Reel-to-reel laser ablation methods and devices in FPC fabrication
OwnerRobert Clinton Laneinventor
Life of this patent
Estimating the term…
Abstract
A reel-to-reel method to laser-ablate a circuitry pattern on the fly in a reel-to-reel machine as part of a process to fabricate a printed flexible circuit. The laser ablation method includes using an appropriate laser to irradiate a metal sheet thus ablating the edges of an intended circuitry pattern. Slugs can be removed by using an optional sacrificial liner, and the slugs can be optionally ablated into smaller parts first. The laser ablation can also include an optional method of creating tie bars to provide structural support to the web of circuitry patterns.
Claims10
A method of creating a circuitry pattern during a manufacturing of a flexible printed circuit, the method comprising:
- feeding a metal foil into a reel-to-reel machine wherein the metal foil has a thickness, a first surface and a second surface;
- attaching a sacrificial liner reel-to-reel to the second surface of the metal foil within the reel-to-reel machine;
- providing a laser ablation module including a laser scanner in the reel-to-reel machine;
- wherein an intended area of the circuitry pattern is surrounded by an outer edge, and the outer edge has a thickness;
- after the attaching step, patterning the circuitry pattern and at least one slug by laser-ablating the first surface of the metal foil within an enclosure using the laser scanner to eventually and thoroughly cut through the thickness of the outer edge;
- wherein the patterning step includes creating tie bars that physically attach an end of the circuitry pattern to another end of the circuitry pattern;
- wherein the patterning step includes laser-ablating the at least one slug into a plurality of sub-parts to facilitate easier removal of the at least one slug;
- after the patterning step, applying a coverlay onto the first surface of the metal foil in the reel-to-reel machine;
- applying a negative pressure to the enclosure with a source of suction;
- removing the at least one slug from the circuitry pattern by
- a. applying compressed air to the at least one slug, or
- b. peeling off the sacrificial liner from the circuitry pattern reel-to-reel, or
- c. both;
- wherein the first surface is opposite of the second surface;
- and
- wherein the enclosure provides a true vacuum condition or a near-vacuum condition.
Dependencies are inferred from the claim text.