Superbrasvie tools containing uniformly leveled superabrasive particles and associated methods
First Claim
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1. A CMP pad dresser having a superabrasive impregnated segment, comprising:
- a flat disk having a 4 inch diameter;
a metal matrix covering a surface of the flat disk, the metal matrix configured for bonding superabrasive particles; and
a plurality of superabrasive particles held in the metal matrix at specific positions according to a predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height, wherein the uniform height has a variance that is less than or equal to 50 μ
m, and wherein the plurality of superabrasive particles are positioned such that superabrasive particles at edges of the flat disk are larger in size as compared to superabrasive particles at a middle portion of the flat disk.
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Abstract
A superabrasive tools having uniformly leveled superabrasive particles and associated methods are provided. In one aspect, for example, a superabrasive can include a metal matrix configured for bonding superabrasive particles and a plurality of superabrasive particles held in the metal matrix at specific positions according to a predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height.
380 Citations
15 Claims
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1. A CMP pad dresser having a superabrasive impregnated segment, comprising:
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a flat disk having a 4 inch diameter; a metal matrix covering a surface of the flat disk, the metal matrix configured for bonding superabrasive particles; and a plurality of superabrasive particles held in the metal matrix at specific positions according to a predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height, wherein the uniform height has a variance that is less than or equal to 50 μ
m, and wherein the plurality of superabrasive particles are positioned such that superabrasive particles at edges of the flat disk are larger in size as compared to superabrasive particles at a middle portion of the flat disk. - View Dependent Claims (2, 3, 4)
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5. A method for making a CMP pad dresser, comprising:
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applying a metal matrix to a flat disk having a 4 inch diameter; arranging a plurality of superabrasive particles in the metal matrix at specific positions such that the plurality of superabrasive particles are held in the metal matrix according to a predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height, wherein the uniform height has a variance that is less than or equal to 50 μ
m, and wherein the plurality of superabrasive particles are positioned such that superabrasive particles at edges of the flat disk are larger in size as compared to superabrasive particles at a middle portion of the flat disk. - View Dependent Claims (6, 7, 8, 9, 10)
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11. A method for making a CMP pad dresser, comprising:
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providing a template disposed on a flat disk having a 4 inch diameter, the template having a plurality of apertures formed therein; filling the apertures of the template with superabrasive particles; removing the template such that the plurality of superabrasive particles are maintained at specific positions according to a predetermined pattern; and forming a metal matrix to hold the plurality of superabrasive particles in the predetermined pattern, wherein tips of each of the plurality of the superabrasive particles protrude from the metal matrix to a uniform height, wherein the uniform height has a variance that is less than or equal to 50 μ
m, and wherein the plurality of superabrasive particles are positioned such that superabrasive particles at edges of the flat disk are larger in size as compared to superabrasive particles at a middle portion of the flat disk. - View Dependent Claims (12, 13, 14, 15)
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Specification