Method and arrangement for attaching a chip to a printed conductive surface

Abstract

A chip attached to and electrically connected with a printed conductive surface, whereby the chip is heated to a temperature, which is lower than what the chip can stand without being damaged by the heat, the heated chip is then pressed against the printed conductive surface with a pressing force, whereby a combination of said temperature and said pressing force is sufficient to at least partly melt the material of at least one of the printed conductive surface, the contact point on the chip, or both, thereby attaching and electrically connecting the chip to the printed conductive surface.

The invention claimed is: 
     
       1. A method for attaching a chip to a printed conductive surface, the method comprising:
 forming the printed conductive surface on a substrate by means of printed electronics to establish, wherein the printed conductive surface establishes at least one conductive pattern on the substrate; 
 heating the chip to a first temperature, which is lower than what the chip and the substrate can stand without being damaged by the heat; wherein said heating is executed utilizing a heater element below the substrate, and 
 pressing the heated chip at the first temperature against the at least one conductive pattern established by the printed conductive surface with a first pressing force, wherein a heated roll is configured to transfer heat to the chip during pressing of the chip at the first temperature, and wherein the heated roll presses the chip against the printed conductive surface in a nip between the heated roll and a support roll, wherein a carrier band provides the chip to the nip for disposition on the substrate and wherein the carrier band brings the chip into thermal contact with the heated roll prior to pressing the chip; against the at least one conductive pattern established by the printed conductive surface with a first pressing force;  
 wherein a combination of said first temperature and said first pressing force is sufficient to at least partly locally melt a material of the at least one conductive pattern established by the printed conductive surface to attach and connect the chip to the printed conductive surface directly. 
 
     
     
       2. The method according to  claim 1 , wherein the chip comprises a metal base, and said first pressing force causes a pressure between the chip and the printed conductive surface that is between 0.1 and 10 megapascals. 
     
     
       3. The method according to  claim 2 , wherein said first temperature is between 75 and 400 degrees centigrade. 
     
     
       4. The method according to  claim 3 , wherein said first temperature is between 75 and 200 degrees centigrade. 
     
     
       5. The method according to  claim 1 , wherein the chip comprises a silicon base, and said first pressing force causes a pressure between the chip and the pattern established by the printed conductive surface that is between 0.02 and 0.5 megapascals. 
     
     
       6. The method according to  claim 5 , further comprising applying flux to selected parts of at least one of the pattern established by the printed conductive surface. 
     
     
       7. The method according to  claim 6 , wherein the flux is applied to contact points on the chip, and allowed to solidify before pressing the heated chip against the at least one conductive pattern established by the printed conductive surface. 
     
     
       8. The method according to  claim 5 , further comprising actively controlling an ambient temperature at the location of pressing the heated chip against the at least one conductive pattern established by the printed conductive surface. 
     
     
       9. The method according to  claim 1 , wherein the printed conductive surface and/or substrate comprising one or more printed conductive surfaces is preheated to temperatures between 25-200 degrees centigrade before attaching the chip to the printed conductive surface. 
     
     
       10. The method according to  claim 1 , further comprising applying flux to selected parts of at least one of the pattern established by the printed conductive surface. 
     
     
       11. The method according to  claim 1 , further comprising actively controlling an ambient temperature at the location of pressing the heated chip against the at least one conductive pattern established by the printed conductive surface. 
     
     
       12. An apparatus for attaching a chip to a printed conductive surface, the apparatus comprising:
 a printed conductive surface formed on a substrate by means of printed electronics, wherein the printed conductive surface establishes at least one conductive pattern on the substrate; 
 a heater configured to heat a chip to a first temperature, which is lower than what the chip and the substrate can stand without being damaged by the heat; wherein the heater is configured below a substrate having the printed conductive surface formed thereon by means of printed electronics, the printed conductive surface establishing at least one conductive pattern on the substrate, and 
 an actuator comprising a heated roll configured to transfer heat to the chip and to press the chip against the printed conductive surface in a nip between the heated roll and a support roll while the chip is at the first temperature with a first pressing force, and a carrier band configured to provide the chip to the nip for disposition on the substrate, wherein the carrier band is configured to bring the chip into thermal contact with the heated roll prior to pressing the chip against the at least one conductive pattern of the printed conductive surface;an actuator configured to press the heated chip against the at least one conductive pattern established by the printed conductive surface with a first pressing force; 
 wherein the apparatus is configured to apply said first temperature and said first pressing force in a combination sufficient to at least partly locally melt a the material of the at least one conductive pattern established by at least the printed conductive surface to attach and connect the chip to the printed conductive surface directly. 
 
     
     
       13. The apparatus according to  claim 12 , wherein the actuator further comprises a manipulator arm configured to pick the chip and to place the chip at a predetermined location on the printed conductive surface corresponding to the location of the at least one conductive pattern. 
     
     
       14. The apparatus according to  claim 13 , wherein at least a part of the heater is configured to heat the chip that is waiting to be picked by the manipulator arm. 
     
     
       15. The apparatus according to  claim 13 , wherein at least a part of the heater is integrated in the manipulator arm for transferring heat to the chip between picking the chip and placing the chip at said predetermined location on the printed conductive surface corresponding to the location of the at least one conductive pattern. 
     
     
       16. The apparatus according to  claim 15 , wherein at least the part of the heater is configured to heat the chip that is waiting to be picked by the manipulator arm. 
     
     
       17. An apparatus for attaching a chip to a printed conductive surface, the apparatus comprising:
 a printing section configured to print patterns of an adhesive on a surface of a substrate; 
 a dielectric transfer roll; 
 an electric charging apparatus configured to maintain a surface of the dielectric transfer roll at an electrically charged state; 
 a particle applicator configured to temporarily cover the electrically charged surface of the dielectric transfer roll with a continuous layer of conductive particles; 
 a section where the surface of the substrate with the patterns of the adhesive is arranged to come into contact with the continuous layer of conductive particles on the electrically charged surface of the dielectric transfer roll,; and  
 a heater configured to heat the chip to a first temperature, the first temperature being lower than what the chip and the substrate can stand without being damaged by the heat; 
 an actuator configured to press the chip against the at least one conductive pattern established by the printed conductive surface while the chip is at the first temperature with a first pressing force, wherein the apparatus is configured to apply said first temperature and said first pressing force in a combination sufficient to at least partly locally melt a material of the at least one conductive pattern established by the printed conductive surface to attach and connect the chip to the printed conductive surface directly; and 
 wherein the apparatus is configured to form the printed conductive surface on the substrate by means of printed electronics, the printed conductive surface establishing at least one conductive pattern on the substrate.