Reel-to-reel slug removal methods and devices in FPC fabrication

1. A method to remove a slug from a metal foil in manufacturing a flexible printed circuit using a reel-to-reel machine, the method comprising:

feeding a metal foil into the reel-to-reel machine wherein the metal foil has a first surface and a second surface, the second surface being opposite of said first surface;

laser ablating, using a first laser scanner, an edge of an intended circuitry pattern on the metal foil to create a circuitry pattern and a slug;

adhering a sacrificial liner to the second surface of the metal foil reel-to-reel;

applying a coverlay reel-to-reel onto the first surface of the metal foil on the fly in the reel-to-reel machine;

removing the slug from the circuitry pattern by

a. applying compressed air to the slug on the fly, or

b. peeling off the sacrificial liner from the circuitry pattern reel-to-reel, or

c. both.

2. The method as recited in claim 1 , wherein the sacrificial liner is either a thermal debonding sheet or a UV debonding sheet, and further comprising selectively irradiating laser energy to an area of the sacrificial liner that entirely or substantially corresponds to the circuitry pattern.

3. The method as recited in claim 2 further comprising curing the coverlay, and removing the sacrificial liner from the circuitry pattern reel-to-reel, leaving the circuitry pattern adhered to the coverlay.

4. The method as recited in claim 2 , after the peeling off step, detecting a presence of a debonding residue on the second surface of the circuitry pattern and cleaning said debonding residue with a second laser scanner.

5. The method as recited in claim 4 , wherein the second laser scanner utilizes a CO2 laser.

6. The method as recited in claim 1 , during the laser ablating step, ablating the slug on the fly with said first laser scanner to create multiple pieces of the slug.

7. The method as recited in claim 1 , during the laser ablating step, using said first laser scanner to ablate an edge of a tie bar out of said slug, wherein the tie bar physically connects a first portion of the circuitry pattern to an adjacent portion of the circuitry pattern, thereby structurally supporting the first portion to the adjacent portion of the circuitry pattern.

8. The method as recited in claim 7 , wherein after removing the slug from the circuitry pattern, using a second laser scanner to ablate the tie bar to physically separate it from the circuitry pattern.

9. The method as recited in claim 8 , wherein the first and the second laser scanners each utilize at least one of a green laser, a CO2 laser, and a UV laser.

10. The method as recited in claim 1 , wherein the coverlay is applied before the peeling off step.

11. The method as recited in claim 1 , passing the metal foil through a vacuum or near-vacuum enclosure, and wherein the laser ablating step using the first laser scanner is performed while the metal foil is in the vacuum or near-vacuum enclosure.

12. The method as recited in claim 1 , further comprising using a second laser scanner to selectively ablate away a portion of an adhesive layer of the coverlay, before applying the coverlay onto the metal foil, and wherein applying the coverlay takes place after laser ablating the edge of the intended circuitry pattern.

13. The method as recited in claim 12 , wherein the portion of an adhesive layer being selectively ablated away corresponds entirely or substantially to an area of the slug.

14. The method as recited in claim 13 , wherein the adhesive layer has a stronger peel strength than an adhesive layer on the sacrificial liner.

15. The method as recited in claim 14 , wherein peeling off the sacrificial liner takes places after the coverlay is applied to the metal foil, and wherein the sacrificial liner is either a thermal debonding sheet or a UV debonding sheet, and further comprising selectively irradiating laser energy to an area of the sacrificial liner that entirely or substantially corresponds to the circuitry pattern.