System for etching patterns of small openings on a continuous strip of metal

An etching system for etching a continuous strip of resist coated metal web to produce an article having a plurality of openings having a minimum dimension on the order of the thickness of the material, comprising:

• a first station for applying a film of protective material to one side of a continuously moving metal web;
• first means for securing the film to one side of the continuously moving metal web;
• further means for propelling the metal web and the protective film, said further means including a first set of drive rollers for propelling the metal web through said system, a second set of brake rollers for supplying a continual braking force to said metal web;
• a first plurality of etching stations for receiving the resist covered metal web and protective film, said plurality of etching stations operable for supplying etchant to the resist covered metal web and the protective film wherein each of said plurality of etching stations includes spray nozzles for spraying etchant on opposite sides of the metal web;
• a protective film removal station for removing the protective film from the resist covered metal web after the resist covered metal web and the protective film have passed through said first plurality of etch stations, said protective film removal station including means for removing the protective film and further means for preventing the metal web from being pulled from its plane of travel;
• a second plurality of etching stations for supplying etchant to both sides of the resist covered metal web after the protective film has been removed;
• and
• said first plurality of etching stations located before said protective film removal stations and said second plurality of etching stations located after said protective film removal stations.