5 details of ladder sandwich, end view pixel chips capacitors
carbon composite ladder backing soft acrylic adhesive flex kapton
cable soft acrylic adhesive wire bonds adhesive extends past bonded
element to avoid bulge due to adhesive pucker Carbon composite
recessed to give room for vacuum chuck backing of kapton and
silicon while wire bonding backer to sector beam adhesive
Slide 6
6 ladder assembly fixture 3/8 OD tube connection to vacuum ID
tube connection to 1 gallon vacuum ballast tank vacuum release
valve for hold down of the vacuum chucks vacuum distribution
manifold
Slide 7
7 fixture parts (SLA and aluminum) for bonding silicon chips v
chuck chip u.SLDPRT chip adhesive stop u.SLDPRT chip stop u.SLDPRT
end drop chip.SLDPRT
Slide 8
8 fixture parts for bonding composite backer v chuck backer
u.SLDPRT backer adhesive stop u.SLDPRT backer stop u.SLDPRT end
drop backer.SLDPRT
Slide 9
9 install chip vacuum chuck install chip vacuum chuck against
stops (arrow toward arrow) open valve to vacuum lock down
line.
Slide 10
10 attach chip adhesive to kapton cable install chip adhesive
stop u.SLDPRT and lock down if necessary with vacuum position paper
backed adhesive and pull down with 10 vacuum lines strip top
backing paper position ladder and lock down with vacuum position
end drop chip.SLDPRT and lock with vacuum work kapton down on
adhesive release adhesive hold down vacuum release ladder and end
pull down vacuum remove ladder and maybe seat adhesive with vacuum
bag
Slide 11
11 install backer vacuum chuck release and remove chip vacuum
chuck note: since this is an O ring seal it may be necessary to use
vacuum release valve (see page 6) install backer vacuum chuck
against stops (arrow toward arrow) open valve to vacuum lock
down
Slide 12
12 backer adhesive to kapton cable install backer adhesive stop
u.SLDPRT and lock down if necessary with vacuum position paper
backed adhesive and pull down with vacuum (chp 1) strip top backing
paper position ladder and lock down with vacuum position end pull
down and lock with vacuum work kapton down on adhesive release
adhesive hold down vacuum release ladder and end pull down vacuum
remove ladder and maybe seat adhesive with vacuum bag
Slide 13
13 attach backer to kapton cable position and lock down backer
stop u.SLDPRT lock down backer on vacuum chuck, may require backing
tape on composite if porous strip adhesive backing paper position
ladder on reference pins and pull down with vacuum position end
pull down and lock with vacuum work kapton down on backer, must
push down on chips release backer hold down vacuum release ladder
and end pull down vacuum remove ladder and seat chips and backer
with vacuum bag
Slide 14
14 attach chips to kapton cable switch to v chuck chip u.SLDPRT
position and lock down chip stop butt chips one at time against
chip stop u.SLDPRT and neighbor chip and lock down with vacuum.
strip adhesive backing paper position ladder on reference pins and
pull down with vacuum position chip end pull down and lock with
vacuum work kapton down on chips release chip hold down vacuum
release ladder and end pull down vacuum remove ladder and seat
chips and backer with vacuum bag
Slide 15
comments Both SLA vacuum chucks have been modified to fit
ultimate ladders Reference holes on the flex PC carrier extensions
have been moved to be compatible with the ladder to sector bonding
tools. That change is accommodated here with adjustments in the SLA
vacuum chucks. New stops are of aluminum, replacing SLA pieces. If
the SLA vacuum chuck is flat enough then stops for the backer could
also be used for the chip and chip adhesive bonding steps. The chip
vacuum chuck has holes reduced from 1.5 mm to.75 mm These
instructions do not include Marios notes. It would be desirable to
include his notes, but they are probably not currently in
electronic form 15
