Manufacturing of micro-objects such as miniature diamond tool tips
First Claim
1. A method of affixing a micro-object to a mounting structure at a desired relative orientation, the method comprising:
- embedding a shaped portion of a workpiece in a reference structure at a first relative orientation;
parting the workpiece into first and second portions, the first portion of which includes the embedded shaped portion of the workpiece and defines the micro-object;
aligning the reference structure with the mounting structure at a second relative orientation, the first and second relative orientations defining the desired relative orientation of the micro-object and the mounting structure;
bonding the micro-object to the mounting structure while the micro-object remains embedded in the reference structure and the reference structure remains aligned with the mounting structure at the second relative orientation; and
separating the micro-object from the reference structure, whereupon the micro-object remains in the desired relative orientation with respect to the mounting structure.
1 Assignment
0 Petitions
Accused Products
Abstract
Techniques for affixing a micro-object to a mounting structure at a desired relative orientation. A shaped portion of a workpiece is caused to become embedded in a reference structure at a first relative orientation. The workpiece is parted into first and second portions, the first portion of which includes the embedded shaped portion of the workpiece and defines the micro-object. The reference structure is aligned with the mounting structure at a second relative orientation, the first and second relative orientations defining the desired relative orientation of the micro-object and the mounting structure. The micro-object is bonded to the mounting structure while the micro-object remains embedded in the reference structure and the reference structure remains aligned with the mounting structure at the second relative orientation. The micro-object is separated from the reference structure, whereupon the micro-object remains in the desired relative orientation with respect to the mounting structure. The micro-object may have dimensions less than 200 microns, and possibly on the order of 15–25 microns.
132 Citations
57 Claims
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1. A method of affixing a micro-object to a mounting structure at a desired relative orientation, the method comprising:
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embedding a shaped portion of a workpiece in a reference structure at a first relative orientation; parting the workpiece into first and second portions, the first portion of which includes the embedded shaped portion of the workpiece and defines the micro-object; aligning the reference structure with the mounting structure at a second relative orientation, the first and second relative orientations defining the desired relative orientation of the micro-object and the mounting structure; bonding the micro-object to the mounting structure while the micro-object remains embedded in the reference structure and the reference structure remains aligned with the mounting structure at the second relative orientation; and separating the micro-object from the reference structure, whereupon the micro-object remains in the desired relative orientation with respect to the mounting structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of fabricating a composite article having a micro-object supported on a mounting structure at a desired orientation with respect to the support structure, the method comprising:
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providing a workpiece having first and second portions, the first portion of the workpiece having a shape suitable for defining at least a portion of the micro-object; immobilizing the first portion of the workpiece relative to a reference structure with the first portion of the workpiece at a first orientation with respect to the reference structure; separating the first portion of the workpiece from the second portion of the workpiece while maintaining the first portion of the workpiece immobilized relative to the reference structure at the first orientation with respect to the reference structure, whereupon the first portion of the workpiece, so separated, defines the micro-object, with the micro-object, so separated, remaining at the first orientation with respect to the reference structure; aligning the reference structure with the mounting structure at a second orientation with respect to the mounting structure, the first orientation of the micro-object relative to the reference structure and the second orientation of the reference structure relative to the mounting structure defining the desired orientation of the micro-object with respect to the mounting structure; bonding the micro-object to the mounting structure while the micro-object remains immobilized relative to the reference structure and the reference structure remains aligned with the mounting structure at the second orientation with respect to the mounting structure; and releasing the micro-object from the reference structure. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A composite article of manufacture comprising a micro-object mounted on a mounting structure where the dimensions of the micro-object are less than 200 microns, and the micro-object is aligned relative to the mounting structure to an angular precision of better than ±
- 1 degree, wherein the micro-object is formed by;
immobilizing a shaped portion of a workpiece relative to a reference structure, the workpiece having a significantly larger dimensions than dimensions of the shaped portion; aligning the workpiece relative to the reference structure; parting the workpiece to leave a parted portion includes the shaped portion still immobilized and aligned relative to the reference structure, the parted portion defining the micro-object; aligning the reference structure relative to the mounting structure; bonding the parted portion to the mounting structure; and separating the parted portion from the reference structure.
- 1 degree, wherein the micro-object is formed by;
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18. A method of affixing a tool head to a tool body, the method comprising:
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causing a shaped portion of a workpiece to penetrate a trapping structure at a desired orientation; parting said workpiece, the tool head comprising a parted portion of said workpiece that includes said shaped portion and an exposed portion, with said shaped portion remaining in said trapping structure; and fastening the tool body to the exposed portion of the tool head. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A method of constructing a tool, the method comprising:
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causing a shaped portion of a workpiece to penetrate a trapping structure; parting said workpiece along a plane parallel to an upper surface of said trapping structure, whereby a parted portion of said workpiece includes said shaped portion and an exposed portion, and said shaped portion remains in said trapping structure; and fastening a tool body to said exposed portion of said parted portion. - View Dependent Claims (41, 42, 43, 44)
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45. A method of constructing a tool, the method comprising:
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causing a shaped portion of a workpiece to penetrate a trapping structure; parting said workpiece, whereby a parted portion of said workpiece remains in said trapping structure; positioning a tool body'"'"'s target surface and said workpiece relative to one another by means of a jig, said trapping structure being disposed upon said target surface; and fastening said tool body to said parted portion. - View Dependent Claims (46)
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47. A method of constructing a tool, the method comprising:
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causing a shaped portion of a workpiece to penetrate a trapping structure; parting said workpiece, whereby a parted portion of said workpiece remains in said trapping structure; thereafter, transporting said trapping structure to a location remote from the site of said parting step; and thereafter, fastening said tool body to said parted portion. - View Dependent Claims (48, 49, 50)
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51. A tool, comprising:
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a tool body; and a tool head coupled with said tool body, wherein said tool head is a portion of a significantly larger workpiece from which said tool head was parted while disposed within a trapping layer; said tool head having been aligned relative to said trapping layer by aligning said workpiece with the trapping layer prior to parting; said trapping layer having been aligned with said tool body after parting. - View Dependent Claims (52, 53, 54, 55, 56)
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57. A method of affixing a tool head to a tool body, the method comprising:
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causing a shaped portion of a workpiece to penetrate a trapping structure for fixing said workpiece in said trapping structure; parting said workpiece along a plane parallel to an upper surface of said trapping structure for forming the tool head from said workpiece, the tool head having dimensions less than 200 microns and including said shaped portion and an exposed portion with said shaped portion remaining in said trapping structure; and fastening said exposed portion of the tool body to the tool head while said shaped portion remains in said trapping structure.
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Specification