Patent US5916641A successfully refreshed from Google Patents.
US5916641A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of forming a monolayer of particles
Assignee: Henkel Loctite Ireland Ltd
•
Filing: 1996-08-01
•
Granted: 1999-06-29
•
Expires: 2016-08-01
Abstract
Abstract The present invention provides for a number of interrelated methods for the production of random and ordered arrays of particles as well as films containing the same. In another aspect, the present invention relates to the random and ordered arrays of particles and films prepared therefrom. The ordered arrays are obtained by the use of ferrofluid compositions which may be curable, solidifiable or non-curing/non-solidifiable. Especially preferred arrays and films contain electrically conductive particles for use in electronic applications for effecting contact between leads or pads.
Inventors
- 👤 Ciaran B. McArdle
- 👤 Joseph Burke
- 👤 II Edward K. Welch
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 22:27
CPC Classifications
H; H05; H05K; H05K3/00; H05K3/30; H05K3/32; H05K3/321; H05K3/323; G; G03; G03F; G03F7/00; G03F7/26; G03F7/34; H01; H01R; H01R4/00; H01R4/04; H05K2201/00; H05K2201/08; H05K2201/083; H05K2201/09; H05K2201/09818; H05K2201/09945; H05K2203/00; H05K2203/07; H05K2203/0756; H05K2203/0769; H05K2203/10; H05K2203/104; H10; H10W; H10W72/00; H10W72/30; H10W72/321; H10W72/325; H10W72/351; H10W72/352
Claims Analysis
Total Claims: 14
Claim 1
Independent Claim
122 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying to a substrate a curable ferrofluid composition having particles contained therein, said particles having a particle size on at least one dimension of at least one micrometer; (b) exposing the particle-containing ferrofluid composition to a source of energy suitable for effecting polymerization of the curable ferrofluid composition for a sufficient time to effect polymerization of a layer of the curable ferrofluid composition having a thickness of no more than 50% of the height of the largest particles, while the particles are arrayed in a non-random pattern as a result of application of a magnetic field; and (c) optionally, removing the uncured curable ferrofluid composition.
Claim 2
Independent Claim
122 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying to a substrate a curable ferrofluid composition having particles contained therein, said particles having a particle size on at least one dimension of at least one micrometer; (b) exposing the particle-containing ferrofluid composition to a source of energy suitable for effecting polymerization of the curable ferrofluid composition for a sufficient time to effect polymerization of a layer of the curable ferrofluid composition having a thickness of no more than 50% of the height of the largest particles, while the particles are arrayed in a non-random pattern as a result of application of a magnetic field; and (c) optionally, removing the uncured curable ferrofluid composition.
Claim 3
Independent Claim
93 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner in the composition; (c) pressing the particles onto the adhesive surface of the substrate; and (d) removing the ferrofluid composition.
Claim 4
Independent Claim
93 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner in the composition; (c) pressing the particles onto the adhesive surface of the substrate; and (d) removing the ferrofluid composition.
Claim 5
Independent Claim
112 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; and (b) subjecting the composition to a magnetic field for a sufficient time to order the particles in a non-random manner in the composition; (c) adhesively binding the particles arrayed in a non-random manner to the substrate by pressing said particles onto the adhesive surface of the substrate and activating the latent adhesive; and (d) removing the ferrofluid composition.
Claim 6
Independent Claim
112 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; and (b) subjecting the composition to a magnetic field for a sufficient time to order the particles in a non-random manner in the composition; (c) adhesively binding the particles arrayed in a non-random manner to the substrate by pressing said particles onto the adhesive surface of the substrate and activating the latent adhesive; and (d) removing the ferrofluid composition.
Claim 7
Independent Claim
146 words
A method of forming a film having a monolayer non-random array of particles therein, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate having a surface of adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner; (c) pressing the particles onto the adhesive surface of the substrate; (d) removing the ferrofluid composition; (e) applying a film-forming material to fill the interstitial spaces between the particles and optionally to cover areas of the adhesive surface flanking the particles to a film-thickness similar to that of the particle-containing areas; (f) optionally, at least partially solidifying the film-forming material; and (g) optionally, removing the so-formed film from the adhesive surface.
Claim 8
Independent Claim
146 words
A method of forming a film having a monolayer non-random array of particles therein, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate having a surface of adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner; (c) pressing the particles onto the adhesive surface of the substrate; (d) removing the ferrofluid composition; (e) applying a film-forming material to fill the interstitial spaces between the particles and optionally to cover areas of the adhesive surface flanking the particles to a film-thickness similar to that of the particle-containing areas; (f) optionally, at least partially solidifying the film-forming material; and (g) optionally, removing the so-formed film from the adhesive surface.
Claim 9
Independent Claim
164 words
A method of forming a film having a monolayer non-random array of particles therein, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner in the composition; (c) adhesively binding the particles arrayed in a non-random manner to the substrate by pressing said particles onto the adhesive surface of the substrate and activating the latent adhesive; (d) applying the film-forming material to fill the interstitial spaces between the particles and optionally to cover areas of the adhesive surface flanking the particles to a film-thickness similar to that of the particle-containing areas; (e) optionally, at least partially solidifying the film-forming material; and (f) optionally, removing the so-formed film from the adhesive surface.
Claim 10
Independent Claim
164 words
A method of forming a film having a monolayer non-random array of particles therein, said method comprising the steps of: (a) applying a composition comprising a ferrofluid composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a substrate which has a surface of latent adhesive material; (b) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner in the composition; (c) adhesively binding the particles arrayed in a non-random manner to the substrate by pressing said particles onto the adhesive surface of the substrate and activating the latent adhesive; (d) applying the film-forming material to fill the interstitial spaces between the particles and optionally to cover areas of the adhesive surface flanking the particles to a film-thickness similar to that of the particle-containing areas; (e) optionally, at least partially solidifying the film-forming material; and (f) optionally, removing the so-formed film from the adhesive surface.
Claim 11
Independent Claim
131 words
A method of forming a stock wax film containing a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid wax composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a first substrate; (b) providing the ferrofluid wax composition at a temperature above its melting point; (c) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner while maintaining the ferrofluid wax composition at a temperature above its melting point; (d) cooling the ferrofluid wax composition to a temperature below its melting point while the particles are arrayed in said non-random pattern; and (e) optionally, removing the first substrate from the wax film.
Claim 12
Independent Claim
131 words
A method of forming a stock wax film containing a monolayer non-random array of particles, said method comprising the steps of: (a) applying a composition comprising a ferrofluid wax composition and particles, said particles having a particle size on at least one dimension of at least one micrometer, to a first substrate; (b) providing the ferrofluid wax composition at a temperature above its melting point; (c) subjecting the composition to a magnetic field for a sufficient time to array the particles in a non-random manner while maintaining the ferrofluid wax composition at a temperature above its melting point; (d) cooling the ferrofluid wax composition to a temperature below its melting point while the particles are arrayed in said non-random pattern; and (e) optionally, removing the first substrate from the wax film.
Claim 13
Dependent Claim
109 words
A method of forming a monolayer non-random array of particles, said method comprising the steps of: (a) applying the wax film prepared in accordance with claim 6 to a second substrate having a surface of, optionally latent, adhesive material; (b) adhesively binding the particles to a second substrate by pressing said particles onto the adhesive surface of the second substrate, activating the latent adhesive, if present, and elevating the temperature of the wax film and/or the second substrate to a temperature above the softening point of the wax film; (c) removing the ferrofluid wax composition; and (d) optionally, removing the first substrate if it has not already been removed.
Claim 14
Dependent Claim
49 words
A method of forming a monolayer non-random array of particles according to claim 7 wherein the adhesive or latent adhesive is a film-forming adhesive and the particles in step (b) are pressed into the adhesive to a depth of at least 50% of the height of the largest particles.
References Cited (Backward Citations)
US2718506A
Cited
GB919502A
Cited
US3359145A
Cited
US3661744A
Cited
US3898349A
Cited
US4008341A
Cited
US3843540A
Cited
US3917538A
Cited
US4092376A
Cited
US4100088A
Cited
US4170677A
Cited
US4368131A
Cited
US4215209A
Cited
US4430239A
Cited
US4846988A
Cited
US4645611A
Cited
US4548862A
Cited
US4698907A
Cited
EP0208391A2
Cited
US4604229A
Cited
JPS62127194A
Cited
US4644101A
Cited
US5076950A
Cited
US4935147A
Cited
EP0232127A2
Cited
US4740657A
Cited
US4737112A
Cited
US4808638A
Cited
US4741850A
Cited
US4855079A
Cited
US4701276A
Cited
US4867910A
Cited
US5085789A
Cited
US4946613A
Cited
US4997717A
Cited
EP0299618A2
Cited
US4963220A
Cited
US4938886A
Cited
EP0330452A2
Cited
US4965007A
Cited
JPH0395298A
Cited
US5128215A
Cited
US5064550A
Cited
EP0402546A2
Cited
US5167850A
Cited
US5180888A
Cited
US5075034A
Cited
US4992190A
Cited
US5124060A
Cited
US5380549A
Cited
US5543397A
Cited
US5147573A
Cited
US5141970A
Cited
US5084490A
Cited
WO1993002148A1
Cited
EP0549159A2
Cited
US5221417A
Cited
US5438223A
Cited
US5349478A
Cited
JPH06122857A
Cited
US5382373A
Cited
US5346558A
Cited
US5366140A
Cited
US5486427A
Cited
WO1995018476A1
Cited
WO1995020820A1
Cited
EP0691660A1
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2002-06-28 | 2002-12-28 | 2003-06-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-06-28 | 2006-12-28 | 2007-06-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-06-28 | 2010-12-28 | 2011-06-29 | $7700.00 | Window Closed / Lapsed |