US5089356A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Carbon fiber reinforced tin-lead alloy as a low thermal expansion solder preform
Assignee: Sony Corp
•
Filing: 1990-09-17
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Granted: 1992-02-18
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Expires: 2010-09-17
Abstract
Abstract A solder joint between two surfaces comprising an intermediate composite solder preform, said preform comprising metal coated carbon fibers contained in a metal matrix, said fibers comprising from 2 to 80 percent by volume of the composite, said metal matrix melting at a temperature below 600 DEG C. and containing at least 15 weight percent tin.
Inventors
- 👤 Deborah D. L. Chung
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 13:22
CPC Classifications
B; B23; B23K; B23K35/00; B23K35/02; B23K35/0222; B23K35/22; B23K35/24; B23K35/26; B23K35/262; H; H05; H05K; H05K3/00; H05K3/30; H05K3/32; H05K3/34; H05K3/3465; H05K3/3478; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12444; Y10T428/12486; Y10T428/12493; Y10T428/12535; Y10T428/12625
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
55 words
A solder joint between two surfaces comprising an intermediate composite solder preform, said preform comprising metal coated carbon fibers contained in a metal matrix, said fibers comprising from 2 to 80 percent by volume of the composite, said metal matrix melting at a temperature below 600° C. and containing at least 15 weight percent tin.
Claim 2
Dependent Claim
55 words
A solder joint between two surfaces comprising an intermediate composite solder preform, said preform comprising metal coated carbon fibers contained in a metal matrix, said fibers comprising from 2 to 80 percent by volume of the composite, said metal matrix melting at a temperature below 600° C. and containing at least 15 weight percent tin.
Claim 3
Dependent Claim
26 words
The solder joint of claim 1 wherein the preform is a sheet and the fibers comprise from 8 to 55 percent by volume of the composite.
Claim 4
Dependent Claim
14 words
The solder joint of claim 2 wherein the metal matrix comprises a eutectic alloy.
Claim 5
Dependent Claim
28 words
The solder joint of claim 2 wherein the metal matrix comprises a metal selected from the group consisting of lead, cadmium, indium, selenium, tellurium, thallium, tin and zinc.
Claim 6
Dependent Claim
43 words
The solder joint of claim 2 wherein the metal matrix comprises a mixture of at least two metals selected from the group consisting of lead, tin, bismuth, tellurium, silver, copper, antimony, aluminum, gold, silver, zinc, cadmium, mercury, indium, selenium, gallium, arsenic and thallium.
Claim 7
Dependent Claim
16 words
The solder joint of claim 5 wherein the mixture comprises at least 50 weight percent tin.
Claim 8
Dependent Claim
16 words
The solder joint of claim 5 wherein the mixture comprises at least 10 weight percent lead.
Claim 9
Dependent Claim
16 words
The solder joint of claim 5 wherein the mixture comprises at least 10 weight percent zino.
Claim 10
Dependent Claim
35 words
The solder joint of claim 5 wherein the mixture comprises less than 10 weight percent combined metal selected from the group consisting of bismuth, tellurium, copper, antimony, aluminum, gold, cadmium, mercury, indium, selenium, and thallium.
Claim 11
Dependent Claim
13 words
The solder joint of claim 9 wherein the mixture is a tin-lead alloy.
Claim 12
Dependent Claim
14 words
The solder joint of claim 1 wherein the carbon fibers are copper coated fibers.
Claim 13
Dependent Claim
14 words
The solder joint of claim 2 wherein the carbon fibers are copper coated fibers.
Claim 14
Dependent Claim
14 words
The solder joint of claim 5 wherein the carbon fibers are copper coated fibers.
Claim 15
Dependent Claim
14 words
The solder joint of claim 6 wherein the carbon fibers are copper coated fibers.
Claim 16
Dependent Claim
14 words
The solder joint of claim 7 wherein the carbon fibers are copper coated fibers.
Claim 17
Dependent Claim
14 words
The solder joint of claim 8 wherein the carbon fibers are copper coated fibers.
Claim 18
Dependent Claim
14 words
The solder joint of claim 9 wherein the carbon fibers are copper coated fibers.
Claim 19
Dependent Claim
12 words
The solder joint of claim 11 wherein the fibers are graphite fibers.
Claim 20
Dependent Claim
22 words
The solder joint of claim 1 wherein the fibers are graphite fibers having an average diameter of from 0.1 to 20 microns.
Claim 21
Dependent Claim
41 words
The solder joint of claim 1 wherein the fibers have an average aspect ratio of at least 4:1, an average diameter of from 0.1 to 100 microns and an average length of from 10 microns to the length of the preform.
Claim 22
Dependent Claim
41 words
The solder joint of claim 2 wherein the fibers have an average aspect ratio of at least 4:1, an average diameter of from 0.1 to 100 microns and an average length of from 10 microns to the length of the preform.
Claim 23
Dependent Claim
41 words
The solder joint of claim 12 wherein the fibers have an average aspect ratio of at least 4:1, an average diameter of from 0.1 to 100 microns and an average length of from 10 microns to the length of the preform.
Claim 24
Dependent Claim
13 words
The solder joint of claim 12 wherein the mixture is a tin-lead alloy.
Claim 25
Dependent Claim
13 words
The solder joint of claim 20 wherein the mixture is a tin-lead alloy.
Claim 26
Dependent Claim
13 words
The solder joint of claim 21 wherein the mixture is a tin-lead alloy.
Claim 27
Dependent Claim
14 words
The solder joint of claim 22 wherein the metal matrix is a tin-lead alloy.
Claim 28
Dependent Claim
72 words
A solder joint comprising composite solder sheet intermediate and securing two surfaces which displays a thermal expansion coefficient ranging from -1×10 -6 /° C. to b 11×10 -6 /° C. at 25° C. in a direction parallel to the sheet, said composite solder substantially comprising continuous copper coated carbon fibers in a solder metal matrix, such that the copper coated carbon fibers occupy from 8 to 55 vol. % of the composite.
Claim 29
Dependent Claim
72 words
A solder joint comprising composite solder sheet intermediate and securing two surfaces which displays a thermal expansion coefficient ranging from -1×10 -6 /° C. to b 11×10 -6 /° C. at 25° C. in a direction parallel to the sheet, said composite solder substantially comprising continuous copper coated carbon fibers in a solder metal matrix, such that the copper coated carbon fibers occupy from 8 to 55 vol. % of the composite.
Claim 30
Dependent Claim
22 words
The solder joint as specified in claim 27, wherein said solder metal is a metal with a solidus temperature below 500° C.
Claim 31
Dependent Claim
36 words
The solder joint as specified in claim 27, wherein said solder metal contains one or more elements selected from the group consisting of tin, lead, antimony, cadmium, copper, silver, gold, zinc, indium, gallium, bismuth and arsenic.
Claim 32
Dependent Claim
23 words
The solder joint as specified in claim 27, wherein said solder metal is selected from the group consisting of tin-lead, gold-tin and lead-tin-silver.
Claim 33
Dependent Claim
14 words
The solder joint as specified in claim 27, wherein said solder metal is tin-lead.
Claim 34
Dependent Claim
17 words
The solder joint as specified in claim 27, wherein said copper coating is about 1 μm thick.
Claim 35
Dependent Claim
39 words
The solder joint as specified in claim 27 produced by a squeeze casting process, wherein the mold temperature is in the range from 100 to 200° C. and the pressure is in the range from 10 to 70 MPa.
Claim 36
Dependent Claim
65 words
The solder joint of claim 29 which displays a thermal expansion coefficient ranging from 0.5×10 -6 /° C. to 8.5×10 -6 /° C. at 25° C. in a direction parallel to the sheet, said composite solder substantially comprising continuous copper coated carbon fibers in a solder metal matrix, such that the copper coated carbon fibers occupy from 17 to 43 vol. % of the composite.
Claim 37
Dependent Claim
60 words
The solder joint of claim 29 wherein the sheet displays a thermal expansion coefficient of about 4×10 -6 /° C. at 25° C. in a direction parallel to the sheet, said composite solder substantially comprising continuous copper coated carbon fibers in a solder metal matrix, such that the copper coated carbon fibers occupy about 29 vol. % of the composite.
Claim 38
Dependent Claim
23 words
The solder joint as specified in claim 29, wherein at least a substantial portion of said carbon fibers extend in the same direction.
Claim 39
Dependent Claim
17 words
The solder joint as specified in claim 29, wherein said carbon fibers are conformed as a fabric.
Claim 40
Dependent Claim
17 words
The solder joint as specified in claim 29, wherein the precursor of said carbon fibers is pitch.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-02-17 | 1995-08-19 | 1996-02-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-02-17 | 1999-08-19 | 2000-02-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-02-17 | 2003-08-19 | 2004-02-18 | $7700.00 | Window Closed / Lapsed |