US3864147A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of improving the bonding capability of polymer surfaces for subsequently applied coatings, and products thereof
Assignee: MacDermid Inc
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Filing: 1972-09-25
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Granted: 1975-02-04
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Expires: 1992-09-25
Abstract
Abstract A procedure is disclosed for modifying the topography of the surface of a polymer substrate to improve the bonding capability of the surface of the polymer in respect to subsequently applied coatings such as metal films, paints and inks. The procedure involved comprises first laminating a sacrificial, anodized metal foil to the substrate surface by heat and pressure, chemically stripping away that foil and then developing preferably, by a supplemental chemical stripping treatment, a network of microscopic fissures and cracks which is believed to incipiently form in the surface by the laminating process. Thereafter the treated substrate may be activated and electrolessly plated by conventional methods, followed by an added electrolytic or electroless plating if desired, to provide a metal film of execellent adhesion. Alternatively, standard vacuum metallizing procedures may be used to provide the initial or finished metal coating. Adhesion of other, nonmetallic, coatings such as paints and inks is also improved by the process.
Inventors
- 👤 John J Grunwald
- 👤 Ottavio Eugene D
- 👤 Michael S Lombardo
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 07:20
CPC Classifications
B; B32; B32B; B32B15/00; B32B15/04; B32B15/08; B05; B05D; B05D3/00; B05D3/10; B32B15/20; H; H05; H05K; H05K3/00; H05K3/38; H05K3/381; B05D2201/00; B05D2350/00; B05D2350/30; B05D2350/33; B05D2350/35; B32B2311/00; B32B2311/24; H05K2203/00; H05K2203/11; H05K2203/1152; H05K3/10; H05K3/18; H05K3/181
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
119 words
A PROCESS OF IMPROVING THE TOPOGRAPHY CHARACTERISTICS OF A PLASTIC SUBSTRATE SURFACE FOR THE BONDING THERETO OF A PERMANENT COATING FILM, WHICH COMPRISES THE STEPS OF INITIALLY FORMING BY HEAT AND PRESSURE A LAMINATE OF THE PLASTIC SUBSTRATE AND A SACRIFICIAL ALUMINUM METAL FOIL HAVING AN OXIDIZED SURFACE FACING THE SUBSTRATE, CHEMICALLY STRIPPING IN AN AQUEOUS ETCHANT SOLUTION ALL VISIBLE TRACES OF SAID SACRIFICIAL ALUMINUM METAL FOIL FROM THE SURFACE OF THE SUBSTRATE, AND THEN SUBJECTING THE STRIPPED SUBSTRATE TO TREATMENT IN AN AQUEOUS SOLUTION OF PHOSPHORIC ACID OR A SOLUBLE PYROPHOSPHATE EFFECTIVE IN REMOVING ALL TRACE METAL OXIDES FROM THE SURFACE OF THE SUBSTRATE AFTER THE FIRST ETCHING STEP, AND THEREAFTER RINSING AND APPLYING SAID PERMANENT COATING FILM.
Claim 2
Dependent Claim
49 words
A process as defined in claim 2, wherein said sacrificial metal foil is aluminum foil anodized in phosphoric or sulfuric acid, and said aqueous solution effective to remove trace metal oxides contains a phosphate material selected from the group consisting of phosphoric acid and the alkali metal ammonium pyrophosphates.
Claim 3
Dependent Claim
20 words
A process as defined in claim 3, wherein the concentration of said phosphate material is at least about 0.25 molar.
Claim 4
Dependent Claim
46 words
A process as defined in claim 3, wherein the supplemental etchant treatment is continued for from 3 minutes to 15 minutes at a solution temperature of from 80*F. to 180*F. with a phosphate concentration equivalent to from 4 percent to 75 percent (weight) of phosphoric acid.
Claim 5
Dependent Claim
84 words
A process as defined in claim 2, wherein said sacrificial metal foil is aluminum which has been anodized in aqueous phosphoric acid solution to produce an anodized film of at least about 200 Angstroms thick; and wherein said laminate of plastic substrate and anodized aluminum foil is contacted with a hydrochloric acid etchant solution to strip said aluminum foil therefrom, and said stripped substrate is supplementally treated in a 45 percent (weight) aqueous phosphoric acid solution at a temperature of 160*F. for 5 minutes.
Claim 6
Dependent Claim
106 words
IN THE ELECTROLESS METAL PLATING OF PLASTIC SUBSTRATE IN WHICH A LAMINATE IS INITIALLY FORMED BY BONDING AN ANODIZED ALUMINUM FOIL TO A RESIN SUBSTRATE BY HEAT AND PRESSURE, THE ALUMINUM FOIL BEING THEN CHEMICALLY STRIPPED FROM THE PLASTIC SURFACE, THE SURFACE ACTIVATED AND THEM PLATED WITH AN ADHERENT FILM BY IMMERSION IN AN ELECTROLESS METAL PLATING SOLUTION THE IMPROVEMENT WHICH COMPRISES: SUBJECTING THE PLASTIC SUBSTRATE TO FURTHER CHEMICAL TREATMENT, SUPPLEMENTAL TO THE SAID REGULAR STRIPPING STEP, TO SUBSTANTIALLY ELIMINATE TRACES OF METAL OXIDES ADHERING TO THE SURFACE, WHEREIN SAID SUPPLEMENTAL TREATMENT INVOLVES IMMERSING THE STRIPPED SUBSTRATE IN A SOLUTION OF PHOSPHORIC ACID OR SOLUBLE PYROPHOSPHATE.
Claim 7
Dependent Claim
65 words
The improvement in electroless plating of thermoset resin substrates as defined in claim 7, wherein said supplemental chemical stripping step is continued until development of a topographically complex but uniform network of distinct fissures and cracks of a depth on the order of at least 200 A appears in the substrate surface, as shown by an electron scan microphotograph of the surface of the substrate.
Claim 8
Dependent Claim
30 words
The improvement in electroless plating as defined in claim 7, wherein said supplemental chemical stripping step comprises immersing the regularly stripped resin substrate in an aqueous solution of phosphoric acid.
Claim 9
Dependent Claim
50 words
The improvement in electroless plating as defined in claim 9, wherein said supplemental chemical treatment solution contains from 4 percent to 75 percent (weight) phosphoric acid and said substrate is maintained in said solution at a temperature of from 80*F. to 180*F. for a period of 3 to 15 minutes.
Claim 10
Dependent Claim
31 words
The improvement in electroless plating as defined in claim 7, wherein said supplemental chemical stripping step comprises immersing the regularly stripped resin substrate in an aqueous solution of a soluble pyrophosphate.
Claim 11
Dependent Claim
45 words
The improvement in electroless plating as defined in claim 11, wherein said pyrophosphate is sodium, potassium or ammonium pyrophosphate at a concentration of from 10 g/1 to saturation for a period of from 3 to 15 minutes at a solution temperature of 100*F. to 180*F.
Claim 12
Dependent Claim
51 words
The improvement in electroless plating as defined in claim 7, wherein said supplemental chemical stripping step comprises immersing the regularly stripped resin substrate in an aqueous cuastic solution of an alkali metal hydroxide followed immediately by immersion of said substrate in an aqueous solution of phosphoric acid or a soluble pyrophosphate.
Claim 13
Dependent Claim
106 words
A PROCESS OF IMPROVING THE TOPOGRAPHY CHARACTERISTICS OF A POLYMERIZED PLASTIC SUBSTRATE SURFACE FOR THE BONDING THERETO OF A PERMANENT METALLIC FILM, WHICH COMPRISES THE STEP OF INITIALLY FORMING A LAMINATE OF THE PLASTIC SUBSTRATE AND A SACRIFICIAL ANODIZED ALUMINUM FOIL BY HEAT AND PRESSURE, CHEMTICALLY STRIPPING SAID FOIL FROM THE SUBSTRATE SURFACE IN AN AQUE OUS ETCHANT SOLUTION OF A STRONG ACID OR BASE TO REMOVE ALL VISIBLE TRACE OF THE METAL, SUPPLEMENTING SAID ETCHANT STEP BY SUBJECTING THE STRIPPED SUBSTRATE TO AN AQUEOUS SOLUTION OF PHOSPHORIC ACID OR A SOLUBLE PYROPHOSPHATE, AND THEREAFTER RINSING AND ELECTROLESSLY PLATING SAID PERMANENT METALLIC FILM ON SAID SUBSTRATE.
Claim 14
Dependent Claim
34 words
A process as defined in claim 14, wherein said sacrificial aluminum foil is chemically stripped from said substrAte in hydrochloric acid solution containing a fluoride ion in a concentration of at least about 0.2M.
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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) | 1978-02-03 | 1978-08-05 | 1979-02-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-02-03 | 1982-08-05 | 1983-02-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-02-03 | 1986-08-05 | 1987-02-04 | $7700.00 | Window Closed / Lapsed |