Source: http://www.google.com/patents/US7250101?dq=4316055
Timestamp: 2014-07-25 07:25:52
Document Index: 554080021

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patent US7250101 - Electrochemically fabricated structures having dielectric or active bases ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsMultilayer structures are electrochemically fabricated on a temporary (e.g. conductive) substrate and are thereafter bonded to a permanent (e.g. dielectric, patterned, multi-material, or otherwise functional) substrate and removed from the temporary substrate. In some embodiments, the structures are...http://www.google.com/patents/US7250101?utm_source=gb-gplus-sharePatent US7250101 - Electrochemically fabricated structures having dielectric or active bases and methods of and apparatus for producing such structuresAdvanced Patent SearchPublication numberUS7250101 B2Publication typeGrantApplication numberUS 10/434,493Publication dateJul 31, 2007Filing dateMay 7, 2003Priority dateMay 7, 2002Fee statusPaidAlso published asUS20040004002, WO2003095711A2, WO2003095711A3Publication number10434493, 434493, US 7250101 B2, US 7250101B2, US-B2-7250101, US7250101 B2, US7250101B2InventorsJeffrey A. Thompson, Adam L. Cohen, Michael S. Lockard, Dennis R. SmalleyOriginal AssigneeMicrofabrica Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (40), Non-Patent Citations (11), Referenced by (8), Classifications (16), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetElectrochemically fabricated structures having dielectric or active bases and methods of and apparatus for producing such structuresUS 7250101 B2Abstract Multilayer structures are electrochemically fabricated on a temporary (e.g. conductive) substrate and are thereafter bonded to a permanent (e.g. dielectric, patterned, multi-material, or otherwise functional) substrate and removed from the temporary substrate. In some embodiments, the structures are formed from top layer to bottom layer, such that the bottom layer of the structure becomes adhered to the permanent substrate, while in other embodiments the structures are form from bottom layer to top layer and then a double substrate swap occurs. The permanent substrate may be a solid that is bonded (e.g. by an adhesive) to the layered structure or it may start out as a flowable material that is solidified adjacent to or partially surrounding a portion of the structure with bonding occurs during solidification. The multilayer structure may be released from a sacrificial material prior to attaching the permanent substrate or it may be released after attachment.
RELATED APPLICATIONS This application claims benefit of U.S. Provisional Patent Application Nos. 60/379,177, filed on May 7, 2002, and 60/442,656, filed on Jan. 23, 2003, both of which are hereby incorporated herein by reference as if set forth in full.
FIELD OF THE INVENTION The present invention relates generally to the field of electrochemical fabrication and the associated formation of three-dimensional structures (e.g. parts, objects, components, or devices) via a layer-by-layer build up of deposited materials and to the processing of such structures after layer formation is complete so that the structures are transferred from a build substrate (i.e. temporary substrate) to a structural substrate.
BACKGROUND OF THE INVENTION A technique for forming three-dimensional structures (e.g. parts, components, devices, and the like) from a plurality of adhered layers was invented by Adam L. Cohen and is known as Electrochemical Fabrication. It is being commercially pursued by Microfabrica Inc. (formerly MEMGen� Corporation) of Burbank, Calif. under the name EFAB�. This technique was described in U.S. Pat. No. 6,027,630, issued on Feb. 22, 2000. This electrochemical deposition technique allows the selective deposition of a material using a unique masking technique that involves the use of a mask that includes patterned conformable material on a support structure that is independent of the substrate onto which plating will occur. When desiring to perform an electrodeposition using the mask, the conformable portion of the mask is brought into contact with a substrate while in the presence of a plating solution such that the contact of the conformable portion of the mask to the substrate inhibits deposition at selected locations. For convenience, these masks might be generically called conformable contact masks; the masking technique may be generically called a conformable contact mask plating process. More specifically, in the terminology of Microfabrica Inc. such masks have come to be known as INSTANT MASKS� and the process known as INSTANT MASKING� or INSTANT MASK� plating. Selective depositions using conformable contact mask plating may be used to form single layers of material or may be used to form multi-layer structures. The teachings of the '630 patent are hereby incorporated herein by reference as if set forth in full herein. Since the filing of the patent application that led to the above noted patent, various papers about conformable contact mask plating (i.e. INSTANT MASKING) and electrochemical fabrication have been published:
1. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, �EFAB: Batch production of functional, fully-dense metal parts with micro-scale features�, Proc. 9th Solid Freeform Fabrication, The University of Texas at Austin, p161, August 1998. 2. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, �EFAB: Rapid, Low-Cost Desktop Micromachining of High Aspect Ratio True 3-D MEMS�, Proc. 12th IEEE Micro Electro Mechanical Systems Workshop, IEEE, p244, January 1999. 3. A. Cohen, �3-D Micromachining by Electrochemical Fabrication�, Micromachine Devices, March 1999. 4. G. Zhang, A. Cohen, U. Frodis, F. Tseng, F. Mansfeld, and P. Will, �EFAB: Rapid Desktop Manufacturing of True 3-D Microstructures�, Proc. 2nd International Conference on Integrated MicroNanotechnology for Space Applications, The Aerospace Co., April 1999. 5. F. Tseng, U. Frodis, G. Zhang, A. Cohen, F. Mansfeld, and P. Will, �EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process�, 3rd International Workshop on High Aspect Ratio MicroStructure Technology (HARMST'99), June 1999. 6. A. Cohen, U. Frodis, F. Tseng, G. Zhang, F. Mansfeld, and P. Will, �EFAB: Low-Cost, Automated Electrochemical Batch Fabrication of Arbitrary 3-D Microstructures�, Micromachining and Microfabrication Process Technology, SPIE 1999 Symposium on Micromachining and Microfabrication, September 1999. 7. F. Tseng, G. Zhang, U. Frodis, A. Cohen, F. Mansfeld, and P. Will, �EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process�, MEMS Symposium, ASME 1999 International Mechanical Engineering Congress and Exposition, November, 1999. 8. A. Cohen, �Electrochemical Fabrication (EFAB�)�, Chapter 19 of The MEMS Handbook, edited by Mohamed Gad-EI-Hak, CRC Press, 2002. 9. �Microfabrication�Rapid Prototyping's Killer Application�, pages 1�5 of the Rapid Prototyping Report, CAD/CAM Publishing, Inc., June 1999. The disclosures of these nine publications are hereby incorporated herein by reference as if set forth in full herein.
An example of a CC mask and CC mask plating are shown in FIGS. 1A�1C. FIG. 1A shows a side view of a CC mask 8 consisting of a conformable or deformable (e.g. elastomeric) insulator 10 patterned on an anode 12. The anode has two functions. One is as a supporting material for the patterned insulator 10 to maintain its integrity and alignment since the pattern may be topologically complex (e.g., involving isolated �islands� of insulator material). The other function is as an anode for the electroplating operation. FIG. 1A also depicts a substrate 6 separated from mask 8. CC mask plating selectively deposits material 22 onto a substrate 6 by simply pressing the insulator against the substrate then electrodepositing material through apertures 26 a and 26 b in the insulator as shown in FIG. 1B. After deposition, the CC mask is separated, preferably non-destructively, from the substrate 6 as shown in FIG. 1C. The CC mask plating process is distinct from a �through-mask� plating process in that in a through-mask plating process the separation of the masking material from the substrate would occur destructively. As with through-mask plating, CC mask plating deposits material selectively and simultaneously over the entire layer. The plated region may consist of one or more isolated plating regions where these isolated plating regions may belong to a single structure that is being formed or may belong to multiple structures that are being formed simultaneously. In CC mask plating, as individual masks are not intentionally destroyed in the removal process, they may be usable in multiple plating operations.
Another example of a CC mask and CC mask plating is shown in FIGS. 1D�1G. FIG. 1D shows an anode 12′ separated from a mask 8′ that comprises a patterned conformable material 10′ and a support structure 20. FIG. 1D also depicts substrate 6 separated from the mask 8′. FIG. 1E illustrates the mask 8′ being brought into contact with the substrate 6. FIG. 1F illustrates the deposit 22′ that results from conducting a current from the anode 12′ to the substrate 6. FIG. 1G illustrates the deposit 22′ on substrate 6 after separation from mask 8′. In this example, an appropriate electrolyte is located between the substrate 6 and the anode 12′ and a current of ions coming from one or both of the solution and the anode are conducted through the opening in the mask to the substrate where material is deposited. This type of mask may be referred to as an anodeless INSTANT MASK� (AIM) or as an anodeless conformable contact (ACC) mask.
An example of the electrochemical fabrication process discussed above is illustrated in FIGS. 2A�2F. These figures show that the process involves deposition of a first material 2 which is a sacrificial material and a second material 4 which is a structural material. The CC mask 8, in this example, includes a patterned conformable material (e.g. an elastomeric dielectric material) 10 and a support 12 which is made from deposition material 2. The conformal portion of the CC mask is pressed against substrate 6 with a plating solution 14 located within the openings 16 in the conformable material 10. An electric current, from power supply 18, is then passed through the plating solution 14 via (a) support 12 which doubles as an anode and (b) substrate 6 which doubles as a cathode. FIG. 2A, illustrates that the passing of current causes material 2 within the plating solution and material 2 from the anode 12 to be selectively transferred to and plated on the substrate 6. After electroplating the first deposition material 2 onto the substrate 6 using CC mask 8, the CC mask 8 is removed as shown in FIG. 2B. FIG. 2C depicts the second deposition material 4 as having been blanket-deposited (i.e. non-selectively deposited) over the previously deposited first deposition material 2 as well as over the other portions of the substrate 6. The blanket deposition occurs by electroplating from an anode (not shown), composed of the second material, through an appropriate plating solution (not shown), and to the cathode/substrate 6. The entire two-material layer is then planarized to achieve precise thickness and flatness as shown in FIG. 2D. After repetition of this process for all layers, the multi-layer structure 20 formed of the second material 4 (i.e. structural material) is embedded in first material 2 (i.e. sacrificial material) as shown in FIG. 2E. The embedded structure is etched to yield the desired device, i.e. structure 20, as shown in FIG. 2F.
Various components of an exemplary manual electrochemical fabrication system 32 are shown in FIGS. 3A�3C. The system 32 consists of several subsystems 34, 36, 38, and 40. The substrate holding subsystem 34 is depicted in the upper portions of each of FIGS. 3A to 3C and includes several components: (1) a carrier 48, (2) a metal substrate 6 onto which the layers are deposited, and (3) a linear slide 42 capable of moving the substrate 6 up and down relative to the carrier 48 in response to drive force from actuator 44. Subsystem 34 also includes an indicator 46 for measuring differences in vertical position of the substrate which may be used in setting or determining layer thicknesses and/or deposition thicknesses. The subsystem 34 further includes feet 68 for carrier 48 which can be precisely mounted on subsystem 36.
Another method for forming microstructures from electroplated metals (i.e. using electrochemical fabrication techniques) is taught in U.S. Pat. No. 5,190,637 to Henry Guckel, entitled �Formation of Microstructures by Multiple Level Deep X-ray Lithography with Sacrificial Metal Layers�. This patent teaches the formation of metal structure utilizing mask exposures. A first layer of a primary metal is electroplated onto an exposed plating base to fill a void in a photoresist, the photoresist is then removed and a secondary metal is electroplated over the first layer and over the plating base. The exposed surface of the secondary metal is then machined down to a height which exposes the first metal to produce a flat uniform surface extending across both the primary and secondary metals. Formation of a second layer may then begin by applying a photoresist layer over the first layer and then repeating the process used to produce the first layer. The process is then repeated until the entire structure is formed and the secondary metal is removed by etching. The photoresist is formed over the plating base or previous layer by casting and the voids in the photoresist are formed by exposure of the photoresist through a patterned mask via X-rays or UV radiation.
SUMMARY OF THE INVENTION It is an object of various aspects of the present invention to supplement electrochemical fabrication techniques to expand the capabilities of electrochemical fabrication process to meet the structural and functional requirements for varying applications and thus to expand the potential applications available to the technology.
BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1A�1C schematically depict side views of various stages of a CC mask plating process, while FIGS. 1D�1G schematically depict a side views of various stages of a CC mask plating process using a different type of CC mask.
FIGS. 2A�2F schematically depict side views of various stages of an electrochemical fabrication process as applied to the formation of a particular structure where a sacrificial material is selectively deposited while a structural material is blanket deposited.
FIGS. 3A�3C schematically depict side views of various example subassemblies that may be used in manually implementing the electrochemical fabrication method depicted in FIGS. 2A�2F.
FIGS. 4A�4F schematically depict the formation of a first layer of a structure using adhered mask plating where the blanket deposition of a second material overlays both the openings between deposition locations of a first material and the first material itself.
FIGS. 6A�6C depict an example of a structure created according to a preferred embodiment of the invention where FIGS. 6A and 6B depict two different perspective views of the structure while FIG. 6C depicts a side view of the structure of FIGS. 6A and 6B.
FIGS. 7A�7O illustrate the production of the structure of FIGS. 6A�6C from a plurality of adhered layers according to a preferred embodiment of the invention.
FIGS. 8A�8D illustrate a variation to the formation of the last layer of the structure of FIGS. 6A�6C and how the permanent substrate mates with that layer.
FIGS. 9A�9E depict the results of various steps during the practice of an embodiment of the invention.
FIGS. 11A�11J depict the results of various steps during the practice of an embodiment of the invention.
FIGS. 13A�13C schematically depict a process for swapping a structure 702 from a first substrate 704 to a second substrate 706.
FIGS. 14A�14C schematically depict a process for modifying a configuration of an attachment layer so that it includes notches as indicated in FIG. 13D.
FIGS. 15A�15F schematically depict a process for modifying a configuration of an attachment layer so that it includes reentrant features for enhancing interlocking of the structure and the substrate.
DETAILED DESCRIPTION FIGS. 1A�1G, 2A�2F, and 3A�3C illustrate various features of one form of electrochemical fabrication. Other electrochemical fabrication techniques are set forth in the '630 patent referenced above, in the various previously incorporated publications, in various other patents and patent applications incorporated herein by reference. Still others may be derived from combinations of various approaches described in these publications, patents, and applications, or are otherwise known or ascertainable by those of skill in the art from the teachings set forth herein. All of these techniques may be combined with those of the various embodiments of various aspects of the invention to yield enhanced embodiments. Still other embodiments may be derived from combinations of the various embodiments explicitly set forth herein.
FIGS. 4A�4F illustrate various stages in the formation of a single layer of a multi-layer fabrication process where a second metal is deposited on a first metal as well as in openings in the first metal so that the first and second metal form part of the layer. In FIG. 4A a side view of a substrate 82 is shown onto which patternable photoresist 84 is cast as shown in FIG. 4B. In FIG. 4C a pattern of resist is shown that results from the curing, exposing, and developing of the resist. The patterning of the photoresist 84 results in openings or apertures 92(a)�92(c) extending from a surface 86 of the photoresist through the thickness of the photoresist to surface 88 of the substrate 82. In FIG. 4D a metal 94 (e.g. nickel) is shown as having been electroplated into the openings 92(a)�92(c). In FIG. 4E the photoresist has been removed (i.e. chemically stripped) from the substrate to expose regions of the substrate 82 which are not covered with the first metal 94. In FIG. 4F a second metal 96 (e.g. silver) is shown as having been blanket electroplated over the entire exposed portions of the substrate 82 (which is conductive) and over the first metal 94 (which is also conductive). FIG. 4G depicts the completed first layer of the structure which has resulted from the planarization of the first and second metals down to a height that exposes the first metal and sets a thickness for the first layer. In FIG. 4H the result of repeating the process steps shown in FIGS. 4B�4G several times to form a multi-layer structure is shown where each layer consists of two materials. For most applications, one of these materials is removed as shown in FIG. 4I to yield a desired 3-D structure 98 (e.g. component or device).
The fabrication process used may be similar to the one illustrated in FIGS. 1A�1C and 2A�2F or it may be another process set forth in the '630 patent, a process set forth in one of the other previously incorporated publications, a process described in one of the applications that is included in the listing of incorporated patents and applications set forth hereafter, or the process may be a combination of various approaches described in these publications, patents, and applications, or otherwise known or ascertainable by those of skill in the art. Of course portions of the structures may be formed by any other three-dimensional modeling process.
After deposition of a layer, the process proceeds to operation 106, in which an inquiry is made as to whether the last layer of the structure has been formed (i.e. the layer that will contact the permanent substrate in certain embodiments of the invention). If the answer is �no�, the process loops back to operation 104 for one or more further depositions. If the answer is �yes�, the process moves forward to operation 108.
FIGS. 6A�6C depict an example of a structure (e.g. a switch) created according to a preferred embodiment of the invention. Two different perspective views of the structure are shown and a side view is shown. The view seen in FIG. 6A allows the structure 122 to be seen in its entirety while the structure is attached to permanent substrate 124. The view seen in FIG. 6B obscures a portion of structure 122 when it is attached to permanent substrate 124 but allows the layer formation process to be seen when the structure is being formed and attached to the temporary substrate as shown in FIGS. 7A�7N. As can be seen in FIG. 6C the structure consists of ten layers numbered 201�210.
FIGS. 7A�7N illustrates the formation of the structure of FIGS. 6A�6C. In this embodiment, successive layers are formed and adhered to the bottom of previously deposited layers. With the exception of the sacrificial material shown in FIG. 7B, when showing structural material and sacrificial material on the current deposition layer, the structural material is fully illustrated while only an outline of the sacrificial material is shown. On a current deposition layer any order of depositing structural material and sacrificial material is acceptable. In alternative embodiments, the layers may be deposited one on top of the other or one beside the other. In this application, unless a different interpretation is required by the context, when a deposition is said to occur onto a previous deposition, no absolute inference of layer orientation should be made but only a relative orientation of deposition order should be inferred.
FIGS. 7D�7L increment through successive deposition layers ranging from layer 209 down to 201. The pattern of structural material 209′ to 201′ for each of the successive deposition layers is also shown along with an outline of the sacrificial material associated with the current layer. Previously deposited layers are shown as solid blocks of material without distinction between the patterning of the structural and sacrificial materials.
FIG. 7M depicts a block of materials including the permanent substrate 200 attached to (1) the stack of layers 201�210, (2) the release layer 211, and (3) the temporary substrate 212.
FIGS. 8A�8D illustrate a variation to the formation of the last layer of the structure of FIGS. 6A�6C and a variation in how the permanent substrate mates with that layer. FIG. 8A shows the final layer including only the structural material 201′. FIG. 8B depicts the permanent substrate being formed or adhered to not only the bottom of the last layer but also to the sides of the last layer such that the structural material of the last layer becomes at least partially embedded in the substrate. FIGS. 8C and 8D depict two perspective views of the resulting structure. As can be seen structural material 201′ is embedded in the substrate and only nine of the ten original layers of structural material extend above the surface of the substrate. The surrounding of the structural material 201′ by the substrate may be achieved in various ways. For example, instead of the substrate being in the form of a performed sheet that is bonded to the layers, it may be in the form of a flowable material that can be molded to partially embed the structural material and to have a desired thickness extending beyond the surface of the last layer of structural material. As another example, the substrate may still be in the form of a sheet that is bonded to the structural material 201′ of the last layer but a portion of the last layer where the sacrificial material has been removed or never deposited may be filled with an epoxy or other flowable/solidifiable material. The permanent substrate may be placed in position and the hardening of the epoxy or other material may not only fill the region around structural material 201′ but also cause bonding between the layers and the substrate.
Though the use of the term �permanent substrate� has been used herein, it should be understood that it is not intended that the permanent substrate must exist throughout the life of the structure but instead that if form part of the structure for at least some portion of its useful life.
FIG. 10 provides a flowchart illustrating the process flow associated with the embodiment of FIGS. 9A�9E. In FIG. 10, the process begins at two points as illustrated by steps 402 and 406. Step 402 calls for the supplying of a substrate that is separable from a component that will be formed thereon. The substrate and component might, for example, be separable as a result of the substrate having a release layer thereon or they might be separable as a result of a release layer that will be formed on the substrate.
FIG. 12 provides a flow chart illustrating the process exemplified in FIGS. 11A�11J. The process starts with step 602 where a substrate is supplied onto which a device is to be formed. Also as the device will be eventually transferred to a different substrate the substrate should either have the release layer already in place or alternatively an appropriate release material (e.g. sacrificial material) may be added during the first one or more layers of electrochemical fabrication.
Examples of two additional embodiments are depicted in FIGS. 13A�13E, 14A�14C, and 15A�15F. These two embodiments depict substrate swapping techniques that include either enhanced surface area (interlacing) between the structure and the adhered substrate or the formation of features in the structure that allow interlocking with the swapped substrate.
FIGS. 13A�13C schematically exemplify a process for swapping a structure 702 from a first substrate 704 to a second substrate 706 where the contact area between the structure and the second substrate is substantially planar and thus no enhanced surface area or interlocking regions exist to aid in improving adhesion.
The modified structure 702′ of FIG. 13D can be implemented in a number of different manners. One implementation is depicted in FIGS. 14A�14C.
The gripping functionality of the transition region between the structure and the substrate of FIG. 13E may be obtainable in a variety of ways. For example, an etching operation may be used that has a tendency to undercut the material that it is cutting into. Such undercutting may be the result of the compression of a conformable contact mask into the hole as it is being formed which may offer protection for the upper portions of the side walls of the openings until a certain depth is reached at which point horizontal etching may form an undercut. Such gripping functionality may also be obtained by modifying the pattern of structural material on the last two or more layers of structure wherein the contacting layer (and maybe one or more additional layers will have relatively small openings in the structural material and one or more previous layers will have wider openings. These smaller and wider openings on different layers may be filled in with a sacrificial material during the layer formation process, which sacrificial material can be removed after layer formation is completed in much the same manner as described with regard to FIGS. 14B and 14C. An example of the formation of these gripping, undercut, or interlocking structures is depicted in FIGS. 15A�15F.
In some embodiments, multi-layer structures may be formed starting with a �top� layer (i.e. intended last layer) which is formed adjacent to a temporary substrate, or possibly separated from the temporary substrate by one or more layers of sacrificial material and then adding on subsequent layers until the first layer is reached. In these cases substrate swapping may occur directly by attaching the structural (e.g. permanent substrate) to the last formed layer (e.g. intended first layer) and then, if not already done, the temporary substrate can be removed. In some other embodiments, the multi layer structure can be formed starting with the intended first layer which may be formed directly on a temporary substrate or may be spaced from the temporary substrate by a sacrificial material which may or may not be the same as the sacrificial material that forms part of the layers including structural material. The building may proceed from the first layer to the last layer and if desired one or more layers of sacrificial materials may be formed above the last layer. The sacrificial material above the last layer may or may not be the same as the sacrificial material used in forming the layers that contain both structural and sacrificial materials. If necessary, a second temporary substrate may be attached to the last layer or the layers above it. The first temporary substrate (i.e. the initial substrate) may then be removed. If any layers of sacrificial material exist below the first layer they may be removed and thereafter a permanent (or structural substrate) may be attached to the first layer, after which the second temporary substrate may be removed along with any sacrificial material that has not yet been removed.
U.S. patent application Ser. No. 09/488,142, filed Jan. 20, 2000, now U.S. Pat. No. 6,572,742, and entitled �An Apparatus for Electrochemical Fabrication Comprising A Conformable Mask� is a divisional of the application that led to the above noted '630 patent. This application describes the basics of conformable contact mask plating and electrochemical fabrication including various alternative methods and apparatus for practicing EFAB as well as various methods and apparatus for constructing conformable contact masks.
U.S. Patent Application No. 60/415,374, filed on Oct. 1, 2002, and entitled �Monolithic Structures Including Alignment and/or Retention Fixtures for Accepting Components� is generally directed to permanent or temporary alignment and/or retention structures for receiving multiple components. The structures are preferably formed monolithically via a plurality of deposition operations (e.g. electrodeposition operations). The structures typically include two or more positioning fixtures that control or aid in the positioning of components relative to one another, such features may include (1) positioning guides or stops that fix or at least partially limit the positioning of components in one or more orientations or directions, (2) retention elements that hold positioned components in desired orientations or locations, and (3) positioning and/or retention elements that receive and hold adjustment modules into which components can be fixed and which in turn can be used for fine adjustments of position and/or orientation of the components.
U.S. Patent Application No. 60/464,504, filed on Apr. 21, 2003, and entitled �Methods of Reducing Discontinuities Between Layers of Electrochemically Fabricated Structures� is generally directed to various embodiments providing electrochemical fabrication methods and apparatus for the production of three-dimensional structures from a plurality of adhered layers of material including operations or structures for reducing discontinuities in the transitions between adjacent layers. Some embodiments improve the conformance between a size of produced structures (especially in the transition regions associated with layers having offset edges) and the intended size of the structure as derived from original data representing the three-dimensional structures. Some embodiments make use of selective and/or blanket chemical and/or electrochemical deposition processes, selective and or blanket chemical and/or electrochemical etching process, or combinations thereof. Some embodiments make use of multi-step deposition or etching operations during the formation of single layers.
U.S. Patent Application No. 60/468,979, filed on May 7, 2003, and entitled �EFAB With Selective Transfer Via Instant Mask� is generally directed to three-dimensional structures that are electrochemically fabricated by depositing a first material onto previously deposited material through voids in a patterned mask where the patterned mask is at least temporarily adhered to a substrate or previously formed layer of material and is formed and patterned onto the substrate via a transfer tool patterned to enable transfer of a desired pattern of precursor masking material. In some embodiments the precursor material is transformed into masking material after transfer to the substrate while in other embodiments the precursor is transformed during or before transfer. In some embodiments layers are formed one on top of another to build up multi-layer structures. In some embodiments the mask material acts as a build material while in other embodiments the mask material is replaced each layer by a different material which may, for example, be conductive or dielectric.
U.S. Patent Application No. 60/469,053, filed on May 7, 2003, and entitled �Three-Dimensional Object Formation Via Selective Inkjet Printing & Electrodeposition� is generally directed to three-dimensional structures that are electrochemically fabricated by depositing a first material onto previously deposited material through voids in a patterned mask where the patterned mask is at least temporarily adhered to previously deposited material and is formed and patterned directly from material selectively dispensed from a computer controlled dispensing device (e.g. an ink jet nozzle or array or an extrusion device). In some embodiments layers are formed one on top of another to build up multi-layer structures. In some embodiments the mask material acts as a build material while in other embodiments the mask material is replaced each layer by a different material which may, for example, be conductive or dielectric.
U.S. patent application Ser. No. 10/271,574, filed on Oct. 15, 2002, and entitled �Methods of and Apparatus for Making High Aspect Ratio Microelectromechanical Structures� is generally directed to various embodiments for forming structures (e.g. HARMS-type structures) via an electrochemical extrusion (ELEX�) process. Preferred embodiments perform the extrusion processes via depositions through anodeless conformable contact masks that are initially pressed against substrates that are then progressively pulled away or separated as the depositions thicken. A pattern of deposition may vary over the course of deposition by including more complex relative motion between the mask and the substrate elements. Such complex motion may include rotational components or translational motions having components that are not parallel to an axis of separation. More complex structures may be formed by combining the ELEX� process with the selective deposition, blanket deposition, planarization, etching, and multi-layer operations of EFAB�.
U.S. Patent Application No. 60/435,324, filed on Dec. 20, 2002, and entitled �EFAB Methods and Apparatus Including Spray Metal or Powder Coating Processes�, is generally directed to techniques for forming structures via a combined electrochemical fabrication process and a thermal spraying process. In a first set of embodiments, selective deposition occurs via conformable contact masking processes and thermal spraying is used in blanket deposition processes to fill in voids left by selective deposition processes. In a second set of embodiments, selective deposition via a conformable contact masking is used to lay down a first material in a pattern that is similar to a net pattern that is to be occupied by a sprayed metal. In these embodiments a second material is blanket deposited to fill in the voids left in the first pattern, the two depositions are planarized to a common level that may be somewhat greater than a desired layer thickness, the first material is removed (e.g. by etching), and a third material is sprayed into the voids left by the etching operation. The resulting depositions in both the first and second sets of embodiments are planarized to a desired layer thickness in preparation for adding additional layers to form three-dimensional structures from a plurality of adhered layers. In other embodiments, additional materials may be used and different processes may be used.
U.S. Patent Application No. 60/429,483, filed on Nov. 26, 2002, and entitled �Multi-cell Masks and Methods and Apparatus for Using Such Masks to Form Three-Dimensional Structures� is generally directed to multilayer structures that are electrochemically fabricated via depositions of one or more materials in a plurality of overlaying and adhered layers. Selectivity of deposition is obtained via a multi-cell controllable mask. Alternatively, net selective deposition is obtained via a blanket deposition and a selective removal of material via a multi-cell mask. Individual cells of the mask may contain electrodes comprising depositable material or electrodes capable of receiving etched material from a substrate. Alternatively, individual cells may include passages that allow or inhibit ion flow between a substrate and an external electrode and that include electrodes or other control elements that can be used to selectively allow or inhibit ion flow and thus inhibiting significant deposition or etching.
U.S. Patent Application No. 60/429,484, filed on Nov. 26, 2002, and entitled �Non-Conformable Masks and Methods and Apparatus for Forming Three-Dimensional Structures� is generally directed to electrochemical fabrication used to form multilayer structures (e.g. devices) from a plurality of overlaying and adhered layers. Masks, that are independent of a substrate to be operated on, are generally used to achieve selective patterning. These masks may allow selective deposition of material onto the substrate or they may allow selective etching of a substrate whereafter the created voids may be filled with a selected material that may be planarized to yield in effect a selective deposition of the selected material. The mask may be used in a contact mode or in a proximity mode. In the contact mode the mask and substrate physically mate to form substantially independent process pockets. In the proximity mode, the mask and substrate are positioned sufficiently close to allow formation of reasonably independent process pockets. In some embodiments, masks may have conformable contact surfaces (i.e. surfaces with sufficient deformability that they can substantially conform to surface of the substrate to form a seal with it) or they may have semi-rigid or even rigid surfaces. Post deposition etching operations may be performed to remove flash deposits (thin undesired deposits).
U.S. patent application Ser. No. 10/309,521, filed on Dec. 3, 2002, and entitled �Miniature RF and Microwave Components and Methods for Fabricating Such Components� is generally directed to RF and microwave radiation directing or controlling components that may be monolithic, that may be formed from a plurality of electrodeposition operations and/or from a plurality of deposited layers of material, that may include switches, inductors, antennae, transmission lines, filters, and/or other active or passive components. Components may include non-radiation-entry and non-radiation-exit channels that are useful in separating sacrificial materials from structural materials. Preferred formation processes use electrochemical fabrication techniques (e.g. including selective depositions, bulk depositions, etching operations and planarization operations) and post-deposition processes (e.g. selective etching operations and/or back filling operations).
U.S. Patent Application No. 60/468,977, filed on May 7, 2003, and entitled �Method for Fabricating Three-Dimensional Structures Including Surface Treatment of a First Material in Preparation for Deposition of a Second Material� is generally directed to a method of fabricating three-dimensional structures from a plurality of adhered layers of at least a first and a second material wherein the first material is a conductive material and wherein each of a plurality of layers includes treating a surface of a first material prior to deposition of the second material. The treatment of the surface of the first material either (1) decreases the susceptibility of deposition of the second material onto the surface of the first material or (2) eases or quickens the removal of any second material deposited on the treated surface of the first material. In some embodiments the treatment of the first surface includes forming a dielectric coating over the surface while the deposition of the second material occurs by an electrodeposition process (e.g. an electroplating or electrophoretic process).
U.S. patent application Ser. No. 10/387,958, filed on Mar. 13, 2003, and entitled �Electrochemical Fabrication Method and Apparatus for Producing Three-Dimensional Structures Having Improved Surface Finish� is generally directed to an electrochemical fabrication process that produces three-dimensional structures (e.g. components or devices) from a plurality of layers of deposited materials wherein the formation of at least some portions of some layers are produced by operations that remove material or condition selected surfaces of a deposited material. In some embodiments, removal or conditioning operations are varied between layers or between different portions of a layer such that different surface qualities are obtained. In other embodiments varying surface quality may be obtained without varying removal or conditioning operations but instead by relying on differential interaction between removal or conditioning operations and different materials encountered by these operations.
U.S. patent application Ser. No. 10/434,494, filed on May 7, 2003, and entitled �Methods and Apparatus for Monitoring Deposition Quality During Conformable Contact Mask Plating Operations� is generally directed to a electrochemical fabrication (e.g. EFAB) processes and apparatus are disclosed that provide monitoring of at least one electrical parameter (e.g. voltage) during selective deposition where the monitored parameter is used to help determine the quality of the deposition that was made. If the monitored parameter indicates that a problem occurred with the deposition, various remedial operations may be undertaken to allow successful formation of the structure to be completed.
10/434,289filed on May 7, 2003, and entitled �Conformable Contact Masking Methods and Apparatus Utilizing In Situ Cathodic Activation of a Substrate� is generally directed to an electroplating processes (e.g. conformable contact mask plating and electrochemical fabrication processes) that includes in situ activation of a surface onto which a deposit will be made. At least one material to be deposited has an effective deposition voltage that is higher than an open circuit voltage, and wherein a deposition control parameter is capable of being set to such a value that a voltage can be controlled to a value between the effective deposition voltage and the open circuit voltage such that no significant deposition occurs but such that surface activation of at least a portion of the substrate can occur. After making electrical contact between an anode, that comprises the at least one material, and the substrate via a plating solution, applying a voltage or current to activate the surface without any significant deposition occurring, and thereafter without breaking the electrical contact, causing deposition to occur.
U.S. patent application Ser. No. 10/434,294, filed on May 7, 2003, and entitled �Electrochemical Fabrication Methods With Enhanced Post Deposition Processing� is generally directed to a electrochemical fabrication process for producing three-dimensional structures from a plurality of adhered layers is provided where each layer comprises at least one structural material (e.g. nickel) and at least one sacrificial material (e.g. copper) that will be etched away from the structural material after the formation of all layers have been completed. A copper etchant containing chlorite (e.g. Enthone C-38) is combined with a corrosion inhibitor (e.g. sodium nitrate) to prevent pitting of the structural material during removal of the sacrificial material. A simple process for drying the etched structure without the drying process causing surfaces to stick together includes immersion of the structure in water after etching and then immersion in alcohol and then placing the structure in an oven for drying.
U.S. patent application Ser. No. 10/434,295, filed on May 7, 2003, and entitled �Method of and Apparatus for Forming Three-Dimensional Structures Integral With Semiconductor Based Circuitry� is generally directed to enhanced electrochemical fabrication processes that can form three-dimensional multi-layer structures using semiconductor based circuitry as a substrate. Electrically functional portions of the structure are formed from structural material (e.g. nickel) that adheres to contact pads of the circuit. Aluminum contact pads and silicon structures are protected from copper diffusion damage by application of appropriate barrier layers. In some embodiments, nickel is applied to the aluminum contact pads via solder bump formation techniques using electroless nickel plating. In other embodiments, selective electroless copper plating or direct metallization is used to plate sacrificial material directly onto dielectric passivation layers. In still other embodiments, structural material deposition locations are shielded, then sacrificial material is deposited, the shielding is removed, and then structural material is deposited.
U.S. patent application Ser. No. 10/434,315, filed on May 7, 2003, and entitled �Methods of and Apparatus for Molding Structures Using Sacrificial Metal Patterns� is generally directed to molded structures, methods of and apparatus for producing the molded structures. At least a portion of the surface features for the molds are formed from multilayer electrochemically fabricated structures (e.g. fabricated by the EFAB� formation process), and typically contain features having resolutions within the 1 to 100 μm range. The layered structure is combined with other mold components, as necessary, and a molding material is injected into the mold and hardened. The layered structure is removed (e.g. by etching) along with any other mold components to yield the molded article. In some embodiments portions of the layered structure remain in the molded article and in other embodiments an additional molding material is added after a partial or complete removal of the layered structure.
U.S. patent application Ser. No. 10/434,103, filed on May 7, 2003, and entitled �Electrochemically Fabricated Hermetically Sealed Microstructures and Methods of and Apparatus for Producing Such Structures� is generally directed to multilayer structures that are electrochemically fabricated from at least one structural material (e.g. nickel), at least one sacrificial material (e.g. copper), and at least one sealing material (e.g. solder). In some embodiments, the layered structure is made to have a desired configuration which is at least partially and immediately surrounded by sacrificial material which is in turn surrounded almost entirely by structural material. The surrounding structural material includes openings in the surface through which etchant can attack and remove trapped sacrificial material found within. Sealing material is located near the openings. After removal of the sacrificial material, the box is evacuated or filled with a desired gas or liquid. Thereafter, the sealing material is made to flow, seal the openings, and resolidify. In other embodiments, a post-layer formation lid or other enclosure completing structure is added.
U.S. patent application Ser. No. 10/434,497, filed on May 7, 2003, and entitled �Multistep Release Method for Electrochemically Fabricated Structures� is generally directed to multilayer structures that are electrochemically fabricated from at least one structural material (e.g. nickel), that is configured to define a desired structure and which may be attached to a substrate, and from at least one sacrificial material (e.g. copper) that surrounds the desired structure. After structure formation, the sacrificial material is removed by a multi-stage etching operation. In some embodiments sacrificial material to be removed may be located within passages or the like on a substrate or within an add-on component. The multi-stage etching operations may be separated by intermediate post processing activities, they may be separated by cleaning operations, or barrier material removal operations, or the like. Barriers may be fixed in position by contact with structural material or with a substrate or they may be solely fixed in position by sacrificial material and are thus free to be removed after all retaining sacrificial material is etched.
U.S. patent application Ser. No. 10/434,519, filed on May 7, 2003, and entitled �Methods of and Apparatus for Electrochemically Fabricating Structures Via Interlaced Layers or Via Selective Etching and Filling of Voids� is generally directed to multi-layer structures that are electrochemically fabricated by depositing a first material, selectively etching the first material (e.g. via a mask), depositing a second material to fill in the voids created by the etching, and then planarizing the depositions so as to bound the layer being created and thereafter adding additional layers to previously formed layers. The first and second depositions may be of the blanket or selective type. The repetition of the formation process for forming successive layers may be repeated with or without variations (e.g. variations in: patterns; numbers or existence of or parameters associated with depositions, etchings, and or planarization operations; the order of operations, or the materials deposited). Other embodiments form multi-layer structures using operations that interlace material deposited in association with some layers with material deposited in association with other layers.
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