Abstract:
An electroplating apparatus carries out an electroplating on a work by using an insoluble anode for keeping the electrolyte clean, and, thereafter, makes up ionized metal into the electrolyte by respectively connecting a soluble anode and the insoluble anode with a positive electrode and a negative electrode, thereby preventing an operator from the make-up work.

Description:
FIELD OF THE INVENTION 
     This invention relates to an electroplating and, more particularly, to an electroplating apparatus and a method using the apparatus. 
     DESCRIPTION OF THE RELATED ART 
     A typical example of the electroplating apparatus is illustrated in FIG. 1 of the drawings, and comprises an electrolysis vessel 1 for electrolyte 2, a soluble anode 3 and an electric power source 4. The anode 3 is connected with a positive electrode 4a of the electric power source 4. 
     In the electroplating, a work 5 is dipped into the electrolyte 2, and is connected with a negative electrode 4b of the electric power source 4. While current is flowing through the electrolyte 2 between the anode 3 and the work 5, the following ionic reaction takes place at the anode 3. 
     
         M→M.sup.+ +e.sup.-                                  ( 1) 
    
     where M is the metal forming the anode 3. The metal ion M +   is supplied from the anode 3 into the electrolyte 2, and the metal ion M +  travels through the electrolyte 2 toward the work 5. The metal M is deposited on the work 5 as follows. 
     
         M.sup.+ +e.sup.- →M                                 (2) 
    
     Thus, the metal M is ionized at the anode 3, and the metal ion M +  is deionized at the work 5. As a result, the ion concentration in the electrolyte 2 is theoretically constant. 
     On the other hand, if the soluble anode 3 is replaced with an insoluble anode, the following reaction takes place around the insoluble anode. 
     
         2OH.sup.- →H.sub.2 O+O.sub.2 /2+2e.sup.-            ( 3) 
    
     The metal ion M in the electrolyte 2 is reacted with the anion at the work 5. 
     
         M.sup.+ +e.sup.- →M                                 (4) 
    
     Thus, the metal ion M +  in the electrolyte 2 is consumed at the work 5 for the electroplating, and the insoluble anode does not supplement the metal ion M + . As a result, the ion concentration of the electrolyte 2 is decreased with time, and an operator supplements the metal ion +  to the electrolyte 2. 
     The electroplating apparatus with the soluble anode 3 encounters a problem in that the metal film deposited on the work 5 is not high in quality. This is because of the fact that sludge dissolves into the electrolyte 2 during the ionization at the anode 3, and the sludge is mixed into the deposited metal film. However, the operator is free from the supplement of the metal ion M + . 
     On the other hand, the electroplating apparatus with the insoluble anode encounters a problem in the periodical supplement of the metal ion into the electrolyte 2. However, the deposited metal is higher in quality than that of the metal film deposited by using the soluble anode 3. 
     Thus, there is a trade-off between the soluble anode 3 and the insoluble anode, and the high quality is incompatible with the simple electroplating. 
     SUMMARY OF THE INVENTION 
     It is therefore an important object of the present invention to provide an electroplating apparatus which reconcile a high quality deposited metal film and a simple electroplating work. 
     It is another important object of the present invention to provide a method for the electroplating. 
     To accomplish the object, the present invention proposes to selectively use a soluble anode and an insoluble anode both dipped in electrolyte together with a work. 
     In accordance with one aspect of the present invention, there is provided an electroplating apparatus used for electroplating a substance on a work, comprising: a) an electrolysis vessel filled with an electrolyte; b) a soluble conductive member dipped in the electrolyte and containing the substance; c) an insoluble conductive member spaced apart from the soluble conductive member in the electrolyte; d) a cathode member retaining the work in the electrolyte in spacing relation to the insoluble conductive member; e) an electric power source having a positive electrode and a negative electrode; and f) a switching unit having a first input port connected with the positive electrode, a second input port connected with the negative electrode, a first output port connected with the insoluble conductive member, a second output port connected with the cathode member and a third output port connected with the soluble conductive member, and shifted between a first position and a second position, the switching unit connecting the first and second input ports with the first and second output ports in the first position and with the third and second output ports. 
     The apparatus may have a filter means provided in association with the soluble conductive member, and operative to filter off a sludge produced from the soluble conductive member during an ionization of the substance. 
     In accordance with another aspect of the present invention, there is provided a method of electroplating comprising the steps of: a) preparing an electrolysis vessel filled with an electrolyte containing an ionized substance, a soluble conductive member dipped in the electrolyte and containing a substance to be ionized, an insoluble conductive member spaced apart from the soluble conductive member in the electrolyte, and a cathode retaining a work in the electrolyte in spacing relation to the insoluble conductive member, b) causing current to flow between the soluble conductive member and the insoluble conductive member for depositing the substance on the insoluble conductive member; and c) causing current to flow between the insoluble conductive member and the work for depositing the substance on said work. 
     A filter means may be provided in association with the soluble conductive member for filtering off a sludge produced from the soluble conductive member during an ionization of the substance. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features and advantages of the electroplating apparatus and the method according to the present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a cross sectional view showing the prior art electroplating apparatus; 
     FIG. 2 is a cross sectional view showing an electroplating apparatus according to the present invention; 
     FIG. 3 is a cross sectional view showing the electroplating apparatus in a plating phase; 
     FIG. 4 is a cross sectional view showing the electroplating apparatus in a make-up phase; and 
     FIG. 5 is a cross sectional view showing another electroplating apparatus according to the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     First Embodiment 
     Referring to FIG. 2 of the drawings, an electroplating apparatus embodying the present invention comprises an electrolysis vessel 11 for electrolyte 12, a soluble anode 13 dipped in the electrolyte 12, an insoluble anode 14 also dipped in the electrolyte 12 and laterally spaced apart from the soluble anode 13 and a cathode 15 also dipped in the electrolyte 12 and positioned over the insoluble anode 14. The cathode 15 can retain a work 16, and keeps the work 16 in opposing relation to the insoluble anode 14 in the electrolyte 12. The shape and the position of the insoluble anode 14 affect the uniformity of a deposited metal film on the work 16, and are carefully determined. 
     In this instance, the insoluble anode 14 is formed of platinum or titanium coated with platinum, and the soluble anode 13 is, by way of example, implemented by granulated solder 13a filled in a conductive net 13b of, for example, titanium. The substance of the soluble anode 13 is changeable depending upon a metal film deposited on the work 16. 
     The conductive net 13b is enclosed in an anode bag 17 serving as a sludge filter, and the anode bag 17 is formed of cloth in this instance. The anode bag 17 and the conductive net 13b can expose the granulated solder 13a to the electrolyte 12. However, the anode bag 17 prevents the electrolyte 12 from sludge produced from the granulated solder 13a. 
     The electroplating apparatus further comprises an electric power source 18 having a positive electrode 18a and a negative electrode 18b, and a switching unit 19 having two input ports 19a and 19b respectively connected with the positive and negative electrodes 18a and 18b. The switching unit 19 has three output ports 19c, 19d and 19e respectively connected with the insoluble anode 14, the cathode 15 and the soluble anode 13. The switching unit 19 interconnects the input ports 19a and 19b and the output ports 19c and 19d or the input ports 19a and 19b and the output ports 19e and 19d depending upon the operational phase of the electroplating apparatus. In this instance, the electric power source 18 is implemented by a rectifier. However, a direct current source is available for the electric power source 18. 
     An electroplating sequence according to the present invention has a plating phase and a make-up phase. In the plating phase, the switching unit 19 connects the input ports 19a and 19b with the output ports 19c and 19d as shown in FIG. 3, and the insoluble anode 14 is positively biased with respect to the cathode 15 and, accordingly, to the work 16. Current flows through the electrolyte 12 between the insoluble anode 14 and the work 16, and an electrolytic reaction takes place in the electrolyte 12. As a result, the metal ion is deposited on the work 16, and the work 16 is coated with a metal film 20. 
     The insoluble anode 14 does not make up the metal ion, and the ion concentration of the electrolyte 12 is decreased with time. 
     When the ion concentration reaches a critical value, the electroplating apparatus enters into the make-up phase, and the switching unit 19 connects the input ports 19a and 19b with the output ports 19e and 19d as shown in FIG. 4. Then, the soluble anode 13 is positively biased with respect to the insoluble anode 14. Current flows through the electrolyte 12 between the soluble anode 13 and the insoluble anode 14, and the soluble anode 13 supplies the metal ion into the electrolyte 12. While making up the metal ion, the anode bag 17 filters off sludge produced from the granulated solder 13a, and the metal ion is deionized at the insoluble anode 14. As a result, the metal 21 is deposited on the insoluble anode 14 without the sludge. Although the soluble anode 13 is consumed, the ion concentration of the electrolyte 12 is constant. 
     If the amount of electric charge flowing in the make-up phase is equal to the amount of electric charge flowing in the plating phase, the soluble anode 13 makes up the metal equal to the consumed metal in the plating phase. The amount of electric charge is given as the product between the current and time. 
     After the make-up phase, the electroplating apparatus returns to the plating phase, and the electric power source 18 positively biases the insoluble anode 14 with respect to the work 16 again. The deposited metal 21 is ionized into the electrolyte 12, and a metal film 20 is deposited on the work without sludge. The electrolyte 12 is maintained constant in ion concentration by ionizing the metal film 21, and the electroplating apparatus alternately repeats the make-up phase and the plating phase. 
     As will be appreciated from the foregoing description, the anode bag 17 allows the metal ion to be deposited on the insoluble anode without sludge, and keeps the quality of the metal film 20 deposited on the work 16 high. Moreover, the soluble anode 13 makes up the metal ion without an operator, and the electroplating apparatus and the method of electroplating reconciles the high quality deposited metal film and the simple electroplating work. 
     Second Embodiment 
     Turning to FIG. 5 of the drawings, another electroplating apparatus embodying the present invention is illustrated. An electrolyte, a soluble anode, an insoluble anode, a cathode, a work, an electric power source and a switching unit are similar to those of the first embodiment, and are labeled with the same references as the corresponding members and units without detailed description. 
     An electrolysis vessel 31 of the apparatus is implemented by two tanks 31a and 31b connected by conduits 31c and 31d. The insoluble anode 14 and the work 16 are dipped in the electrolyte 12 in the tank 31a, and the soluble anode 13 is dipped in the electrolyte 12 in the tank 31b. 
     A filter unit 32 and a pump unit 33 are inserted in the conduit 31c, and a pump unit 34 is provided in the conduit 31d. Since filter unit 32 filters off sludge produced from the soluble anode 13, the soluble anode 13 is not enclosed in an anode bag. The pump unit 33 forces the electrolyte 12 in the tank 31b, and causes the electrolyte 12 to flow through the filter unit 32 into the tank 31a. On the other hand, the pump unit 34 forces the electrolyte 12 in the tank 31a to return to the tank 31b. 
     The electroplating apparatus thus arranged repeatedly enters into the plating phase and the make-up phase as similar to the first embodiment, and deposits a metal film on the work 15 without sludge. 
     The electroplating apparatus implementing the second embodiment achieves all the advantages of the first embodiment. Moreover, the separated tanks 31a and 31b  results in stability of electric field around the work 16. In detail, if the electric field around the work 16 is unstable, the plating speed should be lowered in so far as the manufacturer keeps the quality of the deposited film high. If a vessel is shared between the two anodes, i.e., the soluble anode 13 and the insoluble anode 14, the electric field around the work 16 is liable to be disturbed. However, the insoluble anode 14 and the soluble anode 13 are respectively provided in the tanks 31a and 31b in the second embodiment, and the sole insoluble anode 14 keeps the electric field around the work 16 stable. As a result, the plating speed can be increased ten times larger than that of the prior art without sacrifice of the quality. 
     Although particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. 
     For example, the switching unit 18 may be responsive to a timer for changing the electroplating apparatus between the plating phase and the make-up phase, and a sensor may monitor the electrolyte for providing an appropriate timing to the switching unit 18. Moreover, any filter element is available for eliminating the sludge in so far as the filter element allows the electrolyte to pass therethrough. In the above described embodiment, current firstly flows between the insoluble anode and the work for the plating, thereafter, current flows between the soluble anode and the insoluble anode for supplement of the metal, and the plating and the supplement are repeated. However, current may firstly flow between the soluble anode and the insoluble anode, and the plating follows. 
     The apparatus and the method may be used in an electroplating of solder for a leadframe of a semiconductor device, and the apparatus plates high-purity solder on the leadframe at high-speed.