US4774122A — Resinous product provided with surface coatable w…

Claim 1

Independent Claim 101 words

A resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of microdendrites, the resinous product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface, stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and dissolving out said embedded microdendrites from the resinous product, to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface.

Claim 2

Dependent Claim 101 words

A resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of microdendrites, the resinous product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface, stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and dissolving out said embedded microdendrites from the resinous product, to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface.

Claim 3

Dependent Claim 33 words

A resinous product as claimed in claim 1, in which the resin is a prepreg, and said microdendrites are dissolved away by an etchant to obtain said micro-rough surface on the resinous product.

Claim 4

Dependent Claim 76 words

A resinous product as claimed in claim 2, in which the metal surface is first coated with microdendrites by electrodeposition and further in which the microdendrite-covered metal plate is coated with a resin solution, followed by drying and partially curing said resin solution to form a resin coating on the metal surface, before the resin-coated metal plate is embedded into the prepreg, such that said microdendrites embedded in said cured prepreg are coated with the resin.

Claim 5

Dependent Claim 30 words

A resinous product as claimed in claim 1, in which the resin is thermoplastic, and said microdendrite-coated metal surface is pressed into the thermoplastic resin surface at an elevated temperature.

Claim 6

Dependent Claim 26 words

A resinous product as claimed in claim 1, in which the resinous product has opposed planar surfaces, at least one of which is a micro-rough surface.

Claim 7

Dependent Claim 38 words

A resinous product as claimed in claim 1, in which the resinous product has at least one non-planar micro-rough surface, said product being formed in a metal mold, the inner surfaces of which are coated with said microdendrites.

Claim 8

Dependent Claim 77 words

A resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of embedded microdendrites, the resinous product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface, and stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface.

Claim 9

Dependent Claim 77 words

A resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of embedded microdendrites, the resinous product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface, and stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface.

Claim 10

Dependent Claim 82 words

A resinous product as claimed in claim 7, in which the metal surface is first coated with microdendrites by electrodeposition and further in which the microdendrite-covered metal plate is coated with a resin solution, followed by drying and partially curing said resin solution, to form a resin coating on the metal surface, before the resin-coated metal plate is embedded into the prepreg, such that said microdendrites embedded in said cured prepreg are coated with resin and bonded more securely to the prepreg.

Claim 11

Dependent Claim 51 words

A resinous product as claimed in claim 7, in which the microdendrite-coated metal surface comprises zinc-coated copper microdendrites and in which the process further comprises the initial electrodeposition of copper on the metal surface to form the microdendrite coating, and further electrodeposition with zinc to form copper microdendrites electrodeposited with zinc.

Claim 12

Dependent Claim 55 words

A resinous product as claimed in claim 9, in which said copper microdendrites electrodeposited with zinc, embedded in said cured resinous surface, are treated with a selective etchant to remove only said zinc layer, to obtain a resinous product on which a surface is covered with an array of microcavities partially filled with copper microdendrites.

Claim 13

Dependent Claim 113 words

A metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface, such that the microdendrites penetrate the resinous surface, curing the resinous surface, stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and dissolving out said embedded microdendrites from the resinous product to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface, and coating said micro-rough surface with a metal layer by electroless deposition, to obtain said metal-clad resinous product.

Claim 14

Dependent Claim 113 words

A metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface, such that the microdendrites penetrate the resinous surface, curing the resinous surface, stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and dissolving out said embedded microdendrites from the resinous product to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface, and coating said micro-rough surface with a metal layer by electroless deposition, to obtain said metal-clad resinous product.

Claim 15

Dependent Claim 16 words

A metal-clad resinous product as claimed in claim 11, in which the resin is a prepreg.

Claim 16

Dependent Claim 76 words

A metal-clad resinous product as claimed in claim 12, in which the metal surface is coated with microdendrites by electrodeposition and the microdendrite-coated surface of the metal plate is coated with a resin solution, followed by drying and partially curing said resin solution, to form a resin coating on the metal surface before the resin-coated metal plate is embedded into the prepreg, such that said microdendrites embedded in said cured prepreg are coated with the resin.

Claim 17

Dependent Claim 36 words

A metal-clad resinous product as claimed in claim 11, in which the resin is thermoplastic, and said metal surface is pressed into the resinous surface at an elevated temperature, and then stripped from the resinous surface.

Claim 18

Dependent Claim 24 words

A metal-clad resinous product as claimed in claim 11, in which said metal layer is coated onto the resinous surface in a circuit configuration.

Claim 19

Dependent Claim 82 words

A metal-clad resinous product as claimed in claim 15, in which the resinous product is a flat plate having opposing planar surfaces, and in which the two planar surfaces are treated to form micro-rough surfaces, and further comprising a hole penetrating the plate at a predetermined location and defined by transverse surfaces interconnecting the two planar micro-rough surfaces, and further in which the metal layer is deposited to form an integral coating on the two planar surfaces and on the transverse surfaces.

Claim 20

Dependent Claim 24 words

A metal-clad resinous product as claimed in claim 16, in which the metal deposited is selected from the group consisting of copper and nickel.

Claim 21

Dependent Claim 23 words

A metal-clad resinous product as claimed in claim 17, also comprising a coating of an electrodeposition of copper on said electroless deposited metal.

Claim 22

Dependent Claim 93 words

A metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface and stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and said resinous surface embedded with said microdendrites is coated with a metal layer by electroless deposition to obtain said metal-clad resinous product.

Claim 23

Dependent Claim 93 words

A metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the product being prepared by a process which comprises pressing a metal surface coated with microdendrites into the resinous surface such that the microdendrites penetrate the resinous surface, curing the resinous surface and stripping apart said metal and resinous surfaces such that the microdendrites remain embedded in the cured resinous surface, and said resinous surface embedded with said microdendrites is coated with a metal layer by electroless deposition to obtain said metal-clad resinous product.

Claim 24

Dependent Claim 16 words

A metal-clad resinous product as claimed in claim 19, in which the resin is a prepreg.

Claim 25

Dependent Claim 76 words

A metal-clad resinous product as claimed in claim 20, in which the metal surface is first coated with microdendrites by electrodeposition and the microdendrite-covered metal plate is coated with a resin solution, followed by drying and partially curing said resin solution, to form a resin coating on the metal surface before the resin-coated metal plate is embedded into the prepreg, such that said microdendrites embedded in said cured prepreg are more securely bonded to the resin.

Claim 26

Dependent Claim 36 words

A metal-clad resinous product as claimed in claim 21, in which the resin is thermoplastic, and said metal surface is pressed into the resinous surface at an elevated temperature, and then stripped from the resinous surface.

Claim 27

Dependent Claim 24 words

A metal-clad resinous product as claimed in claim 19, in which said metal layer is coated onto the resinous surface in a circuit configuration.

Claim 28

Dependent Claim 81 words

A metal-clad resinous product as claimed in claim 23, in which the resinous product is a flat plate having opposing planar surfaces, and in which the two planar surfaces comprise an array of embedded microdendrites and further comprising a hole through the plate defined by a transverse surface at a predetermined location, interconnecting the two planar, micro-rough surfaces, and further in which the metal layer is deposited to form an integral coating on the two planar surfaces and the transverse surface.

Claim 29

Dependent Claim 25 words

A metal-clad resinous product as claimed in claim 24, in which the metal electroless deposited is selected from the group consisting of copper and nickel.

Claim 30

Dependent Claim 23 words

A metal-clad resinous product as claimed in claim 25, comprising a coating of an electrodeposition of copper on an electroless deposit of copper.

Claim 31

Dependent Claim 75 words

A process for preparing a resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of embedded microdendrites, the process comprising: pressing a metal base surface coated with microdendrites into the resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; and stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface.

Claim 32

Dependent Claim 75 words

A process for preparing a resinous product having a resinous surface which is coatable with a metal layer so as to be bonded through an array of embedded microdendrites, the process comprising: pressing a metal base surface coated with microdendrites into the resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; and stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface.

Claim 33

Dependent Claim 34 words

A process as claimed in claim 27, further comprising dissolving out said embedded microdendrites from the resinous product, to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface.

Claim 34

Dependent Claim 32 words

A process as claimed in claim 28, in which the resin is a prepreg, and said microdendrites are dissolved away by an etchant to obtain said micro-rough surface on the resinous product.

Claim 35

Dependent Claim 58 words

A process as claimed in claim 28, further comprising initially coating the metal base surface with the microdendrites by electrodeposition; and coating the microdendrite-covered metal surface with a resin solution; and drying and partially curing said resin solution to form a partially cured resin coating on the microdendrites before the resin-coated metal plate is pressed against the prepreg.

Claim 36

Dependent Claim 29 words

The process as claimed in claim 28, in which the resin is thermoplastic, and said microdendrite-coated metal surface is pressed into the thermoplastic resin surface at an elevated temperature.

Claim 37

Dependent Claim 52 words

A process as claimed in claim 27, in which the microdendrite-coated metal surface comprises zinc-coated copper microdendrites, and in which the process further comprises electrodepositing copper on the microdendrite-covered metal surface; and then electrodepositing zinc thereover to form copper microdendrites electrodeposited with zinc, the zinc-coated microdendrites being embedded in the resinous product.

Claim 38

Dependent Claim 51 words

A process as claimed in claim 32, further comprising treating said zinc-coated copper microdendrites embedded in said cured resinous surface, with a selective etchant to remove only said zinc layer, to obtain a resinous product on which a surface is covered with an array of microcavities partially filled with copper microdendrites.

Claim 39

Dependent Claim 111 words

A process for preparing a metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the process comprising pressing a metal surface coated with microdendrites into an uncured resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface; dissolving out said embedded microdendrites from the resinous product to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface, and coating said microrough surface with a metal layer by electroless deposition, to obtain said metal-clad resinous product.

Claim 40

Dependent Claim 111 words

A process for preparing a metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the process comprising pressing a metal surface coated with microdendrites into an uncured resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface; dissolving out said embedded microdendrites from the resinous product to obtain a micro-rough surface comprising an array of microdendrite-shaped cavities extending into the resinous surface, and coating said microrough surface with a metal layer by electroless deposition, to obtain said metal-clad resinous product.

Claim 41

Dependent Claim 42 words

A process as claimed in claim 34, in which the resin is thermoplastic, and said metal surface is pressed into the resin surface at an elevated temperature, and curing by cooling the resinous surface before it is stripped from the metal surface.

Claim 42

Dependent Claim 80 words

A process as claimed in claim 35, in which the resinous product is a flat plate having opposing planar surfaces, and in which the two planar surfaces are each treated to form micro-rough surfaces, and the process further comprising a hole penetrating the plate at a predetermined location interconnecting the two planar microrough surfaces prior to the electroless deposition, such that the metal layer is deposited to form an integral coating on the two planar surfaces and around said hole.

Claim 43

Dependent Claim 16 words

A process as claimed in claim 36, in which the metal deposited is copper or nickel.

Claim 44

Dependent Claim 19 words

A process as claimed in claim 37, further comprising coating said electroless deposited metal by the electrodeposition of copper.

Claim 45

Dependent Claim 90 words

A process for preparing a metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the process comprising pressing a metal surface coated with microdendrites into an uncured resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface; and coating said resinous surface embedded with said microdendrites with a metal layer by electroless deposition to obtain said metal-clad resinous product.

Claim 46

Dependent Claim 90 words

A process for preparing a metal-clad resinous product in which the metal cladding is bonded to the resin through an array of microdendrites, the process comprising pressing a metal surface coated with microdendrites into an uncured resinous surface, such that the microdendrites penetrate the resinous surface; curing the resinous surface; stripping apart said metal and resinous surfaces, such that the microdendrites remain embedded in the cured resinous surface; and coating said resinous surface embedded with said microdendrites with a metal layer by electroless deposition to obtain said metal-clad resinous product.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-09-27	1992-03-28	1992-09-27	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-09-27	1996-03-28	1996-09-27	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-09-27	2000-03-28	2000-09-27	$7700.00	Window Closed / Lapsed

Resinous product provided with surface coatable with metal layer bonded through an array of microdendrites and metal-clad resinous product thereof

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