US5445308A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermally conductive connection with matrix material and randomly dispersed filler containing liquid metal
Assignee: Microelectronics and Computer Technology Corp
•
Filing: 1994-06-22
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Granted: 1995-08-29
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Expires: 2014-06-22
Abstract
Abstract A method of providing a thermally conductive connection between spaced surfaces includes (a) mixing a thermally conductive filler containing a liquid metal into an unhardened matrix material, and (b) contacting the unhardened matrix material and randomly dispersed, separate spaced non-solidified regions of filler within the unhardened matrix material to the surfaces. A solid mechanical bond may be provided by hardening the matrix material or by providing a separate adhesive between the surfaces. Preferably, the regions of filler form separate spaced continuous thermally and electrically conductive paths between the surfaces.
Inventors
- 👤 Richard D. Nelson
- 👤 Thomas P. Dolbear
- 👤 Robert W. Froehlich
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 12:46
CPC Classifications
C; C09; C09J; C09J9/00; C09J9/02; H; H01; H01B; H01B1/00; H01B1/20; H01B1/22; H01R; H01R4/00; H01R4/04; H05; H05K; H05K3/00; H05K3/30; H05K3/32; H05K3/321; H05K3/323; H10; H10W; H10W72/00; H10W72/30; H05K2201/00; H05K2201/02; H05K2201/0203; H05K2201/0206; H05K2201/0209; H05K2201/023; H05K2201/10; H05K2201/10613; H05K2201/10621; H05K2201/10719; H05K2203/00; H05K2203/04; H05K2203/0425; H10W72/071; H10W72/073; H10W72/07331; H10W72/321; H10W72/325; H10W72/351; H10W72/352; H10W72/353; H10W72/354
Claims Analysis
Total Claims: 44
Claim 1
Independent Claim
55 words
A method of providing a thermally conductive connection between spaced surfaces, comprising the steps of: (a) mixing a thermally conductive filler containing a liquid metal into an unhardened matrix material; and (b) contacting said unhardened matrix material and randomly dispersed, separate spaced non-solidified regions of said filler within said unhardened matrix material to said surfaces.
Claim 2
Independent Claim
55 words
A method of providing a thermally conductive connection between spaced surfaces, comprising the steps of: (a) mixing a thermally conductive filler containing a liquid metal into an unhardened matrix material; and (b) contacting said unhardened matrix material and randomly dispersed, separate spaced non-solidified regions of said filler within said unhardened matrix material to said surfaces.
Claim 3
Dependent Claim
21 words
The method of claim 1, further comprising: (c) transforming said unhardened matrix material into a solid mechanical bond between said surfaces.
Claim 4
Dependent Claim
28 words
The method of claim 2 wherein said unhardened matrix material is selected from the group consisting of thermoplastic materials, thermosetting materials, ultra-violet curable materials, epoxies, and solvent-bearing materials.
Claim 5
Dependent Claim
23 words
The method of claim 1, further comprising: (c) preventing said unhardened matrix material from transforming into a solid mechanical bond between said surfaces.
Claim 6
Dependent Claim
38 words
The method of claim 1, further comprising: (d) contacting an unhardened adhesive to said surfaces and an outer region of said unhardened matrix material; and (e) transforming said unhardened adhesive into a solid mechanical bond between said surfaces.
Claim 7
Dependent Claim
20 words
The method of claim 5 wherein said unhardened adhesive is selected from the group consisting of silicones, epoxies and acrylics.
Claim 8
Dependent Claim
102 words
The method of claim 1 further comprising, in sequence: contacting said unhardened matrix material which is thermoplastic and a first plurality of said regions to only one of said surfaces; transforming said unhardened matrix material into a solid matrix material; contacting said solid matrix material to the other of said surfaces; transforming said solid matrix material back into said unhardened matrix material; contacting said unhardened matrix material and a second plurality of said regions to the other of said surfaces; and then transforming said unhardened matrix material back into a solid matrix material thereby providing a solid mechanical bond between said surfaces.
Claim 9
Dependent Claim
13 words
The method of claim 1 wherein said regions have random sizes and shapes.
Claim 10
Dependent Claim
15 words
The method of claim 1 wherein said filler wets at least one of said surfaces.
Claim 11
Dependent Claim
14 words
The method of claim 1 wherein said filler consists essentially of a liquid metal.
Claim 12
Dependent Claim
13 words
The method of claim 10 wherein said filler consists of a liquid metal.
Claim 13
Dependent Claim
24 words
The method of claim 9 wherein said liquid metal is selected from the group consisting of gallium, gallium/indium, gallium/tin, gallium/indium/tin, mercury, and combinations thereof.
Claim 14
Dependent Claim
27 words
The method of claim 1 wherein said unhardened matrix material is sufficiently viscous to prevent said regions from coalescing or separating after said regions contact said surfaces.
Claim 15
Dependent Claim
23 words
The method of claim 1 wherein said unhardened matrix material is selected from the group consisting of liquids, gels, greases, oils and pastes.
Claim 16
Dependent Claim
15 words
The method of claim 1 wherein said unhardened matrix material consists essentially of an oil.
Claim 17
Dependent Claim
14 words
The method of claim 15 wherein said unhardened matrix material consists of an oil.
Claim 18
Dependent Claim
20 words
The method of claim 15 wherein said oil is selected from the group consisting of silicone oils and hydrocarbon oils.
Claim 19
Dependent Claim
34 words
The method of claim 1, further comprising: dispersing spacer particles into said unhardened matrix material; and contacting at least one of said spacer particles to both surfaces thereby assuring a spacing between said surfaces.
Claim 20
Dependent Claim
39 words
The method of claim 1 wherein said filler is dispersed throughout said unhardened matrix material and said filler occupies in the range of 20% to 70% of the volume of the mixture of said filler and said matrix material.
Claim 21
Dependent Claim
23 words
The method of claim 19 wherein said conductive filler occupies in the range of 30% to 50% of the volume of said mixture.
Claim 22
Dependent Claim
24 words
The method of claim 1 wherein a plurality of said regions contact both surfaces thereby forming separate continuous thermally conductive paths between said surfaces.
Claim 23
Dependent Claim
26 words
The method of claim 21 wherein said filler is electrically conductive and said plurality of said regions provide separate continuous electrically conductive paths between said surfaces.
Claim 24
Dependent Claim
29 words
The method of claim 22 wherein at least one of said surfaces is an insulating layer disposed on an electronic component thereby electrically insulating said component from said filler.
Claim 25
Dependent Claim
27 words
The method of claim 21 wherein said filler includes electrically conductive regions of said liquid metal surrounded by an insulative coating thereby rendering said filler electrically insulative.
Claim 26
Dependent Claim
71 words
The method of claim 21 further comprising, in sequence: dispersing spacer particles into said unhardened matrix material; contacting at least one of said plurality of regions to both of said surfaces without contacting any one of said spacer particles to both of said surfaces; moving said surfaces closer together; and then contacting at least one of said spacer particles to both of said surfaces thereby assuring a spacing between said surfaces.
Claim 27
Dependent Claim
19 words
The method of claim 1 wherein during step (b) a temperature of said filler is at most 160° C.
Claim 28
Dependent Claim
16 words
The method of claim 26 wherein said temperature of said filler is at most 100° C.
Claim 29
Dependent Claim
16 words
The method of claim 27 wherein said temperature of said filler is at most 40° C.
Claim 30
Dependent Claim
14 words
The method of claim 28 wherein said temperature of said filler is room temperature.
Claim 31
Dependent Claim
30 words
The method of claim 1 wherein at least one of said surfaces is a protective layer disposed on a metal thereby protecting said metal from attack by said liquid metal.
Claim 32
Dependent Claim
15 words
The method of claim 30, further comprising: anodizing said metal, thereby forming said protective layer.
Claim 33
Dependent Claim
16 words
The method of claim 31 wherein said liquid metal is gallium and said metal is aluminum.
Claim 34
Dependent Claim
31 words
The method of claim 30, further comprising: disposing a second metal on said metal; and oxidizing said second metal to form a continuous refractory oxide layer which provides said protective layer.
Claim 35
Dependent Claim
24 words
The method of claim 33 wherein said liquid metal is gallium and said metal is selected from the group consisting of aluminum and copper.
Claim 36
Dependent Claim
25 words
The method of claim 34 wherein said second metal is selected from the group consisting of nickel, chromium, titanium, tantalum, yttrium, scandium, zirconium and niobium.
Claim 37
Dependent Claim
86 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces, (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces, and (iii) an adhesive in contact with said surfaces and an outer region of said matrix material wherein said adhesive provides a solid mechanical bond between said surfaces.
Claim 38
Dependent Claim
86 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces, (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces, and (iii) an adhesive in contact with said surfaces and an outer region of said matrix material wherein said adhesive provides a solid mechanical bond between said surfaces.
Claim 39
Dependent Claim
76 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces wherein said matrix material is selected from the group consisting of liquids, gels, greases, oils and pastes, and (ii) a thermally conductive non-solidified filler containing a liquid metal, said fiber randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces.
Claim 40
Dependent Claim
76 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces wherein said matrix material is selected from the group consisting of liquids, gels, greases, oils and pastes, and (ii) a thermally conductive non-solidified filler containing a liquid metal, said fiber randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces.
Claim 41
Dependent Claim
66 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces wherein said matrix material includes an oil, and (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces.
Claim 42
Dependent Claim
66 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces wherein said matrix material includes an oil, and (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces.
Claim 43
Dependent Claim
81 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces, (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces, and (iii) solid spacer particles wherein at least one of said spacer particles contacts both surfaces thereby assuring a spacing between said surfaces.
Claim 44
Dependent Claim
81 words
A thermally conductive connection between surfaces, comprising: (i) a matrix material in contact with said surfaces, (ii) a thermally conductive non-solidified filler containing a liquid metal, said filler randomly dispersed in separate spaced regions of said matrix material wherein a plurality of said regions contact both surfaces and form separate spaced continuous thermally conductive paths between said surfaces, and (iii) solid spacer particles wherein at least one of said spacer particles contacts both surfaces thereby assuring a spacing between said surfaces.
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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) | 1998-08-28 | 1999-02-27 | 1999-08-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-08-28 | 2003-02-27 | 2003-08-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-08-28 | 2007-02-27 | 2007-08-29 | $7700.00 | Window Closed / Lapsed |