Apparatus and method for fabricating metal fibers using electroforming

Abstract

An apparatus and method for fabricating metal fibers using electroforming are provided in which continuous metal fibers can be fabricated. Here, any kind of metal which can be electroplated is electro-deposited on the surface of a negative electrode in diameter of a desired size corresponding to a plurality of non-conductive patterns of the negative electrode surface in an electrolyzer, and the electro-deposited metal is continuously separated.

What is claimed is:  
     
         1 . A metal fiber fabrication apparatus for fabricating metal fibers continuously, the metal fiber fabrication apparatus comprising: 
 an electrolyzer containing an electrolyte necessary for electro-deposition of the metal fibers to be aimed;    an insoluble positive electrode member installed in the electrolyte and connected to a negative terminal of a power supply;    a negative electrode member which is connected to a positive terminal of the power supply, and partially soaked in the electrolyte and rotatably installed at a certain distance from the positive electrode member, in which an electro-deposition surface is precisely ground; and    a plurality of non-conductive patterns installed on the outer circumferential surface of the negative electrode member, which form a plurality of annular contact windows which are parallel with each other and whose rotational directions are consistent with that of the negative electrode member,    whereby a number of the electro-deposited metal patterns are continuously exfoliated from the surface of the negative electrode member exposed in the air, in the shape corresponding to the plurality of annular contact windows according to rotation of the negative electrode member at a state where power has been applied, to thereby obtain a number of metal fibers.    
     
     
         2 . The metal fiber fabrication apparatus of  claim 1 , wherein the negative electrode member is formed of a cylindrical body which is rotatably supported, and the positive electrode member is formed of a hemisphere type of a shell which maintains a certain distance from the negative electrode member.  
     
     
         3 . The metal fiber fabrication apparatus of  claim 1 , wherein the negative electrode member may be formed of an endless loop-shaped belt which is rotatably supported, and the positive electrode member may be formed of a flat plate shape which maintains a certain distance from the lower surface of the negative electrode member which is soaked in an electrolyte.  
     
     
         4 . The metal fiber fabrication apparatus of  claim 1 , wherein the negative electrode member is made of a conductive material which does not react upon the electrolyte and the positive electrode member is made of an insoluble material where IrO 2  is coated on a Ti steel plate.  
     
     
         5 . The metal fiber fabrication apparatus of  claim 1 , wherein the respective width and depth of the annular contact windows formed on the surface of the negative electrode member by the non-conductive patterns are determined in correspondence to the width and thickness of metal fibers to be produced.  
     
     
         6 . The metal fiber fabrication apparatus of claims  1 , further comprising an electrolyte circulation unit for circulating an electrolyte to maintain a uniform composition of the electrolyte.  
     
     
         7 . The metal fiber fabrication apparatus of  claim 6 , wherein the electrolyte circulation unit comprises a circulation tube withdrawn from a lower portion of the electrolyzer in which a leading-end nozzle is positioned in a space between the negative electrode member and the positive electrode member, a filter installed in the circulation tube, for removing a foreign matter, and a circulation pump for circulating the electrolyte.  
     
     
         8 . A metal fiber fabrication apparatus for fabricating metal fibers discontinuously, the metal fiber fabrication apparatus comprising: 
 an electrolyzer containing an electrolyte necessary for electro-deposition of the metal fibers to be aimed;    an insoluble and plate-shaped positive electrode member installed in the electrolyte and connected to a negative terminal of a power supply;    a plate-shaped negative electrode member which is connected to a positive terminal of the power supply, and soaked in the electrolyte at a certain distance from the positive electrode member, in which an electro-deposition surface is precisely ground; and    a plurality of non-conductive patterns installed on the outer circumferential surface of the negative electrode member, which form a plurality of annular contact windows which are parallel with each other,    whereby a number of the electro-deposited metal patterns are discontinuously exfoliated from the surface of the negative electrode member, in the shape corresponding to the plurality of annular contact windows at a state where power has been applied, to thereby obtain a number of metal fibers.    
     
     
         9 . A metal fiber fabrication method for fabricating metal fibers continuously by using electroforming, the metal fiber fabrication method comprising the steps of: 
 filling an electrolyzer with an electrolyte necessary for electro-deposition of the metal fibers to be aimed;    applying DC (direct-current) power between an insoluble positive electrode member installed in the electrolyte and a negative electrode member which is partially soaked in the ectrolyte and rotatably installed at a certain distance from the positive electrode member, and on the precisely ground outer circumferential surface of which a plurality of non-conductive patterns which form a plurality of annular contact windows which are parallel with each other and whose rotational directions are consistent with the rotational direction of the negative electrode member are formed, to thereby electro-deposit metal to be aimed on the outer circumferential surface of the negative electrode member through the plurality of annular contact windows, and rotate the negative electrode member; and    continuously exfoliating a number of the electro-deposited metal patterns from the surface of the negative electrode member exposed in the air, in the shape corresponding to the plurality of annular contact windows according to rotation of the negative electrode member at a state to thereby obtain metal fibers.    
     
     
         10 . A metal fiber fabrication method for fabricating metal fibers discontinuously by using electroforming, the metal fiber fabrication method comprising the steps of: 
 filling an electrolyzer with an electrolyte necessary for electro-deposition of the metal fibers to be aimed;    applying DC (direct-current) power between an insoluble and plate-shaped positive electrode member installed in the electrolyte and a plate-shaped negative electrode member which is soaked in the electrolyte at a certain distance from the positive electrode member, and on the precisely ground outer circumferential surface of which a plurality of non-conductive patterns which form a plurality of annular contact windows which are parallel with each other, to thereby electro-deposit metal fibers to be aimed on the outer circumferential surface of the negative electrode member through the plurality of annular contact windows; and    exposing the negative electrode member in the air, in the shape corresponding to the plurality of annular contact windows, thereby exfoliating a number of the electro-deposited metal patterns as metal fibers.    
     
     
         11 . The metal fiber fabrication method of  claim 9  or  10 , further comprising the steps of draining and filtering the electrolyte in the lower portion of the electrolyzer so that composition of the electrolyte is uniformly maintained, and filling the filtered electrolyte into an opposing surface between the negative electrode member and the positive electrode member.