Olin Corporation

Gbc Metals, LLC

William L Brenneman

Szuchain F Chen

Joseph Winter

Michael J Pryor

Eugene Shapiro

John F Breedis

Julius C Fister

Peter W Robinson

Andrew Vacco

Derek E Tyler

Arvind Parthasarathi

Gary L Ungarean

W Gary Watson

Ronald N Caron

Dennis R Brauer

Nina Yukov

Phillip A Chatfield

Richard P Vierod

In one aspect, a copper foil for lamination to a dielectric substrate includes a layer deposited on a surface of the copper foil. The layer is formed from chromium and zinc ions or oxides and is treated with an aqueous solution containing at least 0.5% silane. In another aspect, a peel strength enhancement coating is disposed between a copper foil laminate and a dielectric substrate. The peel strength enhancement coating comprises a metal and metal oxide mixture containing a metal selected from groups 5B, 6B, and 7B of the periodic table of the elements. The effective thickness of the peel strength enhancement coating is that thickness capable of providing less than or equal to 10% loss of peel strength, when measured in accordance with IPC-TM-650 Method 2.4.8.5 using a &#x215b; inch wide test specimen, after being immersed in 4N HCl at about 60&#xb0; C. for 6 hours.

Peel strength enhancement of copper laminates

A composite material useful for the manufacture of a circuit has a support layer, a metal foil layer having opposing first and second sides and a thickness of 15 microns or less and a release layer effective to facilitate separation of the metal foil layer from the support layer, the release layer disposed between and contacting both the support layer and the metal foil layer. A reactive element containing layer, which may be the support layer, effective to react with gaseous elements or compounds to form thermally stable compounds contacts the release layer. The composite material is preferably subjected to a low temperature heat treatment. The combination of the low temperature heat treatment and the reactive element containing layer results in reduced defects including blisters in the copper foil during subsequent processing.

Method for manufacturing a composite material including copper foil and support layer

Support layer for thin copper foil

A composite material, comprising a carrier strip the carrier strip comprising a first side the first side comprising a substantially uniform roughness, an electrolytically deposited copper foil layer having opposing first and second sides and a thickness of from 0.1 micron to 15 microns and the entire metal foil layer thickness having been deposited from a copper containing alkaline electrolyte, and a release layer effective to facilitate separation of the metal foil layer from the carrier strip disposed between and contacting both the first side of the carrier strip and the second side of the metal foil layer.

Copper foil with low profile bond enhancement

A copper alloy having improved resistance to stress relaxation contains controlled additions of iron, phosphorous and magnesium. Free magnesium, in solid solution with the copper, increases the alloy's resistance to stress relaxation. Copper alloys of the invention retain at least 70% of the initial stress following exposure to a temperature of 105.degree. C. for 3000 hours, making the alloys particulary useful for electrical connector components.

Copper alloy having improved stress relaxation

A copper alloy achieves high electrical conductivity, in excess of 70% IACS; high strength, ultimate tensile strength in excess of 75 ksi; good surface cosmetics; and good stampability, above 25% break, by controlled additions of magnesium, iron and phosphorous. There is a critical iron content to achieve both good stampability and high electrical conductivity and a critical phosphorous content to achieve high strength and relatively small metal phosphide particles. There is further, a critical relationship between the amount of iron and phosphorous. An additions of magnesium, in amounts of more than 0.03%, broadens the effective ratio of iron to phosphorous, widening the composition box of the alloys of the invention.

Copper alloy with magnesium addition

There is provided a phosphor bronze alloy having a grain structure that is refined by the addition of a controlled amount of iron. Direct chill cast alloys containing from 1.5% to 2.5%, by weight tin, from 1.65% to 2.65% iron, from 0.03% to 0.35% phosphorous and the remainder copper and inevitable impurities have an as-cast average crystalline grain size of less than 100 microns and are readily hot worked. When the iron content is too low, the average crystalline grain size increases and the alloy cracks during hot working. When the iron content is too high, iron stringers form, detrimentally impacting both the appearance and properties of a wrought strip.

Iron modified phosphor-bronze

A copper alloy having improved resistance to stress relaxation contains controlled additions of iron, phosphorous and magnesium. Free magnesium, in solid solution with the copper, increases the alloy's resistance to stress relaxation. Copper alloys of the invention retain at least 70% of the initial stress following exposure to a temperature of 105.degree. C. for 3000 hours, making the alloys particularly useful for electrical connector components.

There is provided a composite material particularly suited for electrical and electronic applications having a metallic core with a desired surface finish. An acicular superficial coating layer having an apparent thickness of less than 275 angstroms is adjacent to at least a portion of the metallic core. The superficial coating layer is removable from the metallic core without appreciable change to the metallic core surface finish.

Superficial coating layer having acicular structures for electrical

The present invention relates to composites having excellent combinations of bending strength, electrical conductivity, stress relaxation in bending and bend formability and having particular utility in electrical connector applications. The composites of the present invention have a core formed from a copper base alloy having an electrical conductivity of at least about 80% IACS and a clad formed from a copper-nickel alloy containing more than about 30% by weight nickel. Preferred composites are triclad composites formed from copper alloy C151 and MONEL 400 and having clad layer thicknesses of at least about 10%, most preferably at least about 20%, of the overall composite thickness.

Composites having improved resistance to stress relaxation

A process for rolling a metal strip for reducing its thickness and for increasing the maximum reduction attainable per pass using a cooperative type rolling mill comprises applying differential separating forces to the metal strip without changing the magnitude of the compressive force applied to the rolls. By doing this, the maximum strip tension and the forward tension required to pull the strip through the mill may be reduced. The maximum strip tension and the required forward tension force may further be reduced by driving at least one work roll at a desired value of torque as well as applying differential separating forces. The cooperative type rolling mill uses a roll spacing arrangement to space at least some of the rolls for reducing the separating force applied to the metal strip at selected roll bites. In addition, individual drive motors to drive the work rolls at desired torque values may be utilized.

Modifications to a cooperative rolling system for increasing _maximum

A process for forming a composite material from a core material having a first yield strength and a clad material having a second yield strength comprises passing the materials through at least one roll bite formed by at least two rolls rotating at different speeds relative to each other. A bond is formed between the core and clad materials by causing a reduction in the thickness of the materials as they pass through the at least one roll bite. The amount of reduction and the compressive force magnitude required to effect the bond is minimized. The process also includes applying back tension forces to the materials. In a preferred embodiment, different back tension forces are applied to the core and clad materials.

Process for obtaining a composite article

A duplex rolling process and apparatus for working a metal or alloy subject to the formation of strain induced martensite. The metal or alloy is first worked at an elevated temperature wherein the formation of strain induced martensite is substantially suppressed or eliminated. The metal or alloy is then worked at a lower temperature wherein the formation of strain induced martensite is promoted whereby working is carried out more efficiently.

Duplex rolling process and apparatus

An apparatus and process for operating a rolling mill having at least two rolls rotating at different speeds to produce a continuous strip material having a substantially constant final thickness comprises a mechanism for controlling the magnitude of the compressive force between the rolls in response to the ratio of the incoming strip speed to the outgoing strip speed. A mechanism is provided for comparing the ratio of the strip speeds to a ratio of the roll speeds and for adjusting the compressive force magnitude until the two speed ratios are substantially equal. In this manner, the amount of off-stage strip material produced during mill start-up is reduced and process stability and gage control during steady state operation is enhanced.

Growing community of inventors

Cheshire, CT, United States of America

William L Brenneman