Method for forming an etched soft edge metal foil and the product thereof

A thin material processing method comprising the steps of:

• preparing a first surface of a thin base material;
• adhesively bonding a first etch resistant material to the first surface to form an adhesive bond between the first etch resistant material and the first surface;
• forming a first pattern in the first etch resistant material on the first surface, the first pattern defining at least one boundary of the first etch resistant material;
• etching the thin base material to form a rounded edge in the thin base material at the at least one boundary of the first pattern of first etch resistant material by degrading the adhesive bond of the thin base material and the first etch resistant material at the at least one boundary of the first pattern of first etch resistant material,
• cleaning a second surface of the thin base material, the second surface being on a side opposite the first surface;
• adhesively bonding a second etch resistant material to the second surface;
• forming a second pattern in the second etch resistant material on the second surface, the second pattern defining at least one boundary of the second etch resistant material on the second surface;
• and
• forming a sharp edge at the at least one boundary of the second pattern of second etch resistant material,
• whereby the cleaning of the second surface results in substantial adherence between the second surface and the second pattern of second etch resistant material which prevents etching of the thin base material beyond the at least one boundary of the second pattern of second etch resistant material thereby resulting in the sharp edge.

A metal foil processing method comprising the steps of:

• preparing a first surface of a metal foil;
• adhesively bonding a first etch resistant material to the first surface to form an adhesive bond between the first etch resistant material and the first surface;
• forming a first pattern in the first etch resistant material on the first surface, the first pattern defining at least one boundary of the first etch resistant material;
• etching the metal foil to form a rounded edge in the metal foil at the at least one boundary of the first pattern of first etch resistant material by degrading the adhesive bond of the metal foil and the first etch resistant material at the at least one boundary of the first pattern of first etch resistant material,
• cleaning a second surface of the metal foil, the second surface being on a side opposite the first surface;
• adhesively bonding a second etch resistant material to the second surface;
• forming a second pattern in the second etch resistant material on the second surface, the second pattern defining at least one boundary of the second etch resistant material on the second surface;
• and
• forming a sharp edge in the metal foil at the at least one boundary of the second pattern of second etch resistant material,
• whereby the cleaning of the second surface results in substantial adherence between the second surface and the second pattern of second etch resistant material which prevents etching of the metal foil beyond the at least one boundary of the second pattern of second etch resistant material thereby resulting in the sharp edge.

A thin material processing method comprising the steps of:

• preparing a first surface of a thin base material;
• adhesively bonding a first etch resistant material to the first surface to form a first adhesive bond between the first etch resistant material and the first surface;
• forming a first pattern in the first etch resistant material on the first surface, the first pattern defining at least one boundary of the first etch resistant material;
• cleaning a second surface of the thin base material, the second surface being on a side opposite the first surface;
• adhesively bonding a second etch resistant material to the second surface to form a second adhesive bond between the second etch resistant material and second surface, the second adhesive bond being substantially stronger than the first adhesive bond;
• forming a second pattern in the second etch resistant material on the second surface, the second pattern defining at least one boundary of the second etch resistant material on the second surface;
• etching the thin base material to form:
• a rounded edge in the thin base material at the at least one boundary of the first pattern of first etch resistant material by degrading the first adhesive bond of the thin base material and the first etch resistant material at the at least one boundary of the first pattern of first etch resistant material, and
• a sharp edge at the at least one boundary of the second pattern of second etch resistant material by preventing etching of the thin base material beyond the at least one boundary of the second pattern of second etch resistant material by maintaining the second adhesive bond.