Composite and method for making thin copper foil
First Claim
1. An improved method of making a thin, substantially pore-free copper foil, which method comprises:
- a. disposing on the surface of a thin aluminum metal carrier a thin layer of zinc or tin;
b. disposing on said layer of zinc or tin a thin chromium release layer containing a plurality of plating sites;
c. depositing a copper layer on said release layer to form a thin, substantially pore-free copper foil;
d. bonding the exposed face of said copper foil to a substrate to form a laminate; and
e. separating said release layer from said foil.
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Abstract
The improved method of the invention comprises disposing a chromium oxide release layer on the surface of a thin inexpensive metal carrier, such as foil, depositing copper on the release layer to form a thin copper foil, and readily peeling the thus-formed copper foil from the release layer on the carrier. The release layer can be formed in situ from chromium metal electroplated on the carrier. The freshly prepared release layer contains numerous small sites on which electroplating of the copper can be easily carried out to produce pore-free copper foil. The method, which employs the carrier-release layer composite of the invention, is inexpensive and efficient, since readily available, inexpensive metal carriers can be used and no complicated copper foil-carrier separation steps need be resorted to. Moreover, it can increase the bondability of the thin copper foil thus produced to plastic during lamination thereof.
89 Citations
17 Claims
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1. An improved method of making a thin, substantially pore-free copper foil, which method comprises:
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a. disposing on the surface of a thin aluminum metal carrier a thin layer of zinc or tin; b. disposing on said layer of zinc or tin a thin chromium release layer containing a plurality of plating sites; c. depositing a copper layer on said release layer to form a thin, substantially pore-free copper foil; d. bonding the exposed face of said copper foil to a substrate to form a laminate; and e. separating said release layer from said foil. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An improved unitary composite comprising, in combination:
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a. a thin aluminum carrier having a roughened surface; b. a thin metallic layer selected from the group consisting of tin and zinc disposed on said roughened surface; c. a release layer of metal selected from the group consisting of chromium, nickel and cobalt on the surface of said metallic layer; d. a thin copper foil layer disposed on said release layer; e. a layer of copper and copper oxide nodules disposed on said copper foil layer to enhance its bondability to plastic; and
,f. a plastic substrate bonded to said layer of copper and copper oxide nodules.
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11. An improved unitary composite comprising, in combination:
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a. a thin aluminum carrier; b. a thin metallic zinc or tin layer disposed on said aluminum carrier; c. a chromium release layer deposited on the surface of said zinc layer; and d. a thin copper foil disposed on said release layer. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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Specification