Methods and structures for the production of electrically treated items and electrical connections

Abstract

This invention involves unique electroplated items comprising electrically conductive polymers. In addition, novel processing is taught to facilitate continuous production of electrically treated items. Many embodiments employ directly electroplateable resins for particular advantage. Unique methods of establishing electroplated electrical connections are taught.

1 . A method for continuously processing a continuous web, said web comprising an electroplateable material forming a structure at least a portion of which is characterized as having low current carrying ability and having a resistance greater than 0.01 ohms per square prior to processing, said method accomplishing an initial deposition of electrodeposited material over said portion and said method comprising process steps of,
 positioning a separate electrical conductor to extend in the length direction of said web and in electrical communication contact with said electroplateable material,   contacting said separate electrical conductor to a source of cathodic potential,   continuously processing said web and said electrical conductor by immersion through a first electroplating solution to electrodeposit metallic material over said structure and wherein the electrodeposit emanates from points on said structure immediately adjacent said conductor and grows away from said points over said structure in a continuous form.   
     
     
         2 . The method according to  claim 1  wherein said separate conductor comprises a metallic wire, cable or strip. 
     
     
         3 . The method according to  claim 1  wherein said separate conductor comprises a trace or strand formed by an electrically conductive ink. 
     
     
         4 . The method according to  claim 1  wherein said continuous processing employs a drum or roller, said drum or roller at least partially immersed in said electroplating solution and functioning to support said web while in said electroplating solution. 
     
     
         5 . The method according to  claim 1  wherein said electroplateable material comprises an electrically conductive polymer. 
     
     
         6 . The method according to  claim 1  wherein said electroplateable material comprises metal formed by vacuum deposition or chemical deposition. 
     
     
         7 . The method according to  claim 1  wherein said electroplateable material comprises a directly electroplateable resin (DER). 
     
     
         8 . The method according to  claim 1  wherein said structure comprises a buss extending in said length direction of said web, said buss joining multiple appended patterns of electroplateable material. 
     
     
         9 . The method according to  claim 8  wherein said buss comprises a polymer. 
     
     
         10 . The method according to  claim 1  wherein said conductor is positioned to overlay said structure. 
     
     
         11 . The method according to  claim 1  further comprising the steps of,
 separating said conductor from said structure to sever said electrical contact,   subjecting at least a portion of said structure to a second electroplating process wherein additional material is electrodeposited over said structure and wherein electrodeposited metallic material produced by prior electroplating is employed to accomplish primary conveyance of electroplating current associated with said second electroplating process.   
     
     
         12 . A method for continuously processing a continuous web, said web comprising a continuous sheetlike form of insulating polymeric first material, said web further characterized as having a first structural pattern supported over a first surface of said insulating first material, at least a portion of said first structural pattern comprising a second material capable of assisting metal deposition, said method comprising process steps of,
 positioning a separate electrical conductor to extend in the continuous length direction of said web and in contact with said first structural pattern,   providing said separate electrical conductor with a source of cathodic potential,   continuously processing said web and said separate electrical conductor by immersion through a first electroplating solution to electrodeposit metallic material onto said first structural pattern, wherein the electroplated metallic material deposits in a continuous form from said separate electrical conductor over said first structural pattern.   
     
     
         13 . The method according to  claim 12  wherein said second material comprises an electrically conductive polymer. 
     
     
         14 . The method according to  claim 13  wherein said electrically conductive polymer comprises material from the group silver and carbon black. 
     
     
         15 . The method according to  claim 12  wherein said second material comprises a material capable of initiating chemical metal deposition. 
     
     
         16 . The method according to  claim 12  wherein said second material comprises a directly electroplateable resin (DER). 
     
     
         17 . The method according to  claim 12  wherein said wherein at least a portion of said first structural pattern is formed by printing. 
     
     
         18 . The method according to  claim 12  wherein said insulating first material has a second surface, said second surface facing opposite and away from said first surface, and wherein said web has a second structural pattern comprising electroplateable material positioned over said second surface, said second structural pattern being in electrical communication with said first structural pattern. 
     
     
         19 . The method according to  claim 18  wherein said electrical communication is achieved through conductive material extending through holes in said insulating first material from said first to said second surfaces. 
     
     
         20 . The method of  claim 18  wherein said second structural pattern comprises a polymeric material capable of assisting metal deposition. 
     
     
         21 . The method of  claim 12  wherein said providing said separate electrical conductor with cathodic potential is accomplished at a point remote from said web. 
     
     
         22 . The method of  claim 8  wherein a monolithic material forms portions of both said buss and said appended patterns. 
     
     
         23 . The method of  claim 8  wherein said conductor is positioned to overlay said buss. 
     
     
         24 . The method according to  claim 1  wherein said structure is further characterized as having a resistance greater than 0.1 ohms per square prior to processing. 
     
     
         25 . The method according to  claim 1  wherein said conductor has exposed portions such that said electrodeposit covers said exposed portions as well as said structure in the form of a monolithic material deposit.