Articles and methods including patterned substrates formed from densified, adhered metal powders
First Claim
1. An article comprising:
- a flexible substrate;
an adhesive covering a surface of the flexible substrate; and
a densified metal powder adhered to the flexible substrate by the adhesive, wherein the densified metal powder forms a pattern.
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Accused Products
Abstract
In general the disclosure relates to manufacturing methods for producing conductive patterns on flexible substrates. For example, a layer of a metal powder composition is deposited onto an adhesive overlaying a substrate. Pressure is applied to the metal powder composition on the adhesive coated substrate web by a die having one or more projections, in order to reproduce a pattern on the substrate. The metal powder is compressed by the projections of the die, thereby densifying the powder and causing it to adhere to the adhesive in a reproduction of the die pattern. The metal powder does not adhere substantially in uncompressed regions, and may be removed. In this manner, a metal powder composition may be densified and adhered to a substrate forming a web of flexible circuit elements, for example, circuit elements such as antennas, resistors, capacitors, inductive coils, conduction pads and the like.
88 Citations
20 Claims
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1. An article comprising:
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a flexible substrate;
an adhesive covering a surface of the flexible substrate; and
a densified metal powder adhered to the flexible substrate by the adhesive, wherein the densified metal powder forms a pattern. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A process comprising:
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applying an adhesive layer to a first surface of a flexible substrate;
applying a metal powder to the adhesive layer; and
compressing the metal powder on the adhesive layer for a time and at a pressure sufficient to form a pattern of densified adhered metal powder. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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18. A system for making a continuous patterned flexible substrate, comprising:
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a web handling assembly for feeding a continuous flexible substrate bearing a first adhesive layer from a supply roll to a take-up roll;
a first powder applicator for applying a metal powder to the first adhesive layer at a position between the supply roll and the take-up roll;
a patterned die having raised elements in the form of a pattern positioned between the powder applicator and the take-up roll and configured to apply a pressure to the metal powder on the first adhesive layer for a time sufficient to densify the metal powder to at least about 90% and at most less than 100% dense in a pattern corresponding to the raised elements of the patterned die; and
a powder removal device for removing uncompressed metal powder from the first adhesive layer. - View Dependent Claims (19, 20)
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Specification