BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a machining method for a wiring board and a machining apparatus for a wiring board employing a laser beam for machining such as drilling for a through-hole, an inner via hole, and a blind via hole, grooving, and cutting for an outside shape of the wiring board referred to as so-called printed board, and more particularly to a machining method for a wiring board and a machining apparatus for a wiring board in which a fine conduction hole can rapidly and accurately be formed, and a carbonic acid gas laser oscillator to generate a pulsed laser beam most suitable for the above machining.
2. Description of the Prior Art
A printed board includes a plurality of insulating base materials with conductor layers, stacked and joined in a multi-layer fashion. Among the conductor layers applied onto the insulating base materials, the optional conductor layers in a vertical direction are electrically connected through conduction holes referred to as a through-hole, an inner via hole, and a blind via hole.FIG. 33 is a sectional view of such a conventional multi-layer printed board. In the drawing,reference numeral51 means a printed board,52 to56 are conductor layers,57 is metallic deposits,61 to64 are insulating base materials, and65 to68 are conduction holes. In the five-layer printedboard51 including theconductor layers52 to56, theinsulating base materials61 and63 with both sides coated with copper foil and theconductor layer56 including copper foil are stacked and joined by using theinsulating base materials62 and64 referred to as prepreg, and theconduction holes65 to68 are provided to pass through theconductor layers52 to56.
As shown inFIG. 33, theconduction hole65 is mounted for conduction between theconductor layer52 and theconductor layer53 in theinsulating base material61, and theconduction hole66, referred to as blind via hole (BVH), is mounted for conduction between theconductor layer52 in theinsulating base material61 and theconductor layer54 in theinsulating base material63. Theconduction hole67, referred to as inner via hole (IVH), is mounted for conduction between theconductor layer54 and theconductor layer55 in theinsulating base material63. Theconduction hole68, referred to as through-hole (TH), is mounted for conduction between theconductor layer52 in theinsulating base material61 and theconductor layer56 stacked and joined through theinsulating base material64.
Theconduction holes65 to68 shown inFIG. 33 are holes machined by a drill. Further, after drilling, the conduction holes are plated through themetallic deposits57, and the conductor layers are electrically connected.
In the prior art, a machining method for the conduction hole includes, for example, drill machining using a rotary milling cutter. Further, a machining method for grooving or cutting for an outside shape includes, for example, router machining using a rotary milling cutter. On the other hand, in recent years, higher density wiring has been desired for higher performance of an electronic device. A more multi-layered and smaller printed board is required to meet the above requirement. Further, it is essential to provide a finer hole diameter of the conduction hole for this purpose. With the current state of the art, the conduction hole is generally provided in the printed board by the mechanical method using the drill. However, the method has drawbacks in that the finer hole diameter is limited, for example, drilling for a hole diameter of φ 0.2 mm or less is very difficult to cause heavy wear of the drill such as breakage, resulting in poor productivity due to a long time required for replacement of the drill. Further, it is difficult to simultaneously machine adjacent positions, thereby requiring a considerable machining time. In addition, the insulating base material has a thickness of 0.1 mm or less because of the smaller printed board. Since it is difficult to control a hole depth in the drill machining with accuracy of 0.1 mm or less, it is difficult to form the blind via hole in such a thin-walled insulating base material. Further, in order to realize cost reduction by the smaller printed board and an increase in yield, the grooving and the cutting for the outside shape require an accurate depth control in the grooving, a narrower cutting width, and cutting after parts are packaged. However, the mechanical methods such as router machining are unpractical since the above limitation is similarly imposed thereon.
Instead of the machining methods for the printed board including the above mechanical methods, attention has been given to methods, which have partially been put to practical use, employing a laser beam such as an eximer laser or carbonic acid gas laser, disclosed in IBM Journal of Research and Development, Vol. 126, No. 3, pp. 306-317 (1982), and Japanese Patent Publication (Kokoku) No. 4-3676. These laser beam machining methods utilize a difference in absorption coefficient of light energy such as the eximer laser or the carbonic acid gas laser between resin or glass fiber serving as the insulating base material forming the printed board, and copper serving as the conductor layer. For example, since almost the entire laser beam emitted from the above laser can be reflected at the copper, a copper foil removed portion having a required diameter is formed in top copper foil through etching and so forth, and the copper foil removed portion may be irradiated with the laser beam. It is thereby possible to selectively decompose and remove the resin and the glass so as to form a fine through-hole and a fine inner via hole in a short time. If internal-layer copper foil is previously stacked in a machined portion, the decomposition and the removal of the insulating base material are terminated at the internal-layer copper foil. It is thereby possible to form a blind via hole which can surely be terminated at bottom copper foil. There is an advantage of no wear of the tool such as breakage because the laser beam machining methods are contactless machining methods.
The above laser beam machining methods employ a pulse laser such as the eximer laser and a TEA-carbonic acid gas laser, with an extremely narrow pulse width of 1 μs or less. The pulse laser can finely divide into chips (1) a single base material made of high polymeric material such as polyimide, or epoxy, (2) a composite material reinforced by aramid fiber or the like, containing the polyimide, the epoxy, and so forth, and (3) an inorganic material such as glass. It is thereby possible to rapidly and accurately form a good machined hole with a smooth machined portion and less altered layer in a printed board in which as the insulating base material is used composite material dispersed in the polyimide, the epoxy, and so forth.
The conventional laser beam machining method for the wiring board has the above structure. The eximer laser or the TEA-carbonic acid gas laser is used to provide the through-hole and the inner via hole in the most commonly used printed board having the insulating base material made of glass cloth containing the glass fiber and the resin, such as a glass epoxy printed board referred to as FR-4 made of the glass cloth and epoxy resin. In this case, there are problems in that metallic deposit for conduction can not easily be coated on a hole inner wall due to the extremely rough inner wall of the hole, and reliability of the metallic deposit can not be ensured. The problems are generated because the insulating material of the printed board is not only the composite material made of organic material and inorganic material but also heterogeneous material in which the organic material and the inorganic material are contained in clusters to some extent.
Further, there is another problem in that a uniform machined hole can not be provided due to differences in, for example, absorption coefficient of the laser beam, decomposition temperature, and thermal diffusivity between an organic material portion and an inorganic material portion. For example, since a wavelength of the laser beam in the eximer laser can not easily be absorbed by the glass, sufficient energy for decomposition of the glass can not be supplied so that a glass portion is difficult to remove, resulting in a problem of a rough machined hole. On the other hand, both the resin and glass can show high absorption coefficient in case of the TEA-carbonic acid gas laser. However, when energy density of 20 J/cm2required to efficiently machine glass epoxy material is obtained in the TEA-carbonic acid gas laser, excessively high power density of 2×107W/cm2or more is caused due to the narrow pulse width of 1 μs or less. Such high power density may easily cause plasma at the machined portion. Once the plasma is formed, laser energy is absorbed by the plasma, resulting in insufficient energy reaching the machined portion. Hence, it is difficult to remove glass having a high decomposition temperature, thereby causing a problem of the rough machined hole.
If the energy density is set to cause no plasma, the machining progresses extremely slowly, resulting in a problem of a reduction in productivity.
In addition, only when a beam diameter is larger than the machined portion, good machining may be made to the materials (1), (2), and (3) in the conventional laser beam machining method. Otherwise, if the machined portion is larger than the beam diameter, for example, in case of cutting, grooving, and drilling for a large diameter hole, a removed material caused at a beam irradiated portion adheres to a position other than the beam irradiated portion. As a result, after the machining, the machined portion is coated with additionally deposited soot, thereby reducing reliability of insulation and reliability of metallic deposit in the printed board. Hence, there is another problem of the need for the step of, for example, complicated after-treatment such as wet etching.
Other than the extremely short pulse laser such as the eximer laser and the TEA-carbonic acid gas laser, there are other laser beam machining methods for the wiring board, using a typical carbonic acid gas laser of high-speed axial-flow type or three-axes orthogonal type in the prior art. In the conventional carbonic acid gas lasers, more importance is given to a CW output characteristic than a pulse output characteristic to enhance oscillation efficiency. That is, there is in theory a problem of pulse response sensitivity at a time of pulse oscillation, in particular, a characteristic in which a time is required for a fall of a laser pulse. Thus, the machining by the conventional carbonic acid gas laser having such a characteristic results in irradiation of the machined portion with a laser beam for a longer time, thereby causing a gradual temperature gradient around the machined portion. As a result, as shown inFIG. 34, a larger difference is caused in amount of removal between the resin and the glass due to a difference in decomposition temperature therebetween. When only the resin is excessively removed, there are problems in that projection of the glass fibers results in a rough machined hole as shown inFIG. 35, and the long heating time generates a char layer on a wall surface of the hole.
Further, carbides are generated around the machined portion, and the laser beam is absorbed by the copper through the carbides, resulting in frequent damage to the copper foil as shown inFIG. 36. Hence, there is a problem in that the blind via hole is difficult to form in the above laser beam machining methods.
Though descriptions have been given of the machining for the hole, the same problems are caused in the grooving and the cutting.
In order to overcome the above problems, it is an object of the present invention to provide a stable laser beam machining method for a wiring board, in which a printed board with an insulating base material containing cloth-like glass fibers can rapidly and accurately be machined, for example, drilled for a through-hole, an inner via hole and a blind via hole, grooved, or cut for an outside shape without roughness of a machined portion and the need for complicated after-treatment of additional deposit, and no damage is caused to copper foil, and to provide a laser beam machining apparatus for a wiring board, for realizing the laser beam machining method for the wiring board and improving productivity.
It is another object of the present invention to provide a carbonic acid gas laser oscillator for machining a wiring board, which can output a laser beam with a pulse width most suitable for the laser beam machining method for the wiring board.
According to one aspect of the present invention, for achieving the above-mentioned objects, there is provided a laser beam machining method for a wiring board, including the step of irradiating a machined portion of the wiring board with a pulsed laser beam for a beam irradiation time ranging from 10 to 200 μs and with energy density of 20 J/cm2or more.
According to another aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the step of irradiating the same machined portion of the wiring board with a pulsed laser beam with intervals of a beam irradiation pausing time of 15 ms or more and energy density of 20 J/cm2or more.
According to still another aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of combining into one pulse group laser beams including a plurality of pulses having energy density of 20 J/cm2or more and generated at intervals of a predetermined beam irradiation pausing time, and irradiating the same machined portion of the wiring board with a pulsed laser beam with the plurality of pulse groups respectively including the plurality of pulses at intervals of a pulse group interval irradiation pausing time longer than the predetermined beam irradiation pausing time. Preferably, the predetermined beam irradiation pausing time is 4 ms or more, the number of pulses in the pulse group is 4 or less, and the pulse group interval irradiation pausing time exceeds 20 ms.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the step of, at a time of scanning a surface of the wiring board while irradiating a machined portion of the wiring board with the pulsed laser beam, scanning by a laser beam such that the machined portion is not continuously irradiated with the laser beam over 4 pulses at intervals of a beam irradiation pausing time less than 15 ms.
According to a still further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of providing a 1 mm beam diameter on a surface of a machined portion, and scanning a surface of the wiring board at a scanning speed ranging from 8 to 6 m/min while irradiating the machined portion with a laser beam for a beam irradiation time ranging from 10 to 200 μs and at intervals of a beam irradiation pausing time of 2.5 ms.
According to another aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of setting a laser beam to have a square spot effective in machining of a machined portion of the wiring board, and scanning a surface of the wiring board while irradiating the machined portion of the wiring board with the pulsed laser beam. Preferably, the square spot of the laser beam on the machined portion is set to have a size of 0.9 mm×0.9 mm, and the surface of the wiring board is scanned with a scanning speed of 6 m/min and a scanning pitch of 200 μm while the machined portion being irradiated with the laser beam for a beam irradiation time ranging from 10 to 200 μs and at intervals of a beam irradiation pausing time of 1.25 ms.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of previously removing a metallic layer on the wiring board at a portion corresponding to a machined portion of the wiring board, forming a base material removed portion through machining by irradiating a base material of the machined portion with a laser beam through the metallic layer removed portion, and additionally irradiating the base material removed portion and a periphery of the base material removed portion, or only the periphery of the base material removed portion with a laser beam. Preferably, the additionally irradiated laser beam has a smaller peak output than a peak output of the first laser beam, and is used to scan at a higher scanning speed than a scanning speed during first laser beam irradiation.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the step of, at a time of previously removing a metallic layer on the wiring board at a portion corresponding to a machined portion, partially removing the metallic layer such that a laser beam can reach only an outer periphery of a base material removed portion to be formed by irradiating a base material of the machined portion with the laser beam. Preferably, a surface of the wiring board is scanned with a scanning speed of 8 m/min and a scanning pitch of 100 μm while the machined portion being irradiated with the laser beam for a beam irradiation time ranging from 10 to 200 μs and at intervals of a beam irradiation pausing time of 2.5 ms.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of previously removing a metallic layer on the wiring board at a portion corresponding to a machined portion of the wiring board, and flowing a gas in a direction from a laser beam scanning start point to a laser beam scanning end point in the machined portion at a time of machining by irradiating a base material of the machined portion with a laser beam while scanning by the laser beam through the metallic layer removed portion.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of forming a metallic layer having a desired shape by partially removing the metallic layer by pulse irradiation with a laser beam having sufficient intensity to melt and remove the metallic layer on the wiring board, and additionally irradiating a machined portion of the wiring board through a metallic layer removed portion with the laser beam having insufficient intensity to melt the metallic layer and a beam irradiation time ranging from 10 to 200 μs, and including a plurality of pulses forming a train at intervals of a beam irradiation pausing time of 15 ms or more. Preferably, the machined portion is exposed by previously removing, through another machining method such as etching, the metallic layer positioned at a target position for laser beam irradiation and in the range smaller than a shape to be machined. Further, surface roughening may previously be made to a surface of the metallic layer on a surface of the wiring board before the laser beam irradiation.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the step of, at a time of pulse irradiation with a laser beam while sequentially positioning a spot of the laser beam at target positions on the wiring board in synchronization with a pulse frequency of the laser beam, providing a time interval of 15 ms or more between two optional successive pulsed laser beams for irradiation of the respective target positions irrespective of the pulse frequency by irradiating another target position with a pulsed laser beam outputted for the time interval therebetween.
According to a further aspect of the present invention, there is provided a laser beam machining method for a wiring board, including the steps of providing a plurality of machining stations on which the wiring boards to be machined are mounted, sequentially dividing a pulsed laser beam outputted from a laser oscillator among the plurality of machining stations for each pulse, and introducing the pulsed laser beam into the plurality of machining stations at time intervals of 15 ms or more. Preferably, a carbonic acid gas laser is used as a light source of the laser beam. The wiring board may contain glass cloth.
According to a further aspect of the present invention, there is provided a laser beam machining apparatus for a wiring board, including an optical mechanism to change a direction of a laser beam and move the laser beam on the wiring board while sequentially positioning a spot of the laser beam at target positions on the wiring board, and a control mechanism for synchronous control between a pulse oscillating operation of a laser oscillator and an operation of the optical mechanism, and control of the optical mechanism such that a time interval can be set to 15 ms or more between two optional successive pulsed laser beams for irradiation of the target positions irrespective of a pulse frequency of the laser oscillator.
According to a further aspect of the present invention, there is provided a laser beam machining apparatus for a wiring board, including an optical mechanism to sequentially divide a pulsed laser beam outputted from a laser oscillator among a plurality of machining stations for each pulse and introduce the pulsed laser beam into the plurality of machining stations for each pulse at time intervals of 15 ms or more, and a synchronization control mechanism for synchronous control between a dividing operation of the optical mechanism and a pulse oscillating operation of the laser oscillator. Preferably, the optical mechanism is provided with at least one rotary chopper rotated at a predetermined speed of rotation, having a plurality of reflection surfaces and a plurality of passing portions at positions equally dividing a periphery about an axis in a plane perpendicular to the rotation axis. Further, the synchronization control mechanism is provided with a trigger generating apparatus to generate a trigger each time all the equally divided areas including the plurality of reflection surfaces and the plurality of passing portions in the rotary chopper respectively move across an optical axis of the laser beam.
According to a further aspect of the present invention, there is provided a carbonic acid gas laser oscillator for machining a wiring board, in which a length of a discharge space in a gas flow direction is equal to or more than a width of an aperture, an optical axis passing through a center of the aperture is set to be positioned in the range that an entire area of the aperture does not extend off an area extending in the gas flow direction of the discharge space and on the farthest upstream side of the gas flow, and a rise time and a fall time are set to 50 μs or less in discharge power fed to the discharge space.
The above and further objects and novel features of the invention will more fully appear from the following detailed description when the same is read in connection with the accompanying drawings. It is to be expressly understood, however, that the drawings are for purpose of illustration only and are not intended as a definition of the limits of the invention.
FIG. 1 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 1 of the present invention;
FIG. 2 is a graph diagram showing a relationship between energy density of a laser beam and a machining depth of a glass epoxy material in the laser beam machining method for the wiring board according to theembodiment 1 of the present invention;
FIG. 3 is a graph diagram showing a variation in amount of projection of glass cloth at a machined portion and a variation in rate of damage to copper foil when a pulse width is varied in the laser beam machining method for the wiring board according to theembodiment 1 of the present invention;
FIG. 4 is a typical diagram showing a laser beam machining method for a wiring board according to theembodiment 2 of the present invention;
FIG. 5 is a waveform diagram showing an irradiation pattern of a laser beam in the laser beam machining method for the wiring board according to theembodiment 2 of the present invention;
FIG. 6 is a graph diagram showing a variation in thickness of a char layer observed on the rear side of a machined hole immediately after machining when a beam irradiation pausing time is varied in the laser beam machining method for the wiring board according to theembodiment 2 of the present invention;
FIG. 7 is a machined portion temperature characteristic diagram showing a relationship between a distance from a surface of the machined portion and a temperature by using the beam irradiation pausing time as a parameter;
FIG. 8 is a waveform diagram showing an irradiation pattern of a laser beam in theembodiment 3 of the present invention;
FIG. 9 is a graph diagram showing a variation in thickness of a char layer when a beam irradiation pausing time is varied between pulses among pulse groups in a laser beam machining method for a wiring board according to theembodiment 3 of the present invention;
FIG. 10 is a graph diagram showing a variation in thickness of a char layer when a pulse group interval beam irradiation pausing time is varied in the laser beam machining method for the wiring board according to theembodiment 3 of the present invention;
FIG. 11 is a graph diagram showing a variation in machining time required for drilling when the number of pulses among the pulse groups is varied in the laser beam machining method for the wiring board according to theembodiment 3 of the present invention;
FIG. 12 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 4 of the present invention;
FIG. 13 is an explanatory view showing an existence region of a copper foil removed portion and a scanning path for raster scanning in the laser beam machining method for the wiring board according to theembodiment 4 of the present invention;
FIG. 14 is a graph diagram showing a variation in amount of projection of glass cloth at a machined portion when a scanning speed of a laser beam is varied in the laser beam machining method for the wiring board according to theembodiment 4 of the present invention;
FIG. 15 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 5 of the present invention;
FIG. 16(a) is an explanatory view showing a superimposed portion beam irradiated portions in case of square beam scanning in the laser beam machining method for the wiring board according to theembodiment 5 of the present invention;
FIG. 16(b) is an explanatory view showing a superimposed portion of beam irradiated portions in case of circular beam scanning;
FIG. 17 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 6 of the present invention;
FIG. 18 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 7 of the present invention;
FIG. 19(a) is a plan view showing a machined shape of a copper foil removed portion in the laser beam machining method for the wiring board according to theembodiment 7 of the present invention;
FIG. 19(b) is a plan view showing a machined shape of a copper foil removed portion in which copper foil is removed over an entire machined portion;
FIG. 20 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 8 of the present invention;
FIG. 21 is an explanatory view showing a direction of raster scanning by a laser beam, and a gas flow spraying direction in the laser beam machining method for the wiring board according to theembodiment 8 of the present invention;
FIG. 22 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 9 of the present invention;
FIG. 23 is a typical diagram showing the result of machining of a printed board according to theembodiment 9 of the present invention;
FIG. 24 is a typical diagram showing a laser beam machining method for a wiring board according to theembodiment 10 of the present invention;
FIG. 25 is a typical diagram showing a laser beam machining method for a wiring board according to one modification of theembodiment 10 of the present invention;
FIG. 26 is a typical diagram showing a laser beam machining method for a wiring board, and a laser beam machining apparatus for a wiring board according to theembodiment 11 of the present invention;
FIG. 27 is a typical diagram showing a laser beam machining method for a wiring board, and a laser beam machining apparatus for a wiring board according to theembodiment 12 of the present invention;
FIG. 28 is a typical diagram of a rotary chopper according to theembodiment 12 of the present invention;
FIG. 29 is a time chart of a trigger and laser pulses in theembodiment 12 of the present invention;
FIG. 30 is a perspective view of a carbonic acid gas laser oscillator for machining a wiring board according to theembodiment 13 of the present invention;
FIGS.31(a) and31(b) are typical diagrams respectively showing a gain distribution and arrangement of an optical axis in a discharge space in a conventional carbonic acid gas laser oscillator;
FIG. 32 is a typical diagram showing arrangement of an optical axis in the carbonic acid gas laser oscillator for machining the wiring board according to theembodiment 13 of the present invention;
FIG. 33 is a sectional view showing a structure of a conventional multi-layer printed board;
FIG. 34 is a graph diagram showing a mechanism to generate a reduction in quality in a conventional laser beam machining method for a wiring board;
FIG. 35 is a sectional view of a machined portion, showing projection of glass cloth and a thickness of a char layer in the conventional laser beam machining method for the wiring board; and
FIG. 36 is a sectional view of a machined portion, showing damage to copper foil in the conventional laser beam machining method for the wiring board.
A description will now be given of preferred embodiments of the present invention.
FIG. 1 is a typical diagram showing a laser beam machining method for a wiring board according to theembodiment 1 of the present invention. In the drawing, reference numeral1A means a printed board (wiring board),2,3, and4 are conductor layers (metallic layers) including copper foil,8 is a copper foil removed portion formed in thetop conductor layer2 by etching,9 is a ZnSe lens for convergence of alaser beam27 radiated from a carbonic acid gas laser, and10 is an assist gas for lens protection. Air is employed in the embodiment as theassist gas10.Reference numerals11 and12 are insulating base materials, and19 is a gas nozzle through which the assistgas10 is ejected. Here, the copper foil removedportion8 is formed in theconductor layer2 at a portion corresponding to a machined portion of the insulatingbase material11.
In theembodiment 1, a three-layer glass epoxy printed board (FR-4) with both sides coated with copper foil and a thickness of 200 μm is used as the multi-layer printed board1A. Further, the copper foil has a thickness of 18 μm in the conductor layers2,3, and4, and the copper foil removedportion8 with a diameter of 200 μm is formed in thetop conductor layer2 by the etching.
A description will now be given of the operation.
FIG. 2 is a graph diagram showing the result of machining in which the carbonic acid gas laser is used as a light source, and energy per pulse is varied in thelaser beam27 therefrom, thereby varying energy density in the range from 7 to 35 J/cm2at the copper foil removedportion8 corresponding to the machined portion of the printed board1A, and irradiating an exposed portion of the insulatingbase material11 with only one pulse through the copper foil removedportion8. In the graph, the transverse axis defines energy density (J/cm2), and the ordinate axis defines a machining depth (μm) of a glass epoxy material. As is apparent fromFIG. 2, a variation in energy density per pulse of thelaser beam27 varies the machining depth of the printed board1A made of the glass epoxy material. If the energy density is 20 J/cm2or less, machining is carried out with a negligible amount of removal. Thus, it is necessary to irradiate with a lot of pulses so as to pass through the glass epoxy material with a thickness of 100 μm. In view of productivity, a through-hole should be formed by several pulses per hole. Therefore, from the result of experiment shown inFIG. 2, it can be seen that high-speed and efficient machining requires irradiation with thelaser beam27 with the energy density of 20 J/cm2or more.
FIG. 3 is a graph diagram showing the result of machining in which thelaser beam27 per pulse has constant energy density of 200 mJ, thelaser beam27 is condensed through theZnSe lens9 so as to provide a beam diameter of 500 μm on a surface of the machined portion of the printed board1A, and set energy density to 100 J/cm2, and the copper foil removedportion8 is irradiated with only one pulse with a pulse width varying in the range of 1 to 500 μs. In the drawing, the transverse axis defines the pulse width (μs), and the ordinate axes define an amount of projection (μm) of glass cloth and a ratio (%) of damage to the copper foil. In this case, the air was used as theassist gas10 for lens protection, and was supplied to the machined portion through thegas nozzle19 at a flow rate of 10 l/min.
It is possible to check the amount of projection of the glass cloth in a machined hole (or the base material removed portion) at a time of varying the pulse width of thelaser beam27, by observing a section of the machined hole through a microscope as shown inFIG. 35. InFIG. 3, variations in maximum value of the amount of projection of the glass cloth and in ratio of damage to the copper foil are plotted versus a variation in pulse width ranging from 1 to 500 μs. The ratio of damage to the copper foil is expressed as a percentage by using the number of machined holes passing through theconductor layer3 serving as the bottom copper foil among 1,000 machined holes. As shown inFIG. 3, when the pulse width of thelaser beam27 is set in the range from 10 to 200 μs, it is possible to provide a machined hole with a little amount of projection of the glass cloth, and no damage to the bottom copper foil. In such a manner, by setting a beam irradiation time to 200 μs or less, it is possible to provide a sharp temperature gradient of a machined portion during machining (hereinafter, the machined portion as used herein meaning, for example, the machined hole during or after the machining) in the printed board1A in the range from a surface of the machined portion to an inside portion. Further, it is possible to reduce the amount of projection of the glass cloth to a substantially negligible extent. In addition, since an amount of generating carbides is reduced, the damage to the copper foil can be reduced, and a blind via hole can stably be formed.
After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing the section of the hole. It came clear that plasma was caused at the machined portion during the laser beam machining when thelaser beam27 had a pulse width less than 10 μs, and the glass cloth was not completely removed due to the plasma. As a result, the bottom copper foil was not completely conductive in spite of the plating so that the many machined holes could not serve as a through-hole. On the other hand, when thelaser beam27 had a pulse width in the range from 10 to 200 μs, it was possible to provide a good through-hole in which all copper foil including the bottom copper foil were completely conductive through the plating. For comparison, though the same machining was carried out by using a diamond drill with a diameter of 200 μm, it was difficult to control a depth. That is, 10% of the 1,000 machined holes passed through theconductor layer4 serving as bottom copper foil so that theconductor layer3 and theconductor layer4 were short-circuited. As described above, through the drill machining, it was difficult to provide an effect identical with that achieved by the laser beam machining method for the wiring board according to theembodiment 1.
As set forth above, according to theembodiment 1, at a time of irradiating the machined portion with thelaser beam27 having energy density of 20 J/cm2or more required for efficient machining of the printed board1A made of the glass epoxy material containing the glass cloth and the epoxy resin, the beam irradiation time is appropriately set in the range from 10 to 200 μs. Since it is thereby possible to reduce power density to 2×106W/cm2or less, the machining can be carried out without the plasma generating at the machined portion. Further, by setting the beam irradiation time to200 μs or less, it is possible to provide the sharp temperature gradient of the machined portion during machining in the printed board1A in the range from the surface of the machined portion to the inside portion. Further, it is possible to reduce the amount of projection of the glass cloth to the substantially negligible extent. In addition, since the amount of generating carbides can be reduced, the damage to the copper foil can be reduced, and the blind via hole can stably be formed.
FIG. 4 is a typical diagram showing a laser beam machining method for a wiring board according to theembodiment 2 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted. Further, inFIG. 4,reference numeral1B means a multi-layer printed board,5 is a conductor layer,6 is a conductor layer on a rear surface of the multi-layer printedboard1B,7 is metal deposited on an inner surface of a through-hole17, and13 and14 are insulating base materials.FIG. 5 is a waveform diagram showing an irradiation pattern of alaser beam27 in theembodiment 2.
In theembodiment 2, a five-layer glass polyimide board with a thickness of 400 μm was used as the printedboard1B. In atop conductor layer2 and abottom conductor layer6, copper foil had a thickness of 18 μm, and etching was made to form copper foil removedportions8 with a diameter of 200 μm in theconductor layer2 and theconductor layer6 at positions corresponding to a conduction hole to be machined.
A description will now be given of the operation.
A carbonic acid gas laser with a pulse width of 50 μs and pulse energy of 280 mJ was condensed on the printedboard1B through aZnSe lens9 such that a laser beam diameter became 500 μm on a surface of the machined portion, thereby setting energy density to 143 J/cm2. Further, a beam irradiation pausing time shown inFIG. 5 was varied in the range from 12.5 to 50 ms, and a portion of the insulatingbase material11 exposed through the copper foil removedportion8 was irradiated with thepulsed laser beam27. At the time, air was used as anassist gas10 for lens protection, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min.FIG. 6 is a graph diagram showing a variation in thickness (μm) of a char layer observed on the rear side of the machined hole immediately after the machining when the beam irradiation pausing time is varied as described above. It is possible to check the thickness of the char layer by observing a section of the machined hole through a microscope as shown inFIG. 35.
As shown inFIG. 6, when the beam irradiation pausing time is below 15 ms, the thickness of the char layer rapidly increases. After the laser beam machining, the obtained printedboard1B was ultrasonically cleaned by pure water for three minutes. It was thereby possible to completely remove the char layer in case of the beam irradiation pausing time of 15 ms or more. After the ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing the section. It was possible to provide a good through-hole having a diameter of 200 μm and a smooth inner wall in case of the beam irradiation pausing time of 15 ms or more. On the other hand, in case of the beam irradiation pausing time less than 15 ms, a residual char layer and projecting glass cloth were observed between a metallic deposit and a base material of the printedboard1B, the hole had a rough inner wall, and throwing power in plating was insufficient.
It can be considered that, as shown inFIG. 7, the above problems were caused because, in case of the beam irradiation pausing time less than 15 ms, a gradual temperature gradient was provided by machining according to a distance from a surface of the machined portion during the machining, and a temperature was excessively increased at a deep portion from the surface of the machined portion, at which a rise of the temperature was unnecessary. On the other hand, if the same beam irradiated portion is irradiated with thepulsed laser beam27 with the beam irradiation pausing time of 15 ms or more, it is possible to ensure a cooling time required to completely cool the machined portion for each pulse. As shown inFIG. 7, in case of the beam irradiation pausing time of 15 ms or more, it is possible to reduce gradation of the temperature gradient caused due to the temperature rise at the machined portion during irradiation with thelaser beam27, and reduce the projection of the glass cloth.
As set forth above, the carbonic acid gas laser is used for multi-pulse irradiation at appropriate irradiation intervals. It is thereby possible to provide the conduction hole having a high aspect ratio which can not be obtained by a single pulse, and rapidly machine the printed board including the glass cloth with high accuracy.
For comparison, though the same machining was carried out by using a diamond drill with a diameter of 200 μm, the drill was worn out after machining for about 1,000 machined holes, resulting in the rough inner wall of the hole and occasional breakage of the drill. Hence, the method required a machining time about ten times a machining time in the laser beam machining method for the wiring board according to theembodiment 2.
As set forth above, according to theembodiment 2, since the same beam irradiated portion is irradiated with the pulsed laser beam at intervals of the beam irradiation pausing time of 15 ms or more, it is possible to ensure the cooling time required to completely cool the machined portion for each pulse. As shown inFIG. 7, it is possible to increase the temperature gradient of the machined portion, and reduce heating at the machined portion. As a result, it is possible to reduce the projection of the glass cloth, and rapidly machine the printed board containing the glass cloth with high accuracy even in case of multi-pulse irradiation.
FIG. 8 is a waveform diagram showing an irradiation pattern of a laser beam in a laser beam machining method for a wiring board according to theembodiment 3 of the present invention. In theembodiment 3, as shown inFIG. 4 of theembodiment 2, a five-layer glass polyimide board with a thickness of 400 μm was used as a printedboard1B. In atop conductor layer2 and abottom conductor layer6, copper foil had a thickness of 18 μm, and etching was made to form copper foil removedportions8 with a diameter of 200 μm in theconductor layer2 and theconductor layer6 at positions corresponding to a conduction hole to be machined.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with a constant pulse width of 50 μs, and constant pulse energy of 280 mJ. Further, thelaser beam27 was condensed on the printedboard1B through aZnSe lens9 such that a laser beam diameter became 500 μm on a surface of the machined portion, thereby setting energy density to 143 J/cm2. As shown inFIG. 8, there were provided a plurality of pulse groups respectively including two to ten pulses with a beam irradiation pausing time of t1, and the printedboard1B was irradiated with the pulse groups for a pulse group interval beam irradiation pausing time of t2.
In the embodiment, the beam irradiation pausing time t1 was varied in the range from 0 to 10 ms, and the pulse group interval beam irradiation pausing time t2 was varied in the range from 50 to 10 ms. A portion of an insulatingbase material11 exposed through the copper foil removedportion8 was irradiated with 52 pulses. At the time, air was used as anassist gas10 for lens protection, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min.
FIG. 9 is a graph diagram showing a variation in thickness of a char layer observed on the rear side of a machined hole immediately after the machining when the beam irradiation pausing time t1 was varied between pulses among the pulse groups. In this case, the pulse group interval beam irradiation pausing time t2 was set to a sufficiently large value of 50 ms. As shown inFIG. 9, when the beam irradiation pausing time t1 was equal to or more than 4 ms, the thickness of the char layer became thinner than a thickness (ranging from 50 to about 100 μm) of the layer in case of the beam irradiation pausing time t1 of 0 ms. Thus, it can be seen that the variation in beam irradiation pausing time t1 can effectively reduce the thickness of the char layer.
FIG. 10 is a graph diagram showing a variation in thickness of a char layer observed on the rear side of a machined hole immediately after the machining when the pulse group interval beam irradiation pausing time t2 was varied from 50 to 10 ms. In this case, the number of pulses among the pulse groups was set to two, and the beam irradiation pausing time t1 was set to 10 ms. As shown inFIG. 10, when the pulse group interval beam irradiation pausing time t2 was 20 ms or less, the thickness of the char layer rapidly increased.
FIG. 11 is a graph diagram showing a variation in thickness of a char layer observed on the rear side of a machined hole immediately after the machining with respect to a variation in machining time required for drilling when the number of pulses among the pulse groups was varied. At the time, the beam irradiation pausing interval t1 between the pulses was set to 25 ms, and the pulse group interval beam irradiation pausing time t2 was set to 50 ms. As shown inFIG. 11, when the number of pulses is 4 or less, with the same machining quality, it is possible to reduce about 6 to 22% of a machining time required for machining by a single pulse frequency.
After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing a section. When the beam irradiation pausing time t1 between pulses was 4 ms or more, the pulse group interval beam irradiation pausing time t2 was 20 ms or more, and the number of pulses in the pulse groups was 4 or less, it was possible to provide a good through-hole having a diameter of 200 μm and a smooth inner wall as in the case of the single pulse frequency. Further, in case of a thin-walled printed board, it was possible to provide a good through-hole even when the number of pulses among the pulse groups was 4 or more with satisfaction of the above conditions of the beam irradiation pausing time t1 and the pulse group interval beam irradiation pausing time t2. That is, it was possible to reduce the machining time by satisfying the conditions of the beam irradiation pausing time t1 and the pulse group interval beam irradiation pausing time t2 so as to appropriately select the number of pulses among the pulse groups according to a thickness of the printed board. Further, if the conditions of the beam irradiation pausing time t1 and the pulse group interval beam irradiation pausing time t2 were not met, a residual char layer and projecting glass cloth were observed between a metallic deposit and a base material of the printedboard1B, the hole had a rough inner wall, and throwing power in plating was insufficient.
As set forth above, according to theembodiment 3, the appropriate beam irradiation pausing time is provided, and the multi-pulse irradiation is carried out with the pulse groups including the several pulses. It is thereby possible to reduce the machining time to be less than that in case of the single pulse. At the same beam irradiated portion, the machined portion is irradiated with the pulsed laser beam having the plurality of pulse groups respectively including the plurality of pulses with intervals of the predetermined beam irradiation pausing time with intervals of the pulse group interval beam irradiation pausing time longer than the beam irradiation pausing time between the pulses. It is thereby possible to prevent a rise of a temperature at the machined portion, reduce gradation of the temperature gradient with respect to a depth distance from the surface of the machined portion, and reduce the projection of the glass cloth.
FIG. 12 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 4 of the present invention. In the drawing, the same reference numerals are used for component parts identical with or equivalent to those inFIG. 1, and descriptions thereof are omitted. In the embodiment, a three-layer glass epoxy printed board (FR-4) with a thickness of 500 μm was used as a multi-layer printed board1C. Further, copper foil had a thickness of 18 μm inconductor layers2,3, and4, a distance between theconductor layer2 and theconductor layer3 was 200 μm, and a copper foil removedportion8 with a diameter of 200 μm was formed in thetop conductor layer2 by etching.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with constant pulse energy of 280 mJ, a constant pulse width of 50 μs and a constant pulse frequency of 400 Hz. Further, thelaser beam27 was condensed on the printed board1C through aZnSe lens9 such that a laser beam diameter became 1 mm on a surface of a machined portion, thereby setting energy density to 35 J/cm2. As shown inFIG. 13, a raster scanning was made on apath26 with a scanning speed ranging from 8 to 3 m/min and a scanning pitch of 100 μm such that anentire existence region25 of the copper foil removedportion8 was irradiated with thelaser beam27. At the time, air was used as anassist gas10 for lens protection, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min.
FIG. 14 is a graph diagram showing a variation in amount of projection of glass cloth in a machined hole when the scanning speed of thelaser beam27 is varied. In the drawing, as the amount of projection of the glass cloth, the maximum value thereof is plotted. As shown inFIG. 14, when the scanning speed of thelaser beam27 is in the range of 8 to 6 m/min, it is possible to provide a machined hole with a small amount of projection of the glass cloth and no damage to bottom copper foil.
After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing a section. When the scanning speed of thelaser beam27 was 6 m/min or less, the amount of projection of the glass cloth became 20 μm or more due to heat, resulting in insufficient throwing power. As a result, there were observed many printed boards having plating solution soaking into the glass cloth. On the other hand, when the scanning speed of thelaser beam27 was in the range from 8 to 6 m/min, it was possible to highly efficiently provide a good conduction hole in which all the copper foil including the bottom copper foil were completely conductive through the plating.
As set forth above, according to theembodiment 4, it is possible to tremendously increase a machining speed while keeping the same machining quality as that of the same machining by positioning thelaser beam27 for each machined portion. Further, it is possible to reduce, for example, the projection of the glass cloth during the machining of the printed board, thereby enabling high quality machining such as drilling of a through-hole and a blind via hole, grooving, and cutting for an outside shape.
FIG. 15 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 5 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted.Reference numeral48 means a beam shaping optical system to shape alaser beam27 through a kaleidoscope such that thelaser beam27 can have a beam spot size of 0.9 mm×0.9 mm on a surface of a machined portion.
In theembodiment 5, as in theembodiment 4, a three-layer glass epoxy printed board (FR-4) with a thickness of 500 μm was used as a printed board1C. Further, copper foil had a thickness of 18 μm inconductor layers2,3, and4, a distance between theconductor layer2 and theconductor layer3 was 200 μm, and a copper foil removedportion8 with a diameter of 200 μm was formed in thetop conductor layer2 by etching.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with constant pulse energy of 280 mJ, a constant pulse width of 50 μs and a constant pulse frequency of 800 Hz. Further, thelaser beam27 was condensed on the multi-layer printed board1C through aZnSe lens9 after shaping by using the beam shapingoptical system48 including the kaleidoscope such that thelaser beam27 had the beam spot size of 0.9 mm×0.9 mm on the surface of the machined portion, thereby setting energy density to 35 J/cm2. As in theembodiment 4, a raster scanning was made with a scanning speed of 6 m/min and a scanning pitch of 200 μm such that an entire existence region of the copper foil removedportion8 was irradiated with thelaser beam27. At the time, air was used as anassist gas10 for lens protection, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min. Further, for comparison, the same laser beam machining was made by a circular beam with the same energy density and a diameter of 1 mm.
As a result, as shown inFIG. 16(a), when apath26 is scanned by asquare laser beam27ahaving a square laser beam on a machinedportion21, it was possible to provide a machined hole with a small amount of projection of glass cloth and no damage to bottom copper foil. On the other hand, as shown inFIG. 16(b), in case of acircular laser beam27b, there were caused carbonization in the machined hole and breakage of the bottom copper foil.
This is because, as shown in FIGS.16(a) and16(b), a superimposedportion24 of beam irradiated portions can more be reduced in scanning by thesquare laser beam27ahaving the square laser beam on the machinedportion21 of the printed board1C than would be in scanning by thecircular laser beam27b. As a result, thesquare laser beam27acan decrease gradation of a temperature gradient generated according to a temperature rise at the machined portion, and can more reduce a lower limit of a beam irradiation pausing time than would be in thecircular laser beam27b. By scanning the surface of the printed board1C by the pulse carbonic acid gas laser, it is possible to carry out the machining of the printed board1C such as drilling for a through-hole and a blind via hole, grooving, and cutting for an outside shape at a more rapid machining speed than that in case of thecircular laser beam27b, resulting in the same machining quality.
After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing a section. In case of thecircular laser beam27b, the amount of projection of the glass cloth became 20 μm or more due to heat, resulting in insufficient throwing power. As a result, there were observed many printed boards having plating solution soaking into the glass cloth. On the other hand, in case of thesquare laser beam27a, it was possible to provide a good conduction hole in which all the copper foil including the bottom copper foil were completely conductive through the plating.
As set forth above, according to theembodiment 5, the square laser beam is provided on the surface of the sample. It is thereby possible to provide a more rapid machining speed than that in case of thecircular laser beam27bwhile keeping good machining quality.
FIG. 17 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 6 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted. Reference numeral1D means a printed board, and a glass epoxy printed board (FR-4) with a thickness of 200 μm and both sides coated with copper is used as the printed board1D. Copper foil has a thickness of 18 μm inconductor layers2 and3. Etching with a pitch of 10 mm is made to remove copper foil with a width of 1 mm and a length of 10 mm so as to form copper foil removedportions8 in thetop conductor layer2 and thebottom conductor layer3 in the printed board1D at the same position.
A description will now be given of the operation.
According to theembodiment 6, alaser beam27 was emitted from a carbonic acid gas laser with constant pulse energy of 280 mJ, a constant pulse width of 50 μs and a constant pulse frequency of 400 Hz. Further, thelaser beam27 was condensed on the printed board1D through aZnSe lens9 such that thelaser beam27 had a beam diameter of 1 mm on a surface of a machined portion, thereby setting energy density to 35 J/cm2. As shown inFIG. 13, a raster scanning was made with a scanning pitch of 100 μm and a scanning speed of 8 m/min such that anentire existence region25 of the copper foil removedportion8 was irradiated with thelaser beam27. At the time, air was used as anassist gas10 for protection of theZnSe lens9, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min. Though no glass cloth projected and no char layer was generated, there were rigid residual additionally deposited around the machined hole due to large volumes of removed base materials.
After the machining, thelaser beam27 was emitted from the carbonic acid gas laser with the constant pulse energy of 200 mJ, the constant pulse width of 50 μs and the constant pulse frequency of 400 Hz. Further, thelaser beam27 was condensed on the printed board1D through theZnSe lens9 such that thelaser beam27 had the beam diameter of 1 mm on the surface of the machined portion, thereby setting the energy density to 25 J/cm2. As in the above machining, a second raster scanning was made with a scanning speed of 10 m/min and a scanning pitch of 100 μm such that anentire existence region25 of the copper foil removedportions8 was irradiated with thelaser beam27. At the time, air was used as theassist gas10 for protection of theZnSe lens9, and was supplied to the machined portion through thegas nozzle19 at the flow rate of 10 l/min. This can substantially completely remove the additional deposits around the machined hole without damage to the top copper foil.
After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing a section. It was possible to provide a good slit which was completely conductive through the plating without the residual additional deposit around the machined hole.
As set forth above, according to theembodiment 6, after the base material is removed by beam irradiation, the machined hole and a periphery of the machined hole, or only the periphery of the machined hole is irradiated with thelaser beam27 once again to remove soot additionally deposited around the machined hole. The second beam irradiation is used to remove only the soot, resulting in a small amount of removal and no additionally deposited soot. Thereby, even when a portion to be machined is larger than the laser beam diameter, for example, even in case of cutting, grooving, or drilling for a large diameter hole, it is possible to remove the additional deposits without the step for complicated after-treatment such as wet etching to remove the additionally deposited soot serving as the residual in the machined hole after the machining. As a result, it is possible to avoid a reduction in reliability of insulation and reliability of metallic deposit in the printed board.
FIG. 18 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 7 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted.Reference numeral18 means copper foil removed portions. In theembodiment 7, as in theembodiment 6, as a printed board1D was used a glass epoxy printed board (FR-4) with a thickness of 200 μm and both sides coated with copper. Further, copper foil had a thickness of 18 μm inconductor layers2 and3. Etching with a pitch of 2 mm was made to form copper foil removedportions8 with a width of 1 mm and a length of 10 mm in thetop conductor layer2 and thebottom conductor layer3 on the printed board1D at the same position. As shown inFIG. 19(a), the copper foil removedportion18 was formed by removing copper foil with a width of 100 μm corresponding to only anouter periphery18aof the copper foil removedportion18 through the etching. Further, for the purpose of confirmation of an effect in case the copper foil removedportion18 was used, another etching was made to entirely remove a portion corresponding to a machined portion as in theembodiment 6 so as to form a copper foil removedportion8 as shown inFIG. 19(b).
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with constant pulse energy of 280 mJ, a constant pulse width of 50 μs and a constant pulse frequency of 400 Hz. Further, thelaser beam27 was condensed on the printed board1D through aZnSe lens9 such that thelaser beam27 had a beam diameter of 1 mm on a surface of a machined portion, thereby setting energy density to 35 J/cm2. As in theembodiment 6, a raster scanning was made with a scanning speed of 8 m/min and a scanning pitch of 100 μm such that an entire existence region of the copper foil removedportion18 was irradiated with thelaser beam27. At the time, air was used as anassist gas10 for lens protection, and was supplied to the machined portion through agas nozzle19 at a flow rate of 10 l/min.
As a result, in the printed board in which only theouter periphery18aof the copper foil removedportion18 was machined, it was possible to form a good slit without projection of glass cloth, generation of a char layer, and rigid additional deposits on a periphery of a machined hole. On the other hand, in the printed board with the copper foil removedportion8 formed by entirely removing the portion corresponding to the machined portion as shown inFIG. 19(b), as described above, no glass cloth projected and no char layer was generated. However, there were rigid residual additionally deposited around the machined hole due to large volumes of removed base materials.
After ultrasonic cleaning and desmearing of the printed board1D obtained by machining only theouter periphery18aof the copper foil removedportion18, the printed board was plated with copper, and a pattern was formed thereon, thereafter observing a section. It was possible to provide a good slit which was completely conductive through the plating without the residual additional deposit around the machined hole and peeling of the copper foil.
As set forth above, according to theembodiment 7, since only theouter periphery18aof the copper foil removedportion18 is machined, a volume of removal can be reduced at a time of machining so that the machined hole having the same shape can be provided after the machining. At the time, since a small volume of machined materials can reduce a temperature rise around the machined hole, it is possible to reduce gradation of a temperature gradient as shown inFIG. 7. That is, a larger temperature gradient can be provided to enable good machining causing no failure such as peeling of the copper foil even in case of machining with the removed portion larger than a non-removed portion. Further, a shorter beam irradiation pausing time can be provided than that in a method of irradiating the entire machined portion with the beam, resulting in higher speed machining.
FIG. 20 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 8 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted. In theembodiment 8, as in theembodiment 6, as a printed board1D serving as a machining target was used a glass epoxy printed board (FR-4) with a thickness of 200 μm and both sides coated with copper. Further, copper foil had a thickness of 18 μm inconductor layers2 and3. Etching with a pitch of 10 mm was made to form copper foil removedportions8 with a width of 1 mm and a length of 10 mm in thetop conductor layer2 and thebottom conductor layer3 on the printed board1D at the same position.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with constant pulse energy of 280 mJ, a constant pulse width of 50 μs and a constant pulse frequency of 400 Hz. Further, thelaser beam27 was condensed on the printed board1D through aZnSe lens9 such that thelaser beam27 had a beam diameter of 1 mm on a surface of a machined portion, thereby setting energy density to 35 J/cm2. As shown inFIG. 21, a raster scanning was made along apath26 with a scanning speed of 8 m/min and a scanning pitch of 100 μm such that anentire existence region25 of the copper foil removedportion8 was irradiated with thelaser beam27. At the time, air was used as anassist gas10, and was sprayed and supplied to the machined portion at a flow rate of 50 l/min in a direction from a machining start portion to a machining end portion through agas nozzle19 moving integrally with thelaser beam27.
As a result, additional deposits around a machined hole were blown away by the assist gas, and adhered to only a portion to be subsequently machined. The additional deposits were removed by thelaser beam27 at a time of the machining, and a small amount of additional deposits were finally left at the machining end portion. The additional deposits were removed by a method identical with the laser beam machining method for the wiring board described in theembodiment 6.
After ultrasonic cleaning and desmearing of the printed board1D obtained by the above steps, the printed board was plated with copper, and a pattern was formed thereon, thereafter observing a section. It was possible to provide a good slit which was completely conductive through the plating without the residual additional deposit around the machined hole.
As set forth above, according to theembodiment 8, a gas flow is sprayed onto the currently machined printed board1D in the direction from the beam irradiation start portion to the beam irradiation end portion in the machined portion, thereby blowing away the removed material to an area to be subsequently irradiated with thelaser beam27, and depositing the material on a surface thereof. Since the deposit can be removed concurrently with removal of the base material, it is possible to reduce the removed material deposited on a surface of the printed board1D after the machining, and reduce the printed board cleaning step after the machining. Further, it is possible to significantly reduce an area having the residual additional deposit even in machining with large volumes of removed materials.
FIG. 22 is a typical diagram illustrating a laser beam machining method for a wiring board according to theembodiment 9 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted. In theembodiment 9, as a printedboard1E was used a three-layer glass epoxy printed board (FR-4) with a thickness of 200 μm and both sides coated with copper foil. Further, copper foil had a thickness of 18 μm inconductor layers2,3, and4. Thetop conductor layer2 was provided with no copper foil removed portion formed by etching.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with pulse energy of 400 mJ and a pulse width of 100 μs. Further, thelaser beam27 was condensed on the printedboard1E through aZnSe lens9 at a just focus position at which thelaser beam27 had the minimum spot diameter, thereby irradiating with one pulse. Thereafter, at intervals of a beam irradiation pausing time of 50 ms, the printed board was irradiated with ten pulses of thelaser beam27 with pulse energy of 150 mJ and a pulse width of 100 μs. At the time, air was used as anassist gas10 for lens protection, and was supplied to a machined portion at a flow rate of 10 l/min through agas nozzle19. In the firstirradiated laser beam27, pulse energy has sufficient intensity to melt and remove thetop conductor layer2. In the second andlater laser beams27, pulse energy has insufficient intensity to melt thetop conductor layer2.
FIG. 23 is a typical diagram showing one illustrative result of machining for the printed board according to theembodiment 9. In thetop conductor layer2, copper foil including a substantially complete round with a diameter of 200 μm was removed with little effect of heat on a periphery. Further, under theconductor layer2, the machining can be made to form a substantially straight hole reaching the lowermost copper foil with a small amount of projection ofglass cloth29. After ultrasonic cleaning and desmearing of the obtained machined hole, the machined hole was plated with copper, and a pattern was formed, thereafter observing a section. It was possible to provide a good through-hole with the diameter of 200 μm and a smooth inner wall.
As set forth above, even when the copper foil is not previously removed in another step such as etching, the machined portion may be irradiated with thepulsed laser beam27 from the carbonic acid gas laser at the just focus position, thereby increasing the energy density. It is thereby possible to finely remove the top copper foil with little effect of heat on the periphery. Thereafter, the printed board may be irradiated a plurality of times with thelaser beam27 having smaller pulse energy at intervals of a long beam irradiation pausing time, resulting in the through-hole with no char layer. It is thereby possible to omit the etching serving as a previous step which is essential in the prior art, and simplify manufacturing steps. Further, both of the above beam irradiation conditions are identical with those described in, for example, theembodiments 1 and 2. That is, the printed board was irradiated with thepulsed laser beam27 for a beam irradiation time ranging from 10 to 200 μs, most suitable for machining of the glass epoxy board, and at intervals of the beam irradiation pausing time of 15 ms or more. Therefore, it is possible to provide a sharp temperature gradient of the machined portion, and provide a platable hole with a substantially negligible amount of projection of the glass cloth. As set forth above, even in the printed board having surfaces coated with the copper foil and containing the glass cloth, it is possible to rapidly and accurately provide a hole by only the laser beam machining step without previously removing the conductor layer such as the copper foil on the surface of the printed board through the etching, and so forth.
FIG. 24 is a typical diagram showing a laser beam machining method for a wiring board according to theembodiment 10 of the present invention. In the drawing, the same reference numerals are used for component parts identical with those inFIG. 1, and descriptions thereof are omitted. In the embodiment, as in theembodiment 9, as a printedboard1E was used a three-layer glass epoxy printed board (FR-4) with a thickness of 200 μm and both sides coated with copper foil. Further, copper foil had a thickness of 18 μm inconductor layers2,3, and4. Thetop conductor layer2 was provided with a finely removedportion30 in a range smaller than an area to be machined.
A description will now be given of the operation.
Alaser beam27 was emitted from a carbonic acid gas laser with pulse energy of 200 mJ and a pulse width of 100 μs. Further, thelaser beam27 was condensed on the printedboard1E through aZnSe lens9 at a just focus position at which thelaser beam27 had the minimum spot diameter, thereby irradiating with one pulse. Thereafter, at intervals of a beam irradiation pausing time of 50 ms, the printed board was irradiated with ten pulses of thelaser beam27 with pulse energy of 150 mJ and a pulse width of 100 μs. As a result, as in theembodiment 9, in thetop conductor layer2, copper foil including a substantially complete round with a diameter of 200 μm was removed with little effect of heat on a periphery. Further, under theconductor layer2, the machining can be made to form a substantially straight hole reaching copper foil of thelowermost conductor layer4 with a small amount of projection of glass cloth.
Instead of the finely removedportion30 shown inFIG. 24, as shown inFIG. 25, surface roughening shown byreference numeral31 may be made to a surface of theconductor layer2. The surface roughening utilizes, for example, chemical treatment typically used to enhance adhesive properties between a resin layer and a conductor layer. The surface roughening to the surface of theconductor layer2 can improve absorption of thelaser beam27 when the copper foil having a desired shape is removed from theconductor layer2, and enables efficient and more stable drilling.
As set forth above, the slight copper foil of a beam irradiated portion is previously removed by the etching, and the surface roughening is made to the surface. The treated portions trigger the absorption of thelaser beam27 from the carbonic acid gas laser so that the top copper foil can be removed even when the first irradiated beam has low energy density as in theembodiment 9.
Alternatively, the two methods according to theembodiment 10 may concurrently be used including one method in which the slight copper foil of the beam irradiated portion is previously removed by the etching, and the other method in which the surface roughening is made to the surface. Alternatively, either one or both of the methods may be used concurrently with the method in theembodiment 9. In either case, as in theembodiment 9, the top copper foil can be removed even when the first irradiated beam has low energy density.
FIG. 26 is a typical diagram showing a laser beam machining method for a wiring board, and a laser beam machining apparatus for a wiring board according to theembodiment 11 of the present invention. In the drawing,reference numeral32 means a laser oscillator, 33 is an fθ lens to condense alaser beam27,34 is beam scanner apparatus (optical mechanisms) using a galvanometer scanner, and35 is a scanner drive/laser trigger apparatus (control mechanism) to output a drive command for thebeam scanner apparatus34 and a trigger of laser oscillation for thelaser oscillator32.
A description will now be given of the operation.
The scanner drive/laser trigger apparatus35 outputs the trigger of the laser oscillation for thelaser oscillator32 at a predetermined pulse frequency, and the drive commands for the twobeam scanner apparatus34. It is thereby possible to position a spot of thelaser beam27 at high speed at an optional drilling position on the printedboard1F having many drilling positions in synchronization with a pulse frequency of thelaser beam27 radiated from thelaser oscillator32.
A machining speed per unit time becomes higher as the pulse frequency becomes higher. However, when irradiation with a plurality of pulses is required for drilling at one position, successive irradiation with a high pulse frequency makes a char layer thicker so that a good hole can not be provided. For example, as seen from a relationship shown inFIG. 6, the char layer is made thicker by beam irradiation at intervals of a beam irradiation pausing time less than 15 ms, that is, at a frequency more than 67 Hz.
Thus, the spot of thelaser beam27 is sequentially moved to different drilling positions for each pulse. After all of the many drilling positions in the range of a scan vision are irradiated with thelaser beam27 pulse by pulse (after the elapse of a substantial time of 15 ms or more), or after the elapse of a time of 15 ms or more from irradiation of the first drilling position with thelaser beam27, the spot is returned to the first drilling position. The spot is sequentially moved once again, and the movement is repeated several times. It is thereby possible to irradiate one drilling position with the laser beam a plurality of times while ensuring a beam irradiation pausing time of 15 ms or more for each drilling position. Therefore, if in synchronization at a frequency of 200 Hz by using, for example, thebeam scanner apparatus34 having the galvanometer scanner shown inFIG. 26, a time of 5 ms is required for each hole. Consequently, when the scan vision includes three or more drilling positions, and the spot is sequentially moved toward the positions, the beam irradiation pausing time of 15 ms or more can be ensured for each drilling position.
As set forth above, according to theembodiment 11, even if thelaser beam27 having a high pulse frequency is used, the beam irradiation can be made while ensuring the beam irradiation pausing time of 15 ms or more for each machined portion. It is thereby possible to provide a high quality platable hole having little char layer and no projection of glass cloth. Further, a scanning frequency of the spot of thelaser beam27 can be increased to its limitation so as to enable high-speed drilling, and drill for many holes in a short time. Therefore, it is possible to considerably improve productivity of the printed board containing the glass cloth.
FIG. 27 is a typical diagram showing a laser beam machining method for a wiring board, and a laser beam machining apparatus for a wiring board according to theembodiment 12 of the present invention. In the drawing,reference numeral36 means a reflection mirror disposed across an optical axis of alaser beam27, and37 is an XY table on which three printedboards1F are mounted, for moving the printed boards in a horizontal plane. That is, the XY table37 includes three machining stations. In addition,reference numeral38 means a control unit for the XY table37,39 is rotary choppers,40 is a trigger generating apparatus,41 is a trigger counting portion, and ST1 to ST3 are one pulses of thelaser beam27. The laser beam machining method for the wiring board according to theembodiment 12 is used for concurrent machining of the plurality of printedboards1F. The embodiment will be described by way of a method for the concurrent machining of the three printedboards1F as one example. In the embodiment, an optical mechanism includes therotary choppers39 and thereflection mirror38, and a synchronization control mechanism includes thetrigger generating apparatus40 and thetrigger counting portion41.
A description will now be given of the operation.
As shown inFIG. 28, in therotary chopper39, a disk mounted perpendicular to a rotation axis is equally divided into (3×n) areas (n=1, 2, 3, . . . ), and the equally divided areas are repeatedly mounted in the order of areflection surface39a, a passingportion39b, and a passingportion39bin a direction of rotation. InFIG. 28, therotary chopper39 is a cross-shaped reflector obtained by equally dividing a disk into (3×4) areas to have the fourreflection surfaces39a.
As shown inFIG. 27, the tworotary choppers39 are mounted between thelaser oscillator32 and thereflection mirror36, and are set to rotate, with a deviation by one of the equally divided areas, in synchronization with each other at the same speed. Any one of therotary choppers39 is provided with thetrigger generating apparatus40 to output the trigger to thetrigger counting portion41 each time the (3×n) equally divided areas respectively move across the optical axis of thelaser beam27. Thetrigger generating apparatus40 sends the generating trigger to thetrigger counting portion41. Thetrigger counting portion41 counts the received trigger, and sends the trigger to thelaser oscillator32 if a count value is valid (a predetermined count value is not reached). When thelaser oscillator32 receives the trigger from thetrigger generating apparatus40 through thetrigger counting portion41, thelaser oscillator32 immediately outputs thelaser beam27 by only one pulse with a pulse width of 200 μs or less. Thelaser beams27 including optional successive three pulses are outputted in such a manner, and are sequentially reflected at any one of the tworotary choppers39 and thereflection mirror36 so as to be introduced to the three machining stations. Through aZnSe lens9, the three printedboards1F are respectively irradiated with the laser beams27. When the predetermined number of triggers is counted, thetrigger counting portion41 disables the next and later triggers to thelaser oscillator32, and sends a table moving trigger to thecontrol unit38 of the XY table37. When the XY table37 is completely positioned, thetrigger counting portion41 enables a trigger again by receiving a positioning completion signal from thecontrol unit38 of the XY table37.
FIG. 29 is a time chart of the trigger and laser pulses in theembodiment 12. As shown inFIG. 29, the machining stations are respectively irradiated with thelaser beam27 shown by any one of reference numerals ST1, ST2, and ST3 once every generation of any one of three triggers from thetrigger generating apparatus40. For example, when the tworotary choppers39 are rotated such that the trigger from thetrigger generating apparatus40 can have a cycle of 5 ms or more, the machining stations are respectively irradiated with pulses at time intervals of 15 ms or more. As seen from a relationship shown inFIG. 6, it is thereby possible to drill for a good hole with a small amount of a char layer. When the beam irradiation is required m times for each drilling and sequential drilling is made for other holes, the predetermined number of triggers in thetrigger counting portion41 may be set to (3×m). It is thereby possible to machine the entire areas of the three printedboards1F by repeating the beam irradiation and movement of the table.
As set forth above, according to theembodiment 12, there is no decrease in energy of thelaser beam27 in the respective machining stations. Further, the speed of rotation of therotary choppers39 is set such that thelaser beams27 can be transferred to the machining stations at time intervals of 15 ms or more. It is thereby possible to concurrently provide in the plurality of printedboards1F high quality platable holes without projection of glass cloth, and more rapidly machine the printedboard1F containing the glass cloth, resulting in a significant improvement of productivity. Further, the combination of thebeam scanner apparatus34 in theembodiment 11 and theembodiment 12 can reduce a time required for the movement of the table, and enables higher speed machining of the plurality of printed boards.
FIG. 30 is a perspective view showing a structure of a carbonic acid gas laser oscillator for machining a wiring board according to theembodiment 13 of the present invention. In the drawing,reference numeral42 means a pair of discharge electrodes to form adischarge space43 in a gap therebetween,44 is a resonator mirror,45 is a gas flow serving as laser medium,46 is an optical axis of alaser beam27, and47 is an aperture to select the degree of mode of thelaser beam27. The unit including theoptical axis46 of thelaser beam27, thegas flow45, and a direction of discharge in an orthogonal relationship is typically referred to as three-axes orthogonal type laser oscillator.
A description will now be given of the operation.
Discharge power is fed from thedischarge electrodes42 to form thedischarge space43 into which thegas flow45 flows. A molecule in thegas flow45 is excited by energy of discharge to have a gain to light. When thedischarge space43 is formed in a stationary manner, there is formed a stationary gain distribution having a peak in the vicinity of the downstream of thedischarge space43 as shown inFIG. 31(a). Therefore, in order to efficiently provide stationary laser oscillation, that is, successive output (CW output), it is necessary to dispose theoptical axis46 and theaperture47 across a line which vertically travels in the downstream of thedischarge space43 providing the maximum gain distribution as shown inFIG. 31(b). For the purpose, in the prior art, a typical three-axes orthogonal type of carbonic acid gas laser oscillator has the above structure.
However, unlike the prior art, there is provided the carbonic acid gas laser oscillator for machining the printed board according to theembodiment 13 of the present invention having a structure as shown inFIG. 32. In the structure, theaperture47 is disposed in the range in that theaperture47 does not extend off thedischarge space43, and theoptical axis46 is disposed on a line vertically travelling on the farthest upstream side of thedischarge space43.
In a conventional structure shown inFIG. 31(b), it can be considered that energy of an excited molecule at a point A in the upstream of thedischarge space43 is converted into thelaser beam27 at a time of reaching a point B. Further, it can be seen that an excited molecule at the point A at the moment at which the discharge is stopped is converted into thelaser beam27 after the elapse of a time of (X/V) (where V is a gas flow rate, and X is a distance from the point A to the point B). Therefore, when theoptical axis46 is disposed in the downstream of thedischarge space43 as shown inFIG. 31(b), a time required for disappearance of thelaser beam27 after the discharge is stopped becomes longer, and a fall of a laser pulse at a time of pulse oscillation becomes slower than would be in case where theoptical axis46 is disposed in the upstream of thedischarge space43 as in theembodiment 13 shown inFIG. 30. For example, in the conventional laser oscillator with a 30 mm distance between the point A and the point B, that is, a 30 mm width of thedischarge electrode42 and a gas flow rate of 80 m/s, a fall time of the laser pulse becomes 375 μs. Even if a fall time of the discharge power itself is reduced, it is impossible to reduce the fall time of the laser pulse.
On the other hand, according to theembodiment 13 shown inFIG. 32, theaperture47 is disposed in the range that theaperture47 does not extend off thedischarge space43, and theoptical axis46 is disposed on the line vertically travelling on the farthest upstream of thedischarge space43. For example, for a 6.5 mm distance between the point A and the point B and the gas flow of 80 m/s, it is possible to provide an 81 μs fall time of the laser pulse. In this case, it is necessary to provide a sufficiently short fall time of the discharge power because a fall time of the laser pulse is affected by a longer fall time of the discharge power than the fall time of the pulse. When theoptical axis46 is disposed as in the embodiment shown inFIG. 32, the fall time of the discharge power is preferably set to 50 μs or less. When theoptical axis46 is disposed as in theembodiment 13 shown inFIG. 32, a rise time of the discharge power has an effect on a rise time of the laser pulse. Thus, the rise time of the discharge power is preferably set to 50 μs or less in order to obtain a narrow pulse width of 200 μs or less.
As set forth above, according to theembodiment 13, it is possible to provide the laser pulse having a sharp rise, a sharp fall, and the pulse width of 200 μs or less, which can not be provided by the conventional carbonic acid gas laser. The machining can be made without projection of glass cloth and generation of a char layer by applying the laser pulse to the machining of the printed board.
As set forth above, according to the present invention, there is provided the laser beam machining method for the wiring board, including the step of irradiating the machined portion of the wiring board with the pulsed laser beam for the beam irradiation time ranging from 10 to 200 μs and with the energy density of 20 J/cm2or more. As a result, there is an effect in that good and fine machining can be made in, for example, the drilling for the through-hole and the blind via hole, the grooving, and the cutting for the outside shape with respect to the board made of the composite material having inclusion such as glass cloth.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of irradiating the same machined portion of the wiring board with the pulsed laser beam with intervals of the beam irradiation pausing time of 15 ms or more and the energy density of 20 J/cm2or more. As a result, there are effects in that the conduction hole can be obtained with the high aspect ratio which can not be obtained by the single pulse, projection of the glass cloth can be reduced, and the wiring board containing the glass cloth can rapidly and accurately be machined even in case of the multi-pulse irradiation.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of irradiating the same machined portion of the wiring board with the pulsed laser beam with the plurality of pulse groups respectively including the plurality of pulses respectively having the energy density of 20 J/cm2or more at intervals of the pulse group interval irradiation pausing time longer than the predetermined beam irradiation pausing time. As a result, there are several effects of machining for the conduction hole in a shorter time than would be in the machining employing the single pulse frequency, prevention of the temperature rise at the machined portion, a reduction in gradation of the temperature gradient with respect to the depth distance from the surface of the machined portion, and a reduction in projection of the glass cloth.
According to the present invention, there is provided the laser beam machining method for the wiring board, in which the predetermined beam irradiation pausing time is 4 ms or more, the number of pulses in the pulse group is 4 or less, and the pulse group interval beam irradiation pausing time exceeds 20 ms. As a result, there are effects of reduced generation of the char layer in the machined hole, and good and fine machining in the drilling for the through-hole and the blind via hole, the grooving, the cutting for the outside shape, and so forth.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of, at a time of scanning the surface of the wiring board while irradiating the machined portion of the wiring board with the pulsed laser beam, scanning by the laser beam such that the machined portion is not continuously irradiated with the laser beam over 4 pulses and at intervals of the beam irradiation pausing time less than 15 ms. As a result, there are effects in that it is possible to reduce generation of the char layer in the machined hole, and increase the machining speed while keeping the same machining quality as that in machining by positioning the beam at the machined portions.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of providing the 1 mm beam diameter on the surface of the machined portion, and scanning the surface of the wiring board at the scanning speed ranging from 8 to 6 m/min while irradiating the machined portion with the laser beam for the beam irradiation time ranging from 10 to 200 μs and at intervals of the beam irradiation pausing time of 2.5 ms. As a result, there are effects in that it is possible to increase the machining speed while keeping the same machining quality as that in machining by positioning the beam at the machined portions, and provide good and fine machining such as drilling for the blind via hole in the board made of the composite material having inclusion such as glass.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of setting the laser beam to have the square spot effective in the machining of the machined portion of the wiring board, and scanning the surface of the wiring board while irradiating the machined portion of the wiring board with the pulsed laser beam. As a result, there is an effect in that the machining speed can be more increased with good machining quality than would be in case of the circular beam.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of setting the square spot of the laser beam on the machined portion to have the size of 0.9 mm×0.9 mm, and scanning the surface of the wiring board with the scanning speed of 6 m/min and the scanning pitch of 200 μm while irradiating the machined portion with the laser beam for the beam irradiation time ranging from 10 to 200 μs and at intervals of the beam irradiation pausing time of 1.25 ms. As a result, there are effects in that higher quality can be kept than would be in case of the circular beam, and the machining speed can be increased.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of previously removing the metallic layer on the wiring board at the portion corresponding to the machined portion of the wiring board, forming the base material removed portion through the machining by irradiating the base material of the machined portion with the laser beam through the metallic layer removed portion, and additionally irradiating the base material removed portion and the periphery of the base material removed portion, or only the periphery of the base material removed portion with the laser beam. As a result, there is an effect in that the rigid additional deposit generated during the machining can simply be removed without the complicated step such as wet etching even in the machining having large volumes of removed materials.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of previously removing the metallic layer on the wiring board at the portion corresponding to the machined portion of the wiring board, forming the base material removed portion through the machining by irradiating the base material of the machined portion with the laser beam through the metallic layer removed portion, and additionally irradiating and scanning the base material removed portion and the periphery of the base material removed portion, or only the periphery of the base material removed portion with the laser beam having a smaller peak output than that of the above laser beam at a higher scanning speed than a scanning speed during first laser beam irradiation. As a result, there is an effect in that the rigid additional deposit caused during the machining can simply be removed without the complicated step such as wet etching even in the machining having large volumes of removed materials.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of, at the time of previously removing the metallic layer on the wiring board at the portion corresponding to the machined portion, partially removing the metallic layer such that the laser beam can reach only the outer periphery of the base material removed portion to be formed by irradiating the base material of the machined portion with the laser beam. As a result, there is an effect of good machining causing no failure such as peeling of the metallic layer even in case of machining with the removed portion larger than the non-removed portion.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of partially removing the metallic layer such that the laser beam can reach only the outer periphery of the base material removed portion to be formed by irradiating the base material of the machined portion with the laser beam, and scanning the surface of the wiring board with the scanning speed of 8 m/min and the scanning pitch of 100 μm while irradiating the machined portion with the laser beam for the beam irradiation time ranging from 10 to 200 μs and at intervals of the beam irradiation pausing time of 2.5 ms. As a result, there is an effect of good machining causing no failure such as peeling of the metallic layer because the base material removed portion is not entirely removed even in case of machining with the base material removed portion larger than the non-removed portion.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of previously removing the metallic layer on the wiring board at the portion corresponding to the machined portion, and flowing the gas in the direction from the laser beam scanning start point to the laser beam scanning end point in the machined portion at the time of the machining by irradiating the base material of the machined portion with the laser beam while scanning by the laser beam through the metallic layer removed portion. As a result, there are effects in that it is possible to effectively eliminate the adverse effect of the residual additional deposit on the machining even in the machining with large volumes of removed materials, and significantly reduce the area having the residual additional deposit.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of forming the metallic layer having the desired shape by partially removing the metallic layer by pulse irradiation with the laser beam having the sufficient intensity to melt and remove the metallic layer on the wiring board, and additionally irradiating the machined portion of the wiring board through the metallic layer removed portion with the laser beam having the insufficient intensity to melt the metallic layer and the beam irradiation time ranging from 10 to 200 μs, and including the plurality of pulses forming a train at intervals of the beam irradiation pausing time of 15 ms or more. As a result, there is an effect in that rapid and accurate machining can be made simply by the laser beam machining step even in the wiring board having the surface coated with the copper foil and including the glass cloth.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of exposing the machined portion by previously removing, through another machining method such as etching, the metallic layer positioned at the target position for laser beam irradiation and in the range smaller than the area to be machined. As a result, there are effects of improved absorption of the laser beam, and efficient and more stable drilling.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of previously making the surface roughening to the surface of the metallic layer on the surface of the wiring board before the laser beam irradiation. As a result, there are effects in that the metallic layer can be removed by improving the absorption of the laser beam even in case of low peak output of the laser beam, and efficient and more stable drilling can be made.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the step of, at a time of pulsed laser beam irradiation while sequentially positioning the spot of the laser beam at the target positions on the wiring board in synchronization with the pulse frequency of the laser beam, providing the time interval of 15 ms or more between the two optional successive pulsed laser beams for irradiation of the respective target positions irrespective of the pulse frequency by irradiating another target position with the pulsed laser beam outputted for the time interval therebetween. As a result, there is an effect in that the high quality platable hole can be provided with little formation of the char layer and no projection of the glass cloth because the beam irradiation can be made with the beam irradiation pausing time of 15 ms or more ensured for each machined portion even when the laser beam having high pulse frequency is used. Further, there is another effect in that the scanning frequency of the spot of the laser beam can be increased to its limitation so as to enable the high-speed drilling, and drill for many holes in a short time, thereby significantly improving productivity of the wiring board.
According to the present invention, there is provided the laser beam machining method for the wiring board, including the steps of providing the plurality of machining stations on which the wiring boards to be machined are mounted, sequentially dividing the pulsed laser beam outputted from the laser oscillator among the plurality of machining stations for each pulse, and introducing the pulsed laser beam into the plurality of machining stations at the time intervals of 15 ms or more. As a result, there are effects in that rapid machining for the conduction hole can be made at the plurality of machining stations without a reduction in quality of the machined hole, and productivity of the wiring board can significantly be enhanced.
According to the present invention, there is provided the laser beam machining method for the wiring board, in which the carbonic acid gas laser is used as a light source of the laser beam. With the use of the carbonic acid gas laser having high absorption coefficient shown by the glass, there is an effect of rapid and accurate machining even in the wiring board containing the glass cloth, which is difficult to machine in other lasers.
According to the present invention, there is provided the laser beam machining method for the wiring board, in which the wiring board contains the glass cloth. As a result, there are effects in that projection of the glass cloth can be reduced, and the wiring board containing the glass cloth can rapidly and accurately be machined.
According to the present invention, there is provided the laser beam machining apparatus for the wiring board, including the optical mechanism to change a direction of the laser beam and move the laser beam on the wiring board while sequentially positioning the spot of the laser beam at the target positions on the wiring board, and the control mechanism for synchronous control between the pulse oscillating operation of the laser beam oscillator and the operation of the optical mechanism, and control of the optical mechanism such that the time interval can be set to 15 ms or more between the two optional successive pulsed laser beams for irradiation of the target positions irrespective of the pulse frequency of the laser oscillator. As a result, there is an effect in that the high quality platable hole can be provided with little formation of the char layer and no projection of the glass cloth because the beam irradiation can be made with the beam irradiation pausing time of 15 ms or more ensured for each machined portion even when the laser beam having high pulse frequency is used. Further, there is another effect in that the scanning frequency of the spot of the laser beam can be increased to its limitation so as to enable the high-speed drilling, and drill for many holes in a short time, thereby significantly improving productivity of the wiring board.
According to the present invention, there is provided the laser beam machining apparatus for the wiring board, including the optical mechanism to sequentially divide the pulsed laser beam outputted from the laser oscillator among the plurality of machining stations for each pulse and introduce the pulsed laser beam into the plurality of machining stations for each pulse at time intervals of 15 ms or more, and the synchronization control mechanism for synchronous control between the dividing operation of the optical mechanism and the pulse oscillating operation of the laser oscillator. As a result, there is an effect in that rapid machining for the conduction hole can be made at the plurality of machining stations without a reduction in quality of the machined hole.
According to the present invention, there is provided the laser beam machining apparatus for the wiring board, including the optical mechanism provided with the at least one rotary chopper rotated at the predetermined speed of rotation, having the plurality of reflection surfaces and the plurality of passing portions at positions equally dividing the periphery about the axis in the plane perpendicular to the rotation axis, and the synchronization control mechanism provided with the trigger generating apparatus to generate the trigger each time all the equally divided areas including the plurality of reflection surfaces and the plurality of passing portions in the rotary chopper respectively move across the optical axis of the laser beam. As a result, there is an effect in that rapid machining for the conduction hole can be made at the plurality of machining stations without a reduction in quality of the machined hole.
According to the present invention, there is provided the carbonic acid gas laser oscillator for machining the wiring board, in which the length of the discharge space in the gas flow direction is equal to or more than the width of the aperture, the optical axis passing through the center of the aperture is set to be positioned in the range that the entire area of the aperture does not extend off the area extending in the gas flow direction of the discharge space and on the farthest upstream side of the gas flow, and the rise time and the fall time are set to 50 μs or less in the discharge power fed to the discharge space. As a result, there are effects in that it is possible to reduce the rise and the fall of the laser beam, and obtain the laser beam with the short beam irradiation time suitable for machining of the wiring board.
While preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
