Process for making chip carriers using anodized aluminum

Claim 2

A process for making chip carriers with an anodized aluminum substrate comprising: punching registration and center holes in an aluminum substrate; anodizing the aluminum substrate; coating the top surface of said substrate with adhesive; laminating a thin metal foil to said top surface; coating said metal surface with photo resist; pin registration printing the image of a circuit by masking said photo resist covered metal surface with a photo template registered to said substrate and irradiating the exposed photo resist; developing the image of the electrical circuit by removing the exposed or non-exposed portions of the photo resist; etching the bared developed portions of said thin metal foil to form leads; recoating the substrate with photo resist; exposing the photoresist in areas overlying said leads to radiation; baring said leads by developing of the photoresist; plating said leads with thick nickel; exposing the remainder of said photoresist to bare the remainder of said circuit; and activating and plating said circuit, said circuit comprising the nickel coated leads and the bared metal foil, with gold.

Claim 3

The process of claim 1 wherein said step or printing and developing said image further includes coating the back surface of said substrate with screen resist to protect the metal foil extending over said punched holes.

Claim 4

A process for making chip carriers with an anodized aluminum substrate comprising: punching registration and center holes in an aluminum substrate; anodizing the aluminum substrate; coating the top surface of said substrate with adhesive; laminating a thin metal foil to said top surface; coating said metal surface with photo resist; pin-registration printing the image of a circuit by masking said photo resist covered metal surface with a photo template registered to said substrate and irradiating the exposed photo resist; developing the image of said electrical circuits by removing the exposed or non-exposed portions of the photo resist; plating said circuit with gold; removing the resist; etching the bared developed portions of said foil to form leads; recoating said substrate with photo resist; exposing the photoresist in areas overlying said leads to radiation; baring said leads by developing of the photoresist; activating said circuit; plating said leads with nickel to build up thickness; plating the entire circuit, said circuit comprising the gold plated areas and the gold and nickel plated leads, with gold; and removing the resist.

Claim 5

A process for making chip carriers with an anodized aluminum substrate comprising: punching registration and center holes in an aluminum substrate; anodizing the aluminum substrate; coating the top surface of said substrate with adhesive; laminating a thin metal foil to said top surface; coating said metal surface with photo resist; pin-registration printing the image of a circuit by masking said photo resist covered metal surface with a photo template registered to said substrate and irradiating the exposed photo resist; developing the image of said electrical circuits by removing the exposed or non-exposed portions of the photo resist; plating said circuit with gold; removing the resist; etching the bared developed portions of said foil to form leads; recoating said substrate with photo resist; exposing the photoresist in areas overlying said leads to radiation; baring said leads by developing of the photoresist; activating said circuit; plating said leads with nickel to build up thickness; plating the entire circuit, said circuit comprising the gold plated areas and the gold and nickel plated leads, with gold; and removing the resist.

Claim 6

The process of claim 3 wherein said step of printing and developing the image further includes coating the back surface of said substrate with screen resist, to protect the metal foil extending over said punched holes.

Claim 7

The process of claim 3 wherein said step of removing the resist further includes coating the back surface of said substrate with screen resist, to protect the metal foil extending over said punched holes.