Electrode connection method

• US 6,089,442 A
• Filed: 04/07/1997
• Issued: 07/18/2000
• Est. Priority Date: 04/10/1996
• Status: Expired due to Fees

• Current Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Original Assignee: Canon Kabushiki Kaisha (Canon Inc.)
• Inventors: Takahashi, Masanori, Saito, Riichi, Ouchi, Toshimichi
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): STONER, KILEY SHAWN
• Application Number:
  US08/826,689
• Time in Patent Office: 1,198 Days
• Field of Search: 228/118, 228/215, 228/46, 228/180.21, 228/6.2, 228/222
• US Class Current: 228/180.1
• CPC Class Codes: B23K 1/0004 Resistance soldering
• CPC Class Codes: B23K 2101/40 Semiconductor devices
• CPC Class Codes: H05K 2201/0394 Conductor crossing over a hole in the substrate or a gap between two separate substrate parts
• CPC Class Codes: H05K 2203/0195 Tool for a process not provided for in H05K3/00, e.g. tool for handling objects using suction, for deforming objects, for applying local pressure
• CPC Class Codes: H05K 2203/1121 Cooling, e.g. specific areas of a PCB being cooled during reflow soldering details related to cooling of mounted components H05K1/0203
• CPC Class Codes: H05K 3/3452 Solder masks
• CPC Class Codes: H05K 3/363 by soldering

Abstract

A method of connecting first electrodes formed on a first substrate to second electrodes formed on a second substrate and partially coated with a resist pattern so as to substantially expose an opening thereof at a surface of the second electrodes includes (a) coating the second electrodes with a solder at the opening of the resist pattern, (b) aligning the first electrodes with the second electrodes, and (c) electrically connecting the first electrodes to the second electrodes through the solder by heat-pressing the first and second electrodes with a heat-pressure bonding head including a tip face having a width smaller than a width of the opening of the resist pattern so as to heat-press the first and second electrodes at an entire region of the tip face of the heat-pressure bonding head. The method is effective in performing a good electrical connection between electrodes through a solder irrespective of an amount of the solder.

Claims

1. A method of connecting first electrodes formed on a first substrate to second electrodes formed on a second substrate and partially coated with a resist pattern so as to substantially expose an opening thereof at a surface of the second electrodes, said method comprising the steps of:

(a) coating the second electrodes with a solder at the opening of the resist pattern,

(b) aligning the first electrodes with the second electrodes, and

(c) electrically connecting the first electrodes to the second electrodes through the solder by heat-pressing the first and second electrodes with a heat-pressure bonding head including a substantially flat rectangular tip face having a width smaller than a width of the opening of the resist pattern so as to uniformly heat-press the first and second electrodes at an entire region of the tip face of the heat-pressure bonding head.

2. A method according to claim 1, wherein the first substrate comprises a flexible film substrate.

3. A method according to claim 1, wherein the first substrate is provided with a semiconductor device and the first electrodes comprising input electrodes and output electrodes, and the second substrate comprises a circuit board provided with the second electrodes comprising connection electrodes for supplying control signals and a power to the semiconductor device;

in the step (c) of said method, the input electrodes of the semiconductor device of the first substrate are electrically connected to the connection electrodes of the second substrate.

4. A method according to claim 3, wherein the first substrate comprises a flexible film substrate.

5. A method according to claim 1, wherein the first substrate is provided with a semiconductor device and the first electrodes comprising input electrodes and output electrodes to constitute a tape carrier package structure, the output electrodes being connected to electrode terminals of an electronic device;

and the second substrate comprises a circuit board provided with the second electrodes comprising connection electrodes for supplying control signals and a power to the semiconductor device;

in the step (c) of said method, the input electrodes of the semiconductor device of the first substrate are electrically connected to the connection electrodes of the second substrate.

6. A method according to claim 5, wherein the first substrate comprises a flexible film substrate and the semiconductor device is mounted on the flexible film substrate by a tape-automated bonding method.

7. A method according to claim 5, wherein the electronic device comprises an optical modulation device.

8. A method according to claim 5, wherein the electronic device comprises a display device.

9. A method according to claim 5, wherein the electronic device comprises a liquid crystal display device.

10. A method according to claim 1, wherein the resist pattern comprises a solder resist.

11. A method according to claim 1, wherein in the step (c), a cooling gas is supplied toward the second substrate via the first substrate.

32. A method according to claim 3, wherein said opening of the resist pattern comprises an inner portion, a connection portion and an outer portion closer to an end portion of the first substrate and in the step (c), the input electrodes are electrically connected to the connection electrodes at the connection portion so as to leave the inner portion and the outer portion, the inner portion having a width larger than a width of the outer portion.

33. A method according to claim 3, wherein each of the input electrodes has a first region and a second region, said second region corresponding to the opening of the solder resist.

34. A method according to claim 5, wherein said opening of the resist pattern comprises an inner portion, a connection portion and an outer portion closer to an end portion of the first substrate and in the step (c), the input electrodes are electrically connected to the connection electrodes at the connection portion so as to leave the inner portion and the outer portion, the inner portion having a width larger than a width of the outer portion.

35. A method according to claim 5, wherein each of the input electrodes has a first region and a second region, said second region corresponding to the opening of the solder resist.

38. A method according to claim 1, wherein, in the step (c), the first electrodes are electrically connected.

12. A method of connecting first electrodes formed on a first substrate to second electrodes formed on a second substrate, said method comprising the steps of:

(a) aligning the first electrodes with the second electrodes, and

(b) electrically connecting the first electrodes to the second electrodes by heat-pressing the first and second electrodes using a heat-pressure bonding head including a substantially flat rectangular tip face having a width smaller than a width of the opening of the resist pattern so as to uniformly heat-press the first and second electrodes at an entire region of the tin face of the heat-pressure bonding head, while supplying a cooling gas to at least one of the first and second substrates.

13. A method according to claim 12, wherein the first substrate comprises a flexible film substrate and the cooling gas is supplied to the flexible film substrate so as to cool the second substrate disposed thereunder.

14. A method according to claim 12, wherein the first substrate is provided with a semiconductor device and the first electrodes comprising input electrodes and output electrodes, and the second substrate comprises a circuit board provided with the second electrodes comprising connection electrodes for supplying control signals and a power to the semiconductor device;

in the step (b) of said method, the input electrodes are electrically connected to the connection electrodes while supplying the cooling gas is supplied to the first substrate so as to cool the second substrate disposed thereunder.

15. A method according to claim 14, wherein the first substrate comprises a flexible film substrate.

16. A method according to claim 12, wherein the first substrate is provided with a semiconductor device and the first electrodes comprising input electrodes and output electrodes to constitute a tape carrier package structure, the output electrodes being connected to electrode terminals of an electronic device;

and the second substrate comprises a circuit board provided with the second electrodes comprising connection electrodes for supplying control signals and a power to the semiconductor device;

in the step (b) of said method, the input electrodes are electrically connected to the connection electrodes while supplying the cooling gas is supplied to the first substrate so as to cool the second substrate disposed thereunder.

17. A method according to claim 16, wherein the first substrate comprises a flexible film substrate and the semiconductor device is mounted on the flexible film substrate by a tape-automated bonding method.

18. A method according to claim 16, wherein said tape carrier package structure comprises a plurality of tape carrier package structures and the steps (a) and (b) are repeatedly performed with respect to the respective tape carrier package structures.

19. A method according to claim 18, wherein in each step (b) repeatedly performed, the cooling gas is supplied in synchronism with a heat-pressure bonding operation.

20. A method according to claim 18, wherein in each step (b) repeatedly performed, the cooling gas is supplied irrespective of a heat-pressure bonding operation.

21. A method according to claim 16, wherein the electronic device comprises an optical modulation device.

22. A method according to claim 16, wherein the electronic device comprises a display device.

23. A method according to claim 16, wherein the electronic device comprises a liquid crystal display device.

24. A method according to claim 16, wherein the circuit board comprises a glass-epoxy resin board.

25. A method for producing an optical modulation apparatus which includes:

an optical modulation panel;

a tape carrier package structure comprising a flexible substrate, a semiconductor device for driving the panel mounted on the flexible substrate, and input electrodes and output electrodes for the semiconductor device; and

a circuit board provided with connection electrodes partially coated with resist pattern so as to leave an opening thereof and supplying power and supplying control signals to the semiconductor device;

said processing comprising the steps of;

(a) electrically connecting electrode terminals of the optical modulation panel to the output electrodes of the tape carrier package structure,

(b) coating the connection electrodes with a solder at the opening of the resist pattern,

(c) aligning the input electrodes of the tape carrier package structure with the connection electrodes of the circuit board, and

(d) electrically connecting the input electrodes to the connection electrodes through the solder by heat-pressing the input and connection electrodes with a heat-pressure bonding head including a substantially flat rectangular tip face having a width smaller than a width of the opening of the resist pattern so as to uniformly heat-press the input and connection electrodes at an entire region of the tip face of the heat-pressure bonding head.

26. A method according to claim 25, wherein the optical modulation panel comprises a display panel including a substrate provided with the electrode terminals at an edge portion thereof.

27. A method according to claim 25, wherein the optical modulation panel comprises a display panel including a pair of substrates at least one of which is provided with the electrode terminals to an edge portion thereof.

28. A method according to claim 25, wherein in the step (d), a cooling gas is supplied toward the circuit board via the flexible substrate.

36. A method according to claim 25, wherein said opening of the resist pattern comprises an inner portion, a connection portion and an outer portion closer to an end portion of the first substrate and in the step (c), the input electrodes are electrically connected to the connection electrodes at the connection portion so as to leave the inner portion and the outer portion, the inner portion having a width larger than a width of the outer portion.

37. A method according to claim 25, wherein each of the input electrodes has a first region and a second region, said second region corresponding to the opening of the solder resist.

29. A method for producing an optical modulation apparatus which includes:

an optical modulation panel;

a tape carrier package structure comprising a flexible substrate a semiconductor device for driving the panel mounted on the flexible substrate, and input electrode and output electrodes for the semiconductor device; and

a circuit board provided with connection electrodes for supplying power and supplying control signals to the semiconductor device;

said process comprising the steps of;

(a) electrically connecting electrode terminals of the optical modulation panel to the output electrodes of the tape carrier package structure,

(b) aligning the input electrodes of the tape carrier package structure with the connection electrodes of the circuit board, and

(c) electrically connecting the input electrodes to the connection electrodes by a heat-pressure bonding using a heat-pressure bonding head including a substantially flat rectangular tip face having a width smaller than a width of the opening of the resist pattern so as to uniformly heat-press the input and connection electrodes at an entire region of the tip face of the heat-pressure bonding head, while supplying a cooling gas toward the circuit board via the flexible substrate.

30. A method according to claim 29, wherein the optical modulation panel comprises a display panel including a substrate provided with the electrode terminals at an edge portion thereof.

31. A method according to claim 29, wherein the optical modulation panel comprises a display panel including a pair of substrates at least one of which is provided with the electrode terminals to an edge portion thereof.