U.S. patent application number 11/705949 was filed with the patent office on 2007-06-28 for electrostatic methods and apparatus for mounting and demounting particles from a surface having an array of tacky and non-tacky areas.
This patent application is currently assigned to The Regents of the University of California. Invention is credited to Thomas Kenneth Bednarz, Allan Cairncross, John Edwin JR. Gantzhorn, George Yeaman JR. Thomson.
Application Number | 20070145103 11/705949 |
Document ID | / |
Family ID | 22793826 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070145103 |
Kind Code |
A1 |
Bednarz; Thomas Kenneth ; et
al. |
June 28, 2007 |
Electrostatic methods and apparatus for mounting and demounting
particles from a surface having an array of tacky and non-tacky
areas
Abstract
Methods and associated apparatus are disclosed for use in
mounting particles on and de-mounting particles from a substrate
having an array of tacky and non-tacky areas. The particles can be
either electrically conducting or electrically non-conducting.
Selection of electrically conducting particles is preferred. The
substrate having an array of tacky and non-tacky areas can either
be electrically nonconducting (e.g., a dielectric substrate) or
electrically-conducting. The methods involve use of first and
second electrode plates with the substrate therebetween, the plates
having applied thereto a direct current potential, which potential
in preferred embodiments is reversed in polarity for a number N of
cycles. Methods and articles are disclosed using an electrically
conductive surface adjacent the tacky and non-tacky areas to
minimize static buildup on the particles and tacky and non-tacky
areas.
Inventors: |
Bednarz; Thomas Kenneth;
(Richmond, VA) ; Cairncross; Allan; (Hockessin,
DE) ; Gantzhorn; John Edwin JR.; (Hockessin, DE)
; Thomson; George Yeaman JR.; (Oxford, PA) |
Correspondence
Address: |
Medlen & Carroll, LLP
Suite 350
101 Howard Street
San Francisco
CA
94105
US
|
Assignee: |
The Regents of the University of
California
Oakland
CA
|
Family ID: |
22793826 |
Appl. No.: |
11/705949 |
Filed: |
February 12, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10753738 |
Jan 7, 2004 |
7191930 |
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11705949 |
Feb 12, 2007 |
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10322283 |
Dec 17, 2002 |
6871777 |
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10753738 |
Jan 7, 2004 |
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09876237 |
Jun 7, 2001 |
6540127 |
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10322283 |
Dec 17, 2002 |
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60213128 |
Jun 22, 2000 |
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Current U.S.
Class: |
228/101 ;
257/E23.068 |
Current CPC
Class: |
H01L 2924/01005
20130101; H01L 2924/01029 20130101; H01L 2924/01082 20130101; H01L
2924/01033 20130101; H01L 2224/13099 20130101; H01L 2924/01013
20130101; H01L 2924/01022 20130101; H01L 2924/01027 20130101; H01L
2924/01078 20130101; H05K 2203/1492 20130101; H01L 2924/01049
20130101; H01L 2924/14 20130101; H01L 2224/742 20130101; H05K
3/3478 20130101; H05K 2203/041 20130101; H01L 2924/01068 20130101;
H01L 2924/01015 20130101; H01L 2924/01039 20130101; H01L 2924/01075
20130101; H01L 2224/11334 20130101; H01L 2924/01079 20130101; H05K
2203/0525 20130101; H01L 2924/01073 20130101; H05K 2203/0522
20130101; H05K 2203/105 20130101; H01L 2924/3025 20130101; H01L
21/4853 20130101; H01L 2924/12042 20130101; H01L 24/742 20130101;
H01L 24/11 20130101; H01L 2924/01322 20130101; H01L 2924/01023
20130101; H01L 23/49811 20130101; H01L 2924/01052 20130101; H01L
2924/014 20130101; H01L 2924/01006 20130101; H01L 2924/12042
20130101; H01L 2924/00 20130101 |
Class at
Publication: |
228/101 |
International
Class: |
A47J 36/02 20060101
A47J036/02 |
Claims
1-30. (canceled)
31. An article for use in mounting free-flowing particles in an
array, comprising: (a) a substrate having thereon an array of tacky
and non-tacky areas; and (b) a conducting layer adjacent the tacky
and non-tacky areas; wherein each of the tacky areas has a size and
bounding strength suitable for adhesion of one particle
thereto.
32. The article of claim 31 wherein the substrate (a) and the
conducting layer (b) are present in one layer.
33. The article of claim 31 wherein the conducting layer (b)
comprises a material selected from the group consisting of a metal,
a metal oxide, and an electrically-conductive polymer.
34. The article of claim 33 wherein the metal or the metal oxide is
selected from the group consisting of aluminum, copper, and indium
tin oxide.
35. An article for use in mounting an array of particles to contact
pads of an electronic device, comprising: (a) a surface having
thereon an array of tacky and non-tacky areas and wherein each of
the tacky areas has a size and bounding strength suitable for
adhesion of one particle thereto, the tacky areas arranged on the
contact pads; and (b) a conducting layer adjacent the tacky and
non-tacky areas; and (c) an electrically-conductive particle is
attached to each tacky area and the non-tacky area is essentially
free of particles.
36. The article of claim 35 wherein the electrically-conductive
particle comprises a material selected from the group consisting of
a metal, a metal oxide, an electrically-conductive polymer, solder
and solder with flux.
37-42. (canceled)
Description
FIELD OF THE INVENTION
[0001] This invention relates to an improved method for
transporting particles from one surface to another using electrode
plates having a direct current potential difference between them.
The invention also relates to methods and articles for minimizing
static buildup on particles and surfaces.
TECHNICAL BACKGROUND OF THE INVENTION
[0002] The placement of particles, such as electrically conductive
solder, on contact pads is critical to the adoption of array style
semiconductor packages such as ball grid arrays (BGA). Such
placement is also critical in the attachment of integrated circuits
(IC) to packages or printed circuit boards through flip chip
processes. Recent attempts have been made to improve, for example,
solder ball interconnects, such that more reliable and/or less
costly. solder connections are made in electronic applications.
Despite these efforts, there are still problems associated with the
handling and transfer of particles, primarily conductive particles
such as solder balls to form solder bumps, on the contact pads of
electronic devices. There is a need for further improvements,
particularly with regard to the efficiency, precision, and
robustness of the process.
SUMMARY OF THE INVENTION
[0003] The present invention is a method for transferring particles
from an electrode plate to tacky areas present on a substrate
comprising: [0004] a) placing a substrate having both tacky and
non-tacky areas between first and second electrode plates, the
substrate and electrode plates arranged substantially horizontally
and stacked substantially vertically, wherein the first electrode
plate [0005] (i) lies below the substrate, [0006] (ii) has a
surface which faces tacky and non-tacky areas on the substrate, and
[0007] (iii) is spaced from the substrate and the second electrode
plate; [0008] b) applying particles over the surface of the first
electrode plate; and [0009] c) applying a direct current potential
between the first and second electrode plates for a time T.sub.1,
establishing a polarity on the first electrode and thereby causing
the particles to be charged and be propelled toward the second
electrode plate, resulting in at least a portion of the charged
particles becoming adhered to tacky areas on the substrate.
[0010] Another embodiment of the invention having additional
step(s) includes as step d) changing the direct current potential
on the first electrode plate for a time T2 after step c) to cause
at least some of the particles to leave non-tacky areas of the
substrate, be propelled against the first electrode, again be
charged and be propelled toward the second electrode. Still other
embodiments include repeating steps c) and d) for a number, N, of
cycles as step e), eliminating the direct current potential between
the electrode plates and removing particles from the non-tacky
areas as steps f) and g), and placing a non-conductive shield
between the substrate and the first electrode plate as step h).
[0011] In another embodiment, the invention is a method for
mounting particles on a substrate having both tacky and non-tacky
areas thereon, wherein a direct current potential between first and
second electrode plates is used in the method and in which the
particles are first applied to a substrate having tacky and
non-tacky areas, which substrate is placed over the first
electrode.
[0012] In further embodiments, the tacky areas are heated to
improve adhesion and centering of the particles in the tacky areas.
The invention also comprises apparatuses for practicing the above
methods. The invention also comprises an article having a substrate
or surface with tacky and non-tacky areas that has an electrically
conductive surface adjacent to the tacky and non-tacky areas to
dissipate electrostatic charges and a method for changing the tacky
and non-tacky areas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a simplified section view of one embodiment of a
surface having an array of tacky and non-tacky areas thereon, which
surface is suitable for use with the inventive methods, wherein the
tacky and non-tacky areas are disposed coplanar with one
another.
[0014] FIG. 2 is a simplified section view of another embodiment of
a surface having an array of tacky and non-tacky areas thereon,
which surface is suitable for use with the inventive methods,
wherein the tacky areas are disposed below the plane of the
non-tacky areas.
[0015] FIG. 3 is a simplified section view of still another
embodiment of a surface having an array of tacky and non-tacky
areas thereon, which surface is suitable for use with the inventive
methods, wherein the tacky areas are disposed above the plane of
the non-tacky areas.
[0016] FIG. 4 is a simplified section view of the array of FIG. 1,
shown in combination with a particle adhered to each tacky
area.
[0017] FIG. 5 is a simplified section view of the array of FIG. 2,
shown in combination with a particle adhered to each tacky
area.
[0018] FIG. 6 is a simplified section view of the array of FIG. 3,
shown in combination with a particle adhered to each tacky
area.
[0019] FIG. 7A is section view of a spherical particle initially
adhering to a tacky area on a substrate.
[0020] FIG. 7B is a plan view of FIG. 7A looking through a
translucent substrate and tacky area.
[0021] FIG. 7C is the section view of FIG. 7A after a predetermined
dwell time when the condition is that the spherical particle
contacts the substrate before contacting the complete circumference
of the tacky dot.
[0022] FIG. 7D is a plan view of FIG. 7C looking through a
translucent substrate and tacky area.
[0023] FIG. 7E is an alternative section view of FIG. 7A after a
predetermined dwell time when the condition is that the spherical
particle contacts the complete circumference of the tacky dot
before the particle contacts the substrate.
[0024] FIG. 7F is plan view of FIG. 7E looking through a
translucent substrate and tacky area.
[0025] FIG. 8 illustrates the geometrical relationships involved
for self-centering of a sphere of diameter 2r in a tacky area of
thickness z with contact diameter x and with the sphere penetrating
all of the tacky area and resting on the substrate at the bottom of
the tacky area.
[0026] FIG. 9 is a schematic of an apparatus for mounting particles
on a substrate having an array of tacky and non-tacky areas
thereon, wherein the substrate is a discrete portion of web.
[0027] FIG. 10 is a schematic of an apparatus for mounting
particles on a substrate having an array of tacky and non-tacky
areas thereon, wherein the surface is a continuous elongated
web.
[0028] FIG. 11 is a schematic of the equipment used in Example 6
demonstrating the effect of a conductive substrate.
DETAILED DESCRIPTION OF THE INVENTION
[0029] This invention relates to an improved method and apparatus
based upon electrostatics for precisely and efficiently adhering
particles to tacky areas on a surface of a substrate having an
array of tacky and non-tacky areas and removing particles from the
non-tacky areas without removing particles from the tacky areas.
This net adhering of particles to the tacky areas on the surface is
termed net population of the substrate. For most applications of
this invention, it is desired that there be one and only one
particle attached to each tacky area of the substrate.
[0030] In one embodiment of this invention, the substrate and
particles are placed between two electrodes and an electric field
is applied to propel the particles onto the substrate to populate
the tacky areas. In another embodiment, the electric field is
applied to remove particles from the non-tacky areas of the
substrate after populating the tacky areas. The method and
apparatus are useful with both electrically conductive and
non-conductive particles and substrates.
[0031] Cairncross et al., U.S. Pat. No. 5,356,751, which is
incorporated by reference discloses a process and product for
mounting free-flowing particles, which employs a support having a
support surface with an array of tacky areas which have a size and
bonding strength suitable for adhesion of either one or two of said
particles. In the process, the particles flow across the support
surface to allow particles to contact the tacky areas and adhere
thereto.
Substrates Having Arrays of Tacky and Non-Tacky Areas and
Associated Methods
[0032] The array and method described herein are particularly
suited for use with free-flowing particles. By free-flowing is
meant that there is no substantial binding force to be overcome
when separating a mass of particles into separate discrete
particles and that the particles do not stick to one another or
clump together under normal conditions of use. A discussion of
particle to particle binding forces is presented in U.S. Pat. No.
5,356,751.
[0033] For most electronic applications, the preferred particles
for use in connection with this invention are electrically
conductive materials, such as Cu, In, Pb, Sn, Au, and alloys
thereof. Most preferred are solder balls. It will be apparent to
those skilled in the art, however, that the type of particle used
in connection with the present invention is dictated by the
particular application and is not an inherent limitation of the
invention. For example, a particular application may require that
an electrically insulating material be applied to a solder bump on
a contact pad; e.g., to space one contact pad from another in a
stack of circuit boards. The present invention may be used to
advantage in such circumstances. Generally speaking, spherical
particles will be preferred in the practice of this invention
because of their ease in handling and particle symmetry, however,
the size and shape of the particles are not critical to the
invention. For example, slightly off-round particles, such as
seeds, work well with this invention.
[0034] For other applications outside the electronic field, the
particles can have properties without any particular size or shape
limitations except for the limitation that the particles must have
sufficient compatibility with the tacky areas such that the
adhesive force bonding each particle to a given tacky area is at
least the minimal value specified herein (i.e., at least 2
grams/mm2). The particles, such as beads, can either be
electrically-conductive or electrically-non-conductive such as
glass; organic, inorganic, organometallic, or mixtures thereof;
polymeric or non-polymeric; and living or non-living. Examples of
suitable particles for this invention include, but are not limited
to, mineral grains, chemical products, salt and sugar granules,
polymer particles, mechanically ground solids, pollen, spores, and
seeds. Some specific chemical product particles are solder,
alumina, and silica; a specific minieral grain is glass. Some
specific polymer particles are poly(styrene),
poly(methylmethacrylate) and poly(ethylene). Organic, inorganic, or
organometallic chemical compounds that are pharmaceuticals,
herbicides, pesticides, or have other biological activity are
suitable particles for this invention; these compounds can be
present at levels lower than or equal to 100% of the particle
composition. If lower, other components can be present in the
particles without limit. The particles can comprise any gas(es)
and/or liquid(s) compounded with (e.g. absorbed on) any solid(s).
For example, particles comprising dimethylsulfoxide (a liquid)
absorbed onto alumina (a solid) are suitable in this invention.
[0035] As used herein, the term tacky areas means areas, volumes,
or regions having adhesive properties to enable a bond to form
immediately upon contact with free-flowing particles under low
pressure (e.g., the weight of the particles or the wetting action
between the adhesive and the particles). The areas have a thickness
that plays a role in centering the particles and maximizing the
surface area for adhesive contact. In accordance with this
invention, the tacky areas have a size and bonding strength
suitable for adhesion of one particle per tacky area. Typically,
the tacky areas are small shapes (i.e., dots) from about 0.25 um to
1000 um and for many embodiments they are from about 10 um to 500
um. The tacky area shapes may be circular, square, rectangular,
oval, or another shape suitable for retention of the particle.
Generally, circular shaped tacky areas are preferred.
[0036] The spacing of the tacky areas is such that the position of
one particle on one tacky area relative to the position of other
particles on adjacent tacky areas matches the distance between and
relative position of the contact pads of the electronic (or other)
device to which the particles will be transferred and become
attached. The actual dimensions used for the tacky area spacing and
the contact pad spacing must take into account differences in
thermal expansion that may occur between the material of the
substrate and the material of the electronic device. At the
temperature used during transferring, the spacings should match.
The location of the tacky areas at least must allow the particles
to touch some part of the contact pad to which it will become
attached. In the embodiment where the particle melts (e.g., solder
particles in contact with solder flux and a metallized contact
pad), direct contact is required between the molten particle and
the pad so that the molten particle can wet the pad and flow across
the metal surface to cover the metallized pad. The initial contact
of the particle with the metallized contact pad may be off-center
because the wetting action of the molten particle will center the
particle over the pad during attachment. For these noncritical
embodiments, the original pattern of tacky areas is such that the
location of each tacky area must align and overlap somewhere within
the area of the corresponding contact pad area to which it will
attach, and the size of the tacky area must be smaller than the
particle so that only one particle is attached to each tacky area.
Typically, for a tacky area having a particular size and bonding
strength, there is an upper limit to the size and weight of
particle, above which there is no substantial particle adherence,
and there is a lower limit to the particle size which will adhere
singly to each tacky area. For tacky areas with a tackiness of 2 to
6 grams/mm2 and particles of 0.127 to 0.762 mm (0.005 to 0.030
inch) diameters, the tacky area may be as small as 15% of the
particle diameter to as large as 100% of the particle diameter and
still get single particle attachment per tacky area. A tacky area
of 30 to 60% of the particle diameter is preferred.
[0037] In cases where the contact pads are close together relative
to the size of the particle, care must be taken so that the
particles on adjacent tacky areas do not touch before and during
attachment to the contact pads so as to avoid bridging adjacent
contact pads. As the space between contact pads become smaller
relative to the width of the pad and hence, to the width of the
particle to be attached to the contact pad, it becomes critical to
align the tacky areas and particles closer to the center of the
matching contact pads to which the particle will become attached.
This is accomplished by centering the tacky area positions in the
imaging step to match the center of the contact pads and using a
combination of smaller tacky areas and an optimum combination of
tacky area thickness and diameter for the particular surface
curvature of the particle to achieve self-centering of the particle
in the tacky area (see later discussion of self-centering).
[0038] Single particle attachment to each tacky area is assured
when the size of the particle is large enough to cover the tacky
area upon attachment, thus preventing further particles from ever
touching the tacky area of an occupied tacky area. For the
preferred embodiments of spherical particles and circular tacky dot
areas, this is achieved once the diameter of the tacky dot area is
less than the diameter of the smallest particle. A narrow size
range for the particles is also desired to control the volume after
the particle is attached to the contact pad. A uniform particle
diameter is also desired for good contact between particles
attached to tacky areas on a transfer substrate and the contact
pads of the electronic device to which the particle is to be
transferred. A size range of +/-10% for the particle diameter is
preferred.
[0039] The array of tacky and non-tacky areas preferably has
clearly defined tacky areas and has no foreign material adhered
thereto. Preferably, the non-tacky areas are flat and smooth and
are either disposed coplanar with the tacky areas or the tacky
areas are disposed below the plane of the non-tacky areas. Most
preferably, the non-tacky areas are flat and smooth and are
disposed co-planar with the tacky areas. Although less preferred,
the tacky areas may be disposed above the plane of the non-tacky
areas. In each of these cases, there can be material at the
interface of a given tacky area with the non-tacky area that is
slightly out of plane right at the interface (either above or below
the plane of the interface even starting with a coplanar substrate
prior to imaging to form the array of tacky and non-tacky areas).
While not being bound by any theory, it is believed in the case of
a photopolymer layer that this effect results from the diffusion of
unpolymerized components from the tacky areas into the non-tacky
areas thickening the border around the tacky areas. Also lightly
crosslinked tacky areas are less dense and slightly thicker than
more highly crosslinked non-tacky areas.
[0040] In a particularly preferred embodiment, the array of tacky
and non-tacky areas comprises a photosensitive element that has
been imagewise exposed to create the array. A variety of positive
and negative photosensitive compositions are known to produce tacky
images and may be used in the practice of this invention.
Phototackifiable compositions become tacky where struck by light
and are exemplified by compositions described in U.S. Pat. No.
5,093,221, U.S. Pat. No. 5,071,731, U.S. Pat. No. 4,294,909, U.S.
Pat. No. 4,356,252 and German Patent No. 3,514,768. Photohardenable
compositions are those which become hardened in light struck areas.
A number of photohardenable compositions include Cromalin.RTM.
Positive Proofing Film SN 556548, Cromalin.RTM. 4BX, Surphex.TM.
(embossable photopolymer film, Cromatone.RTM. Negative Overlay Film
SN 031372, and Cromalin.RTM. Negative Film C/N all available from
E.I. du Pont de Nemours and Company, Wilmington, Del. Cromalin.RTM.
Positive Film SN 556548, Cromalin.RTM. 4BX and Surphex.TM. are
preferred. These and other photosensitive products are disclosed in
U.S. Pat. No. 3,649,268, U.S. Pat. No. 4,174,216, U.S. Pat. No.
4,282,308, U.S. Pat. No. 4,948,704 and U.S. Pat. No. 5,001,037.
[0041] Photohardenable compositions are generally a combination of
polymeric binder and photopolymerizable monomers. Suitable binders
include co(methyl methacrylate/methacrylic acid) and monoethyl
ester of poly(methyl vinyl ether/maleic anhydride), each of which
may be copolymerized in various proportions. Suitable
plotopolymerizable monomers include ethylenically unsaturated
monomers which have been found useful are those disclosed in U.S.
Pat. No. 2,760,863; U.S. Pat. No., 3,380,831 and U.S. Pat. No.
3,573,918. Examples are dipentaerytliritol acrylate (50% tetra and
50% penta), pentaerytlhritol triacrylate and tetraacrylate,
polypropylene glycol (50) ether of pentaerythritol tetraacrylate,
polyethylene glycol (200) dimethacrylate, dipentaerythritol
triacrylate b-hydroxyethyl ether, polypropylene glycol (550) ether
of pentaerythritol tetramethacrylate, pentaerythritol
tetramethacrylate, polypropylene glycol (425) dimethacrylate,
trimethylolpropane trimethacrylate, and polypropylene glycol (340)
ether of trimethylol propane triacrylate. (Note: Numbers within
parentheses in this paragraph, e.g., 550, 425, 340, and 50, are
number average molecular weights.) Also useful are epoxy monomers
containing ethylene unsaturation, e.g., monomers of the type
disclosed in U.S. Pat. No. 3,661,576 and British Pat. No.
1,006,587. The binder may be varied widely in its ratio with the
monomer but in general it should be in the range of 3:1 to 1:3. The
monomer should be compatible with, and may be a solvent for, and/or
have a plasticizing action on the binder. The choice and
proportions of monomer and binder are made in accordance with the
requirements of selective photoadherence.
[0042] When the pattern of tacky areas is not used immediately, or
is stored or shipped, it is useful to keep the tacky areas clean by
protecting them with a cover sheet such as a polyester film,
polypropylene film, or silicone release polyester film. Generally a
thin 0.0127 mm (0.0005 inch) Mylar.RTM. polyester film (E.I. du
Pont de Nemours and Company, Wilmington, Del.) is sufficient.
[0043] When using photosensitive compositions to create the array
of tacky and non-tacky areas, the photosensitive composition is
first applied to a suitable substrate and is then imagewise exposed
to create the desired array of tacky and non-tacky areas. As
discussed more fully below, the choice of substrate will largely
depend upon the method selected to mount the array of particles to
the contact pads. Generally speaking, however, the substrate should
be stable under the conditions of intended use, smooth, and show
good adherence to the photosensitive composition. As will be
recognized by those skilled in the art, one or more intermediate
layers may be applied to the substrate to improve adhesion of the
photosensitive layer. In one embodiment of this invention, the
photosensitive composition is applied to a metallic layer (or to a
layer of another material that is electrically-conductive) to
afford a preferred article of this invention--see detailed
discussion infra.
[0044] There should be facile control of the tacky areas with
respect to size and placement. For the aforementioned
photosensitive products, the array pattern is first composed by
manual or computer assisted design, and is usually transferred to a
photographic film that is used as a photo tool in contact with the
photosensitive product and with strong ultraviolet light to pattern
the tacky array in the photosensitive product. For the
Cromanlin.RTM. products, the photosensitive material would first be
laminated to or coated onto the substrate and then exposed through
the phototool to create the pattern. The pattern could be made to
coincide with the interconnect positions of a circuit board. For
Cromatone.RTM., a clear plastic film substrate is provided with the
product so that it may be exposed directly through the phototool.
Other patterning methods include projection exposure and direct
writing as in digital imaging using a laser output device.
[0045] With reference now being made to FIG. 1, an article or web 8
having an array of tacky and non-tacky areas suitable for use in
accordance with the process of the invention is illustrated
therein. In the embodiment shown, the article comprises a
photosensitive layer 10 applied to a substrate 12. The
photosensitive layer 10 has been imagewise exposed to produce
alternating areas 14 which are non-tacky and areas 16 which are
tacky. If the photosensitive layer 10 is a phototackifiable
composition, the areas 16 would correspond to the exposed areas
whereas if the photosensitive layer 10 is a photohardeniable
composition, areas 16 would correspond to the unexposed areas.
[0046] The substrate as shown in FIG. 1 may itself be electrically
non-conductive or electrically conductive, or a conductive layer
can be present as a separate layer 12a on a substrate base 12b, in
which case normally the conductive layer 12a would be between the
photosensitive layer 10 and the substrate base 12b. The conductive
material may be useful in controlling electrostatic charge on the
web. The conducting layer is comprised of an
electrically-conducting material. Suitable materials that are
electrically-conducting include, but are not limited to, metal(s),
metal oxide(s), and electrically-conducting polymers. Suitable
metals or metal oxides include, but are not limited to, aluminum,
copper, and indium tin oxide. Electrically-conducting polymers may
also be used which may include polymers containing very fine
electrically conductive particles, such as carbon particles.
[0047] The conducting layer can either be present as a separate
layer 12a that is adjacent to and in contact with a substrate 12b,
or, alternatively, the conducting layer can be present without a
separate substrate, in which case it serves as its own substrate
12. In the case of the former, the conducting layer 12a can be
applied to the substrate 12b by any methods known to the art, which
include, but are not limited to, coating, vacuum deposition, and
electroless plating. In the case of the latter, illustratively, one
example where the surface and the conducting layer are present in
one layer is a layer of copper or aluminum (e.g., copper foil or
aluminum foil) of sufficient thickness such that the layer
simultaneously serves as the substrate 12 as well as being the
conducting layer. In a further alternative, the conductive layer
can be present on the substrate as palt of the tacky and non-tacky
area, that is, the tacky and non-tacky areas themselves may be
electrically conductive.
[0048] An alternative to the tacky and non-tacky areas being a
phototackifiable composition, is for the article to be formed by
attaching a thin sheet material having an array of holes to an
adhesive coated substrate. Examples of such sheet material include
screen mesh or stencils wherein holes have been formed by, for
example, laser ablation, punching, drilling, etching, or
electroforming. The article may also be formed by providing
photoresist hole patterns on an adhesive coated substrate. An
example of such an alternate article or web 108 is illustrated in
FIG. 2, wherein an adhesive layer 110 is applied to a substrate
112. The substrate can itself be non-conductive or conductive, or a
conductive layer can be present as a separate layer on a
non-conductive substrate, in which case normally the conductive
layer would be between the photosensitive layer and the substrate.
The tacky and non-tacky areas themselves may be conductive. A thin
sheet material 114 having holes 116 therein is then applied over
the adhesive layer 110. The adhesive layer 110 is an outer surface
in the areas of the holes 116 in the sheet material 114, thereby
affording the tacky areas. It will be apparent to those skilled in
the art that a similar type of structure, that is, a non-tacky
surface having recessed tacky areas, will also result from the use
of certain photosensitive materials (e.g., negative Cromalin.RTM.
or Cromotone.RTM.) which produce a peel-apart image. Generally, the
further the tacky area is recessed in relation to the non-tacky
area, the more likely size exclusion will occur, where no particles
larger than the width at the tacky area recess, will attach. This
effect becomes particularly pronounced as the tacky area recess
approaches the size of the tacky area, that is, the depth of the
tacky area is approximately equal to its width.
[0049] With reference now being made to FIG. 3, still another
embodiment of an article or web 208 having an array of tacky and
non-tacky areas suitable for use in accordance with the process of
the invention is illustrated therein. In the embodiment shown, the
article 208 comprises an array of tacky areas 216 on a non-tacky
substrate 212.
[0050] It is noted that in the embodiment shown in FIG. 1, the
tacky areas 16 are disposed co-planar with the non-tacky areas 14
whereas in the embodiment of FIG. 2, the tacky areas, corresponding
to holes 116, are disposed below the plane of the sheet material
114, which defines the non-tacky areas. It is further noted that in
the embodiment shown in FIG. 3, the tacky areas 216 are disposed
above the plane of the non-tacky conductive layer 212.
[0051] This invention relates to improved articles and methods for
efficiently and precisely adhering particles to the tacky areas (as
described above) on a surface containing an array of tacky and
non-tacky areas and removing particles from the non-tacky areas
without removing the particles from the tacky areas. The improved
articles and methods are discussed in depth in the section
following this one.
[0052] Following the population process, in many applications for
this invention, the array of mounted particles described above is
transferred to contact pads of an electronic device. The contact
pads are usually made of a conductive metal such as copper,
aluminum, gold, or a lead/tin solder. In a preferred method of
transfer of the mounted particles, an array having a single
conductive (e.g., solder) particle adhered to the tacky areas
thereof is placed in contact with the contact pads of an electronic
device such that the particles are placed in registered contact
with each of the contact pads and the particles are then released
from the tacky areas of the array and are adhered to the contact
pads. The array of tacky and non-tacky areas may themselves be
electrically conductive or they may be on a substrate surface and
have a conductive surface adjacent to these areas. This method will
be referred to as the transfer method. In an alternate method of
transfer, the array of tacky and non-tacky areas is formed directly
on the contact pads (such as by coating, laminating etc.) prior to
the particles being adhered thereto. Once again, the array of tacky
and non-tacky areas may themselves be electrically conductive or
they may be on a surface layer and have a conductive surface
adjacent the tacky and non-tacky areas; the contact pads where the
tacky areas are located are already, by definition, electrically
conductive and may serve as the conductive layer adjacent the tacky
areas. This method will be referred to as the direct method.
[0053] In either the transfer method or the direct method, it is
necessary to disassociate the particles from the tacky areas of the
array. There are many alternate methods to accomplish this step,
some of which ate more applicable to either the direct method or
the transfer method than to the other. For example, disassociation
of the particles can be accomplished by mechanical forces, that is,
an adhesive compound (e.g., a viscous flux, acting as an adhesive
or having an adhesive component) can be applied to the contact pad.
Upon contact of the solder ball to the adhesive compound, a bond
forms which is stronger than the bond between the solder ball and
the tacky area of the array. Thus, upon removal of the array from
the contact pads, the particles are released from the tacky areas
and remain adhered to the contact pads. Mechanical disassociation
of the particles is particularly applicable to the transfer
method.
[0054] Thermal disassociation is yet another method of
disassociating the particles from the array. By thermal
disassociation is meant the application of heat sufficient to cause
the particles to melt, wet the surface of the contact pads and flow
to cover the pads. Preferably, as the particles melt, the substrate
is brought closer to the contact pads to make sure that all
particles contact their respective contact pads. Spacers may be
used to keep the surface uniformly off contact from the contact
pads themselves so as not to squeeze solder beyond the contact
pads.
[0055] The heat necessary to melt the particles may be provided by
use of an oven, laser, microwave, infrared radiation or other
convenient source. Temperatures in the range of 150.degree. C. to
400.degree. C. are normally sufficient to cause the reflow of the
particles, particularly solder balls. It will be apparent to the
skilled artisan that, in the event the substrate will be heated
together with the particles, the substrate should be capable of
withstanding such temperatures; that is, it should be thermally
stable. Non-conductive substrates, such as Kapton.RTM. (a polyimide
film available from E.I. du Pont de Nemours and Company,
Wilmington, Del.), quartz, glass and the like, may be used to
advantage. Likewise, with regard to the material used to form the
tacky and non-tacky array, such material should not melt during the
heat step, but rather should be thermally stable or, alternatively,
should completely volatilize at such temperatures. Negative
Cromalin.RTM. in particular has a tendency to melt during an oven
heating disassociation step and thus is largely unsuitable for use
with oven heating. In the event that the heat source used will not
heat the substrate or tacky and non-tacky areas (e.g., a laser),
thermal stability is not of great concern.
[0056] Another method that may be used to disassociate the
particles is photodisassociation. In this method, the tacky areas
are exposed to actinic radiation whereby they lose their adhesive
properties to disassociate the particle.
[0057] To improve the wetting and adhesion of the particle,
particularly solder balls, to the contact pads, a suitable flux may
be used. A solder flux combination (e.g., rosin types, no-clean
types, organic acid or synthetic activated) can be coated on the
pads areas and/or on the solder balls to help clean oxide layers
from the pad and solder, improving wetting of the metallized pad by
molten solder thereby effecting disassociation of the solder ball
from the tacky area and adhesion thereof to the contact pad.
[0058] In the direct method, it is critical that the molten
particle disassociate or displace the tacky area on the contact pad
and completely wet the contact pad with the molten particle (e.g.,
solder). This could be accomplished by decomposing the tacky areas
to volatile compounds when the melting temperature of the particles
is reached or by using thermally stable tacky area materials that
would be displaced by the molten particle.
[0059] Once the particles have been released from the tacky areas
and melted, they are allowed to cool and resolidify on the contact
pads, e.g., to form a solder bump.
Population
[0060] This invention encompasses electrostatic methods for
mounting and demounting particles from a surface having an array of
tacky and non-tacky areas. In populating the array of tacky and
non-tacky areas, it is desired to effect placement of a controlled
number of particles on each tacky area while ensuring that there
are no excess particles remaining in any area that is non-tacky, at
the end of the population process. Most often for electronic
applications in particular, it is desirable to place precisely one
particle on each tacky area.
[0061] In general, the population step may be accomplished in a
number of ways. Generally the article with the pattern of tacky
areas is placed in a container with an excess of particles and the
container gently moved so as to allow the particles to move across
the array until all tacky areas become occupied. Alternatively,
excess particles are sprinkled onto the tacky areas until all tacky
areas are covered with particles. Excess particles are removed from
the fully occupied pattern of tacky areas by gravity, gentle
tapping, gentle blowing, vacuum and other methods. The force used
in the clean up of excess particles depends on the adhesive
strength of the bond between the tacky areas and the particles.
This step, the application of free flowing particles to patterns of
tacky areas, is accomplished best when electrostatic charging is
avoided by using electrically conducting, grounded containers,
humidified atmosphere and with the use of ion generators, as in the
use of ionized air. This step is further aided by a clean
atmosphere to prevent the attachment of foreign matter to the tacky
areas.
[0062] FIGS. 4, 5, and 6 illustrate the different cases of the
arrays shown in FIGS. 1, 2, and 3 respectively, with spherical
particles 20 attached to the tacky areas 16, 116, and 216 of the
array to form populated articles or webs 8p, 108p, and 208p,
respectively.
[0063] The figures above showing particles attached to tacky areas
of an array of tacky and non-tacky areas are schematic. It should
be understood that these figures depict representation(s)
not-to-scale. In actual practice of this invention, typically
particles initially attach to tacky areas near the perimeter of the
tacky area with relatively light wetting of the particle by the
tacky area. Later, at equilibrium wetting, typically there is full
or nearly full embedding of particles in the tacky areas with
centering of the particles.
[0064] The process of attaching particles to patterns of tacky
areas is aided by the tacky areas having sufficient tackiness to
grab and hold the particles immediately upon contact. It is further
desired for the attachment of the particle to the tacky area to be
strong enough to withstand the various forces (e.g., vibrating,
tapping, shaking, jiggling, moving, bumping contact, vacuum or
blowing forces, electrostatic propulsion, etc.) that occur while
populating the array with particles and during the removal of
excess particles from the fully populated array. In a preferred
method vibrating is employed at not greater than 1000 cycles per
minute to distribute particles over the tacky and non-tacky areas
and dislodge particles from the non-tacky areas. In addition, it is
advantageous to have sufficient adhesive strength between the
particles and the tacky areas to hold the particles in place during
handling and possible shipment. Furthermore, tacky areas with a
tackiness of at least 0.5 grams/mm2 can be populated by particles,
but it is preferred that the tacky areas have a tackiness of at
least 2 g/mm2 and it is most preferred that the tacky areas have a
tackiness of at least 5 g/mm2, especially when patterns of tacky
areas populated with particles are to be shipped without loss of
the particles.
[0065] The goal is perfect population with one particle per tacky
area and no extras; with total errors (TE) per populated article of
zero. Expressed as an equation: TE=V+TW+EX where [0066] TE=total
errors per article [0067] V=total number of vacant tacky areas per
article [0068] TW=total number of extra particles associated with a
tacky area or "twins" per article [0069] EX=total number of extra
particles left on non-tacky areas per article
[0070] Then the error rate ER for the populated surface becomes
ER=1,000,000(TE)/TA where [0071] ER=error rate in parts per million
(ppm) tacky areas [0072] TA=total number of tacky areas per article
[0073] TE=total errors per article
[0074] For almost all tacky areas small particles will attach to
the edge of the tacky areas as soon as the particles flow across
the tacky areas provided that the kinetic energy of the particle is
less than the initial bonding strength of the particle to the tacky
area. Once the tacky areas are buried with excess particles at rest
the number of vacancies V is very low. Remaining vacancies can be
filled by gentle agitation of the particles across the article with
periods of rest and V becomes essentially zero. However, the number
of excess particles TW+EX is near infinity. If sufficient cleaning
force is applied, all the excess particles can be removed and TW+EX
becomes zero. To be successful the cleaning force must be enough to
remove all the excess particles from the non-tacky areas yet the
cleaning force must be less than the adhesive force between the
particles and the tacky areas. We find that in many cases of
freshly populated tacky areas that immediate attempts to remove the
excess particles results in removing many particles from the tacky
areas. The initial adhesion (Adh0) of the particle to the tacky
areas can be very low, such that the forces applied to clean off
excess particles TW+EX exceeds the adhesive force of the particle
to the tacky area, and V becomes large. This is particularly true
with rough particles that are not wet well by the tacky areas
(adhesion increases as the wetting area of the particle by the
tacky area increases).
[0075] Holding the array of tacky and non-tacky areas with
particles adhered thereon for a period of time and at a temperature
of greater than or equal to 30.degree. C. allows the particles to
adhere and center better to the tacky areas. During this time
period the surface area of the particle wet by the tacky area
increases, the particle is drawn deeper into the tacky area and the
particle moves toward the center of the tacky area. This process
stops when the particle penetrates through the tacky area and comes
to rest in contact with the bottom of the tacky area or the
circumferential rim of the tacky area. This process is quite slow
at or near ambient temperature (e.g., 20.degree. C.) and may take
an hour or more to reach equilibrium. The time to reach equilibrium
depends on several factors including the thickness of the tacky
area, the width of the tacky area, the viscosity of the tacky
material, the surface energies of the tacky material and particles
which determines wetting rates and characteristics. Heating the
array of tacky and non-tacky areas covered with particles adhered
thereon greatly speeds up the wetting process and adhesion build-up
of the particles to the tacky areas during the hold period. There
is an advantage in quickly providing robust adhesion of particles
to the tacky areas for it allows for cleaning off the excess
particles shortly after they were applied without the loss of
particles attached to the tacky areas making the overall process
much more convenient and efficient. In some cases it may be
advantageous to heat the particles also, or to just heat the
particles and not the tacky areas when the particles have
sufficient thermal inertia to retain their heat for a brief period
of time until they engage a tacky area.
[0076] Suitable hold times for the methods of this invention vary
with temperature in the heating step. Illustratively, the period of
time for the hold time can broadly range from 5 seconds to 45
minutes. When the temperature in step (d) is at least 30.degree.
C., the period of time in step (d) ranges from 10 seconds to
minutes. When the temperature in step (d) is at least 35.degree.
C., the period of time in step (d) ranges from 10 seconds to 4
minutes. When the temperature in step (d) is at least 40.degree.
C., the period of time in step (d) ranges from 5 seconds to 60
seconds. In special embodiments where the temperature is less than
30.degree. C., the hold time can range from 2 minutes to 1
hour.
[0077] Another surprising benefit of certain process improvements
is centering of the particles in the tacky areas during the hold
period with or without heating. With the correct match of tacky
area thickness, width and particle geometry the wetting process
that occurs during the hold period draws the particle to the exact
center of the tacky area. It is believed that surface tension
forces between the viscous tacky liquid and the particle surface
play a dominant role in this centering process. The wetting process
and centering action has been observed to occur equally well
whether gravity is aiding or opposing the joining of the particle
and tacky area. That is, the process has been demonstrated with the
particle and tack), area on the topside or bottom-side of the
substrate. This self-centering effect can be critical for aligning
particles with receptor pads in a transfer process, especially when
the spacing between particles and between pads is small relative to
the particle size.
[0078] Complete centering depends on the tacky area diameters being
less than or equal to a calculated wetting or contact diameter (x)
of a sphere for a particular sphere diameter (2r) and tacky area
thickness(z). It is only under these conditions that the sphere
rests on the complete perimeter of the tacky area and, by
definition, is completely centered. The relationships of r, x and z
are illustrated in FIG. 8 and described in the equation:
r.sup.2=(0.5x).sup.2+(-z).sup.2 where: [0079] sphere radius=r
[0080] wetting diameter=x [0081] adhesive thickness=z [0082]
approximate contact area=3.1416(1/2x).sup.2
[0083] If the tacky area diameter is too much smaller than the
calculated wetting diameter, the wetted area becomes too small to
achieve good adhesive forces. For conditions where exact centering
is not required, the tacky area diameter may be larger than the
calculated wetting diameter and still be substantially centered as
shown in FIG. 8. Accordingly, the tacky area diameter may be
70%-170% of the calculated wetting diameter and still work well for
purposes of this invention.
[0084] A pattern of tacky dots on 50 micron thick Kaptoni.RTM. E
film was populated with 125 micron solder spheres and immediately
turned upside down and used to cover a hole in a sheet aluminum
spacer on a microscope's hot stage. Using a combination of
reflected and transmitted light the tacky dots and attached solder
spheres were viewed immediately through the Kapton.RTM. E. The
perimeter of the tacky dots and the contact area of the solder
spheres were in sharp focus while the solder sphere appears as a
dark shadow.
[0085] FIG. 7A illustrates the web 8 of FIG. 1 in the condition
where a spherical particle 20 first engages the corner 26 of a
tacky dot 28 on a substrate 12. In FIG. 7B, which is a view looking
in the direction of arrows 7B-7B of FIG. 7A, the cross-hatched
circle 30 represents the contact area on the surface of the
particle 20 that is wetted by the viscous tacky polymer of the
tacky dot 28. The solid line circle 32 represents the perimeter of
the viscous tacky dot 28. The dashed line circle 34 represents the
particle diameter which appears as the dark shadow when actually
viewing the particle through the translucent web from the
bottom-side.
[0086] The following observations were made. The contact area 30 of
the solder sphere 20 most often starts at the perimeter of the
tacky dot 28 and was initially small relative to the area of the
tacky dot. With time the contact area of the solder sphere 20 was
seen to increase as it is wet more and more by the tacky dot
28.
[0087] FIG. 7E illustrates the condition of FIG. 7A after a
substantial hold time has taken place and wherein the relationship
of the particle diameter, tacky dot diameter, and tacky dot
thickness result in the particle contacting the entire perimeter 32
of the tacky dot surface before it bottoms out on the substrate 12.
FIG. 7F illustrates view 7F-7F of FIG. 7E.
[0088] In case of FIG. 7E and 7F the contact area 30 grew until its
perimeter matched the perimeter 32 of the tacky dot 28 in which
case the solder sphere 20 had rimmed out on the surrounding
non-tacky surface and was completely centered over the tacky
dot.
[0089] FIG. 7C illustrates the condition of FIG. 7A after a
substantial hold time has taken place and wherein the relationship
of the particle diameter, tacky dot diameter, and tacky dot
thickness result in the particle bottoming out on the substrate 12
before the particle contacts the entire perimeter 32 of the tacky
dot surface. FIG. 7D illustrates view 7D-7D of FIG. 7C.
[0090] In the case of FIG. 7C and 7D the solder sphere 20 contact
area increased until the sphere had sunk through the tacky dot 28
and rested against the substrate 12 of Kapton.RTM. film, in which
case it had bottomed out and was partially and substantially
centered on the tacky dot.
[0091] The contact area was observed until no further change was
observed with time in which case equilibrium had been reached. Time
to equilibrium is a measure of the embedding rate of the solder
spheres in the tacky dots. Increasing the tacky dot temperature
substantially decreases the time for embedding and centering of
solder spheres in tacky dots. A 4 micron thickness is sufficient to
center a 127 micron solder sphere in a 55 micron tacky dot as in
FIGS. 7E and 7F whereas a 3 micron thickness results in a bottomed
out situation as in FIGS. 7C and 7D before there is complete
centering. Thus in the latter case there is only partial centering
of the sphere with respect to the tacky dot (tacky area).
[0092] Calculations show that for a 4 micron thick adhesive area
and a 127 micron (5 mil) sphere the tacky dot must be 44.4 microns
in diameter or less for complete centering. For a 3 micron thick
adhesive the tacky dot must be 38 microns or less for complete
centering. Thus with the 55 micron tacky dot and 4 micron coating
the 127 micron particle can be 5.3 microns off center. For the 3
micron adhesive the particle can be 8.5 microns off center.
[0093] Summarized below are some comparisons of observed wetting
diameter at equilibrium versus calculated wetting diameter for
several different sphere diameters and coating thicknesses.
TABLE-US-00001 sphere coating calcd. wetting observed wetting
diameter thickness diameter diameter (micron) (micron) (micron)
(micron) 127 3.0 38 37.5-42.9 127 4.0 44.4 41.6-50.0 127 6.0 53.9
127 10.0 68.4 300 4.0 68.8 300 8.0 96.7 300 24.0 162.8 NOTE: calcd
= calculated
[0094] The centering process continues until equilibrium is reached
or the adhesive is inactivated or the particle is removed.
Depending on the need for centering in the final use of the array
of tacky areas populated with particles, it could be advantageous
to speed up the centering and bring it nearer completion by the end
of the population process. Heating the surface having an array of
tacky and non-tacky areas with particles adhered thereon is the
best method for both speeding up the centering process and building
adhesion between the particles and the adhesive areas.
[0095] Significant increases in the adhesion of particles to the
tacky areas occur with a hold time of 30 to 60 inutes and some
improvement is evident in 1 to 2 inutes at 21.degree. C. For hold
times of one minute or less the overall efficiency of the
population process shows significant improvement when the
temperature is 30.degree. C. or higher. Preferably, the population
of the array of tacky and non-tacky areas is conducted at a
temperature that is greater than or equal to 35.degree. C. and less
than the decomposition temperature of the tacky areas and less than
the sticking temperature of the non-tacky areas. For photopolymers
described in this invention the decomposition temperature of the
tacky areas is greater than 100.degree. C. and the sticking
temperature of the non-tacky areas is dependent on the degree of
photocuring and on the hold time. Although the non-tacky areas
soften above 40.degree. C. for a preferred composition for a light
photocuring and above 60.degree. C. for a strong photocuring,
population can still be very efficient at 50.degree. C. as long as
the hold time is short (6 seconds). Preferably, the population of
the array of tacky and non-tacky areas is conducted at a
temperature that is equal to or greater than 35.degree. C. and
which is less than or equal to 80.degree. C. More preferably, the
population of the array of tacky and non-tacky areas is conducted
at a temperature that is equal to or greater than 35.degree. C. and
which is less than or equal to 65.degree. C. Most preferably, the
population of the array of tacky and non-tacky areas is conducted
at a temperature that is equal to or greater than 35.degree. C. and
which is less than or equal to 50.degree. C.
[0096] The particles of this invention must be free flowing
particles as defined supra, but, other than this requirement, can
have any other properties as desired.
[0097] For many or most applications of this invention, it is
desired to populate each tacky area of an array of tacky and
non-tacky areas with one and only one particle. In order to
populate each tacky area with one and only one particle, it is
critical that the particle size be significantly larger than the
size of the tacky area to be populated. In general, for cases
involving population of tacky areas with various shapes, including
irregular shapes, with particles of various shapes, including
irregular shapes, a given tacky area should be no larger than about
30% of that of the particle. This value of 30% specifically applies
for population of circular tacky areas with non-spherical
particles. For spherical particles on circular tacky areas, it is
suitable according to the invention to achieve a population of 1
particle for each tacky area when each tacky area is a circle
having a diameter d1 and each of the particles is a sphere having a
diameter d2, wherein d1/d2 is in the range from 0.1 to 1.0.
Preferably, d1/d2 is in the range from 0.15 to 0.9. Most
preferably, d1/d2 is in the range from 0.3 to 0.6.
Improved Methods
[0098] The invention in one embodiment is an improved method for
transferring particles from an electrode plate to tacky areas
present on a substrate. In this method, a substrate having both
tacky and non-tacky areas (as described supra) is placed between
first and second electrode plates, with the substrate and electrode
plates being arranged substantially horizontally and stacked with
one above or one below the other.
[0099] The particles being transferred in the method of this
invention can be either electrically conductive particles or
non-conductive particles. Conductive particles are preferred for
transfer in this invention.
[0100] The meaning of substantially horizontally in this invention
is that each of the indicated object(s) (e.g., substrate and
electrode plates) has a main plane associated with it and that in
the method of this invention the object is oriented such that its
main plane is perpendicular to the gravitational field of Earth
within 10 degrees, that is, perpendicular within 10 degrees to a
plumb line at a given location on the Earth's surface.
[0101] The meaning of the terms "below" and "above" in this
invention are used in the conventional sense and are used in
reference to there being a stacking arrangement of the electrodes
and the substrate. Specifically this term "below" is in reference
of one object being placed or located closer to Earth's surface
than is another object to which the first is being referenced. In
this invention, the first electrode plate is located closest to
Earth's surface. The substrate is located further from Earth's
surface, such that it is above the first electrode plate. The
second electrode plate is located further from Earth's surface than
is the substrate, such that the second electrode plate is above the
substrate.
[0102] In preferred embodiments, the first and second electrode
plates in this invention have planar or substantially planar
surfaces (for the active electrode area that is either at a
potential or grounded). Similarly, the array of tacky areas in the
substrate in preferred embodiments is planar or substantially
planar. Shapes of the electrode plates and the array of tacky areas
of the substrates otherwise are not limited--they can, for example,
be rectangular, square, circular, or ellipsoidal.
[0103] In this invention, one of the electrode plates is spaced a
distance from the tacky and non-tacky areas of the substrate and is
spaced from the other electrode plate. There is no limit to the
distance for the spacing between the tacky and non-tacky areas and
the electrode except that it must be greater than the diameter of
the largest particle(s). The spacing between electrodes is limited
by the available voltage difference, or potential, between
electrodes, and the particle weight.
[0104] The direct current potential that is applied in this
invention between the first and second electrode plates is at least
500 Volts, preferably is at least 1000 Volts, and still more
preferably is greater than 2000 Volts. The upper limit to the
direct current potential is the value that causes arching between
electrodes at their selected spacing. The direct current potential
is applied for a time T.sub.1 which can be for any time interval
longer than 0.1 millisecond. In most instances, the time T.sub.1
will be in the range from about 0.1 second to about 100 seconds,
preferably in the range of 1 second to 100 seconds, more preferably
in the range of 1 second to 10 seconds, and most preferably in the
range of 2 seconds to 5 seconds.
[0105] In one embodiment of this invention where the particles are
placed in contact with the first electrode, application of the
direct current potential of sufficient magnitude will result in
generation of an electric field, which causes the particles to
become charged with the same charge (positive or negative) as the
first electrode-plate to which the particles are initially in
contact. When the electric field is at least a certain minimal
value, the particles move upwards against the force of gravity when
the upward electrical force on the particles is higher in magnitude
than the gravitational force. The electrical force tends to move
the particles upward since the particles in contact with the first
electrode plate have the same charge as the first electrode plate
and are repelled by it. Also the particles are attracted by the
second electrode plate when it has either the opposite charge or
ground potential. The net result is that the particles can be made
to move upwards against gravity by adjusting the direct current
potential such that an electrical field is produced that acts on
the particles with a higher upward force than is the force of
gravity acting downward (towards Earth's surface). The particles
are attracted towards the second plate electrode, but do not
contact the second plate electrode since the particles first
contact the substrate having an array of tacky and non-tacky areas
that is placed between the two plate electrodes. When the particles
contact the substrate having an array of tacky and non-tacky areas,
some will contact tacky areas and some will contact non-tacky
areas. Essentially all particles remain in contact with the
substrate as long as the direct current potential is applied at the
same level that caused the particles to move upwards. At least a
portion of the particles will become adhered to the tacky areas of
the substrate and these particles will remain adhered to the tacky
areas even in the event the potential difference between the two
electrodes is changed to zero, since the substrate in this
invention is chosen to have an array of tacky areas having
sufficient tack to cause particles that contact it to remain
adhered even against the force of gravity tending to cause the
particles to become unadhered (detached).
[0106] In some embodiments of the method of this invention, the
method further comprises a step of changing the direct current
potential to reverse the polarity on the first electrode plate
while the particles are adhered to the tacky and non-tacky areas,
which causes at least some of the particles to leave the non-tacky
areas of the substrate, be propelled against the first electrode
plate, again be charged and propelled from the first electrode
plate to the substrate. The net result is that at least some of the
particles that had been adhered to non-tacky areas prior to the
polarity reversal become adhered to tacky areas at the end of the
polarity reversal. When the polarity of the first electrode plate
is reversed, the particles adhered to the substrate are now
attracted to the first plate electrode. Predominantly those
particles adhered to non-tacky areas will move away from the
substrate to the first plate electrode. As soon as they contact the
first plate electrode, the particles will become charged with the
same charge (positive or negative) as the first plate electrode and
consequently will now be repelled from the first plate electrode.
The particles now will again move to the substrate since they are
attracted at this point to the second plate electrode.
Statistically, it is very unlikely that a given particle will
contact the same exact spot on the substrate during the second
contact that it did in the first contact with the substrate. There
are various reasons for this, including air currents acting to
displace the particles differently in successive contacts,
particles bouncing against each other causing displacements from
original trajectories in successive contacts, etc. Statistically,
it is likely that the particles will contact different areas of the
substrate in successive contacts with the substrate, which provides
for enhanced probability of the particles contacting additional
tacky areas and becoming adhered with each successive contact with
the substrate.
[0107] Changing the direct current potential to reverse the
polarity on the first electrode plate is done for a time T.sub.2
which can be for any time interval longer than 0.1 millisecond. In
most instances, the time T.sub.2 will be in the range from about
0.1 second to about 100 seconds, preferably in the range of 1
second to 100 seconds, more preferably in the range of 1 second to
10 seconds, and most preferably in the range of 2 seconds to 5
seconds.
[0108] In some embodiments of this invention, the method further
comprises repeating the polarity change for a number N of cycles of
reversing the polarity of the first electrode plate, whereby at
least some of the particles are repeatedly propelled against and
become adhered to the substrate. As explained supra, each
successive cycle increases the probability of a given particle for
contacting a tacky area that is unpopulated and for populating this
tacky area. The net result is that each successive cycle increases
the net population efficiency in the overall population of the
tacky areas of the substrate. There is no limit to the number N of
cycles of reversing the polarity of the first electrode plate. In
most cases, the number of cycles N is in the range from 2 to 1000,
preferably in the range from 10 to 100, and more preferably in the
range from 20 to 50. In some cases, N is 1, i.e., a single cycle,
with only one polarity reversal of the first electrode plate or, in
other cases, N is 1/2, i.e., a half cycle with a direct current
potential being applied to the first electrode plate once with no
polarity reversal(s).
[0109] In this invention, after applying a direct current potential
to the first plate electrode and/or a number N of cycles of
reversing the polarity of the first plate electrode has been
carried out, it is highly desirable to have an efficient method for
removing particles from non-tacky areas. One effective method for
removing particles comprises applying ionized air to the substrate
to at least partially neutralize electrostatic charges. The net
result is that many or all particles disengage readily and separate
from non-tacky areas once the electrostatic charges are reduced or
eliminated.
[0110] Another effective method for removing particles from the
non-tacky areas of the substrate after N cycles of polarity
reversals (where N is 1/2, 1, or a number greater than 1) is a
method which further comprises inserting a dielectric surface
between the first electrode plate and the substrate, and spaced
from the substrate, while the particles are on the substrate; and
changing the direct current potential to reverse the polarity on
the first electrode plate, causing the particles to leave the
non-tacky areas of the substrate and be propelled against the
dielectric surface. With the dielectric surface present, the
particles are prevented from again contacting the first plate
electrode and changing polarity. Once the potential difference
between the two electrodes is brought to zero, the particles in
contact with the dielectric surface readily roll off and/or can be
removed from the dielectric surface.
[0111] Another way to remove particles from the non-tacky areas,
which may be used separately or in addition to other methods just
discussed, is to mechanically tap the substrate. The substrate with
the populated tacky areas would be removed from between the
electrodes and held so there is some tension in the substrate. An
operator's finger, a bar, or a rod can be tapped against the back
side of the substrate opposite the tacky and non-tacky areas to
abruptly deflect the tensioned substrate and allow it to bounce
back. Several such taps may be applied to facilitate removal of
particles from the non-tacky areas.
[0112] FIG. 9 shows a population device 300 that can be used to
process a discrete web or substrate 302 having a surface 303
covered with arrays of tacky and non-tacky areas. A first electrode
plate 326 is positioned below the web 302 and a second electrode
plate 304 is positioned above the web 302. The web and plates are
horizontal so particles can be placed on the electrode and held in
place by gravity. The second electrode 304 may include a heater
330. The web is attached to a non-conductive, annular, support ring
306 which is attached to the lower surface 305 of second electrode
304 by taping or clamping so the web is contacting the surface 305
which is heated by heater 330 thereby heating the tacky areas.
Alternatively, a separate web/substrate support can be provided
(not shown) to position the web/substrate between the electrodes
and spaced from the first electrode 326. Non-conducting material
307 is used to cover any exposed edges and the back side of
electrode 304. Positioned beneath the web is first electrode 326,
which is adapted to hold a plurality of particles on a top surface
328 by placement of a non-conductive, thin, annular ring 327 on
surface 328 to keep the particles away from the edge of the
substrate. Second electrode 304 is electrically connected to a DC
power supply 332 by lead 301. The power supply 332 provides a
source of DC potential and has a connection to ground 321 and
includes a switch 342 for changing the polarity of the DC power
connected to the lead 301. First electrode 326 is electrically
connected to ground 321 by lead 344. The operation of the invention
relies on establishing an electric field between the electrodes and
does not require a closed electrical circuit to establish current
flow. Either electrode could be connected to ground; the lower
electrode was chosen for safety reasons since it is more accessible
to accidental contact than the insulated upper electrode. The first
electrode 326 may have a heater 331 that acts to heat the particles
on surface 328. Above the web is a vibratory tray 308 attached to a
moveable frame 310 that moves in the direction of arrows 312 and
314 being propelled manually or by an actuator 316. The actuator
may be controlled by controller 318 as is the vibratory tray 308.
The tray 308 extends across the width of the web 302 and has an
outlet 309 on one side. The tray is filled with particles, such as
particle 20, to be placed on the tacky areas on the web 302. The
tray may also have a heater 311 for heating the particles as they
rest on the tray bottom. The moving and vibrating tray acts as a
particle dispenser to deliver particles 20 over the entire surface
328 of the first electrode 326. The second electrode 304 is
connected to an actuator 334 which is mounted to a support 320 that
is attached to a machine frame (not shown). The actuator 334 is
controlled by controller 318 to move second electrode 304 toward
and away from first electrode 326. The actuator 334 acts as a plate
moving device that may be attached to the upper second electrode
plate 304, as shove, or may alternatively be attached to the lower
first electrode plate 326. It functions to space the first and
second electrode plates away from each other to facilitate
delivering particles over the first plate and for attaching and
removing the web/substrate 302, and for spacing the plates toward
each other to facilitate particle propulsion.
[0113] An enclosure 348 surrounds major portions of the population
device as shown to contain any straying excess non-mounted
particles for collection and reuse. A container 350 is at the
bottom of the enclosure to capture the excess particles.
[0114] In operation, a sheet of the web 302 is mounted on the
second electrode 304 with the image of tacky areas facing away from
the electrode 304. If a cover sheet is used to protect the tacky
areas of the web it would be removed at this time and the imaged
web 302 would be treated with ionized air to neutralize the web.
Particles such as solder spheres would be placed in the vibratory
tray 308 in a quantity greatly in excess of what is required to
populate the tacky areas. The heater 311 in the tray would be
continually energized to heat the particles as they rest in the
tray. Heating the particles by heaters 311 and 331 illustrate a way
of providing the desired heat for the process to facilitate
attachment and rapid centering of the particles on the tacky areas.
Heating of the particles may be used as the sole heat source for
the process, or in conjunction with substrate (web) heating by the
heater 330 in electrode 304. Alternatively, the heated electrode
304 may be the sole source of heat in the process. Other heating
means, such as radiation or convection means, may alternatively or
additionally be used. What is important in all cases of heating is
that the tacky areas are heated to a temperature of at least about
30.degree. C. by whatever heating means is used. The vibratory tray
would be briefly cycled to distribute the spheres uniformly across
the tray at the outlet. Actuator 316 would be in a position to
place the outlet 309 of the vibratory tray at the left end of
surface 328 of first electrode 326 as shown. The controller 318
would signal the vibrator to turn on and begin dispensing particles
that would fall from outlet 309 to the surface 328 of the first
electrode 326. Controller 318 would signal actuator 316 to move
frame 310 to advance the vibratory tray from left to right so the
outlet 309 dispensing the spheres travels across the electrode.
When the outlet 309 reaches the right end of the first electrode,
the vibratory tray would be turned off and the actuator 316 would
be reversed under the control of controller 318 to return the tray
to the left of the assembly.
[0115] After the particles are dispensed and the tray is retracted,
the controller 318 would signal the actuator 334 to lower second
electrode 304 into close proximity to first electrode 326, until
there is a predetermined gap between the upper electrode surface
305 and the surface 328 of the lower electrode. The gap affects the
voltage level required to establish the desired electric field
between the electrodes. The gap between the surface of the
substrate attached to the top electrode and the bottom electrode
must still be large enough at this electrode gap that some velocity
is imparted to the particles to create a useful lateral scattering
of particles to aid in populating efficiency. A larger gap to the
substrate will result in a higher speed attained by the particles
and more collisions between particles; this is believed to produce
lateral particle motion that increases the probability of particles
encountering tacky areas. A larger gap would require a higher
electrode voltage, however.
[0116] The controller 318 would now control the switch 342 on DC
power supply 332 to connect the negative pole (or positive pole) of
the DC power supply to lead 301. After a predetermined time, the
controller would control the switch to connect the positive pole to
lead 301. After the predetermined time, the controller would cause
the switch to reverse the polarity to the top electrode again. For
solder sphere particles, a preferred predetermined time is 1-10
seconds and a more preferred time is 2-5 seconds. When the initial
polarity is established between the top and bottom electrode, the
particles are propelled toward the top electrode and attach to the
substrate. For each subsequent polarity state change (half-cycle),
the particles leave the substrate on the top electrode, contact the
exposed surface of the bottom electrode and are discharged and
recharged, and they are re-attracted to the substrate on the top
electrode. After a predetermined number of polarity state changes
(which may end with a half-cycle or full cycle), the controller 318
would control the switch 342 to disconnect the positive and
negative poles of power supply 332 from the lead 301 to the second
electrode 304, and connect lead 301 to ground 321. The particles 20
would ordinarily remain on the substrate 302 on the second
electrode 304.
[0117] After the electrostatic cycling is complete, the web is held
at rest for a predetermined time adjacent heated electrode 304.
This heats the tacky areas so they will wet the surface of the
particles 20 quickly which plays a role in increasing the
attachment force and the area contact with the particle. If
additional centering action is desired for a particular set of
conditions, it may be desired to continue with additional holding
time at an elevated temperature before removing the populated
web.
[0118] The top electrode is raised by actuator 334 and the
populated substrate 304 would be removed from the top electrode and
a new unpopulated substrate could be mounted on the top electrode
to repeat the populating process. The populated substrate that was
removed would be treated with an ionized air stream to neutralize
the remaining charge on the particles and substrate. The substrate
would be gently tapped on the side opposite the particles to
dislodge any particles remaining on the non-tacky areas to
depopulate them. This would complete the populating/depopulating
process for a discrete substrate.
[0119] An alternate method to facilitate depopulating the non-tacky
areas of the substrate 302 is to provide a non-conductive sheet 345
and an actuator 346 to insert the sheet 345 between the electrodes
in the gap between the surface 303 of web 302 and first electrode
326 before disconnecting the poles from lead 301. After inserting
the sheet 345, the poles would be changed for the last time which
would repel the particles from the non-tacky areas of the substrate
and toward the first electrode 326. Since the particles would
encounter the sheet 345 before reaching the conductive surface 328
of electrode 326, the charge on the particles would not get
transferred by direct contact with the electrode and the particles
would remain on the sheet 345. The lead 301 would be disconnected
from the last pole and would be connected to ground. The upper
electrode would be raised by actuator 334 and the substrate 302
populated primarily in the tacky areas would be removed. This
technique for depopulating the non-tacky areas has been found to
remove a significant percentage of particles from the non-tacky
areas, but for complete removal, additional depopulating may still
be required.
[0120] Another variation of the invention is possible if the tacky
areas are distributed within a connected field of electrically
conductive non-tacky areas that can be used as an electrode. In
this case, the apparatus of FIG. 9 would remain essentially the
same as discussed except lead 301 would be connected to the field
of non-tacky areas (non-tacky electrode) and what was formerly
electrode 304 would act simply as a support plate for the web 302.
The operation would be changed substantially in that a pole of
power supply 332 would only have to be connected by switch 342 to
the non-tacky electrode once to start a continuous oscillation of
particles between the first electrode 326 and the non-tacky
electrode. As the charged particles contact the exposed electrode
surfaces of either the first electrode 326 or the non-tacky
electrode, each particle is discharged, oppositely charged, and
repelled toward the opposite electrode. The repeated propulsion
toward the substrate with tacky areas distributed throughout the
field of connected non-tacky areas results in many opportunities
for a particle to land on a tacky area and remain stuck there.
After a predetermined time or number of oscillations, the lead 301
to the non-tacky areas is disconnected from the DC pole and
connected to ground 321. The substrate is then processed as first
discussed referring to FIG. 9. In this case just discussed, the
tacky areas could also be electrically conductive and be
electrically connected to the non-tacky areas, or not, and the
process just discussed would operate the same.
[0121] Several variations in the device are possible and still
practice the population process of the invention for a discrete
web. Manual actuation and control can be practiced thereby
eliminating controller 318. If heating of the particles is not
required, heating means 311 (FIGS. 9 and 10) and 331 (FIG. 9) may
be omitted; if heating of the tacky areas is not required, heater
330 (FIG. 9) and 331 (FIG. 10) may be omitted. Alternatively or in
addition to heating with heaters 311, 331, and 330 is to heat the
air in enclosure 348 so all elements of the device are at an
elevated temperature that would tend to heat the tacky areas and
particles. These modifications can still produce results that are
an improvement over the prior art for populating particles on tacky
areas.
[0122] FIG. 10 shows a population device 300a that can be used to
process a continuous elongated web 352 having a surface 354 having
repetitive arrays of tacky and non-tacky areas. In this case, the
web 352 would be presented to the device combined with a continuous
elongated cover 356 to form a protected composite web 358. The web
358 could be provided from a discrete roll 360 or could be provided
from a previous web treatment process as indicated by dashed lines
362, such as an imaging process. The device 300a comprises a first
web support roller 364 and a second web support roller 366 that
support web 352 horizontally over a heated first electrode 368
positioned beneath the web. The horizontal orientation allows
particles to be held in place on the web by gravity. The first
electrode 368 can be raised and lowered (shown lowered) so upper
surface 328 can be in or out of contact with the bottom-side 400 of
the web 352. The plate has a heating means 331 that acts to heat
the web 352 and the tacky areas thereon. The first electrode 368 is
attached to actuators, such as actuators 336 and 338 that are
attached to mounting plate 340 that is part of a machine frame. The
actuators would be in communication with control 318 for
coordination with other machine elements. In the up position, the
actuators place the upper surface 328 of the heated first electrode
in contact with the bottom-side 400 of the web. When the actuators
are in the down position, the surface 328 of electrode 368 is
spaced away from the bottom-side of web 352. Keeping the upper
surface 328 out of contact with web surface 400 during web movement
is believed to minimize static buildup. Non-contact also is
believed to facilitate the neutralization of charges on the web by
ionization devices to aid in depopulation of the non-tacky areas.
The first electrode is electrically connected by lead 344 to ground
321.
[0123] Above the web is a second electrode 369 that is at least as
big as the area covered by the tacky arrays on the web (substrate).
Non-conductive material 371 is used to cover any exposed edges and
the back side of second electrode 369. Lead 301 electrically
connects the second electrode 369 to a switch 342 on a DC power
supply 332. The second electrode surface 373 is spaced a
predetermined distance from the surface 354 of web 352 which is
under tension. When the first electrode is contacting web 352, it
establishes a predetermined gap between surface 328 of electrode
368 and the surface 373 of electrode 369. The gap between
electrodes affects the voltage level required to establish the
desired electric field between the electrodes. The space between
the surface 354 of the substrate and surface 373 of the second
electrode 369 must still be large enough at the electrode gap that
some velocity is imparted to the particles to create a useful,
lateral scattering of particles to aid in populating efficiency as
discussed referring to FIG. 9.
[0124] The incoming composite web 358 is additionally guided by
roller 370 and is tensioned by a braking device 372 acting on roll
360. The cover 356 is additionally guided by roller 374 and is
collected in a discrete roll 376 tensioned by a winding device 378
acting on roll 376. Positioned above the web 352 is an ionization
device 322 to neutralize static charges on the incoming web 352,
especially that generated during stripping of cover sheet 356.
Device 322 is directed at the position where cover 356 is peeled
off web 352. Also above the web 352 is a vibratory tray 308 having
an outlet 309 and heating means 311 as in FIG. 8 for dispensing
particles 20. The vibratory tray is fixed to a machine frame at
position 380. Web 352 is further guided by rollers 382, 384,386,
and 388 before passing between driven roller 390 and nip roller
392. The web 352 passes under nip roller 392 with the tacky area
surface 354 facing roller 392 which is relieved in the central
portion to avoid contact with any of the populated tacky areas.
Cutting means 394 and holding table 396 are adjacent driven roller
390 and in the path of web 352.
[0125] Between rollers 382 and 384, the web is transported
horizontally and passes between ionizing air knife 324 directed at
the web surface 354, and ionizing air knife 324a directed at the
opposite web surface 354b. The air knife is a known device that
uses a row of ac corona discharge needles to ionize the surrounding
air in a band. A sheet-like stream of flowing air is directed past
the needles to forcefully distribute the ionized air over the web
surface. The corona discharge function can also be used effectively
if separated from the air function when air flow is not desired,
The devices 324 and 324a extend across the width of the web 352.
Tapping device 404 is positioned to be able to contact side 354b of
web 352 opposite the tacky and non-tacky arrays. The tapping device
has a moveable member 406 that extends out to contact the web when
desired. The tapping acts to mechanically dislodge particles on the
non-tacky areas of the web. A tapping impact frequency of 1-2 taps
per second and a tapping amplitude of 0.03-0.3 inches web movement
has been found to be effective for depopulating the non-tacky
areas. Beneath the device 300a is a container 398 for collecting
excess particles 20. Controller 318 is used to control the various
elements of the device 300a.
[0126] In operation of the device 300a, an elongated composite web
358, having multiple repeating tacky and non-tacky arrays imaged
thereon, would be provided from roll 360 and would be threaded over
roller 370 and support roller 364 that acts as a first transport
roller for transporting the web between the electrodes. Cover 356
would be peeled off of the composite web at roller 364 leaving web
352 to proceed to support roller 366 that acts as a second
transport roller for transporting the web between the electrodes.
Cover 356 would proceed over roller 374 to roll 376 where it will
be wound, driven by winding device 378. Web 352 would be threaded
around rollers 382, 384, 386, and 388 and through the nip formed by
driven roller 390 and nip roller 392. Driven roller 390 may be
propelled by a drive such as a servo motor, stepping motor, or the
like under the control of controller 318 to achieve precise
movement of web 352. Control of braking device 372 by controller
318 will provide tension control for web 352 and composite web 358.
Control of winding device 378 by control 318 will provide tension
control for web 356.
[0127] The web is stopped to position a complete tacky area array
over heated first electrode 368 and under second electrode 369 and
another adjacent array under ionization device 322. During advance
of the web 352, the electrode 368 is retracted to avoid rubbing
contact with web 352 which would generate electrostatic charges
that would be difficult to neutralize. It is significant that the
web 352 is at one point not contacting any surfaces between support
rollers 364 and 366 to thereby provide good conditions for
electrostatic charge neutralization. During advance of the web 352,
vibratory tray 308 is energized to dispense particles 20 through
outlet 309 to fall onto the static neutralized web 352. As the
particles are cascading onto web 352, one repeat of the multiple
tacky arrays on web 352 passes by the outlet 309 so one entire
array is covered by this relative motion between web 352 and outlet
309. When the covered array stops over electrode 368, the vibratory
tray is deenergized and the flow of particles from outlet 309
stops. It may be desirable to position the outlet 309 so that when
the web 352 stops, the outlet is over a gap between multiple
arrays. The rollers 390 and 392, cutting means 394, and holding
table 396 are preferably positioned so that when the array stops
over plate 368, a populated array also is positioned with the gap
between arrays located at the cutting means 394. The cutting means
can then be actuated by controller 318 to cut between the arrays
and thereby separate one populated array from the continuous web
352 as desired for further handling.
[0128] When the covered array stops over electrode 368, actuators
336 and 338 are signaled by controller 318 to raise electrode 368
to contact the bottom-side 400 of web 352 and establish the
predetermined electrode gap between electrodes 368 and 369. The
heated surface 328 of electrode 368 quickly heats the tacky areas
on the web. The controller 318 would now control the switch 342 on
DC power supply 332 to connect the negative pole (or positive pole)
of the DC power supply to lead 301. This results in particles being
propelled off the web 352, contacting electrode surface 373, and
being propelled back to web 352 to thereby populate previously
unpopulated tacky areas thereon. After a predetermined time, the
controller would control the switch to connect the positive pole to
lead 301 which would again cause propulsion of particles to surface
373 and back to surface 352. After the predetermined time, the
controller would cause the switch to reverse the polarity to the
top electrode again as discussed referring to FIG. 9. After a
predetermined number of polarity cycles, the lead 301 is
disconnected from the power supply poles and is connected to ground
321. The web is held at rest in contact with heated surface 328 for
a predetermined time during which the web is heated and the
particles on the tacky arrays are firmly adhered and centered in
each tacky area. After the predetermined hold time, the electrode
368 is retracted out of contact with web 352 and the controller
causes driven roller 390 to advance the web a distance of one tacky
array. As the just populated array passes over support roller 366,
the particles on the non-tacky areas of the array progressively
cascade down off the web and are collected in container 398. The
progressive cascading and the angled web path at 402 prevent a
large quantity of particles from coming off the web all at once
that might dislodge the particles attached to the tacky areas. The
flexibility of the web permits this progressive change in path over
roller 366.
[0129] As the web with previously populated arrays is moving
between rollers 382 and 384 the controller turns on air flow to air
knives 324 and 324a positioned between the rollers. The ac corona
to the air knives may remain on continuously. Air knife 324 acts to
blow off excess particles that may still be temporarily adhered to
the non-tacky areas as the moving web 352 passes by knife 324.
During web movement, the controller 318 also directs tapping device
404 to tap the web for a predetermined time or number of taps. Air
knife 324a similarly acts to blow off any particles that may have
inadvertently fallen onto the back-side of the web 352. When the
web motion stops for the next cycle, the air-flows to air knives
324 and 324a are turned off by controller 318. Tapping device 404
could alternatively be actuated for its predetermined duration only
during the time the web motion is stopped.
[0130] After stopping the web motion, controller 318 also activates
holding table 396 to grasp populated web 352 with a vacuum while
cutting means 394 is cycled to cut the web between populated
arrays. The entire cycle just described can now repeat for the next
tacky array on the continuous elongated web. Such an automated
device 300a for populating a continuous web offers productivity
advantages and labor savings not possible before.
[0131] Referring to FIG. 10, there can be several variations to the
hold time for the populated web in the process. A first hold time
may occur beginning just after the particles have been agitated by
the electrodes and the web is resting on heated electrode 368 and
before the web is indexed off electrode 368 to present a new array
for populating. During this time no forces are applied to the
excess particles to try to remove them that may result in
disturbing the particles on the tacky areas. A second hold time may
occur beginning just after the web has been advanced to move the
just populated array off the electrode 368 and over the roller 366.
Many of the excess particles will fall off the web due to gravity
as the web is bent over roller 366, but the excess particles will
not yet have been aggressively removed by air jets or vibrations
(tapping). During this hold time the particles on the tacky areas
have not been disturbed and may still be undergoing additional
wetting by the tacky material to improve adhesion and centering.
This second hold time extends until the populated array is advanced
past the air knife 324 during one of the web advances. A third
holding time may occur beginning just after the excess particles
have been aggressively removed by air knife 324 and before the
array leaves the apparatus environment after rollers 390 and 392.
The first, second, and third hold times are controlled times when
the populated web may be treated with independently controlled
heating means, or may not be heated, for predetermined times to
improve adhesion and centering of the particles, if they have not
yet reached the limits of centering, before the populated web is
handled for further use.
[0132] Variations in the device 300a are possible and still
practice the population process of the invention. For instance,
different heating means may be employed to heat the tacky areas
between support rollers 364 and 366. Hot air convection heating may
be employed with the air directed at the surface 354 and/or
back-side 400. Radiant heating may also be alternatively employed
or employed in combination with other heating means and directed at
the surface 354 and/or back-side 400 of web 352. When these
alternate variations are employed, electrode 368 may not be heated
and it may be spaced from the web.
[0133] The process just described referring to FIG. 10 where the
substrate is placed over the first electrode and covered with
particles can also be practiced with a discrete substrate instead
of a continuous substrate. Referring to FIG. 9, the substrate 302
can be removed from electrode 304 and placed on surface 328 of
first electrode 326 with the tacky and non-tacky areas facing
electrode 304. The particles would be distributed over substrate
302 and the DC pole connected to electrode 304. The populating
would take place as described for the similar setup referring to
FIG. 10. Depopulation would take place as already described for
FIG. 9 by removing the substrate from electrode 326 and going
through the depopulating steps.
[0134] The population methods of this invention will afford
populated surfaces having an array of tacky and non-tacky areas in
which almost all of the tacky areas of the surface are populated
with one particle per tacky area upon completion of execution of
the method. Typically, there will be at least 99.99% of tacky areas
of the surface populated with one particle per tacky area.
[0135] The population methods of this invention will afford
populated surfaces having an array of tacky and non-tacky areas in
which very few particles remain attached to non-tacky areas upon
completion of execution of a given method. Typically, there will be
fewer particles than one per 10,000 that remain in the non-tacky
areas.
EXAMPLES
Example C-1
[0136] The photosensitive layer of the unimaged tacky dot film used
in the examples that follow had the following composition:
TABLE-US-00002 Ingredient Amount (g) % by Weight Poly(methyl
methacrylate), 6.97 12.18 MW* = .about.250,000 Poly(methyl
methacrylate), 9.39 16.41 MW* = .about.20-40,000 Pentaerythritol
triacrylate 14.54 25.41 Tetraethylene glycol dimethacrylate 9.02
15.77 Monoacrylate of resin from bisphenol A 12.53 21.90 and
epichlorohydrin, MW* = .about.3,500
2,2'-Bis(o-chlorophenyl)-4,4',5,5'- 4.18 7.31
tetraphenyl-1,2'-biimidazole 4,4'-Bis(diethylamino)benzophenone
0.251 0.44 Leuco Crystal Violet (Aldrich Chemical 0.275 0.48 Co.,
Milwaukee, WI) 1,4,4-Trimethyl-2,3-diazobicyclo- 0.0286 0.05
(3.2.3)-non-2-ene-dioxide 4-Methoxyphenol 0.0286 0.05 TOTAL 57.2132
*MW = weight average molecular weight
[0137] The photosensitive layer was coated onto Kapton.RTM. E (50
microns thickness, DuPont, Wilmington, Del.) and dried to give a
dry coating thickness of the photosensitive layer of 3 to 25
microns.
[0138] The unimaged tacky dot film was imaged in the examples using
contact exposure through a phototool by ultraviolet light at 365 nm
and exposure level of 5 to 20 millijoules/cm2.
Example 1
[0139] This example illustrates a basic process and apparatus used
for electrostatic populating. Two electrodes were used, each
comprising a five inch square aluminum plate 1/8'' thick. One plate
was used as a bottom electrode and was left completely uncovered
and was connected to a ground on a high voltage power supply. The
other plate was used as a top electrode and was covered completely
on one side and the edges and partially covered on the other side
with Kapton.RTM. tape, which is a non-conductive covering. The
partially covered side had a central opening about 4 inches square
where the electrode was uncovered. The top electrode was arranged
to be connected to either the positive or negative lead of a high
voltage power supply which was as follows: [0140] Hipotronics Model
8100B (Brewster, N.Y.) [0141] 0-100 kilovolts [0142] 0-5
milliamperes [0143] DC, reversible, continuous duty, 2% rms ripple
[0144] 115 VAC, 50/60 cycle input
[0145] The particles to be populated on the substrate are 5 mil
diameter solder spheres composed of 63% tin and 37% lead. They were
obtained from Indium Corp. of Utica, N.Y.
Process:
[0146] A non-conductive substrate having a photopolymer adhesive
having an array of tacky and non-tacky areas covering an area of
about 4 inches by 4 inches was taped over the 4 inch by 4 inch
exposed area of the top electrode plate so that none of the top
electrode was exposed. The tacky areas were facing outward. The
process was carried out at ambient conditions without any special
air filtration or humidity or temperature controls.
[0147] A quantity of 5 mil diameter solder spheres (in excess of
the number required to populate all tacky areas with at least one
sphere) was approximately uniformly distributed over the surface of
the bottom electrode plate in a one to two sphere thick layer. The
top electrode plate was placed at a gap of 0.050 inches from the
surface of the bottom electrode, which affects the voltage level to
establish the field. The gap between the surface of the substrate
attached to the top electrode and the bottom electrode must still
be large enough at this electrode gap that some lateral velocity is
imparted to the spheres to create a useful lateral scattering of
spheres to aid in populating efficiency. The bottom plate was
grounded and the top plate was contacted with the negative lead at
a potential of 4 kilovolts DC which was held to the top plate for a
period of time. The solder spheres were observed to leave the
bottom electrode and be propelled toward the top electrode and
impact the substrate having an array of tacky and non-tacky areas.
Some of the spheres were propelled immediately and some were
propelled later such that movement of the spheres between the
bottom electrode and substrate on the top electrode made a sound
that resembled falling rain. After about 2-5 seconds, the motion of
the spheres was greatly reduced and the sound stopped.
[0148] The negative lead was removed from the top electrode and the
positive lead at a potential of 4 kilovolts DC was brought into
contact with the top electrode. The spheres were repelled away from
the top electrode and after contacting the bottom electrode, they
were propelled once again to the top electrode. The "raining"
movement of the spheres was repeated as the positive lead was
maintained in contact for 2-5 seconds. The positive lead was
removed at this point from the top electrode. The above completes
and defines one cycle of polarity reversals from zero to positive
to negative and back to zero. This cycle of polarity reversals
resulted in the spheres being propelled twice from the bottom
toward the top electrode. At the end of the above cycle, the
spheres were observed to reside on the substrate attached to the
top electrode. The top electrode was now grounded to remove any
residual voltage. This grounding had little effect on the spheres
which are believed to have a static charge that resists the effects
of gravity on the spheres.
[0149] After removal of the substrate it was noted that spheres
were attached to both tacky and non-tacky areas. The substrate was
mechanically tapped on the side opposite the spheres and most of
the balls attached to non-tacky areas were dislodged. The tapping
was accomplished by the operator flicking his finger against the
substrate held along one edge and hanging downward. About 4-6
finger flicks were applied about 1 second apart to dislodge the
balls from the non-tacky areas. The population efficiency was
analyzed by dividing the number of correctly populated tacky area
sites by the total number of sites. No attempt was made to account
for failure to populate due to dust or other contamination of tacky
dot sites, nor was any adjustment included for extra spheres in
background non-tacky areas. The population efficiency was 92%,
which was considered good for the uncontrolled conditions used.
Examples 2-4
[0150] To explore the effect of number of propulsion cycles upon
the population efficiency, the following three tests were run
(Examples 2-4).
Example 2
[0151] In Example 2, the lower limit of cycles possible was tested
which is one-half a cycle. The setup of Example 1 was used. The
negative lead was contacted to the top electrode for 2-5 seconds
until the "raining" of spheres from the bottom toward the top
electrode stopped. The negative lead was removed from the top
electrode and the electrode was grounded. The substrate was removed
and tapped, and the population efficiency was then measured as in
Example 1. The population efficiency was found to be 69%, which was
significantly less than that in Example 1. It is believed that only
one propulsion of spheres toward the substrate does not afford
enough opportunities for at least one sphere to contact each tacky
dot in the array.
Example 3
[0152] The setup of Example 1 was used. The negative lead was
contacted to the top electrode for 2-5 seconds until the "raining"
of spheres from the bottom toward the top electrode had stopped.
The negative lead was then removed and the positive lead connected
for 2-5 seconds as in Example 1. This sequence was repeated five
times so that 5 cycles of polarity reversals occurred that
propelled the spheres from the bottom electrode toward the top
electrode a total of 10 times (2 times/cycle and 5 cycles). At the
end of the fifth cycle, the lead was removed from the top electrode
and it was grounded as in Example 1. The substrate was removed and
tapped and the population efficiency was measured as in Example 1.
The population efficiency was 93%, which was slightly better than
that in Example 1.
Example 4
[0153] The setup of Example 1 was used. The negative lead was
contacted to the top electrode for 2-5 seconds until the "raining"
of spheres from the bottom toward the top electrode had stopped.
The negative lead was then removed and the positive lead connected
for 2-5 seconds as in Example 1. This sequence was repeated ten
times so that 10 cycles of polarity reversals occurred that
propelled the spheres from the bottom electrode toward the top
electrode a total of 20 times (2 times/cycle and 10 cycles). At the
end of the tenth cycle, the lead was removed from the top electrode
and it was grounded as in Example 1. The substrate was removed and
tapped and the population efficiency was measured as in Example 1.
The population efficiency was 95%, which was believed to be
significantly better than that in Example 1.
Example 5
[0154] Tests were run to determine the applicability of using an
electrostatic particle propulsion process for propelling
electrically non-conductive particles, (unlike the spheres used in
Examples 1-4, which were all electrically conductive). As this test
was not identical to that in Examples 1-4, the spheres were
included as a point of comparison. In this series of tests, the
substrate was omitted as was the non-conductive covering on the
surface of the top electrode facing the bottom electrode. The top
electrode was 12 inches square and the bottom was 6 inches square.
The electrodes were spaced apart at two distances depending on the
particles and voltage used. Particles were initially placed on the
bottom electrode which was grounded, and the top electrode was
connected to either the negative or the positive lead of the power
supply. Testing indicated the polarity of the lead did not affect
the results. Upon connecting the selected lead to the top
electrode, the particles were propelled to the top electrode. As
soon as the particles contacted the exposed top electrode, they
were repelled back to the bottom electrode from which they were
propelled back again to the top electrode. This oscillation or
bouncing of the particles between the top and bottom electrode
continued until the particles bounced out from between the
electrodes, became attached to one electrode, or until the lead was
removed from the top electrode. The following table summarizes the
results that were obtained. TABLE-US-00003 Size Density Gap Voltage
(KV) to Levitate Particle Micron g/cc mm and Initiate Bouncing
solder spheres 127 .about.9 28.1 13.5 solder spheres 127 .about.9
15.8 7.0 polystyrene spheres 113 1.06 15.8 4.0 glass spheres 125
2.48 15.8 4.0
The solder spheres and glass spheres oscillated about 2-20 seconds
until most had bounced out from between the electrodes aided by air
currents. The polystyrene spheres were observed to eventually stop
bouncing between electrodes after about 10-40 seconds and to cling
to the two electrodes. Somewhere between about 1/3 to 2/3 of the
particles were distributed on each electrode. It is believed this
occurred with the polystyrene due to high charging and the
inability to quickly discharge the polystyrene. The example
demonstrates the ability of electric fields to levitate both
conductive and non-conductive particles.
Example 6
[0155] This example illustrates the effect of a conducting ground
plane on the mobility and electrostatic charging of eutectic solder
spheres rolling across a photocured polymeric coating with and
without an electrically conducting aluminum ground plane between
the coating and a polyester film support.
[0156] The coating was applied by lamination as a 4 micron thick
layer of tacky photopolymer having the composition below:
TABLE-US-00004 Ingredient Amount (g) % by Weight Poly(methyl
methacrylate), 6.97 12.18 MW* = .about.250,000 Poly(methyl
methacrylate), 9.39 16.41 MW* = .about.20-40,000 Pentaerythritol
triacrylate 14.54 25.41 Tetraethylene glycol dimethacrylate 9.02
15.77 Monoacrylate of resin from bisphenol A 12.53 21.90 and
epichlorohydrin, MW* = .about.3,500
2,2'-Bis(o-chlorophenyl)-4,4',5,5'- 4.18 7.31
tetraphenyl-biimidazole 4,4'-Bis(diethylamino)benzophenone 0.251
0.44 Leuco Crystal Violet (Aldrich Chemical 0.275 0.48 Co.,
Milwaukee, WI) 1,4,4-Trimethyl-2,3-diazobicyclo- 0.0286 0.05
(3.2.3)-non-2-ene-dioxide 4-Methoxyphenol 0.0286 0.05 TOTAL 57.2132
*MW = weight average molecular weight
The photosensitive composition is suitable to give a dry coating
thickness on a substrate of 3 to 25 microns.
[0157] The coating was applied as a 4 micron thick layer of tacky
photopolymer onto 2 mil thick aluminized Mylar.RTM. for a first
sample, and was applied by coating as a 4 micron thick layer of
tacky photopolymer onto plain Mylar.RTM. film for a second sample.
The coating was covered by a 0.5 mil polyester film coversheet. The
unimaged tacky dot film was imaged using contact exposure through a
phototool. The coating was photocured by ultraviolet irradiation of
sufficient intensity and duration to make the coating non-tacky,
for instance ultraviolet light at 365 nn and exposure level of 5 to
20 millijoules/cm2.
[0158] The coated samples were cut to fit the bottom and sides of a
six inch long inclined plane sample holder. The samples were folded
at each side to cover the side of the sample holder. The coversheet
was removed from the photocured polymer coating and the surface
discharged by ionized air. The sample then was placed in the
inclined holder.
[0159] Solder spheres 5 mils in diameter consisting of 37% lead,
63% tin from Indium Corporation of America, Utica, N.Y. were
conveyed by a vibratory feeder (Syntron Magnetic Feeder, Model
F-TO, FMC Corporation, Material Handling Division, Homer City,
Pa.), dropped onto the top of the inclined plane sample holder
heated at 50.degree. C., and rolled into a Faraday cup (Model
253/22B, FMC Corporation, Material Handling Division, Homer City,
Pa.) to measure electrostatic charge on the spheres. Drop height d
between the lip of the feeder and the top of the sample holder was
varied from 2.5 to 14 centimeters. Sample holder incline angle
(theta) was varied from 15 to 45 degrees. Critical observations
were:
[0160] 1) whether all the solder spheres rolled across the inclined
plane into the Faraday cup and
[0161] 2) the electrostatic charge generated on the spheres by
rolling across the sample.
All experiments were at 50% relative humidity.
[0162] FIG. 11 illustrates the equipment used in this Example 6. A
vibratory feeder 440 with electrically conductive tray 445 is
mounted on a lab jack 450 such that the drop height d can be
varied. An electrically conductive sample holder 430 was
constructed such that the sample holder incline angle theta
(.THETA.) could be varied. The sample 410 containing an an-ay of
tacky and non-tacky areas was placed on the sample holder 430 as
shown in section view of the sample holder and sample. The
vibratory feeder 440 and sample holder 430 were both grounded with
grounding clips 435. Solder spheres exited the end 420 of the
vibratory feeder 440, dropped a distance d to contact the sample
410, and then rolled down and off the sample 410 along a solder
sphere path 470 to the Faraday Cup 400, where measurement of the
electrostatic charge on the spheres was made. The complete
apparatus was contained in two carbon fiber conductive trays
460.
[0163] It is clear from the experiments that samples without the
conducting ground plane allowed some spheres to stick
electrostatically and gave higher electrostatic charge to the
spheres. None of the spheres stuck electrostatically while rolling
down samples with the aluminum ground plane. TABLE-US-00005 Sphere
charge Aluminum Drop Angle (nonocoulombs Spheres elect-stat Ground
(cm) (deg) per gram) stuck none 14 30 n2.6-4.2 none none 14 45
n3.1-4.4 none yes 14 30 n2.6-3.0 none yes 14 45 n2.0-2.6 none none
10 30 -- many stuck none 10 45 n7.7-8.8 none none 10 45 n3.8-6.3*
some yes 10 30 n3.3-4.0 none yes 10 45 n3.7-4.1 none none 2.5 15 --
most stuck none 2.5 30 p1.8-n3.3* some none 2.5 45 n0.1-3.5* some
yes 2.5 15 n0.1-0.3 none yes 2.5 30 n0.4-0.6 none yes 2.5 45
n1.6-2.1 none *Sphere charge per gram inaccurate when some
electrostatically stick. Actual charge per gram is larger. n =
negative charge; p = positive charge -- Indicates that in this case
most spheres stuck to the film, and did not fall into the Faraday
Cup. Consequently the reading was very low and very inaccurate. The
information gained was that the static was so great that it caused
the spheres to stick to the film, under the conditions as listed.
NOTE: In some tests not recorded above in Example 6, a grounding
clip was attached to the conductive aluminum coating on the sample,
but it was not observed to change the performance
significantly.
* * * * *