Aqueous Electrolyte Composition for Reduced Airborne Emissions
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Solution Overview
Problem
Existing electrolytic deposition methods for metal layers on substrates result in hazardous acidic or alkaline mist due to gas generation, which is difficult to suppress effectively without incurring additional costs for explosion-proof installations and avoiding electrostatic charges, and existing solutions have environmental drawbacks.
Innovation Solution
An aqueous electrolyte composition with a dynamic surface tension of ≤ 35 mN/m, achieved by using non-perfluorinated partially fluorinated surfactants and anti-foaming agents, significantly reduces airborne emissions by minimizing gas bubble size and disintegration forces, thereby minimizing mist formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If foam layers are used to suppress airborne emissions, then mist suppression is improved, but explosion risk increases due to gas accumulation
Solution Approach 1:
The invention extracts the harmful function of foam (gas accumulation leading to explosion risk) and replaces it with a different mechanism. Instead of using foam layers that trap gases, the patent employs specific surfactants that reduce surface tension to prevent mist formation without creating gas-trapping foam structures, thereby eliminating the explosion hazard while maintaining mist suppression.
Solution Approach 2:
The patent introduces surfactants as intermediary substances that mediate between the electrolyte and the air interface. These surfactants modify the surface properties to prevent mist generation without forming foam, serving as a safe intermediary that achieves mist suppression without the harmful side effects of foam-based approaches.
2Object-affected harmful factors
If foam layers are used to suppress airborne emissions, then mist suppression is improved, but additional safety installations are required
Solution Approach 1:
The invention removes the need for complex explosion-proof installations by eliminating the foam layer approach. By using surfactants that suppress mist without creating gas-trapping foam, the system avoids the requirement for expensive safety installations while maintaining effective mist control.
Solution Approach 2:
The patent employs inexpensive surfactant additives that can be introduced into the electrolyte to achieve mist suppression. These chemical additives replace the need for expensive mechanical safety installations, providing a cost-effective solution that eliminates mist hazards without requiring complex safety infrastructure.
3Object-affected harmful factors
If conventional surfactants are used to reduce surface tension, then mist formation is reduced, but environmental harm increases
Solution Approach 1:
The patent applies parameter changes by selecting surfactants with specific molecular structures (sulfonates, sulfates, or carboxylates with particular chain lengths and configurations) that optimize the balance between mist suppression effectiveness and environmental compatibility. This involves adjusting chemical parameters to achieve the desired surface tension reduction while minimizing ecological impact.
Solution Approach 2:
The invention uses composite surfactant systems comprising multiple components (different types of surfactants in combination) that work synergistically to achieve effective mist suppression with reduced environmental harm. The composite approach allows optimization of both performance and environmental properties through careful selection and combination of different surfactant molecules.
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
The composition effectively reduces or eliminates hazardous mist emissions during metal deposition, enhancing safety and reducing environmental impact while avoiding the need for costly explosion-proof installations and electrostatic protection measures.
Implementation Method 1
the dynamic surface tension of which is ≤ 35 mN/m
Data Source
Figure 1
AI summary
The invention is directed to an aqueous electrolyte for the deposition of a metal layer on a substrate surface as well as a method for the deposition of a metal layer on a substrate surface by which electrolyte and in which method the formation of airborne emissions above the surface of the electrolyte in a plating tank is significantly reduced or more preferably omitted. The aqueous electrolyte composition according to the invention comprises at least one surfactant in a concentration affecting a dynamic surface tension of the composition of ‰¤ 35 mN/m.