MEMBRANE ANODE SYSTEM FOR ELECTROLYTIC ZINC-NICKEL ALLOY DEPOSITION

Abstract

The present invention is related to a membrane anode system for electrolytic zinc-nickel alloy deposition, a method for electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated using a membrane anode system, and the use of a membrane anode system for acid or alkaline electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated by such a method.

Claims

1. Membrane anode system for electrolytic zinc-nickel alloy deposition comprising at least a reaction tank, at least a first membrane, at least an anode, at least a cathode, at least a first anolyte compartment, and at least a catholyte compartment; wherein the at least first membrane is arranged between the anode and the cathode, wherein the at least first membrane has a distance to the anode ranging from 0.5 mm to 5 mm, characterized in that the membrane anode system further comprises at least a first non-metallic front plate having a plurality of openings and at least a non-metallic container, wherein said at least first non-metallic front plate and said non-metallic container form together with the at least first membrane, the anode, and the at least first anolyte compartment between the first membrane and the anode, at least a one-side membrane anode modular unit, and the anode can be individually removed from or inserted into the at least one-side membrane anode modular unit without that the entire at least one-side membrane anode modular unit has to be removed from or inserted into the reaction tank.

2. Membrane anode system according to claim 1 characterized in that the at least first membrane has a distance to the anode ranging from 0.75 mm to 4 mm.

3. Membrane anode system according to claim 1 characterized in that the at least one-side membrane anode modular unit provides at least a first encapsulation of the at least first membrane, the at least first anolyte compartment and the anode by encapsulating the at least first non-metallic front plate with the non-metallic container; wherein the at least one-side membrane anode modular unit further comprises at least a first sealing element, which is sealing said at least first encapsulation of said at least first non-metallic front plate with said non-metallic container.

4. Membrane anode system according to claim 1 characterized in that the membrane anode system further comprises at least a second non-metallic front plate having a plurality of openings, at least a second membrane, and at least a second anolyte compartment between the at least second membrane and the anode; wherein the anode comprises at least a first side comprising a first anode surface and at least a second side comprising a second anode surface, wherein the first side of the anode is oppositely arranged to the second side of the anode; wherein on the first side of the anode the at least first membrane and the at least first non-metallic front plate are arranged in a parallel manner to the surface of said first side of the anode while on the second side of the anode the at least second membrane and the at least second non-metallic front plate are arranged in a parallel manner to the surface of said second side of the anode; wherein the at least first and second membrane together with the at least first and second non-metallic front plate, the non-metallic container, the at least first and second anolyte compartment, and the anode form together at least a two-side membrane anode modular unit.

5. Membrane anode system according to claim 4 characterized in that the at least two-side membrane anode modular unit provides at least a first encapsulation of the at least first membrane, the at least first anolyte compartment and the anode by encapsulating the at least first non-metallic front plate with the non-metallic container; wherein the at least two-side membrane anode modular unit further comprises at least a first sealing element, which is sealing said at least first encapsulation of said at least first non-metallic front plate with said non-metallic container; and wherein the at least two-side membrane anode modular unit further provides at least a second encapsulation of the at least second membrane, the at least second anolyte compartment and the anode by encapsulating the at least second non-metallic front plate with the non-metallic container; wherein the at least two-side membrane anode modular unit further comprises at least a second sealing element, which is sealing said at least second encapsulation of said at least second non-metallic front plate with said non-metallic container.

6. Membrane anode system according to claim 4 characterized in that the anode can be individually removed from or inserted into the at least two-side membrane anode modular unit without that the entire at least two-side membrane anode modular unit has to be removed from or inserted into the reaction tank.

7. Membrane anode system according claim 1 characterized in that each membrane is not in direct contact with each anode.

8. Membrane anode system according claim 1 characterized in that each membrane is a cation ion-exchange membrane and/or wherein each anode is an insoluble anode.

9. Method for electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated characterized in that the method uses at least a membrane anode system comprising at least a reaction tank, at least a first membrane, at least an anode, at least a cathode, at least a first anolyte compartment, and at least a catholyte compartment; characterized in that the at least first membrane is arranged between the anode and the cathode, wherein the at least first membrane has a distance to the anode ranging from 0.5 mm to 5 mm.

10. Method according to claim 9 characterized in that the method comprises at least an anolyte feeding system for controlling and/or regulating of at least an anolyte volume flow for providing at least an anolyte to the at least first anolyte compartment or to the at least first and second anolyte compartments of the membrane anode system; wherein said anolyte feeding system comprises at least an anolyte tank, at least a dosing pump, and at least a dosing nozzle; wherein the anolyte volume flow is running from the anolyte tank to the dosing pump, further to the dosing nozzle, and further to the at least first anolyte compartment or to the at least first and second anolyte compartments of the membrane anode system.

11. Method according to claim 10 characterized in that the anolyte feeding system is not using flow meters and ball valves for controlling and/or regulating the anolyte volume flow.

12. Method according to claim 10 characterized in that the anolyte volume flow is controlled and/or regulated in such a way that the anolyte feeding system is a closed circulating system, wherein the anolyte volume flow after leaving again the at least first anolyte compartment or the at least first and second anolyte compartments of the membrane anode system flows back to the initial anolyte tank.

13. Method according to claim 9 characterized in that the anolyte is an aqueous liquid.

14. Method according to claim 9 characterized in that the anolyte is substantially free of any acids.

15. (canceled)

16. Membrane anode system according to claim 2 characterized in that the at least one-side membrane anode modular unit provides at least a first encapsulation of the at least first membrane, the at least first anolyte compartment and the anode by encapsulating the at least first non-metallic front plate with the non-metallic container; wherein the at least one-side membrane anode modular unit further comprises at least a first sealing element, which is sealing said at least first encapsulation of said at least first non-metallic front plate with said non-metallic container.

17. Membrane anode system according to claim 2 characterized in that the membrane anode system further comprises at least a second non-metallic front plate having a plurality of openings, at least a second membrane, and at least a second anolyte compartment between the at least second membrane and the anode; wherein the anode comprises at least a first side comprising a first anode surface and at least a second side comprising a second anode surface, wherein the first side of the anode is oppositely arranged to the second side of the anode; wherein on the first side of the anode the at least first membrane and the at least first non-metallic front plate are arranged in a parallel manner to the surface of said first side of the anode while on the second side of the anode the at least second membrane and the at least second non-metallic front plate are arranged in a parallel manner to the surface of said second side of the anode; wherein the at least first and second membrane together with the at least first and second non-metallic front plate, the non-metallic container, the at least first and second anolyte compartment, and the anode form together at least a two-side membrane anode modular unit.

18. Membrane anode system according claim 5 characterized in that the anode can be individually removed from or inserted into the at least two-side membrane anode modular unit without that the entire at least two-side membrane anode modular unit has to be removed from or inserted into the reaction tank.

19. Method according to claim 11 characterized in that the anolyte volume flow is controlled and/or regulated in such a way that the anolyte feeding system is a closed circulating system, wherein the anolyte volume flow after leaving again the at least first anolyte compartment or the at least first and second anolyte compartments of the membrane anode system flows back to the initial anolyte tank.

20. Membrane anode system according to claim 1 wherein the first non-metallic front plate is made of polypropylene.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0037] As used herein, the term “membrane anode system”, when applied for electrolytic zinc-nickel alloy deposition in accordance with the present invention, refers to a system, which comprises at least a reaction tank, at least a membrane, at least an anode and at least a cathode. These fundamental parts of such a system are always used in membrane based electrolytic zinc-nickel alloy deposition systems.

[0038] Herein, the arrangement of the membrane defines the parts of the reaction tank, which represent the anolyte compartment and the catholyte compartment. This nomenclature is commonly used in the electroplating industry for a membrane based system working with anodes and cathodes (most commonly the substrates to be treated).

[0039] The present invention has been found to be suitable (membrane anode system and method for deposition, both) for barrel and rack plating processes.

[0040] As used herein, the term “distance”, when applied for electrolytic zinc-nickel alloy deposition in accordance with the present invention, refers to the distance between the site of a surface of the anode and the site of an oppositely arranged surface of a membrane being closest together.

[0041] Herein, it is advantageous to make use of flat anodes, which are arranged in a parallel manner to the respective membrane in order to provide a constant distance of the respective surface of the anode to the respective membrane.

[0042] Herein, it is further advantageous to make use of flat membranes, which are arranged in a parallel manner to the anode, preferably to a flat anode, in order to provide a constant distance of the respective surface of the anode, preferably of a flat anode, to the respective membrane, preferably to the flat membrane.

[0043] In the most preferred embodiment, a flat membrane is arranged in a parallel manner to a flat anode leading to a constant distance between the respective surfaces of the membrane and the anode over the entire respective surfaces of the membrane and the anode, which are oppositely arranged against each other.

[0044] The above-cited variations of anodes and membranes are of course also suitable and provided for all other embodiments of the present invention, even when not explicitly repeated for each further embodiment in the following.

[0045] According to the general disclosure of the present text, the membrane anode system further preferably comprises at least a first non-metallic front plate having a plurality of openings and at least a non-metallic container, wherein said at least first non-metallic front plate and said non-metallic container form together with the at least first membrane, the anode, and the at least first anolyte compartment between the first membrane and the anode, at least a one-side membrane anode modular unit.

[0046] Preferred is a membrane anode system of the present invention, wherein the at least one-side membrane anode modular unit provides at least a first encapsulation of the at least first membrane, the at least first anolyte compartment and the anode by encapsulating the at least first non-metallic front plate with the non-metallic container; wherein the at least one-side membrane anode modular unit further comprises at least a first sealing element, which is sealing said at least first encapsulation of said at least first non-metallic front plate with said non-metallic container.

[0047] This offers the advantage that such a one-side membrane anode modular unit provides a very compact design and facilitates maintenance work such as replacements by removing or inserting the entire one-side membrane anode modular unit from or into the reaction tank.

[0048] Such a one-side membrane anode modular unit is provided in such a way that ions can pass through the plurality of openings of the at least first non-metallic front plate, normally made of PP (polypropylene), to reach the at least first membrane and to migrate through said at least first membrane to arrive at the at least first anolyte compartment; and vice versa.

[0049] In a preferred embodiment, the membrane anode system further comprises at least a second non-metallic front plate having a plurality of openings, at least a second membrane, and at least a second anolyte compartment between the at least second membrane and the anode; wherein the anode comprises at least a first side comprising a first anode surface and at least a second side comprising a second anode surface, wherein the first side of the anode is oppositely arranged to the second side of the anode; wherein on the first side of the anode the at least first membrane and the at least first non-metallic front plate are arranged in a parallel manner to the surface of said first side of the anode while on the second side of the anode the at least second membrane and the at least second non-metallic front plate are arranged in a parallel manner to the surface of said second side of the anode; wherein the at least first and second membrane together with the at least first and second non-metallic front plate, the non-metallic container, the at least first and second anolyte compartment, and the anode form together at least a two-side membrane anode modular unit.

[0050] In a preferred embodiment thereof, the at least two-side membrane anode modular unit provides at least a first encapsulation of the at least first membrane, the at least first anolyte compartment and the anode by encapsulating the at least first non-metallic front plate with the non-metallic container; wherein the at least two-side membrane anode modular unit further comprises at least a first sealing element, which is sealing said at least first encapsulation of said at least first non-metallic front plate with said non-metallic container; and wherein the at least two-side membrane anode modular unit further provides at least a second encapsulation of the at least second membrane, the at least second anolyte compartment and the anode by encapsulating the at least second non-metallic front plate with the non-metallic container; wherein the at least two-side membrane anode modular unit further comprises at least a second sealing element, which is sealing said at least second encapsulation of said at least second non-metallic front plate with said non-metallic container.

[0051] This offers the advantage that such a two-side membrane anode modular unit provides a very compact design and facilitates maintenance work such as replacements by removing or inserting the entire two-side membrane anode modular unit from or into the reaction tank. Additionally to the one-side membrane anode modular unit described above, it offers the further advantage that such an even more compact design allows making use of two membranes being in conjunction with just one two-side membrane anode modular unit, namely one on each side of the two-side membrane anode modular unit. This reduces further the space requirements for such a system by saving an entire anode.

[0052] According to the general disclosure of the present text, the anode can preferably be individually removed from or inserted into the at least one-side membrane anode modular unit or the at least two-side membrane anode modular unit without that the entire at least one-side membrane anode modular unit or the entire at least two-side membrane anode modular unit has to be removed from or inserted into the reaction tank.

[0053] In the membrane anode system of the present invention the anode can be individually removed from or inserted into the at least one-side membrane anode modular unit without that the entire at least one-side membrane anode modular unit has to be removed from or inserted into the reaction tank.

[0054] Preferred is a membrane anode system of the present invention characterized in that the anode can be individually removed from or inserted into the at least two-side membrane anode modular unit without that the entire at least two-side membrane anode modular unit has to be removed from or inserted into the reaction tank. This applies to the at least two-side membrane anode modular unit.

[0055] In the context of the present invention, this “can be” denotes “is adapted such that the anode is individually removed from or inserted into the [respective modular unit]”.

[0056] Such an embodiment offers a facilitated possibility to open a small number of fastening elements, which are comprised herein, such as a small number of screws, for removing or inserting just the anode. This enables a much easier maintenance and replacement of used anodes than being forced to remove and insert the entire membrane anode system, in particular the entire one-side or two-side membrane anode modular unit, from or into the reaction tank.

[0057] In one embodiment, each membrane is not in direct contact with each anode.

[0058] The given ranges of the distance between the membrane and the anode according to the present invention are limited on the side of the lower limit only to constructional circumstances. At a certain distance (given by the lower limit of the ranges claimed), it will be too challenging still to ensure a provision of enough anolyte volume between the membrane and the anode to keep the system running. A small anolyte liquid film on the surface of the anode has to be kept in order to keep the process running. Thus, this embodiment expresses again that this invention is not focusing on providing a direct contact membrane anode as Umicore (see background of the invention above) offers it.

[0059] In one embodiment, each membrane is a cation ion-exchange membrane and/or wherein each anode is an insoluble anode, preferably iridium coated mixed metal oxide anode.

[0060] Further, the object of the present invention is also solved by a method for electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated characterized in that the method uses at least a membrane anode system comprising [0061] at least a reaction tank, [0062] at least a first membrane, [0063] at least an anode, [0064] at least a cathode, [0065] at least a first anolyte compartment, and [0066] at least a catholyte compartment;
characterized in that the at least first membrane is arranged between the anode and the cathode, wherein the at least first membrane has a distance to the anode ranging from 0.5 mm to 5 mm.

[0067] The aforementioned regarding the membrane anode system of the present invention preferably applies likewise to the method of the present invention.

[0068] Preferred is a method of the present invention, wherein the at least first membrane has a distance to the anode ranging from 0.75 mm to 4 mm, more preferably from 1 mm to 3 mm.

[0069] More preferred is a method of the present invention, wherein the membrane anode system is the membrane anode system of the present invention, most preferably as defined above as being preferred.

[0070] A method as described above offers the advantages as described above for the different embodiments of the respective inventive membrane anode system. Additionally, such a method enables the miniaturization of supporting equipment, such as pumps, caused by the largely decreased anolyte volume, which is defined by the largely decreased distance from membrane to anode compared to the Hillebrand technology.

[0071] In a preferred embodiment of the method, the method comprises at least an anolyte feeding system for controlling and/or regulating of at least an anolyte volume flow for providing at least an anolyte to the at least first anolyte compartment or to the at least first and second anolyte compartments of the membrane anode system; wherein said anolyte feeding system comprises at least an anolyte tank, at least a dosing pump, and at least a dosing nozzle; wherein the anolyte volume flow is running from the anolyte tank to the dosing pump, further to the dosing nozzle, and further to the at least first anolyte compartment or to the at least first and second anolyte compartments of the membrane anode system.

[0072] Such an anolyte feeding system offers the advantage that the anolyte tank can be chosen much smaller compared to the Hillebrand technology caused by the largely reduced anolyte volume (see above the explanations about waste water treatment; around 100 I instead 1000 I to 3000 I). Customers are often obliged to exchange the entire anolyte tank once a week. This highlights that a reduction of 1000 I or 3000 I to 100 I highly reduces costs for the anolyte chemistry itself as well as for the subsequently required waste water treatment at customer's site.

[0073] In a more preferred embodiment of the method, the anolyte feeding system is not using flow meters and ball valves for controlling and/or regulating the anolyte volume flow.

[0074] This more preferred embodiment saves cost for the customer by avoiding the costly flow meters and ball valves. The dosing nozzles provide a constant high anolyte volume pressure in the respective anolyte conducting lines from the dosing pump to the anolyte compartment of the membrane anode system, which enables a constant and safe supporting of a plurality, preferably up to 100, membrane anode systems in an electrolytic zinc-nickel depositing method.

[0075] In a preferred embodiment of the method, the anolyte volume flow is controlled and/or regulated in such a way that the anolyte feeding system is a closed circulating system, wherein the anolyte volume flow after leaving again the at least first anolyte compartment or the at least first and second anolyte compartments of the membrane anode system flows back to the initial anolyte tank.

[0076] Such an anolyte feeding system offers the advantage that a waste water treatment becomes irrelevant and negligible, which saves enormous cost at customer's site.

[0077] In a preferred embodiment of the method, the anolyte is an aqueous liquid, preferably pure distilled water.

[0078] This embodiment of the invention offers the advantage of avoiding the use of chemistry and using instead in the ideal case pure distilled water (green technology). Such a usage of pure distilled water has not been executed up to now because the distance between the membrane and the anode has been always much higher (around 50 mm at Hillebrand) or even less (0 mm at Umicore). If the distance is chosen above the upper limit given in claim 1, the distance is too high for making use of pure distilled water, which possesses a too low electrical conductivity to be able to initiate the electrolytic deposition method. The initial current would be close to zero leading to a failure in producing enough hydrogen ions from the water. This highlights that the distance ranges claimed in claim 1 are not randomly chosen, but are required for this inventive system and method.

[0079] In a preferred embodiment of the method, the anolyte is substantially free of any acids, preferably completely free of acids, in particular free of mineral acids, especially free of sulfuric acid.

[0080] Commonly used anolytes comprise between 5 and 10% sulfuric acid instead of pure distilled water. Very often, the necessary manpower is no more available at customer's site to take care about the concentration of sulfuric acid in the anolyte. Customer's normally like to have automated systems, which run without any maintenance requirements, such as adding from time to time sulfuric acid to keep the respective concentration in the anolyte in the required range.

[0081] Additionally, such an inventive membrane anode system can be used for acid or alkaline electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated by executing such an inventive method.

[0082] The present invention refers to a use of a membrane anode system comprising [0083] at least a reaction tank, [0084] at least a first membrane, [0085] at least an anode, [0086] at least a cathode, [0087] at least a first anolyte compartment, and [0088] at least a catholyte compartment
characterized in that the at least first membrane is arranged between the anode and the cathode, wherein the at least first membrane has a distance to the anode ranging from 0.5 mm to 5 mm,
for acid or alkaline electrolytic deposition of a zinc-nickel alloy layer on a substrate to be treated by a method according to the present invention (preferably as defined as being preferred).

[0089] The aforementioned regarding the membrane anode system of the present invention and the method of the present invention preferably applies likewise to the use of the present invention.

[0090] Preferred is a use of the present invention, wherein the at least first membrane has a distance to the anode ranging from 0.75 mm to 4 mm, more preferably from 1 mm to 3 mm.

[0091] More preferred is a use of the present invention, wherein the membrane anode system is the membrane anode system of the present invention, most preferably the membrane anode system as defined above as being preferred.

[0092] The present invention thus addresses the problem of minimizing the required volume of anolyte leading to a minimized effort for waste water treatment, ideally even to an avoiding of waste water treatment at all, while at the same time in a preferred embodiment of the present invention pure distilled water without any amount of sulfuric acid can be used as anolyte, which has never been possible up to now.

[0093] While the principles of the invention have been explained in relation to certain particular embodiments, and are provided for purposes of illustration, it is to be understood that various modifications thereof will become apparent to those skilled in the art upon reading the specification. Therefore, it is to be understood that the invention disclosed herein is intended to cover such modifications as fall within the scope of the appended claims. The scope of the invention is limited only by the scope of the appended claims.