Laser etch-back process for forming a metal feature on a non-metal substrate

Claim 2

A laser etch-back process for forming a metal feature on an area of a non-metallic substrate, said process comprising applying a metal layer to the area, said metal layer comprising a first section having a first thickness and said second section having a second thickness substantially less than said first thickness, and irradiating the metal layer with a laser pulse such that the pulse uniformly irradiates the first section and the second section and is effective to heat the second section to vaporize the metal without vaporizing metal from the first section, whereby said second section is vaporized to expose the substrate and further whereby the first section survives said irradiation to form the metal feature.

Claim 3

The process of claim 1 wherein the substrate comprises a polymer surface.

Claim 4

The process of claim 1 wherein the metal layer is formed predominantly of a metal selected from the group consisting of copper, nickel, gold, silver, palladium and platinum.

Claim 5

The process of claim 1 wherein the first section is formed predominantly of electroplated metal.

Claim 6

The process of claim 1 wherein the laser pulse is emitted by an excimer laser apparatus.

Claim 7

A laser etch-back process for forming a metal feature on an area of a polymeric substrate, said area comprising a first region and a second region, said process comprising applying a continuous metal layer to substantially cover the area, said layer comprising a first section overlying a first region of the area and having a thickness of at least about 2.5 microns and a second section overlying a second region of the area and having a thickness less than about 0.6 microns, and uniformly irradiating the metal layer with a laser pulse to heat the metal layer, said pulse having a uniform fluence effective to heat the second section to a temperature sufficient to vaporize the metal but not sufficient to heat the first section to vaporize the metal, said irradiation continuing for a time sufficient to vaporize metal from the second section to expose the substrate.

Claim 8

A laser etch-back process for forming a metal feature on an area of a polymeric substrate, said area comprising a first region and a second region, said process comprising applying a continuous metal layer to substantially cover the area, said layer comprising a first section overlying a first region of the area and having a thickness of at least about 2.5 microns and a second section overlying a second region of the area and having a thickness less than about 0.6 microns, and uniformly irradiating the metal layer with a laser pulse to heat the metal layer, said pulse having a uniform fluence effective to heat the second section to a temperature sufficient to vaporize the metal but not sufficient to heat the first section to vaporize the metal, said irradiation continuing for a time sufficient to vaporize metal from the second section to expose the substrate.

Claim 9

The process of claim 6 wherein the first section is formed predominantly of a metal selected from the group consisting of copper, nickel, gold, silver, palladium and platinum.

Claim 10

The process of claim 6 wherein the metal layer is formed predominantly of copper metal.

Claim 11

The process of claim 6 wherein the metal layer is formed predominantly of copper and includes a thin non-copper coating selected from the group consisting of chromium, titanium and nickel.

Claim 12

The process of claim 6 wherein first section has a thickness between about 3.0 and 4.0 microns.

Claim 13

The process of claim 6 wherein second section has a thickness between about 0.5 and 0.6 microns.

Claim 14

The process of claim 6 wherein the laser beam has a fluence between about 200 and 600 millijoules per square centimeter.

Claim 15

A laser etch-back process for forming a copper trace on a polymeric substrate, said substrate including an area comprising a first region and a second region such that the trace overlies the first region and is bounded by the second region whereat said substrate is exposed, said process comprising depositing a thin metal film having a uniform thickness onto the substrate such that the film substantially covers the area, selectively electrodepositing a copper plate onto the film overlying the first region to form a metal layer comprising a thick section overlying said first region and a thin section formed by said film overlying the second region, and irradiating the metal layer with a laser beam such that the beam uniformly irradiates the thick section and the thin section, said beam having a fluence sufficient to heat the thin section to a temperature effective to vaporize the metal and thereby expose the substrate thereat, but not to vaporize metal at the thick section to thereby produce said trace.

Claim 16

A laser etch-back process for forming a copper trace on a polymeric substrate, said substrate including an area comprising a first region and a second region such that the trace overlies the first region and is bounded by the second region whereat said substrate is exposed, said process comprising depositing a thin metal film having a uniform thickness onto the substrate such that the film substantially covers the area, selectively electrodepositing a copper plate onto the film overlying the first region to form a metal layer comprising a thick section overlying said first region and a thin section formed by said film overlying the second region, and irradiating the metal layer with a laser beam such that the beam uniformly irradiates the thick section and the thin section, said beam having a fluence sufficient to heat the thin section to a temperature effective to vaporize the metal and thereby expose the substrate thereat, but not to vaporize metal at the thick section to thereby produce said trace.

Claim 17

The process of claim 13 wherein the metal film comprises a copper film and wherein the copper plate is deposited directly onto the copper film.

Claim 18

The process of claim 13 wherein the metal film thickness is less than about 0.6 micron thick, and wherein the thick section has a thickness greater than about 2.5 microns.

Claim 19

The process of claim 13 wherein the metal film thickness is between about 0.5 and 0.6 micron, and wherein the thick section has a thickness between about 3.0 and 4.0 microns.

Claim 20

The process of claim 13 further comprising coating the metal layer prior to irradiating with a coating formed of non-copper metal.

Claim 21

The process of claim 13 wherein the polymeric substrate comprises a polyimide resin.

Claim 22

A laser etch-back process for forming a predominantly copper trace on planar surface of a polymeric substrate, said surface comprising an area that includes a first region and a second region such that the trace is formed on said first region and is adjacent to the second region whereat said substrate is exposed, said process comprising depositing a metal coating onto the substrate such that the coating covers the area, said coating comprising an outermost copper film and having a thickness less than about 0.6 micron, applying a polymeric mask onto the substrate to overlie the metal coating, said mask covering the second region and having openings at said first region whereat the copper film is exposed, immersing the masked substrate into an electroplating bath containing a reducible copper ion, while cathodically biasing the metal coating to reduce the copper ion to deposit a metallic copper plate onto the copper film through the openings in the mask, whereby the copper plate cooperates with the metal coating to form a metal layer comprising a thick section at the first region that includes the copper plate and has a thickness greater than about 2.5 microns and a thin section at the second region derived from the metal coating underlying the mask, removing said polymeric mask from the substrate to expose the thin section, and irradiating the metal layer with a laser pulse such that the laser pulse uniformly irradiates the first section and the second section, said laser pulse having a uniform fluence between about 200 and 600 millijoules per square centimeter and effective to heat said second section to a temperature sufficient to vaporize the metal to expose the substrate, the first section dissipating heat generated by the laser beam to maintain a temperature less than the metal vaporization temperature, whereby the thick section survives the irradiation to form the copper trace.

Claim 23

A laser etch-back process for forming a predominantly copper trace on planar surface of a polymeric substrate, said surface comprising an area that includes a first region and a second region such that the trace is formed on said first region and is adjacent to the second region whereat said substrate is exposed, said process comprising depositing a metal coating onto the substrate such that the coating covers the area, said coating comprising an outermost copper film and having a thickness less than about 0.6 micron, applying a polymeric mask onto the substrate to overlie the metal coating, said mask covering the second region and having openings at said first region whereat the copper film is exposed, immersing the masked substrate into an electroplating bath containing a reducible copper ion, while cathodically biasing the metal coating to reduce the copper ion to deposit a metallic copper plate onto the copper film through the openings in the mask, whereby the copper plate cooperates with the metal coating to form a metal layer comprising a thick section at the first region that includes the copper plate and has a thickness greater than about 2.5 microns and a thin section at the second region derived from the metal coating underlying the mask, removing said polymeric mask from the substrate to expose the thin section, and irradiating the metal layer with a laser pulse such that the laser pulse uniformly irradiates the first section and the second section, said laser pulse having a uniform fluence between about 200 and 600 millijoules per square centimeter and effective to heat said second section to a temperature sufficient to vaporize the metal to expose the substrate, the first section dissipating heat generated by the laser beam to maintain a temperature less than the metal vaporization temperature, whereby the thick section survives the irradiation to form the copper trace.

Claim 24

The process of claim 19 wherein the polymeric substrate includes a surface layer composed of a polyimide resin.

Claim 25

The process of claim 19 wherein the metal coating comprises a thin chromium film immediately adjacent to the polymeric substrate and underlying the copper film to enhance bonding of the copper to the substrate.

Claim 26

The process of claim 19 further comprising applying a thin chromium coating to the metal layer prior to irradiation.

Claim 27

The process of claim 19 wherein the metal coating is deposited by sputtering and has a thickness between about 0.5 and 0.6 micron.

Claim 28

The process of claim 19 wherein the thick section has a thickness between about 3.0 and 4.0 microns.

Claim 29

The process of claim 19 wherein laser pulse fluence is between about 250 and 350 millijoules per square centimeter.

Claim 30

A laser etch-back process for forming a predominantly copper trace on a planar surface of a polyimide substrate, said surface comprising an area that includes a first region and a second region such that the trace is formed on said first region and is adjacent to the second region whereat said substrate is exposed, said process comprising sputtering a dual metal coating onto the substrate such that the coating substantially covers the surface, said coating comprising a chromium film immediately adjacent the polyimide substrate and an outermost copper film, said coating having a thickness less than about 0.6 micron, applying a polymeric mask onto the substrate to overlie the metal coating, said mask covering the second region and having openings at said first region whereat the copper film is exposed, immersing the masked substrate into an aqueous electroplating bath containing a reducible copper ion, while cathodically biasing the metal coating to reduce the copper ion to deposit a metallic copper plate onto the copper film through the openings in the mask, whereby the copper plate cooperates with the metal coating to form a metal layer comprising a thick section at the first region that includes the copper plate and has a thickness between about 3.0 and 4.0 microns and a thin section at the second region derived from the metal coating underlying the mask, removing said polymeric mask from the substrate to expose the thin section, depositing a chromium coating having a substantially uniform thickness onto the copper layer to form a coated layer, and irradiating the coated layer at said area with one or more laser pulses produced by an excimer laser apparatus, said area being irradiated such that the laser pulse uniformly irradiates the first section and the second section, and has a uniform between about 250 and 350 millijoules per square centimeter, said pulses being effective to heat said second section to a temperature sufficient to vaporize the metal to expose the substrate, the first section dissipating heat generated by the laser pulse to maintain a temperature less than the metal vaporization temperature, whereby the thick section survives the irradiation to form the copper trace.

Claim 31

A laser etch-back process for forming a predominantly copper trace on a planar surface of a polyimide substrate, said surface comprising an area that includes a first region and a second region such that the trace is formed on said first region and is adjacent to the second region whereat said substrate is exposed, said process comprising sputtering a dual metal coating onto the substrate such that the coating substantially covers the surface, said coating comprising a chromium film immediately adjacent the polyimide substrate and an outermost copper film, said coating having a thickness less than about 0.6 micron, applying a polymeric mask onto the substrate to overlie the metal coating, said mask covering the second region and having openings at said first region whereat the copper film is exposed, immersing the masked substrate into an aqueous electroplating bath containing a reducible copper ion, while cathodically biasing the metal coating to reduce the copper ion to deposit a metallic copper plate onto the copper film through the openings in the mask, whereby the copper plate cooperates with the metal coating to form a metal layer comprising a thick section at the first region that includes the copper plate and has a thickness between about 3.0 and 4.0 microns and a thin section at the second region derived from the metal coating underlying the mask, removing said polymeric mask from the substrate to expose the thin section, depositing a chromium coating having a substantially uniform thickness onto the copper layer to form a coated layer, and irradiating the coated layer at said area with one or more laser pulses produced by an excimer laser apparatus, said area being irradiated such that the laser pulse uniformly irradiates the first section and the second section, and has a uniform between about 250 and 350 millijoules per square centimeter, said pulses being effective to heat said second section to a temperature sufficient to vaporize the metal to expose the substrate, the first section dissipating heat generated by the laser pulse to maintain a temperature less than the metal vaporization temperature, whereby the thick section survives the irradiation to form the copper trace.

Claim 32

The process of claim 26 further wherein the surface includes a first area and a second area, and wherein the process further comprises irradiating the first area with said laser pulses and thereafter irradiating the second area with said laser pulses,