Thickening method of an electroforming shim

Abstract

A thickening method of an electroforming shim is provided to increase the thickness of a metal shim. In this embodiment, an active solder with a rare earth element is used to increase the moisture on the substrate surface for the solder during the combining process. Afterwards the oxides of the rare earth element are expelled by mechanical stirring to produce a clean contact surface. The melted fillers moisturize on the substrate surface to achieve the combination.

1 . A thickening method of an electroforming shim for increasing the thickness of a metal shim, comprising the steps of: 
 acquiring the metal shim and a metal mold;    coating a metal layer on the metal shim and the metal mold, respectively;    preheating the metal shim with the metal layer and the metal mold with the metal layer;    coating a layer of active solder on two joining surfaces of the metal shim and the metal mold, respectively;    pre-moisturizing the metal shim and the metal mold using a mechanical stirring method; and    combining the joining surfaces of the metal shim and the metal mold.    
   
   
       2 . The thickening method of  claim 1 , wherein the active solder contains at least one rare earth element.  
   
   
       3 . The thickening method of  claim 1 , before the step of acquiring the metal shim and a metal mold, further comprising the steps of: 
 providing a preformed mold prototype;    immersing the mold prototype in a conductive solution to electroform the metal mold on its surface; and    separating the mold prototype and the electroformed metal shim to acquire the metal shim.    
   
   
       4 . The thickening method of  claim 1 , wherein the step of coating a metal layer is achieved using a method selected from the group consisting of electroplating, electroless plating, evaporation, chemical vapor deposition, physical vapor deposition, and metal spray.  
   
   
       5 . The thickening method of  claim 1 , wherein the material of the metal shim is selected from the group consisting of copper, nickel, iron, cobalt, and their alloys.  
   
   
       6 . The thickening method of  claim 1 , wherein the material of the metal mold is selected from copper, nickel, carbon steel, die steel, zinc, aluminum, their alloys, and stainless steel.  
   
   
       7 . The thickening method of  claim 1 , wherein the material of the metal layer is selected from the group consisting of tin, indium, silver, and copper.  
   
   
       8 . The thickening method of  claim 1 , wherein the step of pre-moisturizing the metal shim and the metal mold using a mechanical stirring method is the step of pre-moisturizing the metal shim and the metal mold using ultrasonic waves  
   
   
       9 . The thickening method of  claim 1 , wherein the step of pre-moisturizing the metal shim and the metal mold using a mechanical stirring method is the step of pre-moisturizing the metal shim and the metal mold using an ultrasonic soldering machine.  
   
   
       10 . The thickening method of  claim 1 , wherein the step of preheating the metal shim with the metal layer and the metal mold with the metal layer is the step of preheating the metal shim with the metal layer and the metal mold with the metal layer using a hot press machine.  
   
   
       11 . The thickening method of  claim 1 , wherein a preheating temperature for the metal shim and the metal mold in the step of preheating the metal shim with the metal layer and the metal mold with the metal layer is determined by the materials of the metal shim and the metal mold.  
   
   
       12 . The thickening method of  claim 11 , wherein the preheating temperature is between 220° C. and 400° C.  
   
   
       13 . The thickening method of  claim 12 , wherein the preheating temperature is preferably around 250° C.