Electrolysis: processes – compositions used therein – and methods – Electroforming or composition therefor
Patent
1992-04-01
1995-05-23
Niebling, John
Electrolysis: processes, compositions used therein, and methods
Electroforming or composition therefor
204106, C25D 100
Patent
active
054178380
DESCRIPTION:
BRIEF SUMMARY
This invention is concerned with a metal forming process which is particularly, although not exclusively suitable for the formation of articles including profiled building elements such as copper roofing tiles, wall cladding and the like.
Of recent years, roofing tiles formed from pressed steel sheet have gained considerable popularity in the building industry due to ease of installation, relatively low unit cost, low mass and reduced structural costs. Notwithstanding the use of improved corrosion resistant finishes on such steel roofing tiles, they are quite susceptible to corrosion in regions of high air pollution or in seaside areas having high levels of airborne salt.
While it has been proposed to utilize sheet copper to produce pressed metal roofing tiles, the extremely high cost of copper sheet stock has mitigated against the use of this material.
Typically, sheet copper stock is produced initially from a solution of copper ore by an electrowinning process to produce a sheet of relatively pure copper about 3 mm thick on a stainless steel electrode measuring about 1200 mm square. The electrodeposited copper sheets are then stripped from the electrodes and then smelted down to form ingots. Such ingots are subsequently rolled in a rolling mill to produce sheet copper stock.
The major disadvantage associated with the production of sheet copper stock for manufacture of building components is the enormous value adding effect of multiple handling, transportation and processing costs as well as the costs associated with waste trimming in the final production of articles from copper sheet. Frequently, for example, copper ore is mined and a crude concentrate is produced therefrom by chemical means such as leaching, froth flotation, etc. The crude concentrate may then be transported a considerable distance to a source of cheap electricity such as a hydro-electric station. After electrodeposition, the stripped copper plates may then travel to another plant for smelting and casting and thereafter to yet another plant for smelting and casting and thereafter to yet another plant for rolling. It is estimated that marginal cost increases from the initial production of electrodeposited sheets and the purchase of sheet copper stock can increase the cost of copper as a feedstock in manufacturing processes by a factor of as much as five.
Accordingly, it is an aim of the present invention to overcome or ameliorate the disadvantages associated with the use of sheet copper stock in the manufacture of articles therefrom.
According to one aspect of the invention there is provided a method of producing contoured articles having at least one surface of metallic copper, said method comprising: concentrate obtained from beneficiation of copper ores, a layer of copper metal on an electrode of predetermined shape and configuration to produce an article having at least one exposed surface comprised substantially of copper metal.
Suitably the electrode may comprise a reusable electrode from which said article may be removed after electrodeposition.
Alternatively, the electrode may comprise a base for formation of an article of composite structure having at least one exposed surface comprised substantially of copper metal.
The electrode may be selected from any suitable electrically conductive material including metals, plastics, alloys of metals, alloys of plastics, composite materials or any combination thereof.
Alternatively the electrode may comprise a non-electrically conductive or semi-electrically conductive material having a coating of conductive material on at least one face thereof.
If required the electrode may include regions having non conductive surfaces.
The electrode may be adapted from manufacture of a single article, or a plurality of articles which may be the same or different. Preferably the copper containing solution comprises a leachate of copper ore. Alternatively, the copper containing solution may comprise a copper concentrate obtained from the treatment of copper ores.
Although the following description relat
REFERENCES:
patent: 4395313 (1983-07-01), Lindsay et al.
patent: 4484990 (1984-11-01), Bultman et al.
The Encyclopeida of Electrochemistry, Clifford A. Hampel, Ed. Reinhold Publishing Corporation, New York (1964) pp. 246, 579-581.
Electrochemistry, Principles and Applications, Edmund C. Potter, Cleaver-Hume Press Ltd., London (1956), pp. 287, 307, 310.
Mee Brendan
Niebling John
Tube Technology Pty. Ltd.
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