Abstract: A method for patterning electroless plated metal on a polymer substrate. In a first embodiment a substrate is first coated with a polymer suitable for complexing a seed metal which can initiate electroless plating. The polymer is then mixed with a seed metal such as palladium, selectively irradiated to form the desired conductor pattern, and then etched so that the desired pattern remains. The substrate is subsequently placed in an electroless plating bath to form a metal pattern. In a second embodiment, before applying the seed metal a substrate immersed in a polymer solution suitable for complexing a seed metal can be selectively irradiated to selectively deposit polymer on the substrate, followed by applying a seed metal to form a polymer-seed metal mixture and an electroless plating bath. In addition, an alkaline chemical may be added to an acidic polymer to prevent the polymer from etching metal on the substrate.

Abstract: Metal electrical members bonded by coupling to at least one member a frequency doubled pulsed Nd:YAG laser comprising 533 and 1064 nm wavelengths is described. Frequency doubling is accomplished by directing a 1064 nm wavelength pulsed Nd:YAG laser at an intracavity nonlinear crystal such as potassium titanyl phosphate between a highly reflective mirror and a partially reflective mirror to produce frequency doubling. An infrared reflector outside the cavity can reduce the 1064 nm wavelength thereby increasing the percentage of 533 nm wavelength. Alternatively the laser beam can be split and the separate wavelengths directed to separate attenuators to allow the percentage of both 533 nm and 1064 nm wavelengths to be adjusted. A gold bump on an integrated circuit can be bonded to a gold plated copper TAB tape lead.

Abstract: A customizable circuit using a programmable interconnect and a compatible tape design for tape automated bonding of chips to the circuitry. The programmable interconnect comprises layers of wires, with one layer of wires forming overlap regions with the adjacent layer of wires. The wires can be selectively linked later to form the desired interconnect. The selective linkage represents the customization of an otherwise undedicated interconnect. The TAB chip bonding design uses a carrier tape to bond the integrated circuit chips to the programmable interconnect. Also disclosed is a method for forming the interconnect.

Abstract: A plating rack for use in electroplating at least one substrate includes a rack body onto which the subtrate may be placed; a metal ring connected to the rack body so as to surround a substrate placed on the rack body; and bistable, single-tipped cam assemblies for holding a placed substrate in place and for making electrical contact between the metal ring and the substrate.

Abstract: Bonding a plurality of TAB tape leads to electrical pads in and aligned with the surface of a die by covering the pads with a plurality of electrically conductive particles, aligning the electrical leads with the particles and the pads, and simultaneously bonding the particles to the pads and the electrical leads to the particles so that each bonded particle is between and in contact with a pad and a lead. Preferably the particles are solid spheres 1.0 mils in diameter. The spheres may be applied by covering the entire surface with the spheres, covering the pads with an adhesive material prior to the spheres, or covering the pads with a mixture of vehicle and spheres.

Abstract: A method for forming connections between copper conductors disposed on a substrate includes the steps of coating the copper conductors with a layer of nickel, exposing the coated copper conductors to a gas which includes a tungsten-bearing compound, and irradiating the substrate with a laser beam to deposit the tungsten between the copper conductors. A system for forming connections between copper conductors disposed on a substrate, includes means for coating the copper conductors with a layer of nickel, means for exposing the coated copper conductors to a gas which includes a tungsten-bearing compound, and means for irradiating the substrate with a laser beam to deposit the tungsten between the copper conductors.

Abstract: A desoldering material with an opening or window shaped so that the base of an electronic component can fit inside the opening while the desoldering material simultaneously contacts all solder joints which bond the component's outer leads to pads on a surface. A first adhesive secures the base to the surface, a second adhesive secures a retraction device to the base, the first adhesive is heated and softened without softening the second adhesive, and the retraction device removes the desoldered component from the surface. The invention is well suited to removing tape-automated-bonded integrated circuits adhesively attached to high density multichip module substrates.

Abstract: A method of making an electrical multilayer interconnect in which the electrical lines can be protected by an overcoat. The method includes depositing an electrically conductive layer on a substrate, forming a base plating mask on the electrically conductive layer, plating a copper base into an opening in the base plating mask onto the electrically conductive layer, stripping the base plating mask, forming a pillar plating mask on top of the copper base, plating an electrically conductive metal pillar into an opening in the pillar plating mask onto the top of the copper base, stripping the plating mask, and stripping the electrically conductive layer below the stripped base plating mask. Additionally, a protective overcoat layer can be deposited on the exposed copper surfaces.

Abstract: An electrical beam switch for interconnection between a plurality of inputs and outputs and includes a two-dimensional array of electrically charged particle emitters and an array of detectors facing the emitter array for receiving charged particles from various of the emitters. X and y electrical deflectors are positioned adjacent each of the emitters for directing the charged particles from each of the emitters to a selected one or more of the detectors. A screen lens may be positioned adjacent the array of detectors for focusing the directed beams on to the selected detector.

Abstract: Slide forming tape-automated-bonded leads extending from an integrated circuit chip with a support ring on the leads between the outer periphery of the chip and the outer lead ends. After the leads are formed the support ring remains attached to the vertical portion of the leads opposite the chip. The present invention is well suited for minimizing and footprint on relatively long TAB leads which fan out and require a support ring to maintain proper lead pitch.

Abstract: A thermally and electrically conductive paste and its method of use for making a detachable and compliant thermal conductive connection between two surfaces or making an electrical connection between first and second electrical components. The paste is comprised of a liquid metal and particulate solid constituents which is non-solidifying, conformable, compliant, is removable, provides containment to impulsive loading, and is simple to apply.

Abstract: An encapsulated integrated circuit which includes an integrated circuit die having a plurality of electric leads extending from the die. A thermal heat sink is positioned adjacent the die. The heat sink includes a thermoplastic material having a plurality of thermoconductive particles molded therein. A non-electrically conductive plastic material is sealably connected to the heat sink and encloses the die and seals around the leads. The heat sink plastic material is filled approximately 50 percent with metal particles, preferably in the form of powder. The particles may be from a group consisting of copper, aluminum, iron, carbon, aluminum nitride, silicon carbide, and boron nitride. The heat sink and the non-conductive plastic material have coacting interlocking interfaces.

Abstract: An electrical connector having first and second coacting parts which include spaced electrical contacts uses a flexible electrical tape having lead ends for connection to a circuit board. Side panels protect the lead ends from damage, during storage and shipment in one position and are releasably connected in a second position to provide support on the leads for bonding. After bonding, the side panels protect the flexible tape from operational damage.

Abstract: A method is disclosed for laser bonding two highly reflective electrical members. The first electrical member is coated with a coating alloy containing the metal of the second electrical member and a coupling material that is well absorbent of laser energy at the laser beam wavelength, has a lower melting point than either of the electrical members, and has a low solubility in a solid bond alloy of the electrical members. The laser characteristics are selected so that as bonding occurs a bond alloy of the electrical members solidifies and a solidification front drives the molten coupling material away from the bond interface toward the exterior periphery of the bond, so that substantially all of the solidified bond interface and bond interface strength results from the bond alloy. Coating a copper lead with a coating alloy containing gold and a coupling material, and then contacting the coated copper lead with a gold bonding pad provides for gold-to-gold TAB tape laser bonding.

Abstract: A capacitor, having an area smaller than the top area of a chip, is attached above the top of a tape-automated-bonded (TAB) chip and short bonded wires or TAB leads interconnect the capacitor electrodes with the power and ground pads on the chip. The interconnections are made as short as possible, with a maximum distance therebetween and with the greatest number which will reduce the inductance of the leads. The power and ground pads may contain inwardly extending bonding regions for wire bonds or flip chip capacitor attachment.

Abstract: An electrical connector having first and second coacting engagable parts for mating a plurality of spaced electrical contacts in which the system includes predictable alignment, contact force and wiping features. The connector may use flexible circuit tape as the contact elements in which a plurality of modules may be utilized to be aligned separately to avoid cumulative alignment errors. The flexible circuit tape may be a TAB type tape which is configured to allow the end user with the capability to program the signal/ground ratio of the interconnect.

Abstract: A substrate for attaching electrical devices having an interconnect wiring structure and a support for the interconnect, the support having a number of vias, or throughholes, extending therethrough and electrically connected to the interconnect. The substrate allows for attachment of the electrical devices on the side of the support opposite the interconnect at the vias, rather than on the interconnect itself. By so doing, the chips can be packed more density since the area between the chips normally reserved for engineering change pads, test pads and the like is not required, these functions being performed on the interconnect on the opposite side of the substrate.

Abstract: A flexible beam lead tape having three layers having trace conductors, a dielectric and a ground plane. Vias extend through the dielectric layer at the first and second ends of the electrical conductors for providing versatile connections to either ends of the conductors. The ends of the conductors may be provided with electrical connections on either or both sides of the tape and may be connected by pressure contact or by bonding. The tape also includes means for aligning the tape with a substrate to which the tape will be interconnected.

Abstract: A method of replacing a defective electronic component having a plurality of electrical leads bonded to electrical contacts on a support by cutting leads adjacent the bond site, rebonding the stubs to the contacts, replacing the defective component and bonding the leads of the replacement component to the electrical contacts. Preferably, the leads are cut simultaneously with the rebonding of the stubs. The leads may be bonded to the top of the stub or to the side of the stub. A bonding tool is provided for simultaneously cutting a lead and rebonding the resultant stub.

Abstract: A hybrid superconducting-semiconducting field effect transistor-like circuit element comprised of a superconducting field effect transistor and a closely associated cryogenic semiconductor inverter for providing signal gain is described. The hybrid circuit functions as a nearly ideal pass gate in cryogenic applications.