US5340436A
Expired / Lapsed
US
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Demetallizing procedure
Assignee: CAMINE RESOURCES Inc
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Filing: 1992-01-31
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Granted: 1994-08-23
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Expires: 2012-01-31
Abstract
Abstract Selective demetallization of an etchable metal layer supported on a polymeric material or other microwave transparent material, or a self-supporting etchable metal layer, particularly aluminum of thickness at least about 1 micron adhesively joined to a flexible polymeric material substrate, is described. A web of polymeric material bearing the etchable metal layer, or an unsupported etchable metal layer, has a pattern of etchant-resistant material first applied and then the web is immersed in and passed through a bath of aqueous etchant, particularly hot aqueous sodium hydroxide solution, for a time at least sufficient to completely remove the etchable metal from non-protected areas of the web. The demetallized web is washed and dried. Specific structure incorporating the selectively demetallized etchable metal layer also are described.
Inventors
- 👤 D. Gregory Beckett
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 06:31
CPC Classifications
B; B65; B65D; B65D81/00; B65D81/34; B65D81/3446; C; C23; C23F; C23F1/00; C23F1/02; B65D2581/00; B65D2581/34; B65D2581/3437; B65D2581/3463; B65D2581/3467; B65D2581/3471; B65D2581/3472; H; H05; H05K; H05K1/00; H05K1/02; H05K1/03; H05K1/0393; H05K3/00; H05K3/02; H05K3/06; H05K3/061; H05K3/068; Y; Y10; Y10S; Y10S428/00; Y10S428/913; Y10S99/00; Y10S99/14; Y10T; Y10T428/00; Y10T428/12; Y10T428/12361; Y10T428/24; Y10T428/24273; Y10T428/24322; Y10T428/24331; Y10T428/24942; Y10T428/2495; Y10T428/31504; Y10T428/31678
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
135 words
A continuous method of effecting selective demetallization of a layer of aluminum having a thickness of at least about 1 micron supported on a web of flexible polymeric material, which comprises: continuously applying a pattern of sodium hydroxide-resistant material to said aluminum corresponding to a desired pattern of non-etched aluminum, continuously passing said patterned web in an immersed condition through a bath of aqueous sodium hydroxide solution having a temperature of about 10° to about 98° C. and a strength of about 0.1 to about 1 normal for a time of at least 0.5 secs. per micron thickness of said aluminum layer to effect complete removal of aluminum from areas of the web not covered and protected by said pattern, continuously washing said web free from spent sodium hydroxide solution, and drying said washed web.
Claim 2
Dependent Claim
135 words
A continuous method of effecting selective demetallization of a layer of aluminum having a thickness of at least about 1 micron supported on a web of flexible polymeric material, which comprises: continuously applying a pattern of sodium hydroxide-resistant material to said aluminum corresponding to a desired pattern of non-etched aluminum, continuously passing said patterned web in an immersed condition through a bath of aqueous sodium hydroxide solution having a temperature of about 10° to about 98° C. and a strength of about 0.1 to about 1 normal for a time of at least 0.5 secs. per micron thickness of said aluminum layer to effect complete removal of aluminum from areas of the web not covered and protected by said pattern, continuously washing said web free from spent sodium hydroxide solution, and drying said washed web.
Claim 3
Dependent Claim
24 words
The method of claim 1 wherein said layer of aluminum is adhesively bonded to said web of flexible polymeric material to be supported thereby.
Claim 4
Dependent Claim
20 words
The method of claim 2 wherein said layer of aluminum has a thickness of about 1 to about 5 microns.
Claim 5
Dependent Claim
19 words
The method of claim 3 wherein said etchable metal has a thickness of about 3 to about 10 microns.
Claim 6
Dependent Claim
16 words
The method of claim 4 wherein said contact time is about 5 to about 50 seconds.
Claim 7
Dependent Claim
16 words
The method of claim 3 wherein said bath is housed within a substantially enclosed elongate tank.
Claim 8
Dependent Claim
18 words
The method of claim 6 wherein said bath has a temperature of about 50° to about 90° C.
Claim 9
Dependent Claim
18 words
The method of claim 6 wherein said bath has a temperature of about 70° to about 75° C.
Claim 10
Dependent Claim
22 words
The method of claim 7 wherein said aqueous sodium hydroxide solution has a strength of from about 2 to about 3 normal.
Claim 11
Dependent Claim
23 words
The method of claim 1 wherein said web is transported through the method steps at a rate of up to about 350 m/min.
Claim 12
Dependent Claim
24 words
The method of claim 6 wherein said web is transported through the elongate tank at a rate of about 10 to about 250 m/min.
Claim 13
Dependent Claim
19 words
The method of claim 6 wherein said web is transported through the elongate tank in a generally sinusoidal path.
Claim 14
Dependent Claim
19 words
The method of claim 6 wherein said web is transported through the elongate tank in a generally horizontal path.
Claim 15
Dependent Claim
28 words
The method of claim 6 wherein detackifying material is applied to said web subsequent to said drying step to effect detackification of adhesive exposed by said selective demetallization.
Claim 16
Dependent Claim
27 words
The method of claim 14 wherein said detackifying material comprises a layer of dielectric material applied to the etched face of said web following said drying step.
Claim 17
Dependent Claim
30 words
The method of claim 6 wherein said the dissolved aluminum concentration of said bath is maintained at about 5 to about 95% of saturation of the bath by dissolved aluminum.
Claim 18
Dependent Claim
26 words
The method of claim 16 wherein the dissolved aluminum concentration of said bath is maintained within the range of about 15 to about 30% of saturation.
Claim 19
Dependent Claim
19 words
The method of claim 16 wherein said bath is treated to remove dissolved aluminum and to regenerate sodium hydroxide.
Claim 20
Dependent Claim
37 words
The method of claim 18 wherein said dissolved aluminum is in the form of sodium aluminate and said dissolved aluminum is removed and sodium hydroxide regenerated by converting said sodium aluminate to aluminum trihydrate and sodium hydroxide.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-08-22 | 1998-02-21 | 1998-08-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-08-22 | 2002-02-21 | 2002-08-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-08-22 | 2006-02-21 | 2006-08-23 | $7700.00 | Window Closed / Lapsed |