Electrical component assembly and method of fabrication
First Claim
1. A method for joining a first metal surface to a second metal surface, said method comprising the steps of:
- a) applying a plurality of hard particles to at least a portion of one of the first and second metal surfaces, wherein the plurality of hard particles include a substance that is harder than either metal surface;
b) disposing a non-conductive adhesive on one or both of the metal surfaces;
c) aligning the metal surfaces to form an interface;
d) applying compressive force to the first and second metal surfaces in a direction generally normal to said interface, such that at least a piercing portion of the plurality of hard particles penetrate through the adhesive and pierce the second metal surface; and
e) at least partially releasing the compressive force, the first and second surfaces thereafter being secured together by said adhesive, wherein the piercing portion of the plurality of hard particles remain in piercing relationship with at least a portion of the second metal surface.
3 Assignments
0 Petitions
Accused Products
Abstract
An electrical component assembly and method for the fabrication of the assembly in which particles are affixed to metal contact surfaces and pressure is applied to cause the particles to penetrate into at least one of the metal contact surfaces. In one method, hard particles are applied to one of the metal surfaces by electroplating the particles in a plating bath. In another method, the hard particles are applied to a non-conductive adhesive layer positioned between an electronic component and a substrate. Once pressure is applied to either the electronic component on the substrate, a permanent, electrically conductive bond is formed.
62 Citations
92 Claims
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1. A method for joining a first metal surface to a second metal surface, said method comprising the steps of:
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a) applying a plurality of hard particles to at least a portion of one of the first and second metal surfaces, wherein the plurality of hard particles include a substance that is harder than either metal surface;
b) disposing a non-conductive adhesive on one or both of the metal surfaces;
c) aligning the metal surfaces to form an interface;
d) applying compressive force to the first and second metal surfaces in a direction generally normal to said interface, such that at least a piercing portion of the plurality of hard particles penetrate through the adhesive and pierce the second metal surface; and
e) at least partially releasing the compressive force, the first and second surfaces thereafter being secured together by said adhesive, wherein the piercing portion of the plurality of hard particles remain in piercing relationship with at least a portion of the second metal surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. An electrical component assembly comprising:
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a) a substrate having a plurality of electrical contact sites on a surface thereof; and
b) a plurality of hard particles positioned on the substrate, such that each of the electrical contact sites has at least one hard particle associated therewith, the hard particles being affixed to the electrical contact sites. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 30, 31, 32, 33, 34, 35, 36, 38, 39, 40, 41, 42, 43, 44, 45, 46, 49, 50, 51, 52, 53, 54)
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29. A method for making an electrical component assembly comprising the steps of:
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a) providing a substrate having a plurality of electrical contact sites on a surface thereof;
b) positioning a plurality of hard particles on the substrate, such that each of the electrical contact sites has at least one hard particle associated therewith; and
c) affixing each hard particle to its associated contact site.
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37. A method for making an electronic component assemblies comprising:
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a) providing a substrate having a plurality of electronic components thereon, each component having a plurality of electrical contact sites on a surface thereof;
b) positioning a plurality of hard particles on the substrate, such that each of the electrical contact sites has at least one hard particle associated therewith;
c) affixing each hard particle to its associated contact site; and
d) dividing the substrate into at least two electrical component assemblies.
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47. A method for attaching an electrical component to a printed circuit board comprising the steps of:
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a) providing a printed circuit board having a plurality of electrical contact sites on a surface thereof, b) providing an electrical component having a plurality of electrical contact sites on a surface thereof, each electrical contact site on the electrical component having a corresponding electrical contact site on the surface of the printed circuit board, the electrical component further comprising a plurality of hard particles positioned on the electrical component, such that each of the electrical contact sites located on the surface of the electrical component has at least one hard particle associated therewith, the hard particles comprising a substance that is harder than the electrical contact sites on the surface of the printed circuit board, the hard particles being affixed to the electrical contact sites;
c) disposing a non-conductive adhesive on at least one of the electrical component and the printed circuit board, such that at least selected portions of the surfaces of the printed circuit board and the electrical component and the plurality of hard particles are covered by non-conductive adhesive;
d) positioning the electrical component relative to the printed circuit board, such that at least one hard particle on each contact on the substrate is in contact with the corresponding electrical contact site on the printed circuit board;
e) applying a compressive force to the component and printed circuit board so that the hard particles on the component penetrate the non-conductive adhesive and pierce into the electrical contact sites on the printed circuit board; and
f) releasing the applied compressive force, a force thereafter being maintained on the surfaces by the non-conductive adhesive, wherein the piercing portion of the hard particles remain embedded in the electrical contact sites on the printed circuit board.
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48. A printed circuit interconnection assembly comprising:
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a printed circuit board substrate having a plurality of electrical contact sites on a surface thereof; and
a plurality of hard particles positioned on the substrate, such that each of the plurality of electrical contact sites has at least one hard particle associated therewith, wherein the at least one hard particle is affixed to each electrical contact site.
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55. A method for attaching an electrical component to a printed circuit board comprising the steps of:
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a) providing an electrical component having a plurality of electrical contact sites on a surface thereof;
b) providing a printed circuit board having a plurality of electrical contact sites on a surface thereof, each electrical contact site on the board having a corresponding electrical contact site on the surface of the electrical component, the printed circuit board further comprising a plurality of hard particles positioned on the printed circuit board, such that each of the electrical contact sites located on the surface of the board has at least one hard particle associated therewith, the hard particles comprising a substance that is harder than the electrical contact sites on the surface of the electrical component, the hard particles affixed to the electrical contact sites;
c) disposing a non-conductive adhesive on at least one of the electrical component and the printed circuit board, such that at least selected portions of the surfaces of the electrical component and the printed circuit board and the plurality of hard particles are covered by the non-conductive adhesive;
d) positioning the electrical component relative to the printed circuit board, such that at least one hard particle on each contact on the printed circuit is in contact with the corresponding electrical contact site on the electrical component;
e) applying a compressive force to the component and printed circuit board so that the hard particles on the board penetrate the non-conductive adhesive and pierce into the electrical contact sites on the component; and
f) releasing the applied compressive force, a force thereafter being maintained on the surfaces by the non-conductive adhesive, wherein the piercing portion of the hard particles remaining embedded in the electrical contact sites on the printed circuit board. - View Dependent Claims (57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92)
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56. A method for plating hard particles onto a substrate comprising:
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providing a metal plating solution including hard particles in a plating tank;
positioning an anode submerged in the plating solution;
positioning the substrate in proximity to the anode;
agitating the metal plating solution; and
plating metal and hard particles onto the substrate.
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67. A method for plating hard particles onto a flexible tape substrate comprising:
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providing a particle plating solution including hard particles in a plating tank;
positioning an anode in the plating solution;
agitating the particle plating solution;
drawing the flexible circuit tape through the particle plating solution in proximity to the anode; and
plating a layer of hard particles onto the flexible tape substrate.
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Specification