EP0087135A1 - A powder for use for dry activation of a substrate for electroless metallization - Google Patents
A powder for use for dry activation of a substrate for electroless metallization Download PDFInfo
- Publication number
- EP0087135A1 EP0087135A1 EP83101561A EP83101561A EP0087135A1 EP 0087135 A1 EP0087135 A1 EP 0087135A1 EP 83101561 A EP83101561 A EP 83101561A EP 83101561 A EP83101561 A EP 83101561A EP 0087135 A1 EP0087135 A1 EP 0087135A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- powder
- substrate
- compounds
- plastic material
- catalyzing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000843 powder Substances 0.000 title claims abstract description 123
- 239000000758 substrate Substances 0.000 title claims abstract description 61
- 238000001465 metallisation Methods 0.000 title claims abstract description 25
- 230000004913 activation Effects 0.000 title claims description 7
- 239000004033 plastic Substances 0.000 claims abstract description 50
- 229920003023 plastic Polymers 0.000 claims abstract description 50
- 150000001875 compounds Chemical class 0.000 claims abstract description 47
- 239000003054 catalyst Substances 0.000 claims abstract description 32
- 229910052751 metal Inorganic materials 0.000 claims abstract description 26
- 239000002184 metal Substances 0.000 claims abstract description 26
- 230000001133 acceleration Effects 0.000 claims abstract description 11
- 238000002360 preparation method Methods 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 29
- 239000002245 particle Substances 0.000 claims description 23
- 239000004094 surface-active agent Substances 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 22
- 229910002666 PdCl2 Inorganic materials 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 14
- PIBWKRNGBLPSSY-UHFFFAOYSA-L palladium(II) chloride Chemical compound Cl[Pd]Cl PIBWKRNGBLPSSY-UHFFFAOYSA-L 0.000 claims description 14
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 11
- 229910021626 Tin(II) chloride Inorganic materials 0.000 claims description 11
- AXZWODMDQAVCJE-UHFFFAOYSA-L tin(II) chloride (anhydrous) Chemical compound [Cl-].[Cl-].[Sn+2] AXZWODMDQAVCJE-UHFFFAOYSA-L 0.000 claims description 11
- 239000007864 aqueous solution Substances 0.000 claims description 10
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 8
- 239000002253 acid Substances 0.000 claims description 7
- 239000006185 dispersion Substances 0.000 claims description 7
- 238000001035 drying Methods 0.000 claims description 7
- 239000000696 magnetic material Substances 0.000 claims description 6
- 239000012736 aqueous medium Substances 0.000 claims description 5
- 229910052742 iron Inorganic materials 0.000 claims description 5
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 238000001694 spray drying Methods 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 4
- 229910017052 cobalt Inorganic materials 0.000 claims description 4
- 239000010941 cobalt Substances 0.000 claims description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000000839 emulsion Substances 0.000 claims description 4
- 239000002609 medium Substances 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 229910052763 palladium Inorganic materials 0.000 claims description 4
- 230000000737 periodic effect Effects 0.000 claims description 4
- 150000003606 tin compounds Chemical class 0.000 claims description 4
- 150000002739 metals Chemical class 0.000 claims description 3
- 230000003647 oxidation Effects 0.000 claims description 3
- 238000007254 oxidation reaction Methods 0.000 claims description 3
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 2
- 239000003638 chemical reducing agent Substances 0.000 claims description 2
- 229920006026 co-polymeric resin Polymers 0.000 claims description 2
- 150000004679 hydroxides Chemical class 0.000 claims description 2
- 229910052741 iridium Inorganic materials 0.000 claims description 2
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- 229910052703 rhodium Inorganic materials 0.000 claims description 2
- 239000010948 rhodium Substances 0.000 claims description 2
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 2
- 229910052707 ruthenium Inorganic materials 0.000 claims description 2
- 229910052709 silver Inorganic materials 0.000 claims description 2
- 239000004332 silver Substances 0.000 claims description 2
- VBICKXHEKHSIBG-UHFFFAOYSA-N 1-monostearoylglycerol Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(O)CO VBICKXHEKHSIBG-UHFFFAOYSA-N 0.000 claims 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims 1
- YQEMORVAKMFKLG-UHFFFAOYSA-N glycerine monostearate Natural products CCCCCCCCCCCCCCCCCC(=O)OC(CO)CO YQEMORVAKMFKLG-UHFFFAOYSA-N 0.000 claims 1
- UHUSDOQQWJGJQS-UHFFFAOYSA-N glycerol 1,2-dioctadecanoate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OCC(CO)OC(=O)CCCCCCCCCCCCCCCCC UHUSDOQQWJGJQS-UHFFFAOYSA-N 0.000 claims 1
- SVUQHVRAGMNPLW-UHFFFAOYSA-N glycerol monostearate Natural products CCCCCCCCCCCCCCCCC(=O)OCC(O)CO SVUQHVRAGMNPLW-UHFFFAOYSA-N 0.000 claims 1
- 230000003213 activating effect Effects 0.000 abstract description 8
- 230000001427 coherent effect Effects 0.000 abstract description 3
- 238000005530 etching Methods 0.000 abstract description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 18
- 239000000243 solution Substances 0.000 description 17
- 230000008569 process Effects 0.000 description 9
- 239000000725 suspension Substances 0.000 description 9
- 238000000454 electroless metal deposition Methods 0.000 description 8
- 239000004615 ingredient Substances 0.000 description 8
- 239000010970 precious metal Substances 0.000 description 8
- 230000008901 benefit Effects 0.000 description 6
- 230000003197 catalytic effect Effects 0.000 description 5
- 230000001976 improved effect Effects 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 238000000151 deposition Methods 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 150000003839 salts Chemical class 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000001110 calcium chloride Substances 0.000 description 3
- 229910001628 calcium chloride Inorganic materials 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- AYTAKQFHWFYBMA-UHFFFAOYSA-N chromium(IV) oxide Inorganic materials O=[Cr]=O AYTAKQFHWFYBMA-UHFFFAOYSA-N 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 150000004820 halides Chemical class 0.000 description 3
- 230000002209 hydrophobic effect Effects 0.000 description 3
- 238000007654 immersion Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 150000002736 metal compounds Chemical class 0.000 description 3
- 239000003381 stabilizer Substances 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 229910002855 Sn-Pd Inorganic materials 0.000 description 2
- 239000012190 activator Substances 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 239000000084 colloidal system Substances 0.000 description 2
- SZVJSHCCFOBDDC-UHFFFAOYSA-N ferrosoferric oxide Chemical compound O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000005286 illumination Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920006267 polyester film Polymers 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- NWZSZGALRFJKBT-KNIFDHDWSA-N (2s)-2,6-diaminohexanoic acid;(2s)-2-hydroxybutanedioic acid Chemical compound OC(=O)[C@@H](O)CC(O)=O.NCCCC[C@H](N)C(O)=O NWZSZGALRFJKBT-KNIFDHDWSA-N 0.000 description 1
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 229910021592 Copper(II) chloride Inorganic materials 0.000 description 1
- 229910002249 LaCl3 Inorganic materials 0.000 description 1
- HVUMOYIDDBPOLL-XWVZOOPGSA-N Sorbitan monostearate Chemical compound CCCCCCCCCCCCCCCCCC(=O)OC[C@@H](O)[C@H]1OC[C@H](O)[C@H]1O HVUMOYIDDBPOLL-XWVZOOPGSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 230000003679 aging effect Effects 0.000 description 1
- 235000011114 ammonium hydroxide Nutrition 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000012050 conventional carrier Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- ORTQZVOHEJQUHG-UHFFFAOYSA-L copper(II) chloride Chemical compound Cl[Cu]Cl ORTQZVOHEJQUHG-UHFFFAOYSA-L 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000007772 electroless plating Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- IKDUDTNKRLTJSI-UHFFFAOYSA-N hydrazine monohydrate Substances O.NN IKDUDTNKRLTJSI-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- ICAKDTKJOYSXGC-UHFFFAOYSA-K lanthanum(iii) chloride Chemical compound Cl[La](Cl)Cl ICAKDTKJOYSXGC-UHFFFAOYSA-K 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000002075 main ingredient Substances 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 150000002940 palladium Chemical class 0.000 description 1
- ZMLDXWLZKKZVSS-UHFFFAOYSA-N palladium tin Chemical compound [Pd].[Sn] ZMLDXWLZKKZVSS-UHFFFAOYSA-N 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000011949 solid catalyst Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 235000011150 stannous chloride Nutrition 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
- C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
- C23C18/18—Pretreatment of the material to be coated
- C23C18/20—Pretreatment of the material to be coated of organic surfaces, e.g. resins
- C23C18/28—Sensitising or activating
Definitions
- the invention relates to a catalytically active powder, its preparation, as well as a method using said powder to make insulating substrates active for receiving electrolessly deposited metal in a coherent metal layer.
- Catalytically active powders directly suitable foractivat- ing a substrate for electroless metallization were not known previously.
- deposition of metal on insulating substrates such as for instance plastics
- the following methods may be employed: deposition of metal under vacuum, application of conductive paints followed by electrolytical metal deposition as well as electroless metallization, the latter in addition possibly being followed by an electrolytical metallization.
- Electroless metallization has gained a widespread use within electrotechnics as well as for metallizing finished plastics.
- a disadvantage of the known methods for electroless metallization is the series of wet process steps used within the commercial utilization in order to achieve a sufficient adhesion of the metal layer to the surface of the substrate. The process steps are frequently carried out in the following sequence: Etching, neutralizing, sensibilization, activation, acceleration, and electroless metal deposition.
- sensibilization and activation constitute one process step since the purpose thereof is to situate the catalyzing seeds on the surface of the substrate, said seeds catalyzing the metal deposition from the bath in a metallizing bath.
- Such a catalyst sensitizes and activates an insulating surface for electroless metallization in one step and consists for instance of a mixture of SnCl 2 and PdCl 2 , the so-called palladium-tin system.
- This system usually includes an aqueous solution of a colloidal nature since it is important to stabilize the system as precipitation reactions otherwise occur involving aging and destruction of the catalyzing effect.
- the patent literature refers to both organic and aqueous solutions, which by influencing an insulating substrate may make said substrate receptive to electroless metal deposition.
- Danish printed accepted specification No. 132,801 describes how a compound of an element from group 8 or 1B of the periodic system or mixtures thereof in an oraanic solvent,which in addition may contain an adhesive, may wet a substrate and make it catalytically active.
- German Offenlegungsschrift No. 26 36 457 also states an aqueous catalytic lacquer for the production of printed circuits and comprising a binder, a metal compound, a complex builder, and a reducing agent. Upon the application and drying ⁇ said metal compound is present as metal seeds which may be additionally reinforced through electroless metallizing.
- Aqueous solutions have previously been encumbered with the draw-back that hydrophobic plastic substrates can only be wetted with difficulty. This feature was especially recognized by the so-called two-step process with separated sensibilization and activation steps, cf. e.g. US patent specification No. 4,042,730, or more detailed "Metallic Coating of Plastics” . by William Golde, Vol. I, especially Chapter V.
- the Danish patent applications N os. 1507/79, 4277/80, and 3300/81 state a method and powders for a dry sensibilization of the surface of an insulating substrate possessing several advantages compared to the state of the art, inter alia concerning the distribution of the adhesion of the metal and concerning reduced expenses by the metal deposition.
- the sensibilization is a process step in which a chemical "sensitizer" is applied to the surface of a substrate.
- This chemical compound provides good adherence for an activator/catalyst to the substrate which is deposited'in a galvanic process by contact with an aqueous solution containing said activator/catalyst.
- Another manner of making substrates catalytically active for electroless metal deposition includes adhering solid particles to the surface of the substrate, said solid particles being catalytical towards electroless metal deposition.
- Most suitable are the systems including particles of a colloidal nature, and systems are known including precious metals, as well as other systems having an effect with non-precious metals.
- the aqueous SnCl 2 /PdCl 2 catalyst is the most frequently used since a reasonable stability of the aqueous solution is obtainable.
- US patent specification No. 3,011,920 describes a process for preparing such a colloidal catalyst, which before the use is accelerated through addition of acid or base. Solid catalyst mixtures - used for the preparation of an optically transparent liquid - have been described in US patent specification No.
- an accelerator solution means a solution of chemicals with an acid or alkaline reaction, the influence of which on the activated substrate promotes the initiation of an electroless metal deposition.
- the catalyst solution may in addition have an activating effect on the catalytic powder melted down, which corresponds to the fact that the catalyst solution in the hitherto known commercial utilization is activated before use through addition of a chemical.
- the powder according to the invention which is characterized in that it comprises fine-grained particles of a plastic material and at least one chemical compound which is a catalyst for electroless metallization, as well as a surfactant, whereby said chemical compound and said surfactant are present in an amount of 0.2 - 20 % by weight and 0.01 - 10 % by weight, respectively, both parts being calculated on the plastic material.
- the catalytically active chemical compound is contained in the powder in an amount of 1 to 5 % by weight and the surfactant in an amount of 0.1 to 1 % by weight.
- the substrate After being melted down onto a substrate and if desired after a suitable acceleration step the substrate can be electrolessly metallized.
- the use of the powder according to the invention results in a metal layer adhering very well to the melted down plastic powder and showing limits (meaning edges or borders) which are well defined by the distribution (pattern) of the melted down plastic powder.
- Claim 2 deals with catalytically active compounds which have proved particularly suitable as ingredients of a powder active for electroless metallizing.
- Claim 3 deals with hydro-oxides of metals capable of activating for electroless metallizing when unstable metallizing baths may be used.
- Claim 4 deals with a commercial catalyst of the PdCl 2/ SnCl 2 type which may be used as an ingredient in a powder according to the invention.
- Claim 5 deals with a powder where the active chemical compounds for electroless metallizing have been dispersed in the plastic material as colloidal particles.
- Claim 6 deals with a composition of a surfactant which as an ingredient in the powder ensures a good contact with the metallizing bath, whereby a coherent metal layer is obtained.
- Claim 7 indicates that a magnetic material may be incorporated into the powder in such a manner that the powder may be transferred magnetostatically or charged electrostatically in a controlled manner by means of a magneticbrush arrangement.
- Claim 8 deals with a method for the preparation of the powder according to the invention, said method ensuring a homogenous distribution of the catalytically active compounds on each powder particle.
- Claim 9 indicates that the plastic suspension is spray dried, whereby a powder having a uniform particle size is obtained.
- Claim 10 states that prior to the drying of the plastic suspension, a reducing compound is added, the reaction of said reducing compounds with the catalytically active compounds improving the deposition of metal.
- Claim 11 states that the powder melted down onto a substrate is treated in a salt-acid or alkaline medium with the purpose of improving the deposition of metal and obtaining an improved adhesion of the metal to the plastic powder melted down.
- Claim 12 states that the powder is suitable for obtaining metallizing of an insulating substrate.
- Claim 13 indicates that the powder is electrostatically transferable to a substrate.
- Claim 14 states that magnetic compounds built in may ensure a magnetostatic transfer. 5
- the powder according to the invention comprising a plastic powder which contains the well-known PdCl 2 /SnCl 2 catalysts or another precious metal catalyst of colloidal nature or hydro-oxides of non-precious metals as well as a sur-0 factant, has the advantage that after melting down the powder onto a substrate and suitable acceleration, metallization of the substrate with a good adhesion of the deposited metal and sharp metallizing limits becomes possible.
- Such a powder provides an essential improvement compared to 5 the prior art.
- the stability of the catalyzing compounds has been considerably increased, not the least due to the fact that the acceleration is not being carried out until the powder has been melted down onto the substrate, contrary to the conventional wet process where acceleration of the catalyst is carried out prior to immersion of the substrate into the solution or suspension of the catalyst.
- catalysts in the form of catalyzing plastic powder whether said powder contains precious metal systems or non-precious metal compounds, considerable advantages can be obtained. For instance etching of the substrate in order to form cavities in which the catalyzing compound may be sucked up so as to ensure a good adhesion is avoided.
- the colloidal nature of the catalyzing compounds is stabilized in the powder according to the invention in a particular manner by the use of a fine-grained plastic powder.
- the catalytic compounds in the powder according to the invention may include any desired compound of the metals from group VIII of the periodic system, for instance iron, cobalt, nickel, ruthenium, rhodium, palladium and/or iridium, in addition to a tin compound, the tin compound to as large an extent as possible being present in the oxidation number +2 or in addition to another reducing compound of inorganic or organic nature.
- the catalytically active compound may be a compound of a metal from group IB of the periodic system, as copper, silver or gold.
- an accelerator for the metallization which accelerator may be an acid or an alkaline substance.
- an aqueous hydrochloric acid solution (conc. HC1 to H 2 0 e.g. 1:2) is a suitable accelerator.
- the stabilizing alkaline halides are removed from the melted down catalyzing powder, whereby a more water permeable surface is achieved in addition.
- this increased surface porosity causes an extremely good adhesion of the metal to be deposited to the melted down plastic powder.
- Another manner of avoiding undesired properties of the powder including a conventional Sn-Pd catalyst, such as e.g. 9F from Shipley Corp., is to use a plastic emulsion in stead of a jet-ground powder. In this manner the concentration of the double salt is reduced, said double salt containing the catalytically active metal.
- the powder which is capable of activating the surface of a substrate for electroless metallization includes a surfactant.
- the hydrophobic part of this surfactant adheres to the hydrophobic plastic material being the main ingredient of said powder, whereas at the same time the hydrophilic part of the surfactant ensures a good contact between the melted down powder and an aqueous medium.
- the invention brings about an important advantage because said catalyst is not activated for electroless metal deposition until the powder according to the invention has been melted down and the substrate with the melted down powder is treated, if necessary, with an acid or alkaline medium.
- both the powder and the plastic film formed of said melted down powder demonstrate a durability not previously known.
- a method for the preparation of a powder according to the invention includes the steps of mixing the plastic material in fine-grained form or prepared by an emulsion polymerisation in an aqueous medium with an aqueous dispersion of a surfactant, whereafter the catalyzing compounds are added and dried upon adjustment of the desired pH value, e.g. through spray drying.
- the method according to the invention is characterized in that it is carried out in an aqueous medium, and that the colloidal particles present therein or precursors for such particles, inter alia as a consequence of the influcence of the surfactant, adhere strongly to the plastic particles which act as stabilizer as well as a cement during the melting down of the dry powder, said cement binding the activating/catalyzing compounds for the electroless metallization to the surface of the substrate.
- the aqueous medium furthermore has the advantage that partly hydrolysed and oxide-containing compounds are present, which on heating, for instance during the spray drying process, are melted in the surface of the powder particles and thereby improve the wetting characteristics of the melted down powder.
- the preparation of a powder according to the invention including non-precious catalyst compounds may be carried out on the basis of commercially available solutions with stabilizers present therein and which may be accelerated in a suitable manner, or the colloidal particles may be precipitated prior to the drying process through the addition of reducing surface active and precipitating reagents. At the subsequent drying process, the colloidal nature is in a particular manner stabilized-on the surface of each powder grain as islands of catalytically active compounds.
- the powder is melted down in order to obtain a suitable adhesion to the substrate.
- an acceleration can be carried out.
- Such an acceleration may include treating the powder melted down on the substrate in an acid or alkaline medium.
- the catalyzing compounds are made active for electroless metallizing.
- a more porous structure is obtained, which additonally improves the adhesion of the electrolessly deposited metal. With a later- galvanic process it is possible to increase the thickness of the metal layer.
- the magnetic one-component toners have gained increasing use.
- a powder which in accordance with claim 7 includes a magnetic material in each powder particle, e.g. oxides of iron, the particle size of which is usually less than 2.5 ⁇ .
- a thin layer of palladium on these grains of magnetic material e.g. by reducing a palladium salt dissolved in a slurry of said grains onto their surface, e.g. by addition of formaldehyde.
- a powder according to the invention can be prepared, which in each powder grain includes grains of magnetic material. It is most advantageous that these grains are slurried in a plastic can- sion, to which one or more of the catalytically active compounds as well as a surfactant are added, said surfactant improving the hydrophilic properties of the ponder prepared when said powder is melted down onto an insulating substrate.
- the particulate plastic material used in the powder of the invention may be any polymer resin having appropriate surface characteristics as known in the art.
- Preferred plastic materials are styrene/acryl-copolymer resins, but for example polyester resins, polyimide resins or ABS-resins may equally be used.
- the invention thus provides a catalytically active powder which can be used directly to initiate electroless metallization, and which shows the advantage of achieving a good adhesion to the substrate as well as a pore-free merging.
- the stability of the powder prepared has proved to be surprisingly good, and it is of great environmental importance that using the powder according to the invention a catalyst for electroless metallization is applied in form of a stable powder in stead of liquids detrimental to environment.
- a powder including the following ingredients
- a powder as stated in Example 1 is prepared by 100 g of plastic material (Piccolastic D 125) upon crushing being ground on a Trost jet mill. The finely ground powder is slurried in an aqueous dispersion containing the surfactant in an amount corresponding to 0,4%by weight of the plastic material. 5 g of SnCl 2 ⁇ 2H 2 0 are weighed out and heated to 95°C, whereafter 0.1 g of PdCl 2 is added. Upon cooling this mixture is crushed and dissolved in water, whereafter this solution is added to the plastic suspension.
- the plastic suspension Upon adjustment of the pH to 8 by means of ammonia water, the plastic suspension is dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and with a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature werel80°C and 80 o C, respectively.
- a spray drier NIRO Atomizer model Minor
- a powder including the following ingredients:
- a powder as stated in Example 3 is prepared by 100 g of Piccotoner.1200 upon crushing being added to an aqueous dispersion containing 0.3 g of Atmer 122, which is a surfactant, in 1 liter of liquid.
- An amount corresponding to 5 g of solid matter of Catalyst 9 F which is a commercial catalyst of the PdCl2/SnCl2 type produced by Shipley Inc.,. is diluted into a volume of 1 liter and pH is adjusted by means of a 6 N NaOH solution to about 6. Under heavy stirring the diluted catalyst solution is added to the plastic suspension.
- Example 3 The use of powder as stated in Example 3 is performed by applying it to an insulating substrate completely or partly, the powder being sprinkled through a serigraphic mask, transferred electrophotographically or in another manner, whereafter it is melted down at a temperature of 140°C.
- the substrate with the powder melted down is immersed into a solution of concentrated hydrochloric acid and water in the ratio 1:3 for a period of 8 minutes. Subsequently it is treated in an accelerator solution (Shipley 19H) for 3 minutes in order upon rinsing to be metallized in a Shipley 328 electroless copper bath at room temperature.
- an accelerator solution Shipley 19H
- a powder as stated in Example 6 is prepared by 100 g of plastic material upon crushing being ground on a Trost jet mill.
- the finely ground powder is slurried in an aqueous dispersion containing the surfactant (Atmer 114) in an amount corresponding t00,3% by weight of the plastic material.
- An aqueous solution of the metal salt is added in the desired amount, whereafter pH is adjusted to 8 by 6N NaOH.
- the plastic suspension is dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature were 170°C and 70°C, respectively.
- a spray drier NIRO Atomizer model Minor
- Example 7 Analogous with Example 8, a powder as stated in Example 7 was prepared.
- a powder of a plastic material containing hydro-oxides of a metal present in one or more oxidation steps was prepared by 100 g of plastic material (Piccotoner 1200) being slurried in a dispersion of a surfactant (Atmer 122 from ICI-Atlas), the amount of which corresponded to0,3% by weight of the plastic powder.
- An aqueous solution was admixed which contained 8 g of CuCl 2 , and during heavy stirring an aqueous solution of 2g of KBH 4 was additionally added, whereafter a 6 N N aOH solution was added until a pH of about 9 was reached.
- the resulting plastic suspension was dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and a feeding velocity and supply of hot air adapted in such. a manner that the temperature and the output temperature were 200°C and 80°C, respectively.
- a spray drier NIRO Atomizer model Minor
- aqueous plastic emulsion (Dresinol from Hercules I nc.) corresponding to 100 g of solid matter was added to an aqueous dispersion of 0.3g of surfactant (Span 60 from ICI-Atlas). During heavy stirring 30 g of Fe 3 O 4 of a particle size of less than 0.5 p were added to the above. Furthermore an aqueous solution of Catalyst 9F (Shipley Inc.) was added in an amount corresponding to 4% of solid matter, and the pH was adjusted to 8 by 6N NaOH, whereafter a spray drying was carried out on a NIRO Atomizer model Minor with a rate of rotation on the atomizer wheel of 35, 000 r.p.m. and a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature were 160°C and 65°C, respectively.
- a surfactant Span 60 from ICI-Atlas
- a powder including the following ingredients
- a method for the preparation of a powder as stated in Example 12 included the following steps: 0.4 g of PdCl 2 were dissolved in 2.8 g of CaCl 2 6H 2 O, which were kept melted at 95°C. After 15 minutes 2.8 g of SnCl 2 ⁇ 2H 2 0 were added. This solution was now added to a plastic suspension, where 100 g of Piccotoner 1200, which in assemble had been jet-ground, were slurried into 500 ml of distilled water, wherein 300 mq of surfactant Atmer 121 (ICI-Atlas) were dispersed.
- ICI-Atlas surfactant Atmer 121
- the atomizerwheel was adjusted to 35,000 r.p.m., and the feeding velocity and supply of hot air were adjusted in such a manner that the input temperature and the output temperature were 180°C and 80°C, respectively.
- a powder as'prepared by the method described in Example 11 was transferred in a device for photocopying, whereby powders containing magnetic matter are electrostatically transferred to a light-sensitive master, said master optionally being a polyester film coated with a light-sensitive material.
- a picture obtained electrostatically by illumination on the light-sensitive surface charged to a positive high voltage of 2.8 kV was produced by said powder by means of a conventional magnet brush arrangement kept at ground potential. Transfer of the resulting electrostatic picture to an insulating substrate was carried out by charging said substrate.
- a powder as prepared by the method described in Example 11 was used for developing a magnetically structured Cr0 2 -coated polyester film, on which a magnetostatic picture was produced by illumination with a Xenon-flash lamp. During this procedure, said CrO 2 -coated magnetized film was illuminated through a photographic film where the light penetrated the bright areas of the film and heated the magnetized film to more than its Curie point. The developing was carried out by a "powder cloud” technique (powder cloud in flow of air). The powder grains adhering to the magnetized film were subsequently transferred to an insulating substrate by said substrate being brought to a positive potential of about 20 kV.
- Powders as stated in Examples 1, 3, 6, 7, and 11 were in turn transferred electrostatically as follows: The powder was charged electrostatically to a voltage of 2.2 kV in a conventional device for electrostatic powder transfer. By means of a flow of air the powder was transferred to a substrate whereafter it was melted down by heating to the melting temperature.
- a powder with a composition as stated in Example 12 and prepared as stated in Example 13 was mixed in the weight ratio 2 to 100 with iron powder of a particle size of 50 to 100 ⁇ (a conventional carrier for use in magnet brushes).
- iron powder of a particle size of 50 to 100 ⁇ a conventional carrier for use in magnet brushes.
- latent electrostatic pictures were developed 'on a photo-sensitive master, which through conventional corona-discharge had been charged to a negative high voltage of 3.2 kV and subsequently illuminated selectively by means of a pattern. Transfer from said photo-sensitive master was carried out by charging an insulating substrate so that the particles were transferred by attraction. In a conventional manner the particles were fixed to the isolating substrate and electroless metallizing was carried out.
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Abstract
Description
- The invention relates to a catalytically active powder, its preparation, as well as a method using said powder to make insulating substrates active for receiving electrolessly deposited metal in a coherent metal layer.
- Catalytically active powders directly suitable foractivat- ing a substrate for electroless metallization were not known previously.
- In deposition of metal on insulating substrates such as for instance plastics, the following methods may be employed: deposition of metal under vacuum, application of conductive paints followed by electrolytical metal deposition as well as electroless metallization, the latter in addition possibly being followed by an electrolytical metallization.
- Electroless metallization has gained a widespread use within electrotechnics as well as for metallizing finished plastics. A disadvantage of the known methods for electroless metallization is the series of wet process steps used within the commercial utilization in order to achieve a sufficient adhesion of the metal layer to the surface of the substrate. The process steps are frequently carried out in the following sequence: Etching, neutralizing, sensibilization, activation, acceleration, and electroless metal deposition. In a great number of processes, sensibilization and activation constitute one process step since the purpose thereof is to situate the catalyzing seeds on the surface of the substrate, said seeds catalyzing the metal deposition from the bath in a metallizing bath. Such a catalyst sensitizes and activates an insulating surface for electroless metallization in one step and consists for instance of a mixture of SnCl2 and PdCl2, the so-called palladium-tin system. This system usually includes an aqueous solution of a colloidal nature since it is important to stabilize the system as precipitation reactions otherwise occur involving aging and destruction of the catalyzing effect.
- The patent literature refers to both organic and aqueous solutions, which by influencing an insulating substrate may make said substrate receptive to electroless metal deposition. Danish printed accepted specification No. 132,801 describes how a compound of an element from group 8 or 1B of the periodic system or mixtures thereof in an oraanic solvent,which in addition may contain an adhesive, may wet a substrate and make it catalytically active. German Offenlegungsschrift No. 26 36 457 also states an aqueous catalytic lacquer for the production of printed circuits and comprising a binder, a metal compound, a complex builder, and a reducing agent. Upon the application and drying¡ said metal compound is present as metal seeds which may be additionally reinforced through electroless metallizing. Aqueous solutions have previously been encumbered with the draw-back that hydrophobic plastic substrates can only be wetted with difficulty. This feature was especially recognized by the so-called two-step process with separated sensibilization and activation steps, cf. e.g. US patent specification No. 4,042,730, or more detailed "Metallic Coating of Plastics" . by William Golde, Vol. I, especially Chapter V. The Danish patent applications Nos. 1507/79, 4277/80, and 3300/81 state a method and powders for a dry sensibilization of the surface of an insulating substrate possessing several advantages compared to the state of the art, inter alia concerning the distribution of the adhesion of the metal and concerning reduced expenses by the metal deposition. It should in this connection be stated that the sensibilization is a process step in which a chemical "sensitizer" is applied to the surface of a substrate. This chemical compound provides good adherence for an activator/catalyst to the substrate which is deposited'in a galvanic process by contact with an aqueous solution containing said activator/catalyst.
- Another manner of making substrates catalytically active for electroless metal deposition includes adhering solid particles to the surface of the substrate, said solid particles being catalytical towards electroless metal deposition. Most suitable are the systems including particles of a colloidal nature, and systems are known including precious metals, as well as other systems having an effect with non-precious metals. The aqueous SnCl2/PdCl2 catalyst is the most frequently used since a reasonable stability of the aqueous solution is obtainable. US patent specification No. 3,011,920 describes a process for preparing such a colloidal catalyst, which before the use is accelerated through addition of acid or base. Solid catalyst mixtures - used for the preparation of an optically transparent liquid - have been described in US patent specification No. 3,672,923. Such systems are generally encumbered with the problem of a lacking long-term stability, and the literature within the field describes aging effects and the importance of the use of an accelerator solution. Within electroless metallizing, an accelerator solution means a solution of chemicals with an acid or alkaline reaction, the influence of which on the activated substrate promotes the initiation of an electroless metal deposition. In the present connection, the catalyst solution may in addition have an activating effect on the catalytic powder melted down, which corresponds to the fact that the catalyst solution in the hitherto known commercial utilization is activated before use through addition of a chemical. There is still doubt about the actual functioning of these systems, and a discussion thereof appears inter alia from "An Electon Diffraction Study on Mixed PdCl2/SnCl2 Catalysts for Electroless Plating" by T. Osaka et al. in Jour. Electrochem. Soc.', Nov. 1980, p 2443ff and "A Study on Activation and Acceleration by Mixed PdCl2/SnCl2 Catalysts for Electroless Metal Deposition" by R. Zeblenski in the same journal, December 1980, p 2652ff.
- It has long been desired to obtain an improved stability of the PdCl2/SnCl2 catalysts which have gained a widespread use for processes within electrotechnics, cf. inter alia US patent specification No. 4,187,198 and US patent specification No. 4,212,768. Regarding the effect of these cata- . lysts it is considered probable that the precious metal (e. g.Pd) in the elemental form is stabilized by tin compounds in the solution.
- As described in US patent specification No. 3,993,799 it has turned out that systems including colloidal particles of non-precious metals are also catalytic for electroless metal deposition when appropriate baths are employed. It has in connection with such systems been difficult to obtain a high catalytic activity simultaneously with a good stability. US patent specification No. 3,958,048 describes how the colloidal nature could disappear in less than 24 hours. US patent specification No. 4,167,596 describes the use of hydro-oxides understood as a mixture of oxides and hydroxides of cobalt, nickel, iron, copper, and mixtures thereof while adding stabilizers, surfactants, and reactivity-modifying compounds. Upon immersion of the substrate into such a col- loidal system, following rinsing a further immersion is carried out in a solution with a reducing compound. Apart from the wetting of the substrate such a process has the drawback that it cannot be carried out selectively. It has been decribed in the patent literature how an improved adhesion can be obtained, cf. inter alia US patent specification No. 4,233,344, wherein hydrazine hydrate is used as adhesion-improving agent. A change of the pH in the colloidal system, cf. US patent specification No. 4,220,678, changes the charge on the colloidal particles, which has an influence on the adhesion of said particles to the substrate.
- It is the object of the invention to provide a powder for use for dry activation of a substrate for electroless metallization which after being melted down in a prescribed pattern on the substrate results in improved adhesion between the colloidal, catalyzing/activating systems and the insulating substrate.
- It is a further object of the invention to provide a powder of the type mentioned above which contains the catalyzing/ activating chemical compounds for use in electroless metallization in a very stable form.
- These objects are achieved by the powder according to the invention which is characterized in that it comprises fine-grained particles of a plastic material and at least one chemical compound which is a catalyst for electroless metallization, as well as a surfactant, whereby said chemical compound and said surfactant are present in an amount of 0.2 - 20 % by weight and 0.01 - 10 % by weight, respectively, both parts being calculated on the plastic material. Preferably the catalytically active chemical compound is contained in the powder in an amount of 1 to 5 % by weight and the surfactant in an amount of 0.1 to 1 % by weight.
- After being melted down onto a substrate and if desired after a suitable acceleration step the substrate can be electrolessly metallized. The use of the powder according to the invention results in a metal layer adhering very well to the melted down plastic powder and showing limits (meaning edges or borders) which are well defined by the distribution (pattern) of the melted down plastic powder.
- Claim 2 deals with catalytically active compounds which have proved particularly suitable as ingredients of a powder active for electroless metallizing.
- Claim 3 deals with hydro-oxides of metals capable of activating for electroless metallizing when unstable metallizing baths may be used.
- Claim 4 deals with a commercial catalyst of the PdCl2/SnCl2 type which may be used as an ingredient in a powder according to the invention.
- Claim 5 deals with a powder where the active chemical compounds for electroless metallizing have been dispersed in the plastic material as colloidal particles.
- Claim 6 deals with a composition of a surfactant which as an ingredient in the powder ensures a good contact with the metallizing bath, whereby a coherent metal layer is obtained.
- Claim 7 indicates that a magnetic material may be incorporated into the powder in such a manner that the powder may be transferred magnetostatically or charged electrostatically in a controlled manner by means of a magneticbrush arrangement.
- Claim 8 deals with a method for the preparation of the powder according to the invention, said method ensuring a homogenous distribution of the catalytically active compounds on each powder particle.
- Claim 9 indicates that the plastic suspension is spray dried, whereby a powder having a uniform particle size is obtained.
- Claim 10 states that prior to the drying of the plastic suspension, a reducing compound is added, the reaction of said reducing compounds with the catalytically active compounds improving the deposition of metal.
- Claim 11 states that the powder melted down onto a substrate is treated in a salt-acid or alkaline medium with the purpose of improving the deposition of metal and obtaining an improved adhesion of the metal to the plastic powder melted down.
- Claim 12 states that the powder is suitable for obtaining metallizing of an insulating substrate.
- Claim 13 indicates that the powder is electrostatically transferable to a substrate.
- Claim 14 states that magnetic compounds built in may ensure a magnetostatic transfer. 5
- The powder according to the invention comprising a plastic powder which contains the well-known PdCl2/SnCl2 catalysts or another precious metal catalyst of colloidal nature or hydro-oxides of non-precious metals as well as a sur-0 factant, has the advantage that after melting down the powder onto a substrate and suitable acceleration, metallization of the substrate with a good adhesion of the deposited metal and sharp metallizing limits becomes possible.
- Such a powder provides an essential improvement compared to 5 the prior art. Thus the stability of the catalyzing compounds has been considerably increased, not the least due to the fact that the acceleration is not being carried out until the powder has been melted down onto the substrate, contrary to the conventional wet process where acceleration of the catalyst is carried out prior to immersion of the substrate into the solution or suspension of the catalyst. It has not previously been recognized that by using catalysts in the form of catalyzing plastic powder, whether said powder contains precious metal systems or non-precious metal compounds, considerable advantages can be obtained. For instance etching of the substrate in order to form cavities in which the catalyzing compound may be sucked up so as to ensure a good adhesion is avoided. Furthermore,the colloidal nature of the catalyzing compounds is stabilized in the powder according to the invention in a particular manner by the use of a fine-grained plastic powder.
- The catalytic compounds in the powder according to the invention may include any desired compound of the metals from group VIII of the periodic system, for instance iron, cobalt, nickel, ruthenium, rhodium, palladium and/or iridium, in addition to a tin compound, the tin compound to as large an extent as possible being present in the oxidation number +2 or in addition to another reducing compound of inorganic or organic nature. Alternatively, the catalytically active compound may be a compound of a metal from group IB of the periodic system, as copper, silver or gold.
- When the catalyzing compounds are complex compounds, it may be necessary to use an accelerator for the metallization which accelerator may be an acid or an alkaline substance. When commercial catalysts of the PdCl2/SnC'2 type are used, an aqueous hydrochloric acid solution (conc. HC1 to H20 e.g. 1:2) is a suitable accelerator. In this manner the stabilizing alkaline halides are removed from the melted down catalyzing powder, whereby a more water permeable surface is achieved in addition. At the following metallization process, this increased surface porosity causes an extremely good adhesion of the metal to be deposited to the melted down plastic powder.
- For the preparation of a powder according to the invention including an Sn-Pd catalyst it may under certain circumstances be undesired that alkaline halides are used to form a complex compound with PdCl2, since this can result in a very fatty powder. However, U.S. patent specification No. 4,212,768 states that other halides are applicable, e.g. CaCl2·6H2O, and LaCl3·7H2O. It was found particularly advantageous for a powder according to the invention to utilize a double salt of CaCl2·6H2O and PdCl2, since a very electrostatic powder is thereby obtained. Another manner of avoiding undesired properties of the powder including a conventional Sn-Pd catalyst, such as e.g. 9F from Shipley Corp., is to use a plastic emulsion in stead of a jet-ground powder. In this manner the concentration of the double salt is reduced, said double salt containing the catalytically active metal.
- In the field of conventional electroless metallization, surfactants have usually been added to the baths used. It was not previously recognized that an improved effect can be obtained if the powder which is capable of activating the surface of a substrate for electroless metallization includes a surfactant. The hydrophobic part of this surfactant adheres to the hydrophobic plastic material being the main ingredient of said powder, whereas at the same time the hydrophilic part of the surfactant ensures a good contact between the melted down powder and an aqueous medium.
- Especially in case of the use of a commercial catalyst of the PdClZ/SnClz type the invention brings about an important advantage because said catalyst is not activated for electroless metal deposition until the powder according to the invention has been melted down and the substrate with the melted down powder is treated, if necessary, with an acid or alkaline medium. As a result, both the powder and the plastic film formed of said melted down powder demonstrate a durability not previously known.
- A method for the preparation of a powder according to the invention includes the steps of mixing the plastic material in fine-grained form or prepared by an emulsion polymerisation in an aqueous medium with an aqueous dispersion of a surfactant, whereafter the catalyzing compounds are added and dried upon adjustment of the desired pH value, e.g. through spray drying. The method according to the invention is characterized in that it is carried out in an aqueous medium, and that the colloidal particles present therein or precursors for such particles, inter alia as a consequence of the influcence of the surfactant, adhere strongly to the plastic particles which act as stabilizer as well as a cement during the melting down of the dry powder, said cement binding the activating/catalyzing compounds for the electroless metallization to the surface of the substrate. The aqueous medium furthermore has the advantage that partly hydrolysed and oxide-containing compounds are present, which on heating, for instance during the spray drying process, are melted in the surface of the powder particles and thereby improve the wetting characteristics of the melted down powder.
- The preparation of a powder according to the invention including non-precious catalyst compounds may be carried out on the basis of commercially available solutions with stabilizers present therein and which may be accelerated in a suitable manner, or the colloidal particles may be precipitated prior to the drying process through the addition of reducing surface active and precipitating reagents. At the subsequent drying process, the colloidal nature is in a particular manner stabilized-on the surface of each powder grain as islands of catalytically active compounds.
- The powder according to the invention may be applied to an insulating substrate through sprinkling, electrostatic or magneto= static transfer directly to the substrate or via a light-sensitive master, cf. the prior art. The powder is melted down in order to obtain a suitable adhesion to the substrate. If the catalyzing compounds are so stable that they cannot directly iniate an electroless metallizing, an acceleration can be carried out., Such an acceleration may include treating the powder melted down
on the substrate in an acid or alkaline medium. As a result the catalyzing compounds are made active for electroless metallizing. In addition, a more porous structure is obtained, which additonally improves the adhesion of the electrolessly deposited metal. With a later- galvanic process it is possible to increase the thickness of the metal layer. - Within the neighboring field, photocopying, the magnetic one-component toners have gained increasing use. For use in equipment using this principle, it is possible to prepare a powder which in accordance with claim 7 includes a magnetic material in each powder particle, e.g. oxides of iron, the particle size of which is usually less than 2.5 µ. In addition it is possible to precipitate a thin layer of palladium on these grains of magnetic material, e.g. by reducing a palladium salt dissolved in a slurry of said grains onto their surface, e.g. by addition of formaldehyde. Whether these grains of magnetic material have a thin layer of palladium on the surface or not or are commercial powders such as for instance Bayferrox 8600 (Bayer Chemie), a powder according to the invention can be prepared, which in each powder grain includes grains of magnetic material. It is most advantageous that these grains are slurried in a plastic can- sion, to which one or more of the catalytically active compounds as well as a surfactant are added, said surfactant improving the hydrophilic properties of the ponder prepared when said powder is melted down onto an insulating substrate.
- The particulate plastic material used in the powder of the invention may be any polymer resin having appropriate surface characteristics as known in the art. Preferred plastic materials are styrene/acryl-copolymer resins, but for example polyester resins, polyimide resins or ABS-resins may equally be used.
- The invention thus provides a catalytically active powder which can be used directly to initiate electroless metallization, and which shows the advantage of achieving a good adhesion to the substrate as well as a pore-free merging.
- The stability of the powder prepared has proved to be surprisingly good, and it is of great environmental importance that using the powder according to the invention a catalyst for electroless metallization is applied in form of a stable powder in stead of liquids detrimental to environment.
- For further explanation of the powder according to the invention, its preparation and use, the following examples are given:
-
- A powder as stated in Example 1 is prepared by 100 g of plastic material (Piccolastic D 125) upon crushing being ground on a Trost jet mill. The finely ground powder is slurried in an aqueous dispersion containing the surfactant in an amount corresponding to 0,4%by weight of the plastic material. 5 g of SnCl2· 2H20 are weighed out and heated to 95°C, whereafter 0.1 g of PdCl2 is added. Upon cooling this mixture is crushed and dissolved in water, whereafter this solution is added to the plastic suspension. Upon adjustment of the pH to 8 by means of ammonia water, the plastic suspension is dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and with a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature werel80°C and 80oC, respectively.
-
- A powder as stated in Example 3 is prepared by 100 g of Piccotoner.1200 upon crushing being added to an aqueous dispersion containing 0.3 g of Atmer 122, which is a surfactant, in 1 liter of liquid. An amount corresponding to 5 g of solid matter of Catalyst 9F, which is a commercial catalyst of the PdCl2/SnCl2 type produced by Shipley Inc.,. is diluted into a volume of 1 liter and pH is adjusted by means of a 6 N NaOH solution to about 6. Under heavy stirring the diluted catalyst solution is added to the plastic suspension. By 6N NaOH pH is adjusted to 7, and the mixture is dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature were 180°C and 80 C, respectively.
- The use of powder as stated in Example 3 is performed by applying it to an insulating substrate completely or partly, the powder being sprinkled through a serigraphic mask, transferred electrophotographically or in another manner, whereafter it is melted down at a temperature of 140°C. The substrate with the powder melted down is immersed into a solution of concentrated hydrochloric acid and water in the ratio 1:3 for a period of 8 minutes. Subsequently it is treated in an accelerator solution (Shipley 19H) for 3 minutes in order upon rinsing to be metallized in a Shipley 328 electroless copper bath at room temperature.
-
-
- A powder as stated in Example 6 is prepared by 100 g of plastic material upon crushing being ground on a Trost jet mill. The finely ground powder is slurried in an aqueous dispersion containing the surfactant (Atmer 114) in an amount corresponding t00,3% by weight of the plastic material. An aqueous solution of the metal salt is added in the desired amount, whereafter pH is adjusted to 8 by 6N NaOH. Subsequently, the plastic suspension is dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature were 170°C and 70°C, respectively.
- Analogous with Example 8, a powder as stated in Example 7 was prepared.
- A powder of a plastic material containing hydro-oxides of a metal present in one or more oxidation steps was prepared by 100 g of plastic material (Piccotoner 1200) being slurried in a dispersion of a surfactant (Atmer 122 from ICI-Atlas), the amount of which corresponded to0,3% by weight of the plastic powder. An aqueous solution was admixed which contained 8 g of CuCl2, and during heavy stirring an aqueous solution of 2g of KBH4 was additionally added, whereafter a 6N NaOH solution was added until a pH of about 9 was reached. The resulting plastic suspension was dried on a spray drier (NIRO Atomizer model Minor) with a rate of rotation on the atomizer wheel of 35,000 r.p.m. and a feeding velocity and supply of hot air adapted in such. a manner that the temperature and the output temperature were 200°C and 80°C, respectively.
- An aqueous plastic emulsion (Dresinol from Hercules Inc.) corresponding to 100 g of solid matter was added to an aqueous dispersion of 0.3g of surfactant (Span 60 from ICI-Atlas). During heavy stirring 30 g of Fe3O4 of a particle size of less than 0.5 p were added to the above. Furthermore an aqueous solution of Catalyst 9F (Shipley Inc.) was added in an amount corresponding to 4% of solid matter, and the pH was adjusted to 8 by 6N NaOH, whereafter a spray drying was carried out on a NIRO Atomizer model Minor with a rate of rotation on the atomizer wheel of 35, 000 r.p.m. and a feeding velocity and supply of hot air adapted in such a manner that the input temperature and the output temperature were 160°C and 65°C, respectively.
-
- A method for the preparation of a powder as stated in Example 12 included the following steps: 0.4 g of PdCl2 were dissolved in 2.8 g of CaCl2 6H2O, which were kept melted at 95°C. After 15 minutes 2.8 g of SnCl2· 2H20 were added. This solution was now added to a plastic suspension, where 100 g of Piccotoner 1200, which in avance had been jet-ground, were slurried into 500 ml of distilled water, wherein 300 mq of surfactant Atmer 121 (ICI-Atlas) were dispersed. Thealkali- nity was adjusted to pH = 8 by 6N NaOH, and a NIRO Atomizer model Minor was used for the spray drying. The atomizerwheel was adjusted to 35,000 r.p.m., and the feeding velocity and supply of hot air were adjusted in such a manner that the input temperature and the output temperature were 180°C and 80°C, respectively.
- A powder as'prepared by the method described in Example 11 was transferred in a device for photocopying, whereby powders containing magnetic matter are electrostatically transferred to a light-sensitive master, said master optionally being a polyester film coated with a light-sensitive material. A picture obtained electrostatically by illumination on the light-sensitive surface charged to a positive high voltage of 2.8 kV was produced by said powder by means of a conventional magnet brush arrangement kept at ground potential. Transfer of the resulting electrostatic picture to an insulating substrate was carried out by charging said substrate.
- A powder as prepared by the method described in Example 11 was used for developing a magnetically structured Cr02-coated polyester film, on which a magnetostatic picture was produced by illumination with a Xenon-flash lamp. During this procedure, said CrO2-coated magnetized film was illuminated through a photographic film where the light penetrated the bright areas of the film and heated the magnetized film to more than its Curie point. The developing was carried out by a "powder cloud" technique (powder cloud in flow of air). The powder grains adhering to the magnetized film were subsequently transferred to an insulating substrate by said substrate being brought to a positive potential of about 20 kV.
- Powders as stated in Examples 1, 3, 6, 7, and 11 were in turn transferred electrostatically as follows: The powder was charged electrostatically to a voltage of 2.2 kV in a conventional device for electrostatic powder transfer. By means of a flow of air the powder was transferred to a substrate whereafter it was melted down by heating to the melting temperature.
- A powder with a composition as stated in Example 12 and prepared as stated in Example 13 was mixed in the weight ratio 2 to 100 with iron powder of a particle size of 50 to 100 µ (a conventional carrier for use in magnet brushes). By such a developing mixture in a conventional magnet brush arrangement, latent electrostatic pictures were developed 'on a photo-sensitive master, which through conventional corona-discharge had been charged to a negative high voltage of 3.2 kV and subsequently illuminated selectively by means of a pattern. Transfer from said photo-sensitive master was carried out by charging an insulating substrate so that the particles were transferred by attraction. In a conventional manner the particles were fixed to the isolating substrate and electroless metallizing was carried out.
Claims (14)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AT83101561T ATE23572T1 (en) | 1982-02-18 | 1983-02-18 | POWDER FOR DRY ACTIVATION OF A SUBSTRATE FOR ELECTRICAL METALLIZATION. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DK070582A DK153572C (en) | 1982-02-18 | 1982-02-18 | POWDER USED BY TWO ACTIVATION FOR POWERFUL METALLIZATION, PROCEDURE FOR PREPARING THEREOF AND USE THEREOF |
DK705/82 | 1982-02-18 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0087135A1 true EP0087135A1 (en) | 1983-08-31 |
EP0087135B1 EP0087135B1 (en) | 1986-11-12 |
Family
ID=8096587
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP83101561A Expired EP0087135B1 (en) | 1982-02-18 | 1983-02-18 | A powder for use for dry activation of a substrate for electroless metallization |
Country Status (12)
Country | Link |
---|---|
EP (1) | EP0087135B1 (en) |
JP (1) | JPS59500221A (en) |
AT (1) | ATE23572T1 (en) |
AU (1) | AU556818B2 (en) |
CA (1) | CA1212660A (en) |
DE (1) | DE3367628D1 (en) |
DK (1) | DK153572C (en) |
FI (1) | FI73243C (en) |
IE (1) | IE55891B1 (en) |
IL (1) | IL67963A (en) |
NO (1) | NO160452C (en) |
WO (1) | WO1983002960A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0141528A2 (en) * | 1983-09-28 | 1985-05-15 | Rohm And Haas Company | Conducting or catalysing a chemical reation on a surface especially electroless metal deposition and catalyst systems used therein |
EP0191433A1 (en) * | 1985-02-14 | 1986-08-20 | International Business Machines Corporation | Process for manufacturing a concentrate of a palladium-tin colloidal catalyst |
US4719145A (en) * | 1983-09-28 | 1988-01-12 | Rohm And Haas Company | Catalytic process and systems |
WO1993016417A1 (en) * | 1992-02-11 | 1993-08-19 | Elf Technologies, Inc. | A plateable toner and method for producing the same |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1521445A1 (en) * | 1965-06-01 | 1970-10-08 | Photocircuits Corp | Process and catalytic composition for metallizing objects without an external power supply |
DE2613637B2 (en) * | 1975-04-08 | 1978-07-20 | Kollmorgen Corp., Hartford, Conn. (V.St.A.) | Process for the production of catalytically active fillers for insulating materials during electroless metal deposition and their use |
WO1982001382A1 (en) * | 1980-10-10 | 1982-04-29 | Sorensen Gunnar | A powder for use in dry sensitization for electroless plating |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1521442B2 (en) * | 1964-10-16 | 1975-02-27 | Photocircuits Corp., Glen Cove, N.Y. (V.St.A.) | Object that can be used for the production of printed circuits from a carrier material with any electrical properties |
DE2207425A1 (en) * | 1972-02-12 | 1973-08-16 | Schering Ag | Metallising plastics - by process including treatment with aq tenside soln after standard etching |
US4020009A (en) * | 1975-09-30 | 1977-04-26 | Shipley Company, Inc. | Catalyst composition and method of preparation |
US4048354A (en) * | 1975-10-23 | 1977-09-13 | Nathan Feldstein | Method of preparation and use of novel electroless plating catalysts |
DK153337C (en) * | 1979-04-11 | 1988-11-14 | Platonec Aps | PROCEDURES FOR TRANS-SENSITIZATION OF AN INSULATING SURFACE |
DK148327C (en) * | 1981-07-24 | 1985-11-04 | Neselco As | POWDER USED BY THROTTLE SENSIBILIZATION FOR CURRENT METALLIZATION |
-
1982
- 1982-02-18 DK DK070582A patent/DK153572C/en not_active IP Right Cessation
-
1983
- 1983-02-17 CA CA000421842A patent/CA1212660A/en not_active Expired
- 1983-02-17 IE IE339/83A patent/IE55891B1/en unknown
- 1983-02-17 AU AU11631/83A patent/AU556818B2/en not_active Ceased
- 1983-02-18 EP EP83101561A patent/EP0087135B1/en not_active Expired
- 1983-02-18 JP JP83500754A patent/JPS59500221A/en active Pending
- 1983-02-18 AT AT83101561T patent/ATE23572T1/en not_active IP Right Cessation
- 1983-02-18 DE DE8383101561T patent/DE3367628D1/en not_active Expired
- 1983-02-18 WO PCT/DK1983/000017 patent/WO1983002960A1/en active IP Right Grant
- 1983-02-21 IL IL67963A patent/IL67963A/en unknown
- 1983-10-13 NO NO83833723A patent/NO160452C/en unknown
- 1983-10-17 FI FI833778A patent/FI73243C/en not_active IP Right Cessation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1521445A1 (en) * | 1965-06-01 | 1970-10-08 | Photocircuits Corp | Process and catalytic composition for metallizing objects without an external power supply |
DE2613637B2 (en) * | 1975-04-08 | 1978-07-20 | Kollmorgen Corp., Hartford, Conn. (V.St.A.) | Process for the production of catalytically active fillers for insulating materials during electroless metal deposition and their use |
WO1982001382A1 (en) * | 1980-10-10 | 1982-04-29 | Sorensen Gunnar | A powder for use in dry sensitization for electroless plating |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0141528A2 (en) * | 1983-09-28 | 1985-05-15 | Rohm And Haas Company | Conducting or catalysing a chemical reation on a surface especially electroless metal deposition and catalyst systems used therein |
GB2164954A (en) * | 1983-09-28 | 1986-04-03 | Rohm & Haas | Conducting or catalysing a chemical reaction on a surface especially electroless metal deposition and catalyst systems used therein |
EP0141528A3 (en) * | 1983-09-28 | 1987-06-03 | Rohm And Haas Company | Conducting or catalysing a chemical reation on a surface especially electroless metal deposition and catalyst systems used therein |
US4719145A (en) * | 1983-09-28 | 1988-01-12 | Rohm And Haas Company | Catalytic process and systems |
EP0191433A1 (en) * | 1985-02-14 | 1986-08-20 | International Business Machines Corporation | Process for manufacturing a concentrate of a palladium-tin colloidal catalyst |
WO1993016417A1 (en) * | 1992-02-11 | 1993-08-19 | Elf Technologies, Inc. | A plateable toner and method for producing the same |
US5304447A (en) * | 1992-02-11 | 1994-04-19 | Elf Technologies, Inc. | Plateable toner and method for producing the same |
Also Published As
Publication number | Publication date |
---|---|
FI833778A0 (en) | 1983-10-17 |
AU1163183A (en) | 1983-08-25 |
FI73243C (en) | 1987-09-10 |
EP0087135B1 (en) | 1986-11-12 |
FI73243B (en) | 1987-05-29 |
DK70582A (en) | 1983-08-19 |
FI833778A (en) | 1983-10-17 |
NO833723L (en) | 1983-10-13 |
DK153572C (en) | 1988-12-19 |
JPS59500221A (en) | 1984-02-16 |
DE3367628D1 (en) | 1987-01-02 |
CA1212660A (en) | 1986-10-14 |
DK153572B (en) | 1988-07-25 |
WO1983002960A1 (en) | 1983-09-01 |
NO160452B (en) | 1989-01-09 |
ATE23572T1 (en) | 1986-11-15 |
AU556818B2 (en) | 1986-11-20 |
IL67963A (en) | 1986-03-31 |
IE55891B1 (en) | 1991-02-14 |
NO160452C (en) | 1989-04-19 |
IE830339L (en) | 1983-08-18 |
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