ELECTROLYTIC PRINTING ELECTRODE

Abstract: An electrode (10) for electrolytic printing on a printing medium (14) comprises a metal substrate, preferably of Ti, which has a thin layer (18) of TiO₂ between 200Å and 1,000Å deposited thereon and a tip layer (12) of RuO₂ between 5,000Å and 10,000Å on the TiO₂ layer. The RuO₂ layer is at the extremity of the electrode which during the printing is in close proximity to the printing medium. This oxide layer provides an increase in wear resistance of about two orders of magnitude over non-oxidized electrodes.

Description: ELECTROLYTIC PRINTING ELECTRODE This invention relates to electrolytic printing electrodes and methods for making the same. Electrolytic printers are currently available which employ non-consumable electrodes. A non-consumable electrode is defined as one which does not participate in the chemical reaction which produces the resulting image. While these non-consumable electrodes do not particpate in the reaction, they have been found to be subject to substantial wear. In U.S. 3,761,954 it is suggested that wear might be the result of corrosion due to arcing and other atmospheric conditions at the tip of the electrode. It is also suggested that iridium has been found to be an acceptable material for printing electrodes since it is a good conductor and also highly resistant to the corrosion that occurs at the tip of the electrode when it is in actual use. In US 4,042,936, the use of electrodes made from tungsten, iridium, silver, stainless steel or the like, is suggested. It is pointed out that one of the problems associated with electrolytic printing is wear of the electrodes and suggested that the problem may be overcome by employing a special printing medium. while noble metal oxides have been employed for electrode materials for the electrolysis of aqueous solutions containing alkaline metal halides, these solutions are not analogous to the solutions employed in electrolytic printing. In U.S. 4,100,050 it is suggested that for a highly alkaline liquor employed in electrolysis, the rate of consumption of noble metal electrodes is greater than that of the noble metal oxide electrodes. It is reported that the consumption rate is reduced by about an order of magnitude when a ruthenium electrode is replaced with a ruthenium oxide (RuO2) electrode, It should be pointed out that the liquors or solutions used for electrolysis are substantially more corrosive than those employed in electrolytic printing operations. It is nowhere suggested in the prior art that the wear rate of an electrode used for electrolytic printing is related to the dissolution rate of electrodes used in electrolysis. The invention seeks to provide a wear resistant electrode for electrolytic printing, and in particular a coating for a metallic electrode which will enhance the wear resistance of the resulting electrode. According to the invention, an electrode for electrolytic printing on a printing medium, is characterised by a region which is of an oxide of a metal from the group of Ru, Ir, Rh, Pt, or an alloy thereof, the oxide region being at an extremity of the electrode, which during printing is in close proximity to the printing medium. The invention also seeks to provide a method for applying a protective layer to an electrode to enhance the life of the electrode, and for adhering the protective layer to a metal substrate. According to this other aspect of the invention, a method of fabricating an electrode tip on a metal substrate, comprises forming a TiO2 layer onto the metal substrate, and forming an RuO2 layer onto the TiO2 layer. The scope of the invention is defined by the appended claims; and how it can be carried into effect is hereinafter particularly described with reference to the accompanying drawings, in which : FIGURE 1 is a schemtatic representation of one embodiment of an electrode according to the present invention; and FIGURE 2 is a schematic representation of an electrode test configuration employed for comparative wear studies. The present invention is an improved electrode for use in electrolytic printers. The electrode has a region which is an oxide of a metal from the group of ruthenium, iridium, rhodium, platinum or an alloy thereof. The oxide region is at the extremity of the electrode and during printing this region is in close proximity to the printing medium. The present invention also provides a method for attaching a region of the metal oxide to a metal substrate. The oxide region is attached by forming a titanium oxide layer onto the metal substrate and thereafter forming the oxide region onto the titanium oxide layer. An electrode 10 (Fig.l) for electrolytic printing on a printing medium has a region 12 which is an oxide of a metal from the group of ruthenium, iridium, rhodium, platinum, or an alloy thereof. The oxide region 12 is at the extremity of the electrode 10 which is held in closest proximity to a printing medium 14. A bus electrode 15 is maintained in contact with the printing medium 14. During printing the electrode 10 is maintained at an electrical potential which is higher than the electrical potential of the bus electrode 15. Preferably, the electrode 10 has a body of plastic or ceramic, which is metallized to form a metal substrate 16 with an electrically conductive surface. When the electrode 10 comprises a metal substrate 16 to which the oxide region 12 is attached, it is preferable to employ an intermediate layer 18 of titanium oxide (TiO2) to ensure adhesion between the oxide region 12 and the metal substrate 16. It is found that the use of ruthenium oxide (Ru02) provides a very wear resistant coating when applied to a metal substrate 16. It has also beein found that the optimum thickness for the RuO2 region is between about 5,000A and 50,000. A ruthenium oxide layer of 5,000cm is thick enough to provide good quality printing. A RuO2 layer less than 5,000i is not advisable because defects such as pinholes, adhesion failures, may occur in the RuO2 layer. With Ru02 layer thickness of about 50,000ski the electrode will print billions (milliards) of characters. Likewise, it has been found that titanium oxide (TiO2) provides a very effective bonding medium for the ruthenium oxide layer 12. It has also been found that the most effective thickness for the titanium oxide layer is from about 2009 to about 10,000A. A layer of about 2002 of TiO is of sufficient 2 thickness to provide a good crystallographic substrate for the subsequent deposition of the Ru02. The reason for employing the TiO2 layer is that TiO2 and Ru02 have compatible crystal structures (rutile structures). A minimum thickness layer of about 2002 for the TiO2 layer is necessary to provide sufficient crystallographic planes of the TiO2 structure to superimpose the isomorph RuO2 crystal. TiO2 layers of up to 10,0002 have been found to work well when the underlying metal substrate is titanium or steel. The resistance of the metal electrode 10 is not increased significantly when the TiO2 layer is maintained below about 10,0002 in thickness. While the electrode 10 is shown as a composite structure in Fig.1, it is possible to make an electrode which is composed of only the oxide, in particular RuO2 in crystal form. Comparative studies on different electrode materials were done with a series of cylindrical electrodes. Four electrodes 10 (a rhodium, a ruthenium oxide, a platinum, and another ruthenium oxide) were prepared and maintained in close proximity to the bus electrode 15, as shown in Fig.2. The electrodes 10 were maintained at a positive potential with respect to the bus electrode 15. This potential produces a current between the electrodes 10 and bus electrode 15, which is carried by the printing medium 14. After the electrodes had been used for many print cycles, the bus electrode 15 was examined. It was found that opposite the ruthenium oxide electrodes there were no deposits on the surface of the bus electrode 15 whereas opposite the metallic electrodes (rhodium and platinum), deposits of rhodium and platinum, deposits of rhodium and platinum, respectively, were found. This study indicates that a substantial portion of the wear results from metal transport from the metal electrodes 10 to the bus electrode 15. In analogous studies on Ru metal electrodes transport of Ru was observed. In order to further characterize the improvement resulting from the use of ruthenium oxide, a series of cylindrical electrodes 0.5 mm (20 mil) in diameter were prepared and tested for 105 printing cycles. The results of these tests are summarized in Table I. TABLE I Wear characteristic under printing conditions No. of print Material cycles Wear microns Pt - 100,000 20m Ru - 100,000 26pm Rh - 100,000 16pm TiO /RuO - 100,000 < O.lpm 2 2 As can be seen from examination of the test data, the use of ruthenium oxide resulted in an increase of about two orders of magnitude in the wear resistance over either the platinim, rhodium or the ruthenium electrodes. The Ru electrode was fabricated by plating Ru onto a Pt cylinder. The increase in the wear rate over the other metal electrodes can be explained by the fact that deposited metals generally have reduced wear resistance. It should furthermore be pointed out that the inherent weakness of the deposited Ru does not occur when deposited Ru is subsequently oxidized. The electrodes 10 had a 0.5 mm (20 mil) diameter. For the TiO2/Ru02 electrode a layer of 7,000A TiO2 was evaporated onto a Ti cross section and another layer of 30,000Â RuO2 was deposited onto the TiO2. A gold bus electrode 15, 2.5 mm long, 0.5 mm wide was set alongside the electrodes 10 at a distance from them of 0.1 mm. A positive voltage of 50 volts was applied to the electrodes 10, and the bus electrode 15 was earthed. Paper saturated with an electrolytic printing solution was used as the printing medium. In addition to the wear that results from the printing process there is also wear associated with mechanical abrasion between the electrode and the printing medium. In order to characterize mechanical wear, steel spheres 6.2 mm in diameter were plated with ruthenium oxide with an intermediate layer of titanium oxide. The spheres were rigidly held with 100 gm force applied between the sphere and the abrasive surface. The abrasive surface was chosen to simulate the characteristics of the printing medium. Wear tests were done both wet and dry. For comparative purposes steel spheres without the ruthenium oxide coating were tested. Steel was chosen as the most wear resistant. These results are tabulated in Table II. TABLE II Test Wear resulting from Material Condition mechanical abrasive* 5 RuO2 wet - 1.27 x 105m/pm (5 x 106 in/pm) 3 RuO2 dry - 8.89 x 103m/pm (3.5 x 10 in/pm) 3 Steel wet - 6.35 x 103m/pm (2.5 x 105 in/pm) 2 Steel dry - 2.032 x 102m/pm (8 x 103 in/pm) (*) Wear is here measured in metres per micron (inches per micron) representing the length of paper that will pass under the head at 100g force for the sample to wear 1 micron. As can be seen from examination of the data the use of ruthenium oxide increases the wear resistance by about an -4 order of magnitude. With a wear rate of 1 x 10 pm per one hour, an oxide layer of approximately 50,000 should be adequate to provide an electrode which would offer trouble free service for approximately 2 years. The thickness of the layer can be increased to increase the life expectancy of the electrode. However, an upper practical limit for the thickness of the ruthenium oxide for a composite electrode would be about 250,000 or 25 microns (1 mil). A film or layer thickness of above 50 microns (2 mils) could introduce stress factors into the RuO2 film. A preferred general method for fabricating the improved electrode of this invention consists of building up a composite on a conductive substrate. The first layer is for bonding purposes and is isomorph with Ru02, preferably TiO2. The second layer should be an electronic conductor, with reduced mechanical and electrochemical wear and is preferably RuO2. A composite electrode can be fabricated with a metal substrate 16 onto which is formed a layer of titanium oxide 18. The titanium oxide layer may be formed by depositing titanium onto the substrate 16 and thereafter oxidizing the titanium layer, or alternatively reactive ion sputtering the titanium oxide layer directly onto the metal substrate. The preferred method of depositing Ti onto the metal substrate is by evaporation, or sputtering from Ti targets. This is followed by exposure to 5066.25 pascals (0.5 atmospheres) of 2 at about 5000C. Alternatively, the metal substrate itself can be titanium. In this case, the intermediate bonding TiO2 layer can easily be formed to receive the ruthenium oxide layer by heating in 5066.25 pascals (0.5 atmosphere) of 2 at 2000C for 1 hour. Onto the titanium oxide layer, a ruthenium oxide layer is formed The ruthenium oxide layer can be formed either by depositing a ruthenium layer thereon and subsequently oxidizing the ruthenium or alternatively by reactive ion sputtering. The deposition of the ruthenium metal layer is accomplished by one of the following methods: (a) electrolysis from aqueuous ruthenium solutions, (b) by evaporation, or (c) by sputtering, from Ru metal targets. Once formed, the Ru layer is oxidized to RuO2 by exposure to 5066.25 pascals (0.5 atmospheres) of 2 at 5000C. The electrolytic deposition method is preferred because it does not require any masking.

Claims: CLAIMS 1 An electrode for electrolytic printing on a printing medium, characterized by a region (12) which is of an oxide of a metal from the group of Ru, Ir, Rh, Pt, or an alloy thereof, the oxide region (12) being at an extremity of the electrode, which during printing is in close proximity to the printing medium (14). 2 An electrode according to claim 1, in which the oxide is RuO2. 3 An electrode according to claim 2, in which the thickness of the RuO2 layer is between about 5,0002 and 50,OOO. 4 An electrode according to claim 2 or 3, including an intermediate region of TiO2 between the region of RuO2 and the body of the electrode. 5 An electrode according to claim 4, in which the thickness of the region of TiO2 is between about 200A and 10,0002. 6 An electrode according to any preceding claim in which the electrode includes an electrically conductive surface upon a substrate of metallized plastic or ceramic. 7 An electrode according to claim 6, in which the substrate metallization is of titanium. 8 A method of fabricating an electrode tip on a metal substrate, comprising forming a TiO2 layer (18) onto the metal substrate (16), and forming an RuO2 layer (12) onto the TiO2 layer. 9 A method according to claim 8, in which the TiO2 layer is formed by deposition of a layer of Ti about 200A to 1,0002 thick onto the metal substrate, and the subsequent oxidation of the Ti layer by heating the Ti layer to about 500C and exposing to oxygen at an oxygen pressure of about 5066.25 pascals (0.5 atmospheres). 10 A method according to claim 8 or 9, in which the RuO2 layer is formed by deposition of a layer of Ru about 5,0002 to 50,0002 onto the TiO2 layer, and subsequent oxidation of the Ru layer by heating to 5000C and exposing to oxygen with an oxygen pressure of about 5066.25 pascals (0.5 atmospheres).

Inventors: MITCHELL, JOSEPH WILLIAM, SAMBUCETTI, CARLOS JUAN, SHAFER, MERRILL WILBERT
Applicants: INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1981
Main classification: B41J3
IPC codes: C25D7, B41J2, G01D15, C23C14