Fabricating metal articles from printed images

• US 5,403,649 A
• Filed: 07/13/1993
• Issued: 04/04/1995
• Est. Priority Date: 12/21/1989
• Status: Expired due to Term

• Current Assignee: Laird Technologies Incorporated (DuPont de Nemours, Inc.)
• Original Assignee: Monsanto Company (Bayer AG)
• Inventors: Vaughn, George D., Morgan, Albert W.
• Primary Examiner(s): Ryan, Patrick J.
• Assistant Examiner(s): Krynski, William A.
• Application Number:
  US08/091,145
• Time in Patent Office: 630 Days
• Field of Search: 428/209, 428/221, 428/332, 428/457, 428/901, 428/333, 174/257, 174/251, 174/250, 361/398, 430/311, 430/313
• US Class Current: 428/209
• CPC Class Codes: B41M 1/10 Intaglio printing ; Gravure printing
• CPC Class Codes: B41M 3/006 Patterns of chemical products used for a specific purpose, e.g. pesticides, perfumes, adhesive patterns; use of microencapsulated material; Printing on smoking articles
• CPC Class Codes: B41M 7/009 using thermal means, e.g. infrared radiation, heat
• CPC Class Codes: B41N 1/20 made of metal or similar inorganic compounds, e.g. plasma coated ceramics, carbides
• CPC Class Codes: C23C 18/28 Sensitising or activating
• CPC Class Codes: C23C 18/30 Activating or accelerating or sensitising with palladium or other noble metal
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H05K 3/182 characterised by the patterning method
• CPC Class Codes: H05K 3/387 for electroless plating H05K3/4661 takes precedence
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10S 428/901 Printed circuit
• CPC Class Codes: Y10T 428/24917 including metal layer
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/31678 Of metal

Abstract

Methods for fabricating two-dimensional imaged metal articles on webs by electroless deposition of metal onto a catalytic pattern rotogravurely printed onto moving webs travelling at linear speeds of up to 500 meters/minute using low viscosity catalytic ink comprising polymer and compound, complex or colloid of a Group 1B or Group 8 metal. Such two-dimensional imaged metal articles comprise areas or fine lines, e.g. less than 100 micrometers wide, which are useful as electrical devices such as circuit connectors, antennas and the like or as mechanical devices such as levers, gears and the like. With modification of the metal component or addition of other materials, such two-dimensional imaged metal articles can be useful a electronic devices such as diodes, resistors, capacitors and the like or as energy conversion devices such as batteries, sensors or fuel cells. The catalytic inks have appropriate rheological properties of viscosity and surface tension that permit non-sagging, non-spreading images to be printed onto a web which can travel vertically into a drying zone.

Claims

1. A web having on at least one side thereof repetitive patterns of conductive metal lines wherein at least one line has a width not greater than than 100 micrometers.

2. A web according to claim 1 wherein at least part of said metal lines functions as a circuit connector, induction heater, radiation reflector, antenna, axle, gear, wheel, lever or combination thereof.

3. A web according to claim 2 wherein said metal lines are copper, iron, cobalt, tin, gold, palladium, platinum, nickel or a combination thereof.

4. A web according to claim 3 wherein said width is not greater than 80 micrometers.

5. A web according to claim 1 wherein said pattern is modified by conversion of at least a part thereof to a metal oxide.

6. A web according to claim 5 wherein said modified image is adapted to be used as a diode, capacitor, transistor, resistor, inductor, pi circuit, battery, fuel cell, sensor or combination thereof.

7. A web according to claim 1 wherein at said pattern is modified by coating at least a part thereof with a dielectric, electrochromic, electrolyte or liquid crystal layer.

8. A web according to claim 7 wherein said modified mage is adapted to be used as a diode, capacitor, transistor, resistor, inductor, pi circuit, battery, fuel cell, sensor or combination thereof.