Stock material or miscellaneous articles – All metal or with adjacent metals – Foil or filament smaller than 6 mils
Patent
1989-05-03
1992-02-18
Zimmerman, John J.
Stock material or miscellaneous articles
All metal or with adjacent metals
Foil or filament smaller than 6 mils
428626, 428409, 428457, 428458, 72166, B32B 1508, B21D 100
Patent
active
050893556
DESCRIPTION:
BRIEF SUMMARY
DESCRIPTION
1. Technical Field
This invention relates to an elongated flexible metal clad laminate (hereinafter abbreviated as "FMCL") which includes a layer of a function plastic, e.g., a plastic excellent in heat resistance, electrical characteristics and mechanical characteristics such as a polyimide, a low dielectric-constant plastic such as polytetrafluoroethylene, a heat-sealable plastic such as polyethylene or a chemical resistant plastic such as polypropylene, and a metal layer having electrical conductivity, heat conductivity, electromagnetic shielding properties, gas barrier properties and the like, and which is useful in application fields such as the electrical, electronic, packaging and ornamentation fields. This invention is concerned with a flexible metal clad laminate formed of at least one metal layer and at least one plastic layer and having a smaller interlayer dimensional difference and excellent processability. A defect occurred in the step of lamination between the metal layer and plastic layer or a like step, that a dimension of the metal layer is longer than a corresponding dimension of the plastic layer when they are compared to each other as discrete layers, has been successfully corrected by causing the metal layer to continually undergo compression plastic deformation in the form of the laminate and hence compressing the metal layer. This invention also relates to a production method of the flexible metal clad laminate and to an apparatus for practising the method.
2. Background Art
Flexible metal clad laminates (FMCLs) formed of at least one metal layer and at least one plastic layer are used as materials making full use of characteristics of both a metal and a plastic, for example, as wrapping materials, substrates for flexible printed circuits, covering materials for electromagnetically-shielded wires and cables, electromagnetically-shielding films, etc.
It is necessary for these FMCLs that a suitable dimensional relationship be satisfied between a metal layer and its associated plastic layer in view of processing means and application purposes.
However, the production of FMCL is generally conducted by bonding a metal foil and a plastic film with an adhesive under heat, continually forming a plastic film over a metal foil, coating a metal foil with a solvent solution of a plastic polymer, or forming a metal on a plastic film by sputtering, vacuum evaporation or electroless plating. There is therefore a dimensional difference, in general, of about 0.1-5% between the metal layer and plastic layer due to the difference in the coefficient of thermal expansion, tensile strength, compression strength, the modulus of elasticity or percentage water absorption between the metal and plastic, the occurrence of shrinkage upon drying of the solvent, the occurrence of shrinkage upon curing. Although the tolerable dimensional difference varies from one application field to another, the dimensional difference tends to fall outside of a desired tolerable range in many instances. Those engaged in the present field of art hence have difficulties in coping with inconvenience caused by such a dimensional difference. For example, this dimensional difference is required not to exceed 0.3% in the field of flexible printed circuit boards and 0.05% in the field of TAB (tape automated bonding).
Although such a dimensional difference cannot be quantitatively measured so long as FMCL is measured as is. Its measurement is however feasible provided that the elements, namely, the metal layer and plastic layer are separated from each other into discrete elements by a method not inducing a stress.
In many instances, the dimension of a plastic layer is generally smaller than a suitable range, in other words, shorter compared to the dimension of its associated metal layer.
A shorter plastic layer brings about adverse effects, which may be divided into the following two types roughly.
a) FMCL is curled with the plastic layer being located inside. Extreme difficulties are therefore encountered upon its further w
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Morita Moritsugu
Naito Mitsuyuki
Sato Takushi
Shishido Shigeyuki
Tanabe Kenji
Mitsui Toatsu Chemicals Incorporated
Zimmerman John J.
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