Nanoporous Metal Locking Structures for Interconnect Alignment
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Solution Overview
Problem
Conventional techniques for assembling electronic components at sub-micron sizes often result in misalignment due to lateral forces, as existing alignment methods lack accuracy and precision, especially in devices smaller than 3 μm.
Innovation Solution
The use of nanoporous metal structures extending from one body and corresponding locking structures on another body, where the nanoporous metal structures collapse into the locking structures under pressure, resisting lateral forces and maintaining alignment between the two bodies during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment techniques are used for assembling electronic components at sub-micron sizes, then the assembly process is simple, but misalignment occurs due to lateral forces
Solution Approach 1:
The nanoporous metal structures are formed on the first body before assembly, and the locking structures are formed on the second body before assembly. These preliminary structures are designed to automatically engage and resist lateral forces during the assembly process, eliminating the need for complex real-time alignment control systems
Solution Approach 2:
Nanoporous metal structures are used to create locking features that can deform and engage with the locking structures on the second body. The porous nature of the metal allows for controlled deformation under pressure, enabling the structures to lock together and resist lateral forces that would cause misalignment
2Manufacturing precision
If equipment lacking alignment accuracy tolerance is used, then the assembly equipment is simpler, but misalignment occurs during assembly
Solution Approach 1:
The nanoporous metal structures and locking structures are designed in advance to counteract lateral forces that would cause misalignment. The structures are pre-configured to engage and lock together, providing built-in resistance against forces that would otherwise degrade alignment accuracy during assembly
Solution Approach 2:
The material properties of the nanoporous metal are utilized, where application of pressure changes the physical state of the material, causing it to collapse and lock into the locking structures. This parameter change enables simple equipment to achieve precise alignment through material behavior rather than complex mechanical control
3Manufacturing precision
If optical alignment techniques are used, then alignment can be achieved, but the techniques are inaccurate for sub-micron devices
Solution Approach 1:
The patent replaces optical alignment measurement systems with a mechanical locking system. Instead of relying on optical techniques to measure and maintain alignment, the nanoporous metal structures and locking structures provide direct mechanical engagement that physically maintains alignment, eliminating dependence on inaccurate optical measurement at sub-micron scales
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 solution effectively reduces the risk of assembly misalignment by resisting lateral forces and improving bonding between the bodies, ensuring accurate alignment and electrical connection during and after assembly.
Implementation Method 1
as pressure is applied to the first and second surfaces, the nanoporous metal collapses vertically into the locking structures of the second body
Implementation Method 2
the nanoporous metal structures resist lateral forces acting orthogonal to the surfaces of both the first and second body
Data Source
AI summary
Embodiments relate to the design of a device capable of maintaining the alignment an interconnect by resisting lateral forces acting on surfaces of the interconnect. The device comprises a first body comprising a first surface with a nanoporous metal structure protruding from the first surface. The device further comprises a second body comprising a second surface with a locking structure to resist a lateral force between the first body and the second body during or after assembly of the first body and the second body.