Method for photo-forming small shaped metal containing articles from porous precursors
First Claim
1. A method for making a metal-containing article, comprising the steps of:
- a. providing a layer of a porous ground on a selected area of a base substantially immersed within a fluid that contains a metal source;
b. exposing selected regions of said layer of porous ground to light, thereby metallizing said selected regions;
c. repeating steps (a) and (b) a selected number of times to produce a selected number of layers; and
d. joining said metallized regions of at least two of said layers.
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Abstract
The invention is a method for making a metal containing article, comprising the steps of: providing a layer of a porous ground in a selected area; exposing selected regions of the layer of porous ground to light, thereby metallizing the selected regions; repeating the foregoing steps a selected number of times to produce a selected number of layers; and selectively modifying the metallized regions of the layers. The initial metallization can be by electroless or semiconductor photo deposition plating. The subsequent modification of the metallized regions can be by electroless plating, electroplating or sintering. It is also possible, in some instances, to forego the second phase modification, the initial phase having provided the desired parameters. In a third preferred embodiment, the invention is a method using an initial metallization phase effected by exposure of a metal salt, such as a metal halide, to light, thereby inducing activation of the halide. A subsequent metallization step is conducted, as well as subsequent modification according to any of the methods mentioned above. A continuous embodiment of the invention is also disclosed, where a continuously deposited bed of powder particles is exposed to light and metallized. Subsequently, the metallized regions are further modified as above. An apparatus for the practice of the continuous methods is also proposed. ?
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Citations
32 Claims
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1. A method for making a metal-containing article, comprising the steps of:
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a. providing a layer of a porous ground on a selected area of a base substantially immersed within a fluid that contains a metal source; b. exposing selected regions of said layer of porous ground to light, thereby metallizing said selected regions; c. repeating steps (a) and (b) a selected number of times to produce a selected number of layers; and d. joining said metallized regions of at least two of said layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method for making a metal-containing article comprising the steps of:
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a. providing a layer of a porous ground on a selected area of a base; b. contacting said porous ground with an electroless plating solution; c. exposing selected regions of said layer of porous ground to light, thereby metallizing said selected regions; d. repeating steps (a) and (b) and (c) a selected number of times, each successive layer provided adjacent a layer that has already been formed, to produce a selected number of metallized layers, said metallization adding metal within said metallized regions of each individual layer and between said metallized regions of adjacent layers. - View Dependent Claims (15)
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16. A method for making a metal-containing article, comprising the steps of:
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a. providing a layer of a porous, metal salt-containing ground on a selected area of a base; b. exposing selected regions of said layer of porous ground to light, thereby activating said selected regions; c. repeating steps (a) and (b) a selected number of times to produce a selected number of layers; d. metallizing said activated regions; and e. joining said metallized regions of at least two of said layers. - View Dependent Claims (17, 18, 19, 20, 21)
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22. A method for making a metal-containing article, comprising the steps of:
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a. providing porous ground on a selected area of a base substantially immersed within a fluid that contains a metal source; b. while the providing of step (a) is continuing, exposing selected regions of said porous ground to light, thereby metallizing said selected regions to a selected degree and to a preselected depth; and c. joining said metallized regions of porous ground that are adjacent to each other. - View Dependent Claims (23, 24, 25, 26, 27)
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28. A method for making a metal-containing article, comprising the steps of:
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a. providing porous ground on a selected area of a base; b. contacting said porous ground with an electroless plating solution; c. while the providing of step (a) is continuing, exposing selected regions of said porous ground to light, thereby metallizing said selected regions to a preselected degree and to a preselected depth.
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29. A method for making a metal-containing article, comprising the steps of:
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a. providing porous metal salt ground on a selected area of a base; b. while the providing of step (a) is continuing, exposing selected regions of said porous ground to light, thereby activating said selected regions to a preselected degree and to a preselected depth; c. metallizing the selectively activated regions and d. joining said metallized regions of porous ground that are adjacent to each other. - View Dependent Claims (30, 31, 32)
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Specification