Mechanical pulse reflow bonding process

A process for effecting a mechanical pulse reflow bond between one or more pairs of electrically conductive elements of a microcomponent device using a reciprocable thermode for applying both heat and force at the bonding site,

• said thermode comprising a clamp having a tip thereon for applying a mechanical bonding force directly to the conductive elements to be bonded at the bonding site, and a coaxial heated anvil outboard of said clamp and reciprocable relative thereto for selectively supplying heat for effecting the bond, said anvil being at a steady state temperature above that of the clamp,
• effecting said bond by moving the clamp tip into engagement with the conductive elements at the bond site for directly clamping said elements to each other at the bond site, moving said heated anvil into mechanical contact with an element to be bonded at a position remote from the bond site and thereby causing heat to flow from said anvil to said bond site, holding said anvil in contact with the conductive element for sufficient time so that heat flows along a conductive path through the element to the bond site, and then withdrawing the tip from contact with the bond site, maintaining said anvil in contact with said element for a sufficient time so that a predetermined temperature (T) versus time (t) heat pulse profile is generated to cause a reflow bond to be effected at the site, and maintaining the clamping force at the site by continued engagement of the clamp until the reflow bond has solidified, and then withdrawing the clamp tip, thereby effecting a mechanical pulse reflow bond at the bond site.