US4044816A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Formation of metal parts
Assignee: Individual
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Filing: 1976-01-12
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Granted: 1977-08-30
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Expires: 1996-01-12
Abstract
Abstract The invention provides a new apparatus and method for forming thin metal parts of simple or intricate shape and depositing the same onto selected receiving surfaces. The parts may be in the form of wire leads which are bonded to the receiving surfaces. The invention consists in providing a hollow tool which includes a porous body with an exposed surface having a selected two-dimensional or three-dimensional geometry, immersing the surface of the porous body in a melt of a metal which will not wet the surface, pulling the tool away from the melt while applying a suction force to the porous body so that a portion of the melt will adhere to the surface, bringing the tool into contact with a receiving surface, and cooling the surface and removing the suction force so that the adhering portion of the melt will be deposited as a solid or partially solidified body onto the receiving surface. The deposited part will bond securely to the receiving surface if the latter is made of a material which is wetted by the melt.
Inventors
- 👤 Theodore H. Krueger
- 👤 Robert Eller
- 👤 John O'Brien
- 👤 William L. Robbins
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 18:47
CPC Classifications
H; H05; H05K; H05K3/00; H05K3/10; H05K3/20; B; B22; B22D; B22D21/00; B22D21/02; B22D21/027; B22D27/00; B22D27/15; H05K2203/00; H05K2203/01; H05K2203/0104; H05K2203/0113; H05K2203/12; H05K2203/128
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
249 words
Method of forming a material from the class consisting of metals and alloys as a solid part having a predetermined geometry, said method comprising the steps of: a. providing a hollow body having at one end a porous surface and a non-porous surface that are made of substances which are not wettable by said material and are disposed so that a selected area of said porous surface is exposed through an opening in said non-porous surface; b. immersing said one end of said hollow body in a melt of said material far enough so that said selected area of said porous surface contacts said melt; c. withdrawing said one end of said hollow body from said melt with at least a portion of said selected area of said porous surface and at least a portion of said non-porous surface at a temperature at least as high as the melting point of said material, d. providing a suction force on said porous surfaces as said body is withdrawn from the melt so as to cause a portion of said melt to adhere in liquid form to said selected area of said porous surface by suction; and e. thereafter cooling the adhering portion of said melt by removing heat from said one end of said hollow body and removing said suction force so that said adhering portion is released from said porous surface and forms a solid part having substantially the same geometry as the exposed area of said porous surface.
Claim 2
Dependent Claim
249 words
Method of forming a material from the class consisting of metals and alloys as a solid part having a predetermined geometry, said method comprising the steps of: a. providing a hollow body having at one end a porous surface and a non-porous surface that are made of substances which are not wettable by said material and are disposed so that a selected area of said porous surface is exposed through an opening in said non-porous surface; b. immersing said one end of said hollow body in a melt of said material far enough so that said selected area of said porous surface contacts said melt; c. withdrawing said one end of said hollow body from said melt with at least a portion of said selected area of said porous surface and at least a portion of said non-porous surface at a temperature at least as high as the melting point of said material, d. providing a suction force on said porous surfaces as said body is withdrawn from the melt so as to cause a portion of said melt to adhere in liquid form to said selected area of said porous surface by suction; and e. thereafter cooling the adhering portion of said melt by removing heat from said one end of said hollow body and removing said suction force so that said adhering portion is released from said porous surface and forms a solid part having substantially the same geometry as the exposed area of said porous surface.
Claim 3
Dependent Claim
30 words
Method according to claim 1 wherein said porous surface is part of a porous member whose pores are in the range of from about 40 A to about 50 microns.
Claim 4
Dependent Claim
27 words
Method according to claim 2 wherein said porous and non-porous surfaces are made of a substance from the class consisting of alumina, mullite and an aluminum silicate.
Claim 5
Dependent Claim
44 words
Method according to claim 3 wherein said material is a member of the class consisting of (a) a gold alloy, (b) Wood's metal, (c) a tin-lead solder, (d) a silver-bearing solder, (e) a fusible alloy containing indium, and (f) a fusible alloy containing bismith.
Claim 6
Dependent Claim
35 words
Method according to claim 1 wherein said one end of said body is held immersed in said melt at least until said porous and non-porous surfaces have reached substantially the same temperature as said melt.
Claim 7
Dependent Claim
23 words
Method according to claim 1 wherein said suction force is applied before said one end of said body is immersed in said melt.
Claim 8
Dependent Claim
23 words
Method according to claim 1 wherein said suction force is terminated after said adhering portion of melt has undergone at least partial solidification.
Claim 9
Dependent Claim
51 words
Method according to claim 1 wherein said one end of said body is brought into contact with a receiving surface after it is withdrawn from the melt and before said suction force is terminated, whereby said adhering portion of melt is released and forms a solid part on said receiving surface.
Claim 10
Dependent Claim
15 words
Method according to claim 1 wherein said porous surface is made of a ceramic material.
Claim 11
Dependent Claim
39 words
Method according to claim 1 wherein said exposed porous surface is recessed with respect to said non-porous surface so that a cavity is formed by said porous and non-porous surfaces, and said adhering portion of melt fills said cavity.
Claim 12
Dependent Claim
11 words
Method according to claim 1 wherein said non-porous surface is flat.
Claim 13
Dependent Claim
17 words
Method according to claim 1 wherein said non-porous surface is part of an oxidized etched metal sheet.
Claim 14
Dependent Claim
16 words
Method according to claim 1 wherein said solid part is in the form of a wire.
Claim 15
Dependent Claim
227 words
Method of forming a material from the class consisting of metals and alloys as a solid part having a predetermined geometry, said method comprising the steps of: a. providing a hollow body with a porous surface and a non-porous surface that are made of substances which are not wettable by said material and are disposed so that a selected area of said porous surface is exposed through an opening in said non-porous surface; b. immersing said body in a melt of said material so that said non-porous surface and said selected area of said porous surface contact said melt and attain a temperature at least as high as the melting point of said material; c. withdrawing said body from said melt; d. providing a suction force on said porous surface as said body is withdrawn from the melt so as to cause a portion of said melt to adhere to said selected area of said porous surface by suction; e. bringing said body into contact with a receiving surface which is wettable by said melt and cooling the adhering portion of said melt by removing heat from said body; and f. removing said suction force so that said adhering portion of said melt is released from said porous surface and forms a solid part having substantially the same geometry as said selected area of said porous surface.
Claim 16
Dependent Claim
227 words
Method of forming a material from the class consisting of metals and alloys as a solid part having a predetermined geometry, said method comprising the steps of: a. providing a hollow body with a porous surface and a non-porous surface that are made of substances which are not wettable by said material and are disposed so that a selected area of said porous surface is exposed through an opening in said non-porous surface; b. immersing said body in a melt of said material so that said non-porous surface and said selected area of said porous surface contact said melt and attain a temperature at least as high as the melting point of said material; c. withdrawing said body from said melt; d. providing a suction force on said porous surface as said body is withdrawn from the melt so as to cause a portion of said melt to adhere to said selected area of said porous surface by suction; e. bringing said body into contact with a receiving surface which is wettable by said melt and cooling the adhering portion of said melt by removing heat from said body; and f. removing said suction force so that said adhering portion of said melt is released from said porous surface and forms a solid part having substantially the same geometry as said selected area of said porous surface.
Claim 17
Dependent Claim
12 words
Method according to claim 14 wherein said receiving surface is a metal.
Claim 18
Dependent Claim
16 words
Method according to claim 15 wherein said receiving surface is part of an electrical circuit component.
Claim 19
Dependent Claim
26 words
Method according to claim 14 wherein said adhering portion of melt is cooled enough to solidify after it is brought into contact with said receiving surface.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-08-29 | 1981-02-28 | 1981-08-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-08-29 | 1985-02-28 | 1985-08-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-08-29 | 1989-02-28 | 1989-08-30 | $7700.00 | Window Closed / Lapsed |