Patents by Inventor Donald J. Hayes

Donald J. Hayes has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 6805902
    Abstract: Micro-optical elements such as lenses and wave-guides are manufactured by printing a hardenable optical fluid using digitally driven ink-jet technology. An array of micro-optical elements are precisely positioned in an electroformed substrate having a surface containing structural openings which serve as molds for micro-droplets of optical fluids deposited from an ink-jet printhead. The structural openings have a stepped down edge, a shelf-like support surface below the edge and a centered aperture in the substrate. The micro-optical element formed is controlled by the shape of the edge in the surface of the substrate and the radius by the volume of micro-droplets deposited into the structural opening. The structural openings can be circular, or any desired shape which is easily and precisely formed in an electroformed substrate.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: October 19, 2004
    Assignee: Microfab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 6672129
    Abstract: A method and apparatus is disclosed which employs a pulse-controlled microdroplet fluid delivery system for precisely dispensing fragrances and other odor producing vapors. The pulse-controlled fluid delivery device is capable of ejecting microdroplets of fluid with a diameter less than 350 micrometers at a controlled ejection rate based upon inkjet printing technology. The pulse-controlled fluid delivery system includes mechanisms for vaporizing the fluids and delivery of the vapors to the nose, which is controlled by a programmable system controller capable of real time data-driven dispensing with a multi-fluid capability. Synthesis of custom fragrances is made possible by a multijet programmed control system which adjusts dispensing rates of components. Calibration of a prior art “electronic nose” is disclosed. A precise calibration gas is produced in real-time to counteract the effect of drifting.
    Type: Grant
    Filed: February 7, 2002
    Date of Patent: January 6, 2004
    Assignee: MicroFab Technologies, Inc.
    Inventors: Christopher J. Frederickson, Donald J. Hayes, David B. Wallace, David W. Taylor, Matthew D. Hayes
  • Patent number: 6642068
    Abstract: A method for forming a micro-optical switch component includes providing a semiconductor substrate having a surface. An opto-electronic device is integrated into the semiconductor substrate at a site. A pedestal of microlens material is formed on the semiconductor substrate surface at the site of the opto-electronic device. The pedestal extends from the semiconductor substrate surface and has a top surface spaced apart from the semiconductor substrate surface. A print head is provided and contains an optical fluid which is hardenable and capable of serving as a micro-optical element. The printhead includes an orifice from which micro-droplets of the optical fluid are ejected in response to control signals. Optical fluid is deposited onto the top surface of the pedestal to thereby form a micro-optical element on the pedestal.
    Type: Grant
    Filed: May 3, 2002
    Date of Patent: November 4, 2003
    Inventors: Donald J. Hayes, Ting Chen, W. Royall Cox
  • Patent number: 6620283
    Abstract: A method for making a laminated carrier film for use in releasing interstitial fluid from skin for collection or measurement includes providing a printhead having an orifice and a reservoir containing a meltable absorber substance, the printhead being capable in response to electrical signals, to eject droplets of said meltable absorber substance from the orifice; supporting a carrier film having a series of spaced apart openings for a meltable absorber substance on a support base, in close proximity to the printhead, whereby the spaced apart openings on the carrier film can be positioned relative to the orifice to receive absorber substance droplets ejected from the printhead; filling the spaced apart openings of the carrier film with meltable absorber substance ejected from the printhead; and covering the carrier film on one side with a clear polymer film strip selected to allow laser energy to pass through the clear polymer film in order to reach the meltable absorber substance inside the openings.
    Type: Grant
    Filed: November 27, 2001
    Date of Patent: September 16, 2003
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, David W. Taylor, David B. Wallace
  • Patent number: 6440212
    Abstract: A process of making thermoelectric coolers by direct printing of n- and p-type semiconductor materials suitable for making thermoelectric coolers is disclosed. Micro Jet Printing of arrays on n and p-type materials belong to conductive site pads on non-conductive substrate and crystalization of these materials in the preferred direction as they cool produces thermoelectric cooler components without the need for sawing and machining operations. A non-conductive top substrate having conductive bonding pads is secured to the tops of the columns n and p-type semiconductor materials thereby forming an electrical and physical bond to make a thermoelectric cooler package.
    Type: Grant
    Filed: February 27, 2001
    Date of Patent: August 27, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 6390453
    Abstract: A method and apparatus is disclosed which employs a pulse-controlled microdroplet fluid delivery system for precisely dispensing fragrances and other odor producing vapors. The pulse-controlled fluid delivery device is capable of ejecting microdroplets of fluid with a diameter less than 350 micrometers at a controlled ejection rate based upon ink-jet printing technology. The pulse-controlled fluid delivery system includes mechanisms for vaporizing the fluids and delivery of the vapors to the nose, which is controlled by a programmable system controller capable of real time data-driven dispensing with a multi-fluid capability. Synthesis of custom fragrances is made possible by a multijet programmed control system which adjusts dispensing rates of components. Calibration of a prior art “electronic nose” is disclosed. A precise calibration gas is produced in real-time to counteract the effect of drifting.
    Type: Grant
    Filed: April 30, 2001
    Date of Patent: May 21, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventors: Christopher J. Frederickson, Donald J. Hayes, David B. Wallace, David W. Taylor, Matthew D. Hayes
  • Patent number: 6367925
    Abstract: A low cost digitally operated dispenser apparatus and method of operation and construction is obtained by combining flat sided, preferably rectangular tubular capillary tube having an orifice, with a flat elongated strip of piezoelectric material. Microdroplets are dispensed from an internal chamber within the capillary tube, or a separate feed supply, upon application of voltage pulses through electrodes connected to conductive layers on the piezoelectric material. The piezoelectric strip may be parallel to the flat capillary tube or perpendicular to it. On a variation, a fixture can be used to improve performance in combination with the capillary tube and piezoelectric strip. A standoff strip allows the piezoelectric operator to be thermally isolated from a flat rectangular capillary tube.
    Type: Grant
    Filed: February 28, 2000
    Date of Patent: April 9, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventors: Ting Chen, Donald J. Hayes
  • Patent number: 6339897
    Abstract: A method and apparatus for dispensing pheromones, semiochemicals, and other materials that can control the behavior or physiology of insects and other pests are described. The dispensers (AgJets) use electronic dispensing technology such as that used in ink jet printing. The units have a self-containing reservoir for the to-be-dispensed chemical, and they are capable of being activated to dispense by an electromagnetic signal from a broadcasting controller unit. Picoliter volumes of pheromones and semiochemicals can be dispensed in drop-on-demand mode. The units for dispensing shall be powered by battery and/or solar energy for hands-off operation in remote sites. The units may also have weather monitoring devices (thermometer, anemometer, humidity measurement), and such climactic information can be transmitted to central receiving stations and/or used locally in the AgJet device to control chemical dispensing.
    Type: Grant
    Filed: March 8, 2001
    Date of Patent: January 22, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, Christopher J. Frederickson, Murray Sinks
  • Patent number: 6338715
    Abstract: A more reliable and precise method of determining the olfactory threshold is provided by a digitally operated apparatus that dispenses controlled amounts of a volatile test fluid from a digital jetting device of the type used for ink jet printing. A precise number and size of micro droplets are dispensed onto a heater which vaporizes the fluid at a test location where a patient can sniff and report whether the odor is sensed. Incremental adjustments are made to determine the approximate threshold of olfactory perception of the odor. Sensors are included to verify dispensing and to coordinate dispensing with breathing.
    Type: Grant
    Filed: March 31, 2000
    Date of Patent: January 15, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, Ioan Achiriloaie, David W. Taylor, Norman Comparini, David B. Wallace
  • Patent number: 6334980
    Abstract: Miniaturized, self-contained apparatus for conducting bio-chemical reactions and analyses is formed in a compact structure comprising a substrate which includes a plurality of reaction chambers and a plurality of analysis chambers which are in fluid communication with the reaction chambers. Independently controllable heaters and coolers are positioned in thermal contact with the reaction chambers to permit parallel processing of biological samples at different temperature cycles. The apparatus is especially useful for performing and analyzing the results of a polymerase chain reaction.
    Type: Grant
    Filed: September 25, 1998
    Date of Patent: January 1, 2002
    Assignee: Microfab Technologies Inc.
    Inventors: Donald J. Hayes, David B. Wallace, Christopher J. Frederickson
  • Patent number: 6334851
    Abstract: A carrier film has one or more openings or wells loaded with a meltable absorbing substance for absorbing laser energy. The carrier film has a clear film which covers one side of the opening containing the absorber substance and the open side of the opening in the carrier film is positioned adjacent to the skin and irradiated through the clear cover film by a laser beam. The melted laser energy absorbing substance is ejected to form a spot laying on the skin. After moving the carrier film, a laser beam impinges the spot thereby raising a tiny blister on the skin containing interstitial fluid. The interstitial fluid is collected for diagnosis and analysis. A method of making and loading the carrier film with a digitally operated dispenser of the type used for ink jet printing is disclosed. Special construction of the opening appears to enhance ejection.
    Type: Grant
    Filed: May 10, 2000
    Date of Patent: January 1, 2002
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, David W. Taylor, David B. Wallace
  • Patent number: 6325475
    Abstract: An ink-jet dispenser for the micro-dispensation of airborne materials into an individual's airspace for inhalation or sniffing. The ink-jet dispenser will allow the study of temporal integration times, inter-nostril summation, backwards and forwards masking, and other olfactory phenomena.
    Type: Grant
    Filed: April 21, 1997
    Date of Patent: December 4, 2001
    Assignee: Microfab Technologies Inc.
    Inventors: Donald J. Hayes, Christopher J. Frederickson, David B. Wallace
  • Patent number: 6188416
    Abstract: An ink jet printhead assembly for ink jet printing apparatus and a method for the manufacture thereof. The piezoelectrically operable ink jet printhead assembly has two arrays of driving channels aligned with a single orifice array in which each orifice connects through a fluid channel to a single driving channel.
    Type: Grant
    Filed: February 13, 1997
    Date of Patent: February 13, 2001
    Assignee: MicroFab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 6114187
    Abstract: Solder jetting technology is employed to prepare a chip scale package which is "bumped" in preparation for making electrical interconnections with pads on a connection surface of the chip. The chip scale packages can be produced in wafer form before severing the wafer to produce individually packaged chips. In one embodiment a column is built on each pad of the chip connection surface and then the pads and columns are covered with a layer of dielectric jetted on to the connection surface to provide the package. The upper surface portion of the dielectric layer is removed to expose the ends of the columns. The ends of the columns are then bumped using solder jet technology to ready the package for subsequent electrical interconnections. An alternate embodiment employs taller columns which extend above the layer of dielectric. A solder reflow operation is applied to convert the exposed upper ends of the columns into generally spherical balls.
    Type: Grant
    Filed: January 8, 1998
    Date of Patent: September 5, 2000
    Assignee: MicroFab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 6077380
    Abstract: Solid spheres of substantially uniform size and shape and coated with a lower temperature melting material are formed for use in interconnect arrays, solder pastes, Z-axis conduction adhesives, etc. Drops of two materials are merged in flight forming a coating of the lower melting temperature material on the drop of higher melting temperature material.
    Type: Grant
    Filed: March 9, 1998
    Date of Patent: June 20, 2000
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, Mary W. Hartnett
  • Patent number: 6015083
    Abstract: A method has been formed for direct solder "bumping" of wafers, chips and interconnection pads or traces on hard to solder surfaces such as aluminum and indium tin oxide. It has been discovered that conventional solders modified by the addition of a light reactive metal can be jetted in the form of microdroplets onto a hard to solder substrate and that the modified droplets will wet and bond to the surface of the hard to solder substrate. This makes it possible for the first time to create solder bumps on bare uncoated hard to solder substrates such as aluminum and indium tin oxide without the need for first applying a different surface which conventional solder will wet.
    Type: Grant
    Filed: January 27, 1997
    Date of Patent: January 18, 2000
    Assignee: MicroFab Technologies, Inc.
    Inventors: Donald J. Hayes, Michael T. Boldman, Virang G. Shah
  • Patent number: 5861323
    Abstract: Process for manufacturing arrays of metal balls for interconnect testing and/or interconnect bonding of microelectronic devices and the like with substrates are formed by securing metal balls in predetermined patterns of apertures in an insulating membrane or film. The pattern of apertures corresponds with the pattern of metal interconnect pads on a microelectronic device or the like and the corresponding pattern of interconnect pads on the substrate. The metal ball arrays may be used for testing and/or may be heated and reflowed to bond the microelectronic device to the substrate.
    Type: Grant
    Filed: June 6, 1994
    Date of Patent: January 19, 1999
    Assignee: MicroFab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 5858190
    Abstract: A method for manufacturing ink jet printheads and the product printheads derived therefrom. The method involves the electro-deposition passivation of ink channels in ink jet printheads.
    Type: Grant
    Filed: September 25, 1997
    Date of Patent: January 12, 1999
    Assignee: MicroFab Technologies, Inc.
    Inventor: Donald J. Hayes
  • Patent number: 5849208
    Abstract: Miniaturized, self-contained apparatus for conducting bio-chemical reactions and analyses is formed in a compact structure made from a substrate which includes a plurality of reaction chambers and a plurality of analysis chambers which are in fluid communication with the reaction chambers. Independently controllable heaters and coolers are positioned in thermal contact with the reaction chambers to permit parallel processing of biological samples at different temperature cycles. The apparatus is especially useful for performing and analyzing the results of a polymerase chain reaction.
    Type: Grant
    Filed: September 7, 1995
    Date of Patent: December 15, 1998
    Assignee: MicroFab Technoologies, Inc.
    Inventors: Donald J. Hayes, David B. Wallace, Christopher J. Frederickson
  • Patent number: 5772106
    Abstract: A compact printhead assembly is designed for employment in a soldering operation without the need for fluxes and without conducting the operation in a confined chamber. A self-contained printhead assembly has an internal reservoir and internal heating elements for raising the temperature above the melting temperature of solder or other liquid to be dispensed in microdroplets from a working surface at one end of the printhead housing. A jetting device containing an electro-mechanical transducer is pulsed to produced droplets at an exit orifice located at the working surface. Inert gas is preheated by the housing and delivered to the working surface to establish an oxygen-free atmosphere around the exit orifice and between the working surface and a substrate located a working distance away, whereby microdrops can be formed and deposited without harmful oxidation.
    Type: Grant
    Filed: December 29, 1995
    Date of Patent: June 30, 1998
    Assignee: MicroFab Technologies, Inc.
    Inventors: Scott D. Ayers, Donald J. Hayes, Michael T. Boldman, David B. Wallace