Sheet material, metal mesh and manufacturing methods thereof

Patent metadata

Field	Value
Publication number	US-11466368-B2
Application number	US-201816046422-A
Country	US
Kind code	B2
Filing date	Jul 26, 2018
Priority date	Jul 27, 2017
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

A sheet material includes a resin layer containing a binder and polypyrrole particles, an electroless plating film provided on the side of one main surface of the resin layer and including first electroless plating films and a second electroless plating film, and a transparent base material provided on the side of the other main surface of the resin layer.

First claim

What is claimed is:

1. A sheet material comprising an electroless plating layer and a transparent base material with a resin layer interposed therebetween in a stacked relationship:
the resin layer comprising a binder and a plurality of polypyrrole particles; the electroless plating layer comprising a plurality of first electroless plating films and a second electroless plating film, wherein
at least some of the plurality of polypyrrole particles respectively have exposure surfaces exposed from a surface of the resin layer on which the electroless plating layer is stacked, and the plurality of exposure surfaces are scattered on said surface of the resin layer,
the plurality of first electroless plating films are provided on said surface of the resin layer to respectively surround the plurality of exposure surfaces of the polypyrrole particles,
the second electroless plating film is provided to cover the first electroless plating films, and forms concave portions, respectively, along surfaces of the first electroless plating films, and
the first electroless plating films and the second electroless plating film, respectively, contain metals or metal compounds different from each other.

2. The sheet material according to claim 1 , wherein an average value of respective longest diameters of the first electroless plating films is 18 to 90 nm when the surface of the resin layer on which the electroless plating layer is stacked is viewed in a planar view from the side of the electroless plating layer.

3. The sheet material according to claim 1 , wherein an area ratio of the first electroless plating films to the surface of the resin layer on which the electroless plating layer is stacked is 80 to 99% when said surface is viewed in a planar view from the side of the electroless plating layer.

4. The sheet material according to claim 1 , wherein the electroless plating layer has a surface, on the opposite side of the surface of the resin layer on which the electroless plating layer is stacked, wherein said surface on the opposite side is a rough surface.

5. A method for manufacturing the sheet material according to claim 1 , comprising:
a step of forming a resin layer comprising a binder and a plurality of polypyrrole particles on a transparent base material, at least some of the plurality of polypyrrole particles respectively having exposure surfaces exposed from one main surface of the resin layer, the plurality of exposure surfaces being scattered on the one main surface of the resin layer, and the transparent base material being provided on the side of the other main surface of the resin layer;
a step of making a solution comprising a catalyst contact the exposure surfaces of the polypyrrole particles, to form catalyst nuclei respectively adhering to the plurality of exposure surfaces;
a step of forming first electroless plating films on the one main surface of the resin layer to respectively surround the plurality of exposure surfaces and the catalyst nuclei; and
a step of forming a second electroless plating film to cover the first electroless plating films, a main surface, on the side of the first electroless plating films, of the second electroless plating film forming concave portions, respectively, along surfaces of the first electroless plating films.

6. A method for manufacturing a metal mesh, comprising a step of performing etching for the electroless plating film in the sheet material according to claim 1 to form an electroless plating film having a mesh-shaped pattern.

7. A metal mesh comprising an electroless plating layer and a transparent base material with a resin layer interposed therebetween in a stacked relationship:
the resin layer comprising a binder and a plurality of polypyrrole particles; an electroless plating layer provided to form a mesh-shaped pattern on a surface of the resin layer on which the electroless plating layer is stacked, the electroless plating layer comprising first electroless plating films and a second electroless plating film, wherein
at least some of the plurality of polypyrrole particles respectively have exposure surfaces exposed from a said surface of the resin layer, and the plurality of exposure surfaces are scattered on said surface of the resin layer,
the plurality of first electroless plating films are provided on said surface of the resin layer to respectively surround the plurality of exposure surfaces of the polypyrrole particles,
the second electroless plating film is provided to cover the first electroless plating films, and forms concave portions, respectively, along surfaces of the first electroless plating films, and
the first electroless plating films and the second electroless plating film, respectively, contain metals or metal compounds different from each other.

8. A metal mesh comprising:
a transparent base material; a resin layer provided to form a mesh-shaped pattern on the transparent base material and comprising a binder and a plurality of polypyrrole particles; and an electroless plating layer provided on the transparent base material along the mesh-shaped pattern of the resin layer while covering the resin layer and comprising a plurality of first electroless plating films and a second electroless plating film, wherein
at least some of the plurality of polypyrrole particles respectively have exposure surfaces exposed from a surface of the resin layer, and the plurality of exposure surfaces are scattered on the surface of the resin layer,
the plurality of first electroless plating films are provided on the surface of the resin layer to respectively surround the plurality of exposure surfaces of the polypyrrole particles, and
the second electroless plating film is provided to cover the first electroless plating films, and a surface, on the side of the first electroless plating films, of the second electroless plating film forms concave portions, respectively, along surfaces of each of the first electroless plating films, and
the first electroless plating films and the second electroless plating film, respectively, contain metals or metal compounds different from each other.

9. The metal mesh according to claim 7 , wherein a surface, on the opposite side of the electroless plating layer is a rough surface.

10. The sheet material according to claim 1 , wherein the exposed surfaces of the polypyrrole particles contain catalyst nuclei adsorbed thereon.

11. The sheet material according to claim 10 , wherein the catalyst nuclei are at least one selected from the group consisting of palladium, silver, platinum, gold, nickel, copper, and compounds thereof.

12. The sheet material according to claim 11 , wherein the catalyst nuclei include phosphorus.

13. The sheet material according to claim 1 , wherein the first electroless plating films contain at least one metal selected from a group consisting of nickel, palladium, gold, silver, and compounds thereof.

14. The sheet material according to claim 1 , wherein second electroless plating film contains at least one metal selected from a group consisting of copper, nickel, silver, and compounds thereof.

15. The sheet material according to claim 1 , wherein the first electroless plating films contain nickel or a nickel compound and the second electroless plating film contains copper.

Assignees

• Tdk Corp

Inventors

• Orikasa Makoto
• Horikawa Yuhei
• Kanbayashi Yoshihiro
• Abe Hisayuki
• Ashizawa Hiroki
• Mori Miho
• Tamura Misaki

Classifications

• C23C18/30

  Activating {or accelerating or sensitising with palladium or other noble metal} · CPC title

• H05K3/181

  by electroless plating (adhesives therefor H05K3/387) · CPC title

• G06F2203/04112

  Electrode mesh in capacitive digitiser: electrode for touch sensing is formed of a mesh of very fine, normally metallic, interconnected lines that are almost invisible to see. This provides a quite large but transparent electrode surface, without need for ITO or similar transparent conductive material · CPC title

• C23C18/1651 Primary

  Two or more layers only obtained by electroless plating · CPC title

• H05K1/0373

  containing additives, e.g. fillers (H05K1/036 takes precedence) · CPC title