 further comprising: a plurality of high current density treatment anodes.
Claim 33
Dependent Claim
67 words
The apparatus of claim 26 further comprising: at least two primary anode in said cell, said primary anodes being spaced from said cathodic surface and from each other so as to form at leat on fluid passeageway; and agitating means comprising means for causing said electrolyte to flow at a desired rate through said passageway and said space between each said primary anode and said cathodic surface.
Claim 34
Dependent Claim
13 words
The apparatus of claim 26 wherein said cathodic surface comprises a rotating drum.
Claim 35
Dependent Claim
13 words
The apparatus of claim 26 wherein said cathodic surface comprises an aluminum carrier.
References Cited (Backward Citations)
US4549941A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-02-05 | 1993-08-07 | 1994-02-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-02-05 | 1997-08-07 | 1998-02-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-02-05 | 2001-08-07 | 2002-02-06 | $7700.00 | Window Closed / Lapsed |