Pattern Metallization: Selective Deposition of Metals on Polymer Films for Functional Applications

Transcription

1 Pattern Metallization: Selective Deposition of Metals on Polymer Films for Functional Applications Wolfgang Decker FILMS, Ltd. 101 Aid Drive Darlington, PA Phone: Fax:

2 Pattern Metallization: Outline What is Pattern Metallization Technologies Demetallization In Chamber Patterning Applications Decorative Functional Security In-Chamber Pattern Metallization: Capabilities and Limitations

3 Pattern Metallizing Patterned - / Selective - / De-Metallized Films Partially Metallized Films, where the metal free areas have distinct patterns: Lines Used e.g. in Capacitors Geometric Areas: Squares, Triangles, Circles etc. Windows in Mailing Envelopes Abstract Patterns Fuse Pattern in Capacitors Decorative Patterns Pictures Source: US Pat: 5,953,202; Walters Source: US Pat: 4,494,168; Kume et.al.

4 Selective Metallization Techniques (1) Demetallization 2 Methods: 1. Masking of Metal supposed to remain metallized 2. Application of Caustic Past on Areas to be cleared Step #1 Step #2 Vacuum Metallizing Demetallizing Demetallizing Process Apply Masking Solution Cure stage Acid Bath (demetallize) Web Cleaning Stage Web Drying Stage

5 Selective Metallization Techniques (2) Masking during Metallization See Patent 3,799,794 to Stanley Rying, 1974, assigned to TI Masking Belt is moving with the Web

6 Selective Metallization Techniques (3) In Chamber Pattern Metallization Applications of Oil Mask that prevents deposition of Metal. Commonly used for Clear Edge Metallization for Capacitors Unwind Wind-up Steel Rubber Roller Roller Patterned with pattern Aluminum Ceramic Roll Oil pattern Heat of Al condensation for fluid transport evaporates oil and prevents Al deposition Al evaporation Special oil (low surface tension) Picture Courtesy of Flex Products 27

7 Applications: Decorative Metal Ink Replacement Selective Metal provides better Graphics Print Design Enhancements Reduction on Overcoat Varnishes Windows in Metallized Packages Hot Stamping / Transfer Films Higher Resolutions Possible Holographic Films Allows Selective Holographic Effects

8 Applications: Functional (1) Microwave Susceptors Metallized at ~ 0.27 O.D. Patterns create areas with different heating Allows more uniform and quicker heating of foodstuff Capacitors High End Fail Safe Film Capacitors Source: Inline Packaging, * Electronic Circuits Flexible Circuits for Electronic and Medical Applications RFID Antenna Circuits: Still disputes about minimum metal thickness for proper absorption of RF Energy RFID Antennae grown from conductive inks and electroless plating (QINETIQ). Source: * Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any relations between FILMS and the sources of these Products and Pictures.

9 Applications: Functional (2) Security Threads for Currency Applications (Flex Products) Text in transmission, OVD in reflection Magenta-to-green with silver background all reflection * Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any relations between FILMS and the sources of these Products and Pictures.

10 In Chamber Patterning: Process Capabilities, Issues and Limitations (1) Process Capabilities Pattern Metallization possible at high Speeds (up to ~ 10m/s) Resolution up to 300 lpi High Edge Resolution Millimeter Scale 150 lpi Gray Scale

11 In Chamber Patterning: Process Capabilities, Issues and Limitations (2) Millimeter Scale Process Capabilities 70 µ Pictures Courtesy of Flex Products * Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any business relations between FILMS and the sources of these Products and Pictures.

12 In Chamber Patterning: Process Capabilities, Issues and Limitations (3) Edge Resolution: AFM Analysis of Oil Ablated Side Wall Pictures Courtesy of Flex Products * Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any business relations between FILMS and the sources of these Products and Pictures.

13 In Chamber Patterning: Process Capabilities, Issues and Limitations (3) Issues and Limitations: Maximum Oil Coverage limited Interaction between Al and Oil possible Too much Oil Vapor increases Residuals Food Packaging Needs Food Compatible Oil due to Residuals Compatibility of Oil to Substrate Some substrates may absorb some Oil Types

14 In Chamber Patterning: Process Capabilities, Issues and Limitations (4) Issues and Limitations: Residuals Can be removed with O2 Treatment Before After: 10º and 30º Viewing Pictures Courtesy of Flex Products * Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any business relations between FILMS and the sources of these Products and Pictures.

15 Conclusion Pattern Metallizing via In-Chamber Patterning offers a wide range of interesting applications for metallized films.

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