Cathode surface treatment for electroforming metallic foil or strip

Claim 2

An electrodeposited metal foil suitable for use in electronic and electrical applications being characterized by substantially isotropic tensile elongation properties, said foil having a first major surface whose surface roughness in a longitudinal direction is within about 20% of its surface roughness in a transverse direction.

Claim 3

The foil of claim 1 wherein the surface roughness of said first surface in the longitudinal direction is within about 10% of the surface roughness in the transverse direction.

Claim 4

The foil of claim 1 wherein said foil is a substantially pore free copper foil for a printed circuit.

Claim 5

The foil of claim 1 wherein the surface roughness of said first major surface in the longitudinal direction is from about 5 to about 30 micro inches and wherein the surface roughness of said first major surface in the transverse direction is from about 5 to about 30 micro inches.

Claim 6

The foil of claim 4 wherein said surface roughnesses are from about 5 to about 30 micro inches and wherein said tensile elongation properties are generally isotropic in substantially any direction in said plane of said foil.

Claim 7

A process for providing an improved plating surface for forming electrodeposited metal foil, said process coprising: polishing said plating surface in a generally random fashion to provide a surface roughness in a longitudinal direction which is within about 20% of the surface roughness of said surface in a transverse direction.

Claim 8

A process for providing an improved plating surface for forming electrodeposited metal foil, said process coprising: polishing said plating surface in a generally random fashion to provide a surface roughness in a longitudinal direction which is within about 20% of the surface roughness of said surface in a transverse direction.

Claim 9

A process as in claim 6 wherein said polishing step comprises: subjecting said plating surface to a plurality of sequential polishing steps; and each said polishing step comprising abrading said surface with an abrasive having a particularly grit size, wherein succeeding polishing steps utilize an abrasive grit size finer than that used in the previous polishing step.

Claim 10

A process as in claim 7 wherein at least the final polishing step comprises polishing said plating surface using a random motion so as to form a series of randomly oriented scratches in said plating surface.

Claim 11

A process as in claim 8 wherein each said polishing step comprises polishing said plating surface using a random motion so as to form a series of randomly oriented scratches in said plating surface, with each succeeding step removing the scratches formed by preceding steps.

Claim 12

A process for forming electrodeposited metal foil having substantially isotropic tensile elongation properties comprising: providing a cell with an electrolyte containing a concentration of metal ions and a first electrode at least partially immersed in said electrolyte; providing a second electrode having a plating surface; polishing said plating surface in a generally random fashion to provide a surface roughness in a longitudinal direction which is within about 20% of the surface roughness in a transverse direction; arranging said second electrode in said electrolyte so as to form an interelectrode gap with said first electrode; moving said plating surface relative to said first electrode; flowing an electrolyte at a desired flow rate into said interelectrode gap; and applying a current between said electrodes to form said foil having said substantially isotropic tensile elongation properties.

Claim 13

A process for forming electrodeposited metal foil having substantially isotropic tensile elongation properties comprising: providing a cell with an electrolyte containing a concentration of metal ions and a first electrode at least partially immersed in said electrolyte; providing a second electrode having a plating surface; polishing said plating surface in a generally random fashion to provide a surface roughness in a longitudinal direction which is within about 20% of the surface roughness in a transverse direction; arranging said second electrode in said electrolyte so as to form an interelectrode gap with said first electrode; moving said plating surface relative to said first electrode; flowing an electrolyte at a desired flow rate into said interelectrode gap; and applying a current between said electrodes to form said foil having said substantially isotropic tensile elongation properties.

Claim 14

The process of claim 10 further comprising: polishing said substantially isotropic plating surface on said second electrode prior to said arranging step.

Claim 15

The process of claim 11 wherein said polishing step comprises: subjecting said plating surface to a plurality of sequential polishing steps; each said polishing step comprising abrading said surface with an abrasive having a particular grit size, wherein succeeding polishing steps utilize an abrasive grit size finer than that used in the previous polishing step.

Claim 16

The process of claim 12 wherein at least the final polishing step comprises polishing said plating surface using a random motion so as to form a series of randomly oriented scratches in said plating surface.

Claim 17

The process of claim 10 wherein each of said polishing steps comprises polishing said plating surface using a random motion so as to form a series of randomly oriented scratches in said plating surface, with each succeeding step removing the scratches formed by preceding steps.

Claim 18

The process of claim 10 wherein said polishing step comprises polishing said surface so as to form scratch marks in said plating surface which are equally distributed in a first longitudinal direction parallel to the direction of movement of said plating surface and in a second direction transverse to said first direction.

Claim 19

A substantially pore free metal foil having substantially isotropic tensile elongation properties formed by the process of claim 10.

Claim 22

The apparatus of claim 17 wherein said substantially isotropic surface finish comprises a series of randomly oriented scratch marks in said plating surface.

Claim 23

The apparatus of claim 18 further comprising: said plating surface being movable in a first direction; and said substantially isotropic surface finish comprising a pattern of scratch marks equally distributed in both a direction parallel to said first direction and a direction transverse to said first direction.

Claim 24

An electrodeposited metal foil as in claim 1 which comprises copper and which is adapted for use in a printed circuit board.

Claim 25

An apparatus as in claim 18 wherein said substantially isotropic surface finish comprises a surface having a surface roughness in a longitudinal direction within about 20% of the surface roughness in a transverse direction.

Claim 26

An apparatus as in claim 21 wherein said surface roughness in said longitudinal direction is within about 10% of said surface roughness in said transverse direction.

Claim 27

An apparatus as in claim 21 wherein said surface roughness in said longitudinal direction is from about 5 to about 30 micro inches and wherein said surface roughness in said transverse direction is from about 5 to about 30 micro inches.

Claim 28

An apparatus as in claim 23 wherein said surface roughnesses are from about 5 to 30 micro inches.