Source: http://www.google.com/patents/US7229542?dq=6188988
Timestamp: 2016-06-29 12:42:52
Document Index: 685656700

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', 'Application No. 60']

Patent US7229542 - Methods of and apparatus for molding structures using sacrificial metal patterns - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsMolded structures, methods of and apparatus for producing the molded structures are provided. 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...http://www.google.com/patents/US7229542?utm_source=gb-gplus-sharePatent US7229542 - Methods of and apparatus for molding structures using sacrificial metal patternsAdvanced Patent SearchPublication numberUS7229542 B2Publication typeGrantApplication numberUS 10/434,315Publication dateJun 12, 2007Filing dateMay 7, 2003Priority dateMay 7, 2002Fee statusPaidAlso published asEP1576207A2, EP1576207A3, US20030234179, US20070199822, US20100213068, WO2003095708A2, WO2003095708A3Publication number10434315, 434315, US 7229542 B2, US 7229542B2, US-B2-7229542, US7229542 B2, US7229542B2InventorsChristopher A. BangOriginal AssigneeMicrofabrica Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (6), Non-Patent Citations (1), Referenced by (17), Classifications (31), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetMethods of and apparatus for molding structures using sacrificial metal patterns
US 7229542 B2Abstract
Molded structures, methods of and apparatus for producing the molded structures are provided. 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.
This application claims benefit of U.S. Provisional Patent Application No. 60/379,135, filed on May 7, 2002 which is hereby incorporated herein by reference as if set forth in full.
The present invention relates generally to the field of Electrochemical Fabrication and the associated formation of three-dimensional structures via a layer-by-layer build up of deposited materials. More particularly it relates to the use of electrochemically fabricated structures as sacrificial molding patterns.
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. of Burbank, Calif. 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, p 161, 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, p 244, 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-El-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.
It is an object of some embodiments of some aspects of the invention to supplement electrochemical fabrication techniques to expand the capabilities of electrochemical fabrication processes to meet the structural and functional requirements for varying applications and thus to expand the potential applications available to the technology.
The process moves forward to inquiry 104 where the question is posed as to whether the molding structure obtained is the complete molding pattern? If the answer is “no”, the process proceeds to operation 106, and if the answer is “yes” the process proceeds to operation 108. At operation 106 one or more additional molding surfaces are placed and potentially bonded to or otherwise fixed in position relative to the molding structure obtained in operation 102. The process then loops back to inquiry 104 and again poses the question as to whether the formation of the mold structure is completed. The process continues to loop through operations 104 and 106 until, a “yes” response is obtained from operation 104.
U.S. Provisional 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. Provisional 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. Provisional 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. Provisional 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 thickens. 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. Provisional 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. Provisional 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 multi-layer 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. Provisional 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 multi-layer 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. Provisional 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. 10/434,289, filed on May 7, 2003, and entitled “Conformable Contact Masking Methods and Apparatus Utilizing In Situ Cathodic Activation of a Substrate” is generally directed to a 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. 10/434,493, filed on May 7, 2003, and entitled “Electrochemically Fabricated Structures Having Dielectric or Active Bases and Methods of and Apparatus for Producing Such Structures” is generally directed to multi-layer structures that 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 multi-layer structure may be released from a sacrificial material prior to attaching the permanent substrate or it may be released after attachment.
U.S. patent application Ser. No. 10/434,103, filed on May 7, 2003 now U.S. Pat. No. 7,160,429, and entitled “Electrochemically Fabricated Hermetically Sealed Microstructures and Methods of and Apparatus for Producing Such Structures” is generally directed to multi-layer 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 multi-layer 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.
Patent CitationsCited PatentFiling datePublication dateApplicantTitleUS5190637 *Apr 24, 1992Mar 2, 1993Wisconsin Alumni Research FoundationFormation of microstructures by multiple level deep X-ray lithography with sacrificial metal layersUS5234571 *Nov 24, 1992Aug 10, 1993Microparts GmbhStepped mold inserts, a process for the manufacture of stepped mold inserts, and stepped microstructural bodies with the mold insertsUS6027630 *Apr 3, 1998Feb 22, 2000University Of Southern CaliforniaMethod for electrochemical fabricationUS6422528 *Jan 17, 2001Jul 23, 2002Sandia National LaboratoriesSacrificial plastic mold with electroplatable baseUS6660151 *Dec 21, 1995Dec 9, 2003Steag Microparts GmbhMicrostructure elements and process for the production thereofUS6692680 *Oct 3, 2001Feb 17, 2004Board Of Supervisors Of Louisiana State University And Agricultural And Mechanical CollegeReproduction of micromold inserts* Cited by examinerNon-Patent CitationsReference1 *Cohen et al., "EFAB: Rapid, low-cost desktop micromachining of high aspect ratio true 3-D MEMS," 12th IEEE International Conference on Microelectromechanical Systems, pp. 244-251 (Jan. 17-21, 1999).* Cited by examinerReferenced byCiting PatentFiling datePublication dateApplicantTitleUS8070931Dec 29, 2008Dec 6, 2011Microfabrica Inc.Electrochemical fabrication method including elastic joining of structuresUS8258044 *Sep 4, 2012Commissariat A L'energie Atomique Et Aux Energies AlternativesMethod for fabricating chip elements provided with wire insertion groovesUS8262916Jun 30, 2010Sep 11, 2012Microfabrica Inc.Enhanced methods for at least partial in situ release of sacrificial material from cavities or channels and/or sealing of etching holes during fabrication of multi-layer microscale or millimeter-scale complex three-dimensional structuresUS8601405Mar 28, 2012Dec 3, 2013Microfabrica Inc.Methods of and apparatus for electrochemically fabricating structures via interlaced layers or via selective etching and filling of voidsUS8702955Nov 2, 2011Apr 22, 2014Microfabrica Inc.Electrochemical fabrication method including elastic joining of structuresUS8713788Aug 8, 2011May 6, 2014Microfabrica Inc.Method for fabricating miniature structures or devices such as RF and microwave componentsUS9282964Dec 13, 2012Mar 15, 2016Microfabrica Inc.Releasable tissue anchoring device and method for usingUS20070158200 *Jun 29, 2006Jul 12, 2007Microfabrica Inc.Electrochemical fabrication processes incorporating non-platable metals and/or metals that are difficult to plate onUS20070199822 *Jan 9, 2007Aug 30, 2007Bang Christopher AMethods of and Apparatus for Molding Structures Using Sacrificial Metal PatternsUS20090020433 *May 15, 2008Jan 22, 2009Microfabrica Inc.Electrochemical Fabrication Methods for Producing Multilayer Structures Including the use of Diamond Machining in the Planarization of Deposits of MaterialUS20090022615 *Jul 18, 2008Jan 22, 2009Phillips Plastics CorporationMethod of molding complex structures using a sacrificial materialUS20100094320 *Nov 6, 2009Apr 15, 2010Microfabrica Inc.Atherectomy and Thrombectomy Devices, Methods for Making, and Procedures for UsingUS20100133109 *Nov 23, 2009Jun 3, 2010Microfabrica Inc.Electrochemically Fabricated Hermetically Sealed Microstructures and Methods of and Apparatus for Producing Such StructuresUS20100134131 *Nov 24, 2009Jun 3, 2010Microfabrica Inc.Electrochemically Fabricated MicroprobesUS20110022207 *Jan 27, 2011Microfabrica Inc.Methods of and Apparatus for Electrochemically Fabricating Structures Via Interlaced Layers or Via Selective Etching and Filling of VoidsUS20110092988 *Oct 21, 2010Apr 21, 2011Microfabrica Inc.Microdevices for Tissue Approximation and Retention, Methods for Using, and Methods for MakingUS20110287606 *Nov 24, 2011Commissariat A L'energie Atomique Et Aux Energies AlternativesMethod for fabricating chip elements provided with wire insertion grooves* Cited by examinerClassifications U.S. Classification205/67, 205/70, 264/328.1, 264/271.1, 264/318, 264/313, 264/219, 264/259, 264/299, 264/317, 264/221International ClassificationG01P15/08, G01P15/125, B81B3/00, B29B13/00, B81C1/00, C25D1/10, B29C45/14, B29C33/40, B41C3/02, C25D5/02Cooperative ClassificationB81C2201/0197, G01P15/0802, G01P15/125, B81B2201/042, B81C2201/0109, B81C2201/0107, B81C99/0085European ClassificationB81C99/00R4, G01P15/08A, G01P15/125Legal EventsDateCodeEventDescriptionSep 2, 2003ASAssignmentOwner name: MEMGEN CORPORATION, CALIFORNIAFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BANG, CHRISTOPHER A.;REEL/FRAME:014467/0506Effective date: 20030827Nov 4, 2010FPAYFee paymentYear of fee payment: 4Oct 9, 2014FPAYFee paymentYear of fee payment: 8May 4, 2015SULPSurcharge for late paymentRotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services