Satin nickel electroplating techniques that include homogenization units

Abstract

Certain example embodiments of this invention relate to improved electroplating techniques. More particularly, certain example embodiments of this invention relate to electroplating techniques that incorporate a homogenization unit to help maintain an emulsion within an electrolyte solution (e.g., a nickel electrolyte solution) used in creating a finish (e.g., a satin nickel finish) in an electroplating process. By varying the operational characteristics of the unit (including, for example, pressure, velocity, pore size, ultrasound wave frequency, sonication time, etc.), it becomes possible to control the emulsion particle size distribution so as, for example, increase or decrease the diameter of such particles and thereby resulting in a deposit with a desired surface topography. It will be appreciated that the variations in size will cause variation in surface topography which, in turn, will change the surface appearance.

1 . A satin nickel electroplating system, comprising:
 a satin chemistry process tank to receive a flow of a solution including an emulsion to form a bath used in electroplating an article;   a satin dosing system configured to add further emulsion to the flow at a controlled rate;   a flow meter provided between the satin dosing system and the satin chemistry process tank; and   a homogenization unit configured to break down agglomerates formed in the electroplating system and/or the bath such that the bath and the emulsion in the tank are substantially free from agglomerates larger than 25 microns in diameter.   
     
     
         2 . The system of  claim 1 , wherein the homogenization unit is located upstream of the satin dosing system. 
     
     
         3 . The system of  claim 1 , wherein the homogenization unit is operable to provide a flow so as to break down substantially all agglomerates larger than 15 microns in diameter. 
     
     
         4 . The system of  claim 1 , wherein the homogenization unit is operable to provide a flow so as to break down substantially all agglomerates larger than 10 microns in diameter. 
     
     
         5 . The system of  claim 1 , wherein the bath in the satin chemistry process tank is stable over a period of at least about 2 days. 
     
     
         6 . The system of  claim 1 , wherein the bath in the satin chemistry process tank is stable over a period of at least about 2.5 days. 
     
     
         7 . The system of  claim 1 , wherein the homogenization unit is configured to run continuously. 
     
     
         8 . The system of  claim 1 , wherein the homogenization unit is configured to run when a sensor detects agglomerates larger than a predetermined threshold. 
     
     
         9 . The system of  claim 1 , further comprising a filtration system configured to filter out at least some agglomerates. 
     
     
         10 . An electroplating system, comprising:
 a process tank for holding an electroplating bath;   a dosing system configured to provide an additive used for the electroplating bath;   a flow meter provided between the process tank and the dosing system configured to regulate the flow of the additive into the bath, the additive at least initially provided as a substantially homogenized emulsion or colloidal solution; and   at least one homogenization unit configured to break down any agglomerates of particles of the additive of a predetermined size that form over time, the predetermined size being 40 microns in diameter.   
     
     
         11 . The system of  claim 10 , wherein the predetermined size is 25 microns in diameter. 
     
     
         12 . The system of  claim 10 , wherein the predetermined size is 15 microns in diameter. 
     
     
         13 . The system of  claim 11 , wherein the homogenization unit is configured to run continuously. 
     
     
         14 . The system of  claim 11 , wherein the homogenization unit is configured to run when a sensor detects agglomerates larger than the predetermined size. 
     
     
         15 . The system of  claim 11 , further comprising a filtration system configured to filter out at least some agglomerates and/or other depleted chemicals from the electroplating bath. 
     
     
         16 . A method of making an electroplated article, the method comprising:
 providing an using an electroplating system including a process tank, a dosing system configured to provide an additive used in an electroplating bath, a flow meter provided between the process tank and the dosing system configured to regulate the flow of the additive into the bath, and at least one homogenization unit;   providing the electroplating bath to the process tank, wherein the additive is at least initially as a substantially homogenized emulsion;   breaking down, via the homogenization unit, any agglomerates of particles of the additive of a predetermined size that form over time, the predetermined size being 25 microns in diameter; and   electroplating an article such that a substantially uniform finish is provided thereon.   
     
     
         17 . The method of  claim 16 , wherein the predetermined size is 15 microns in diameter. 
     
     
         18 . The method of  claim 16 , wherein the homogenization unit is configured to run continuously. 
     
     
         19 . The method of  claim 16 , further comprising detecting agglomerates larger than the predetermined size and running the homogenization unit. 
     
     
         20 . The method of  claim 16 , further comprising:
 filtering out at least some agglomerates larger than the predetermined size; and   providing a further amount of the additive to compensate for the filtered out agglomerates.