Anode Titanium Basket Channels for Uniform Continuous Electroplating

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Solution Overview

Problem

Current continuous electroplating apparatuses face issues with uneven electric field distribution, irregular thickness of electroplated layers, and high waste generation due to phosphorus-containing chemicals, leading to increased costs and environmental impact.

Innovation Solution

The apparatus includes an anode titanium basket with channels for continuous passage of the electroplated object, combined with a rotating conductive roller set and a power supply, which ensures uniform electric and flow fields, and uses lubricating powders instead of phosphorus-containing chemicals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a continuous electroplating apparatus is used to increase production yield, then productivity is improved, but the plate electrode dissolves causing inconsistent spacing between cathode and anode, resulting in reduced manufacturing precision of the electroplated layer thickness

Engineering Contradiction:

Improveyield of metal composite wiresVSAvoidthickness uniformity of electroplated layer

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The plate electrode is segmented into a tubular anode with longitudinal channels, dividing the continuous electrode into functional sections that maintain consistent spacing while enabling continuous operation. The channel structure segments the electroplating space to ensure uniform current distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tubular anode structure allows for dynamic continuous operation where the electrode can be rotated or moved while maintaining consistent spacing. The design enables continuous electroplating without the electrode dissolution issues that plague static plate electrodes.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If phosphorus-containing chemicals are used in the electroplating solution, then the electroplating process can proceed, but large amounts of phosphate metal salt waste and wastewater are generated, resulting in increased loss of substance and higher environmental harm

Engineering Contradiction:

Improveelectroplating process feasibilityVSAvoidphosphate metal salt waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The electroplating solution composition is changed by replacing phosphorus-containing chemicals with alternative additives. This parameter change eliminates phosphate waste generation while maintaining the electroplating process functionality and producing self-lubricating coatings.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the harmful phosphorus-containing chemicals into a beneficial waste-free process. By using alternative chemistry, the process eliminates environmental harm while adding the beneficial property of self-lubrication to the metal composite wire.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If phosphorus-containing chemicals are used in the electroplating solution, then the electroplating process can proceed, but large amounts of wastewater are generated, resulting in increased loss of time and resources for waste treatment

Engineering Contradiction:

Improveelectroplating process feasibilityVSAvoidwaste treatment time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The electroplating solution chemistry is modified to eliminate phosphorus-containing compounds, fundamentally changing the waste stream characteristics. This parameter change reduces wastewater volume and eliminates the need for extensive waste treatment processes.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration enhances deposition uniformity, reduces waste and chemical costs, and minimizes carbon emissions by improving electric and flow field uniformity while providing a self-lubricating metal composite wire.

Implementation Method 1

the power supply is used to provide power to the rotating conductive roller set and the anode titanium basket, so that the electroplating solution forms a metal composite layer on the surface of the electroplated object

Methodology Applied

Scientific EffectElectroplating: Electrodeposition

Data Source

PatentUS20250207291A1Anode titanium basket and continuous electroplating apparatus including the same

Publication Date: 2025.06.26 IND TECH RES INST

AI summary

An anode titanium basket and a continuous electroplating apparatus including the same are provided. The continuous electroplating apparatus includes an electroplating tank, an anode titanium basket, a rotating conductive roller set, and a power supply. The electroplating tank has an electroplating solution accommodation space. The anode titanium basket is disposed in the electroplating solution accommodation space and includes an accommodation space and a channel. The accommodation space consists of a first surface, a second surface, and a side surface. The channel includes a first channel opening penetrating through the first surface and a second channel opening corresponding to the first channel opening and penetrating through the second surface. The rotating conductive roller set corresponds to the first channel opening and the second channel opening. The power supply is disposed outside the electroplating tank and is electrically connected to the rotating conductive roller set and the anode titanium basket.