Anode for continuous electroforming of metal foil

Claim 3

The apparatus of claim 1 further comprising: said manifold including a slot through which said electrolyte flows, said slot having a width; and said perforated zone having a width substantially equal to said slot width.

Claim 4

The apparatus of claim 2 further comprising: said perforated zone including a plurality of perforations; and each said perforation having at least one dimension less than about twice said interlectrode gap.

Claim 5

The apparatus of claim 2 further comprising: said gap having a cross-sectional area; and said perforated zone having an overall area at least equal to about twice the cross-sectional area of said interelectrode gap.

Claim 6

The apparatus of claim 2 wherein said anode further comprises: each of said solid sections being formed from a first electrically conductive material; and said perforated zone being formed from a second electrically conductive material different from said first electrically conductive material.

Claim 7

The apparatus of claim 1 wherein: said manifold comprises a slotted manifold through which said electrolyte flows into said interelectrode gap.

Claim 8

The apparatus of claim 6 further comprising: said interelectrode gap being less than about 50 mm.

Claim 9

The apparatus of claim 7 further comprising: said interelectrode gap being in the range of about 5 mm. to about 15 mm.

Claim 10

The apparatus of claim 3 further comprising: each said perforation having at least one dimension less than about said interelectrode gap.

Claim 11

The apparatus of claim 4 further comprising: said perforated zone area being greater than twice said cross-sectional area.

Claim 12

A process for electroforming a continuous strip of metal foil having a substantially uniform thickness, said process comprising: providing a tank containing an electrolyte solution; providing in said tank a drum cathode having a plating surface at least partially immersed in said electrolyte solution, said immersed plating surface defining the extent of a plating zone; generating a substantially uniform current distribution throughout said plating zone for promoting formation of said substantially uniform thickness metal foil; said generating step comprising providing a substantially continuous anode having an arcuate configuration and being formed by a substantially continuous member having two solid sections connected by a central perforated zone, said anode being mounted in said tank in substantially concentric relationship with said cathode so that said anode and said cathode define a substantially constant interelectrode gap; flowing said electrolyte only through said central perforated zone of said anode so that said electrolyte flows initially into a central portion of said interelectrode gap, then between each of said solid sections and said plating surface and finally over the terminal portions of said solid sections back into said tank; and applying a current having a desired current density to said cathode and said substantially continuous anode for plating metal values from said electrolyte solution onto said plating surface, said arcuate configuration of said anode and said perforated zone promoting said substantially uniform current distribution throughout said plating zone.

Claim 13

A process for electroforming a continuous strip of metal foil having a substantially uniform thickness, said process comprising: providing a tank containing an electrolyte solution; providing in said tank a drum cathode having a plating surface at least partially immersed in said electrolyte solution, said immersed plating surface defining the extent of a plating zone; generating a substantially uniform current distribution throughout said plating zone for promoting formation of said substantially uniform thickness metal foil; said generating step comprising providing a substantially continuous anode having an arcuate configuration and being formed by a substantially continuous member having two solid sections connected by a central perforated zone, said anode being mounted in said tank in substantially concentric relationship with said cathode so that said anode and said cathode define a substantially constant interelectrode gap; flowing said electrolyte only through said central perforated zone of said anode so that said electrolyte flows initially into a central portion of said interelectrode gap, then between each of said solid sections and said plating surface and finally over the terminal portions of said solid sections back into said tank; and applying a current having a desired current density to said cathode and said substantially continuous anode for plating metal values from said electrolyte solution onto said plating surface, said arcuate configuration of said anode and said perforated zone promoting said substantially uniform current distribution throughout said plating zone.

Claim 14

The process of claim 11 further comprising: said solution comprising a copper sulfate-sulfuric acid solution; and maintaining said solution at a temperature in the range from about room temperature to about 100° C., whereby said plated metal values comprise copper values.

Claim 15

The process of claim 12 further comprising: flowing said electrolyte through said perforated zone at a flow rate in the range of about 1 m/sec. to about 4 m/sec.; and applying a current having a current density in the range of about 0.4 A/cm 2 to about 2 A/cm 2 .

Claim 16

The process of claim 13 further comprising: said flow rate being in the range of about 1 m/sec. to about 2.5 m/sec.; and said current density being in the range of about 0.5 A/cm 2 to about 1.5 A/cm 2 .

Claim 17

The process of claim 14 further comprising: rotating said cathode at a desired speed.

Claim 18

The process of claim 15 wherein said flowing step further comprises: flowing said electrolyte through a plurality of perforations in said central perforated zone for substantially preventing said electrolyte from directly impinging on said rotating cathode, for creating a more uniform current distribution in the region of said perforated zone, and for creating turbulence in said electrolyte flow, each said perforation having a dimension less than about twice said gap.