Method of Roughening Surfaces

Cross-reference to related patent, the disclosure of which is incorporated by reference: U.S. Pat. No. 4,844,781, SANCHEZ et al.

The present invention relates generally to surface treatment of pressed graphite bodies and, more particularly, to electrochemical treatment in an alkaline solution in order to roughen the surfaces of the graphite bodies.

The term "pressed bodies" in the following description refers to filling-containing masses which are processed without tension into structural elements by compression, injection molding, and extrusion. Typical graphite pressed bodies are, for example, carbon commutators. For fastening of commutator lamella on the rotor of an electric motor, the carbon commutator is, for example, soldered to a metallic carrier. For that purpose, the carbon commutators are often provided with a solderable adhered metallic layer or coating, by means of which the carbon commutator is soldered to the carrier. For improved adhesion of the solderable metallic layer, pre-treatment of the surface of the pressed body is necessary. The previously known methods for pre-treatment of carbon commutators are mechanical roughening methods, e.g., sandblasting methods.

U.S. Pat. No. 4,844,781, SANCHEZ et al., discloses a method of surface treating carbon fibers in a substantially water-free solution of an amine compound in a bipolar solvent, preferably an aprotic bipolar solvent such as acetonitrile, dimethyl-formamide or dimethylsulfoxide ("DMSO"). This treatment leads to oxidation of the carbon fibers, which improves bonding between the fibers and an embedding matrix of synthetic resin. This bonding is a function of chemical processes which need not be detailed here.

It is an object of the present invention to improve adhesion of a metallic layer or coating applied to the surface of a graphite pressed or sintered body. The metal coating then facilitates attachment of the graphite body to a copper carrier.

Briefly, this is achieved by immersing the graphite body in an alkali metal containing aqueous solution, such as sodium hydroxide or potassium hydroxide, at a concentration of about 0.025 mol/liter to about 5 mol/liter, connecting the body as an anode, and running current through the thus-formed cell at a current density of greater than about 0.1 amperes/dm.sup.2 (A/dm.sup.2), preferably about 14 A/dm.sup.2, for two or three minutes. The solution has a pH of greater than 12. The method is performed at a temperature of 10.degree. C. to 110.degree. C. This causes oxidation of some carbon and/or constituents of the binder, leading to sloughing off from the pressed body surface of oxidation products. This forms irregular cavernous depressions or roughening, into which the metallic coating can penetrate before it hardens. Much better adhesion results.

The method of the present invention is not only faster than prior art roughening methods, but also can be integrated into the chemical or galvanic process conventionally used to apply the metallic coating to the pressed body.

It is preferred to perform the method at room temperature of about 25.degree. C., for two or three minutes, preferably for about 2.5 minutes and using a solution concentration of about 1 mol/liter. The treatment times set forth hereinabove apply to the entire method and preferably relate to the step of application of electrical current.

The drawing is an elevational view in cross-section of an apparatus for carrying out the method of the invention.

The invention will be explained with reference to a preferred use of the method, namely roughening the surface of a carbon part used in making an electrical commutator. Such carbon commutator parts serve as races or running surfaces for brushes in electric motors. The carbon commutators are generally attached to a copper body which serves as a compact carrier or substrate for the carbon commutator. A solderable adhered metallic layer is formed on the carbon commutator surface to which the copper carrier is to be attached. Solder is applied to the metallic layer, and, in a soldering step, the carbon commutator is soldered to the copper carrier. The carbon commutator of the present example is made by pressing or sintering a mixture of graphite and a binder. A suitable binder is polyphenylene sulfide (PPS), sold under the mark "RYTON" (U.S. Reg. No. 896,253 of Phillips Petroleum Co.). Specifically, "RYTON V-1" is employed. "RYTON V-1" is a powder coating product which is a "neat" resin of 100 wt. % PPS.

To improve adhesion of the metallic layer to the carbon commutator, it is necessary to roughen the surface on which the metallic layer is to be adhered. For roughening, the carbon commutator is electrochemically treated in an alkali metal containing bath, in which the commutator is connected as an anode.

The electrochemical treatment of the graphite pressed body oxidizes the carbon and/or other constituents of the binder, e.g. sulfur in the polyphenylene sulfide. This leads to sloughing off of the oxidation products from the surface of the graphite pressed body, so that cavernous recesses form on the surface. It is also within the scope of the inventive concept that the sloughing off of the oxidation products could lead to ejection of non-anodizable particles, and that those places could instead form the cavernous depressions. These cavernous depressions form engagement points for the metallic layer, analogous to press-studs or "moly" bolts, all over the interface between the graphite pressed body and the metal layer.

After the electrochemical treatment, the carbon commutator is subjected to the usual various cleaning steps. Subsequently, the metallic layer or coating is applied by conventional means to the carbon commutator surface, which is later intended to fasten to the copper carrier. The apparatus for carrying out the method of the present invention is a conventional electrolysis bath. The drawing illustrates this apparatus.

In the drawing, an alkaline solution (NaOH- or KOH-solution) forms an electrolyte 1. In electrolyte 1 are a cathode rod 2 and an anode rod 3, which are connected by electrical leads 4 to a constant voltage source 5. On the anode rod 3 are multiple brackets 7, onto each of which is disposed a carbon commutator 6. Between carbon commutator 6, bracket 7, and anode rod 3, there is an electrical connection. To prevent bracket 7 and anode rode 3 from being attacked by an oxidation reaction occurring on at the anode, they are made of a resistant metal, e.g., titantium, niobium, or tantalum. To prevent attack by a reduction reaction at the cathode, cathode rod 2 is made of iron, stainless steel, or titanium.

A pressed graphite body formed with a binder and a metal additive is immersed in a sodium hydroxide solution (NaOH concentration is 1 mol/liter). The graphite body is connected as an anode and a direct current is run through the thus-formed cell at a current density of 14 A/dm.sup.2 for two to three minutes at a temperature of 25.degree. C. The conditions for Example 1 are summarized as follows:

Solution: NaOH, concentration 1 mol/liter

Current: direct, with density 14 A/dm.sup.2

Temperature: 25.degree. C.

Time period: 2.5 minutes

Example 2 is carried out in the same manner as Example 1, except a potassium hydroxide solution is used instead of the sodium hydroxide solution. The conditions for Example 2 are summarized as follows:

Solution: KOH, concentration 1 mol/liter

Current direct, with density 14 A/dm.sup.2

Temperature: 25.degree. C.

Time period: 2.5 minutes

Various changes and modifications are possible within the scope of the inventive concept.