Abstract:
A laser machining device is capable of simultaneously machining two- or three dimentional patterns on the surface of a workpiece. A micromirror array positioned within a laser cavity generates a patterned plurality of laser beamlets which can be homogenized and deflected by a second micromirror array onto the surface of a workpiece to create a two-dimensional pattern. Alternatively, the second micromirror array can deflect laser beamlets of unequal energy density to produce a three-dimensional pattern.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority of provisional U.S. Application Serial No. 60/207,066 filed on May 25, 2000 and entitled “Modulation of Laser Energy with a Predefined Patter” by Jay J. Brandinger, Brian D. Hoffman and Edward To Polkowski the entire contents and substance of which are hereby incorporated in total by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to an apparatus and method for simultaneous laser machining of defined patterns on the surface of a workpiece. 
     2. Description of Related Art 
     Lasers are used for a variety of materials machining purposes including drilling, contouring surfaces, cutting, scribing, trimming and pattern depositions. Typically, carbon dioxide lasers are used for scribing, drilling and machining. Excimer lasers are used for film ablation, flex circuits and relief cutting. YAG lasers are used for trimming resistors, capacitors, marking and cutting of metals, semiconductors and absorptive synthetics. An apparatus and method for sequentially drilling small holes in a workpiece using a laser are described by LaPlante et. al in U.S. Pat. No. 5,168,454. Orienting and focusing a single laser beam to scan a workpiece using such a method is slow and inefficient compared to parallel processing using multiple laser beams. 
     In the past, the creation of a plurality of beamlets for laser machining has been dependent on external beam shaping optics and deflecting devices to machine different points on a workpiece simultaneously. Typically, optical interface, scattering and transmission losses reduce system efficiency, requiring increased energy from the laser. Further, the use of a separate deflecting device not only increases system complexity but also increases the optical path length and required alignment precision. 
     In U.S. Pat. No. 5,676,866, Baumen et al. describes a microlens optical element which divides a laser beam into a plurality of beamlets which in turn are deflected by separate independent mirrors. This arrangement permits the simultaneous machining of a workpiece, e.g., the drilling of multiple holes. The position of the individual beams can be rapidly displaced in their coordinate location or with sufficient mirror deflection, removed from the optical path. The complexity and optical inefficiency of this system adds significant structure and cost. 
     In U.S. Pat. No. 6,037,564, Tatah describes a diffractive element which diffracts a single laser beam into a plurality of beamlets that are in turn deflected by individual micromirrors so as to simultaneously machine a workpiece. The micromirrors are two state devices either directing the beamlets to the workpiece or away from it. Galvo mirrors are used to displace the beamlets in their coordinate position. The complexity and optical inefficiency of this system adds significantly more structure and cost when compare to the Baumen et. al. technique described above. 
     Other laser machining devices such as described in U.S. Pat. Nos. 5,268,554 and 5,113,055 have the disadvantages of sequential scanning and changing beam size with deflection. 
     In U.S. Pat. No. 5,864,430, Dickey et al. discloses a laser with a Gaussian beam profile which is modified to produce a beam with a uniform profile using the Fourier transform properties of lenses. Complex optical elements, including a telescope to control the beam radius, transform lenses to set the target spot and focal length. Phase elements are required to determine the quality of the system. The system is complex and requires precision alignment, which adds to its cost. Further, physical elements must be changed to change beam characteristics. 
     Other beam shaping systems such as described in U.S. Pat. Nos. 5,925,271, 5,848,091 and 4,744,615 use fixed optical elements external to the laser to shape the beam profile. Optical interface, scattering and transmission losses reduce system efficiency requiring increased energy from the laser resulting in cost and complexity disadvantages. 
     It is clear from the foregoing analysis that a serious need exists for a laser machining apparatus which avoids the problem of non-uniform laser beam profiles which results from multimode oscillations in the laser cavity, and which allows for the creation of multiple beamlets from a single laser beam for rapid material machining. Prior art solutions use external optical elements and mirrors to solve both of these problems resulting in complex structures, optical inefficiency, precision alignment and significant added cost. 
     SUMMARY OF THE INVENTION 
     Briefly described, the invention comprises a laser apparatus for simultaneous machining at several points on the surface of a workpiece. The apparatus includes a laser laser cavity containing a first micromirror array having a first plurality of individual micromirrors for generating a patterned beam of discrete laser beamlets from a single laser beam. The apparatus also includes a second micromirror array having a second plurality of individual micromirrors for modifying the patterned plurality of laser beamlets and deflecting them onto several points on the surface of a workpiece. Also included in the apparatus are means for controlling each of the micromirrors of both micromirror arrays so that each is changeable in position independently of each other. When the individual micromirrors of the second array are positioned to reflect laser beamlets of equal energy distribution, a two-dimentional pattern is produced on the surface of the workpiece. Alternatively, when the individual micromirrors of the second array are positioned to reflect laser beamlets of unequal energy distribution, a three-dimentional pattern is produced on the surface of the workpiece. 
     The invention may be more fully understood by reference to the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic diagram of a preferred apparatus for the simultaneous laser machining of defined patterns according to the present invention. 
     FIG. 2 illustrates the laser generating element of FIG. 1 in more detail. 
     FIGS. 3 a,b,c    4  illustrates the types of arbitrary pattern shapes that can be created by the first micromirror array. 
     FIG. 4 illustrate the first array of micromirrors on FIG. 2 in more detail. 
     FIG. 5 illustrates an alternate embodiment of the laser of FIG.  1 . 
     FIG. 6 illustrates a selection of deformable mirror arrays. 
     FIG. 7 is a photomicrograph of a single mirror element of a 6×6 displacement mirror array. 
     FIG. 8 is a schematic diagram of a Thin-film Micromirror Array. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     During the course of this description like numbers will be used to identify like elements according to the different views that illustrate the invention. 
     A preferred embodiment of the apparatus of this invention for simultaneous machining of defined patterns is shown in FIG.  1 . Laser  12  has a laser cavity  14 , which contains a first micromirror array  16  for generating a plurality of laser beamlets  20   a,b,c  . . . , and a partial reflector  18 . Each of the individual beamlets  20   a,b,c , . . . emerging from laser  12  via partial reflector  18  is imaged by first imaging means  22  onto an addressable second micromirror array  24 , which modulates the beamlets  20   a,b,c  . . . , and in turn deflects them through a second imaging means  30  onto a workpiece  40 . Spatial beam limiting is provided by optical element  26 . The positions of the individual beamlets  20   a,b,c , . . . impinging on the workpiece  40  are adjusted by deflection of the mirrors of the second micromirror array  24 , based on input from computer  32 , through first interface board  34 . 
     In FIG. 1, the beamlets  20   a,b,c  . . . are imaged by a beam splitter  28 , which deflects a small portion of the beamlets on to a pattern verifier  36 , so as to determine the position and integrity of the beamlets. The pattern verifier  36 , in turn, provides the computer  32  with the electrical image for comparison with the chosen material machining pattern input  38 . The location of index marks  42 , on the workpiece  40 , are determined by the feature location and endpoint detection device  44 . 
     As shown, illumination of the workpiece index marks  42  is provided by the beamlets but it is also understood that a separate workpiece illuminator may also be used to locate index marks  42 . End point detection is provided by the reflecting surface of the workpiece holder  46 . The beamlets  20   a,b,c  . . . shine through the drilled hole  48 , reflect off the surface of the holder  46 , and are detected by the feature and location device  44 . This information is feed to computer  32 , which identifies the corresponding micromirror of micromirror array  16 , to be turned off. The computer  32 , turns off the appropriate micromirror through interface  50 . 
     The workpiece holder  46 , is mounted on an x-y table consisting of a base  52 , and x-y adjusting micrometers  54 , and  56 . It is understood that the micrometers  54  and  56  can be servo driven under computer control to position the workpiece  46  appropriately. 
     FIG. 2 illustrates the laser of FIG. 1 in more detail. The laser  12 , consists of laser cavity  14 , partial reflector  18 , a first micromirror array  16 , and an a source of energy  58  and an amplifying medium  60 . The micromirror array  16 , is simplified by showing only two mirrors, one ( 16   a ) positioned to reflect the laser energy parallel to the cavity  14  axis and the other ( 16   b ) reflecting the laser energy in a zig-zag path within the cavity. 
     For micromirror  16   a , which is positioned to reflect energy parallel to the axis of laser cavity  14 , multiple passes through the amplifying medium  60  occur, and laser energy is generated sufficient to provide an output beam which emanates from the partial reflector  18  at the end of the laser cavity  14  opposite the micromirror array  16 . Thus, the output of the laser  12  for each of such parallel aligned mirrors is a small beamlet, which when taken together comprise the plurality of beamlets  20 . For micromirror  16   b , which is so as to reflect the energy in a zigzag path through the cavity  14 , no amplification takes place and no laser output beam results. 
     Since each individual micromirror  16   a,b,c , . . . can be set to reflect energy either parallel or non-parallel to the axis of laser cavity  14 , an array of laser output beamlets can be formed to produce two-dimensional patterns for a variety of applications including photolithography and material ablation. Further, since the beamlets can be turned on or off by computer  32 , in accordance with input pattern  38 , contoured patterns as illustrated in FIGS. 3 a,b,c  can be produced and imaged onto workpiece  50 , for material machining. 
     It is understood that the micromirrors maybe operated in various modes including tilt, rotation, displacement and combinations thereof to produce various beamlet characteristics. Where displacement is used, different beamlet wavefronts are created, i.e. different lasing modes. 
     An individual micromirror  16   a  of micromirror array  16  is depicted in FIG.  4 . The reflectivity of each mirror  16   a,b,c  . . . in the micromirror array  16  is optimized for the laser cavity wavelength. For operation at a particular wavelength the mirrors may be coated with additional or different reflective materials that are well known in the state of the art. For example, in the Digital Mirror Device (DMD) manufactured by Texas Instruments of Dallas, Tex., the individual mirrors are made of aluminum and can be coated for optimum reflectivity with multiple dielectric layers. It is understood that the Thin film Micromirror Array manufactured by Daewoo Electronics of Souel, Korea, and described below with respect to FIG. 7, as well as other devices made by other manufacturers of standard MEMS, are suitable for use in the device of FIG.  2 . 
     In the apparatus shown in FIG. 1, micromirror array  16 , may be replaced by a deformable mirror array  16 D as shown in FIG.  5 . The simplified drawing illustrates two deformable micromirrors,  16 D a  and  16 D b , of micromirror array  16 D, with different axial displacements. These displacements are arranged in accordance with the desired beam profile set by input  38 , and fed to array  16 D, through the interface board  50 . Different beam profiles can be produced including single and multi-beam Gaussians, rectangular, and triangular. 
     FIG. 6 illustrates several deformable mirrors manufactured by Xinetics Inc. Model number DM37PMNS4, has 37 mirrors deformable to 4 mm displacement, with electroceramic actuators spaced 7 mm apart to provide an aperture of 1.85 inches. The Xinetics drivers have a digital front end that uses a parallel interface which can be connected to a computer at rates up to 10 million bits per second. The actuators have a 2 kHz full amplitude bandwidth. Other higher resolution devices are available from Xinetics of Devens, Mass. 
     FIG. 7 illustrates a micromirror displacement element of a 6×6 array fabricated by MEMS Optical that maybe used as an alternate. 
     The individual micromirrors of second micromirror array  24  can be positioned to reflect laser beamlets of equal energy density, thereby acting as a homogenizer and producing a two-dimensional pattern on the surface of the workpiece. Alternatively, individual micromirrors of micromirror array  24  can be positioned to reflect laser beamlets of unequal energy density, thereby producing a three-dimensional pattern on the surface of the workpiece. 
     An addressable micromirror array  24  suitable for use in the present invention is shown in FIG.  8 . The array  24 , known as a Thin film Micromirror Array (TMA), is manufactured by Daewoo Electronics, and consists of 1024×768, 50×50 micron mirrors  24   a,b,c  . . . , deflected by piezoelectric actuators  62   a,b,c , . . . that in turn are addressed by an active matrix  64 , and are linearly deflected as a function of the applied signal voltage. The TMA panel size is 2.54 inches diagonal. Each deflected laser beamlet is reimaged on to the workplace and its position adjusted by varying the tilt of mirrors  24   a,b,c  . . . Other acceptable linearly deflected micromirror arrays are made by Standard MEMS. 
     While the invention has been described with reference to a preferred embodiment thereof, it will be appreciated by those of ordinary skill in the art that modifications can be made to the structure and elements of the invention without departing from the spirit and scope of the invention as a whole.