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US 2003/0189746 A1Published application
System, method and article of manufacture for improved laser direct imaging a printed circuit board utilizing a mode locked laser and scophony operation
OwnerMarc Vernacktinventor
Life of this patent
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Abstract
A system, method and article of manufacture is disclosed that provides an improved, higher efficiency, more accurate laser direct imaging on a photosensitive medium on a substrate using a ultraviolet, mode-locked laser having a low average power and a short pulse width. The ultraviolet, mode-locked laser is modulated in a scophony mode. The resulting in-scan edges having improved perpendicularity relative to the underlying substrate. The resulting cross scan beginning and end having improved perpendicularity relative to the underlying substrate. The improved perpendicularity resulting in improved accuracy over the prior art.
Claims55
A laser direct imaging apparatus for imaging a pixel on a photosensitive medium with a laser beam, the apparatus comprising:
- a) a substrate held in a frame, said substrate including:
- (i) a width of between 6 inches and 25 inches and a length of between 6 inches and 36 inches;
- (ii) a first surface and an opposing second surface;
- (iii) a first photosensitive layer on said first surface and said second surface;
- and
- (iv) a first intermediate layer between said substrate and said first photosensitive layer;
- b) a UV, mode locked laser operable to emit a pulsed laser beam, said pulsed laser beam including:
- (i) a wavelength of between 200 nm and 532 nm;
- (ii) a pulse width of between 1 ps and 20 ps;
- (iii) a pulse frequency of between 50 MHz and 400 MHz;
- (iv) an average power of between 0.050 watts and 20 watts;
- and
- (v) a duty cycle of between 125 to 1 and 20,000 to 1;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam to cause an acoustic wave to travel in said crystal at an acoustic speed;
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction at an in-scan scanning speed to substantially expose one or more first pixels of said first photosensitive layer, said first pixel defined by a surface area contacted by said modulated, pulsed laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first′ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein the first side, said first′ side, said first beginning and said first end are substantially perpendicular to said substrate;
- and
- said imaging apparatus provides an optical magnification between the acousto-optical modulator and said photosensitive layer, wherein the in-scan scanning speed is matched to the acoustic speed and any optical magnification to achieve scophony mode scanning.
17 more elements
A method for laser direct imaging a pixel on a photosensitive medium with a laser beam, comprising:
- a) providing a substrate in a frame, said substrate including:
- (i) a width of between 6 inches and 25 inches and a length of between 6 inches and 36 inches;
- and
- (ii) a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) providing a first intermediate layer between said substrate and said first photosensitive layer;
- d) emitting a UV, mode locked laser beam said laser beam including:
- (i) a wavelength of between 200 nm and 532 nm;
- (ii) a pulse width of between 1 ps and 20 ps;
- (iii) a pulse frequency of between 50 MHz and 400 MHz;
- (iv) an average power of between 0.050 watts and 20 watts;
- and
- (v) a duty cycle of between 125 to 1 and 20,000 to 1;
- e) receiving said laser beam in an acousto-optical modulator having an acoustic speed;
- f) receiving a modulating signal in said acousto-optical modulator;
- g) modulating said laser beam in said acousto-optical modulator;
- h) receiving said modulated laser beam in a first scanner unit;
- i) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction at an in-scan scanning speed to substantially expose one or more first pixels of the first photosensitive layer, said first pixel defined by a surface area contacted by said modulated, pulsed laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first′ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein said first side, said first′ side, said first beginning and said first end are substantially perpendicular to said substrate;
- j) providing an optical magnification between the acousto-optical modulator and said photosensitive layer;
- and
- k) matching the in-scan scanning speed to the acoustic speed and any optical magnification to achieve scophony mode scanning.
18 more elements
A laser direct imaging apparatus for imaging a pixel on a photosensitive medium with a laser beam, comprising:
- a) a substrate, said substrate including:
- (i) a first surface and an opposing second surface;
- (ii) a first photosensitive layer on said first surface;
- and
- b) a mode locked laser operable to emit a pulsed laser beam, said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam;
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction to substantially expose one or more first pixels of said first photosensitive layer, said first pixel defined by a surface area contacted by said modulated, pulsed laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first′ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein said first side and said first′ side are substantially perpendicular to said substrate.
7 more elements
A method for laser direct imaging a pixel on a photosensitive medium with a laser beam, comprising:
- a) providing a substrate including a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) emitting a mode locked laser beam, said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1;
- d) receiving said laser beam by an acousto-optical modulator;
- e) receiving a modulating signal in said acousto-optical modulator;
- f) modulating said laser beam in said acousto-optical modulator;
- g) receiving said modulated laser beam in said first scanner unit;
- and
- h) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction to substantially expose one or more first pixels of the first photosensitive layer, said first pixel defined by a surface area contacted by said modulated laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first′ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein said first side and said first′ side are substantially perpendicular to said substrate.
6 more elements
An improved laser direct imaging apparatus for imaging a pixel on a photosensitive medium with a laser beam, the apparatus comprising:
- a) a substrate, said substrate including:
- (i) a first surface and an opposing second surface;
- (ii) a first photosensitive layer on said first surface;
- b) a mode locked laser operable to emit a pulsed laser beam;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam;
- and
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1, wherein one or more first pixels are substantially exposed, said first pixel having a first side and a first′ side in said in-scan direction, wherein the accuracy of said first side and said first′ side are improved by having improved perpendicularity to said substrate.
9 more elements
An improved laser direct imaging method for imaging a pixel on a photosensitive medium with a laser beam, the method comprising:
- a) providing a substrate including a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) emitting a mode locked laser beam;
- d) receiving said laser beam by an acousto-optical modulator;
- e) receiving a modulating signal in said acousto-optical modulator;
- f) modulating said laser beam in said acousto-optical modulator;
- g) receiving said modulated laser beam in said first scanner unit;
- and
- h) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- providing said mode locked laser with a duty cycle of between 125 to 1 and 20,000 to 1, exposing one or more first pixels, said first pixel having a first side and a first′ side in said in-scan direction, wherein the accuracy of said first side and said first′ side are improved by having improved perpendicularity to said substrate.
8 more elements
A laser direct imaging apparatus providing improved efficiency of imaging a pixel on a photosensitive medium with a laser beam, comprising:
- a) a substrate, said substrate including:
- (i) a first surface and an opposing second surface;
- (ii) a first photosensitive layer on said first surface;
- and
- b) a mode locked laser operable to emit a pulsed laser beam;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam;
- and
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1, wherein one or more first pixels are substantially exposed, said first pixel having a first side and a first″ side in said in-scan direction, wherein said first side and said first″ side have improved perpendicularity and efficiency of exposing said pixel is improved by a factor of at least 2.5.
10 more elements
A method of improved efficiency of exposing a pixel on a photosensitive medium with a laser beam, the method comprising:
- a) providing a substrate including a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) emitting a mode locked laser beam;
- d) receiving said laser beam by an acousto-optical modulator;
- e) receiving a modulating signal in said acousto-optical modulator;
- f) modulating said laser beam in said acousto-optical modulator;
- g) receiving said modulated laser beam in said first scanner unit;
- and
- h) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- providing said mode locked laser with a duty cycle of between 125 to 1 and 20,000 to 1, exposing one or more first pixels, said first pixel having a first side and a first″ side in said in-scan direction, wherein said first side and said first″ side have improved perpendicularity to said substrate and efficiency of exposing said pixel is improved by a factor of at least 2.5.
8 more elements
A laser direct imaging apparatus providing improved efficiency of imaging a pixel on a photosensitive medium with a laser beam, comprising:
- a) a substrate, said substrate including:
- (i) a first surface and an opposing second surface;
- (ii) a first photosensitive layer on said first surface;
- and
- b) a mode locked laser operable to emit a pulsed laser beam;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam;
- and
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1, wherein one or more first pixels are substantially exposed, and efficiency of exposing said pixel is improved by a factor of at least 2.5.
10 more elements
A method of improved efficiency of exposing a pixel on a photosensitive medium with a laser beam, the method comprising:
- a) providing a substrate including a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) emitting a mode locked laser beam;
- d) receiving said laser beam by an acousto-optical modulator;
- e) receiving a modulating signal in said acousto-optical modulator;
- f) modulating said laser beam in said acousto-optical modulator;
- g) receiving said modulated laser beam in said first scanner unit;
- and
- h) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction;
- wherein the improvement comprises:
- providing said mode locked laser with a duty cycle of between 125 to 1 and 20,000 to 1, exposing one or more first pixels, and efficiency of exposing said pixel is improved by a factor of at least 2.5.
8 more elements
An apparatus for producing a printed circuit board by laser direct imaging a pixel on the printed circuit board, comprising;
- a) a substrate, said substrate including:
- (i) a first surface and an opposing second surface;
- (ii) a first photosensitive layer on said first surface;
- and
- (iii) a first intermediate layer between said first photosensitive layer and said substrate;
- b) a mode locked laser operable to emit a pulsed laser beam, said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1;
- c) an acousto-optical modulator including:
- (i) a crystal oriented to receive said pulsed laser beam;
- and
- (ii) a transducer, said transducer in contact with said crystal, said transducer operable to receive a modulating signal from an external source and to emit said modulating signal into said crystal to modulate said pulsed laser beam;
- d) a first scanner unit oriented to receive said modulated, pulsed laser beam, said first scanner unit operable to direct and move said modulated, pulsed laser beam across said first photosensitive layer in an in-scan direction to substantially expose one or more first pixels of said first photosensitive layer, said first pixel defined by a surface area contacted by said modulated, pulsed laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first″ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein said first side and said first′ side are substantially perpendicular to said substrate.
8 more elements
A method for producing a printed circuit board by laser direct imaging a pixel on the printed circuit board, comprising:
- a) providing a substrate including a first surface and an opposing second surface;
- b) providing a first photosensitive layer on said first surface;
- c) providing a first intermediate layer between said first photosensitive layer and said substrate;
- d) emitting a mode locked laser beam, said mode locked laser having a duty cycle of between 125 to 1 and 20,000 to 1;
- e) receiving said laser beam by an acousto-optical modulator;
- f) receiving a modulating signal in said acousto-optical modulator;
- g) modulating said laser beam in said acousto-optical modulator;
- h) receiving said modulated laser beam in a first scanner unit;
- and
- i) directing and moving said modulated laser beam across said first photosensitive layer in an in-scan direction to substantially expose one or more first pixels of the first photosensitive layer, said first pixel defined by a surface area contacted by said modulated laser beam and substantially penetrating through said first photosensitive layer, said first pixel having a first side and a first′ side in said in-scan direction and a first beginning and a first end in a cross scan direction, wherein said first side and said first′ side is substantially perpendicular to said substrate.
7 more elements
Dependencies are inferred from the claim text.