Composite Mold for Metal Articles via Anodic Oxide and Photoresist
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Solution Overview
Problem
Existing methods for manufacturing metal molded articles, such as contact pins, face challenges in achieving precise dimensional accuracy and sufficient thickness due to limitations in laser cutting technology and the use of single-layer photoresist films in MEMS processes, which result in reduced production speed and inaccurate reproduction of features with dimensions in the range of several tens of micrometers.
Innovation Solution
A method involving a composite mold composed of a first mold made of anodic aluminum oxide film and a second mold made of a patternable material, such as a photoresist film, is used to form metal molded articles by electroplating, allowing for increased thickness and precise shape reproduction with vertical side surfaces and fine trenches, enhancing electrical conductivity and deformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser cutting technology is used to manufacture contact pins, then production speed can be maintained, but dimensional accuracy and thickness control deteriorate
Solution Approach 1:
The patent replaces mechanical laser cutting with electroplating deposition. Instead of removing material through laser cutting, the invention builds up metal contact pins through electroplating using a photoresist mold, achieving both high precision in dimensional control and sufficient thickness while maintaining production efficiency through batch processing capability
Solution Approach 2:
The patent changes the manufacturing parameter from subtractive (laser cutting thickness) to additive (electroplating thickness). By controlling plating time and current density, the thickness of contact pins can be precisely controlled at several tens of micrometers, achieving dimensional accuracy that laser cutting cannot provide
2Device complexity
If single-layer photoresist film is used as mold, then process simplicity is maintained, but thickness and dimensional accuracy of contact pins deteriorate
Solution Approach 1:
The patent divides the photoresist mold into multiple layers (first photoresist film and second photoresist film) with different functions. The first layer provides basic patterning while the second layer enhances thickness control and dimensional accuracy. This segmentation allows each layer to be optimized for its specific function while maintaining overall process feasibility
Solution Approach 2:
The patent transitions from single-layer to multi-layer photoresist film structure, adding the vertical dimension of layer stacking. This enables precise thickness control through cumulative layer thickness while maintaining lateral patterning accuracy, solving the limitation of single-layer films in achieving both simplicity and precision
3Length of stationary object
If photoresist films are stacked in multiple layers to increase thickness, then contact pin thickness can be increased, but shape accuracy and verticality of side surfaces deteriorate
Solution Approach 1:
The patent applies different properties to different parts of the multi-layer photoresist mold. The first photoresist film layer is optimized for patterning with specific thickness and material properties, while the second layer is optimized for thickness enhancement with different material composition or processing conditions. This local quality differentiation maintains shape accuracy while achieving desired thickness
Solution Approach 2:
The patent performs preliminary patterning and alignment of the first photoresist film layer before adding the second layer. This preliminary action ensures that the multi-layer structure maintains precise shape accuracy and vertical side surfaces by establishing the geometric framework early in the process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of highly reliable metal molded articles with improved dimensional accuracy, increased thickness, and enhanced electrical and mechanical properties, including vertical side surfaces and fine trenches, which improve torsional resistance and thermal dissipation.
Implementation Method 1
a first mold (210) made of an anodic aluminum oxide film
Implementation Method 2
forming a metal molded article by filling a plurality of openings of the composite mold with a metal material
Data Source
AI summary
Proposed are a highly reliable metal molded article manufactured using a combination of a mold made of an anodic aluminum oxide film and a patternable mold, and a method for manufacturing the same.