US5421985A — Electrodeposited copper foil and process for maki…

Claim 1

Independent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 2

Dependent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 3

Dependent Claim 12 words

The process of claim 1 wherein said electric current is direct current.

Claim 4

Dependent Claim 17 words

The process of claim 1 wherein said electric current is alternating current with a direct current bias.

Claim 5

Dependent Claim 16 words

The process of claim 1 wherein said chloride ion concentration is less than about 10 ppm.

Claim 6

Dependent Claim 16 words

The process of claim 1 wherein said chloride ion concentration is less than about 5 ppm.

Claim 7

Dependent Claim 23 words

The process of claim 1 wherein said current density is in the range of about 1000 to about 1500 amps per square foot.

Claim 8

Dependent Claim 23 words

The process of claim 1 wherein said current density is in the range of about 800 to about 17000 amps per square foot.

Claim 9

Dependent Claim 23 words

The process of claim 1 wherein said current density is in the range of about 1000 to about 3000 amps per square foot.

Claim 10

Dependent Claim 12 words

The process of claim 1 wherein said active sulfur-containing mater is thiourea.

Claim 11

Dependent Claim 14 words

The process of claim 1 wherein said bath further comprises at least one gelatin.

Claim 12

Dependent Claim 12 words

The process of claim 1 wherein said bath further comprises animal glue.

Claim 13

Dependent Claim 51 words

The process of claim 1 wherein said bath further comprises molasses, gum arabic, polyethylene glycol, polypropylene glycol, polyisopropylene glycol, dithiothreitol, proline, hydroxyproline, cysteine, acrylamide, sulfopropyl disulfide, teteraethylthiuram disulfide, benzyl chloride, epichlorohydrin, chlorohydroxylpropyl sulfonate, ethylene oxide, propylene oxide, sulfonium alkane sulfonate, thiocarbamoyldisulfide, selenic acid, or a mixture of two or more thereof.

Claim 14

Dependent Claim 15 words

The process of claim 1 wherein said bath is characterized by the absence of tri-isopropanolamine.

Claim 15

Dependent Claim 15 words

The process of claim 1 wherein said bath is characterized by the absence of triethanolamine.

Claim 16

Dependent Claim 15 words

The process of claim 1 wherein said bath is characterized by the absence of pyrophosphate.

Claim 17

Dependent Claim 25 words

The process of claim 1 wherein said bath has a copper ion concentration in the range of about 50 to about 120 grams per liter.

Claim 18

Dependent Claim 25 words

The process of claim 1 wherein said bath has a sulfate ion concentration in the range of about 50 to about 110 grams per liter.

Claim 19

Dependent Claim 27 words

The process of claim 1 wherein the concentration of said active sulfur-containing material in said bath is in the range of about 0.1 to about 15 ppm.

Claim 20

Dependent Claim 32 words

The process of claim 1 wherein said bath further comprises at least one gelatin, the concentration of said gelatin in said bath being in the range of up to about 20 ppm.

Claim 21

Dependent Claim 32 words

The process of claim 1 wherein said bath is at a temperature ranging from above the crystallization point of copper sulfate to below the temperature at which water vaporizes from said bath.

Claim 22

Dependent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions, and at least one active sulfur-containing material, said bath containing less than about 10 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 23

Dependent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions, and at least one active sulfur-containing material, said bath containing less than about 10 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 24

Dependent Claim 149 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions and being characterized by the absence of tri-isopropanolamine, triethanolamine and pyrophosphate; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 25

Dependent Claim 149 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions and being characterized by the absence of tri-isopropanolamine, triethanolamine and pyrophosphate; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 26

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 27

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 28

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 1000 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 29

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 1000 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 30

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 1700 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 31

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 15 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 1700 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 32

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 5 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 33

Dependent Claim 152 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 5 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 3000 amps per square foot, and continuously removing copper foil from said cathode, said electric current being direct current or alternating current with a direct current bias; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 34

Dependent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 5 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 1700 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Claim 35

Dependent Claim 138 words

A process for making electrodeposited copper foil comprising: preparing a copper deposition bath comprising water, copper ions, sulfate ions and at least one active sulfur-containing material, said bath containing less than about 5 ppm chloride ions; applying electric current to said bath to electrodeposit copper from said bath on to a rotating cathode using a current density in the range of about 800 to about 1700 amps per square foot, and continuously removing copper foil from said cathode; and wherein said foil has an ultimate tensile strength measured at 23° C. in excess of about 66,000 psi, an elongation measured at 180° C. in excess of about 5.5%, an ultimate tensile strength measured at 180° C. in excess of about 25,000 psi and a matte-side roughness R tm in the range of about 4.5 to about 18 μm.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1998-06-05	1998-12-05	1999-06-06	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2002-06-05	2002-12-05	2003-06-06	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2006-06-05	2006-12-05	2007-06-06	$7700.00	Window Closed / Lapsed

Electrodeposited copper foil and process for making same using electrolyte solutions having low chloride ion concentrations

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