US5411602A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Solder compositions and methods of making same
Assignee: Microfab Technologies Inc
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Filing: 1994-02-17
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Granted: 1995-05-02
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Expires: 2014-02-17
Abstract
Abstract Spherical solder drops having precise and accurate shape are formed by an ejection device and solidified to form solder balls for making solder pastes. The diameters of the solidified solder balls are determined by an excitation signal applied to the ejection device and changes in the diameter of the orifice in the ejection device. A solder paste is produced by mixing solidified solder balls of a single diameter or a combination of several different diameters with a carrier.
Inventors
- 👤 Donald J. Hayes
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 05:14
CPC Classifications
B; B22; B22F; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F1/00; B22F1/06; B22F1/065; B23; B23K; B23K35/00; B23K35/02; B23K35/0222; B23K35/0244; B23K35/025; H; H05; H05K; H05K3/00; H05K3/30; H05K3/32; H05K3/34; H05K3/3465; H05K3/3485; B22F2999/00; H05K2201/00; H05K2201/02; H05K2201/0203; H05K2201/0263; H05K2201/0266
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
97 words
A method of making solder paste comprising the steps of: (a) ejecting a stream of liquid solder from an ejection device toward a receptacle; (b) separating said stream of liquid solder into a plurality of substantially spherically-shaped liquid balls of a first predetermined uniform diameter; (c) providing an atmosphere of inert gas between said ejection device and said receptacle; (d) solidifying said liquid balls to form solid balls in said atmosphere of inert gas; (e) catching said solid balls in said receptacle; and (f) mixing the spherically-shaped solid balls with a fluid carrier to form a paste.
Claim 2
Independent Claim
97 words
A method of making solder paste comprising the steps of: (a) ejecting a stream of liquid solder from an ejection device toward a receptacle; (b) separating said stream of liquid solder into a plurality of substantially spherically-shaped liquid balls of a first predetermined uniform diameter; (c) providing an atmosphere of inert gas between said ejection device and said receptacle; (d) solidifying said liquid balls to form solid balls in said atmosphere of inert gas; (e) catching said solid balls in said receptacle; and (f) mixing the spherically-shaped solid balls with a fluid carrier to form a paste.
Claim 3
Dependent Claim
25 words
A method as set forth in claim 1 wherein said separating step comprises excitation of said ejection device with a signal of first predetermined frequency.
Claim 4
Dependent Claim
16 words
A method as set forth in claim 1 wherein said ejection device is a piezoelectric device.
Claim 5
Dependent Claim
16 words
A method as set forth in claim 1 wherein said ejection device is an electro-mechanical device.
Claim 6
Dependent Claim
47 words
A method as set forth in claim 1 further including the steps of: a) separating said stream of liquid solder into a plurality of substantially spherically-shaped liquid balls of a second predetermined uniform diameter; and b) catching said balls of a second predetermined diameter in a receptacle.
Claim 7
Dependent Claim
42 words
A method as set forth in claim 5 wherein separating said stream of liquid solder into a plurality of substantially spherically-shaped liquid balls of a second predetermined uniform diameter includes excitation of said ejection device with a signal of second predetermined frequency.
Claim 8
Dependent Claim
47 words
A method as set forth in claim 5 further including the steps of: a) separating said stream of liquid solder into a plurality of substantially spherically-shaped liquid balls of a third predetermined uniform diameter; and b) catching said balls of a third predetermined diameter in a receptacle.
Claim 9
Dependent Claim
41 words
A method as set forth in claim 7 wherein separating said stream liquid solder into a plurality of substantially spherically-shaped liquid balls of a third predetermined uniform diameter includes excitation of said ejection device with a signal of third predetermined frequency.
Claim 10
Dependent Claim
34 words
A method as set forth in claim 1 further including the steps of: a) maintaining liquid solder in an ejection chamber; and b) transferring liquid solder from said ejection chamber to said ejection device.
Claim 11
Dependent Claim
25 words
A method as set forth in claim 9 further including the step of maintaining the transferred solder in the liquid state in said ejection device.
Claim 12
Dependent Claim
17 words
A method as set forth in claim 1 wherein said ejection device comprises a continuous ejection device.
Claim 13
Dependent Claim
20 words
A method as set forth in claim 1 wherein said liquid solder is a mixture of at least two metals.
Claim 14
Dependent Claim
41 words
A method as set forth in claim 1 wherein said liquid solder is a mixture of at least two metals selected from the group consisting of tin, bismuth, nickel, cobalt, cadmium, antimony, indium, lead, silver, gallium, aluminum, germanium, silicon and gold.
Claim 15
Dependent Claim
35 words
A method as set forth in claim 1 wherein said carrier includes at least one component selected from the group consisting of rosin, solvent, a thixotropic agent, and active hydrogen-containing compound, diluents, polymers and flux.
Claim 16
Dependent Claim
22 words
A method as set forth in claim 1 wherein said solid balls comprise at least 80% by weight of the solder paste.
Claim 17
Independent Claim
127 words
A method of making solder paste comprising the steps of: a) maintaining a supply of liquid solder in an ejection chamber; b) transferring liquid solder from said ejection chamber to an ejection device; c) positioning a receptacle remote from said ejection device; d) providing an atmosphere of inert gas between said ejection device and said receptacle; e) ejecting a stream of liquid solder from said ejection device by use of pressure; f) separating said stream of liquid solder into a plurality of substantially spherically-shaped drops of liquid solder; g) solidifying said drops of liquid solder to form solder balls in said atmosphere of inert gas; h) catching said solder balls in said receptacle; and i) mixing said solder balls with a fluid carrier to form a paste.
Claim 18
Independent Claim
127 words
A method of making solder paste comprising the steps of: a) maintaining a supply of liquid solder in an ejection chamber; b) transferring liquid solder from said ejection chamber to an ejection device; c) positioning a receptacle remote from said ejection device; d) providing an atmosphere of inert gas between said ejection device and said receptacle; e) ejecting a stream of liquid solder from said ejection device by use of pressure; f) separating said stream of liquid solder into a plurality of substantially spherically-shaped drops of liquid solder; g) solidifying said drops of liquid solder to form solder balls in said atmosphere of inert gas; h) catching said solder balls in said receptacle; and i) mixing said solder balls with a fluid carrier to form a paste.
Claim 19
Dependent Claim
42 words
A method as set forth in claim 16 wherein said separating step comprises excitation of said ejection device with a signal which varies in a predetermined manner through a range of frequencies to form solder balls having a predetermined range of diameters.
Claim 20
Dependent Claim
24 words
A method as set forth in claim 17 wherein said range of frequencies comprises the frequencies between about 5,000 hertz and about 1,000,000 hertz.
Claim 21
Dependent Claim
24 words
A method as set forth in claim 17 wherein said predetermined range of diameters comprises diameters from about 10 μm to about 80 μm.
Claim 22
Dependent Claim
16 words
A method as set forth in claim 16 wherein said ejection device is a piezoelectric device.
Claim 23
Dependent Claim
16 words
A method as set forth in claim 16 wherein said ejection device is an electro-mechanical device.
Claim 24
Dependent Claim
33 words
A method as set forth in claim 16 further including the steps of: a) maintaining liquid solder in a reservoir; and b) transferring said liquid solder from said reservoir to said ejection chamber.
Claim 25
Dependent Claim
25 words
A method as set forth in claim 22 further including the step of maintaining the transferred solder in the liquid state in said ejection device.
Claim 26
Dependent Claim
17 words
A method as set forth in claim 16 wherein said ejection device comprises a continuous ejection device.
Claim 27
Dependent Claim
20 words
A method as set forth in claim 16 wherein said liquid solder is a mixture of at least two metals.
Claim 28
Dependent Claim
41 words
A method as set forth in claim 16 wherein said liquid solder is a mixture of at least two metals selected from the group consisting of tin, bismuth, nickel, cobalt, cadmium, antimony, indium, lead, silver, gallium, aluminum, germanium, silicon and gold.
Claim 29
Dependent Claim
35 words
A method as set forth in claim 16 wherein said carrier includes at least one component selected from the group consisting of rosin, solvent, a thixotropic agent, an active hydrogen-containing compound, diluents, polymers and flux.
Claim 30
Dependent Claim
22 words
A method as set forth in claim 16 wherein said solder balls comprise at least 80% by weight of the solder paste.
Claim 31
Independent Claim
122 words
A method of producing solder balls of spherical shape comprising the steps of: a) maintaining a supply of liquid solder in an ejection chamber; b) transferring liquid solder from said ejection chamber to an ejection device; c) positioning a receptacle remote from said ejection device; d) providing an atmosphere of inert gas between said ejection device and said receptacle; e) ejecting a stream of liquid solder from said ejection device by use of pressure; f) separating said stream of liquid solder into a plurality of spherically-shaped drops of liquid solder of a first substantially uniform size; g) solidifying said drops of liquid solder to form solder balls in said atmosphere of inert gas; and h) catching said solder balls in said receptacle.
Claim 32
Independent Claim
122 words
A method of producing solder balls of spherical shape comprising the steps of: a) maintaining a supply of liquid solder in an ejection chamber; b) transferring liquid solder from said ejection chamber to an ejection device; c) positioning a receptacle remote from said ejection device; d) providing an atmosphere of inert gas between said ejection device and said receptacle; e) ejecting a stream of liquid solder from said ejection device by use of pressure; f) separating said stream of liquid solder into a plurality of spherically-shaped drops of liquid solder of a first substantially uniform size; g) solidifying said drops of liquid solder to form solder balls in said atmosphere of inert gas; and h) catching said solder balls in said receptacle.
Claim 33
Dependent Claim
16 words
A method as set forth in claim 29 wherein said ejection device is a piezoelectric device.
Claim 34
Dependent Claim
16 words
A method as set forth in claim 29 wherein said ejection device is an electro-mechanical device.
Claim 35
Dependent Claim
52 words
A method as set forth in claim 29 further including the steps of: a) separating said stream of liquid solder into a plurality of spherically-shaped drops of liquid solder of a second substantially uniform size; and b) solidifying said drops of liquid solder of said second uniform size to form solder balls.
Claim 36
Dependent Claim
23 words
A method as set forth in claim 32 wherein said separating steps comprise excitation of said ejection device with signals of predetermined frequency.
Claim 37
Dependent Claim
32 words
A method as set forth in claim 29 further including the steps of: a) maintaining liquid in a liquid reservoir; and b) transferring liquid solder from said reservoir to said ejection chamber.
Claim 38
Dependent Claim
25 words
A method as set forth in claim 29 further including the step of maintaining the transferred solder in the liquid state in said ejection device.
Claim 39
Dependent Claim
17 words
A method as set forth in claim 29 wherein said ejection device comprises a continuous ejection device.
Claim 40
Dependent Claim
20 words
A method as set forth in claim 29 wherein said liquid solder is a mixture of at least two metals.
Claim 41
Dependent Claim
41 words
A method as set forth in claim 29 wherein said liquid solder is a mixture of at least two metals selected from the group consisting of tin, bismuth, nickel, cobalt, cadmium, antimony, indium, lead, silver, gallium, aluminum, germanium, silicon and gold.
Claim 42
Dependent Claim
30 words
A solder paste made by mixing the solder balls of claim 29 with a carrier in which said solder balls comprise at least 80% by weight of the solder paste.
Claim 43
Dependent Claim
38 words
A solder paste as defined in claim 39 wherein said carrier is a mixture of at least one component selected from the group consisting of rosin, solvent, a thixotropic agent, an active hydrogen-containing compound, diluents, polymers and flux.
Claim 44
Dependent Claim
30 words
A solder paste made by mixing the solder balls of claim 32 with a carrier in which said solder balls comprise at least 80% by weight of the solder paste.
Claim 45
Dependent Claim
35 words
A solder paste as defined in claim 41 wherein said carrier includes at least one component selected from the group consisting of rosin, solvent, a thixotropic agent, an active hydrogen-containing compound, diluents, polymers and flux.
Claim 46
Dependent Claim
27 words
A solder paste as defined in claim 41 wherein the diameters of the solder balls are within the range of about 10 μm to about 80 μm.
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) | 1998-05-01 | 1998-10-31 | 1999-05-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-05-01 | 2002-10-31 | 2003-05-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-05-01 | 2006-10-31 | 2007-05-02 | $7700.00 | Window Closed / Lapsed |