Roll-to-roll electroless plating system for controlled substrate depth

Abstract

A roll-to-roll electroless plating system for controlled substrate depth includes electroless plating solution disposed within an electroless plating bath, a conveyor system configured to convey a roll-to-roll substrate material through the electroless plating solution, a first depth setting roller disposed at an entry location of the roll-to-roll substrate material to the electroless plating solution, and a second depth setting roller disposed at an exit location of the roll-to-roll substrate material from the electroless plating solution. A diameter of the first and the second depth setting rollers is selected to dispose the roll-to-roll substrate material at a predetermined depth of the electroless plating solution.

What is claimed is: 
     
         1 . A roll-to-roll electroless plating system for controlled substrate depth comprising:
 electroless plating solution disposed within an electroless plating bath;   a conveyor system configured to convey a roll-to-roll substrate material through the electroless plating solution;   a first depth setting roller disposed at an entry location of the roll-to-roll substrate material to the electroless plating solution;   a second depth setting roller disposed at an exit location of the roll-to-roll substrate material from the electroless plating solution,   wherein a diameter of the first and the second depth setting rollers is selected to dispose the roll-to-roll substrate material at a predetermined depth of the electroless plating solution.   
     
     
         2 . The system of  claim 1 , further comprising;
 a cover disposed between the first depth setting roller and the second depth setting roller, wherein the cover covers at least a portion of an exposed surface area of the electroless plating solution.   
     
     
         3 . The system of  claim 1 , further comprising:
 a plurality of wheels disposed within the electroless plating bath, wherein the plurality of wheels assist conveyance of the roll-to-roll substrate material while submerged at the predetermined depth.   
     
     
         4 . The system of  claim 1 , wherein the depth setting roller comprises:
 a cylindrical sleeve having a radius greater than the predetermined depth;   a cylindrical cover disposed within a distal end of the cylindrical sleeve, wherein the cylindrical cover comprises a plug hole disposed at a center of the cylindrical cover;   a plug disposed within the plug hole, wherein the plug comprises a pin hole disposed at a center of the plug;   a spring disposed within the pin hole; and   an axial pin partially disposed within the pin hole.   
     
     
         5 . The system of  claim 1 , wherein the depth setting roller comprises a material resistant to electroless plating. 
     
     
         6 . The system of  claim 1 , wherein the first depth setting roller and the second depth setting roller are removable. 
     
     
         7 . The system of  claim 1 , wherein the predetermined depth may be controlled by a diameter of the first depth setting roller and the second depth setting roller. 
     
     
         8 . The system of  claim 1 , wherein the predetermined depth is in a range between approximately 2 inches and approximately 3 inches. 
     
     
         9 . The system of  claim 1 , wherein the first depth setting roller and the second depth setting roller are not driven. 
     
     
         10 . The system of  claim 1 , wherein the first depth setting roller and the second depth setting roller are driven with a motor. 
     
     
         11 . A method of controlling a submerged depth of a roll-to-roll substrate material comprising:
 disposing a first depth setting roller at an entry location of the roll-to-roll substrate material to an electroless plating solution disposed in an electroless plating bath;   disposing a second depth setting roller at an exit location of the roll-to-roll substrate material from the electroless plating solution;   conveying the roll-to-roll substrate material through the electroless plating solution at a predetermined depth,   wherein a diameter of the first and the second depth setting rollers is selected to dispose the roll-to-roll substrate material at the predetermined depth.   
     
     
         12 . The method of  claim 11 , further comprising;
 disposing a cover over at least a portion of an exposed surface area of the electroless plating solution in a location between the first depth setting roller and the second depth setting roller.   
     
     
         13 . The method of  claim 11 , further comprising:
 disposing a plurality of wheels within the electroless plating bath, wherein the plurality of wheels assist conveyance of the roll-to-roll substrate material while submerged at the predetermined depth.   
     
     
         14 . The method of  claim 11 , wherein the depth setting roller comprises:
 a cylindrical sleeve having a radius greater than the predetermined depth;   a cylindrical cover disposed within a distal end of the cylindrical sleeve, wherein the cylindrical cover comprises a plug hole disposed at a center of the cylindrical cover;   a plug disposed within the plug hole, wherein the plug comprises a pin hole disposed at a center of the plug;   a spring disposed within the pin hole; and   an axial pin partially disposed within the pin hole.   
     
     
         15 . The method of  claim 11 , wherein the depth setting roller comprises a material resistant to electroless plating. 
     
     
         16 . The method of  claim 11 , wherein the first depth setting roller and the second depth setting roller are removable. 
     
     
         17 . The method of  claim 11 , wherein the predetermined depth may be controlled by a diameter of the first depth setting roller and the second depth setting roller. 
     
     
         18 . The method of  claim 11 , wherein the predetermined depth is in a range between approximately 2 inches and approximately 3 inches. 
     
     
         19 . The method of  claim 11 , wherein the first depth setting roller and the second depth setting roller are not driven. 
     
     
         20 . The method of  claim 11 , wherein the first depth setting roller and the second depth setting roller are driven with a motor.