US4985116A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Three dimensional plating or etching process and masks therefor
Assignee: MINT-PAC TECHNOLOGIES Inc
•
Filing: 1990-02-23
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Granted: 1991-01-15
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Expires: 2010-02-23
Abstract
Abstract In a process for plating or etching metalization patterns on the surface of a three dimensional substrate, a flexible plastic mask is fabricated by first coating the surface of a thin plastic sheet with vacuum formable ink. The mask is then molded into the shape of the surface into which the pattern is to be formed. A low power YAG laser is used to remove areas of the ink through which light is to be allowed to pass. This mask may then be used in either a print and plate process or a print and etch process by drawing the mask into intimate contact with the workpiece by applying a vacuum between the mask and the workpiece. The workpiece may then be exposed to light through the clear areas of the mask.
Inventors
- 👤 John H. Mettler
- 👤 William L. Johnson
- 👤 William C. Strickland
- 👤 Victor V. Zaderej
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 16:43
CPC Classifications
G; G03; G03F; G03F1/00; G03F1/68; H; H05; H05K; H05K3/00; H05K3/0002; H05K3/0073; H05K3/0082; H05K1/00; H05K1/02; H05K1/0284; H05K2203/00; H05K2203/05; H05K2203/0548; H05K2203/056; H05K2203/08; H05K2203/085; H05K2203/10; H05K2203/107; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1028
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
45 words
A method for fabricating a mask, comprising in combination the steps of: coating one surface of a sheet of transparent vacuum formable material with a vacuum formable ink; vacuum forming said sheet; and removing portions of said ink to reveal transparent areas of said mask.
Claim 2
Independent Claim
45 words
A method for fabricating a mask, comprising in combination the steps of: coating one surface of a sheet of transparent vacuum formable material with a vacuum formable ink; vacuum forming said sheet; and removing portions of said ink to reveal transparent areas of said mask.
Claim 3
Dependent Claim
24 words
The method of claim 1, wherein said removing step is carried out by illuminating said portions of said ink with a low power laser.
Claim 4
Dependent Claim
12 words
The method of claim 2, wherein said laser is a YAG laser.
Claim 5
Dependent Claim
16 words
The method of claim 1, wherein said sheet is approximately 0.005 to 0.050 inch in thickness.
Claim 6
Dependent Claim
21 words
The method of claim 2, wherein said ink is removed from said surface by illuminating said surface through said transparent material.
Claim 7
Dependent Claim
24 words
The method of claim 2, wherein said ink is removed from said surface by illuminating said surface from the inked surface of said sheet.
Claim 8
Dependent Claim
13 words
The method of claim 2, wherein said laser comprises a computer controlled laser.
Claim 9
Dependent Claim
16 words
The method of claim 7, wherein said laser can be controlled with five degrees of freedom.
Claim 10
Dependent Claim
18 words
The method of claim 2, wherein said laser has a power output of less than about 50 watts.
Claim 11
Independent Claim
67 words
A method for fabricating a mask, comprising in combination the steps of: coating one surface of a sheet of transparent vacuum formable material having thickness between 0.005 and 0.050 inch with a vacuum formable ink; vacuum forming said sheet; and removing portions of said ink to reveal transparent areas of said mask by illuminating said portions of said ink with a low power computer controlled YAG laser.
Claim 12
Independent Claim
67 words
A method for fabricating a mask, comprising in combination the steps of: coating one surface of a sheet of transparent vacuum formable material having thickness between 0.005 and 0.050 inch with a vacuum formable ink; vacuum forming said sheet; and removing portions of said ink to reveal transparent areas of said mask by illuminating said portions of said ink with a low power computer controlled YAG laser.
Claim 13
Dependent Claim
21 words
The method of claim 10, wherein said ink is removed from said surface by illuminating said surface through said transparent material.
Claim 14
Dependent Claim
24 words
The method of claim 10, wherein said ink is removed from said surface by illuminating said surface from the inked surface of said sheet.
Claim 15
Dependent Claim
80 words
A mask for use in a plating or etching process to be carried out on a workpiece, comprising in combination: a vacuum formed sheet of flexible transparent plastic carrying the approximate shape of a surface of said workpiece; a coating of an opaque material covering a portion of said sheet; at least one area of said sheet having an absence of said opaque material to expose transparent plastic; and registration means for providing alignment between said mask and said workpiece.
Claim 16
Dependent Claim
80 words
A mask for use in a plating or etching process to be carried out on a workpiece, comprising in combination: a vacuum formed sheet of flexible transparent plastic carrying the approximate shape of a surface of said workpiece; a coating of an opaque material covering a portion of said sheet; at least one area of said sheet having an absence of said opaque material to expose transparent plastic; and registration means for providing alignment between said mask and said workpiece.
Claim 17
Dependent Claim
19 words
The mask of claim 13, wherein said sheet is made of material approximately 0.005 to 0.050 inch in thickness.
Claim 18
Dependent Claim
20 words
The mask of claim 13, further comprising a vacuum port for application of vacuum between said mask and said workpiece.
Claim 19
Dependent Claim
16 words
The mask of claim 13, further comprising a vacuum seal surrounding a periphery of said mask.
Claim 20
Dependent Claim
23 words
The mask of claim 13, wherein said registration means comprises at least one dimple adapted to seat within an aperture in said workpiece.
Claim 21
Dependent Claim
13 words
The mask of claim 13, wherein said plastic is transparent to ultraviolet light.
Claim 22
Independent Claim
69 words
A method for applying a mask to a workpiece for use in a plating or etching process, the method comprising in combination the steps of: providing a flexible mask having a surface which conforms with a surface of said workpiece; registering said mask over said surface of said workpiece; and drawing said mask into close contact with said workpiece by applying a vacuum between said mask and said workpiece.
Claim 23
Independent Claim
69 words
A method for applying a mask to a workpiece for use in a plating or etching process, the method comprising in combination the steps of: providing a flexible mask having a surface which conforms with a surface of said workpiece; registering said mask over said surface of said workpiece; and drawing said mask into close contact with said workpiece by applying a vacuum between said mask and said workpiece.
Claim 24
Dependent Claim
19 words
The method of claim 19, further comprising the step of selectively exposing said workpiece to light through said mask.
Claim 25
Dependent Claim
15 words
The method of claim 20, wherein said light is produced by a non-collimated light source.
Claim 26
Independent Claim
55 words
A method for processing a substrate, comprising in combination the steps of: coating a plated substrate with photoresist; installing a flexible mask over said coated substrate; pulling said substrate and said mask into close contact by applying a vacuum between said substrate and said mask; and exposing said coated substrate to light through said mask.
Claim 27
Independent Claim
55 words
A method for processing a substrate, comprising in combination the steps of: coating a plated substrate with photoresist; installing a flexible mask over said coated substrate; pulling said substrate and said mask into close contact by applying a vacuum between said substrate and said mask; and exposing said coated substrate to light through said mask.
Claim 28
Dependent Claim
30 words
The method of claim 22, wherein said mask includes transparent areas and opaque areas, and wherein said transparent areas correspond to areas where metal is to be on said substrate.
Claim 29
Dependent Claim
31 words
The method of claim 22, wherein said mask includes transparent areas and opaque areas, and wherein said transparent areas correspond to areas where metal is to be removed from said workpiece.
Claim 30
Dependent Claim
20 words
The method of claim 22, further comprising the step of developing said exposed resist coated substrate to expose conductive areas.
Claim 31
Dependent Claim
11 words
The method of claim 22, wherein said light is non-collimated light.
Claim 32
Dependent Claim
25 words
The method of claim 22, further comprising the steps of electroless plating an insulating substrate prior to said coating step to produce said plated substrate.
Claim 33
Dependent Claim
29 words
The method of claim 27, further comprising the step of electroplating said electroless plated substrate with a conductive metal prior to said coating step to produce said plated substrate.
Claim 34
Dependent Claim
19 words
The method of claim 25, further comprising the step of electroplating said exposed conductive areas with a conductive material.
Claim 35
Dependent Claim
16 words
The method of claim 25, further comprising the step of etching away said exposed conductive areas.
Claim 36
Dependent Claim
15 words
The method of claim 25, further comprising the step of stripping away said developed resist.
Claim 37
Dependent Claim
24 words
The method of claim 31, further comprising the step of etching away conductive material exposed by the step of stripping away said developed resist.
Claim 38
Dependent Claim
18 words
The method of claim 31, further comprising the step of cleansing said substrate to remove a catalyst therefrom.
Claim 39
Independent Claim
141 words
A method for printing and plating a substrate, comprising the ordered steps of: molding an insulative substrate to a predetermined shape; annealing said insulative substrate; electroless plating said substrate with copper; electroplating said substrate with a photoresist material; drying and baking said photoresist material; installing a flexible mask over said substrate; pulling said flexible mask into close registration with said substrate by applying a vacuum between said mask and said substrate; exposing said substrate to non-collimated light through said mask; removing said mask from said substrate; developing said photoresist material to expose areas of plated substrate while covering other areas of plated substrate; electroplating said exposed areas of plated substrate with a conductive material; etching said other areas of plated substrate to remove said plating on said other areas; and stripping said photoresist to expose said other areas of plated substrate.
Claim 40
Independent Claim
141 words
A method for printing and plating a substrate, comprising the ordered steps of: molding an insulative substrate to a predetermined shape; annealing said insulative substrate; electroless plating said substrate with copper; electroplating said substrate with a photoresist material; drying and baking said photoresist material; installing a flexible mask over said substrate; pulling said flexible mask into close registration with said substrate by applying a vacuum between said mask and said substrate; exposing said substrate to non-collimated light through said mask; removing said mask from said substrate; developing said photoresist material to expose areas of plated substrate while covering other areas of plated substrate; electroplating said exposed areas of plated substrate with a conductive material; etching said other areas of plated substrate to remove said plating on said other areas; and stripping said photoresist to expose said other areas of plated substrate.
Claim 41
Independent Claim
60 words
A method for fabricating a mask, comprising in combination the steps of: providing a sheet of transparent material which turns opaque when exposed to laser light of adequate intensity; forming said sheet of material into a predetermined shape; and exposing said formed sheet to laser light of adequate intensity to cause selected areas of said formed sheet to turn opaque.
Claim 42
Independent Claim
60 words
A method for fabricating a mask, comprising in combination the steps of: providing a sheet of transparent material which turns opaque when exposed to laser light of adequate intensity; forming said sheet of material into a predetermined shape; and exposing said formed sheet to laser light of adequate intensity to cause selected areas of said formed sheet to turn opaque.
Claim 43
Dependent Claim
25 words
The method of claim 35, wherein said sheet of material is made of acrylic and wherein said laser burns opaque patterns in said selected areas.
Claim 44
Independent Claim
132 words
A method for printing and etching a substrate, comprising the ordered steps of: molding an insulative substrate to a predetermined shape; annealing said insulative substrate; electroless plating said substrate with a conductive material; electroplating said substrate with a conductive material; electroplating said substrate with a photoresist material; drying and baking said photoresist material; installing a flexible mask over said substrate; pulling said flexible mask into close registration with said substrate by applying a vacuum between said mask and said substrate; exposing said substrate to non-collimated light through said mask; removing said mask from said substrate; developing said photoresist material to expose areas of plated substrate while covering other areas of plated substrate; etching away said exposed areas of plated substrate; and stripping said photoresist to expose said other areas of plated substrate.
Claim 45
Independent Claim
132 words
A method for printing and etching a substrate, comprising the ordered steps of: molding an insulative substrate to a predetermined shape; annealing said insulative substrate; electroless plating said substrate with a conductive material; electroplating said substrate with a conductive material; electroplating said substrate with a photoresist material; drying and baking said photoresist material; installing a flexible mask over said substrate; pulling said flexible mask into close registration with said substrate by applying a vacuum between said mask and said substrate; exposing said substrate to non-collimated light through said mask; removing said mask from said substrate; developing said photoresist material to expose areas of plated substrate while covering other areas of plated substrate; etching away said exposed areas of plated substrate; and stripping said photoresist to expose said other areas of plated substrate.
Claim 46
Dependent Claim
15 words
The method of claim 35, wherein said laser burns opaque patterns in said selected areas.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-01-14 | 1994-07-16 | 1995-01-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-01-14 | 1998-07-16 | 1999-01-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-01-14 | 2002-07-16 | 2003-01-15 | $7700.00 | Window Closed / Lapsed |