Method of demetallizing a web in an etchant bath and web suitable therefor

A method of effecting selective demetallization of a web in an etchant bath to form a plurality of product units for products, the web having a thick layer of metal-containing material supported on flexible substrate layer, the method comprising:

• establishing a pattern having a first part to define product units on the web, and a second part to define protected areas on the web outside of the product units for preventing excessive heat generation in the etchant bath and maintaining the etchant bath stable and controllable;
• placing etchant-resistant material on a first side of the web over the metal-containing layer in accordance with the pattern;
• passing the web in an immersed condition through the etchant bath to remove the metal-containing material from areas of the web not protected by the pattern, whereupon the etchant bath is not overheated and remains stable and controllable;
• and
• removing the web from the etchant bath.

A method of effecting selective demetallization of a web in an etchant bath to form a plurality of product units for products, the web having a thick layer of metal-containing material supported on flexible substrate layer, the method comprising:

• establishing a pattern having a first part to define product units on the web, and a second part to define protected areas on the web outside of the product units for imparting predetermined flex characteristics to the web;
• placing etchant-resistant material on a first side of the metal-containing layer in accordance with the pattern;
• passing the web in an immersed condition through the etchant bath to remove the metal-containing material from areas of the web not protected by the pattern, whereupon the web acquires the predetermined flex characteristics;
• and
• removing the web from the etchant bath.

A metal-containing web comprising:

• a substrate;
• a plurality of etched metal-containing first product units disposed on a first side of the substrate, adjacent ones of the first product units being contiguous over peripheral portions thereof and being separated over other peripheral portions thereof to gaps between the adjacent product units;
• and
• a plurality of first metal patches disposed on the first side of the substrate, at least one of the first metal patches being disposed in each of the gaps between the adjacent first product units to improve rigidity in the web.

A metal-containing web comprising:

• a substrate;
• a plurality of etched metal-containing first features disposed on a first side of the substrate, each of the first features having a function in a product;
• and
• a metal-containing first field disposed on the first side of the substrate substantially throughout the web, at least a substantial portion of the first field having no function in a product and having discontinuities to establish predetermined flex characteristics in the web;
• wherein the first features are distributed through the first field.

A metal-containing web comprising:

• a substrate;
• a plurality of etched metal-containing first features disposed on a first side of the substrate, each of the first features having a function in a product, and at least some of the first features being different than others of the first features;
• and
• a metal-containing first field disposed on the first side of the substrate substantially throughout the web, at least a substantial portion of the first field having no function in a product;
• wherein the first features are distributed through the first field.

A metal-containing web comprising:

• a substrate;
• a plurality of etched metal-containing first features disposed on a first side of the substrate, each of the first features having a function in a product;
• and
• a metal-containing first field disposed on the first side of the substrate substantially throughout the web, at least a substantial portion of the first field having no function in a product;
• wherein the first features are distributed through the first field.

A method of effecting selective demetallization of a web in an etchant bath to form a plurality of product units for products, the web having a thick layer of metal-containing material supported on flexible substrate layer, the method comprising:

• establishing a pattern having a first part to define product units on the web, and a second part to define protected areas on the web outside of the product units for preventing excessive heat generation in the etchant bath, maintaining the etchant bath stable, and controllable imparting predetermined flex characteristics to the web;
• placing etchant-resistant material on a first side of the metal-containing layer in accordance with the pattern;
• passing the web in an immersed condition through the etchant bath to remove the metal-containing material from areas of the web not protected by the pattern, whereupon the etchant bath is not overheated and remains stable and controllable, and the web acquires the predetermined flex characteristics;
• and
• removing the web from the etchant bath.