Three dimensional plating or etching process and masks therefor
First Claim
1. 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.
2 Assignments
0 Petitions
Accused Products
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.
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Citations
38 Claims
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1. A method for fabricating a mask, comprising in combination the steps of:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for fabricating a mask, comprising in combination the steps of:
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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. - View Dependent Claims (11, 12)
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13. A mask for use in a plating or etching process to be carried out on a workpiece, comprising in combination:
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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. - View Dependent Claims (14, 15, 16, 17, 18)
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19. 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:
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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. - View Dependent Claims (20, 21)
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22. A method for processing a substrate, comprising in combination the steps of:
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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. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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34. A method for printing and plating a substrate, comprising the ordered steps of:
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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.
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35. A method for fabricating a mask, comprising in combination the steps of:
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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. - View Dependent Claims (36, 38)
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37. A method for printing and etching a substrate, comprising the ordered steps of:
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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.
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Specification