Process for the Laser Soldering of Flexible Wiring

This invention relates to a process for laser soldering of flexible wiring, in particular, to soldering of wiring mounted on a brittle substrate.

In order to join two parts by means of soldering it has been possible to use, for a direct transmission of heat, the metallization of one part, or to transmit the heat for the soldering process indirectly over soldered strip conductors.

Spot-welding (soldering) of connections on hybrid circuits has only very recently come under consideration as a possible application for a laser. In a welding process, the materials to be welded are brought to the melting point which results in a direct joining of the two materials. A prerequisite for a permanent joint is the availability of sufficient material. When this condition is not satisfied, a soldering process must be used. For this purpose the materials must be covered with a solderable mass (soft or hard solder). In this case the laser acts as a source of heat, which operates very precisely only on the exact points to be joined. This process cannot be used to solder flexible wiring to glass substrates.

It is an object of the invention to describe a process which makes it possible to solder flexible wiring which is not amenable to heat transfer by means of a soldering iron or similar tool. The objective is realized as follows: In order to solder flexible wiring that is arranged on a translucent carrying film and has been provided at the contact points with a flux, the parts to be joined are held together by a clamp made of transparent material in such a manner that they are fixed in the desired position with regard to one another, and the wires that are opposite one another are in contact with the surfaces to which the solder has been applied, and the non-contact heat transmission for the soldering process is provided by a laser beam. Since the heat transmission is accomplished without contact, there is no danger of breakage when glass substrates are used, since no forces are exerted on the substrate. The carrying film is not damaged and the heat distribution is maintained.

According to a further preferred embodiment of the invention, the laser used is preferably a continuous wave solid-state Nd:YAG laser. This laser's wavelength of 1.064 um is particularly well-suited for a soldering process of this type.

In order to apply the heat over a substantial area and to prevent damage to the carrying film, it is preferable to use a defocused laser beam. The defocused non-contact heat source ensures that no injury occurs to the joint between the conductors and the film, and also that no impairment of the metallization due to deterioration of alloys results. In addition, overheating is avoided by this process.

Other features and advantages of the invention will be apparent from the following description of the preferred embodiments, and from the claims.

For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention and to the accompanying drawings.

FIG. 1 shows the glass carrier in a side view.

FIG. 2 shows the application of the invention to a section of a glass carrier of this type.

Preferred embodiments of the invention will now be described with reference to the drawings.

Reference numeral 1 is used to designate a glass carrier. Reference numeral 2 shows the wiring to be connected. Components on the wiring films are designated by 3.

As shown in FIG. 2, the glass carrier 1 lies on a holder 4. The joint between the glass carrier 1 and the glass substrate 6 consists of glass solder 5. Reference number 7 indicates the external connections of the strip conductors to be joined between the connecting wiring and the glass substrate. The parts to be joined are held together by a clamp 8 made of transparent material, for example, glass. The laser beam is identified by reference numeral 9.

As may be seen in FIG. 2, according to this embodiment the strip conductors are covered in one direction of the flexible wiring by a polyamid film and in the other direction by the glass substrate 6. The external terminals that are to be joined are held together by the clamp 8. A heat track is traced with a continuous wave laser and the solder is thus preheated and melted. The next step is the stress-free hardening of the solder to form a solid solder joint. Using this process, a large number of adjacent connections can be made in one operation.

The process described in the invention is particularly well-suited for the soldering of flexible wiring to the wiring of printed circuit boards made of glass, ceramics or plastics.

There has thus been shown and described a novel method for flexible wiring soldering which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings which disclose preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.