# US 5,341,555 A · Method of preparing film adhesive thermal foil

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- Number: US 5,341,555 A
- Document ID: US5341555A
- Status: Granted
- Kind: A
- Application number: 07/922,678
- Filed: 1992-07-30
- Granted: 1994-08-30
- Earliest claimed: 1992-07-30
- Assignees: Biomagnetic Technologies, Inc.
- Inventors: Laurence Warden; Keith Esser
- Web page: https://patentgrep.com/patent/US5341555A

## CPC

- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B29C 48/05: Filamentary, e.g. strands
- B29C 48/08: flexible, e.g. films
- B29C 61/006: {the force created by the liberation of the internal stresses being used for compression moulding or for pressing preformed material}
- B29C 69/001: {a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts (for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence)}
- B29C 70/885: {with incorporated metallic wires, nets, films or plates (as lost heating elements B29C35/0272, B29C61/0625)}
- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 27/08: of synthetic resin
- B32B 37/185: {Laminating sheets, panels or inserts between two discrete plastic layers}
- B29C 48/001: {Combinations of extrusion moulding with other shaping operations}
- B29C 48/06: Rod-shaped
- B29C 48/07: Flat, e.g. panels
- B29C 48/09: Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
- B29C 48/151: Coating hollow articles
- B29C 48/21: the layers being joined at their surfaces
- B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material
- B29K 2305/00: Use of metals, their alloys or their compounds, as reinforcement
- B29K 2995/0013: Conductive
- B29K 2995/0072: Roughness, e.g. anti-slip
- B29L 2031/752: {Measuring equipment}
- B29L 2031/753: {Medical equipment; Accessories therefor (bloodbags, medical bags B29L2031/7148; artificial eyes B29L2011/0008)}
- B32B 2305/74: Partially cured
- B32B 2307/302: Conductive
- B32B 2311/00: Metals, their alloys or their compounds
- B32B 2311/04: Gold
- B32B 2311/08: Silver
- B32B 2311/12: Copper
- B32B 2311/24: Aluminium
- Y10T 29/4935: Heat exchanger or boiler making
- Y10T 29/49906: Metal deforming with nonmetallic bonding
- Y10T 29/4998: Combined manufacture including applying or shaping of fluent material
- Y10T 29/49984: and casting
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A thermal foil material is made of a layer of B-staged curable epoxy film adhesive and a plurality of substantially parallel insulated copper wires embedded in the epoxy layer. The copper wires are arranged in a side-by-side fashion in at least one layer within the epoxy. Such a thermal foil material is prepared by furnishing a first sheet of a B-staged film adhesive material, preferably wrapped over a mandrel, and placing a layer of metallic elements onto the first sheet with the metallic elements arranged in a side-by-side fashion. A second sheet of a B-staged film adhesive material is placed over the layer of metallic elements and the first sheet. The stack is heated and pressure is applied perpendicular to the first and second sheets to cause the B-staged film adhesive mate rial to flow into the interstices between the metallic elements. This material may be used immediately or stored to prevent further curing of the epoxy until it is used.

## Claims

### Claim 1

A method of preparing a thermal foil material, comprising the steps of:
furnishing a first sheet of a B-staged film adhesive material;
placing a layer of metallic elements onto the first sheet, the metallic elements being arranged in a side-by-side fashion with interstices therebetween;
placing a second sheet of a B-staged film adhesive material over the layer of metallic elements and the first sheet, the second sheet being in direct contact with the first sheet so that the layer of metallic elements is sandwiched between the first sheet and the second sheet; and
applying a pressure perpendicular to the first and second sheets to cause the B-staged film adhesive material to flow into the interstices between the metallic elements, without substantial curing of the first and second sheets of film adhesive material past the B-stage cure level.

### Claim 2 (depends on 1)

The method of claim 1, wherein the film adhesive material of the first sheet is an epoxy.

### Claim 3 (depends on 1)

The method of claim 1 wherein the metallic elements are wires.

### Claim 4 (depends on 1)

The method of claim 1, wherein the metallic elements are arranged in a single layer.

### Claim 5 (depends on 1)

The method of claim 1, wherein the metallic elements are arranged in at least two layers.

### Claim 6 (depends on 1)

The method of claim 1, wherein the metallic elements are made of a material selected from the group consisting of copper, aluminum, silver, gold, and alloys thereof.

### Claim 7 (depends on 1)

The method of claim 1, wherein the step of applying includes the step of heating the first sheet, the metallic elements, and the second sheet.

### Claim 8 (depends on 1)

The method of claim 1, wherein the step of furnishing includes the step of wrapping the first sheet around a mandrel.

### Claim 9

A method of preparing a thermal foil material, comprising the steps of:
furnishing a first sheet of a B-staged film adhesive material;
placing a layer of metallic elements onto the first sheet, the metallic elements being arranged in a side-by-side fashion with interstices therebetween;
placing a second sheet of a B-staged film adhesive material over the layer of metallic elements and the first sheet, the second sheet being in direct contact with the first sheet so that the layer of metallic elements is sandwiched between the first sheet and the second sheet;
applying a pressure perpendicular to the first and second sheets to cause the B-staged film adhesive material to flow into the interstices between the metallic elements, without substantial curing of the first and second sheets of film adhesive material past the B-stage cure level; and
cooling the material to retard further curing prior to use.