LASER ABLATION TOOLING VIA SPARSE PATTERNED MASKS
First Claim
Patent Images
1. A sparse patterned mask for use in imaging a laser onto a substrate, comprising:
- a mask having apertures for transmission of light and non-transmissive areas around the apertures, wherein the apertures individually form a portion of a complete pattern, and wherein at least a portion of the non-transmissive areas exist on the mask in regions between the apertures that correspond to non-imaged regions on the substrate that are subsequently imaged by the apertures to create the complete pattern.
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Accused Products
Abstract
A sparse patterned mask for use in a laser ablation process to image a substrate. The mask has a plurality of apertures for transmission of light and non-transmissive areas around the apertures. The apertures individually form a portion of a complete pattern, and a plurality of apertures from one or more masks together form the complete pattern when the masks are imaged. Making a mask sparse provides for a path to remove debris from the substrate during the laser ablation process. Multiple interlaced sparse repeating patterns can create a more complex pattern with repeat distances larger than the individual patterns.
54 Citations
34 Claims
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1. A sparse patterned mask for use in imaging a laser onto a substrate, comprising:
a mask having apertures for transmission of light and non-transmissive areas around the apertures, wherein the apertures individually form a portion of a complete pattern, and wherein at least a portion of the non-transmissive areas exist on the mask in regions between the apertures that correspond to non-imaged regions on the substrate that are subsequently imaged by the apertures to create the complete pattern. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for laser imaging a substrate using a sparse patterned mask, comprising:
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imaging the substrate through a first mask having apertures for transmission of light and non-transmissive areas around the apertures, wherein the apertures in the first mask form a first portion of a complete pattern; and imaging the substrate through one or more second masks each having apertures for transmission of light and non-transmissive areas around the apertures, wherein the apertures in the second mask form a second portion of the complete pattern, wherein the first mask and the one or more second masks together form the complete pattern when the first mask and the one or more second masks are individually imaged onto the substrate. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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19. A method for laser imaging a substrate using a sparse patterned mask, comprising:
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imaging the substrate through first apertures for transmission of light, wherein non-transmissive areas surround the first apertures and wherein the first apertures in the mask form a first portion of a complete pattern; and imaging the substrate through one or more second apertures for transmission of light, wherein the non-transmissive areas surround the one or more second apertures and wherein the one or more second apertures in the mask form a second portion of the complete pattern, wherein the first apertures and the one or more second apertures together form the complete pattern when the first apertures and the one or more second apertures are individually imaged onto the substrate. - View Dependent Claims (20, 21, 22, 23, 24)
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25. A method of generating a patterned cylindrical tool, comprising:
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forming a first portion of a complete pattern in a surface of a cylindrical substrate, the first portion comprising a first plurality of discrete rows; and forming a second portion of the complete pattern in the surface of the cylindrical substrate, the second portion comprising a second plurality of discrete rows interlaced with the first plurality of discrete rows, wherein the first and second portions together form the complete pattern. - View Dependent Claims (26, 27)
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28. A method of generating a patterned cylindrical tool, comprising:
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forming a first portion of a complete pattern in a surface of a cylindrical substrate along a first helical path; and forming a second portion of the complete pattern in the surface of the cylindrical substrate along a second helical path, wherein the second portion is interlaced with the first portion and wherein the first and second portions together form the complete pattern. - View Dependent Claims (29, 30)
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31. A microreplicated article comprising:
two or more repeating arrays of features, each of the arrays of features forming a constituent pattern as part of a complete pattern, that are interlaced to create the complete pattern, wherein the complete pattern of the features repeats over a distance greater than a repeat distance of any of the constituent patterns.
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32. A patterned cylindrical tool, comprising:
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a first portion of a complete pattern of features in a surface of a cylindrical substrate, the first portion comprising a first plurality of discrete rows of features; and a second portion of the complete pattern of features in the surface of the cylindrical substrate, the second portion comprising a second plurality of discrete rows of features interlaced with the first plurality of discrete rows, wherein the first and second portions each form a constituent pattern of the complete pattern, the first and second portions together form the complete pattern of features, and the complete pattern repeats over a distance greater than a repeat distance of any of the constituent patterns.
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33. A patterned cylindrical tool, comprising:
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a first portion of a complete pattern of features in a surface of a cylindrical substrate along a first helical path; and a second portion of the complete pattern of features in the surface of the cylindrical substrate along a second helical path, wherein the first and second portions each form a constituent pattern of the complete pattern, the second portion is interlaced with the first portion, the first and second portions together form the complete pattern of features, and the complete pattern repeats over a distance greater than a repeat distance of any of the constituent patterns.
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34. A flat patterned tool comprising:
two or more repeating arrays of features on a substantially flat substrate, each of the arrays of features forming a constituent pattern as part of a complete pattern, that are interlaced to create the complete pattern of features, wherein the complete pattern repeats over a distance greater than a repeat distance of any of the constituent patterns.
Specification