Method for cold bonding
First Claim
1. A method for bonding two surfaces together without applying heat, the bond being formed via a metal matrix that is created when the two surfaces, having been prepared so that both surfaces have an outermost layer of aluminum, are brought into contact with each other in a manner so as to displace any aluminum oxide present, thus providing the contact of two virgin (non-oxidized) aluminum surfaces, wherein one of the surfaces to be bonded is prepared so that, at desired bonding points, aluminum coated particles protrude from the surface, providing discrete contact points with the other surface.
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Accused Products
Abstract
The present invention is a method for bonding two surfaces without applying heat. The surfaces are prepared so that they both have an outermost layer of aluminum. One of the surfaces has metallized particles that protrude at the desired bonding points. When the two surfaces are brought into contact, the particles pierce the aluminum surface, displacing any aluminum oxide that may be present. This provides two virgin aluminum surfaces on contact with each other, which allows the formation of a metal matrix, thus bonding the two surfaces. The strength of the bond can be controlled by varying the piercing depth and size of the particles. The material for the particles may be chosen so that the bond is both electrically and thermally conductive, either electrically or thermally conductive, or both electrically and thermally insulative.
232 Citations
18 Claims
- 1. A method for bonding two surfaces together without applying heat, the bond being formed via a metal matrix that is created when the two surfaces, having been prepared so that both surfaces have an outermost layer of aluminum, are brought into contact with each other in a manner so as to displace any aluminum oxide present, thus providing the contact of two virgin (non-oxidized) aluminum surfaces, wherein one of the surfaces to be bonded is prepared so that, at desired bonding points, aluminum coated particles protrude from the surface, providing discrete contact points with the other surface.
- 9. A method for die/package interconnect bonding, the bond being a metal matrix formed between an outer layer of virgin aluminum on the die and an outer layer of virgin aluminum on a bond pad of the package, wherein the package is formed to include a plurality of metalized particles protruding from its surface at the desired bonding spots so that when the die and package are brought together, said particles first contact the bond pad and displace any aluminum oxide that may be present, thus providing the mating of two virgin aluminum surfaces.
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14. A method for bonding together a first generally locally planar surface and a second generally locally planar surface, in steps comprising:
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A. coating the first surface with a first layer of aluminum; B. coating the second surface with a second layer of aluminum including a plurality of discrete particles embedded therein at selected bonding zones, said discrete particles being completely coated, on the exterior facing surfaces thereof, by said second layer of aluminum; and C. forcing the first surface against the second surface in a perpendicular manner such that said particles embedded in said second layer of aluminum pierce both said second layer and said first layer of aluminum, the force of such piercing exposing juxtaposed areas of virgin aluminum in both of said first and said second layers, such that adjacent exposed areas of virgin aluminum are caused to bond to each other by material affinity. - View Dependent Claims (15, 16, 17, 18)
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Specification