JP2016512574A - Electrolytic production of manganese (III) ions in concentrated sulfuric acid - Google Patents

Abstract

An electrolytic cell and a method of electrochemical oxidation of manganese (II) ions to manganese (III) ions in the electrolytic cell are described. The electrolytic cell includes (1) an electrolytic solution of manganese (II) ions in a solution of at least one acid, (2) a cathode immersed in the electrolytic solution, and (3) in the electrolytic solution. And an anode that is immersed and isolated from the cathode. Various anode materials such as glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, and lead alloys are described. After the electrolyte is oxidized to form a metastable complex of manganese (III) ions, the plateable plastic may be contacted with the metastable complex to etch the plateable plastic. In addition, a pretreatment assembly process may be performed on the plateable plastic to adjust the surface of the plastic before contacting the plateable plastic with the metastable complex.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of currently pending US patent application Ser. No. 13 / 356,004 (filed Jan. 23, 2012), now pending US patent application Ser. No. 13/677. 798 (filed on Nov. 15, 2012), which is incorporated herein by reference in its entirety.

  The present invention generally relates to an improved method for etching plateable plastics such as ABS and ABS / PC.

  It is well known in the art to plate non-conductive substrates (ie plastics) with metal for various purposes. Plastic molded products are relatively inexpensive to manufacture, and metal-plated plastics are used in many applications. For example, metal-plated plastic is used for decoration and manufacturing of electronic devices. Examples of decorative applications include automotive parts such as trim. Examples of electronic applications include printed circuits in which metal plated in a selective pattern constitutes the conductor of a printed circuit board, and metal plated plastics used for EMI shielding. ABS resins are the most commonly plated plastics for decorative purposes, and phenolic resins and epoxy resins are the most commonly plated plastics for printed circuit board manufacturing applications.

  Plating on plastic surfaces is used in the manufacture of various consumer goods. Plastic molded articles are relatively inexpensive to manufacture, and plated plastic is used in many applications such as automotive trim. There are many stages in plastic plating. The first stage provides mechanical adhesion of subsequent metal coatings and adsorption of palladium catalysts generally applied to catalyze the deposition of the initial metal layer from an autocatalytic nickel or copper plating process Etching the plastic to provide a suitable surface. After this, a deposit of at least one of copper, nickel and chromium can be applied.

  The initial etching of plastic parts is an important part of the whole process. However, only certain types of plastic parts are suitable for plating. The most common type of plastic for electroplating is acrylonitrile / butadiene / styrene (ABS) or a mixture of ABS and polycarbonate (ABS / PC). ABS consists of two phases. The first phase is a relatively hard phase made of acrylonitrile / styrene copolymer, and the second phase is a softer polybutadiene phase.

  Currently, this material is etched almost exclusively using a mixture of chromic acid and sulfuric acid which is very effective as an etchant for ABS and ABS / PC. The polybutadiene phase of the plastic contains double bonds that are oxidized with chromic acid in the polymer backbone, causing complete destruction and dissolution of the polybutadiene phase exposed on the surface of the plastic, which effectively etches the plastic surface. Give.

  One problem with the conventional chromic acid etching process is that chromic acid is a widely recognized carcinogen and is increasingly limited, and the use of chromic acid requires that it be replaced by a safer alternative whenever possible. It is a point. The use of chromic acid etchants also makes the chromic acid residue difficult to dispose of, the chromic acid residue remaining on the polymer surface to inhibit electroless deposition, and the chromic acid residue from the polymer surface following treatment It has well-known serious drawbacks such as difficulty in rinsing. Furthermore, hot hexavalent chromium sulfate solutions are naturally dangerous to workers. Burns and upper respiratory tract bleeding are common to workers routinely involved in these chromium etchants. Therefore, it is highly desirable to develop safer acidic chrome etchant alternatives.

  Early attempts to replace the use of chromic acid to etch plastics typically focused on the use of permanganate ions as an alternative to chromic acid. The use of permanganate in combination with an acid is described in U.S. Patent No. 6,053,028, which is incorporated herein by reference in its entirety. Subsequently, the use of permanganate in combination with an ionic palladium activation step was suggested in US Pat. No. 6,057,028, which is incorporated herein by reference in its entirety. The use of an acid permanganate solution in combination with a perhalo ion (eg, perchlorate or periodate) is described in US Pat. No. 6,057,028, which is incorporated herein by reference in its entirety. ing. Finally, the use of permanganate ions in the absence of alkali metal cations or alkaline earth metal cations is described in U.S. Patent No. 6,057,028, which is incorporated herein by reference in its entirety. Yes.

  Permanganate solutions are also described in U.S. Patent No. 6,053,077, which is incorporated herein by reference in its entirety. U.S. Patent No. 6,057,059 suggests the suitability of either a chromium and sulfuric acid bath or a permanganate solution to prepare the surface. In addition, US Pat. No. 6,057,028, which is incorporated herein by reference in its entirety, further describes substances such as sodium hypochlorite having an oxidation potential higher than that of the permanganate solution. A hot alkaline permanganate solution containing is described. U.S. Patent No. 6,057,028, which is incorporated herein by reference in its entirety, is an alkaline permanganate solution comprising potassium permanganate and sodium hydroxide, at elevated temperatures, i.e., about 165 ° F. Describes the use of alkaline permanganate solutions maintained at ~ 200 ° F.

  As can be readily appreciated, many etchants have been proposed as an alternative to chromic acid in the process of preparing a non-conductive substrate for metallization. However, none of these methods has been well proven for at least one of various economic, performance, and environmental reasons, and thus none of these methods has achieved commercial success. Or is not accepted by the industry as a suitable alternative to chromic acid etching. In addition, the stability of these permanganate-based etchants is poor and may lead to the formation of manganese dioxide sludge.

  The tendency of permanganate-based solutions to form sludge and undergo autolysis has been studied herein by the inventors. Under strongly acidic conditions, permanganate ions may react with hydrogen ions according to the following reaction to produce manganese (II) ions and water.

4MnO ₄ ⁻ + 12H ⁺ → 4Mn ²⁺ + 6H ₂ O + 5O ₂ (1)

  Manganese (II) ions formed by this reaction may then undergo further reactions according to the following reaction to form manganese dioxide sludge.

2MnO ₄ ⁻ + 2H ₂ O + 3Mn ²⁺ → 5MnO ₂ + 4H ⁺ (2)

  Thus, the composition of the strongly acidic permanganate solution system is essentially unstable regardless of whether permanganate ions are added by alkali metal salts or are generated electrochemically in situ. It is. Due to the poor chemical stability of acidic permanganate compared to currently used chromic acid etchants, its large-scale commercial use is impractical. Alkaline permanganate etchants are more stable and are widely used in the printed circuit board industry to etch epoxy-based printed circuit boards, but alkaline permanganate can be used as ABS or ABS / ABS / It is not effective as an etching solution for plastics such as PC. Therefore, it is unlikely that manganese (VII) is widely accepted commercially as an etchant for these materials.

  Attempts to etch ABS without the use of chromic acid have involved the use of electrochemically produced silver (II) or cobalt (III). Certain metals can be anodized and oxidized to a highly oxidized state. For example, cobalt can be oxidized from cobalt (II) to cobalt (III), and silver can be oxidized from silver (I) to silver (II).

  However, currently suitable commercial by using permanganate (either acidic or alkaline), manganese of any other oxidation state, or other acids or oxidants No plastic etchant has been successfully developed.

  Accordingly, there remains a need in the art for improved etchants that are commercially acceptable without containing chromic acid to prepare plastic substrates for subsequent electroplating. .

US Pat. No. 4,610,895 (Tubergen et al.) US Patent Application Publication No. 2005/019958 (Bengston) US Patent Application Publication No. 2009/0092757 (Satou) International Publication No. 2009/023628 (Enthone) US Pat. No. 3,625,758 (Stahl et al.) US Pat. No. 4,948,630 (Courduvelis et al.) US Pat. No. 5,648,125 (Cane)

  An object of the present invention is to provide an etching solution for a plastic substrate which does not contain chromic acid.

  It is another object of the present invention to provide a commercially acceptable plastic substrate etchant.

  Another object of the present invention is to provide an etching solution for a manganese ion-based plastic substrate.

  Yet another object of the present invention is to provide an electrode that is suitable for use in strong acid oxidizing electrolytes but is not decomposed by the electrolyte.

  Yet another object of the present invention is to provide a commercially acceptable electrode suitable for the production of manganese (III) ions in concentrated sulfuric acid.

  Yet another object of the present invention is to provide an improved pretreatment process for conditioning a plastic substrate prior to etching.

In one embodiment, the present invention generally comprises:
An electrolyte containing manganese (III) ions in a solution of sulfuric acid and a further acid selected from the group consisting of methanesulfonic acid, methanedisulfonic acid and combinations thereof;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte;
It is related with the electrolytic cell characterized by including.

In another embodiment, the present invention generally comprises:
An electrolyte containing manganese (III) ions in a solution of at least one acid;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte solution,
The present invention relates to an electrolytic cell wherein the anode includes a material selected from the group consisting of glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, lead alloy, and one or more combinations thereof.

In another embodiment, the present invention generally relates to a method for preparing a solution capable of etching a plastic substrate comprising:
Providing an electrolytic solution containing a manganese (II) ion solution in a solution of at least one acid in an electrolytic cell, wherein the electrolytic cell includes an anode and a cathode;
Applying a current to the anode and cathode of the electrolytic cell;
Oxidizing the electrolyte to form manganese (III) ions, the manganese (III) ions forming a metastable complex;
It is related with the method characterized by including.

  In another embodiment, the present invention generally relates to an electrode suitable for electrochemical oxidation of manganese (II) ions to manganese (III) ions in a strong acid solution.

In another embodiment, the present invention is generally a method of electrochemical oxidation of manganese (II) ions to manganese (III) ions comprising:
An electrolytic solution comprising a manganese (II) ion solution in a solution comprising at least one acid comprising sulfuric acid and a further acid selected from the group consisting of methanesulfonic acid, methanedisulfonic acid and combinations thereof; Providing in a bath, wherein the electrolyzer comprises an anode and a cathode;
Applying a current between the anode and the cathode;
Oxidizing the electrolyte to form manganese (III) ions, the manganese (III) ions forming a metastable complex;
It is related with the method characterized by including.

  In yet another embodiment, the present invention generally relates to a method of etching a plastic part comprising contacting the plastic part with a solution comprising manganese (III) ions and at least one acid. It is related with the method characterized by including.

  The inventors have found that trivalent manganese can be easily produced by electrolyzing divalent manganese ions at low current density in a strong acid solution, preferably concentrated sulfuric acid solution, most preferably at least 8M sulfuric acid solution. It was. More specifically, the inventors have discovered that a trivalent manganese ion solution in a strongly acidic solution can etch ABS.

  Trivalent manganese is unstable and has strong oxidizing power (standard redox potential is 1.51 with respect to a standard hydrogen electrode). In solution, trivalent manganese disproportionates to manganese dioxide and divalent manganese very rapidly by the following reaction.

2Mn ³⁺ + 2H ₂ O → MnO ₂ + Mn ²⁺ + 4H ⁺ (3)

  However, in concentrated sulfuric acid solution, trivalent manganese ions become metastable and form cherry purple / cherry red sulfate complexes. The present inventors have found that this sulfate complex is a suitable medium for ABS etching and has many advantages over prior art chromium-free etchants.

Accordingly, in one embodiment, the present invention generally relates to a method for preparing a solution capable of etching a plastic substrate comprising:
Providing an electrolytic solution containing a manganese (II) ion solution in a solution of at least one acid in an electrolytic cell, wherein the electrolytic cell includes an anode and a cathode;
Applying a current to the anode and cathode of the electrolytic cell;
Oxidizing the electrolyte to form manganese (III) ions, the manganese (III) ions forming a metastable complex;
Relates to a method comprising:

  In a preferred embodiment, the plastic substrate comprises ABS or ABS / PC.

  While it is believed that both phosphoric acid and sulfuric acid would be suitable for the composition of the present invention, in a preferred embodiment, the acid is sulfuric acid. At ambient temperature, the half-life of manganese (III) ions in 7M sulfuric acid is about 2 years. In comparison, the half-life of manganese (III) ions in similar 7M phosphoric acid was about 12 days. The very high stability of manganese (III) ions in sulfuric acid is suggested to be due to the formation of manganese-sulfate complexes and the high concentration of hydrogen ions available in sulfuric acid solutions. . A further problem with the use of phosphoric acid is the limited solubility of manganese (III) phosphate. Thus, although inorganic acids such as phosphoric acid may be available in the composition of the present invention, it is generally preferred to use sulfuric acid.

The remarkable stability of manganese (III) ions in concentrated sulfuric acid provides the following advantages when used:
1) Since the Mn (III) ions are formed at a low current density, the process power requirements are generally very low.
2) Since the anode operates at a very low current density, a small cathode in relation to the anode surface area can be used to prevent cathodic reduction of Mn (III) ions. This eliminates the need for a divided tank and simplifies the technique of an etching solution regeneration tank.
3) Since the process does not produce permanganate ions, there is no possibility of producing manganese heptaoxide in the solution (manganese heptaoxide is a serious safety problem since it is highly explosive).
4) Due to the high stability of Mn (III) ions in concentrated sulfuric acid, the etchant can be sold in a usable state. In manufacturing, in order to maintain the Mn (III) content of the etchant and prevent accumulation of Mn (II) ions, the etchant requires only a small regeneration tank on the tank side.
5) Since the other etching processes are permanganate-based, the reaction between the permanganate and Mn (II) ions results in the rapid formation of manganese dioxide “sludge” and the lifetime of the etchant is very high. Becomes shorter. This may not be a problem for Mn (III) based etching (although there may be some disproportionation over time).
6) The electrolytic production of manganese (III) of the present invention does not generate any toxic gas. Some hydrogen can be produced at the cathode, but due to the low current requirements this will be less than that produced by many plating processes.

  As described herein, in a preferred embodiment, the acid is sulfuric acid. The concentration of sulfuric acid is preferably at least 8 mol / L, more preferably from about 9 mol / L to about 15 mol / L. The concentration of sulfuric acid in the process is important. When the concentration is less than about 9 mol / L, the etching rate is slow. When the concentration is higher than about 14 mol / L, the solubility of manganese ions in the solution decreases. Also, very high concentrations of sulfuric acid tend to absorb moisture from the air and are dangerous to handle. Thus, in the most preferred embodiment, the concentration of sulfuric acid is about 12 mol / L to 13 mol / L, which is sufficiently dilute to allow safe addition of water to the etchant and etches plastic. Concentration high enough to optimize speed. At this sulfuric acid concentration, up to about 0.08M manganese sulfate can be dissolved at the preferred operating temperature for etching. For optimal etching, the concentration of manganese ions in the solution should be as high as possible.

  The manganese (II) ions are preferably selected from the group consisting of manganese sulfate, manganese carbonate, and manganese hydroxide, although other similar sources of manganese (II) ions known in the art are also available. It could also be used in the practice of the present invention. The concentration of manganese (II) ions can range from about 0.005 mol / L to a saturated concentration. In one embodiment, the electrolyte includes colloidal manganese dioxide. This may form to some extent as a natural consequence of the disproportionation of manganese (III) in solution, or may be intentionally added.

  Manganese (III) ions can be conveniently generated by electrochemical means by oxidation of manganese (II) ions. Moreover, it is preferable that electrolyte solution does not contain permanganate ion generally.

  As described herein, in order to obtain a rapid etch rate of ABS plastic, it is necessary to use a high concentration of acid. In order to form a complex with manganese ions, the presence of sulfate ions or bisulfate ions is necessary, and in order to obtain good stability of the etchant, a molar concentration of at least 8M sulfuric acid is required. It is. It has been found that for good etching of plastics, a concentration of sulfuric acid of at least about 12M is required for rapid etching. This has the effect of reducing the solubility of manganese ions in the bath, and the maximum solubility of manganese ions in the bath at the operating temperature is about 0.08M. The etch rate depends on the concentration of manganese (III) ions in the solution, and the maximum conversion to maintain stability is about 50%, thus increasing the amount of manganese that can be dissolved in the bath It would be desirable.

  The inventors have found that the amount of manganese that can be dissolved in the bath can be increased by replacing a portion of the sulfuric acid with another acid in which manganese ions are more soluble.

  The choice of suitable acid is limited. For example, hydrochloric acid produces chlorine at the anode and nitric acid produces nitric oxide at the cathode. Perchloric acid and periodic acid are expected to generate permanganate ions that can be decomposed into manganese dioxide. Organic acids are generally rapidly oxidized by manganese (III) ions. Thus, acids that have both the required stability to oxidation and the ability to increase the solubility of manganese ions in the bath are methanesulfonic acid and methanedisulfonic acid. Since the solubility of manganese (II) is much better in methanesulfonic acid (and sulfuric acid) than in methanedisulfonic acid, the former choice yields excellent results. Therefore, methanesulfonic acid is the preferred further acid and sulfuric acid is the preferred primary acid.

  Based thereon, the present invention also generally includes ABS plastics and ABS containing sulfuric acid in combination with either methanesulfonic acid or methanedisulfonic acid to obtain excellent solubility of manganese ions in the bath. / Electrolyte for etching PC plastics, comprising at least 8M sulfuric acid and comprising about 0M to about 6M methanesulfonic acid or methanedisulfonic acid, preferably about 1M to about 6M methanesulfonic acid About.

More particularly, the present invention generally includes:
An electrolyte containing manganese (III) ions in a solution of sulfuric acid and a further acid selected from the group consisting of methanesulfonic acid, methanedisulfonic acid and combinations thereof;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte;
It is related with the electrolytic cell containing.

Furthermore, the present invention generally includes:
An electrolyte containing manganese (III) ions in a solution of at least one acid;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte solution,
The anode relates to an electrolytic cell including a material selected from the group consisting of glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, lead alloy, and one or more combinations thereof.

Furthermore, the present invention generally relates to a method for electrochemical oxidation of manganese (II) ions to manganese (III) ions, comprising:
Providing an electrolytic solution containing a manganese (II) ion solution in a solution of at least one acid in an electrolytic cell, the electrolytic cell including an anode and a cathode;
Applying a current between the anode and the cathode;
Oxidizing the electrolyte to form manganese (III) ions, the manganese (III) ions forming a metastable complex;
Relates to a method comprising:

  After the electrolyte is oxidized to form a metastable complex, the plateable plastic may be immersed in the metastable complex for a period of time to etch the surface of the plateable plastic. In one embodiment, the plateable plastic is immersed in the metastable complex at a temperature between 30 ° C and 80 ° C. The etching rate increases with temperature, and is slow below 50 ° C.

  The upper temperature limit is determined by the nature of the plastic being etched. In the preferred embodiment, the temperature of the electrolyte is maintained at about 50 ° C. to about 70 ° C., especially when etching ABS material, because ABS begins to deform above 70 ° C. The immersion time of the plastic in the electrolyte is preferably about 10 minutes to about 30 minutes.

  Articles etched in this manner can then be electroplated using conventional pretreatments of plated plastics, or the etched surfaces of plastics can be adhered to paints, lacquers, or other surface coatings. It can be used to enhance the properties.

  The concentration of manganese (II) ions used in the etching solution of the present invention can be determined using cyclic voltammetry. Since oxidation is diffusion controlled, efficient stirring of the etchant is required during the electrolytic oxidation process.

  The anode and cathode that can be used in the electrolyzer described herein can include a variety of materials. The cathode can include a material selected from the group consisting of platinum, platinized titanium, niobium, iridium oxide coated titanium, and lead. In a preferred embodiment, the cathode comprises platinum or platinized titanium. In another preferred embodiment, the cathode comprises lead. The anode can also include platinized titanium, platinum, iridium oxide / tantalum oxide, niobium, boron doped diamond, or any other suitable material.

  We have found that the combination of manganese (III) ions and concentrated sulfuric acid (i.e., 8 mol / L to 15 mol / L) can etch ABS plastics, while the etchant contains manganese (III) ions. It has been found that it is also very corrosive to the electrodes required to produce. Specifically, an anode having a titanium substrate can be rapidly decomposed by an etchant.

Therefore, various other electrode materials such as lead and graphite were tested in an attempt to determine a more suitable electrode material. Glassy carbon and reticulated vitreous carbon is more robust, (based on the nominal surface area) preferably when the current of 0.1A ^/ dm ² ~0.4A ^/ dm 2 is applied, manganese (III) ions Found that can be generated. It has also been found that the anode may be made from a carbon fiber fabric because glassy carbon and reticulated glassy carbon can be cost-effective to use as electrodes in commercial applications. .

Carbon fibers are made from polyacrylonitrile (PAN) fibers. These fibers go through an oxidation step at elevated temperature followed by a carbonization step at very high temperature in an inert atmosphere. The carbon fibers are then typically used in combination with various resin systems and woven into sheets to produce high strength parts. Carbon fiber sheets also have good electrical conductivity, and the fibers typically have a turbulent (ie, disordered layer) structure. Although not wishing to be bound by theory, it is believed that this structure makes carbon fiber an effective electrode. SP ² hybrid carbon atoms in the lattice give good conductivity, while SP ³ hybrid carbon atoms bind the graphite layers together and fix them in place, thereby providing good chemical resistance. .

  Preferred materials for use in the electrodes of the present invention include carbon fiber fabrics that contain at least 95% carbon and are not impregnated with any resin. To facilitate handling and the weaving process, carbon fibers are typically sized with an epoxy resin, which can contain up to 2% of the fiber weight. At this low rate, when used as an electrode, epoxy sizing is rapidly removed by the concentrated sulfuric acid contained in the etchant. This may cause an initial slight discoloration of the etchant, but does not affect performance. Following this initial “running in” phase, the anode appears to be resistant to electrolyte and effective in oxidizing manganese (II) ions to manganese (III).

  The anode can be constructed by attaching the carbon fiber fabric material to a suitable frame with electrical contact equipment. Carbon fiber can be used as a cathode in the production of manganese (III) ions, but especially when using an undivided cell, the cathode is much smaller than the anode, so lead is used. Is convenient.

The current density that can be applied to the electrolyzer is limited in part by the oxygen overvoltage to the selected anode material. As an example, for a platinized titanium anode, if the current density is greater than about 0.4 A / dm ² , the potential of the anode is high enough to liberate oxygen. At this point, since the conversion efficiency of manganese (II) ions to manganese (III) ions decreases, further increase in current density is wasted. Furthermore, operating the anode at the high overvoltage required to produce a high current density tends to produce manganese dioxide on the anode surface rather than manganese (III) ions.

  Surprisingly, it has been found that a lead anode can be effectively used in the electrolyzer described herein. Lead becomes inactive in concentrated sulfuric acid by forming a surface layer of lead sulfate with very limited solubility in sulfuric acid. This inactivates the anode until a very high overvoltage (2V higher than the standard hydrogen electrode) is reached. A voltage greater than this level produces a mixture of oxygen and lead dioxide. On the other hand, such a high operating potential favors oxygen generation and permanganate ion formation over manganese ion (III) ion formation, and in experiments using lead anodes, manganese (III) It is expected to produce only ions and not permanganate. This can be confirmed by diluting the etching solution with water. That is, manganese (III) ions cause disproportionation to produce brown manganese dioxide and manganese (II) ions. Filtration of the solution produces a substantially colorless solution characteristic of manganese (II) ions rather than the purple color of permanganate ions.

  The inventors have found that when using lead anodes, the oxidation rate of manganese (II) ions must be monitored because these anodes are very efficient in oxidizing manganese (II) ions. Thus, if the oxidation rate is not monitored and controlled, too high a proportion of manganese (II) ions will be oxidized and the remaining manganese (II) concentration will be very low. In the absence of manganese (II) ions, the anode begins to oxidize manganese (III) ions to manganese (IV), which rapidly forms insoluble manganese dioxide.

  Based on this, in order to maintain the stability of the electrolyte, it is important that the manganese (III) ions are oxidized to 50% or less, preferably 25% or less of the initial manganese (II) ion concentration. It is. In the case of a lead anode, this monitors the accumulation of manganese (III) ions by titration of the etchant or the use of a redox electrode and electrolysis when the manganese (III) content reaches the desired level. Including stopping. At a concentration of 12.5M sulfuric acid, for effective etching and maximum stability, based on a total manganese content of 0.08M, manganese (III) ion concentration above 0.01M and not above 0.04M It is necessary to have.

  The anode can include lead or a suitable lead alloy, and the type of alloy selected can affect the conversion efficiency. Pure lead, or lead containing a small percentage of tin, is particularly effective and produces a conversion efficiency of about 70%. It was also found that surprisingly high current density can be applied with moderate agitation and this conversion rate can be maintained.

  It was observed that when the electrolysis was extended using a lead anode, a final manganese dioxide film was formed. Once a significant amount of manganese dioxide nucleates on the electrode surface, it tends to grow very quickly and thickly. However, manganese dioxide is easily electrochemically reduced back to manganese (II) ions. Therefore, accumulation of manganese dioxide can be reduced or eliminated by periodically reversing the cell current. In order to reduce the amount of manganese dioxide deposited on the surface back to manganese (II) ions, the time between current reversals is not important as long as sufficient Coulomb charges are applied during the inversion phase. .

  Based on that, when using lead and lead alloy electrodes for the purpose of etching ABS or ABS / PC to produce manganese (III) ions in sulfuric acid solution, the bath is stable and an excess amount of manganese dioxide is removed. The electrolysis process is preferably 0.01M-0.O based on a total manganese content of 0.08M manganese (III) ions so that an effective amount of manganese (II) ions remains in the solution so as not to precipitate. Interrupted when the preferred operating concentration of 04M is reached. Suitable electrode materials include, for example, pure lead, lead antimony containing about 4% antimony, lead tin anodes containing up to 5% tin, and lead / tin / calcium anodes. Other suitable lead alloys can also be used in the practice of the present invention. Also, the use of periodically reversed current prevents the accumulation of manganese dioxide film on the anode. This is useful for maintaining the conversion efficiency of the anode and reducing or eliminating the need to remove and clean the etching tank or regeneration tank anode.

  In order to efficiently produce manganese (III) ions, it is generally necessary to use an anode area that is larger than the area of the cathode. Preferably, the anode to cathode area ratio is at least about 10: 1. This allows the cathode to be immersed directly in the electrolyte and does not need to have a divided bath. This process can work with a split tank arrangement, but this leads to unnecessary complexity and cost.

  The invention will now be described with reference to the following non-limiting examples.

Comparative Example 1
A 0.08 mol / L manganese (II) sulfate solution (500 mL) in 12.5 mol / L sulfuric acid was heated to 70 ° C., and a piece of ABS of quality that could be plated was immersed in the solution. Even after 1 hour of immersion in this solution, no identifiable etching of the test panel was observed, and the surface was not “wetted” during rinsing, and the water film could not be retained without breaks.

Example 1
The anode of platinum-plated titanium surface area of 1 dm ^2, and a cathode of platinized titanium surface area of 0.01Dm ^2, by dipping to apply a current of 200 mA 5 hours in the solution, the solution of Comparative Example 1 Electrolyzed.

  During this electrolysis, a color change of the solution from almost colorless to very deep purple / red was observed. It was confirmed that no permanganate ion was present.

  The solution was then heated to 70 ° C. and a plateable quality ABS piece was immersed in the solution. After 10 minutes of immersion, the specimens were completely wetted and kept the water film unbroken after rinsing. After soaking for 20 minutes, the samples were rinsed with water, dried and observed using a scanning electron microscope (SEM). By this test, the specimen was sufficiently etched and many etch pits were observed.

Example 2
A solution containing 12.5 M sulfuric acid and 0.08 M manganese (II) sulfate was electrolyzed at a current density of 0.2 A / dm ² using a platinum plated titanium anode. In order to prevent cathodic reduction of Mn (III) ions produced at the anode, a platinum plated titanium cathode having a surface area of less than 1% of the surface area of the anode was used. A sufficient length of electrolysis was performed to pass enough Coulomb to oxidize all the manganese (II) ions to manganese (III). The resulting solution was deep cherry purple / cherry red. No permanganate ions were produced during this step. This was also confirmed by visible spectroscopy. That is, the Mn (III) ion gave an absorption spectrum that was completely different from that of the permanganate solution.

Example 3
The etchant prepared as described above in Example 2 was heated to 65 ° C. to 70 ° C. on a magnetic stirrer / hot plate, and ABS specimens were immersed in the solution for 20 and 30 minutes. Some of these specimens were observed by SEM, and some were plated in the normal plastic pretreatment sequence (M reduction-neutralization, presoaking, activation, promotion, electroless nickel, 25 μm-30 μm). Up to copper plating). These specimens were then annealed and subjected to a peel strength test using an Instron testing machine.

  Peel strength tests performed on specimens plated for 30 minutes showed peel strengths ranging from about 1.5 N / cm to 4 N / cm.

Cyclic voltammograms were obtained from solutions containing 12.5 M sulfuric acid and 0.08 M manganese sulfate on platinum rotating disk electrodes (RDE) having a surface area of 0.196 cm ² at various rotational speeds. A model 263A potentiostat and a silver / silver chloride reference electrode were used in combination with the RDE.

  In all cases, the forward scan peaked around 1.6V versus Ag / AgCl, followed by a plateau up to around 1.75V, followed by an increase in current. The reverse scan produced a similar plateau (peak near 1.52 V at slightly lower current). The dependence of these results on the rotation speed of the electrode indicates that mass transfer rate limiting is the main factor in this mechanism. The plateau indicates the potential range where Mn (III) ions are formed by electrochemical oxidation.

A constant voltage scan was performed at 1.7V. It was observed that the current first dropped and then increased with time. Current density at this potential ^{spans 0.15A / dm 2 ~0.4A / dm 2} .

Following this experiment, constant current measurement was performed at a constant current density of 0.3 A / dm ² . Initially, the applied current density was achieved at a potential of about 1.5V, but as the experiment progressed, a potential increase to about 1.75V was observed after about 2400 seconds.

  After an etching period of 10 minutes or more, the surface of the ABS specimen was observed to be completely wetted, and the water film could be kept intact after rinsing. After 20 or 30 minutes, the panel was significantly etched.

Example 4
A solution containing 10.5 M sulfuric acid and 2 M methanesulfonic acid was formulated. At a temperature of 68 ° C. to 70 ° C., when dissolving manganese sulfate in 12.5M sulfuric acid solution, only 0.08M can be dissolved, whereas 0.16M manganese sulfate is easy It was possible to dissolve in The formulation is electrolyzed to produce manganese (III) with a manganese (III) ion concentration of 0.015 M, which is obtained from a 12.5 M sulfuric acid solution having a manganese (III) concentration of 0.015 M. An etching rate equivalent to that obtained was given.

  Electrolysis was continued in the bath of Example 4 and the other panels were etched until the manganese (III) content reached 0.04M. With this high manganese (III) ion concentration, an improved etch rate (about 25% higher than that obtained with a concentration of 0.015 M) was obtained.

Comparative Example 2
An electrode containing graphite and having a nominal measured surface area of 1 dm ² was immersed at a temperature of 65 ° C. in a 500 mL solution containing 0.08 M manganese sulfate in 12.5 M sulfuric acid. The cathode of this cell was a lead piece having a nominal measured surface area of 0.1 dm ² . Applying a current of 0.25A to the bath was applied nominal anode current density of 0.25A / dm ^2, and the nominal cathode current density of 2.5A / dm ^2.

  It was observed that the graphite anode collapsed rapidly and decomposed in less than 1 hour of electrolysis. Moreover, oxidation from manganese (II) ions to manganese (III) was not observed.

Comparative Example 3
An electrode comprising a titanium substrate having a tantalum oxide / iridium oxide mixed coating (50% tantalum oxide, 50% iridium oxide) and having a nominal measured surface area of 1 dm ² is 0.08 M sulfuric acid in 12.5 M sulfuric acid. It was immersed at a temperature of 65 ° C. in a 500 mL solution containing manganese. The cathode of this cell was a lead piece having a nominal measured surface area of 0.1 dm ² . Applying a current of 0.25A to the bath was applied nominal anode current density of 0.25A / dm ^2, and the nominal cathode current density of 2.5A / dm ^2.

  It was observed that manganese (III) was rapidly formed in the solution, and the resulting solution can etch the ABS plastic to produce good adhesion during subsequent electroplating of the treated plastic Met. However, after a 2 week operating period (8 hours / day of electrolysis of the solution), it was observed that the coating lifted from the titanium substrate and the titanium substrate itself dissolved in the solution.

Comparative Example 4
An electrode comprising a titanium substrate coated with platinum and having a nominal measured surface area of 1 dm ² was immersed in a 500 mL solution containing 0.08 M manganese sulfate in 12.5 M sulfuric acid at a temperature of 65 ° C. The cathode of this cell was a lead piece having a nominal measured surface area of 0.1 dm ² . Applying a current of 0.25A to the bath was applied nominal anode current density of 0.25A / dm ^2, and the nominal cathode current density of 2.5A / dm ^2.

  It was observed that manganese (III) was rapidly formed in the solution, and the resulting solution can etch the ABS plastic to produce good adhesion during subsequent electroplating of the treated plastic Met. However, after a 2 week operating period (8 hours / day of electrolysis of the solution), it was observed that the coating lifted from the titanium substrate and the titanium substrate itself dissolved in the solution.

Example 5
An electrode containing glassy carbon and having a nominal measured surface area of 0.125 dm ² was immersed in a 100 mL solution containing 0.08 M manganese sulfate in 12.5 M sulfuric acid at a temperature of 65 ° C. The cathode of this cell was a platinum wire with a nominal measured surface area of 0.0125 dm ² . And applying a current of 0.031A to the bath was applied nominal anode current density of 0.25A / dm ^2, and the nominal cathode current density of 2.5A / dm ^2.

  It was observed that manganese (III) was rapidly formed in the solution, and the resulting solution can etch the ABS plastic to produce good adhesion during subsequent electroplating of the treated plastic Met. The electrode appeared to be unaffected by extending the period of electrolysis.

Example 6
An electrode comprising carbon fiber fabric pieces (1.5% epoxy-sized, Panex 35 50K Tow, available from Zoltek Corporation) was attached to a plastic frame composed of polyvinylidene fluoride (PVDF). An electrode having a nominal measured surface area of 1 dm ² was immersed at a temperature of 65 ° C. in a 500 mL solution containing 0.08 M manganese sulfate in 12.5 M sulfuric acid. The cathode of this cell was a lead piece having a nominal measured surface area of 0.1 dm ² . Applying a current of 0.25A to the bath was applied nominal anode current density of 0.25A / dm ^2, and the nominal cathode current density of 2.5A / dm ^2.

  It was observed that manganese (III) was rapidly formed in the solution, and the resulting solution can etch the ABS plastic to produce good adhesion during subsequent electroplating of the treated plastic Met. The electrode appeared to be unaffected by extending the period of electrolysis. No observable deterioration was detected after electrolysis over 2 weeks using this electrode. This material is suitable for many commercial applications because of its low cost and availability.

Example 7
An anode made of lead having an effective surface area of 0.4 dm ² (ie, the back side of the electrode is not totaled) is placed in a beaker containing 2 L of a solution containing 0.08 M manganese sulfate in 12.5 M sulfuric acid. And dipping at a temperature of 68 ° C to 70 ° C. The other electrode in the cell consisted of a lead cathode having a surface area of about 0.04 dm ² . The solution was stirred using a magnetic stirrer to cause moderate stirring on the surface of the electrolyte. A current density of 0.4 A / dm ² was applied to the anode and the ratio of manganese (III) to electrolysis time was measured. The amount of manganese (III) is determined by diluting the bath sample with phosphoric acid to prevent the disproportionation of manganese (III) and using diphenylamine dissolved in acid as an indicator in a solution of ammonium ferrous sulfate. It was measured by titration.

The experiment was repeated using a current density of 0.8 A / dm ² and 1.6A / dm ^2. Under the hydrodynamic conditions of this experiment (ie, moderate agitation using a magnetic stirrer), the conversion efficiency is the same (70%) as obtained at 0.4 Adm ² , 1.6 A / dm ^At a current density of ² , oxidation did not appear to be limited by mass transfer. In further experiments at 3.2 A / dm ² , the conversion efficiency dropped to 42% and the production rate of manganese (III) was only about 10% than that obtained at 1.6 A / dm ^2. It turns out that it is only expensive. This is because, in the stirring conditions used in this experiment, the overall critical current density for manganese generation indicates was about 1.6A / dm ^2. This corresponds to a conversion that is about four times higher than can be achieved with a platinum plated titanium anode.

  These experimental results show that manganese (III) ions are produced by electrosynthesis using manganese (II) ions in a relatively high concentration of sulfuric acid and operating at a low current density using a platinum or platinum-plated titanium anode. It has been demonstrated that further improvements in this process can be realized by using various other anode materials, including glassy carbon, carbon fiber, lead, and lead alloy anodes.

  Further, the slow etching rate of the manganese-based etching solution of the present invention compared to the etching rate obtained with the chromic acid etching solution provides a pretreatment process that increases the adhesive strength and enables the etching time to be shortened. Showed the need.

  The purpose of the pretreatment step is to condition the surface of the plastic to be etched so that the surface of the plastic is etched more quickly and uniformly, resulting in shorter etching times and better adhesion.

  The use of solvents to condition the surface of ABS plastics is known. However, since volatile solvents are often flammable and have health and safety issues (many are reproductive toxic and can cause liver damage), recent regulations have been The feasibility of using volatile solvents in the line is severely limited. Therefore, the choice of solvent is limited.

  Propylene carbonate is a relatively safe solvent with good water solubility, low toxicity, low flammability (with a flash point of 135 ° C) and is ideal from a health and safety standpoint . γ-Butyrolactone also functions, but is more toxic and is a drug that is regulated for recreational use in several countries.

  In the present invention, when the use of propylene carbonate is combined with an organic hydroxy acid such as lactic acid, glycolic acid, or gluconic acid, excellent results are obtained in combination with the manganese-based etching solution described herein. It was found to be obtained. The use of propylene carbonate alone or in combination with a wetting agent provides good adhesion and shortens the etching time, but tends to cause pitting, so etching, activation, and subsequent The aesthetic appearance of the ABS / PC mixture after plating is inadequate. The combination of propylene carbonate and these hydroxy acids in the pretreatment stage is effective in preventing this problem.

  Typically, the concentration of propylene carbonate is about 100 mL / L to about 500 mL / L, and the concentration of organic acid is about 100 mL / L to about 500 mL / L. Also, the operating temperature is typically about 20 ° C. to 70 ° C., and the immersion time is about 2 minutes to about 10 minutes.

  Thus, the present invention also generally relates to a pre-treatable composition for a platable plastic substrate comprising γ-butyrolactone or propylene carbonate in combination with an organic hydroxy acid such as lactic acid, glycolic acid, or gluconic acid. .

Comparative Example 5
A test piece composed of an ABS / PC mixture made of 45% polycarbonate was immersed in a solution containing 150 mL / L of propylene carbonate at the time and temperature shown in Table 1. Following this, the panel was rinsed and etched in a solution containing 12.5 M sulfuric acid and 0.08 M manganese, where 0.015 M manganese ions were oxidized to manganese (III). Etching was performed at a temperature of 68 ° C. to 70 ° C. for 30 minutes. Following this treatment, the panel is rinsed and using a standard plastic plating pretreatment sequence (According to Technical Data Sheet, MacDermid D34 Palladium Activator, MacDermid Accelerator, and MacDermid J64 Electroless Nickel). Activated and then electroplated with copper. The panel was examined for aesthetic appearance and a quantitative adhesion test was performed by pulling the deposit from the substrate using an Instron tensile tester. The adhesion values obtained are shown in Table 1.

（表１：接着値）

(Table 1: Adhesion values)

  It was found that the adhesion value fluctuated greatly, and spots and pitching were observed at the plating site. The copper coating also caused pitting.

Example 8
The experiment conducted in Comparative Example 5 was repeated using a pre-conditioner containing 150 mL / L of propylene carbonate and 250 mL / L of 88% lactic acid solution. The results of these tests are shown in Table 2.

（表２：接着値）

(Table 2: Adhesion values)

  Using this pretreatment solution containing lactic acid improved the consistency of adhesion. After plating, it was found that there was no spot or pitching and the aesthetic appearance was excellent.

Claims (52)

An electrolyte containing manganese (III) ions and manganese (II) ions in a solution containing sulfuric acid and a further acid selected from the group consisting of methanesulfonic acid, methanedisulfonic acid, and combinations thereof;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte;
An electrolytic cell comprising:   The electrolytic cell according to claim 1, wherein the solution contains at least 8 M sulfuric acid.   The electrolytic cell according to claim 2, wherein the solution contains at least 12 M sulfuric acid.   The electrolytic cell of claim 1, wherein the solution comprises about 1M to about 6M methanesulfonic acid or methanedisulfonic acid.   The electrolytic cell according to claim 1, wherein the solution comprises 9 mol / L to 15 mol / L sulfuric acid and about 1 M to about 6 M methanesulfonic acid.   The anode is composed of glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, lead alloy, platinum-plated titanium, platinum, iridium oxide / tantalum oxide, niobium, boron-doped diamond, and a combination of one or more thereof. The electrolytic cell of Claim 1 containing the raw material selected from.   The electrolytic cell according to claim 6, wherein the anode contains lead or a lead alloy.   The electrolytic cell according to claim 1, wherein the cathode includes a material selected from the group consisting of platinum, platinized titanium, iridium oxide / tantalum oxide, niobium, and lead.   The electrolytic cell according to claim 9, wherein the cathode contains lead.   The electrolytic cell according to claim 7, further comprising means for monitoring the concentration of Mn (II) in the solution.   The electrolytic cell according to claim 1, wherein an area of the anode is larger than an area of the cathode. An electrolyte containing manganese (III) ions and manganese (II) ions in a solution of at least one acid;
A cathode in contact with the electrolyte;
An anode in contact with the electrolyte solution,
The anode is composed of glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, lead alloy, platinum-plated titanium, platinum, iridium oxide / tantalum oxide, niobium, boron-doped diamond, and a combination of one or more thereof. An electrolytic cell comprising a material selected from: An electrochemical oxidation method of manganese (II) ions to manganese (III) ions, comprising:
An electrolytic solution comprising a manganese (II) ion solution in a solution of at least one acid and a further acid selected from the group consisting of methanesulfonic acid, methanedisulfonic acid, and combinations thereof is provided in an electrolytic cell. And wherein the electrolytic cell includes an anode and a cathode;
Applying a current between the anode and the cathode;
Oxidizing the electrolyte to form manganese (III) ions, the manganese (III) ions forming a metastable complex;
A method comprising the steps of:   The method of claim 13, wherein the at least one acid comprises a sulfuric acid solution.   The method of claim 14, wherein the at least one acid comprises sulfuric acid at a concentration of at least 8M.   The method of claim 15, wherein the electrolyte comprises at least 8 M sulfuric acid and from about 1 M to about 6 M methanesulfonic acid.   The method of claim 13, wherein the anode comprises lead or a lead alloy.   The method of claim 17, comprising monitoring the accumulation of manganese (III) ions in the solution.   19. The method of claim 18, wherein 50% or less of the initial manganese (II) ion concentration is oxidized to manganese (III) ions.   20. The method of claim 19, wherein 25% or less of the initial manganese (II) ion concentration is oxidized to manganese (III) ions.   19. The method of claim 18, wherein the redox electrode is used to monitor the accumulation of manganese (III) ions and the electrolysis is stopped when the manganese (III) content reaches a desired level.   19. The method of claim 18, wherein the accumulation of manganese (III) ions is monitored by titration of the etchant and electrolysis is stopped when the manganese (III) content reaches a desired level.   14. The method of claim 13, comprising periodically reversing the current in the electrolytic cell, thereby preventing manganese dioxide accumulation on the anode.   14. The method of claim 13, further comprising contacting a plateable plastic with the metastable complex for a period of time and etching the plateable plastic.   Prior to contacting the plateable plastic with the metastable complex, the plateable plastic is contacted with a pretreatment composition to condition the surface of the plateable plastic, the pretreatment composition being 25. The method of claim 24, comprising a solvent selected from the group consisting of: propylene carbonate, γ-butyrolactone, and combinations thereof.   26. The method of claim 25, wherein the solvent comprises propylene carbonate.   26. The method of claim 25, wherein the pretreatment liquid further comprises an organic hydroxy acid.   28. The method of claim 27, wherein the organic hydroxy acid is selected from the group consisting of lactic acid, glycolic acid, gluconic acid, and one or more combinations thereof.   19. The method of claim 18, further comprising monitoring the concentration of manganese (II) ions in the solution.   28. The method of claim 27, wherein the pretreatment composition is maintained at a temperature of about 20 <0> C to about 70 <0> C, and the plateable plastic is contacted with the pretreatment composition for about 2 minutes to about 10 minutes.   14. The method of claim 13, wherein the manganese (II) ion is derived from a compound selected from the group consisting of manganese sulfate, manganese carbonate, and manganese hydroxide.   The method of claim 13, wherein the solution further comprises colloidal manganese dioxide.   The method according to claim 13, wherein the concentration of the manganese (II) ion in the electrolytic solution is about 0.005 mol / L to a saturated concentration.   The method of claim 13, wherein the cathode comprises a material selected from the group consisting of platinum, platinized titanium, iridium oxide / tantalum oxide, niobium, and lead.   The method of claim 34, wherein the cathode comprises lead.   35. The method of claim 34, wherein the cathode comprises platinized titanium or platinum. The method of claim 13 the current density of the anode is about 0.1 A / dm ² ~ about 0.4 A / dm ^2.   The method of claim 13, wherein the temperature of the electrolyte is maintained at about 30 ° C. to about 80 ° C.   The method of claim 13, wherein the electrolyte does not contain permanganate.   25. The method of claim 24, wherein the plateable plastic comprises acrylonitrile-butadiene-styrene or acrylonitrile-butadiene-styrene / polycarbonate.   A method of etching a plastic part, the method comprising the step of contacting the plastic part with a solution comprising manganese (III) ions and at least one acid.   42. The method of claim 41, wherein the at least one acid comprises sulfuric acid.   43. The method of claim 42, wherein the at least one acid further comprises methane sulfonic acid or methane disulfonic acid.   44. The method of claim 43, wherein the acid solution comprises at least 8M sulfuric acid and from about 1M to about 6M methanesulfonic acid.   42. The method of claim 41, wherein the plastic part comprises acrylonitrile / butadiene / styrene.   44. The method of claim 43, wherein the manganese (III) ions are generated in the solution by electrolytic oxidation of manganese (II).   47. The method of claim 46, wherein the electrolytic oxidation occurs at an anode in the solution, the anode comprising glassy carbon, reticulated glassy carbon, carbon fiber fabric, lead, or lead alloy.   Prior to contacting the plastic part with a solution comprising manganese (III) ions and at least one acid, the plastic part is contacted with a pretreatment composition to condition the surface of the plastic part; 42. The method of claim 41, wherein the pretreatment composition comprises a solvent selected from the group consisting of propylene carbonate, [gamma] -butyrolactone, and combinations thereof.   49. The method of claim 48, wherein the solvent comprises propylene carbonate.   49. The method of claim 48, wherein the pretreatment liquid further comprises an organic hydroxy acid.   51. The method of claim 50, wherein the organic hydroxy acid is selected from the group consisting of lactic acid, glycolic acid, gluconic acid, and one or more combinations thereof.   51. The method of claim 50, wherein the pretreatment composition comprises about 100 mL / L to about 500 mL / L propylene carbonate, and about 100 mL / L to about 500 mL / L organic hydroxy acid.