Method of making metal-film laminate resistant to delamination
First Claim
1. A process for the manufacture of a metal-polymeric film laminate resistant to the separation of the metal from the film, which process comprises:
- (a) contacting a polymeric film with a plasma, produced from at least two metallic electrodes, said plasma comprising ionized oxygen, to form on said film a non-continuous random distribution of a metal or a metal-oxide, said metal being selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof, said distribution being less than 20 atomic layers in thickness, said metal or metal-oxide being derived from said metallic electrodes; and
(b) forming by vapor metallization a metal layer having a thickness of about 50 to 500 nanometers on the metal-oxide treated film, wherein no metallic tie-coat layer is formed in the manufacture of the laminate.
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Accused Products
Abstract
A flexible metal-film laminate can comprise a layered film structure having a metal layer securely bonded to a film layer. The laminate contains a unique metal-oxide attachment structure between the film and metal layer comprising randomly distributed regions of metal-oxide. The peel strength of such a laminate is significantly improved over prior laminates and is resistant to peel strength reduction due to environmental stress. The preferred metal-film laminates made with polyester or polyimide can be used in the manufacture of high-quality, low cost, flexible printed circuit boards.
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Citations
30 Claims
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1. A process for the manufacture of a metal-polymeric film laminate resistant to the separation of the metal from the film, which process comprises:
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(a) contacting a polymeric film with a plasma, produced from at least two metallic electrodes, said plasma comprising ionized oxygen, to form on said film a non-continuous random distribution of a metal or a metal-oxide, said metal being selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof, said distribution being less than 20 atomic layers in thickness, said metal or metal-oxide being derived from said metallic electrodes; and (b) forming by vapor metallization a metal layer having a thickness of about 50 to 500 nanometers on the metal-oxide treated film, wherein no metallic tie-coat layer is formed in the manufacture of the laminate. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A process for the manufacture of a metal-polymeric film laminate resistant to the separation of the metal from the film, which process comprises:
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(a) contacting a polymeric film with a plasma, produced from at least two metallic electrodes, said plasma comprising ionized oxygen, to form on said film a non-continuous random distribution of a metal or a metal-oxide, said metal being selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof, said distribution being less than 20 atomic layers in thickness, said metal or metal-oxide being derived from said metallic electrodes; and (b) forming by vapor metallization a first metal layer having a thickness of about 50 to 500 nanometers on the metal-oxide treated film; and (c) forming a second metal layer having a thickness of about 0.1 to 40 μ
m on the first metal layer, wherein no metallic tie-coat layer is formed in the manufacture of the laminate. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A process for the manufacture of a flexible printed circuit board, having a copper circuit pattern on a polymeric film support, resistant to the delamination of the copper circuit pattern from the polymeric film, which process comprises:
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(a) contacting a polymeric film with a plasma, produced from at least two metallic electrodes, said plasma comprising ionized oxygen, to form on said film a non-continuous random distribution of a metal or metal-oxide, said metal being selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof, said distribution being less than 20 atomic layers in thickness, said metal or metal-oxide being derived from said metallic electrodes; (b) forming by vacuum metallization a first copper layer having a thickness of about 50 to 500 nanometers on the metal-oxide treated film; and (c) electro-plating a second copper layer on the first copper layer to form a copper film laminate resistant to the separation of the metal from the film wherein no chromium tie-coat layer is formed in the manufacture of the laminate. - View Dependent Claims (20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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Specification