Contact bonding and packaging of integrated circuits

Claim 1

A method for fabricating a plurality of structures for electrical devices utilizing automated manufacturing apparatus in such fabricating to provide on the outside of each such structure a plurality of electrical connecting means from an electrical unit in the structure and with each such electrical unit having thereon a plurality of contact portions on one surface thereof to which the connecting means are electrically connected, which method comprises: providing an elongated first member in a strip form having a plurality of conductive portions therewith arranged in a plurality of groups separated from one another over the length of said first member and with the transverse dimension of a group at the perimeter hereof defining generally the width of the elongated member but being specifically less than such width whereby to provide a frame portion outside said perimeter, the conductive portions of each said group corresponding in number to the contact portions of an electrical unit for a structure to be fabricated, each of the conductive portions of each said group having an inner portion adjacent a central area in the group and said inner end portions being spaced apart from one another at said central area and positioned in a pattern corresponding to the pattern in which the contact portions are placed on an electrical unit, with each conductive portion extending outwardly from the inner end portion to an outer portion thereof toward the perimeter of that group on said first member, bringing together an electrical unit and a group of conductive portions on the elongated first member at the central area of the group so that each inner end portion of a conductive portion in a group is in alignment with a corresponding contact portion on the electrical unit, simultaneously securing all said inner end portions of a group and said contact portions of an electrical unit together in a secure electrical and mechanical connection to provide an independent assembly which includes an electrical unit and a corresponding group of conductive portions on said first member in said strip form, providing an elongated one-piece metallic second member in a strip form having a plurality of groups of lead portions preformed therein with the lead portions of each group corresponding in number to the contact portions and to the conductive portions in an independent assembly, and with each lead portion having an inner end portion, said lead portions in a said group each having an inner end portion at a central area of the group and each lead portion extending outwardly from that central area for a predetermined length, bringing said elongated first member in strip form and said elongated second member in strip form into position with respect to one another such that an independent assembly with said first member and a single group of lead portions in said second member are stacked relative to one another, with the outer portions of the conductive portions of a group with said first member and the inner end portions of said lead portions of a group with said second member being in alignment with one another, securing together in secure electrical and mechanical connections the corresponding outer portions of the conductive portions of a group in said first member and the inner end portions of the lead portions of a group in said second member, and separating said first member and said second member by severing from said first member excess portions of the conductive portions and the frame portion in a single group which are outwardly of said electrical and mechanical connections to the lead portions of said second member group.

Claim 2

A method for fabricating a plurality of structures for electrical devices utilizing automated manufacturing apparatus in such fabricating to provide on the outside of each such structure a plurality of electrical connecting means from an electrical unit in the structure and with each such electrical unit having thereon a plurality of contact portions on one surface thereof to which the connecting means are electrically connected, which method comprises: providing an elongated first member in a strip form having a plurality of conductive portions therewith arranged in a plurality of groups separated from one another over the length of said first member and with the transverse dimension of a group at the perimeter hereof defining generally the width of the elongated member but being specifically less than such width whereby to provide a frame portion outside said perimeter, the conductive portions of each said group corresponding in number to the contact portions of an electrical unit for a structure to be fabricated, each of the conductive portions of each said group having an inner portion adjacent a central area in the group and said inner end portions being spaced apart from one another at said central area and positioned in a pattern corresponding to the pattern in which the contact portions are placed on an electrical unit, with each conductive portion extending outwardly from the inner end portion to an outer portion thereof toward the perimeter of that group on said first member, bringing together an electrical unit and a group of conductive portions on the elongated first member at the central area of the group so that each inner end portion of a conductive portion in a group is in alignment with a corresponding contact portion on the electrical unit, simultaneously securing all said inner end portions of a group and said contact portions of an electrical unit together in a secure electrical and mechanical connection to provide an independent assembly which includes an electrical unit and a corresponding group of conductive portions on said first member in said strip form, providing an elongated one-piece metallic second member in a strip form having a plurality of groups of lead portions preformed therein with the lead portions of each group corresponding in number to the contact portions and to the conductive portions in an independent assembly, and with each lead portion having an inner end portion, said lead portions in a said group each having an inner end portion at a central area of the group and each lead portion extending outwardly from that central area for a predetermined length, bringing said elongated first member in strip form and said elongated second member in strip form into position with respect to one another such that an independent assembly with said first member and a single group of lead portions in said second member are stacked relative to one another, with the outer portions of the conductive portions of a group with said first member and the inner end portions of said lead portions of a group with said second member being in alignment with one another, securing together in secure electrical and mechanical connections the corresponding outer portions of the conductive portions of a group in said first member and the inner end portions of the lead portions of a group in said second member, and separating said first member and said second member by severing from said first member excess portions of the conductive portions and the frame portion in a single group which are outwardly of said electrical and mechanical connections to the lead portions of said second member group.

Claim 5

A method for fabricating structures utilizing electrical units having a plurality of connections on the outside of each such structure electrically connected to a plurality of contact portions on an electrical unit in the structure, which method comprises, providing a first member having a plurality of conductive portions therewith arranged in a group, the conductive portions of said group corresponding in number to the contact portions of an electrical unit for a structure to be fabricated, and said first member having a portion outside the group of conductive portions which maintains said conductive portions in a predetermined pattern, each of the conductive portions of said group having an inner portion adjacent an open central area in the group and said inner end portions being spaced apart from one another at said central area and positioned in a pattern corresponding to the pattern in which the contact portions are placed on an electrical unit, with each conductive portion extending outwardly from the inner end portion to an outer portion thereof toward the outside portion for that group on said first member, bringing together an electrical unit and the group of conductive portions on said first member at the central area of the group so that each inner end portion of a conductive portion in the group is in alignment with a corresponding contact portion on the electrical unit, securing together substantially simultaneously said inner end portions of a group and said contact portions of an electrical unit in an electrical and mechanical connection to provide an independent assembly which includes an electrical unit and the conductive portions of the group on said first member, providing a second member having a plurality of lead portions in a group and having a portion of said second member outside of the group of lead portions which maintains said lead portions in a predetermined pattern, with the lead portions of the group corresponding in number to the contact portions and conductive portions in an independent assembly, said lead portions in said group each having an inner end portion at a central area of the group and each lead portion extending outwardly from that central area to said portion outside of the group, bringing said first member and said second member into position with respect to one another such that an independent assembly with said first member and the group of lead portions in said second member are stacked relative to one another, with the outer portions of the conductive portions of said first member and the inner end portions of said lead portions of said second member being in alignment with one another, securing together substantially simultaneously in electrical and mechanical connections the corresponding outer portions of the conductive portions in said first member and the inner end portions of the lead portions in said second member, and separating said first member and said second member by severing from said first member excess portions of the conductive portions and the outside portion thereof which are outwardly of said electrical and mechanical connections of the lead portions and the conductive portions to provide a fabricated structure, with the conductive portions of said first member being more flexible than the lead portions of said second member and the flexibility being such as to relieve undue stresses at the contact portions of the electrical unit in the structure.

Claim 6

A method for fabricating structures utilizing electrical units having a plurality of connections on the outside of each such structure electrically connected to a plurality of contact portions on an electrical unit in the structure, which method comprises, providing a first member having a plurality of conductive portions therewith arranged in a group, the conductive portions of said group corresponding in number to the contact portions of an electrical unit for a structure to be fabricated, and said first member having a portion outside the group of conductive portions which maintains said conductive portions in a predetermined pattern, each of the conductive portions of said group having an inner portion adjacent an open central area in the group and said inner end portions being spaced apart from one another at said central area and positioned in a pattern corresponding to the pattern in which the contact portions are placed on an electrical unit, with each conductive portion extending outwardly from the inner end portion to an outer portion thereof toward the outside portion for that group on said first member, bringing together an electrical unit and the group of conductive portions on said first member at the central area of the group so that each inner end portion of a conductive portion in the group is in alignment with a corresponding contact portion on the electrical unit, securing together substantially simultaneously said inner end portions of a group and said contact portions of an electrical unit in an electrical and mechanical connection to provide an independent assembly which includes an electrical unit and the conductive portions of the group on said first member, providing a second member having a plurality of lead portions in a group and having a portion of said second member outside of the group of lead portions which maintains said lead portions in a predetermined pattern, with the lead portions of the group corresponding in number to the contact portions and conductive portions in an independent assembly, said lead portions in said group each having an inner end portion at a central area of the group and each lead portion extending outwardly from that central area to said portion outside of the group, bringing said first member and said second member into position with respect to one another such that an independent assembly with said first member and the group of lead portions in said second member are stacked relative to one another, with the outer portions of the conductive portions of said first member and the inner end portions of said lead portions of said second member being in alignment with one another, securing together substantially simultaneously in electrical and mechanical connections the corresponding outer portions of the conductive portions in said first member and the inner end portions of the lead portions in said second member, and separating said first member and said second member by severing from said first member excess portions of the conductive portions and the outside portion thereof which are outwardly of said electrical and mechanical connections of the lead portions and the conductive portions to provide a fabricated structure, with the conductive portions of said first member being more flexible than the lead portions of said second member and the flexibility being such as to relieve undue stresses at the contact portions of the electrical unit in the structure.

Claim 8

A method using assembly apparatus for attaching each of a plurality of semiconductor chips to corresponding independent groups of conductive portions with a continuous strip-like member, each semiconductor chip having a plurality of contact pads located within the lateral dimensions of the chip and said continuous strip-like member being originally provided on a reel and adapted to be rewound on a reel after such attaching, which method comprises providing a flexible strip-like metal member which is originally wound on a reel, said member having a plurality of spaced apart independent electrical connector groups over the length of said member with each group comprising a plurality of conductive portions and each conductive portion having an originally unsupported inner end portion and each said group including an excess portion of the strip-like metal member outwardly of the conductive portions, positioning a portion of the metal member in the assembly apparatus, providing a plurality of such semiconductor chips, with each chip adapted to be attached to an independent group of conductive portions of said striplike member at contact pads on said chip, aligning a semiconductor chip at its contact pads with respect to corresponding inner end portions of a group of conductive portions, said inner end portions each being spaced apart from one another adjacent an open area in a predetermined pattern corresponding to the pattern in which the contact pads are placed on the semiconductor chip, maintaining in engagement with one another the contact pads on the semiconductor chip and a group of conductive portions so that each inner end portion of a conductive portion in the group is in alignment with a contact pad, attaching together by a substantially simultaneous operation said inner end portions of a group and said contact pads of a semiconductor chip in an electrical and mechanical connection within the lateral dimensions of the chip, thereby to provide an independent assembly of a semiconductor chip and the conductive portions of each group on said member, with the excess portion of the strip-like metal member for each group adapted to ultimately be removed so that the conductive portions each then serve as an independent electrical connection from a semiconductor chip contact pad, and rewinding the strip-like member with the plurality of said independent assemblies attached thereto on to a reel to provide for subsequent handling of the member on the reel, said strip-like member being sufficiently flexible so that the attachments of the contact pads to the conductive portions will not be disturbed in the rewinding operation.

Claim 9

A method using assembly apparatus for attaching each of a plurality of semiconductor chips to corresponding independent groups of conductive portions with a continuous strip-like member, each semiconductor chip having a plurality of contact pads located within the lateral dimensions of the chip and said continuous strip-like member being originally provided on a reel and adapted to be rewound on a reel after such attaching, which method comprises providing a flexible strip-like metal member which is originally wound on a reel, said member having a plurality of spaced apart independent electrical connector groups over the length of said member with each group comprising a plurality of conductive portions and each conductive portion having an originally unsupported inner end portion and each said group including an excess portion of the strip-like metal member outwardly of the conductive portions, positioning a portion of the metal member in the assembly apparatus, providing a plurality of such semiconductor chips, with each chip adapted to be attached to an independent group of conductive portions of said striplike member at contact pads on said chip, aligning a semiconductor chip at its contact pads with respect to corresponding inner end portions of a group of conductive portions, said inner end portions each being spaced apart from one another adjacent an open area in a predetermined pattern corresponding to the pattern in which the contact pads are placed on the semiconductor chip, maintaining in engagement with one another the contact pads on the semiconductor chip and a group of conductive portions so that each inner end portion of a conductive portion in the group is in alignment with a contact pad, attaching together by a substantially simultaneous operation said inner end portions of a group and said contact pads of a semiconductor chip in an electrical and mechanical connection within the lateral dimensions of the chip, thereby to provide an independent assembly of a semiconductor chip and the conductive portions of each group on said member, with the excess portion of the strip-like metal member for each group adapted to ultimately be removed so that the conductive portions each then serve as an independent electrical connection from a semiconductor chip contact pad, and rewinding the strip-like member with the plurality of said independent assemblies attached thereto on to a reel to provide for subsequent handling of the member on the reel, said strip-like member being sufficiently flexible so that the attachments of the contact pads to the conductive portions will not be disturbed in the rewinding operation.

Claim 10

A method utilizing assembly apparatus for attaching electrical connecting means to an electrical unit which has a plurality of contact portions on one surface thereof which comprises providing a first frame member having a plurality of inwardly extending conductive portions therewith and an end portion on each such conductive portion adapted for alignment with and attachment to a corresponding contact portion of the electrical unit, providing support means in said assembly apparatus for supporting said first frame member for an attaching operation, supporting said first frame member at a portion of said first frame member which lies outside said inwardly extending conductive portions so as to make said end portions available for attaching to said contact portions, providing two assembly means in said apparatus, each of which is separate from said support means, bringing into engagement with one another said electrical unit at said contact portions and said conductive portions at said end portions, maintaining said end portions of said conductive portions and said contact portions in said engagement by utilizing said two assembly means, applying pressure at least to one of said two assembly means, attaching substantiallY simultaneously said conductive portions at said end portions to said contact portions, providing an electrically conductive second frame member with an area dimension larger than the area dimension of said first frame member, said second frame member having a plurality of inwardly extending conductive portions each of which is stiffer than the conductive portions of said first frame member, positioning the second frame member relative to the first frame member with the conductive portions of the second frame member aligned with corresponding first frame member conductive portions at the outer end portions of said first frame member conductive portions, attaching said conductive portions of said first and second frame members in a substantially simultaneous attaching operation at a place where each is in engagement with one another to provide an electrical and mechanical connection therebetween, and removing excess portions of the conductive portions of said first frame member not required for electrically connecting the electrical unit to the conductive portions of the second frame member and for the purpose of separating said first and second frame members from one another outside the attaching places therefor.

Claim 11

A method utilizing assembly apparatus for attaching electrical connecting means to an electrical unit which has a plurality of contact portions on one surface thereof which comprises providing a first frame member having a plurality of inwardly extending conductive portions therewith and an end portion on each such conductive portion adapted for alignment with and attachment to a corresponding contact portion of the electrical unit, providing support means in said assembly apparatus for supporting said first frame member for an attaching operation, supporting said first frame member at a portion of said first frame member which lies outside said inwardly extending conductive portions so as to make said end portions available for attaching to said contact portions, providing two assembly means in said apparatus, each of which is separate from said support means, bringing into engagement with one another said electrical unit at said contact portions and said conductive portions at said end portions, maintaining said end portions of said conductive portions and said contact portions in said engagement by utilizing said two assembly means, applying pressure at least to one of said two assembly means, attaching substantiallY simultaneously said conductive portions at said end portions to said contact portions, providing an electrically conductive second frame member with an area dimension larger than the area dimension of said first frame member, said second frame member having a plurality of inwardly extending conductive portions each of which is stiffer than the conductive portions of said first frame member, positioning the second frame member relative to the first frame member with the conductive portions of the second frame member aligned with corresponding first frame member conductive portions at the outer end portions of said first frame member conductive portions, attaching said conductive portions of said first and second frame members in a substantially simultaneous attaching operation at a place where each is in engagement with one another to provide an electrical and mechanical connection therebetween, and removing excess portions of the conductive portions of said first frame member not required for electrically connecting the electrical unit to the conductive portions of the second frame member and for the purpose of separating said first and second frame members from one another outside the attaching places therefor.