Claims Analysis
Total Claims: 8
Claim 1
Independent Claim
271 words
A method of electrically interconnecting first conductors and second conductors, comprising, in the order recited: (a) providing a plurality of first and second conductors which are discrete and at least one of which plurality is made of soft magnetic material that can be temporarily magnetized; (b) arranging the plurality of first conductors in a predetermined arrangement on a surface of a substrate; (c) disposing an adhesive layer comprised of a mixture on the surface of the substrate and over the plurality of first conductors, the mixture being comprised of an adhesive and a predetermined concentration of conductive metal particles made of soft magnetic materials that can be temporarily magnetized, wherein the adhesive has a predetermined viscosity which allows the conductive metal particles to be suspended within the adhesive, and wherein the mixture is substantially insulating at the predetermined concentration of conductive metal particles; (d) arranging the plurality of second conductors above the layer of the mixture such that individual conductors of the plurality of second conductors are vertically aligned with the individual conductors of the plurality of first conductors; (e) heating the adhesive layer to reduce the viscosity of the mixture; (f) applying a magnetic field to the plurality of first and second conductors such that the conductive metal particles within the heated adhesive mixture are gathered by the magnetic field to produce a higher concentration of conductive metal particles between the aligned individual conductors of the plurality of first and the second conductors, and provide electrical interconnection therebetween, and to provide a lower concentration of conductive metal particles in adjacent areas of the layer; and (g) hardening the adhesive layer.
Claim 2
Independent Claim
271 words
A method of electrically interconnecting first conductors and second conductors, comprising, in the order recited: (a) providing a plurality of first and second conductors which are discrete and at least one of which plurality is made of soft magnetic material that can be temporarily magnetized; (b) arranging the plurality of first conductors in a predetermined arrangement on a surface of a substrate; (c) disposing an adhesive layer comprised of a mixture on the surface of the substrate and over the plurality of first conductors, the mixture being comprised of an adhesive and a predetermined concentration of conductive metal particles made of soft magnetic materials that can be temporarily magnetized, wherein the adhesive has a predetermined viscosity which allows the conductive metal particles to be suspended within the adhesive, and wherein the mixture is substantially insulating at the predetermined concentration of conductive metal particles; (d) arranging the plurality of second conductors above the layer of the mixture such that individual conductors of the plurality of second conductors are vertically aligned with the individual conductors of the plurality of first conductors; (e) heating the adhesive layer to reduce the viscosity of the mixture; (f) applying a magnetic field to the plurality of first and second conductors such that the conductive metal particles within the heated adhesive mixture are gathered by the magnetic field to produce a higher concentration of conductive metal particles between the aligned individual conductors of the plurality of first and the second conductors, and provide electrical interconnection therebetween, and to provide a lower concentration of conductive metal particles in adjacent areas of the layer; and (g) hardening the adhesive layer.
Claim 3
Dependent Claim
35 words
The method as claimed in claim 1, wherein the adhesive includes a polymeric resin having a viscosity ranging from 10,000 to 40,000 cps and from 10 wt % to 35 wt % of nickel particles.
Claim 4
Dependent Claim
35 words
The method as claimed in claim 1, wherein the adhesive layer is heated to a temperature ranging from 50° C. to 90° C. to reduce the viscosity of the mixture to be below 1000 cps.
Claim 5
Dependent Claim
19 words
The method as claimed in claim 1, wherein the applied magnetic field ranges from 200 Gauss to 4000 Gauss.
Claim 6
Dependent Claim
20 words
The method as claimed in claim 1, wherein the magnetic field is applied until the adhesive layer has been hardened.
Claim 7
Dependent Claim
33 words
The method as claimed in claim 1, wherein the adhesive layer is hardened by heat treatment at a temperature above 120° C. for a time period ranging from 4 minutes to two hours.
Claim 8
Dependent Claim
23 words
The method as claimed in claim 1, wherein the adhesive layer is hardened by illuminating the adhesive layer with an infra-red light beam.