Method of forming a patterned aluminum layer and article

• US 5,043,201 A
• Filed: 04/03/1989
• Issued: 08/27/1991
• Est. Priority Date: 07/20/1987
• Status: Expired due to Term

• Current Assignee: GAR DOC Incorporated
• Original Assignee: GAR DOC Incorporated
• Inventors: Cote, Paul F.
• Primary Examiner(s): McCamish, Marion E.
• Assistant Examiner(s): WEDDINGTON, JACQUELIN
• Application Number:
  US07/331,837
• Time in Patent Office: 876 Days
• Field of Search: 156/635, 427/272, 428/195, 428/209, 428/332, 428/411.1, 428/457, 428/913, 428/68, 428/76, 428/413, 428/415, 428/417, 428/418, 428/458
• US Class Current: 428/195.1
• CPC Class Codes: C23F 1/02 Local etching
• CPC Class Codes: H05K 1/09 Use of materials for the conductive, e.g. metallic pattern
• CPC Class Codes: H05K 2203/0789 Aqueous acid solution, e.g. for cleaning or etching
• CPC Class Codes: H05K 2203/1545 Continuous processing, i.e. involving rolls moving a band-like or solid carrier along a continuous production path
• CPC Class Codes: H05K 3/061 Etching masks
• CPC Class Codes: Y10S 428/913 Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 428/23 Sheet including cover or casing
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24917 including metal layer
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31681 Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]

Abstract

A process is described for the microdemetalization of an aluminized mylar film, the steps including the printing of a micropattern of a caustic resistant, U.V. curable resin on the aluminum surface, etching of the exposed aluminum with a warm saturated caustic solution, followed immediately by rinsing the patterned surface with an acidic solution to neutralize the caustic and stop the etching. Micropatterns having line widths as small as 0.2 mils may be formed by the process.

Claims

1. An article of manufacture comprising:

a) a web,

b) a thin, patterned aluminum layer on at least one surface of the web, and

c) a thin, patterned layer of a caustic resistant material overlying and in contact with the aluminum layer,

characterized in that at least a portion of the pattern is a micropattern having a line width of from about 0.2 to 10 mils.

2. The article of claim 1 in which the overlying layer consists essentially of a U.V. cured resin.

3. The article of claim 1 in which the web is substantially optically transparent.

4. The article of claim 2 in which the web is substantially optically transparent.