Pattern Metallization: Selective Deposition of Metals …...Pattern Metallization: Selective Deposition of Metals on Polymer Films for Functional Applications Wolfgang Decker VAST

AIMCAL Fall Conference 2005VAST VAST Value Added Surface Technology

Pattern Metallization: Selective Deposition of Metals

on Polymer Films for Functional Applications

Wolfgang DeckerVAST FILMS, Ltd.

101 Aid DriveDarlington, PA 16115

[email protected]: 724 827 8827Fax: 724 827 2020

www.vastfilm.com

VAST VAST Value Added Surface Technology


Pattern Metallization: Outline

• What is Pattern Metallization

• Technologies– Demetallization

– In Chamber Patterning

• Applications– Decorative

– Functional

– Security

• In-Chamber Pattern Metallization: Capabilities and Limitations


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: 4,494,168; Kume et.al.

Source: US Pat: 5,953,202; Walters


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

Apply Masking Solution

Vacuum Metallizing

Step #1

Demetallizing

Step #2

Cure stage

Acid Bath (demetallize)

Web Drying Stage

DemetallizingProcess

Web Cleaning Stage



• Masking during Metallization– See Patent 3,799,794

to Stanley Rying, 1974, assigned to TI

– Masking Belt is moving with the Web



• In Chamber Pattern Metallization

– Applications of Oil Mask that prevents deposition of Metal.

– Commonly used for Clear Edge Metallization for Capacitors

20

21

22

24

23

26

27

28 25

for fluid transport

Special oil(low surface tension)

Oil pattern

Al evaporation

Heat of Al condensationevaporates oil and

prevents Al deposition

PatternedAluminum

Unwind Wind-up

SteelRoller

Picture Courtesy of Flex Products

Rubber Rollerwith pattern

Ceramic Roll


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


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

• Electronic Circuits– Flexible Circuits for Electronic

and Medical Applications

• RFID– Antenna Circuits: Still disputes

about minimum metal thickness for proper absorption of RF Energy

Source: Inline Packaging, www.inline-pkg.com. *

* Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any relations between VAST FILMS and the sources of these Products and Pictures.

RFID Antennae “grown” from conductive inks and electrolessplating (QINETIQ). Source: www.rfid-journal.com


Applications: Functional (2)• Security Threads for Currency Applications (Flex Products)

* Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any relations between VAST FILMS and the sources of these Products and Pictures.

Text in transmission, OVD in reflection

Magenta-to-green with silver background – all reflection


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



• Process Capabilities

Mil

lim

eter

Sca

le

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 VAST FILMS and the sources of these Products and Pictures.



• 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 VAST FILMS and the sources of these Products and Pictures.



• 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



• Issues and Limitations:

– Residuals• Can be removed with O2 Treatment

Pictures Courtesy of Flex Products

* Disclaimer: Products and Pictures shown are for demonstration purpose only, and do not imply any business relations between VAST FILMS and the sources of these Products and Pictures.

After: 10º and 30ºViewing

Before


Conclusion• Pattern Metallizing via In-Chamber Patterning

offers a wide range of interesting applications for metallized films.

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Pattern Metallization: Selective Deposition of Metals …...Pattern Metallization: Selective Deposition of Metals on Polymer Films for Functional Applications Wolfgang Decker VAST