Metal foil for base material

Patent metadata

Field	Value
Publication number	US-9296180-B2
Application number	US-201113885278-A
Country	US
Kind code	B2
Filing date	Nov 16, 2011
Priority date	Nov 17, 2010
Publication date	Mar 29, 2016
Grant date	Mar 29, 2016

Abstract

A metal foil including: a steel layer whose thickness is 10 to 200 μm; an alloy layer which contains Fe and Al and which is formed on the steel layer; and an Al-containing metal layer arranged on the alloy layer, wherein, when a cutting-plane line of a surface of the Al-containing metal layer is defined as a contour curve and an approximation straight line of the contour curve is defined as a contour average straight line, a maximum point, whose distance from the contour average straight line is more than 10 μm, is absent on the contour curve, and a thickness of the alloy layer is 0.1 to 8 μm and the alloy layer contains an Al 7 Cu 2 Fe intermetallic compound or FeAl 3 based intermetallic compounds.

First claim

The invention claimed is:

1. A metal foil for a base material of a solar cell and an organic electroluminescence, the metal foil comprising:
a carbon steel layer whose thickness is 10 to 200 μm;
an alloy layer which contains Fe and Al and which is formed on the carbon steel layer; and
an Al-containing metal layer arranged on the alloy layer,
wherein, a distance between (1) a maximum point of a cutting-plane line of a surface of the Al-containing metal layer appearing on a cross-section of the metal foil that is cut perpendicular to a rolling direction, wherein the cutting-plane line is a contour curve and the maximum point is an extremal point that is convex toward the surface of the Al-containing metal layer, and (2) an approximation straight line of the cutting-plane line, is not more than 10 μm,
wherein a thickness of the alloy layer is 0.1 to 8 μm and the alloy layer contains an Al 7 Cu 2 Fe intermetallic compound or FeAl 3 based intermetallic compounds, and
wherein a Vickers hardness of the alloy layer is 500 Hv to 600 Hv.

2. The metal foil according to claim 1 , further comprising a Cu layer whose thickness is 2 to 10 μm or a Ni layer whose thickness is 2 to 10 μm between the carbon steel layer and the alloy layer.

3. The metal foil according to claim 1 , wherein a thickness of the Al-containing metal layer is 0.1 to 30 μm.

4. The metal foil according to claim 1 , further comprising an AlN layer whose thickness is 0.01 to 0.08 μm or an Al 2 O 3 layer whose thickness is 0.01 to 50 μm on the Al-containing metal layer.

5. The metal foil according to claim 1 , further comprising a Cr layer whose thickness is 0.1 to 8 μm or a Ni layer whose thickness is 0.1 to 8 μm on the Al-containing metal layer.

6. The metal foil according to claim 1 , further comprising at least a film selected from a sol-gel layer and a lamination layer on the Al-containing metal layer.

7. The metal foil according to claim 1 , wherein a glossiness of the surface of the Al-containing metal layer is 75% or more as compared with a silver mirror.

8. The metal foil according to claim 1 , wherein a Cu is solid-soluted in the FeAl 3 based intermetallic compounds.

Assignees

• Terashima Shinichi
• Kobayashi Takayuki
• Tanaka Masamoto
• Fujishima Masami
• Kurosaki Masao
• Maki Jun
• Suda Hideaki
• Nagasaki Shuji
• Nippon Stell & Sumikin Materials Co Ltd
• Nippon Steel & Sumitomo Metal Corp

Inventors

• Terashima Shinichi
• Kobayashi Takayuki
• Tanaka Masamoto
• Fujishima Masami
• Kurosaki Masao
• Maki Jun
• Suda Hideaki
• Nagasaki Shuji

Classifications

• C25D7/0614

  Strips or foils · CPC title

• C25D5/50

  by heat-treatment · CPC title

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C18/1254

  Sol or sol-gel processing · CPC title

• C25D11/08

  containing inorganic acids · CPC title