Foil Laminate Intermediate and Method of Manufacturing

A method of making a conductive metal foil laminate, comprising the steps of:

• providing a substrate having first and second sides;
• applying an adhesive pattern to the first side of the substrate;
• providing a metal foil having first and second sides such that the second side of the foil is in contact with the adhesive;
• cutting a first pattern in the metal foil coincident with the adhesive pattern to create a first conductive foil pattern and a matrix;
• and
• removing the matrix from the first conductive foil pattern.

A method of making a conductive pattern, comprising the steps of:

• providing a metal foil laminate, the metal foil laminate having a foil layer, an adhesive layer beneath the foil layer and a substrate beneath the adhesive layer;
• making a first cut in the metal foil laminate, through the foil layer to create a first conductive pattern;
• allowing energy/weakness in the metal foil laminate to dissipate;
• and
• providing a second cut in the metal foil laminate to create a second conductive pattern only in the foil layer, the second conductive pattern being distinct from the first pattern.

A web of foil laminate intermediate assemblies, comprising:

• a web that includes a substrate having first and second sides;
• a plurality of foil laminate intermediates provided on the web;
• the substrate having first and second faces the substrate having a plurality of registration marks along at least one of the first and second sides;
• a pattern of adhesive disposed on the first face of the substrate and adjacent the plurality of registration marks, wherein the plurality of registration marks are each provided with an optical brightener within each registration mark and at least one foil laminate intermediate is aligned with at least one of the plurality of registration marks such that each of the plurality of foil laminate intermediates do not cover the plurality of registration marks;
• a metal foil applied over the pattern of adhesive;
• and
• the metal foil having at least a first pattern with the at least first pattern corresponding to the pattern of adhesive.