US5863666A
Expired / Lapsed
US
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High performance flexible laminate
Assignee: Gould Electronics Inc
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Filing: 1997-08-07
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Granted: 1999-01-26
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Expires: 2017-08-07
Abstract
Abstract This invention relates to an improved high performance flexible laminate, comprising: a layer of electrodeposited copper foil overlying a layer of a flexible polymeric material, said copper foil being characterized by an ultimate tensile strength at 23° C. of at least about 60,000 psi, a loss of ultimate tensile strength at 23° C. of no more than about 15% after being annealed at 180° C. for 30 minutes, an average grain size of up to about 1 micron, and a fatigue performance characterized by at least about 5000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%. In one embodiment, the copper foil is electrodeposited using an electrolyte solution characterized by a free chloride ion concentration of up to about 4 ppm and an organic additive concentration of at least about 0.3 ppm.
Inventors
- 👤 Harish D. Merchant
- 👤 Sidney J. Clouser
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 19:31
CPC Classifications
C; C25; C25D; C25D3/00; C25D3/02; C25D3/38; H; H05; H05K; H05K1/00; H05K1/02; H05K1/09; H05K1/03; H05K1/0393; H05K2201/00; H05K2201/03; H05K2201/0332; H05K2201/0335; H05K2201/0355; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12431; Y10T428/12493; Y10T428/24; Y10T428/24802; Y10T428/24917; Y10T428/28; Y10T428/2804
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
94 words
A flexible laminate comprising a layer of electrodeposited copper foil overlying a layer of a flexible polymeric material, said copper foil being characterized by an ultimate tensile strength at 23° C. of at least about 60,000 psi, a loss of ultimate tensile strength at 23° C. of no more than about 15% after being annealed at 180° C. for 30 minutes, an average grain size of up to about 1 micron, and a fatigue performance characterized by at least about 5000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 2
Dependent Claim
94 words
A flexible laminate comprising a layer of electrodeposited copper foil overlying a layer of a flexible polymeric material, said copper foil being characterized by an ultimate tensile strength at 23° C. of at least about 60,000 psi, a loss of ultimate tensile strength at 23° C. of no more than about 15% after being annealed at 180° C. for 30 minutes, an average grain size of up to about 1 micron, and a fatigue performance characterized by at least about 5000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 3
Dependent Claim
33 words
The laminate of claim 1, characterized in that the copper foil has an ultimate tensile strength at 23° C. in the range of about 60,000 to about 120,000 psi prior to being annealed.
Claim 4
Dependent Claim
33 words
The laminate of claim 1, characterized in that the copper foil exhibits a loss in ultimate tensile strength of not more than about 5% after being annealed at 180° C. for 30 minutes.
Claim 5
Dependent Claim
40 words
The laminate of claim 1, characterized in that the copper foil is electrodeposited using an electrolyte solution characterized by a chloride ion concentration of up to about 4 ppm and an organic additive concentration of at least about 0.3 ppm.
Claim 6
Dependent Claim
14 words
The laminate of claim 4, characterized in that the organic additive is a gelatin.
Claim 7
Dependent Claim
15 words
The laminate of claim 5, characterized in that the organic additive is an animal glue.
Claim 8
Dependent Claim
24 words
The laminate of claim 4, characterized in that the organic additive concentration is in the range from about 0.3 ppm to about 10 ppm.
Claim 9
Dependent Claim
18 words
The laminate of claim 4, characterized in that the chloride ion concentration is up to about 1 ppm.
Claim 10
Dependent Claim
33 words
The laminate of claim 1, wherein the fatigue performance of the copper foil is characterized by at least about 50,000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 11
Dependent Claim
33 words
The laminate of claim 1, wherein the fatigue performance of the copper foil is characterized by at least about 500,000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 12
Dependent Claim
27 words
The laminate of claim 1, characterized in that said copper foil has a matte side R tm in the range of about 1 to about 10 microns.
Claim 13
Dependent Claim
24 words
The laminate of claim 1, characterized in that said copper foil has a shiny side R tm that is less than about 6 microns.
Claim 14
Dependent Claim
28 words
The laminate of claim 1, characterized in that said copper foil has at least one roughened layer of copper applied to one or both sides of said foil.
Claim 15
Dependent Claim
51 words
The laminate of claim 1, characterized in that said copper foil has at least one metallic layer applied to one or both sides of said foil, the metal in said metallic layer being selected from the group consisting of indium, zinc, tin, nickel, cobalt, copper-zinc mixture, copper-tin mixture, and zinc-nickel mixture.
Claim 16
Dependent Claim
47 words
The laminate of claim 1, characterized in that said copper foil has at least one metallic layer applied to one or both sides of said foil, the metal in said metallic layer being selected from the group consisting of tin, chromium, chromium-zinc mixture, zinc, and zinc-nickel mixture.
Claim 17
Dependent Claim
100 words
The laminate of claim 1, characterized in that said copper foil has at least one roughened layer of copper applied to one or both sides 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 mixture, copper-tin mixture, and zinc-nickel mixture, 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, chromium-zinc mixture, zinc, and zinc-nickel mixture.
Claim 18
Dependent Claim
26 words
The laminate of claim 1, characterized in that said copper foil has at least one silane coupling agent overlying one or both sides of said foil.
Claim 19
Dependent Claim
28 words
The laminate of claim 1, characterized in that the polymeric material is comprised of a thermosetting resin, thermoplastic resin, condensation polymer, or mixture of two or more thereof.
Claim 20
Dependent Claim
17 words
The laminate of claim 1, characterized in that the polymeric material is comprised of polyimide or polyester.
Claim 21
Dependent Claim
24 words
The laminate of claim 1, characterized in that the layer of copper foil is adhered to the layer of polymeric material by an adhesive.
Claim 22
Dependent Claim
19 words
The laminate of claim 20, characterized in that the adhesive is an epoxy, acrylic, polyimide, phenolic butyral or polyester.
Claim 23
Dependent Claim
25 words
The laminate of claim 1, characterized in that the layer of copper foil is adhered to the layer of polymeric material using an adhesiveless technique.
Claim 24
Dependent Claim
27 words
The laminate of claim 22, characterized in that a copper seed coat layer is positioned between the layer of copper foil and the layer of polymeric material.
Claim 25
Dependent Claim
21 words
The laminate of claim 1, characterized in that the layer of copper foil is in the form of an etched pattern.
Claim 26
Dependent Claim
97 words
A flexible laminate comprising a layer of electrodeposited copper foil overlying a layer of a flexible polymeric material, said copper foil being characterized by an ultimate tensile strength at 23° C. of about 90,000 psi to about 105,000 psi, a loss of ultimate tensile strength at 23° C. of no more than about 8% after being annealed at 180° C. for 30 minutes, an average grain size of about 0.1 to about 0.5 micron, and a fatigue performance characterized by at least about 100,000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 27
Dependent Claim
97 words
A flexible laminate comprising a layer of electrodeposited copper foil overlying a layer of a flexible polymeric material, said copper foil being characterized by an ultimate tensile strength at 23° C. of about 90,000 psi to about 105,000 psi, a loss of ultimate tensile strength at 23° C. of no more than about 8% after being annealed at 180° C. for 30 minutes, an average grain size of about 0.1 to about 0.5 micron, and a fatigue performance characterized by at least about 100,000 cycles to failure when the strain amplitude is about 0.05% to about 0.2%.
Claim 28
Dependent Claim
41 words
The laminate of claim 25, characterized in that the copper foil is electrodeposited using an electrolyte solution characterized by a chloride ion concentration of up to about 1 ppm and an animal glue concentration of about 2 to about 4 ppm.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2002-01-25 | 2002-07-27 | 2003-01-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-01-25 | 2006-07-27 | 2007-01-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-01-25 | 2010-07-27 | 2011-01-26 | $7700.00 | Window Closed / Lapsed |