Patterned array of metal balls and methods of making
First Claim
1. A method for making an array of metal balls comprising the steps of:
- generating a first pattern on a continuous sheet of metal foil, the first pattern including a plurality of metal foil projections on the continuous sheet of metal foil;
generating a second pattern on a carrier substrate, the second pattern including a plurality of carrier recesses arranged and configured to correspond with the foil projections of the first pattern;
placing the continuous sheet of metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate such that the opposing surfaces of the metal foil and carrier substrate are in intimate contact with one another prior to melting the metal foil; and
melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate.
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Accused Products
Abstract
The present invention relates to a method for making an array of metal balls. The method includes the step of generating a first pattern on a metal foil which includes a plurality of foil projections. The method also includes the step of generating a second pattern on a carrier substrate. The second pattern includes a plurality of carrier recesses that are arranged and configured to correspond with the foil projections of the first pattern. The method further includes the steps of placing the metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate, and melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate. The invention also relates to metal ball arrays constructed via the above method.
108 Citations
13 Claims
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1. A method for making an array of metal balls comprising the steps of:
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generating a first pattern on a continuous sheet of metal foil, the first pattern including a plurality of metal foil projections on the continuous sheet of metal foil; generating a second pattern on a carrier substrate, the second pattern including a plurality of carrier recesses arranged and configured to correspond with the foil projections of the first pattern; placing the continuous sheet of metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate such that the opposing surfaces of the metal foil and carrier substrate are in intimate contact with one another prior to melting the metal foil; and melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13)
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9. A method for making an array of metal balls comprising the steps of:
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generating a first pattern on a metal foil, the first pattern including a plurality of metal foil projections; generating a second pattern on a carrier substrate, the second pattern including a plurality of carrier recesses arranged and configured to correspond with the foil projections of the first pattern; placing the metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate; and melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate, wherein the first and second patterns are generated by concurrently embossing both the carrier substrate and the metal foil with an embossing tool.
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Specification