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Method of Fabricating a Microweld Tip

IP.com Disclosure Number: IPCOM000041626D
Original Publication Date: 1984-Feb-01
Included in the Prior Art Database: 2005-Feb-02
Document File: 2 page(s) / 29K

Publishing Venue

IBM

Related People

Bryant, RM: AUTHOR [+3]

Abstract

In a microweld apparatus a DC electrical pulse of high power and short duration is applied to a wire positioned across two spaced electrodes that form the microweld tip. The dielectric material used to space the electrodes, normally an epoxy polymer resin, is subjected to high temperature and degrades with use. In this process a glass dielectric material is formed to hold the tip electrodes in accurately spaced relation and to provide a durable dielectric material that will withstand the operating temperatures of the tip. In this process a glass sheet is formed by tape casting a mixture of glass frit and a binder resin. The sheet can be cast to a thickness that is twice the desired spacing, with the density of the mixture ranging 50% of the theoretical. The thickness can be varied with the density of the material.

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Method of Fabricating a Microweld Tip

In a microweld apparatus a DC electrical pulse of high power and short duration is applied to a wire positioned across two spaced electrodes that form the microweld tip. The dielectric material used to space the electrodes, normally an epoxy polymer resin, is subjected to high temperature and degrades with use. In this process a glass dielectric material is formed to hold the tip electrodes in accurately spaced relation and to provide a durable dielectric material that will withstand the operating temperatures of the tip. In this process a glass sheet is formed by tape casting a mixture of glass frit and a binder resin. The sheet can be cast to a thickness that is twice the desired spacing, with the density of the mixture ranging 50% of the theoretical. The thickness can be varied with the density of the material. A small amount of solvent is applied to the cast green sheet to produce a "tacky" condition, and the sheet 10 assembled with electrodes 12 and 14. The composite is placed in a sintering furnace and heated to a temperature of approximately 1450OEC in a wet hydrogen atmosphere. During the sintering operation the glass sheet 10 will bond to the electrodes 1 2 and 14 and shrink in thickness to about 1 mil when a 2-mil-thick glass sheet is used.

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