Direct chip attachment (DCA) with electrically conductive adhesives
First Claim
Patent Images
1. A method of making integrated circuit chips comprising the steps of:
- applying an insulative thermoplastic adhesive paste, over a semiconductor wafer substrate having a plurality of chip sites and integrated circuits communicating with a matrix of conductive metal pads on a major surface of the substrate;
drying the insulative thermoplastic;
forming holes in the insulative thermoplastic layer at the metal pads;
filling the holes with a conductive thermoplastic adhesive paste; and
drying the conductive thermoplastic to form a dry composite adhesive layer dividing the wafer into a plurality of chips after forming the composite layer.
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Abstract
A simple process for card assembly by Direct Chip Attachment (DCA) uses electrically conductive adhesives. Two methods create the same intermediate wafer product with a layer of insulative thermoplastic and conductive thermoplastic bumps. After sawing or dicing the wafer to form the chips, the chips are adhered to chip carriers with conductive pads which match the conductive thermoplastic bumps, using heat and pressure. Chips may be easily removed and replaced using heat.
71 Citations
15 Claims
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1. A method of making integrated circuit chips comprising the steps of:
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applying an insulative thermoplastic adhesive paste, over a semiconductor wafer substrate having a plurality of chip sites and integrated circuits communicating with a matrix of conductive metal pads on a major surface of the substrate; drying the insulative thermoplastic; forming holes in the insulative thermoplastic layer at the metal pads; filling the holes with a conductive thermoplastic adhesive paste; and drying the conductive thermoplastic to form a dry composite adhesive layer dividing the wafer into a plurality of chips after forming the composite layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of making integrated circuit chips comprising the steps of:
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providing a semiconductor wafer substrate having a plurality of chip sites and integrated circuits communicating with a matrix of conductive metal contact pads on a major surface of the substrate; depositing conductive thermoplastic adhesive paste bumps on the metal pads; drying the conductive adhesive; applying an insulative thermoplastic adhesive over the substrate surface between the conductive adhesive deposits; curing the insulative adhesive to form a dry composite adhesive layer; and dividing the wafer into a plurality of chips after forming the composite layer. - View Dependent Claims (10, 11, 12, 13)
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14. A method of preparing substrates for attachment comprising the steps of:
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providing a first semiconductor wafer substrate having a plurality of chip sites with a matrix of conductive metal pads on a major surface; depositing an electrically conductive thermoplastic adhesive paste on the metal pads; depositing an electrically insulating thermoplastic adhesive on the substrate surface around the metal pads; drying the paste; and dividing the semiconductor wafer into a plurality of individual chips after said depositing steps and said drying step. - View Dependent Claims (15)
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Specification