SURFACE PREPARATION USING OPTICAL ENERGY

A fabrication resource receives a base material such as metal or other suitable material. The fabrication resource applies optical energy to a surface of the base material. Application of the optical energy transforms a texture on the surface of the base material. Subsequent to transforming the texture on the surface of the base material, the fabrication resource then adheres a supplemental material such as paste including glass powder to the transformed texture on the surface. Application of heat to the paste fuses the glass powder of the applied paste into a glass layer that adheres to the transformed texture. The fabrication resource contacts an electronic circuit device onto an exposed facing of the glass layer and reheats the combination of the electronic circuit device, glass layer, and base material. The application of heat secures the electronic circuit device to the layer of glass and corresponding base material.

BACKGROUND

Conventional techniques of processing a surface can include sandblasting. In general, sandblasting is an abrasive operation in which sand (or other suitable material such as glass) is physically propelled at a high speed onto a surface. The target material to be sandblasted can be metal, wood, plastic, etc.

Typically, the purpose of sandblasting is to remove undesirable material from a respective surface. However, sandblasting can be performed for other reasons as well. For example, sandblasting can be performed to smooth a rough surface, roughen a smooth surface, shape a surface, etc.

During conventional sandblasting, a pressurized fluid such as air is typically used to propel the media towards the target surface. The force of the propelled media striking the target surface removes undesirable material. In certain instances, as mentioned, if the media is propelled at a substantially high velocity against a target object, the texture of the target object will be modified.

BRIEF DESCRIPTION

Conventional techniques of modifying a surface on a target object such as via sandblasting suffer from a number of deficiencies. For example, the media used to sandblast a surface can include contaminants, which sometimes adhere to the surface of the target object. Additionally, part of the sandblast media (possibly considered to be a contaminant) itself can adhere to crevices on the surface as formed by the sandblasting process. To remove the contaminants such as embedded sandblast media, the surface of the target object has to be cleaned. In certain instances, this is very difficult.

Moreover, it is typically difficult to precisely control which portion on the surface of the target object is to be sandblasted because the propulsion of sandblast media is somewhat random and difficult to control. For this reason, a roughness of the surface of the target object can vary substantially when sandblasting.

In contrast to conventional techniques, embodiments herein include a fabrication resource that is configured to produce a circuit assembly.

In one embodiment, the fabrication resource receives a base material such as metal or other suitable material. The base material can include a surface to be prepared by the fabrication resource. To prepare a surface, the fabrication resource applies optical energy to a surface of the base material. Application of the optical energy transforms a texture on the surface of the base material. Subsequent to transforming the texture on the surface of the base material, the fabrication resource then adheres a supplemental material such as glass or other suitable material to the transformed surface texture of the base material.

In accordance with further embodiments, adhering the supplemental material to the transformed texture on the surface of the base material can include: i) applying a paste to the transformed texture, the paste can include glass powder; and ii) applying heat to the paste disposed on the transformed surface texture, application of the heat fusing molten glass into a glass layer that adheres to the transformed texture; and iii) cooling the base material and glass layer.

Thereafter, the fabrication resource can be configured to adhere a device (or any suitable material) such as an electronic circuit device onto an exposed facing of the glass layer. As an example, adhering the electronic circuit device (an integrated circuit device) onto the exposed facing of the glass layer can include: i) contacting the electronic circuit device to the exposed facing of the glass layer, and ii) applying heat to a combination of the electronic circuit device, glass layer, and base material. The application of heat secures the electronic circuit device to the layer of glass.

Accordingly, embodiments herein can include fabricating an assembly. The assembly can be a multilayer be a multilayer assembly including: a base material, a surface texture of which is transformed via application of optical energy, a supplemental layer of material such as glass, and a circuit device. The supplemental material such as insulation material adheres to the transformed texture on the surface. The electronic circuit device adheres to an exposed facing of the glass layer opposite a facing of the glass layer adhered to the transformed surface texture.

In accordance with further embodiments herein, a fabrication resource can be configured to receive boundary location information defining a region on the surface of the base material. In other words, the boundary location information indicates a portion of the surface on base material that is to be prepared. The fabrication and assembly applies a sequence of optical pulses to specified locations such as within the boundaries as specified by the boundary location information. By way of non-limiting example, in one embodiment, the boundaries as specified by boundary location information define a contiguous region in which to produce the transformed texture (i.e., modified surface).

In yet further embodiments, the method of fabrication can include application of the sequence of optical pulses. Application of the sequence of optical pulses can include: applying a first optical pulse to a first location within the contiguous region, the first optical pulse creating a first surface modification such as a depression in the contiguous region; applying a second optical pulse to a second location within the contiguous region, the second optical pulse creating a second surface modification such as a depression in the contiguous region; applying a third optical pulse to a third location within the contiguous region, the third optical pulse creating a third surface modification such as a depression in the contiguous region; applying a fourth optical pulse to a fourth location within the contiguous region, the fourth optical pulse creating a fourth surface modification such as a depression in the contiguous region; and so on.

In comparison to an initial state in which a corresponding surface of the base material is smooth, the surface modifications (as produced by application of the optical energy) roughen the surface of the base material.

The surface modifications such as depressions formed by the optical pulses can overlap each other. For example, the second depression can at least partially overlap with the first depression; the third depression can at least partially overlap with the second depression; the fourth depression can at least partially overlap with the third depression; and so on.

The pattern of modifications such as depressions on the surface of the base material can be formed in any suitable manner. For example, in one embodiment, the fabrication resource scans a laser beam across the surface of the base material. The laser beam conveys a sequence of optical pulses (each pulse being a burst of optical energy) within the boundaries of the contiguous region to produce the transformed texture.

As discussed herein, the texture of the surface in the contiguous region can vary depending upon an amount of optical energy applied to the corresponding surface of the base material. Application of a higher optical energy to the surface typically results in a deeper depression (more substantial modification) and rougher surface. Application of lower optical energy to the surface of base material typically results in a more shallow depression (less substantial modification) and less rough surface.

The pattern of modifications on the surface of the base material can be formed via a single pass or multipass application of optical energy. For example, in one embodiment, the fabrication resource can be configured to first scan a generated laser beam in a first direction across the surface of the base material. This can be repeated in a raster manner to modify an entire region.

If further modification of the respective surface is desired, the fabrication resource then scans the laser beam in a second direction across the surface of the base material. In one embodiment, the second direction is substantially nonparallel with respect to the first direction. Embodiments herein can include scanning in any number of directions.

Accordingly, embodiments herein can include producing the transformed texture to be a cross hatched pattern of overlapping surface modifications produced by the optical energy.

Embodiments herein are beneficial over conventional techniques of sandblasting a respective surface to transform a texture of the surface. For example, first, because optical energy is used to modify the respective surface, there are no contaminants deposited on the surface. Thus, no contaminants are trapped between the glass layer and the surface of the base material. Second, the optical energy can be precisely directed to a particular region of interest on the target object. This reduces an amount of wasted surface area or usable space on a surface of the target object. Third, the optical energy can be precisely controlled to produce a desired amount of roughness on the surface of the object. Additional benefits are discussed below.

These and other embodiment variations are discussed in more detail below.

As mentioned above, note that embodiments herein can include a configuration of one or more computerized devices, hardware processor devices, assemblers, fabrication resources, or the like to carry out and/or support any or all of the method operations disclosed herein. In other words, one or more computerized devices, processors, digital signal processors, assemblers, etc., can be programmed and/or configured to perform the method as discussed herein.

Additionally, although each of the different features, techniques, configurations, etc., herein may be discussed in different places of this disclosure, it is intended that each of the concepts can be executed independently of each other or in combination with each other. Accordingly, the one or more present inventions, embodiments, etc., as described herein can be embodied and viewed in many different ways. Also, note that this preliminary discussion of embodiments herein does not specify every embodiment and/or incrementally novel aspect of the present disclosure or claimed invention(s). Instead, this brief description only presents general embodiments and corresponding points of novelty over conventional techniques. For additional details and/or possible perspectives (permutations) of the invention(s), the reader is directed to the Detailed Description section and corresponding figures of the present disclosure as further discussed below.

DETAILED DESCRIPTION

FIG. 1is an example diagram of a fabrication environment in which to transform a surface texture on base material according to embodiments herein.

As shown, fabrication environment100includes fabrication resource110. Fabrication resource110includes control resource140, optical energy generator150, and beam steering resource160. As its name suggests, the control resource140controls optical energy generator150and beam steering resource160.

By way of non-limiting example, in one embodiment, the optical energy generator150is a laser device configured to generate optical energy111such as a laser beam. The beam steering resource160can include one or more mirrors. The controller resource140controls an orientation of the minors to steer the received optical energy111in any suitable manner towards base material in131.

Via application and steering of the optical energy111to the original surface texture121on base material131, the fabrication resource110converts a corresponding portion of the surface of base material131into transformed surface texture122. A degree of roughness associated with the transformed surface texture122can vary depending upon settings such as a power level of optical energy applied to corresponding locations on base material131.

Multiple parameters of the optical energy generator150can be controlled to produce transformed surface texture122on base material131. For example, the rate of sweeping optical energy111across the surface of base material131can be controlled; a magnitude of the frequency of pulses in optical energy111can be controlled; and so on.

Base material131can be any suitable material such as metal, plastic, etc. base material131may be received in any suitable form. As shown, a top surface to which the optical energy111is applied can be substantially planar.

In accordance with further embodiments herein, the controller resource140in fabrication resource110can be configured to receive surface preparation information132indicating how to prepare a corresponding surface of base material131.

Surface preparation information132can include settings information136. In one embodiment, the settings information136indicates settings associated with optical energy generator150. Via settings information136, the controller resource140can be informed how to control optical energy generator150such that the optical energy generator150produces optical energy111at a desired power level, pulse frequency, etc.

Surface preparation information132can also include location information135. In one embodiment, location information135indicates which region or locations on base material131to apply corresponding generated optical energy111. By way of non-limiting example, in one embodiment, the location information135can define a contiguous region on the surface of the base material131in which to apply optical energy111.

Thus, in one embodiment, the fabrication resource110produces optical energy111such as a sequence of optical pulses in accordance with settings information136. The controller resource140uses the location information135to steer the sequence of optical pulses to locations on the surface of base material131such as within a bounded or contiguous region to produce transformed surface texture122.

FIG. 2is an example perspective view illustrating transformation of a surface texture according to embodiments herein.

As shown, a region220on top surface of base material131includes transformed surface texture122. Original surface texture121on surface of base material131can be substantially smooth (i.e., a low degree of roughness). In comparison to the original surface texture121, transformed surface texture122as produced via application of optical energy111on region220has a higher degree of roughness.

A degree of roughness associated with transformed surface texture122can vary depending upon the embodiment. For example, the region220on-base material131can be substantially rougher by producing a higher level of optical energy111. Lower levels of optical energy111will produce a less rough surface texture. As previously discussed, settings information136can indicate and/or control a degree of roughness associated with transformed surface texture122.

FIG. 3is an example top view diagram illustrating a single pass preparation of a surface on a base material according to embodiments herein.

The pattern of modifications such as depressions, craters, spots, etc., on the surface of the base material can be formed via a single pass or multi-pass application of optical energy.

By way of non-limiting example, in the single pass application as shownFIG. 3, the fabrication resource110can be configured to first scan a generated beam of optical energy111such as a sequence of optical pulses in a direction310across the surface of the base material131to modify the original surface texture121and produce transformed surface texture122.

Scanning of the optical energy111can include can include: applying a first optical pulse to a first location within the contiguous region220, the first optical pulse creating a first surface modification305-1such as a depression in the contiguous region220; applying a second optical pulse to a second location within the contiguous region220, the second optical pulse creating a second surface modification305-2such as a depression in the contiguous region220; applying a third optical pulse to a third location within the contiguous region220, the third optical pulse creating a third surface modification305-3such as a depression in the contiguous region220; and so on.

The surface modifications305such as depressions formed by the optical pulses can overlap each other. For example, the second modification305-2can at least partially overlap with the first modification305-1; the third modification305-3can at least partially overlap with the second modification305-2; and so on. The process of generating optical energy111and steering the optical energy111can be repeated in a rasterized manner to modify the texture of base material131in the region220.

Accordingly, in one embodiment, the fabrication resource110repeatedly scans optical energy111such as a laser beam across the surface of the base material131. The optical energy111conveys a sequence of optical pulses within region220to produce the transformed surface texture122. As previously discussed, a corresponding roughness associated with the transformed surface texture122in the contiguous region220can vary depending upon an amount of optical energy applied to the corresponding surface of the race material.

This single pass application of optical energy111can complete preparation of the surface of base material131.

FIG. 4is an example top view diagram illustrating a multiple pass preparation of a surface on a base material according to embodiments herein.

In accordance with another example embodiment, the fabrication resource110can be configured to perform a multi-pass preparation of the surface of base material131as opposed to a single pass surface preparation as discussed above.

For example, as shown, in a first direction310, the fabrication resource110performs a first pass application of optical energy111to region220in a manner as previously discussed. Thereafter, on the second pass, the fabrication resource110generates and scans a respective beam of optical energy111in a second direction420across the surface of the base material131.

By way of non-limiting example, the second direction420is substantially nonparallel with respect to the first direction310. In this way, embodiments herein can include scanning generated optical energy111in any number of directions within region220.

Accordingly, embodiments herein can include producing the transformed texture to be a cross hatched pattern of overlapping surface modifications produced by the optical energy.

FIG. 5Ais an example side view diagram illustrating surface preparation according to conventional techniques.

FIG. 5Bis an example side view diagram illustrating surface preparation according to embodiments herein.

Embodiments herein are beneficial over conventional techniques of sandblasting a respective surface505to transform a texture of the surface505.

For example, first, because optical energy111is used to modify the respective surface of base material131to form transformed surface texture122, there are no contaminants deposited on the surface of base material131. Thus, no contaminants are trapped between a subsequently applied glass layer and the transformed surface texture122of the base material131. Second, the optical energy111can be precisely directed to a particular region of interest on the target object such as base material131. This reduces an amount of wasted surface area on the target object. Third, the optical energy111can be precisely controlled to produce a desired amount of roughness on the surface of the base material131.FIG. 6is an example top view pictorial diagram illustrating a transformed surface texture according to embodiments herein.

FIG. 7Ais an example side view diagram illustrating application of a layer of a paste material and subsequent application of heat according to embodiments.

As previously discussed, the fabrication resource110applies optical energy111to a surface of the base material131to produce transformed surface texture122. Application of the optical energy111transforms a texture on the surface of the base material131between boundary B1and boundary B2.

Subsequent to transforming the texture on the surface of the base material131, the fabrication resource110(or other suitable resource) adheres a layer of supplemental material such as glass or other suitable insulation material to the transformed surface texture122of base material131.

To achieve this end, the fabrication resource110applies material720-1(i.e., supplemental material) to the transformed surface texture122between boundary M1and boundary M2. By way of non-limiting example, this can include: first applying a material720-1such as a paste material to the transformed surface texture122.

The material720-1can be a paste including glass powder. In one embodiment, the paste material (such as material720-1) is lead free sealing glass paste part number DL11-205manufactured by Ferro Electronic Materials ™.

The thickness of the applied paste can vary. By way of a non-limiting example, the thickness of paste applied to the laser prepared surface is between 50 and 200 microns, although the thickness can be outside this range if desired. By way of a non-limiting example, where flow out of material is controlled when heating, the thickness of the applied paste is in a range such as between 117 and 167 microns.

The fabrication resource110applies heat750to the material720-1. By further way of a non-limiting example, prior to heating, the thickness may be117to167microns. Application of the heat750melts the glass powder to form a layer of material720-2(e.g., a layer of insulation material such as glass) as shown inFIG. 7B. After application of the heat and melting of layer720-1, in one embodiment, the glass media burns off such that the thickness of layer720-2is between52and87microns. In one embodiment, as shown, the proper preparation of the transformed surface texture122in accordance with surface preparation information132prevents flowing of material720-1outside of boundary M1and boundary M2even after the glass in material720-1melts due to application of heat750.

Note that the optical energy111can be controlled such that a roughness of transformed surface texture122has a Rz roughness value between 2.5 and 11.0 microns (or any suitable range) depending on whether it is desirable that corresponding layer of material720or820on base material131flows or not when melted.

Roughness values of transformed surface texture122allow less flow at the low end of the Rz range (near 3.5) and progressively more flow at the higher end of the Rz range (near 9.5) when paste is melted. In a manner as shown, a surface roughness of transformed surface texture122in the lower end of the range near Rz=4.0 allows relatively little or no flow of layer720-2along the surface of base material131when melting material720-1.

FIG. 7Bis an example side view diagram illustrating a layer of material disposed on transformed surface texture according to embodiments herein.

After cooling of the base material131and layer of material720-2, and because transformed surface texture122has some degree of roughness as a result of surface preparation as previously discussed, the layer of material720-2strongly adheres to the transformed surface texture122. Again, preparation of transformed surface texture122prevents flowing of such material along the transformed surface texture122. More specifically, the resulting layer material720-2remains within boundary M1and boundary M2.

Thus, in one embodiment, the resulting region covered by material720-2is substantially the same as the original region of base material131on which material720-1was applied.

FIG. 7Cis an example side view diagram illustrating mounting of a device according to embodiments herein.

Subsequent to adhering layer of material720-2to transformed surface texture122, the fabrication resource110mounts a corresponding circuit device762onto exposed surface of material720-2.

In one embodiment, the fabrication resource110receives an object such as circuit device760. The fabrication resource110places the circuit device762onto an exposed surface of material720-2. Subsequent to contacting the electronic circuit device762to the exposed facing of the glass layer, the fabrication resource110applies heat to a combination of the electronic circuit device762, layer of material720-2, and base material131. The application of heat760secures a backside of the electronic circuit device762to the layer of material720-2.

Accordingly, the resulting multilayer assembly can include: a layer of base material131, layer of material720-2such as insulation layer, and a corresponding object electronic circuit device762. As previously discussed, a texture of the surface on the base material131is transformed via application of optical energy111. The layer of material720-2adheres to the transformed surface texture122. The electronic circuit device762adheres to the layer of material720-2.

FIG. 8Ais an example side view diagram illustrating application of a layer of a paste material and subsequent application of heat according to embodiments.

In this example embodiment, the fabrication resource110applies material820-1to the transformed surface texture122in a region between boundary M1and boundary M2as shown. The fabrication resource110initiates application of heat850to the material820-1disposed on transformed surface texture122. Assume that the transformed surface texture122has a degree of roughness higher than a given threshold value. For example, assume that the roughness of transformed surface texture122inFIGS. 8A,8B, and8C, is substantially rougher than the transformed surface texture122inFIGS. 7A,7B, and7C. In such an instance, due to a high degree of roughness associated with transformed surface texture122, application of heat850causes the material820-1to melt and flow outside of boundary M1and boundary M2as shown inFIG. 8B.

As mentioned, in one embodiment, the optical energy111is controlled such that a roughness of transformed surface texture122has a roughness Rz value between 2.5 and 11.0 (or any suitable range) depending on whether it is desirable that layer of material820on base material131flows or not when melted. In a manner as shown, a surface roughness of transformed surface texture122in the higher end of the range near Rz=9.5 allows relatively substantial flow of layer820-2along the surface of base material131when melting material820-1.

FIG. 8Bis an example side view diagram illustrating the flow of a layer of material disposed on transformed surface texture according to embodiments herein.

As shown, in this example embodiment, while in a molten state, the material820-2flows outside of boundary M1and boundary M2. Accordingly, the degree of roughness associated with the transformed surface texture122can be controlled depending upon whether it is desirable that the supplemental material820-1in a molten state flow or not flow along a surface of base material131.

FIG. 8Cis an example side view diagram illustrating mounting of a device according to embodiments herein.

In a similar manner as previously discussed, the fabrication resource110can receive circuit device and862. The fabrication resource110contacts a backside of the circuit device862onto layer of material820-2. The fabrication resource110then applies heat862to circuit device862and the layer of material820-2. Application of heat860affixes the circuit device862to material820-2.

FIG. 9is a flowchart900illustrating an example method according to embodiments. Note that there will be some overlap with respect to concepts as discussed above.

In processing block910, a fabrication resource110(i.e., an assembler) receives base material131.

In processing block915, the fabrication resource110applies optical energy111to a surface of the base material131. Application of the optical energy111transforms an original texture of the base material131into transformed surface texture122.

In processing block920, the fabrication resource110receives location information135defining a contiguous region on the surface of the base material131.

In processing block925, the fabrication resource110applies optical energy111such as a sequence of optical pulses within boundaries as specified by the location information135. As previously discussed, the location information135can define boundaries associated with the region220.

In processing block930, the fabrication resource110adheres a supplemental material to the transformed surface texture122.

In processing block935, the fabrication resource110applies material such as a paste to the transformed surface texture122. As previously discussed, in one embodiment, the paste can include among other things, glass powder.

In processing block940, the fabrication resource110applies heat to the paste. Application of the heat melts the glass powder. The resulting molten glass fuses together to form a glass layer adhering to the transformed surface texture122.

In processing block945, the fabrication resource110cools the base material131and corresponding glass layer.

In processing block950, the fabrication resource110affixes an electronic circuit device onto an exposed facing of the glass layer.

In processing block955, the fabrication resource110contacts the electronic circuit device to the exposed facing of the glass layer.

In processing block960, the fabrication resource110applies heat to a combination of the electronic circuit device, glass layer, and base material131.

Note again that techniques herein are well suited for surface preparation using optical energy. However, it should be noted that embodiments herein are not limited to use in such applications and that the techniques discussed herein are well suited for other applications as well.