Patent ID: 7662708

Claim:
A method of forming a self-assembled electrical contact structure comprising the operations of: forming a contact pad on a substrate, the contact pad including an outer layer of first reactive molecules; exposing the substrate to a plurality of first particles that are freely moving, the first particles having a dimension greater than 10 micrometers, an entire outer surface of the first particles including a corresponding outer layer of second reactive molecules such that when the first reactive molecules and the second reactive molecules come into contact, the first reactive molecules and the second reactive molecules form a covalent bond that bonds the first particles to the contact pad, after bonding to the contact pad, a portion of the first particles creates an uneven surface including a contact asperity extending above an immediately surrounding area of the contact pad; and exposing the first particles to second particles that are freely moving but smaller in size than the first particles, the second particles including an outer layer of third reactive molecules such that when the second reactive molecules come into contact with the third reactive molecules, corresponding molecules are formed that bond the second particles to a surface of the first particles, the second particles to create a rough outer surface of the first particles.