Variable size segmented anode array for electroplating

Apparatus for electroplating an article, comprising:

• a housing including means defining a receptacle for a bath of electroplating solution;
• an anode positioned within the receptacle to contact the bath and comprising a plurality of individual anode segments arranged in a generally planar configuration, the anode segments positioned in the configuration to form a plurality of different-sized patterns which generally increase from a smaller size at a mid-location of the configuration to a larger size at an outer location of the configuration;
• the plurality of anode segments are generally U-shaped and the U-shaped segments generally nest within one another in the planar configuration;
• support means for supporting an article to be electroplated in the receptacle and in the bath at a location spaced from the planar configuration of the array;
• means for electrically energizing selected ones of the anode segments to act as anodes in an electroplating cell for electroplating;
• and
• means associated with the support means and operative for electrically connecting the article to act as a cathode in an electroplating cell.

Apparatus for electroplating a generally planar article, comprising:

• a housing including means defining a receptacle for a bath of electroplating solution;
• an anode array position within the receptacle to contact the bath and comprising a plurality of individual anode segments arranged in a generally planar configuration, the anode segments positioned in the configuration to form a plurality of different-sized patterns which generally increase from a smaller size at a mid-location of the configuration to a larger size at an outer location of the configuration;
• support means for supporting a generally planar article to be electroplated in the receptacle and in the bath generally parallel to the planar configuration of the anode at a location spaced from the planar configuration of the anode;
• means for selectively electrically energizing each of the anode segments to act as anodes in an electroplating cell for electroplating;
• means associated with the support means and operative for electrically connecting the article to act as a cathode in an electroplating cell;
• and
• a generally planar electrophoretic fines filter positioned in a generally parallel planar orientation between the anode array and the article.

A method of electroplating an article with a generally uniform thickness coating by adjusting the effective size or area of an anode to electrolytically transfer ions of the coating material from the anode at a substantially uniform deposition rate over the article, comprising the steps of:

• forming an anode of a plurality of individual anode segments,
• arranging the anode segments in a plurality of individual patterns of different sizes,
• selecting at least one of the predetermined patterns as an anode of predetermined size which has a predetermined relationship with the size of the article to result in approximately uniform ion deposition rate over the article during electroplating, and
• conducting anodic current from only the anode segments of each selected pattern to electroplate the article.