US5403465A — Electrodeposited copper foil and process for maki…

Claim 1

Independent Claim 88 words

An electrodeposited copper foil having a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6% to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 40,000 psi, an elongation measured at 180° C. of about 4% to about 15%, and a thermal stability less than about -20%.

Claim 2

Dependent Claim 88 words

An electrodeposited copper foil having a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6% to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 40,000 psi, an elongation measured at 180° C. of about 4% to about 15%, and a thermal stability less than about -20%.

Claim 3

Dependent Claim 93 words

The foil of claim 1 having said matte-side raw foil R tm of about 4 to about 7 microns, said ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 80,000 psi, said elongation measured at 23° C. of about 6% to about 15%, said ultimate tensile strength measured at 180° C. in the range of about 32,000 psi to about 38,000 psi, and said elongation measured at 180° C. of about 4% to about 10%, and further having a weight of about 1/2 ounce per square foot.

Claim 4

Dependent Claim 94 words

The foil of claim 1 having said a matte-side raw foil R tm of about 4 to about 8 microns, said ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 75,000 psi, said elongation measured at 23° C. of about 12% to about 18%, said ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 37,000 psi, and said elongation measured at 180° C. of about 6% to about 12%, and further having a weight of about 1 ounce per square foot.

Claim 5

Dependent Claim 93 words

The foil of claim 1 having said matte-side raw foil R tm of about 6 to about 10 microns, said ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 70,000 psi, said elongation measured at 23° C. of about 16% to about 25%, said ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 36,000 psi, and said elongation measured at 180° C. of about 8% to about 14%, and further having a weight of about 2 ounce per square foot.

Claim 6

Dependent Claim 26 words

The foil of claim 1 further having at least one roughened layer of copper or copper oxide applied to at least one side of said foil.

Claim 7

Dependent Claim 44 words

The foil of claim 1 further having at least one metallic layer applied to at least one side of said foil, the metal in said metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy.

Claim 8

Dependent Claim 38 words

The foil of claim 1 further having at least one metallic layer applied to at least one side of said foil, the metal in said metallic layer being selected from the group consisting of chromium, and chromium-zinc alloy.

Claim 9

Dependent Claim 78 words

The foil of claim 1 further having at least one first metallic layer applied to at least one side of said foil, the metal in said first metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy, and at least one second metallic layer applied to said first metallic layer, the metal in said second metallic layer being selected from the group consisting of tin, chromium, and chromium-zinc alloy.

Claim 10

Dependent Claim 93 words

The foil of claim 1 further having at least one roughened layer of copper or copper oxide applied to at least one side of said foil, at least one first metallic layer applied to said roughened layer, the metal in said first metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy, and at least one second metallic layer applied to said first metallic layer, the metal in said second metallic layer being selected from the group consisting of tin, chromium, and chromium-zinc alloy.

Claim 11

Dependent Claim 100 words

A laminate comprising at least one copper foil adhered to a dielectric substrate, said copper foil having a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6% to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 40,000 psi, an elongation measured at 180° C. of about 4% to about 15%, and a thermal stability less than about -20%.

Claim 12

Dependent Claim 100 words

A laminate comprising at least one copper foil adhered to a dielectric substrate, said copper foil having a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength measured at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6% to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 psi to about 40,000 psi, an elongation measured at 180° C. of about 4% to about 15%, and a thermal stability less than about -20%.

Claim 13

Dependent Claim 217 words

A process for making electrodeposited copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.2 to about 4.5 ppm, an organic additive at a concentration of about 0.4 to about 20 ppm, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.1 to about 3 A/cm 2 , and depositing copper on said cathode; and (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said copper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%.

Claim 14

Dependent Claim 217 words

A process for making electrodeposited copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.2 to about 4.5 ppm, an organic additive at a concentration of about 0.4 to about 20 ppm, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.1 to about 3 A/cm 2 , and depositing copper on said cathode; and (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said copper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%.

Claim 15

Dependent Claim 11 words

The process of claim 11 wherein said organic additive is gelatin.

Claim 16

Dependent Claim 12 words

The process of claim 11 wherein said organic additive is animal glue.

Claim 17

Dependent Claim 13 words

The process of claim 11 wherein said organic additive is active-sulfur containing material.

Claim 18

Dependent Claim 11 words

The process of claim 11 wherein said organic additive is thiourea.

Claim 19

Dependent Claim 53 words

The process of claim 11 wherein said organic additive is selected from the group consisting of molasses, guar gum, polyethylene glycol, polypropylene glycol, polyisopropylene glycol, dithiothreitol, proline, hydroxyproline, cysteine, acrylamide, sulfopropyl disulfide, tetraethylthiuram disulfide, benzyl chloride, epichlorohydrin, chlorohydroxylpropylsulfonate, ethylene oxide, propylene oxide, sulfonium alkane sulfonate, thiocarbamoyldisulfide, and mixtures of two or more thereof.

Claim 20

Dependent Claim 51 words

The process of claim 11 wherein said impurity is an inorganic impurity containing one or more elements selected from the group consisting of Ag, Al, As, Ba, Bi, Ca, Cd, Co, Cr, Fe, In, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sb, Se, Si, Sn, Sr, Ti, V and Zn.

Claim 21

Dependent Claim 44 words

The process of claim 11 wherein said electrolyte solution has a copper ion concentration in the range of about 50 to about 150 grams per liter and a free sulfuric acid concentration in the range of about 10 to about 150 grams per liter.

Claim 22

Dependent Claim 26 words

The process of claim 11 wherein the ratio of said current density to the diffusion limited current density during step (B) is about 0.4 or less.

Claim 23

Dependent Claim 22 words

The process of claim 11 wherein the current density during step (B) is from about 0.5 to about 1.8 A/cm 2 .

Claim 24

Dependent Claim 23 words

The process of claim 11 wherein said electrolyte solution during step (B) has a temperature of about 25° C. to about 100° C.

Claim 25

Dependent Claim 35 words

The process of claim 11 wherein said flowing of said electrolyte solution between said anode and said cathode during step (B) is at a rate of from about 0.2 to about 5 meters per second.

Claim 26

Dependent Claim 29 words

The process of claim 11 further comprising the step of applying to at least one side of said foil at least one roughened layer of copper or copper oxide.

Claim 27

Dependent Claim 47 words

The process of claim 11 further comprising the step of applying to at least one side of said foil at least one metallic layer, the metal in said metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy.

Claim 28

Dependent Claim 42 words

The process of claim 11 further comprising the step of applying to at least one side of said foil at least one metallic layer, the metal in said metallic layer being selected from the group consisting of tin, chromium, and chromium-zinc alloy.

Claim 29

Dependent Claim 81 words

The process of claim 11 further comprising the steps of applying to at least one side of said foil at least one first metallic layer, the metal in said first metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy, then applying to said first metallic layer at least one second metallic layer, the metal in said second metallic layer being selected from the group consisting of tin, chromium, and chromium-zinc alloy.

Claim 30

Dependent Claim 97 words

The process of claim 11 further comprising the steps of applying to at least one side of said foil at least one roughened layer of copper or copper oxide, then applying to said roughened layer at least one first metallic layer, the metal in said first metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc alloy and copper-tin alloy, then applying to said first metallic layer at least one second metallic layer, the metal in said second metallic layer being selected from the group consisting of tin, chromium, and chromium-zinc alloy.

Claim 31

Dependent Claim 230 words

A process for making a copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.4 to about 3.9 ppm, about 0.6 to about 20 ppm of animal glue, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.5 to about 1.8 A/cm 2 , the ratio of said current density to the diffusion limited current density being about 0.4 or less, and depositing copper on said cathode; and (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said cooper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%.

Claim 32

Dependent Claim 230 words

A process for making a copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.4 to about 3.9 ppm, about 0.6 to about 20 ppm of animal glue, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.5 to about 1.8 A/cm 2 , the ratio of said current density to the diffusion limited current density being about 0.4 or less, and depositing copper on said cathode; and (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said cooper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%.

Claim 33

Dependent Claim 247 words

A process for making a copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.2 to about 4.5 ppm, an organic additive at a concentration of about 0.6 to about 20 ppm, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.1 to about 3A/cm 2 , and depositing copper on said cathode; (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said copper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%; and (D) adding copper ions and additional amounts of said organic additive to said electrolyte solution, the rate at which said organic additive is added being about 0.1 to about 14 mg/min/kA.

Claim 34

Dependent Claim 247 words

A process for making a copper foil comprising: (A) preparing an electrolyte solution comprising copper ions, sulfate ions, chloride ions at a concentration of about 1.2 to about 4.5 ppm, an organic additive at a concentration of about 0.6 to about 20 ppm, and an impurity at a concentration of about 0.01 to about 20 grams per liter; (B) flowing said electrolyte solution between an anode and a rotating cathode, applying an effective amount of voltage across said anode and said cathode to provide an electric current between said anode and said cathode having a current density in the range of about 0.1 to about 3A/cm 2 , and depositing copper on said cathode; (C) continuously removing deposited copper from said cathode as a thin web of copper foil; wherein said copper foil has a matte-side raw foil roughness R tm of about 4 to about 10 microns, an ultimate tensile strength at 23° C. in the range of about 65,000 to about 80,000 psi, an elongation measured at 23° C. of about 6 to about 25%, an ultimate tensile strength measured at 180° C. in the range of about 30,000 to about 40,000 psi, an elongation measured at 180° C. of about 4 to about 15%, and a thermal stability less than about -20%; and (D) adding copper ions and additional amounts of said organic additive to said electrolyte solution, the rate at which said organic additive is added being about 0.1 to about 14 mg/min/kA.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-04-03	1998-10-03	1999-04-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-04-03	2002-10-03	2003-04-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-04-03	2006-10-03	2007-04-04	$7700.00	Window Closed / Lapsed

Electrodeposited copper foil and process for making same using electrolyte solutions having controlled additions of chloride ions and organic additives

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