WO2005024089A2 - Composite wires for vapour deposition - Google Patents

Composite wires for vapour deposition Download PDF

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Publication number
WO2005024089A2
WO2005024089A2 PCT/GB2004/003792 GB2004003792W WO2005024089A2 WO 2005024089 A2 WO2005024089 A2 WO 2005024089A2 GB 2004003792 W GB2004003792 W GB 2004003792W WO 2005024089 A2 WO2005024089 A2 WO 2005024089A2
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WO
WIPO (PCT)
Prior art keywords
inner core
composite wire
metallic material
outer sheath
core comprises
Prior art date
Application number
PCT/GB2004/003792
Other languages
French (fr)
Other versions
WO2005024089A3 (en
Inventor
Serdar Atamert
Jean-Louis Scandella
John Coupland
Original Assignee
Welding Alloys Limited
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Welding Alloys Limited filed Critical Welding Alloys Limited
Publication of WO2005024089A2 publication Critical patent/WO2005024089A2/en
Publication of WO2005024089A3 publication Critical patent/WO2005024089A3/en

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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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/0015—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterized by the colour of the layer
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/20—Metallic material, boron or silicon on organic substrates
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24—Vacuum evaporation
    • C23C14/246—Replenishment of source material

Definitions

  • This invention relates to composite wires for use in vapour deposition and to the manufacture of coated substrates, such as plastics films, fabrics, papers or insulating boards for printed circuitry, employing vacuum deposition techniques using composite wires.
  • metal or other coating material is supplied as a wire fed from a spool which is mounted in the vacuum chamber and evaporated from a resistance heated crucible or boat.
  • the manufacturing process in accordance with current technology usually uses a number of such boats, spools of wire or other suitable wire feed systems within the vacuum deposition chamber, to allow the coating of, say, a wide web of substrate.
  • the most commonly used wire material is aluminium but other solid wires, for example, copper or precious wires, have been used to obtain particular metallised effects .
  • a coloured metallised substrate which does not have the conventional aluminised finish and which can be manufactured in one step within a vapour deposition chamber. It is a further object of the invention to provide, in one manufacturing step within a vapour metallising chamber, a substrate, such as a clear or semi-opaque plastics film substrate, metallised with a particular colour effect visible on both sides thereof.
  • a first aspect of the invention provides a method of manufacturing a coated substrate, comprising placing a substrate to be coated within a deposition chamber and evaporating a wire within the chamber to coat the substrate, wherein the wire is provided as a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material .
  • At least one of the outer sheath and inner core may comprise aluminium, an aluminium alloy, copper, a copper alloy or any combination thereof.
  • the core of the wire may be provided in solid form or particulate form and any aluminium or aluminium alloy may be provided further in a ratio sufficient to provide a required colour effect when applied to a substrate by a vapour deposition method.
  • both the core and sheath may comprise the same or different metallic material (s).
  • the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner solid wire.
  • the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powders.
  • the aluminium and zinc wires are likely to be substantially separate wires, whereas in the latter case, the powders could be mixed together.
  • the wire used in the manufacturing method defined above can be of any suitable diameter for use in a particular metal deposition technique but is preferably in the range of 1.5 mm to 2.5 mm.
  • the inner core preferably comprises the material in particulate form.
  • a second aspect of the invention provides, in the use in a method of manufacturing a coated substrate, a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material .
  • At least one of the outer sheath and the inner core comprises aluminium or an aluminium alloy, when a metallised substrate is required.
  • the inner core may comprise a solid material or a particulate material.
  • the metallic material may be the same or different and can comprise an elemental metal or a metal alloy.
  • the outer sheath may comprise copper and the inner core, aluminium, preferably in the form of an inner wire. Further, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powders.
  • Metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouring, when applied to a substrate by, say, a vacuum metallising method.
  • the wire can have any suitable diameter for the particular vacuum metallising method in which it is employed but may be typically in the range of 1.5 mm to 2.5 mm.
  • metal is used to describe a material which is a metal per se, namely a metal in elemental form, or a metal alloy.
  • non-metallic is used to describe a material whose composition does not contain an elemental metal or a metal alloy but which may include a metal in, say, ionic form, for example, a metal oxide, such as zinc oxide.
  • a third aspect of the invention resides in a composite wire when used in the manufacture of a coated substrate, the wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material.
  • At least one of the outer sheath and the inner core comprises aluminium, an aluminium alloy, copper and/or or a copper alloy.
  • the inner core may comprise a solid metallic or non-metallic material or a particulate metallic or non-metallic material.
  • the metallic material of the sheath and core may be the same or different and may be elemental metal or an alloy.
  • the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner wire.
  • the outer sheath may again comprise copper, with the inner core comprising an aluminium and/or zinc wire and/or powder.
  • the metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouration, when applied to a substrate by, say, a vacuum deposition metallising method.
  • the wire may be of any suitable diameter for the particular metallising method in which it is used but may be typically in the range of 1.5 mm to 2.5 mm.
  • a fourth aspect of the invention resides in a method of manufacturing a metallised substrate, comprising placing a substrate to be metallised within a deposition chamber and evaporating a composite wire within the chamber to metallise the substrate, wherein the composite wire comprises an outer sheath comprising a metallic material and an inner core comprising a metallic material.
  • the deposition chamber is a vacuum chamber.
  • At least one of the outer sheath and inner core comprises aluminium or an aluminium alloy.
  • the core of the wire may be provided in solid form or particulate form and any aluminium or aluminium alloy may be provided further in a ratio sufficient to provide a required colour effect when applied to a substrate by, say, a vapour deposition method.
  • the metallic material of the core and sheath may be the same or different.
  • the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner wire.
  • the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powder.
  • An aluminium and zinc wire core could be _ substantially separate wires, whereas aluminium and zinc powder would probably, but not necessarily, be mixed.
  • the composite wire used in the manufacturing method defined above can be of any suitable diameter for use in a particular metal deposition technique but is preferably in the range of 1.5 mm to 2.5 mm.
  • a fifth aspect of the invention provides, in the use in a method of manufacturing a metallised substrate, a composite metallic wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material.
  • a composite metallic wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material.
  • at least one of the outer sheath and inner core comprises aluminium or an aluminium alloy.
  • the inner core may comprise a solid metallic material or a particulate metallic material.
  • the metallic material may be the same or different and can be an elemental metal or a metal alloy.
  • the outer sheath may comprise copper and the inner core, aluminium, preferably in the form of an inner wire. Further, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wire and/or powder.
  • the metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouring, when applied to a substrate by a vacuum deposition metallising method.
  • the wire can have any suitable diameter for the particular metallising method in which it is employed but may be typically in the range of 1.5 mm to 2.5 mm.
  • a sixth aspect of the invention resides in a composite metallic wire for use in the manufacture of a metallised substrate, the wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material.
  • the wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material.
  • at least one of the outer sheath and the inner core comprises aluminium, an aluminium alloy, copper or a copper alloy.
  • the inner core may comprise a solid metallic material or a particulate metallic material.
  • the metallic material of the sheath and core may be the same or different and may be elemental metal or an alloy.
  • the outer sheath comprises copper and the inner core, aluminium, preferably comprises an inner wire.
  • the outer sheath may again comprise copper, with the inner core comprising aluminium and/or zinc wire and/or powder.
  • the metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouration, when applied to a substrate by, say, a vacuum deposition metallising method.
  • the invention provides further a substrate coated with a layer in accordance with any aspects of the invention defined above and any modification thereof described above.
  • Figure 1 is a section of a composite metallic wire with a solid wire core
  • FIG 2 is a section of a composite metallic wire with a powder-filled core.
  • a composite metallic wire for use in metallising a substrate such as a plastics film, fabric or paper, in a vacuum deposition chamber, is indicated generally at 1 and comprises an outer sheath 2 of elemental copper and an inner core 3 of elemental aluminium.
  • the composite metallic wire 1 is manufactured in a conventional manner, with one longitudinal edge of the copper sheath 2 overlapping the other.
  • compositions of wire have been used to provide various shades of gold colouration on a substrate
  • a composite powder-filled wire indicated generally at 11, comprises an outer sheath 12 of elemental copper and an inner core 13 of elemental aluminium and zinc powders, the materials being in the necessary ratio to provide the required colour, such as gold, effect when the wire 11 is used to metallise a substrate.
  • a substrate such as a plastics film
  • the metallic wire 1, 11 is provided in spooled form.
  • the wire 1, 11 is mounted in and evaporated from a resistance heated crucible or boat, resulting in the plastics film being metallised with a desired colour effect, such as gold colouration, provided by the predetermined ratio of the outer sheath 2, 12 and inner core 3, 13 of the wire 1, 11.
  • composition of the wire is as follows: OUTER SHEATH INNER CORE 80.0wt% Copper 13.0wt% Zinc 7.0wt% Aluminium
  • the inner core 3, 13 may comprise a non-metallic material rather than a metallic material.
  • the inner core 3, 13 may comprise a suitable semiconductive material, preferably in powdered form.
  • metal oxides such as zinc oxide, preferably in powder form, may be included in or as the inner core 3, 13.

Abstract

A method of manufacturing a coated, such as metallised, substrate, comprising placing a substrate to be coated within a deposition chamber and evaporating a wire (1, 11) within the chamber to coat the substrate, wherein the wire (1, 11) is provided as a composite wire (1, 11) comprising an outer sheath (2, 12) and an inner core (3, 13), at least the outer sheath (2, 12) comprising a metallic material.

Description

COMPOSITE WIRES FOR VAPOUR DEPOSITION
DESCRIPTION
This invention relates to composite wires for use in vapour deposition and to the manufacture of coated substrates, such as plastics films, fabrics, papers or insulating boards for printed circuitry, employing vacuum deposition techniques using composite wires.
In the conventional manufacture of a coated substrate employing a vapour deposition technique in a vacuum chamber, metal or other coating material is supplied as a wire fed from a spool which is mounted in the vacuum chamber and evaporated from a resistance heated crucible or boat.
The manufacturing process in accordance with current technology usually uses a number of such boats, spools of wire or other suitable wire feed systems within the vacuum deposition chamber, to allow the coating of, say, a wide web of substrate. The most commonly used wire material is aluminium but other solid wires, for example, copper or precious wires, have been used to obtain particular metallised effects .
It is common to apply a coating of lacquer to an aluminised substrate, to produce an alternative colour. Where a metallic coloured effect, for example, a gold colour effect, is required, this known technology suffers from the following disadvantageous:
1. It is necessary to apply the lacquering as a separate process step;
2. Unless the lacquering step is performed twice, there is only a coloured surface on one side of the substrate; and
3. If only commercially-available solid metals, such as copper or brass, are used, the resulting metallised coating does not possess the necessary brightness or lustre which is required for many applications .
It is an object of the present invention to provide a method of manufacturing a metallised substrate, as well as to provide suitable wires for use in that method, which overcomes, or at least substantially reduces, the disadvantages associated with the conventional metallising operations discussed above .
Also, it is another object of the invention to provide a coloured metallised substrate which does not have the conventional aluminised finish and which can be manufactured in one step within a vapour deposition chamber. It is a further object of the invention to provide, in one manufacturing step within a vapour metallising chamber, a substrate, such as a clear or semi-opaque plastics film substrate, metallised with a particular colour effect visible on both sides thereof.
Also, it is yet a further object of the invention to provide a metallised substrate which retains a higher degree of brightness or lustre than substrates metallised with, say, copper or brass, by known methods in the past.
Yet further, it is an additional object of the invention to provide a method of manufacturing a coated substrate, as well as to provide a suitable wire for use in that method, which represents a single stage coating process in a vapour deposition chamber. A first aspect of the invention provides a method of manufacturing a coated substrate, comprising placing a substrate to be coated within a deposition chamber and evaporating a wire within the chamber to coat the substrate, wherein the wire is provided as a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material .
For providing a metallised coating, at least one of the outer sheath and inner core may comprise aluminium, an aluminium alloy, copper, a copper alloy or any combination thereof. The core of the wire may be provided in solid form or particulate form and any aluminium or aluminium alloy may be provided further in a ratio sufficient to provide a required colour effect when applied to a substrate by a vapour deposition method.
When the inner core comprises a metallic material, both the core and sheath may comprise the same or different metallic material (s).
In one preferred embodiment for metallising a substrate, the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner solid wire.
Also, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powders. In the former case, the aluminium and zinc wires are likely to be substantially separate wires, whereas in the latter case, the powders could be mixed together.
The wire used in the manufacturing method defined above can be of any suitable diameter for use in a particular metal deposition technique but is preferably in the range of 1.5 mm to 2.5 mm.
For coating substrates with non-metallic materials, such as metal oxides, for example, zinc oxide, or semiconductive materials, the inner core preferably comprises the material in particulate form. A second aspect of the invention provides, in the use in a method of manufacturing a coated substrate, a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material .
Preferably, at least one of the outer sheath and the inner core comprises aluminium or an aluminium alloy, when a metallised substrate is required.
The inner core may comprise a solid material or a particulate material. For a metallic outer sheath and a metallic inner core, the metallic material may be the same or different and can comprise an elemental metal or a metal alloy. Again, the outer sheath may comprise copper and the inner core, aluminium, preferably in the form of an inner wire. Further, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powders.
Metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouring, when applied to a substrate by, say, a vacuum metallising method.
The wire can have any suitable diameter for the particular vacuum metallising method in which it is employed but may be typically in the range of 1.5 mm to 2.5 mm.
Throughout this specification, the word "metallic" is used to describe a material which is a metal per se, namely a metal in elemental form, or a metal alloy. The term "non-metallic" is used to describe a material whose composition does not contain an elemental metal or a metal alloy but which may include a metal in, say, ionic form, for example, a metal oxide, such as zinc oxide.
A third aspect of the invention resides in a composite wire when used in the manufacture of a coated substrate, the wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material.
Preferably, at least one of the outer sheath and the inner core comprises aluminium, an aluminium alloy, copper and/or or a copper alloy.
The inner core may comprise a solid metallic or non-metallic material or a particulate metallic or non-metallic material.
For a composite wire having a metallic outer sheath and a metallic inner core, the metallic material of the sheath and core may be the same or different and may be elemental metal or an alloy. In an embodiment, the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner wire. The outer sheath may again comprise copper, with the inner core comprising an aluminium and/or zinc wire and/or powder.
The metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouration, when applied to a substrate by, say, a vacuum deposition metallising method.
The wire may be of any suitable diameter for the particular metallising method in which it is used but may be typically in the range of 1.5 mm to 2.5 mm.
A fourth aspect of the invention resides in a method of manufacturing a metallised substrate, comprising placing a substrate to be metallised within a deposition chamber and evaporating a composite wire within the chamber to metallise the substrate, wherein the composite wire comprises an outer sheath comprising a metallic material and an inner core comprising a metallic material.
Preferably, the deposition chamber is a vacuum chamber.
Preferably also, at least one of the outer sheath and inner core comprises aluminium or an aluminium alloy. The core of the wire may be provided in solid form or particulate form and any aluminium or aluminium alloy may be provided further in a ratio sufficient to provide a required colour effect when applied to a substrate by, say, a vapour deposition method.
The metallic material of the core and sheath may be the same or different.
In an alternative embodiment, the outer sheath comprises copper and the inner core, aluminium, preferably in the form of an inner wire. Also, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wires and/or powder. An aluminium and zinc wire core could be _ substantially separate wires, whereas aluminium and zinc powder would probably, but not necessarily, be mixed.
The composite wire used in the manufacturing method defined above can be of any suitable diameter for use in a particular metal deposition technique but is preferably in the range of 1.5 mm to 2.5 mm.
A fifth aspect of the invention provides, in the use in a method of manufacturing a metallised substrate, a composite metallic wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material. Preferably, at least one of the outer sheath and inner core comprises aluminium or an aluminium alloy.
The inner core may comprise a solid metallic material or a particulate metallic material.
For the outer sheath and/or the inner core, the metallic material may be the same or different and can be an elemental metal or a metal alloy.
Again, the outer sheath may comprise copper and the inner core, aluminium, preferably in the form of an inner wire. Further, the outer sheath may again comprise copper but the inner core may comprise aluminium and/or zinc wire and/or powder.
The metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouring, when applied to a substrate by a vacuum deposition metallising method.
The wire can have any suitable diameter for the particular metallising method in which it is employed but may be typically in the range of 1.5 mm to 2.5 mm.
A sixth aspect of the invention resides in a composite metallic wire for use in the manufacture of a metallised substrate, the wire comprising an outer sheath comprising a metallic material and an inner core comprising a metallic material. Preferably, at least one of the outer sheath and the inner core comprises aluminium, an aluminium alloy, copper or a copper alloy. The inner core may comprise a solid metallic material or a particulate metallic material.
For the outer sheath and/or the inner core, the metallic material of the sheath and core may be the same or different and may be elemental metal or an alloy.
In an embodiment, the outer sheath comprises copper and the inner core, aluminium, preferably comprises an inner wire. The outer sheath may again comprise copper, with the inner core comprising aluminium and/or zinc wire and/or powder.
The metallic materials are preferably provided in ratios sufficient to provide a required colour effect, such as a gold colouration, when applied to a substrate by, say, a vacuum deposition metallising method. The invention provides further a substrate coated with a layer in accordance with any aspects of the invention defined above and any modification thereof described above. In order that the invention may be more fully understood, embodiments of composite wire in accordance therewith will now be described by way of example and with reference to the accompanying drawings in which:
Figure 1 is a section of a composite metallic wire with a solid wire core; and
Figure 2 is a section of a composite metallic wire with a powder-filled core. Referring firstly to Figure 1 of the accompanying drawings, a composite metallic wire for use in metallising a substrate, such as a plastics film, fabric or paper, in a vacuum deposition chamber, is indicated generally at 1 and comprises an outer sheath 2 of elemental copper and an inner core 3 of elemental aluminium.
The composite metallic wire 1 is manufactured in a conventional manner, with one longitudinal edge of the copper sheath 2 overlapping the other.
The following compositions of wire have been used to provide various shades of gold colouration on a substrate
OUTER COPPER SHEATH INNER ALUMINIUM CORE 92.5wt% 7.5wt% 85.0wt% 15.0wt% 80.0wt% 20.0wt%
Finished wire diameters of 1.5 mm, 1.6 mm and 2.0 mm have been used. Turning now to Figure 2 of the accompanying drawings, a composite powder-filled wire, indicated generally at 11, comprises an outer sheath 12 of elemental copper and an inner core 13 of elemental aluminium and zinc powders, the materials being in the necessary ratio to provide the required colour, such as gold, effect when the wire 11 is used to metallise a substrate.
In use of either metallic wire 1, 11, a substrate, such as a plastics film, is placed in a vacuum deposition chamber, with the metallic wire 1, 11 being provided in spooled form. The wire 1, 11 is mounted in and evaporated from a resistance heated crucible or boat, resulting in the plastics film being metallised with a desired colour effect, such as gold colouration, provided by the predetermined ratio of the outer sheath 2, 12 and inner core 3, 13 of the wire 1, 11.
In this particular case, the composition of the wire is as follows: OUTER SHEATH INNER CORE 80.0wt% Copper 13.0wt% Zinc 7.0wt% Aluminium
The wire has been made to a finished diameter of 1.6 mm. It is to be appreciated that the inner core 3, 13 may comprise a non-metallic material rather than a metallic material. For example, for coating insulating baseboards for electrical circuitry, the inner core 3, 13 may comprise a suitable semiconductive material, preferably in powdered form. For other types of non-metallic coatings, metal oxides, such as zinc oxide, preferably in powder form, may be included in or as the inner core 3, 13.

Claims

1. A method of manufacturing a coated substrate, comprising placing a substrate to be coated within a deposition chamber and evaporating a wire within the chamber to coat the substrate, wherein the wire is provided as a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material.
2. A method according to claim 1, wherein the inner core comprises a metallic material.
3. A method according to claim 2, wherein at least one of the outer sheath and inner core comprises aluminium, an aluminium alloy, copper, a copper alloy or any combination thereof.
4. A method according to claim 2 or 3, wherein the outer sheath and inner core comprise the same metallic material .
5. A method according to claim 2 or 3, wherein the outer sheath and inner core comprise different metallic materials.
6. A method according to any of claims 2 to 5, wherein the inner core comprises a solid metallic material .
7. A method according to claim 6, wherein the inner core comprises a wire of metallic material.
8. A method according to claim 7, wherein the inner core comprises an aluminium wire and a zinc wire.
9. A method according to claim 8, wherein the outer sheath comprises copper.
10. A method according to claim 8 or 9, wherein the aluminium and zinc wires of the inner core are substantially separate from each other.
11. A method according to any of claims 2 to 10, wherein the inner core comprises particulate metallic material .
12. A method according to claim 11, wherein the inner core comprises different particulate metallic materials .
13. A method according to claim 12, wherein different particulate metallic materials of the inner core are mixed together.
14. A method according to claim 12 or 13, wherein the different particulate metallic materials are aluminium and zinc powder.
15. A method according to any preceding claim, wherein the inner core comprises a non-metallic material.
16. A method according to claim 15, wherein the non- metallic material of the inner core comprises a metal oxide .
17. A method according to claim 16, wherein the metal oxide is zinc oxide.
18. A method according to claim 15, wherein the non- metallic material of the inner core comprises a semiconductive material.
19. A method according to any preceding claim, wherein the deposition chamber is a vacuum deposition chamber.
20. A method of manufacturing a metallised substrate according to any preceding claim.
21. In the manufacture of a coated substrate, the use of a composite wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material.
22. Use of a composite wire according to claim 21, wherein the inner core comprises a metallic material.
23. Use of a composite wire according to claim 22, wherein at least one of the outer sheath and inner core comprises aluminium, an aluminium alloy, copper, a copper alloy or any combination thereof.
24. Use of a composite wire according to claim 22 or 23, wherein the outer sheath and inner core comprise the same metallic material.
25. Use of a composite wire according to claim 22 or 23, wherein the outer sheath and inner core comprise different metallic materials.
26. Use of a composite wire according to any of claims 22 to 25, wherein the inner core comprises a solid metallic material.
27. Use of a composite wire according to claim 26, wherein the inner core comprises a wire of metallic material.
28. Use of a composite wire according to claim 27, wherein the inner core comprises an aluminium wire and a zinc wire.
29. Use of a composite wire according to claim 28, wherein the outer sheath comprises copper.
30. Use of a composite wire according to claim 28 or 29, wherein the aluminium and zinc wires of the inner core are substantially separate from each other.
31. Use of a composite wire according to any of claims 22 to 30, wherein the inner core comprises particulate metallic material.
32. Use of a composite wire according to claim 31, wherein the inner core comprises different particulate metallic materials.
33. Use of a composite wire according to claim 32, wherein different particulate metallic materials of the inner core are mixed together.
34. Use of a composite wire according to claim 32 or 33, wherein the different particulate metallic materials are aluminium and zinc powder.
35. Use of a composite wire according to any of claims 21 to 34, wherein the inner core comprises a non-metallic material.
36. Use of a composite wire according to claim 35, wherein the non-metallic material of the inner core comprises a metal oxide.
37. Use of a composite wire according to claim 36, wherein the metal oxide is zinc oxide.
38. Use of a composite wire according to claim 35, wherein the non-metallic material of the inner core comprises a semiconductive material.
39. Use of a composite wire in the manufacture of a metallised substrate, according to any of claims 21 to 38.
40. A composite wire when used in the manufacture of a coated, such as a metallised, substrate, the wire comprising an outer sheath and an inner core, at least the outer sheath comprising a metallic material.
41. A composite wire according to claim 40, wherein the inner core comprises a metallic material.
42. A composite wire according to claim 41, wherein at least one of the outer sheath and inner core comprises aluminium, an aluminium alloy, copper, a copper alloy or any combination thereof.
43. A composite wire according to claim 41 or 42, wherein the outer sheath and inner core comprise the same metallic material.
44. A composite wire according to claim 41 or 42, wherein the outer sheath and inner core comprise different metallic materials.
45. A composite wire according to any of claims 41 to 44, wherein the inner core comprises a solid metallic material .
46. A composite wire according to claim 45, wherein the inner core comprises a wire of metallic material.
47. A composite wire according to claim 46, wherein the inner core comprises an aluminium wire and a zinc wire .
48. A composite wire according to claim 47, wherein the outer sheath comprises copper.
49. A composite wire according to claim 47 or 48, wherein the aluminium and zinc wires of the inner core are substantially separate from each other.
50. A composite wire according to any of claims 41 to 49, wherein the inner core comprises particulate metallic material.
51. A composite wire according to claim 50, wherein the inner core comprises different particulate metallic materials.
52. A composite wire according to claim 51, wherein different particulate metallic materials of the inner core are mixed together.
53. A composite wire according to claim 51 or 52, wherein the different particulate metallic materials are aluminium and zinc powder.
54. A composite wire according to any of claims 40 to 53, wherein the inner core comprises a non-metallic material.
55. A composite wire according to claim 54, wherein the non-metallic material of the inner core comprises a metal oxide.
56. A composite wire according to claim 55, wherein the metal oxide is zinc oxide.
57. A composite wire according to claim 54, wherein the non-metallic material of the inner core comprises a semiconductive material.
PCT/GB2004/003792 2003-09-06 2004-09-06 Composite wires for vapour deposition WO2005024089A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0320921.0 2003-09-06
GB0320921A GB0320921D0 (en) 2003-09-06 2003-09-06 Wires for manufacturing metallised substrates

Publications (2)

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WO2005024089A2 true WO2005024089A2 (en) 2005-03-17
WO2005024089A3 WO2005024089A3 (en) 2005-06-30

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US20010055696A1 (en) * 2000-06-26 2001-12-27 Hitachi Metals, Ltd. Method for forming composite vapor-deposited film having varied film composition at initial and final stages of vapor deposition, composite vapor-deposition material for producing the same, and method for producing the composite vapor-deposition material
US20030072960A1 (en) * 2001-10-16 2003-04-17 Hitachi Metals, Ltd. Manufacturing process of composite vacuum vapor-deposition material wire and wire manufactured thereby

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JPS57164978A (en) * 1981-04-02 1982-10-09 Mitsubishi Heavy Ind Ltd Wire rod for vapor deposition
US4423119A (en) * 1981-11-05 1983-12-27 Brown Roger K Composite wire for forming wear resistant coatings, and method of manufacture
JPS59196506A (en) * 1983-04-22 1984-11-07 日本原子力研究所 Titanium evaporated wire
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JPH02209472A (en) * 1989-02-10 1990-08-20 Toyo Commun Equip Co Ltd Material for vapor deposition and vapor deposition device
JPH06235057A (en) * 1992-12-07 1994-08-23 Ford Motor Co Combined metallizing line and method for use thereof
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DE1077499B (en) * 1953-12-09 1960-03-10 Degussa Process for vacuum evaporation of coatings from multi-component mixtures
US20010055696A1 (en) * 2000-06-26 2001-12-27 Hitachi Metals, Ltd. Method for forming composite vapor-deposited film having varied film composition at initial and final stages of vapor deposition, composite vapor-deposition material for producing the same, and method for producing the composite vapor-deposition material
US20030072960A1 (en) * 2001-10-16 2003-04-17 Hitachi Metals, Ltd. Manufacturing process of composite vacuum vapor-deposition material wire and wire manufactured thereby

Also Published As

Publication number Publication date
GB2406102A (en) 2005-03-23
GB0320921D0 (en) 2003-10-08
WO2005024089A3 (en) 2005-06-30
GB0419745D0 (en) 2004-10-06

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