Patent ID: 8857234
Filing Date: 2014-10-14
Classification: B81C

Abstract:
1. A method for producing microscale metal or metal alloy structures, said method comprising the steps of: (a) providing a roller having surface features whose sizes and shapes are complementary to the sizes and shapes of the desired microscale structures, wherein the roller comprises a refractory metal or refractory metal alloy; and wherein a bond inhibitor layer adheres to the refractory metal or refractory metal alloy; wherein the bond inhibitor layer is selected from the group consisting of metal carbides, metal borides, and metal nitrides; (b) simultaneously rolling and pressing a metal plate or metal alloy plate with the roller to impress microscale structures into the plate; wherein at least one of the microscale structures has at least one dimension between about 1 micron and about 10 microns; wherein the plate comprises copper, aluminum, a copper alloy, or an aluminum alloy; and wherein said simultaneous rolling and pressing step occurs at a temperature below 40% of the melting point of the plate; and (c) continuing step (b) for a plurality of rotations of the roller on the same plate, either to produce a plurality of substantially identical high aspect ratio microscale metal or metal alloy structures on the plate, or to produce one or more continuous microscale structures on the plate having at least one dimension that is longer than the circumference of the roller, or both.