US5314003A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Three-dimensional metal fabrication using a laser
Assignee: Microelectronics and Computer Technology Corp
•
Filing: 1991-12-24
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Granted: 1994-05-24
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Expires: 2011-12-24
Abstract
Abstract Three-dimensional metal parts are fabricated by irradiating a thin layer of a mixture of metal powder and temperature equalization and unification vehicle to melt the metal powder and form a solid metal film. The vehicle also protects the molten metal from oxidation. The metal powder can contain an elemental metal or several metals, the vehicle can be an organic resin or an amalgam, and the irradiation can be selectively applied by a YAG laser.
Inventors
- 👤 Colin A. MacKay
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 09:27
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/10; B22D; B22D23/00; B22D23/06; B33; B33Y; B33Y10/00; B33Y40/00; B33Y70/00; B22F10/00; B22F10/20; B22F10/28; B22F12/00; B22F12/40; B22F12/41; Y; Y02; Y02P; Y02P10/00; Y02P10/25; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12063; Y10T428/12104; Y10T428/12111; Y10T428/1234
Claims Analysis
Total Claims: 38
Claim 1
Independent Claim
47 words
A method for forming three-dimensional metal articles comprising the steps of: obtaining a mixture of metal powder in a temperature equalization and unification vehicle; forming a thin layer of said mixture; and irradiating said thin layer wherein said metal powder melts and forms a solid metal film.
Claim 2
Independent Claim
47 words
A method for forming three-dimensional metal articles comprising the steps of: obtaining a mixture of metal powder in a temperature equalization and unification vehicle; forming a thin layer of said mixture; and irradiating said thin layer wherein said metal powder melts and forms a solid metal film.
Claim 3
Dependent Claim
55 words
A method as recited in claim 1, further comprising the steps of: forming another thin layer of said mixture on top of said metal film; and irradiating said another thin layer; wherein said metal powder in said another thin layer melts and solidifies into another metal film which is structurally interconnected to said metal film.
Claim 4
Dependent Claim
83 words
A method as recited in claim 1, further comprising the steps of: obtaining another mixture of metal powder in a temperature equalization and unification vehicle, wherein said another mixture differs at least in part from said mixture; forming a thin layer of said another mixture on top of said metal film; and irradiating said thin layer of said another mixture; wherein said metal powder in said another mixture melts and solidifies into another metal film which is structurally interconnected to said metal film.
Claim 5
Dependent Claim
21 words
A method as recited in claim 1, wherein said step of forming said thin layer comprises the step of screen printing.
Claim 6
Dependent Claim
33 words
A method as recited in claim 1, wherein said metal powder comprises copper particles, said vehicle comprises a resin cream containing tin and lead, and said irradiation is effected by a YAG laser.
Claim 7
Dependent Claim
16 words
A method as recited in claim 1, wherein said metal film is a continuous metal film.
Claim 8
Dependent Claim
16 words
A method as recited in claim 1, wherein said metal film does not contain said vehicle.
Claim 9
Dependent Claim
51 words
A method as recited in claim 1, wherein said step of irradiating said thin layer divides said mixture into an irradiated portion of mixture and a non-irradiated portion of mixture, and wherein said vehicle which is irradiated moves outside said metal film and becomes incorporated into said non-irradiated portion of mixture.
Claim 10
Dependent Claim
20 words
A method as recited in claim 1, wherein said vehicle comprises an amalgam and said metal film contains said vehicle.
Claim 11
Dependent Claim
12 words
A method as recited in claim 9, wherein said amalgam comprises gallium.
Claim 12
Dependent Claim
45 words
A method as recited in claim 1, wherein said step of irradiating said thin layer divides said mixture into an irradiated portion of mixture and a non-irradiated portion of mixture, and further comprising removing said non-irradiated portion of mixture after said metal film is formed.
Claim 13
Dependent Claim
28 words
A method as recited in claim 11, wherein said non-irradiated portion of mixture is removed by a solution selected from the group consisting of isopropyl alcohol and water.
Claim 14
Dependent Claim
16 words
A method as recited in claim 1, wherein the irradiation is performed by a laser beam.
Claim 15
Dependent Claim
16 words
A method as recited in claim 1, wherein said vehicle protects the molten metal from oxidation.
Claim 16
Dependent Claim
50 words
A method as recited in claim 1, wherein said temperature equalization and unification vehicle performs a temperature equalization process in the area of particles being melted via irradiation, and wherein said temperature equalization and unification vehicle further performs a unification process in the area of particles being melted via irradiation.
Claim 17
Dependent Claim
42 words
A method as recited in claim 1, wherein said temperature equalization and unification vehicle reacts rapidly with heat so as to spread the melting process, and wherein said temperature equalization and unification vehicle further provides a protective atmosphere for the metal powder.
Claim 18
Dependent Claim
54 words
A method as recited in claim 1, wherein said step of obtaining a mixture of metal powder in a temperature equalization and unification vehicle comprises the step of obtaining a mixture of metal powder in a temperature equalization and unification vehicle selected from the group consisting of sodium, potassium, calcium, carbonates, silicates and aluminum.
Claim 19
Dependent Claim
14 words
A method as recited in claim 17, wherein said vehicle comprises an organic resin.
Claim 20
Dependent Claim
15 words
A method as recited in claim 1, wherein said metal powder comprises a single metal.
Claim 21
Dependent Claim
16 words
A method as recited in claim 1, wherein said metal powder comprises a plurality of metals.
Claim 22
Dependent Claim
15 words
A method as recited in claim 1, wherein said metal powder comprises an alloy powder.
Claim 23
Dependent Claim
17 words
A method as recited in claim 1, wherein said metal powder comprises copper particles and solder particles.
Claim 24
Dependent Claim
26 words
A method as recited in claim 1, wherein said vehicle is selected from the group consisting of sodium, potassium, calcium, carbonates, silicates, aluminium and combinations thereof.
Claim 25
Dependent Claim
18 words
A method as recited in claim 23, wherein said metal powder has a melting point above 400° C.
Claim 26
Dependent Claim
18 words
A method as recited in claim 24, wherein said metal powder has a melting point above 900° C.
Claim 27
Dependent Claim
19 words
A method as recited in claim 1, wherein said vehicle comprises a resin cream comprising tin and lead particles.
Claim 28
Dependent Claim
16 words
A method as recited in claim 1, wherein said vehicle protects the molten metal from oxidation.
Claim 29
Dependent Claim
14 words
A method as recited in claim 1, wherein said vehicle comprises an organic resin.
Claim 30
Dependent Claim
23 words
A method as recited in claim 28, wherein said vehicle further comprises dimer and trimer variants of said resin as rheological control additives.
Claim 31
Dependent Claim
34 words
A method as recited in claim 29, wherein said dimer and timer variants are at the 0.3 percent level and said mixture is dissolved in a solvent to produce a 55 percent volume mixture.
Claim 32
Dependent Claim
25 words
A method as recited in claim 30, wherein said organic resin is selected from the group consisting of water white rosin and tall oil rosin.
Claim 33
Dependent Claim
22 words
A method as recited in claim 30, wherein said solvent is selected from the group consisting of butyl carbitol and isobutyl alcohol.
Claim 34
Dependent Claim
22 words
A method as recited in claim 28, wherein the metal powder has a melting point less than or equal to 400° C.
Claim 35
Dependent Claim
20 words
A method as recited in claim 1, wherein said vehicle is an amalgam and said metal film includes said amalgam.
Claim 36
Dependent Claim
15 words
A method as recited in claim 34, wherein said mixture includes copper, nickel and gallium.
Claim 37
Dependent Claim
21 words
A method as recited in claim 1, wherein said metal film is a continuous film which does not contain said vehicle.
Claim 38
Dependent Claim
27 words
A method as recited in claim 1, wherein said mixture contains thick and thin distributions of said metal powder which result in thick and thin films, respectively.
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