Electrode attachment to anode assembly

Abstract

The invention relates to electroplating. In particular, the invention relates to an improved anode for electroplating metals onto substrates, and to a method of electroplating metals onto substrates utilizing the anode. The anode has a solid metal portion, and a metal electrode shaft having one or more barbs projecting outwardly from a periphery of the shaft at one end of the shaft. The barbs are fixed through the body extend a distance therethrough.

What is claimed is:  
     
         1 . An anode comprising a shaped, substantially solid, metal body; a metal electrode shaft having one or more barbs projecting outwardly from a periphery of the shaft at one end of the shaft; the one or more barbs being fixed within the body.  
     
     
         2 . The anode of  claim 1  wherein the shaft comprises a plurality of barbs which are fixed within the body.  
     
     
         3 . The anode of  claim 1  wherein the one or more barbs are fixed within the body by casting the body around the one or more barbs.  
     
     
         4 . The anode of  claim 1  wherein the portion of the shaft outside of the body is absent of barbs.  
     
     
         5 . The anode of  claim 1  wherein the body comprises tin, lead, copper, aluminum, silver, bismuth, indium, antimony, tin-lead alloy, tin-silver-copper alloy, silver-bismuth alloy, or combinations thereof.  
     
     
         6 . The anode of  claim 1  wherein the body comprises from about 0% to about 100% tin and from about 0% to about 100% lead.  
     
     
         7 . The anode of  claim 1  wherein the body comprises from about 5% to about 63% tin and from about 37% to about 95% lead.  
     
     
         8 . The anode of  claim 1  wherein the shaft and one or more barbs comprise titanium, copper, silver, platinum, tantalum, stainless steel, gold or combinations thereof.  
     
     
         9 . The anode of  claim 1  wherein the shaft and one or more barbs comprise nickel plated titanium.  
     
     
         10 . The anode of  claim 1  comprising a plurality of barbs projecting outwardly from a periphery of the shaft at one end of the shaft, said barbs being fixed within the body and wherein the body comprises from about 5% to about 63% tin and from about 37% to about 95% lead; and wherein the shaft and one or more barbs comprise nickel plated titanium.  
     
     
         11 . The anode of  claim 1  wherein the body has a solid rectangular, square, circular, oval, trapezoidal, triangular, ring or irregular shape, and either with or without apertures therein.  
     
     
         12 . An anode comprising a metal electrode shaft and a shaped, substantially solid metal body cast around one end of the shaft.  
     
     
         13 . The anode of  claim 12  comprising a metal electrode shaft having one or more barbs projecting outwardly from a periphery of the shaft at one end of the shaft, a substantially solid, metal body cast around the barbs.  
     
     
         14 . A method for producing an anode which comprises: 
 a) providing a metal electrode shaft having one or more barbs projecting outwardly from a periphery of the shaft at one end of the shaft;    b) providing a shaped, substantially solid, metal body;    c) fixing the one or more barbs through the metal body.    
     
     
         15 . The method of  claim 14  comprising a plurality of barbs projecting outwardly from a periphery of the shaft at one end of the shaft, said barbs being fixed within the body and wherein the body comprises from about 5% to about 63% tin and from about 37% to about 95% lead; and wherein the shaft and one or more barbs comprise nickel plated titanium.  
     
     
         16 . A method for producing an anode which comprises: 
 a) providing a metal electrode shaft;    b) casting a molten metal around one end of the shaft and cooling the molten metal to thus form an anode comprising a solid metal body enveloping said end of the shaft; and    c) subsequently removing the anode from the mold.    
     
     
         17 . The method of  claim 16  which comprises: 
 a) providing a metal electrode shaft;  
 b) placing one end of the electrode into a fixture;  
 c) placing the fixture and the end of the electrode within the fixture into a casting mold;  
 d) casting a molten metal into the casting mold and cooling the molten metal to thus form an anode comprising a solid metal body enveloping said end of the shaft; and  
 f) subsequently removing the anode from the mold.  
 
     
     
         18 . The method of  claim 16  which comprises: 
 a) providing a metal electrode shaft;  
 b) applying a flux composition to one end of the shaft;  
 c) placing the flux applied end of the electrode into a fixture;  
 d) placing the fixture and the flux applied end of the electrode into a casting mold;  
 e) casting a molten metal into the casting mold and cooling the molten metal to thus form an anode comprising a solid metal body enveloping the flux applied end of the shaft; and  
 f) subsequently removing the anode from the mold.  
 
     
     
         19 . The method of  claim 16  wherein the flux applied end of the shaft has one or more barbs projecting outwardly from a periphery of the shaft at one end of the shaft, which one or more barbs are fixed within the body.  
     
     
         20 . The method of  claim 16  comprising a plurality of barbs projecting outwardly from a periphery of the shaft at one end of the shaft, said barbs being fixed within the body and wherein the body comprises from about 5% to about 63% tin and from about 37% to about 95% lead; and wherein the shaft and one or more barbs comprise nickel plated titanium.  
     
     
         21 . The anode produced by the method of  claim 16 .  
     
     
         22 . The anode produced by the method of  claim 17 .  
     
     
         23 . The anode produced by the method of  claim 18 .  
     
     
         24 . The anode produced by the method of  claim 19 .  
     
     
         25 . The anode produced by the method of  claim 20 .  
     
     
         26 . An electrolytic arrangement which comprises: 
 a) a vessel containing an electrically conductive fluid; and    b) the anode of  claim 1  in the electrically conductive fluid, which anode is connected to an electric circuit; and    c) a cathode in the electrically conductive fluid, which cathode is connected to an electric circuit.    
     
     
         27 . The electrolytic arrangement of  claim 26  wherein the electrically conductive fluid comprises water and at least one ionic species.  
     
     
         28 . The electrolytic arrangement of  claim 26  wherein the electrically conductive fluid comprises an ionic species derived from the anode material.  
     
     
         29 . The electrolytic arrangement of  claim 26  wherein the cathode comprises a material selected from the group consisting of semiconductors, ceramics, silicon and combinations thereof.