US6060175A
Expired / Lapsed
US
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Metal-film laminate resistant to delamination
Assignee: Multek Flexible Circuits Inc
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Filing: 1997-07-10
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Granted: 2000-05-09
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Expires: 2017-07-10
Abstract
Abstract A flexible metal-film laminate can comprise a layered film structure having a metal layer securely bonded to a film layer. The laminate contains a unique metal-oxide attachment structure between the film and metal layer comprising randomly distributed regions of metal-oxide. After the metal/metal-oxide layer, a chromium metal or chromium alloy layer is formed before subsequent layers of copper, gold, etc. The peel strength of such a laminate is significantly improved over prior laminates and is resistant to peel strength reduction due to environmental stress. The preferred metal-film laminates made with polyester or polyimide can be used in the manufacture of high-quality, low cost, flexible printed circuit boards.
Inventors
- 👤 Richard L. Swisher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 11:22
CPC Classifications
H; H05; H05K; H05K3/00; H05K3/38; H05K3/388; C; C23; C23C; C23C14/00; C23C14/02; C23C14/021; C23C14/022; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12472; Y10T428/12493; Y10T428/12535; Y10T428/12542; Y10T428/12549; Y10T428/12556; Y10T428/12569; Y10T428/12771; Y10T428/12861; Y10T428/12903; Y10T428/1291
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
162 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof; and (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (i) a sputtered first metal layer comprising a chromium metal composition having a thickness of about 10 to 100 Å; (ii) a second metal layer, formed on the first metal layer by vapor metallization, having a thickness of about 50 to 5000 Å; and (iii) a third metal layer having a thickness of 0.1 to 40 μm formed on the second layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 2
Dependent Claim
162 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof; and (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (i) a sputtered first metal layer comprising a chromium metal composition having a thickness of about 10 to 100 Å; (ii) a second metal layer, formed on the first metal layer by vapor metallization, having a thickness of about 50 to 5000 Å; and (iii) a third metal layer having a thickness of 0.1 to 40 μm formed on the second layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 3
Dependent Claim
42 words
The laminate of claim 1 wherein the metal-oxide distribution results from a film treatment with a plasma comprising ionized oxygen, produced from a metallic electrode comprising a metal selected from the group consisting of manganese, chromium, nickel, iron, molybdenum or mixtures thereof.
Claim 4
Dependent Claim
23 words
The laminate of claim 1 wherein the first metal layer comprises chromium metal and has a thickness of about 20 to 100 Å.
Claim 5
Dependent Claim
18 words
The laminate of claim 1 wherein the second metal layer is copper and is formed by metal vaporization.
Claim 6
Dependent Claim
17 words
The laminate of claim 1 wherein the third metal layer is a copper layer formed by electrodeposition.
Claim 7
Dependent Claim
23 words
The laminate of claim 5 wherein a further metal layer comprising gold, silver, palladium, nickel or mixtures thereof is formed using electroless techniques.
Claim 8
Dependent Claim
153 words
A metal-film laminate, resistant to delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium, or mixtures thereof, said distribution less than 20 atomic layers in thickness; and (b) a metallic surface adhered to the film through the random distribution, said surface comprising: (i) a sputtered first metal layer comprising an alloy comprising nickel and chromium having a thickness of 10 to 100 Å; (ii) a second metal layer formed on the first layer by vapor metallization, having a thickness of about 50-5000 Å; and (iii) a third layer comprising copper having a thickness of 0.1 to 40 μm formed on the second metal layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 9
Dependent Claim
153 words
A metal-film laminate, resistant to delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium, or mixtures thereof, said distribution less than 20 atomic layers in thickness; and (b) a metallic surface adhered to the film through the random distribution, said surface comprising: (i) a sputtered first metal layer comprising an alloy comprising nickel and chromium having a thickness of 10 to 100 Å; (ii) a second metal layer formed on the first layer by vapor metallization, having a thickness of about 50-5000 Å; and (iii) a third layer comprising copper having a thickness of 0.1 to 40 μm formed on the second metal layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 10
Dependent Claim
27 words
The laminate of claim 7 wherein the first metal layer comprises about 5-25% chromium and 55-75% nickel and has a thickness of about 20 to 100 Å.
Claim 11
Dependent Claim
13 words
The laminate of claim 7 wherein the third layer is formed by electro-deposition.
Claim 12
Dependent Claim
12 words
The laminate of claim 7, wherein the polyimide film comprises a polyetherimide.
Claim 13
Dependent Claim
160 words
A metal-film laminate, resistant to delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of a metal and an oxide of a metal selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof; and (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (i) a sputtered first metal layer comprising an alloy of chromium and nickel having a thickness of about 10 to 100 Å; (ii) a first copper layer, formed on the first metal layer by vapor metallization, having a thickness of about 50 to 5000 Å; and (iii) a second copper layer having a thickness of 0.1 to 40 μm formed on the first copper layer; wherein the laminate is free of a metal tie-coat and the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 14
Dependent Claim
160 words
A metal-film laminate, resistant to delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one surface bearing a non-continuous random distribution of a metal and an oxide of a metal selected from the group consisting of iron, chromium, nickel, molybdenum, manganese, zirconium or mixtures thereof; and (b) a metal surface adhered to the film through the random distribution, said metal surface comprising: (i) a sputtered first metal layer comprising an alloy of chromium and nickel having a thickness of about 10 to 100 Å; (ii) a first copper layer, formed on the first metal layer by vapor metallization, having a thickness of about 50 to 5000 Å; and (iii) a second copper layer having a thickness of 0.1 to 40 μm formed on the first copper layer; wherein the laminate is free of a metal tie-coat and the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 15
Dependent Claim
19 words
The laminate of claim 11 wherein the first metal layer has a thickness of about 20 to 100 Å.
Claim 16
Dependent Claim
14 words
The laminate of claim 11 wherein the second copper layer is formed by electrodeposition.
Claim 17
Dependent Claim
148 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one through hole, said layer and through hole bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium and mixtures thereof, said distribution less than 20 atomic layers in thickness; and (b) a metal surface adhered to the film and through-hole through the random distribution, said metal surface comprising: (i) a first metal layer comprising a chromium metal composition, formed on the metal-oxide regions by sputtering, having a thickness of about 10 to 100 Å; and (ii) a copper metallized vapor layer having a thickness of 10 to 1800 Å formed on the first metal layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 18
Dependent Claim
148 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film layer having at least one through hole, said layer and through hole bearing a non-continuous random distribution of metal-oxide, said metal-oxide selected from the group consisting of oxides of iron, chromium, nickel, molybdenum, manganese, zirconium and mixtures thereof, said distribution less than 20 atomic layers in thickness; and (b) a metal surface adhered to the film and through-hole through the random distribution, said metal surface comprising: (i) a first metal layer comprising a chromium metal composition, formed on the metal-oxide regions by sputtering, having a thickness of about 10 to 100 Å; and (ii) a copper metallized vapor layer having a thickness of 10 to 1800 Å formed on the first metal layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 19
Dependent Claim
42 words
The laminate of claim 14 wherein the metal-oxide regions result from a film treatment with a plasma comprising ionized oxygen, produced from a metallic electrode comprising a metal selected from the group consisting of manganese, chromium, nickel, iron, molybdenum or mixtures thereof.
Claim 20
Dependent Claim
153 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film having at least one through-hole; (b) a non-continuous random distribution on the polyimide film, said distribution comprising a metal-oxide, said metal-oxide selected from the group consisting of oxides of chromium, iron, nickel, manganese, molybdenum, zirconium and mixtures thereof; and (c) a metal surface adhered to the film through the random distribution, said surface comprising: (i) a sputtered first metal layer comprising an alloy comprising nickel and chromium having a thickness of 10 to 100 Å; (ii) a metal layer comprising copper formed on the first metal layer by vapor metallization having a thickness of about 50 to 1800 Å; and (iii) a second copper layer having a thickness of 0.1 to 40 μm formed on the metallized layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 21
Dependent Claim
153 words
A metal-film laminate, resistant to the delamination of the metal from the film, which laminate comprises: (a) a polyimide film having at least one through-hole; (b) a non-continuous random distribution on the polyimide film, said distribution comprising a metal-oxide, said metal-oxide selected from the group consisting of oxides of chromium, iron, nickel, manganese, molybdenum, zirconium and mixtures thereof; and (c) a metal surface adhered to the film through the random distribution, said surface comprising: (i) a sputtered first metal layer comprising an alloy comprising nickel and chromium having a thickness of 10 to 100 Å; (ii) a metal layer comprising copper formed on the first metal layer by vapor metallization having a thickness of about 50 to 1800 Å; and (iii) a second copper layer having a thickness of 0.1 to 40 μm formed on the metallized layer; wherein the peel strength of the metal-film laminate is at least 3 pounds per inch.
Claim 22
Dependent Claim
19 words
The laminate of claim 16 wherein the metal-oxide regions result from an oxygen plasma produced from a metallic electrode.
Claim 23
Dependent Claim
14 words
The laminate of claim 16 wherein the second copper layer is formed by electrodeposition.
Claim 24
Dependent Claim
21 words
The laminate of claim 16 wherein the random distribution comprises a chromium-oxide in a thickness of less than 5 atom monolayers.
Claim 25
Dependent Claim
12 words
The laminate of claim 16 wherein the polyimide film comprises a polyetherimide.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2003-05-09 | 2003-11-08 | 2004-05-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2007-05-09 | 2007-11-08 | 2008-05-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2011-05-09 | 2011-11-08 | 2012-05-09 | $7700.00 | Window Closed / Lapsed |