Hermetically sealed micro-device package using cold-gas dynamic spray material deposition
First Claim
1. A method for manufacturing a cover assembly that can be joined to a micro-device package base to form a hermetically sealed micro-device package, the cover assembly including a transparent window portion and a metallic frame, the method comprising the following steps:
- providing a sheet of a transparent material having a window portion defined thereupon, the window portion having finished top and bottom surfaces;
preparing a frame-attachment area on the sheet, the frame-attachment area circumscribing the window portion;
spraying a first quantity of powdered metal particles onto the prepared frame-attachment area of the sheet using a jet of gas, the gas being at a temperature below the fusing temperature of the metal particles, the jet of gas having a velocity sufficient to cause the metal particles to merge with one another upon impact with the sheet and with one another so as to form an initial continuous metallic coating adhering to the frame-attachment area of the sheet; and
applying successive quantities of powdered metal particles over the initial continuous metallic coating using the jet of gas so as to form a continuous built-up metallic frame incorporating the initial continuous metallic coating as its base and having an overall thickness that is a predetermined thickness.
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Accused Products
Abstract
A method for manufacturing a cover assembly including a transparent window portion and a metallic frame that can be joined to a micro-device package base to form a hermetically sealed micro-device package. A sheet of a transparent material is provided having a window portion defined thereupon, the window portion having finished top and bottom surfaces. A frame-attachment area is prepared on the sheet, the frame-attachment area circumscribing the window portion. A first quantity of powdered metal particles is sprayed onto the prepared frame-attachment area of the sheet using a jet of gas, the gas being at a temperature below the fusing temperature of the metal particles. The jet of gas has a velocity sufficient to cause the metal particles to merge with one another upon impact with the sheet and with one another so as to form an initial continuous metallic coating adhering to the frame-attachment area of the sheet. Successive quantities of powdered metal particles are applied over the initial continuous metallic coating using the jet of gas so as to form a continuous built-up metallic frame incorporating the initial continuous metallic coating as its base and having an overall thickness that is a predetermined thickness.
78 Citations
46 Claims
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1. A method for manufacturing a cover assembly that can be joined to a micro-device package base to form a hermetically sealed micro-device package, the cover assembly including a transparent window portion and a metallic frame, the method comprising the following steps:
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providing a sheet of a transparent material having a window portion defined thereupon, the window portion having finished top and bottom surfaces;
preparing a frame-attachment area on the sheet, the frame-attachment area circumscribing the window portion;
spraying a first quantity of powdered metal particles onto the prepared frame-attachment area of the sheet using a jet of gas, the gas being at a temperature below the fusing temperature of the metal particles, the jet of gas having a velocity sufficient to cause the metal particles to merge with one another upon impact with the sheet and with one another so as to form an initial continuous metallic coating adhering to the frame-attachment area of the sheet; and
applying successive quantities of powdered metal particles over the initial continuous metallic coating using the jet of gas so as to form a continuous built-up metallic frame incorporating the initial continuous metallic coating as its base and having an overall thickness that is a predetermined thickness. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method for manufacturing a cover assembly for a micro-device package, the method comprising the following steps:
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providing a sheet of a transparent material having a window portion defined thereupon;
spraying a first quantity of powdered particles onto the sheet using a jet of gas, the gas being at a temperature below the fusing temperature of the particles, the jet of gas having a velocity sufficient to cause the particles to merge with one another upon impact with the sheet and with one another so as to form an initial continuous coating adhering to the sheet and circumscribing the window portion thereof; and
applying successive quantities of powdered particles over the initial continuous coating using the jet of gas so as to form a continuous built-up frame circumscribing the window portion and incorporating the initial continuous coating. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28)
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29. A method for manufacturing a cover assembly that can be joined to a micro-device package base to form a hermetically sealed micro-device package, the cover assembly including a transparent window portion and a frame, the method comprising the following steps:
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providing a sheet of a transparent material having a window portion defined thereupon;
preparing a frame-attachment area on the sheet, the frame-attachment area circumscribing the window portion;
depositing metal onto the prepared frame-attachment area of the sheet using cold-gas dynamic spray deposition until a built-up metal frame is formed upon the sheet having a predetermined thickness above the frame-attachment area. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46)
plating a layer of nickel over the cold-gas dynamic spray deposited metal of the frame until the nickel layer has a thickness within the range from about 0.002 microns to about 25 microns; and
plating a layer of gold over the nickel layer until the gold layer has a thickness within the range from about 0.0508 microns to about 0.508 microns.
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44. A method in accordance with claim 29, further comprising the step of annealing the built-up frame by heating after its deposition onto the sheet.
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45. A method in accordance with claim 44, wherein the step of annealing includes annealing the totality of the sprayed-on metals and alloys.
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46. A method in accordance with claim 44, wherein the step of annealing includes annealing only the outermost portions of the integral built-up frame.
Specification