Connection component with releasable leads

Claim 2

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being permanently connected to said dielectric structure, (c) a release interface between said second region of said lead and said dielectric structure having a peel strength of less than about 0.35×10 6 dynes/cm, whereby said release interface releasably connects said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure.

Claim 3

A component as claimed in claim 1 wherein said peel strength of said interface is less than about 0.175×10 6 dynes/cm.

Claim 4

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanently connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can by detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said interface is formed by electroless plating of said release metal on said polymeric material.

Claim 5

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanently connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can by detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said interface is formed by electroless plating of said release metal on said polymeric material.

Claim 6

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanenty connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said interface is formed by chemical vapor deposition of said release metal on said polymeric material.

Claim 7

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanenty connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said interface is formed by chemical vapor deposition of said release metal on said polymeric material.

Claim 8

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanently connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said polymeric material in said release interface is substantially unoxidized.

Claim 9

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being a permanently connected to said dielectric structure; (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a release metal on said second region of said lead directly abutting said polymeric material at said surface, wherein said polymeric material in said release interface is substantially unoxidized.

Claim 10

A component as claimed in claim 3 or claim 4 or claim 5 wherein said release metal is selected from the group consisting of copper, nickel, gold, palladium and alloys.

Claim 11

A component as claimed in claim 3 or claim 4 or claim 5 wherein said release metal consists essentially of copper.

Claim 12

A component as claimed in claim 3 or claim 4 or claim 5 wherein said polymeric material at said surface is selected from the group consisting of polyimide, polyamide, polyetherimide.

Claim 13

A component as claimed in claim 8 wherein said polymeric material at said surface consists essentially of polyimide.

Claim 14

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being permanently connected to said dielectric structure, (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a first release metal bonded to said polymeric material at said surface and a second release metal on said second region of said lead, said second release metal being releasable from said first release metal.

Claim 15

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface and a polymeric material at said surface; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead being permanently connected to said dielectric structure, (c) a release interface between said second region of said lead and said dielectric structure, said release interface releasably connecting said second region to said dielectric structure so that said second region can be detached from the dielectric structure by forcing the lead downwardly relative to the dielectric structure, said release interface including a first release metal bonded to said polymeric material at said surface and a second release metal on said second region of said lead, said second release metal being releasable from said first release metal.

Claim 16

A component as claimed in claim 10 wherein said first release metal is selected from the group consisting of chromium, nickel and alloys.

Claim 17

A component as claimed in claim 11 wherein said second release metal is selected from the group consisting of gold, copper, nickel, titanium, and alloys.

Claim 18

A component as claimed in claim 1 or claim 3 or claim 4 or claim 5 or claim 11 wherein said permanent connection between said first region of each said lead and said dielectric element includes a fastening element secured to said first region of each said lead and extending into said dielectric structure from said surface.

Claim 19

A component as claimed in claim 13 wherein each said fastening element is mechanically interlocked with said dielectric element.

Claim 20

A component as claimed in claim 14 wherein said surface is a bottom surface of said dielectric element and wherein said dielectric element has a top surface, each said fastening element extending through a hole in said dielectric layer to said top surface, each said fastening element including a head extending outwardly over a portion of said top surface from such hole.

Claim 21

A component as claimed in claim 13 wherein each said fastening element is metallic and wherein said first region of each said lead includes a metallic portion metallurgically bonded to the fastening element.

Claim 22

A component as claimed in claim 3 or claim 4 or claim 5 or claim 11 wherein said permanent connection between said first region and said dielectric structure includes a bond interface having higher peel strength than said release interface.

Claim 23

A component as claimed in claim 17 wherein said bond interface includes a layer of an anchor metal selected from the group consisting of nickel, and chromium directly abutting said polymeric material on said bottom surface.

Claim 24

A component as claimed in claim 18 wherein said layer of anchor metal is formed by sputtering said anchor metal onto said bottom surface.

Claim 25

A component as claimed in claim 1 or claim 3 or claim 4 or claim 5 or claim 11 wherein each said lead includes a structural metal extending throughout the first and second regions and a contact bonding material overlying the structural metal and facing away from the dielectric layer in the second region of each said lead, said contact bonding material being adapted to bond with contacts of a microelectronic element.

Claim 26

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface including, said first and second zones having different surface conditions; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead overlying said first zone of said surface, said second region of each said lead overlying said second zone of said surface, said different surface conditions in said first and second zones providing a release interface having a relatively low peel strength between said lead in said second region and said surface of the dielectric structure and a bond interface having a relatively high peel strength between said lead in said first region and said bottom surface of the dielectric structure, whereby said second region of each said lead can be peeled away from said bottom surface of said dielectric structure and the first region is securely anchored to said bottom surface.

Claim 27

A connection component for making a semiconductor assembly, said component including: (a) a support structure including a dielectric structure having a surface including, said first and second zones having different surface conditions; (b) a plurality of leads extending along the surface of said dielectric structure, each said lead having a first region and a second region, said first region of each said lead overlying said first zone of said surface, said second region of each said lead overlying said second zone of said surface, said different surface conditions in said first and second zones providing a release interface having a relatively low peel strength between said lead in said second region and said surface of the dielectric structure and a bond interface having a relatively high peel strength between said lead in said first region and said bottom surface of the dielectric structure, whereby said second region of each said lead can be peeled away from said bottom surface of said dielectric structure and the first region is securely anchored to said bottom surface.