US5709957A — Metallic body with vapor-deposited treatment laye…

Claim 1

Independent Claim 90 words

A metal body having at least one vapor-deposited treatment layer overlying and adhered to at least one side of the metal body, and a layer of adhesion-promoting material overlying and adhered to at least one of the at least one treatment layer, provided that when two treatment layers are deposited on one side of the body and the first treatment layer is vapor-deposited zinc, the second treatment layer is not vapor deposited silica or vapor-deposited alumina, said adhesion-promoting material being suitable for enhancing adhesion between said body and a substrate.

Claim 2

Dependent Claim 90 words

A metal body having at least one vapor-deposited treatment layer overlying and adhered to at least one side of the metal body, and a layer of adhesion-promoting material overlying and adhered to at least one of the at least one treatment layer, provided that when two treatment layers are deposited on one side of the body and the first treatment layer is vapor-deposited zinc, the second treatment layer is not vapor deposited silica or vapor-deposited alumina, said adhesion-promoting material being suitable for enhancing adhesion between said body and a substrate.

Claim 3

Dependent Claim 14 words

The metal body of claim 1 wherein the metal body is a metal foil.

Claim 4

Dependent Claim 21 words

The metal body of claim 1 wherein at least one of the at least one treatment layer is a metallic layer.

Claim 5

Dependent Claim 14 words

The metal foil of claim 1 wherein the metal body is a copper foil.

Claim 6

Dependent Claim 15 words

The metal foil of claim 2 wherein the metal foil is an electrodeposited copper foil.

Claim 7

Dependent Claim 48 words

The copper foil of claim 5 wherein the copper foil is a controlled low profile electrodeposited copper foil having a substantially uniform randomly oriented grain structure that is essentially columnar grain free and twin boundary free and has an average grain size of up to about 10 microns.

Claim 8

Dependent Claim 48 words

The copper foil of claim 5 wherein the copper foil is a standard profile electrodeposited copper foil having a columnar grain structure of preferred orientation and high densities of crystal defects including discolorations and twin boundaries and having an average grain size of up to about 20 microns.

Claim 9

Dependent Claim 14 words

The metal foil of claim 2 wherein the foil is a wrought copper foil.

Claim 10

Dependent Claim 27 words

The metal foil of claim 2 wherein the metal foil is selected from the group consisting of an as-plated copper foil and an annealed electrodeposited copper foil.

Claim 11

Dependent Claim 26 words

The metal foil of claim 2 wherein the foil is selected from the group consisting of an as-rolled copper foil and an annealed wrought copper foil.

Claim 12

Dependent Claim 29 words

The metal foil of claim 2 wherein at least one of the at least one treatment layer is a metallic layer on at least one side of the foil.

Claim 13

Dependent Claim 31 words

The metal foil of claim 2 wherein at least one of the at least one treatment layer is a metallic layer overlying and adhered to both sides of the metal foil.

Claim 14

Dependent Claim 53 words

The metal foil of claim 2 wherein at least one of the at least one treatment layer is a metallic layer overlying and adhered to both sides of the metal foil and a layer of the adhesion-promoting material is overlying and adhered to the metallic layer on both sides of the metallic foil.

Claim 15

Dependent Claim 47 words

The metal foil of claim 11 wherein the metal foil is an electrodeposited copper foil having a shiny side and a matte side, and at least one of the at least one vapor-deposited treatment layer overlies and is adhered to the matte side of the copper foil.

Claim 16

Dependent Claim 50 words

The metal foil of claim 11 wherein the metallic layer comprises a metal selected from the group consisting of magnesium, aluminum, titanium, chromium, copper, bismuth, manganese, cobalt, nickel, zinc, indium, tin, molybdenum, silver, gold, tungsten, zirconium, antimony, chromium-zinc alloys, brass, bronze, and mixtures of two or more of said metals.

Claim 17

Dependent Claim 42 words

The metal foil of claim 14 wherein the metallic layer on the matte side is selected from the group consisting of indium, tin, cobalt, nickel, copper, manganese, chromium, titanium, bismuth, zinc, zinc-chromium alloys, and mixtures of two or more of said metals.

Claim 18

Dependent Claim 60 words

The metal foil of claim 14 wherein at least one of the at least one vapor-deposited treatment layer overlies and is adhered to the shiny side of the copper foil and comprises a metal selected from the group consisting of indium, magnesium, aluminum, copper, zinc, chromium, tin, nickel, cobalt zinc-chromium alloys, and mixtures of two or more of said metals.

Claim 19

Dependent Claim 15 words

The metal foil of claim 2 wherein the adhesion-promoting layer is applied by vapor deposition.

Claim 20

Dependent Claim 14 words

The metal foil of claim 2 wherein the adhesion-promoting material is an organic material.

Claim 21

Dependent Claim 28 words

The metal foil of claim 2 wherein the adhesion-promoting layer is selected from the group consisting of thermosetting polymers, thermosetting copolymers, thermoplastic polymers, thermoplastic copolymers, and mixtures thereof.

Claim 22

Dependent Claim 28 words

The metal foil of claim 2 wherein the adhesion-promoting material is selected from the group consisting of epoxy resins, organofunctional silanes, formaldehyde resins, polyester resins, and mixtures thereof.

Claim 23

Dependent Claim 16 words

The metal foil of claim 2 wherein the adhesion-promoting material is at least one organometallic compound.

Claim 24

Dependent Claim 100 words

The metal foil of claim 2 wherein the adhesion-promoting material is at least one organosilane compound represented by the formula R.sub.4-n SiX.sub.n wherein R is selected from the group consisting of an alkyl group, an aryl group, and a functional group represented by the formula C x H 2x Y; x is from 0 to 20; Y is selected from the group consisting of amino, amido, hydroxy, alkoxy, halo, mercapto, carboxy, aryl, vinyl, allyl, styryl, epoxy, isocyanate, glyeidoxy, and acryloxy groups, X is a hydrolyzable group; and n is selected from the group consisting of 1, 2, 3 and 4.

Claim 25

Dependent Claim 26 words

The metal foil of claim 23 wherein n is selected from the group consisting of 1, 2, and 3 and x is from 1 to 5.

Claim 26

Dependent Claim 28 words

The metal foil of claim 23 wherein each X is an OR group wherein each R is an alkyl group containing from 1 to about 5 carbon atoms.

Claim 27

Dependent Claim 30 words

The metal foil of claim 11 wherein a base surface of said foil underlying the at least one metallic layer is characterized by the absence of any added surface roughening.

Claim 28

Dependent Claim 38 words

The metal foil of claim 2 wherein at least one roughened layer selected from the group consisting of copper and copper oxide is positioned between the foil and the first of said at least one vapor-deposited treatment layer.

Claim 29

Dependent Claim 27 words

The metal foil of claim 11 wherein the at least thickness of the at least one metallic layer is from about 10 Å to about 3000 Å.

Claim 30

Dependent Claim 72 words

The metal foil of claim 2 wherein the adhesion-promoting layer comprises at least one epoxy silane represented by the formula ##STR11## wherein R 1 , R 2 and R 3 are selected from the group consisting of hydrogen groups and hydrocarbon groups; R 4 and R 5 are selected from the group consisting of alkylene groups and alkylidene groups; and R 6 , R 7 and R 8 are independently hydrocarbon groups.

Claim 31

Dependent Claim 34 words

The metal foil of claim 11 wherein the at least one vapor-deposited metallic layer is subjected to an elevated temperature of from 80° C. to 800° C. prior to application of the adhesion-promoting layer.

Claim 32

Dependent Claim 29 words

The metal foil of claim 11 wherein at least one side of the foil has two vapor-deposited metallic layers wherein the metal or metals in each layer are different.

Claim 33

Dependent Claim 157 words

An electrodeposited copper foil or wrought copper foil having at least one vapor-deposited metallic layer overlying and adhered to at least one side of the copper foil, and a layer of an organic adhesion-promoting material overlying and adhered to at least one of the at least one metallic layer, said adhesion-promoting layer being suitable for enhancing adhesion between said foil, and a substrate, wherein one of the at least one metallic layer is selected from the group consisting of metals, metal oxides, metal nitrides, and mixtures thereof wherein said metals are selected from the group consisting of magnesium, aluminum, titanium, chromium, manganese, cobalt, nickel, copper, bismuth, zinc, indium, tin, molybdenum, antimony, zirconium, silver, gold, chromium-zinc alloy, brass, bronze and mixtures of two or more of said metals, provided that when the foil has two metallic layers on one side, the second metallic layer does not contain vapor-deposited alumina or silica when the first metallic layer contains zinc.

Claim 34

Dependent Claim 157 words

An electrodeposited copper foil or wrought copper foil having at least one vapor-deposited metallic layer overlying and adhered to at least one side of the copper foil, and a layer of an organic adhesion-promoting material overlying and adhered to at least one of the at least one metallic layer, said adhesion-promoting layer being suitable for enhancing adhesion between said foil, and a substrate, wherein one of the at least one metallic layer is selected from the group consisting of metals, metal oxides, metal nitrides, and mixtures thereof wherein said metals are selected from the group consisting of magnesium, aluminum, titanium, chromium, manganese, cobalt, nickel, copper, bismuth, zinc, indium, tin, molybdenum, antimony, zirconium, silver, gold, chromium-zinc alloy, brass, bronze and mixtures of two or more of said metals, provided that when the foil has two metallic layers on one side, the second metallic layer does not contain vapor-deposited alumina or silica when the first metallic layer contains zinc.

Claim 35

Dependent Claim 13 words

The copper foil of claim 32 wherein the foil is an electrodeposited foil.

Claim 36

Dependent Claim 40 words

The copper foil of claim 33 wherein the copper foil has a matte side and a shiny side, and the at least one vapor-deposited metallic layer overlies and is adhered to at least the matte side of the copper foil.

Claim 37

Dependent Claim 36 words

The copper foil of claim 33 wherein the copper foil has a matte side and a shiny side, and the at least one vapor-deposited metallic layer overlies and adheres to both sides of the copper foil.

Claim 38

Dependent Claim 25 words

The copper foil of claim 35 wherein the adhesion-promoting layer overlies and is adhered to the vapor-deposited metallic layer on both sides of the foil.

Claim 39

Dependent Claim 45 words

The copper foil of claim 34 wherein the metal of the metallic layer on the matte side is selected from the group consisting of indium, zinc, tin, cobalt, copper, nickel, manganese, chromium, titanium, bismuth, zinc-chromium alloys, and mixtures of two or more of said metals.

Claim 40

Dependent Claim 32 words

The copper foil of claim 29 wherein a base surface of the metal foil underlying said at least one vapor-deposited metallic layer is characterized by the absence of any added surface toughening.

Claim 41

Dependent Claim 34 words

The copper foil of claim 33 wherein a roughened layer selected from the group consisting of copper and copper oxide is positioned between the copper foil and said at least one vapor-deposited metallic layer.

Claim 42

Dependent Claim 48 words

The copper foil of claim 32 wherein the copper foil is a controlled low profile electrodeposited copper foil having a substantially uniform randomly oriented grain structure that is essentially columnar grain free and twin boundary free and has an average grain size of up to about 10 microns.

Claim 43

Dependent Claim 47 words

The copper foil of claim 32 wherein the copper foil is a standard profile electrodeposited copper having a columnar grain structure of preferred orientation and high densities of crystal defects including discolorations and twin boundaries and having an average grain size of up to about 20 microns.

Claim 44

Dependent Claim 23 words

The metal foil of claim 32 wherein the organic adhesion-promoting material is selected from the group epoxy resins, formaldehyde resins, and mixtures thereof.

Claim 45

Dependent Claim 16 words

The metal foil of claim 32 wherein the adhesion-promoting layer comprises at least one organometallic compound.

Claim 46

Dependent Claim 101 words

The metal foil of claim 43 wherein the organometallic compound comprises at least one organo silane compound represented by the formula R.sub.4-n SiX.sub.n wherein R is selected from the group consisting of an alkyl group, an aryl group, and a functional group represented by the formula C x H 2x Y; x is from 0 to 20; Y is selected from the group consisting of amino, amido, hydroxy, alkoxy, halo, mercapto, carboxy, aryl, vinyl, allyl, styryl, epoxy, isocyanate, glycidoxy, and acryloxy groups, X is a hydrolyzable group; and n is selected from the group consisting of 1, 2, 3, and 4.

Claim 47

Dependent Claim 15 words

The copper foil of claim 32 wherein the adhesion-promoting layer is applied by vapor deposition.

Claim 48

Dependent Claim 76 words

A metal body having at least one side which has been chemically or physically treated to etch the side or to deposit a metallic coating electrochemically, at least one vapor-deposited treatment layer overlying and adhering to the at least one etched or electrochemically-deposited coating, and a layer of adhesion-promoting material overlying and adhered to the at least one vapor-deposited treatment layer, said adhesion-promoting layer material being suitable for enhancing adhesion between said body and a substrate.

Claim 49

Dependent Claim 76 words

A metal body having at least one side which has been chemically or physically treated to etch the side or to deposit a metallic coating electrochemically, at least one vapor-deposited treatment layer overlying and adhering to the at least one etched or electrochemically-deposited coating, and a layer of adhesion-promoting material overlying and adhered to the at least one vapor-deposited treatment layer, said adhesion-promoting layer material being suitable for enhancing adhesion between said body and a substrate.

Claim 50

Dependent Claim 14 words

The metal body of claim 46 wherein the metal body is a metal foil.

Claim 51

Dependent Claim 14 words

The metal body of claim 46 wherein the metal body is a copper foil.

Claim 52

Dependent Claim 63 words

A laminate comprising (A) a metal foil; (B) at least one vapor-deposited treatment layer overlying and adhered to at least one side of the metal foil; (C) a layer of adhesion-promoting material overlying and adhered to at least one of the at least one vapor-deposited treatment layer; and (D) a layer of an electrically non-conductive material overlying and adhered to the adhesion-promoting layer.

Claim 53

Dependent Claim 63 words

A laminate comprising (A) a metal foil; (B) at least one vapor-deposited treatment layer overlying and adhered to at least one side of the metal foil; (C) a layer of adhesion-promoting material overlying and adhered to at least one of the at least one vapor-deposited treatment layer; and (D) a layer of an electrically non-conductive material overlying and adhered to the adhesion-promoting layer.

Claim 54

Dependent Claim 21 words

The laminate of claim 49 wherein at least one of the at least one treatment layer is a vapor-deposited metallic layer.

Claim 55

Dependent Claim 27 words

The laminate of claim 50 wherein at least one of the at least one metallic layer overlies and is adhered to each side of the metal foil.

Claim 56

Dependent Claim 41 words

The laminate of claim 50 wherein at least one of the at least one metallic layer overlies and is adhered to both sides of the metal foil, and the adhesion-promoting layer overlies and adheres to the metallic layer on both sides.

Claim 57

Dependent Claim 13 words

The laminate of claim 49 wherein the metal foil is a copper foil.

Claim 58

Dependent Claim 67 words

An etched laminate comprising (A) an electroconductive metal foil having one side etched; (B) at least one vapor-deposited treatment layer overlying and adhering to another side of the electroconductive metal foil; (C) a layer of adhesion-promoting material overlying and adhered to at least one of the at least one treatment layer; and (D) a layer of an electrically non-conductive material overlying and adhered to the adhesion-promoting layer.

Claim 59

Dependent Claim 67 words

An etched laminate comprising (A) an electroconductive metal foil having one side etched; (B) at least one vapor-deposited treatment layer overlying and adhering to another side of the electroconductive metal foil; (C) a layer of adhesion-promoting material overlying and adhered to at least one of the at least one treatment layer; and (D) a layer of an electrically non-conductive material overlying and adhered to the adhesion-promoting layer.

Claim 60

Dependent Claim 67 words

A multi-layer etched laminate comprising an etched electrically conductive metal foil having opposed first and second sides; a vapor-deposited metallic layer overlying and adhered to said first side and the second side of the metal foil; (C) a layer of adhesion-promoting material overlying and adhered to the two metallic layers; and (D) a layer of an electrically non-conductive material overlying and adhered to the two adhesion-promoting layers.

Claim 61

Dependent Claim 67 words

A multi-layer etched laminate comprising an etched electrically conductive metal foil having opposed first and second sides; a vapor-deposited metallic layer overlying and adhered to said first side and the second side of the metal foil; (C) a layer of adhesion-promoting material overlying and adhered to the two metallic layers; and (D) a layer of an electrically non-conductive material overlying and adhered to the two adhesion-promoting layers.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-01-19	2001-07-21	2002-01-20	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-01-19	2005-07-21	2006-01-20	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-01-19	2009-07-21	2010-01-20	$7700.00	Window Closed / Lapsed

Metallic body with vapor-deposited treatment layer(s) and adhesion-promoting layer

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