Solder medium for circuit interconnection
First Claim
1. An electronic device comprising a pair of components with mating contact pads, said contact pads being in juxtaposed alignment each to another, and mating solder joints electrically and mechanically interconnecting said mating contact pads, wherein each of said solder joints is a high-aspect-ratio subdivided solder joint structure comprising a plurality of subdivided solder paths between said mating contact pads, said solder joints being formed by embedding a plurality of solder wires longitudinally in an insulating matrix, deforming said insulating matrix so as to elongate said insulating matrix and to reduce the diameter of said plurality of solder wires, and cutting said elongated insulating matrix transverse to its longitudinal axis into slices, the length of said slices being determined by a spacing between said mating pads, said ratio between the length of each wire and its diameter being at least 2:
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Accused Products
Abstract
Electronic devices having at least two components wire mating contact pads are provided with high-aspect-ratio solder joints between the mating pads. These joints ar formed by placing a composite solder medium containing solder wires in an electrically insulating matrix such that at least two solder wires are in contact with the mating pads, and fusing the wires to the pads. The insulating matrix with remainder of solder wires is then optionally removed from between the said at least two component. The composite solder medium is formed by preparing an elongated body of solder wires in an insulating matrix and cutting off slices of the composite solder medium, the solder wires having a high-aspect-ratio of length to the diameter. Alternatively sheets of the composite solder medium are prepared by magnetically aligning solder coated magnetic particles into columns arranged transverse of an insulating matrix and heating sufficiently to fuse the solder in each column into a continuously conducting solder path.
54 Citations
47 Claims
- 1. An electronic device comprising a pair of components with mating contact pads, said contact pads being in juxtaposed alignment each to another, and mating solder joints electrically and mechanically interconnecting said mating contact pads, wherein each of said solder joints is a high-aspect-ratio subdivided solder joint structure comprising a plurality of subdivided solder paths between said mating contact pads, said solder joints being formed by embedding a plurality of solder wires longitudinally in an insulating matrix, deforming said insulating matrix so as to elongate said insulating matrix and to reduce the diameter of said plurality of solder wires, and cutting said elongated insulating matrix transverse to its longitudinal axis into slices, the length of said slices being determined by a spacing between said mating pads, said ratio between the length of each wire and its diameter being at least 2:
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9. A method of fabricating an electronic device including interconnecting one component of said electronic device to another component of said device, said components having aligned mating contact pads, which comprises
placing a thin electrically insulating body between the surfaces of said mating pads, said body being formed by embedding a plurality of solder wires longitudinally in an insulating matrix, deforming said insulating matrix so as to elongate said insulating matrix and to reduce the diameter of said plurality of solder wires, and cutting said elongated insulating matrix transverse to its longitudinal axis into slices to obtain said body, the length of said slices being determined by a spacing between said mating pads, and wherein the placement of the body is such that opposite ends of at least some of said plurality of solder wires contact the surfaces of the mating pads, at least two of said wires contacting each pair of said mating pads, and applying heat energy to fuse those ends of the wires to the pads which are being contacted by the wires.
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16. A method of fabricating an electronic device including interconnecting one component of said electronic device to another component of said device, said components having aligned mating contact pads, which comprises
placing a thin electrically insulating body between the surfaces of said mating pads, said body having a plurality of solder wires embedded in an insulating matrix such that opposite ends of at least some wires contact the surfaces of the mating pads, at least two of said wires contacting each pair of said mating pads, and applying heat energy to fuse those ends of the wires to the pads which are being contacted by the wires, and wherein said wires are formed by magnetically aligning solder-coated magnetic particles within a sheet of compliant or dissolvable matrix into a plurality of columns arranged transversely to the major surfaces of the sheet, and fusing the solder of individual particles forming continuously electrically conductive wires extending traversely of the sheet.
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20. A solder medium for interconnecting mating pads of circuit components, which comprises
a sheet of an insulating matrix material and a plurality of solder-containing wires distributed throughout the matrix transversely to opposite major surfaces of the sheet, wherein said sheet is formed by embedding the plurality of solder-containing wires longitudinally in the insulating matrix, deforming said insulating matrix so as to elongate said insulating matrix and to reduce the diameter of said plurality of solder-containing wires, and cutting said elongated insulating matrix transverse to its longitudinal axis into slices, the length of said slices being determined by a spacing between said mating pads, each of said wires having a high-aspect of length-to-diameter ratio.
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29. A method of preparing a solder medium for use in circuit interconnections wherein contact pads on one component of a circuit are connected to mating pads on another component of the circuit, which comprises forming an elongated body, said elongated body being formed by
longitudinally embedding a plurality of solder wires in an electrically insulating plastically deformable matrix to form an embedded body, deforming the embedded body longitudinally so as to elongate the embedded body and to reduce the diameter of the solder wires, and cutting said elongated embedded body transverse to its longitudinal axis into slices the length of said slices being determined by a spacing between said mating contact pads.
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43. A method of preparing a solder medium for use in circuit interconnections wherein contact pads on one component of a circuit are connected to mating pads on another component of the circuit, which comprises forming an elongated body having a plurality of elongated solder wires supported within a matrix of an insulating material, said wires extended longitudinally of the body and being separated each from another by said matrix, and
cutting said elongated embedded body transverse to its longitudinally axis into slices, the length of said slices being determined by a spacing between said mating contact pads, and wherein said elongated body is formed by embedding a plurality of solder particles in a matrix of an electrically insulating material forming a composite structure into an elongated structure in which said particles are deformed into elongated wires or ribbons.
Specification