Laser scoring of metal/polymer structures

1. A method of scoring a multi-layer film structure comprising a metal layer positioned between a first and a second polymer layer, the metal layer being bonded to the first polymer layer, the method comprising:

scoring with a single laser beam, the laser beam being incident to the first polymer layer and having a wavelength such that laser energy is not absorbed but transmitted through the first polymer layer, the wavelength being sufficiently absorbable by the metal layer such that a plume is generated from the metal layer of sufficient energy to cut through the first polymer layer such that the film structure is selectively scored concurrently through the first polymer layer and the metal layer while the second polymer layer is either not scored or only partially scored.

2. The method of claim 1 wherein the laser beam has a pulse length in the range of between about 1 to 200 nanoseconds.

3. The method of claim 1 wherein the first polymer layer is positioned such that the laser beam travels through the first polymer layer scoring the metal layer.

4. The method of claim 1 where the first polymer layer is cut by an upwardly directed heat plume produced as a result of the absorption of energy from the laser beam by the metal layer.

5. The method of claim 1 wherein the scoring of the film structure extends into the second polymer layer.

6. The method of claim 1 wherein the scoring of the film structure extends through the first polymer layer and the metal layer and the second polymer layer is not scored.

7. The method of claim 1 wherein the scoring extends through the first polymer layer and partially through the metal layer while the second polymer layer is not scored.

8. The method of claim 1 wherein the metal layer and the second polymer layer are partially bonded in some areas and not bonded in other areas.

9. The method of claim 1 wherein the laser beam comprises a wavelength in the range of about 0.4 to 4 microns.

10. The method of claim 9 wherein the laser beam wavelength is in the range of about 0.5-2 microns.

11. The method of claim 1 wherein the laser beam comprises laser energy density and wherein the laser energy density delivered to the multi-layer film structure is sufficient to melt and vaporize the metal layer.

12. The method of claim 11 wherein the laser energy density is in the approximate range of 5 J/cm 2 to 150 J/cm 2 .

13. A method of using a single laser beam to selectively score a multi-layer film structure comprising a first polymer layer and a metal layer bonded to each other, the metal layer being positioned beneath the first polymer layer, the method comprising:

scoring at least the first polymer layer with the single laser beam, the laser beam being incident to the first polymer layer and being transmitted through the first polymer layer, the laser beam being sufficiently absorbable by the metal layer to generate a plume from the metal layer of sufficient energy to cut through the first polymer layer such that the film structure is selectively scored through the first polymer layer and the metal layer concurrently.

14. The method of claim 13 wherein the laser beam has a pulse length in the range of between about 1 to 200 nanoseconds.

15. The method of claim 13 wherein the first polymer layer is positioned such that the single laser beam travels through the first polymer layer while scoring the metal layer.

16. The method of claim 13 wherein the first polymer layer is scored by an upwardly directed heat plume produced from absorption of energy by the metal layer from the single laser beam.

17. The method of claim 13 wherein the multi-layer film structure is scored such that the first polymer layer is fully cut and the metal layer is partially cut in depth.

18. The method of claim 13 wherein the laser beam comprises a wavelength in the range of about 0.4 to 4 microns.

19. The method of claim 18 wherein the laser beam comprises a wavelength in the range of about 0.5 to 2 microns.

20. The method of claim 13 wherein the laser beam comprises laser energy density and wherein the laser energy density delivered to the multi-layer film is sufficient to vaporize the metal layer.

21. The method of claim 20 wherein the delivered laser energy density is preferably in the range from 5 J/cm 2 to 150 J/cm 2 .

22. A laser system consisting essentially of a single laser beam for selectively scoring a multiple layer film structure comprising at least one metal layer and a first polymer layer, the laser system comprising:

the laser beam produced by the laser system, the laser beam transmitted through the first polymer layer and being readily absorbed by the metal layer;

the laser beam having a laser energy density sufficiently high to melt and vaporize a portion of the metal layer generating a plume for cutting through the first polymer layer; and

the laser beam having a laser pulse length sufficiently short such that melting and vaporization of the metal layer on a side of the laser incidence occurs at a time shorter than a time in which heat conduction of the metal layer allows a side of the metal layer opposite to the laser incidence to reach the melt temperature.

23. The laser system of claim 22 wherein the laser beam is generated by either a fiber laser, solid-state laser, semiconductor laser, gaseous laser or dye laser.

24. The laser system of claim 22 where in the laser pulse is generated by self-pulsing, mode-locking, chirping, modulation, Q-switching, MOPA or the use of dispersive saturable absorber.

25. The laser system of claim 22 wherein the laser pulse length is in the approximate range of about 1 to 200 nanoseconds.

26. The laser system of claim 22 wherein the laser energy density is in the approximate range of 5 J/cm 2 to 150 J/cm 2 .

27. The laser system of claim 22 wherein the laser wavelength is generally in the range of about 0.4 to 4 microns.

28. The laser system of claim 27 wherein the laser wavelength is in the approximate range of 0.5 to 2 microns.

29. A method of making a multilayer product using a multilayer film structure comprising a metal layer and a first polymer layer bonded to each other, the metal layer positioned beneath the first polymer layer, the method comprising:

using one laser type to concurrently score the metal layer and the top polymer layer with a laser beam having a wavelength such that the beam is transmitted through the top polymer layer and absorbed by the metal layer sufficiently to generate a plume from the metal layer of sufficient energy to cut through the top polymer layer to form a scored multi-layer film; and fabricating the scored multilayer film structure to form the multilayer product.

30. The method of claim 29 wherein the laser source comprises a near infrared laser source.

31. The method of claim 29 wherein the laser source generates a sufficient secondary energy plume to cut the first polymer layer.

32. The method of claim 29 wherein the multi-layer film structure further comprises a second polymer layer on a side of the metal layer opposite from the first polymer layer.

33. The method of claim 29 wherein an adhesive layer is present between the metal layer and the second polymer layer.

34. The method of claim 33 and further comprising a plurality of polymer layers on a side of the metal layer as the first polymer layer and wherein all the polymer layers on the side of the first polymer layer are cut.