US20010023860A1 - Excimer laser ablation process control of multilaminate materials - Google Patents
Excimer laser ablation process control of multilaminate materials Download PDFInfo
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- US20010023860A1 US20010023860A1 US09/863,215 US86321501A US2001023860A1 US 20010023860 A1 US20010023860 A1 US 20010023860A1 US 86321501 A US86321501 A US 86321501A US 2001023860 A1 US2001023860 A1 US 2001023860A1
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- 239000000463 material Substances 0.000 title claims abstract description 28
- 238000000608 laser ablation Methods 0.000 title claims description 8
- 238000004886 process control Methods 0.000 title description 2
- 238000000034 method Methods 0.000 claims abstract description 28
- 239000002648 laminated material Substances 0.000 claims abstract description 18
- 238000010030 laminating Methods 0.000 claims description 3
- 239000000758 substrate Substances 0.000 claims description 3
- 238000002679 ablation Methods 0.000 description 13
- 239000004642 Polyimide Substances 0.000 description 10
- 229920001721 polyimide Polymers 0.000 description 10
- 239000000203 mixture Substances 0.000 description 7
- 238000009472 formulation Methods 0.000 description 5
- 238000000059 patterning Methods 0.000 description 5
- 238000003475 lamination Methods 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- -1 e.g. Substances 0.000 description 3
- 238000004880 explosion Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 238000005530 etching Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 230000001151 other effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
- B23K26/382—Removing material by boring or cutting by boring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/40—Removing material taking account of the properties of the material involved
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/16—Composite materials, e.g. fibre reinforced
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/30—Organic material
- B23K2103/42—Plastics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0011—Working of insulating substrates or insulating layers
- H05K3/0017—Etching of the substrate by chemical or physical means
- H05K3/0026—Etching of the substrate by chemical or physical means by laser ablation
- H05K3/0032—Etching of the substrate by chemical or physical means by laser ablation of organic insulating material
Definitions
- the instant invention relates to ablation patterning, particularly to ablation patterning of multilaminate materials.
- a beam of laser energy is directed against an exposed surface of a body to be ablated.
- the laser energy is absorbed by the material and, as a result of photochemical, thermal and other effects, localized explosions of the material occur, driving away, for each explosion, tiny fragments of the material.
- the process requires that significant amounts of energy be both absorbed and retained within small volumes of the material until sufficient energy is accumulated in each small volume to exceed a threshold energy density at which explosions occur.
- Polymeric materials such as polyimides, are well suited for use in the process because such materials have a high absorptivity for U.V. light while having a relatively low thermal diffusivity for limiting the spread of the absorbed energy away from the volume where the energy was absorbed. Thus, the energy level quickly builds above the required energy density threshold.
- One aspect of the invention is a method of ablating holes in a material, the method comprising providing a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer; providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer, changing the temperature of the laminated material so as to place said target region under tension; and directing said laser source onto said target region and ablating a portion thereof.
- the coefficient of thermal expansion of the first laminate layer may be greater than or less than that of the second laminate layer.
- a further aspect of the invention is a method of preparing a laminated material for laser ablation, comprising laminating a first layer to a second layer, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that when the laminated substrate is formed, a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- a further aspect of the invention is a laminated material comprising first and second layers, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- Excimer laser ablation enables precise drilling and/or ablation processes to less than one micron. To be useful, however, many such ablated devices must be laminated to other polymeric materials. Since the ablation process is often very precise, it is useful from a manufacturing point of view in many instances to ablate the polymer after the lamination process. Furthermore, because of the unique optical focusing requirements of the excimer laser it is important to the manufacturing process that the material to be ablated be flat, with a typical peak-to peak roughness of less than about 20 microns, i.e., ⁇ 10 microns for a given ablation operation.
- the typical of choice for excimer laser ablation is polyimide. Since polyimide has the lowest coefficient of expansion of most commonly used polymers, maintaining requisite flatness during an ablation process can be very difficult, as any change in temperature can cause materials (e.g., the polyimide component of the multilaminate) to become under compression. In such a scenario, surface flatness is no longer maintained. In order to maintain surface flatness for an ablation operation, it is desirable that the ablated material be under surface tension relative to its laminate layer.
- the instant invention addresses this problem in a method which comprises providing a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer; providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer; changing the temperature of the laminated material so as to place said target region under tension; and directing said laser source onto said target region and ablating a portion thereof.
- the coefficient of thermal expansion of the first laminate layer may be greater than or less than that of the second laminate layer.
- the instant invention also provides a method of preparing a laminated material for laser ablation, comprising laminating a first layer to a second layer, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that when the laminated substrate is formed, a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- the instant invention also provides a laminated material comprising first and second layers, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- the lamination process will be conducted at an elevated temperature relative to the temperature at which the material will be drilled or ablated.
- An example of such a laminate is polyimide laminated to polyethylene, where the polyethylene layer has a small window relative to the total size of the laminate cut out where the laser ablation will occur. In this case, upon cooling after the lamination process, the window will enlarge during cooling, and put the polyimide in tension.
- the lamination process will be conducted at a reduced temperature relative to the temperature at which the material will be ablated.
- a large window relative to the total size of the laminate is provides, such that the laminate heating results in window size growth, thereby placing the polyimide in tension.
Abstract
The instant invention discloses a method of ablating holes in a material, using a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer; providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer; changing the temperature of the laminated material so as to place said target region under tension; and directing said laser source onto said target region and ablating a portion thereof.
Description
- The instant invention relates to ablation patterning, particularly to ablation patterning of multilaminate materials.
- The use of ablation patterning of various polymeric materials, e.g., polyimides, is known. U.S. Pat. No. 4,508,749, for example, disclosed the use of ultraviolet (U.V.) radiation for etching through a polyimide layer. This patent is primarily directed to producing tapered openings through a polyimide layer for exposing surface areas of an underlying layer of metal. Electrical connections are then made through the openings to the metal layer. U.S. Pat. No. 5,236,551 likewise disclosed ablation etching for patterning a polymeric material layer which is then used as an etch mask for etch patterning, using wet or chemical etchants, an underlying layer of metal.
- In a typical ablation process, a beam of laser energy is directed against an exposed surface of a body to be ablated. The laser energy is absorbed by the material and, as a result of photochemical, thermal and other effects, localized explosions of the material occur, driving away, for each explosion, tiny fragments of the material. The process requires that significant amounts of energy be both absorbed and retained within small volumes of the material until sufficient energy is accumulated in each small volume to exceed a threshold energy density at which explosions occur.
- Polymeric materials, such as polyimides, are well suited for use in the process because such materials have a high absorptivity for U.V. light while having a relatively low thermal diffusivity for limiting the spread of the absorbed energy away from the volume where the energy was absorbed. Thus, the energy level quickly builds above the required energy density threshold.
- When an excimer laser is used, because of the unique optical focusing requirements of the excimer laser it is important to the manufacturing process that the material to be ablated be flat, with a typical peak-to peak roughness of less than about 20 microns, i.e., ±10 microns for a given ablation operation. This need an others are addressed by the instant invention.
- One aspect of the invention is a method of ablating holes in a material, the method comprising providing a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer; providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer, changing the temperature of the laminated material so as to place said target region under tension; and directing said laser source onto said target region and ablating a portion thereof. The coefficient of thermal expansion of the first laminate layer may be greater than or less than that of the second laminate layer.
- A further aspect of the invention is a method of preparing a laminated material for laser ablation, comprising laminating a first layer to a second layer, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that when the laminated substrate is formed, a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- A further aspect of the invention is a laminated material comprising first and second layers, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- Before the present method of excimer laser ablation process control is described, it is to be understood that this invention is not limited to the particular methodology, devices and formulations described, as such methods, devices and formulations may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention which will be limited only by the appended claims.
- It must be noted that as used herein and in the appended claims, the singular forms “a,” “and,” and “the ” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a formulation” includes mixtures of different formulations, reference to “an analog” refers to one or mixtures of analogs, and reference to “the method of treatment” includes reference to equivalent steps and methods known to those skilled in the art, and so forth.
- Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods, devices and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety for the purpose of describing and disclosing devices, formulations and methodologies which are described in the publication and which might be used in connection with the presently described invention.
- Excimer laser ablation enables precise drilling and/or ablation processes to less than one micron. To be useful, however, many such ablated devices must be laminated to other polymeric materials. Since the ablation process is often very precise, it is useful from a manufacturing point of view in many instances to ablate the polymer after the lamination process. Furthermore, because of the unique optical focusing requirements of the excimer laser it is important to the manufacturing process that the material to be ablated be flat, with a typical peak-to peak roughness of less than about 20 microns, i.e., ±10 microns for a given ablation operation.
- The typical of choice for excimer laser ablation is polyimide. Since polyimide has the lowest coefficient of expansion of most commonly used polymers, maintaining requisite flatness during an ablation process can be very difficult, as any change in temperature can cause materials (e.g., the polyimide component of the multilaminate) to become under compression. In such a scenario, surface flatness is no longer maintained. In order to maintain surface flatness for an ablation operation, it is desirable that the ablated material be under surface tension relative to its laminate layer.
- The instant invention addresses this problem in a method which comprises providing a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer; providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer; changing the temperature of the laminated material so as to place said target region under tension; and directing said laser source onto said target region and ablating a portion thereof. The coefficient of thermal expansion of the first laminate layer may be greater than or less than that of the second laminate layer.
- The instant invention also provides a method of preparing a laminated material for laser ablation, comprising laminating a first layer to a second layer, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that when the laminated substrate is formed, a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- The instant invention also provides a laminated material comprising first and second layers, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
- Thus, in an embodiment where cooling of the laminate places the ablation material in tension, the lamination process will be conducted at an elevated temperature relative to the temperature at which the material will be drilled or ablated. An example of such a laminate is polyimide laminated to polyethylene, where the polyethylene layer has a small window relative to the total size of the laminate cut out where the laser ablation will occur. In this case, upon cooling after the lamination process, the window will enlarge during cooling, and put the polyimide in tension.
- In an embodiment where heating of the laminate places the ablation material in tension, the lamination process will be conducted at a reduced temperature relative to the temperature at which the material will be ablated. Typically, a large window relative to the total size of the laminate is provides, such that the laminate heating results in window size growth, thereby placing the polyimide in tension.
Claims (5)
1. A method of ablating holes in a material, comprising:
providing a laminated material comprising first and second layers, said first and second layers having different coefficients of thermal expansion, said first layer having within it a hole, wherein a target region of said second layer in said laminated material is not laminated to said first layer but is surrounded entirely by laminated regions wherein the first layer is laminated to the second layer;
providing a laser source producing energy of a wavelength and a power level that can ablate material from said first layer;
changing the temperature of the laminated material so as to place said target region under tension;
directing said laser source onto said target region and ablating a portion thereof.
2. The method of , wherein the coefficient of thermal expansion of the first laminate layer is greater than that of the second laminate layer.
claim 1
3. The method of , wherein the coefficient of thermal expansion of the second laminate layer is greater than that of the first laminate layer.
claim 1
4. A method of preparing a laminated material for laser ablation, comprising:
laminating a first layer to a second layer, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that when the laminated substrate is formed, a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
5. A laminated material comprising first and second layers, wherein said first and second layers have different coefficients of thermal expansion, and wherein said second layer has an interior hole such that a region of the first layer aligned with said hole is not laminated to the second layer and is surrounded by laminated regions.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/863,215 US20010023860A1 (en) | 1999-07-14 | 2001-05-22 | Excimer laser ablation process control of multilaminate materials |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US09/353,125 US6288360B1 (en) | 1999-07-14 | 1999-07-14 | Excimer laser ablation process control of multilaminate materials |
US09/863,215 US20010023860A1 (en) | 1999-07-14 | 2001-05-22 | Excimer laser ablation process control of multilaminate materials |
Related Parent Applications (1)
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US09/353,125 Division US6288360B1 (en) | 1999-07-14 | 1999-07-14 | Excimer laser ablation process control of multilaminate materials |
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US20010023860A1 true US20010023860A1 (en) | 2001-09-27 |
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US09/616,582 Expired - Fee Related US6369354B1 (en) | 1999-07-14 | 2000-07-14 | Excimer laser ablation process control of multilaminate materials |
US09/863,215 Abandoned US20010023860A1 (en) | 1999-07-14 | 2001-05-22 | Excimer laser ablation process control of multilaminate materials |
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US09/616,582 Expired - Fee Related US6369354B1 (en) | 1999-07-14 | 2000-07-14 | Excimer laser ablation process control of multilaminate materials |
Country Status (10)
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US (3) | US6288360B1 (en) |
EP (1) | EP1214171B1 (en) |
JP (1) | JP2003504214A (en) |
AT (1) | ATE500919T1 (en) |
AU (1) | AU770886B2 (en) |
CA (1) | CA2377855C (en) |
DE (1) | DE60045712D1 (en) |
ES (1) | ES2360429T3 (en) |
MX (1) | MXPA02000407A (en) |
WO (1) | WO2001005551A1 (en) |
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JPH11170076A (en) * | 1997-12-09 | 1999-06-29 | Sumitomo Metal Ind Ltd | Manufacture of titanium covered steel |
US6288360B1 (en) * | 1999-07-14 | 2001-09-11 | Aradigm Corporation | Excimer laser ablation process control of multilaminate materials |
-
1999
- 1999-07-14 US US09/353,125 patent/US6288360B1/en not_active Expired - Lifetime
-
2000
- 2000-07-14 MX MXPA02000407A patent/MXPA02000407A/en unknown
- 2000-07-14 WO PCT/US2000/019199 patent/WO2001005551A1/en active IP Right Grant
- 2000-07-14 EP EP00957250A patent/EP1214171B1/en not_active Expired - Lifetime
- 2000-07-14 AT AT00957250T patent/ATE500919T1/en active
- 2000-07-14 US US09/616,582 patent/US6369354B1/en not_active Expired - Fee Related
- 2000-07-14 AU AU68898/00A patent/AU770886B2/en not_active Ceased
- 2000-07-14 DE DE60045712T patent/DE60045712D1/en not_active Expired - Lifetime
- 2000-07-14 ES ES00957250T patent/ES2360429T3/en not_active Expired - Lifetime
- 2000-07-14 JP JP2001510621A patent/JP2003504214A/en active Pending
- 2000-07-14 CA CA002377855A patent/CA2377855C/en not_active Expired - Fee Related
-
2001
- 2001-05-22 US US09/863,215 patent/US20010023860A1/en not_active Abandoned
Patent Citations (4)
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US3770560A (en) * | 1971-10-21 | 1973-11-06 | American Cyanamid Co | Composite laminate with a thin, perforated outer layer and cavitated bonded backing member |
US4786558A (en) * | 1986-01-31 | 1988-11-22 | Toray Industries, Ltd. | Composite film and antistatic composite film comprising a swellable inorganic silicate |
US5296291A (en) * | 1989-05-05 | 1994-03-22 | W. R. Grace & Co.-Conn. | Heat resistant breathable films |
US5833759A (en) * | 1996-11-08 | 1998-11-10 | W. L. Gore & Associates, Inc. | Method for preparing vias for subsequent metallization |
Also Published As
Publication number | Publication date |
---|---|
US6369354B1 (en) | 2002-04-09 |
EP1214171A4 (en) | 2003-07-02 |
JP2003504214A (en) | 2003-02-04 |
EP1214171B1 (en) | 2011-03-09 |
MXPA02000407A (en) | 2004-05-21 |
AU6889800A (en) | 2001-02-05 |
CA2377855C (en) | 2006-11-14 |
ES2360429T3 (en) | 2011-06-03 |
ATE500919T1 (en) | 2011-03-15 |
AU770886B2 (en) | 2004-03-04 |
CA2377855A1 (en) | 2001-01-25 |
US6288360B1 (en) | 2001-09-11 |
EP1214171A1 (en) | 2002-06-19 |
DE60045712D1 (en) | 2011-04-21 |
WO2001005551A1 (en) | 2001-01-25 |
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