Ultra Thin Foil and Its Applications

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An ultra thin foil is a copper foil which has a thickness less than 12 mm. It can be used as an outer layer in a multi-layer printed wiring board. However, handling the foil can be challenging as it can wrinkle and tear during production and handling.

Several organic compounds have been found to be useful in making composite foils. They retain their ability to bond with copper even after exposure to temperatures used in laminating copper foil to an insulating substrate. These composite foils have sufficient peel strength after lamination to a substrate and do not separate during processing into a printed circuit board.

They can be used as the anode in a pouch cell for new generation lithium metal batteries, such as li-ion batteries. This is a very important technology for energy storage applications and has been successfully utilized in space.

These composite foils have been shown to be very robust in the rigors of launch and space environments. This has been documented in the laboratory as well as by examining the flight histories of several different types of space instruments using foils.

Moreover, the durability of these composite foils is very good when they are used as an anode in a pouch cell for a Li-ion battery. They have been used in space for over a decade and have maintained their functionality over long mission lifetimes, demonstrating that these foils are a mature and reliable technology for space flight.