CA1322898C - Solder delivery systems - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

Mechanical means and methods for delivery of solder preforms arranged in generally rectilinear patterns and oriented so that the ends of the solder preforms may join two planar surfaces upon the application of heat are disclosed. Several embodiments facilitate the delivery of solder preforms in the forms of posts, clips3 and rings.

Description

The present invention relates to the fabrication of electronic circuit packages and in particular to methods, and mechanical means for attaching electronic components, especially leadless ceramia packages for electronic devices, to each other or to supporting substrates such as circuit boards.

The microelectronics lndustry is steadily moving toward the use of smaller electronic circuit devices giving rise to the need for smaller and smaller connecting devices and mounting means for the circuit devices. Circuit devices, such as integrated circuits of complex nature, are embodied in large chips and chip carrier packages (CCP) which have connection pads on the faces and/or edges of the packages.
Chip carrier packages can be produced with leads attached (leaded) or they can be leadless.

Leaded CCP's can be soldered directly onto printed circuit boards or printed wire boards. Leadless CCP's can be soldered onto ceramic boards or installed into connectors.
However, with glass/epoxy printed circuit boards or othar printed wiring boards (hereinafter substrates) leadless CCP's are usually mounted into connectors which are, in turn, mounted on the substrates because of the effect of different thermal expansion coefficients of the materials involved when subjected to temperature fluctuations. Specificallyl the CCP
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different thermal characteristics leading to in-plane stress and strain therebetween as a result of thermal mismatch. Also, any flexure of the substrate result in out-of-plane stresses. Prior art techniques have used small solder sphere~ or solder paste to attach packages to sub~trates. Although such known techni~ues have been used ~or such surface mounting, there exists a need for a compliant solder joint to compensate for the large stresses resulting from thermal mismatches between the CCP and the substrate, as well as from board warpage and flexure.
Different solutions have been proposed for the foregoing problems. The proper positioning of a prede-termined quantity of solder may be achieved with the use of solder preforms spaced on a carrier template in the locations corresponding to the points where the solder joints are to be formed, Examples of this tech-nique may be found in U.S. Patents 3,320,658, issued to Bolda et al; 3,396,894, issued to Ellis; 3,472,365 issued to Tiedema; 3,719,981 issued to Steitz;
3,744,129, issued to Dewey; 4,209,893, issued to Dyce et al; and 4,216,350, issued to Reid.
Although the foregoing techniques provide for the correct placement of a predetermined quantity of solder or other suitable joint-forming material, and with the proper dimensioning of the carrier or template, sufficiently small quantities of solder can be posi-tioned on close spacing between centers, these propo-sals do not address the problems of high shear strains in the solder joints.
In U.S. Patent No. 4,412,642 to Fisher, leadless chip carriers are converted to '~cast-leaded chip carriers" by molding high melting point leads to the chip carrier. Additional examples of methods and . .
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1~2~ '3 devlces for soldering terminals to a printed circuit board are shown in U.S. Patent No. 3,926,360 to Moister and in the IBM Techical Disclosure Bulletin, Vol. 21, No. 6, dated November 1978.

While the above disclosures have addressed the problem of connections which must be able to withstand the stresses from thermal cycles, none discloses a satisfactory solution which both solves the problem and is suitable for reliable manufacturing processes.
Because of the significant problems associated with the attempt to position preferred material such as a solder and --to effect electrical contact, alternative less desirable conductive materials and/or mechanical approaches have been developed. U.S. Patent 4,064,623 to Moore shows an electrical connector utilizing conductive rubber rods. U.~.
Patent No. 4,295,700 to Sado discloses a similar press-contact type interconnector utilizing elastic material having anisotropical electroconductivity. U.S. Patent No. 3,991,463 to Squitieri et al, diæcloses a method of forming an interconnector having a row of electrically conductive flexible plastic strips. U.S. Patent No. 4,027,936 to Nemoto et al discloses a connector having electroconductive rubber terminals. U.S. Patent No. 4,144,648 to Grovender, discloses a connector utilizing conductive elastomer medium. U.S.
Patent No. 4,402,450 to Abraham et al, discloses contact pads of a device which are adapted for bonding components such as contacts of a circuit assembly thereto.

Unfortunately, none of the above disclosures provide the superior electrical interconnection accomplished by solder.
It wsuld therefore be highly desirable to have a solder preform delivery system ~.

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with a precise placement of a predetermined quantity of material in a preferred geometric preform for the formation o~ a solder-type connection.

Commonly assigned published U.K. patent application GB

2,142,~68 A to ~llen et al, discloses a chip carrier mounting device which includes a retaining member having a defined pattern of apertures in which are positioned preforms of joint-forming material such as solder or conductive elastomer. The instant invention is an improvement to that mounting device wherein the problem of solder preform positioning and solder preform configuration are addressed.

In one aspect, the invention provides a solder post delivery system comprising: a positioning means for positioning solder posts, said positioning means being elongated along a longitudinal axis, said positioning means having a plurality of longitudinally spaced openings therethrough, each of said openings having a top and a bottom generally parallel to said longitudinal axis wherein said 2Q positioning means is folded along a line generally parallel to the tops and bottoms of said openings providing unobstructed access to said solder posts; an elongated and flexible backing means having at least one adhesive surface, said backing means connected to said positioning means by said surface and to solder posts to be positioned through said openings; and a plurality of solder posts positioned by ~-said openings and held therein by said backing means, said positioning means capable of being bent with respect to said longitudinal axis to align the ends of said solder posts with respect to electrical components to be interconnected.

In preferred embodiments of this aspect, the invention provides~ ' ~ !

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The above delivery system wherein longitudinal ends of said positioning means are closed into a loop which is capable of bein~ curved outwardly to conform to a geometric 5 configuration and is capable of being retai.ned in said configurat.ion for intercon~ec~ion of said solder posts; an~
wherein said loop is capable of being bent from a generally circular cross-section to a generall~ rectangular cross~
section.

The above delivery system wherein said backing means includes an adhesive surface on both sides thereof, said positioning means capable of being placed against external support and being retained in position by said backing means.

The above delivery system wherein said positioning means is folded along a line passing generally midway between the tops and bottoms of said openings providing unobstructed access to said solder posts, said backing means extending beyond at least one longitudinal periphery of said positioning means to provide a surface for securing said positioning means.

The above delivery system w~erein said positioning means is folded along lines coincident with the tops and bottoms, respectively, of said openings to form a Ushaped cross-section having top and bottom flanges that extend transversely at right angles to said longitudinal axis; and wherein at least one. of said flan~es is provided with at least one notch, said adhesive surface o~ said backing means being exposed through said notch; and further including cover means in removable contact with said exp~sed adhesive surface to protect said surface before installation of said system;
and wherein said flanges are cut transversely to allow said positioning means to be bent.

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The above delivery system wherein said positioning means is folded along a line coincident with tops of said openings to form an L-shaped cross-section having a top flange that extends transversely at a right angle to said longitudinal axis, said backing means conforming to said top flange to provide an adhesive surface capable o~ securing said positioning means with respect to a substrate; and wherein said flange is cut transversely to allow said positioning means to be bent; and wherein said flange includes at least one window opening therethrough, said adhesive surface being exposed through said window opening; and further including cover means in removable contact with said exposed adhesive surface to protect said surface before installation of the system.

The above delivery system wherein at least two of said openings are empty and said positioning means is folded transversely with respect to said longitudinal axis between said two openings, said adhesive surface of said backing means extending through each of said two openings to contact itself to define a tab and a corner for said positioning means.

In a further aspect, the invention provides a solder post delivery system comprising: a positioning means for positioning solder posts, said positioning means including at least three layers of sheetlike material, each of said layers having a plurality of openings therethrough, the openings in each layer being in general axial alignment with the openings -in the other layers, said openings being capable of being ~ --slightly misaligned by movement of the layers with respect to each other; and a plurality of solder posts, one solder post being positioned in each generally aligned opening and being secured therein by a force fit created by said slight .,~.

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misalignment.

In a preferred embodiment of this aspect, the invention provides:

The above system wherein said positioning means is slit through said layers and said layers are bent slightly out of the plane of said layers to define abutmant means for contact and alignment of electrical components to be interconnected by the system.

In a still further aspect the invention provides a solder post delivery system comprising: a positioning means for positioning solder posts comprising a ~ontinuous frame having an inner and outer periphery, said frame capable of being discontinuous, said positioning means having securing portions which are capable of removably securing solder posts thereto when said frame is continuous and which are capable of releasing solder posts that may be secured thereto when said frame is discontinuous; and a plurality of solder posts in contact with said securing portions of said positioning means; and wherein said frame has a generally U-shaped cross-section having top and bottom flanges and a securing portion on the inner periphery of said frame comprising a plurality of spaced openings, each of said openings extending across the width of said inner periphery and into said top and bottom flange, each of said solder posts being positioned and held within one of said openings by contact with the edges of each of said openings.

The invention also provides:

A solder post deli~ery system comprising: a positioning means for positioning solder posts comprising a continuous ~'~
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~rame having an inner and outer periphery, said frame capable of being discontinuous, said positioning means having securing portions which are capable of removably securing solder posts thereto when said frame is continuous and which are capable o~ releasing solder posts that may be secured thereto wh~n said ~rame is discontinuous; and a plurality of solder posts in contact with said securing portions of said positioning means; and wherein the inner periphery of said frame is contoured to provide spaced securing portions thereof that are complementary to said solder posts to secure said solder posts thereto, said frame having corners, said frame being dis~ontinuous at one of said corners of said frame including separate removable fastening means to hold said corner together, said other corners being bendable in hinge-liXe fashion to open said frame with respect to said solder posts to release said solder posts from said securing portions.

A solder delivery system comprising: a positioning means for positioning solder posts, æaid positioning means having a plurality of openings therethrough; and a plurality of solder posts with one post per opening, said posts comprising solder paste which fills said openings to define individual solder posts: and wherein said positionin~ means and said solder paste are co-extruded in one direction to .
define a continuous composite, said composite being sliced ::-thxough at an angle perpendicular to the direction of co-extrusion to define an individual solder delivery system.

A solder posk delivery system comprising: a positioning means for positioning solder posts, said positioning means being generally planar and having a plurality of openings therethrough, said positioning means being made from a heat recoverable polymeric material, said positioning means having ''. ~

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-8a-a first dimens.ion including a first thickness wherein said openings have a first diameter, said positioning means having a second dimension including a smaller, second thickness wherein said openings have a smaller second diameter: and a plurality of solder posts with one post per opening, said posts secured by a force fit within said openings when said openings are at sai.d second diameter and being released when said openings are at said first diameter, said positioning means capable of going from said second dimension to said first dimension upon application of heat.

A solder clip delivery system comprising: a positioning means for positioning solder clips comprising a frame having top and bottom surfaces and an inner and an outer periphery, said inner peripherv of said frame having portions having a solderable metal deposited thereon and having solder plated on said metal, to define individual solder clips; and wherein said frame is capable of being detached from said clips when heat is applied to said clips, heat melting said solder to cause a permanent joint between the metal and the component to be connected and loosening the frame from said metal.

A solder clip delivery system comprising: a positioning means for positioning solder clips comprising a frame having top and bottom surfaces and an inner and an outer periphery, said inner periphery of said frame having portions having a .
solderable metal deposited thereon and having solder plated on said metal, to define individual solder clips; and wherein said portions are inwardly project.ing finger-like portions having metal deposited on the top surface thereof, said portions being bent out of the plane of said surface to form a generally C-shaped solder clip.

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-8b-In a preferred embodiment of the above delivery system said frame is defined by two parallel layers, each layer having portions projecting from only two opposed sides the~eof, said layers being oriented at right angles to each other so that portions project inwardly from all sides of the frame.

Moreover, the invention provides a solder ring delivery system comprising: a positioning means for positioning solder rings, said positioning means including a plurality of diametrically heat-recoverable rods, said rods being adjacent to each other in general spaced parallel relationship; and a - -plurality of solder rings positioned about said rods, said rods having surface portions about said rods upon which a solderable metal has been deposited and having solder plated on said metal, said metal and solder defining said solder rings, said rods being diametrically shrinkable upon application of heat and capable of being removed.

Figure 1 is a perspective view of an embodiment of the solder post delivery system.

Figure 2 is a perspective view of an alternate embodiment of a solder post delivery system having a chip carrier package positioned thereabove.

Figure 3 is a perspective view of a delivery system being expanded by a fixture into a generally rectangular shape.

Figure 4 is a perspective view of a delivery system being transformed from a generally circular cross-section to a generally rectangular cross-section.

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Figure 6 is a plan and paxtially schematic view of a process for manufacturing a delivery system.

Figure 7 is a partial perspective view of an alternate embodiment of a delivery system fabricated by the process illustrated in Figure 6.

Figure 8 is a partial perspective view of yet another alternate embodiment of delivery system.

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Figure 9 is a partial perspective view similar to Figure 8 illustrating an optional feature of a delivery system.
Figure 10 i5 a partial perspective view of yet another embodiment of delivery system wherein a chip carrier package is poæitioned above the system.
Figure 11 is a partial perspective view of yet another embodiment of delivery system.
Figure 12 is a partial perspective view of an alternate delivery system comprising a plurality of layers of sheet- -like material.
Figure 13 is a partial cross-sectional view taken along section lines 13-13 in Figure 12.
Figure 14 is an enlarged partial perspective view of the embodiment shown in Figures 12 and 13 illustrating an optional feature of abutment means.
Figure 15 is a partial perspective view of yet another embodiment of delivery means wherein a portion of the system upon being discontinuous is shown in phantom.
Figure 16 is a perspective view of another delivery -system having a positioning means which may be ripped away from the solder post after installation.
Figure 17 is a perspective view of yet another delivery means having an external, reusable hinged positioning means.
Figure 18 is a perspective view of still another delivery system having swaged ~older pxaforms in a pre-punched array.
Figure 19 is a perspective view of yet anther delivery system having solder preforms delivered by positioning means comprising remaining attached flash. Die apparatus for forming this embodiment of the delivery system are shown in~
phantom.

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Figure 20 is a perspective view of yet another delivery system having a filed column array of solder posts. The figure illustrates a process ~or filling openings to form the solder posts.
Fi~ure 21 is a partial perspective view of another embodiment of delivery system similar to that illustrated in Figure 20 created by the simultaneous extrusion of the solder post and holder material.
Figure 22 is a composite view of a reusable delivery system. 22A illustrates a chip carrier package positioned above th~ system. Figure 22B illustrates the bottom side of the system containing the chip carrier package with solder posts being positioned through the system in contact with the chip carrier package. Figure 22C illustrates the application of tempexature and presæure to the system. Figure 22D
illustrates the finished chip carrier package having solder posts installed thereon.
Figure 23 is a perspective view of an alternate embodiment of delivery system having a positioning means which is made from heat recoverable polymeric material. The positioning means having a first dimension is shown in Figure 23.
Figure 24 is a perspective view of the delivery system illustrated in Figure 23 wherein the positioning means i8 in its non-heat recovered smaller dimension wherein the solder posts are secured within openings in the positioning means.
Figure 25 is a perspective view of a solder clip delivery system.
Figure 26 is a partial cross-sectional view illustrating the formation of an individual solder -- 10 ~

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clip. The conflguration of the final clip is shown in phantom line.
Figure 27 is a partial cross-sectional view similar to Figure 26 illustrating the posi~ioning of a solder clip with respect to electronic substrates to be interconnected.
Figure 2~ is a partial cross-sectional view similar to Figure 27 wherein the solder clip has been --installed and the positioning means is being removed.
Figure 29 is an exploded partial perspective view of an alternate embodiment of a solder clip deli-very system similar to Figure 25 wherein the ~ystem comprises two layers, the lower layer solder clips shown to be already formed and the top layer positioned for placement on top of the lower layer wher~in the clips of the top layer have not yet been formed. The finished clips of the top layer are shown in phantom in the bottom part of the figure.
Figure 30 is a partial plan view of an alternate solder clip delivery system wherein traces of solderable metal having solder plated thereon are depo-sited in given arrays on the suraces of a positioning means.
Figure 31 is a partial cross-sectional view taken along section lines 31-31 in Figure 30.
Figure 32 is a partial perspective view of a solder ring delivery system having heat recoverable rods with plated on solder rings separated by insulative heat recoverable rods. This figure also illustrates an optional plating buss wire which may be peeled off and discarded.
Figure 33 is a partial cross-sectional view taken along section lines 33-33 in Figure 32.

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Figure 34 is a partial cross-sectional view similar to Figure 33 wherein the heat recoverable rods have been recovered to a smaller dimension while the solder rings have electrically interconnected the substrates.
Figure 35 is a multiple view of an alternate embodiment wherein A shows an exploded view of initial components, B
shows a finished product, C and D are enlarged partial cross-sectional views taken along section lines C-C and D-D, respectively.
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With continued reference to the drawing, Figure 1 illustrates one embodiment of a solder post delivery system having a positioning means 10 for positioning solder posts 12, the positioning means being elongated along a longitudinal axis and having a plurality of longitudinally spaced openings 14 therethrough, each of the openings having a top 16 and a bottom 18 generally parallel to the longitudinal axis. The positioning means is preferably a ribbon of Kapton* tape having windows punched through it.
The system further comprises an elongated and flexible backing means 20 having at least one adhesive surface 22, the backing means conne~ted to the positioning means by the adhesive surface to secure solder posts 12 through said openings 14. This bandolier construction may be placed in a fixture such as that illustrated in Figure 2, the chip carrier package set on top and the entire assembly heated to reflow solder.

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*KAPTON is a trademark of the EI Dupont du Nemours ~ Company 1 3?.2g~'~

It can be seen that the above delivery system makes the handling of the small solder posts easier, especially in a high speed production environment wherein a bandolier like system wound on reels lends itself to continuous process manuf`acturing. After re~low the positioning means and backing means may be stripped off without the need for a chemical wash.

As mentioned above, Figure 2 illustrates the solder post delivery system of Figure 1 placed in a fixture 22 and having a chip carrier package 24 positioned with respect thereto such that the connection pads 26 on the edges of the package are in alignment with solder 12. It is within the scope of the invention as illustratèd in Figure 2 to have backing means 20 include an additional adhesive surface on the back side thereof to secure the delivery system with respect to the fixture 22. Figure 2 illustrates such a delivery system wherein the longitudinal ends of the positioning means are closed into a loop which is capable of being pressed outwardly to conform to a geometric configuration and is capable of being retained in the con~iguration by the additional adhesive surface for the interconnection of the solder posts.

Figure 3 illustrates yet another fixture having two members 28 and 30 which are movable with respect to each other on the inside of a delivery system. As seen in the ~igure, the closed loop of the delivery system shown generally at 32 is dropped onto the members 28 and 30 which are expanded and which bend the delivery system from the generally circular cross-section to a generally rectangular cross-section, i.e., a desired cross-section that is comple-mentary to the substrates to be interconnected.

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Figure 4 shows yet another one-piece fixture wherein a loop of the delivery system is capable of being bent from a generally circular cross-section to a generally rectangular cross-section. It can be appreciated that various geometries of delivery systems can be conEigured with fixtures like those illustrated in Figures 2-4 or the like.
Figure 5 discloses a delivery system similar to that disclosed in Figure 1 but wherein the positioning means 34 is folded along a line 36 passing generally midway between the tops 38 and the bottoms 40 of the openings 42 providing unobstructed access to the solder posts 44. ~t is also within the scope of the invention for positioning means 34 to be folded in more than one location along the longitudinal axis. Multiple folds de~ining a serpentine structure secure the solder posts in a redundant manner. The positioning means 34 may be pulled away from the soldered posts, each fold pulling away from the columns. It is understood that the width of the openings 42 is preferably slightly smaller than the diameter of the solder post 44 so as to create an interference fit to secure the solder post 44 within the openings 42. ~he delivery system also includes an elongated and flexible backing means 46 as in the earlier described embodiments but wherein the backing means 46 extends beyond at least one longitudinal periphery 48 of the positioning means 34 to provide a surface for securing the positioning ~eans 34. It can be seen that the backing means 46 has an adhesive surface which is exposed through the openings 42 and which extends beyond the periphery 48 of the positioning means to secure the positioning means 34 with respect to a substrate (not shown) to be interconnected.

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Figure 5 also discloses that the positioning means 34 may be cut transversely, as shown generally at 48, to allow the positioning means to be bent with respect to the longitudinal axis of the positioning means.

Figure 6 discloses in a plan and partially schematic view a continuous method of fabricating a variety of delivery systems including those described ~earlier. Speci~ically, there is illustrated a ribbon of tape 50 (preferably Kapton) having windows 52 punched by punch 54 as the tape is moved in the direction generally indicated at 56. Subsequent to the punching operation, a 1exible backing means 58 having at least one adhesive sur~aae is applied to the back side of the tape 50 and simultaneously or subsequently solder posts 60 are placed within the openings 52. At a further point, the composite tape is severed by cutting by means shown symbolically at 62. It is understood that it is within the scope of the invention to cut by various means such as laser, heat, blade, etc. The result is the solder post delivery system shown at 64. In the embodiment shown in Figure 6, the backing means 58 is cut by a separate cutting means 66 which allows the backing means to extend beyond the longitudinal periphery of the positioning means on one side thereof much like the embodiment shown in Figure 5. It is understood that the width of the positioning means may be varied to extend beyond the tops and bottoms of th~ solder posts 60 or as shown in Figure 6 may be generally coincident with the tops and the bottoms of the solder posts 60. It is also within the scope of the invention to use a tape 50 which is slightly heat-recoverable in the transverse direction but not in tha longitudinal direction. Heating of the delivery system is , ji',~,~, ' acccmplished by heating means 68 shown symbolically to be an infrared heat source. The result is that the solder poqts as shown at ~0' extend beyond the transverse periphery of the positioning means 50' to facilitate engagement with substrates to be interconnected.
Figure 7 discloses the solder post delivery system embodiment typically fabricated by the process and apparatus shown in Fiyure 6. In this embodiment the positioning means 50' positions the solder posts 60' and the flexible backing means 58 having at least one adhesive surface is connected to the positioning means 50' and to the solder posts 60'. The backing means 58 extends beyond at least the one longitudinal periphery of the positioning means as shown to provide a surface for securing the positioning means 50~O
Figure 8 discloses yet another embodiment wherein the positioning means 70 is folded along lines 72 and 74 coincident with the tops and the bottoms, respectively, of the openings 76 to form a U-shaped cross-section haYing a top flange 78 and a bottom flange 80 that extend transversely at right angles to the longitudinal axis of the delivery system.
This figure also illustrates a cut 82 in the top flange 78, it being understood that a similar cut exists in the bottom flange 80 to allow the positioning means to be bent out of the plane of the positioning means.
Figure 9 discloses a solder post delivery system substantially identical to that illustrated in Figure 8 but wherein at least one of ths flanges 78' is provided with at least one notch 84, the adhesive surface 86 of the backing means being exposed through the notch 84. In this embodiment an optional cover means 88 may be provided in removable contact with the exposed adhesive surface 86 to protect the surface before installation of the system.

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Figure 10 illustrates yet another embodiment encompassing many of the features illustrated in Figures 7-9 but wherein the positioning means 90 is folded along line 92 coincidant with the tops of the openings to form an L-shaped cross-section having a top flange 94 that extends transversely at a general right angle to the longitudinal axis, the backing means 96 conforming to the top flange 94 to provide an adhesive surface capable of securing the positioning means with respect to a substrate. In this embodiment the solder posts 98 are secured against the inside of the delivery system in openings shown in phantom. The view illustrates the back of the backing means, it being understood that the adhesive surface is on the inside of the backing means ~6.
Figure 10 also illustrates a cut 100 which allows the positioning means and corresponding backing means to be bent out of the plane of the positioning means or at an angle to the longitudinal axis o~ the delivery system. By longitudinal axis it is understood that in the embodiments shown in Figures 1-4 the delivery system and its components comprise a single sheet of material which is readily flexible along the longitudinal axis. However, the embodiments of Figures 5-10 disclose delivery systems having bends which add structural integrity along the longitudinal axes and are therefore provided with cuts to allow the positioning means and attached components to be bent out of the plane of the positioning means along the longitudinal axis.
Figure 10 also illustrates a chip carrier package 102 having connection pads 104 to which the 3~ `

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aolder po~ts wlll beeome attached during installation of the delivery system~ Thc figure illu~trateq that the flange 9~ may be provided with a window opening, the adhe~lve ~urface of the backing ~eans 96 bein~
exposed through the window openlng. An optional cover mean3 106 ls in removabl~ contact with the exposed adhe3ive surf`ace to protect the gurface before instal-lation of the system, It i~ und~r~tood that window ios ar~ the equivalent of tha notch 84 as sho~n in Figure 9 and lq u~eful in all of the embodiments whereln it i~ de~ired to have th~ pogl~ionlng means in contact with a 3ub~trate and where it i~ de~irable to have the adhesive gurface of the backing means avail-able to secure th~ sy~tem wlth re~pect to a sub~trate.
Figure 11 illugtrateg yet another embodiment wherein at least ~wo o~ tha opening~ 108 and llO
(shown in phantom) of the positioning means ll2 are e~pty and the positioning means is folded tran~versely wlth respect to said longitudinal axis between the t~o openingsp the adheqive surface of the backing ~eans ll4 extending through each of the two openings to contact itself to deflne a tab and a corner for the po~itlonin~ meana ll2 and for the delivery ~y~tem. As sho~n in Fl~ura ll four opening~ at each corner are empty and the positioning mean~ i~ folded midway between the four opening~ to define a tab having two open1ngs on each qide, a~ can be better 3een by viewing opening~ ll6 and ll~ (~hown in phantom).
It should be appreciated that the u e of the empty openings and interfacing o~ the backing mean~
allaw~ for a less severe bend to be placed in the positioning means l12 on the interior of the deliver~
~ystem. SpecLfically, a3 seen in the figure, the positioning means ll2, as noted generally at l20, is -..

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bent at an angle of 45 from each interior ~urface to fonm a total of a 90 bend in the positioning means.
Since the preferred material for the positioning means i9 a Kapton tape which i~ relatively stiff, the 45 bend i~ easier to aocompligh than thc more severe 90. It is understood that at the far end 122 of the tab, the po~itioning mean9 Ls bent a full 180 back ont~ itself and may even be fractured. However, the integrity of the tab is maintainQd by the matin6 of the adhe ive surfaceg th~ough the openin~s as dis-cus~ed earlier.
Figure~ 12-14 disclo~e yet another embodi-ment of the instant invention wherein a solder post delivery ~y~tem i3 provided having a positioning mean~
shown generally at 144 for pogitionins solder posts 146 wherein the positioning meang includes at least three layer~ 148, 150 and 152. Each of the layer~ are provided with a plurality of opening~ 154 there~
through, the openings in each layer being in generally axial allgnment with the openings in the other layers, the openings bein6 3l12htly ~isaligned (See Figure 13). The plurality of qolder po~t3 146' one solder po~t being positloned in each generally aligned open-ing are aecured therein by a force-fit created by the sli~ht ml~alIgnment of the layer As ~een ~y the arrows in Fl~ure 13, the misalignment i9 created by movement of the layer with reqpect to each other.
~ Figure 14 iLlu~trate~ that the positioning means 144 may be slit throu4h the Jeveral layer~ and that the layer~ may be bent ~lightly out of plane of the layer~ to define abuttment mean~ 156 for contact and alignment of electrical component~ quch a~ the one shown in phantom to be in:erconnecbed by the ~ystem.

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, ~ ~ 2 C$ ~ ~ 3 Figure 15 illustrates yet another embodi~ent of the instant invention wherein the positioning means 124 comprises a continuous frame having an inner periphery 126 and an outer periphery 128. The positioning means 124 is provided with 5 securing portions 130 which are capable o f removably seauring solder posts 132 thereto when the frame is continuous and which are capable of releasing the solder posts that may be seaured thereto when the frame is discontinuous as shown in phantom at 134. The plurality of solder posts 132 in contact with securing portions 130 of the positioning means are secured in the embodiment of Figure 15 by a force fit with openings in the positioning means 124.
Specifically, a frame of Figure 15 has a generally U-shaped cross-section having top flange 136 and bottom flange 13~.
In this embodiment the securing portion on the inner periphery of the frame comprises a plurality of spaced openings 130 extending across the width of the inner periphery 126 and into the top and the bottom flanges 136 and 138. Each of the solder posts 132 which can be more clearly seen in the broken portion of the frame are held within one of the openings 130 by contact with the edges of the opening.
The figure also illustrates that the frame may be cut as shown generally at 140 so that the frame may be bent at the corners thereof. At one corner 142 of the frame the positioning means and backing means are discontinuous to form a tab which may be separated after installation of the solder post, the positioning means being separable from the solder posts, again as shown in phantom.
The array of solder posts 132 are held in the fram~
which may be made of any temperature-resistant, non-solderable material. The frame is formed as shown to have .

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enough rigidity along each row to deliver the-solder post in a straight line and the frame is made in a semi-continuous strip making it convenient to snap in the solder posts. It is folded at the predetermlned points to form the U-shaped cross-section and extensions of the ~rame at the corner 142 are welded, glued or stapled.
Figure 16 illustrates another embodiment of the instant invention wherein the positioning means 158 is made of a low-durometer elastomer and includes a plurality of openings 160 therethrough to receive solder posts 162. Each of the openings 160 is connected to the inner periphery of the positioning means 158 by a slit 164, the slits 164 capable of being widened to enlarge the openings 160 to release solder posts secured therein when the frame is made discontinuous 15 such as by tearing the frame at cut 166. The openings 160 and slits 164 form a keyhole-type cut which allows the positioning means to be simply pulled away from the solder posts 162. Typical elastomers that may be utilized are silicone rubber, Viton, (a trademark) polyurethane and nitrile rubber. These types of low-durometer materials are compliant enough that after the solder posts are reflowed at the tops and the bottoms thereof the elastomeric positioning means may be ripped off leaving the pins in place.
Figure 17 illustrates yet another embodiment of solder post delivery system comprising an external, reusable, hinged frame. Specifically, there is disclosed a positioning means for positioning solder posts having a continuous, generally rectangular frame 168, the frame capable of being di~continuous at 170 upon removal of the pin 172, the positioning means having securing portions 174 which are capable of r~ ~
, 1 .L ~ J U ;i releasing solder posts 176 that may be secured thereto when the frame is made discontinuous. In this embodi-ment the inner periphery oE the frame 168 is contoured to provide spaced securing portions 174 that are complementary to some portion of the surface of the solder po~ts to secure the solder pQst thereto. The frame 168 is provided with corners, one of them being discontinuous at 170 and including the separate remo-vable fastening meaos in the form of the pin 172 to hold the corner together. The other corners 178 are bendable in a hinge-like fashion to open the frame with respect to the solder posts -~o release the posts from the securing portions. The solder posts 17S are held in place against the spaced securin~ portions by the use of a very small amount of glue or adhesive-type material to temporarily hold the solder posts in position.
Figure 18 illustrates another embodiment of solder post delivery system having a positioning means for positioning solder posts comprising a continuous, generally rectangular frame 180, having an inner and outer periphery, but wherein the frame remains con~
tinuous in overall configuration and is made from a dielectric material. In this ~bodiment it is understood that the frame 180 may be left in place after the reflow of the solder posts 182. The solder posts 182 are preferably a filled solder and the frame 180 is shaped and perforated to fit the individual applicationO In this embodiment the securing portions comprise openings 184 through the frame, the diameter of the openings 184 being smaller in diameter as noted at 186 than the general diameter of the solder posts where the solder posts are secured within the openings 184. The figure also illustrates an alternate shape , ;
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of solder post 188 which extends generally from only one side of the frame 180. Each type of solder post is held in place by the offset of post material. The posts are shown to be preferably somewhat tapered to provide support. The dielectric material of the rame 180 may be any suitable dielectric material such as mica or Kapton, etc.
Figure 19 illustrates a solder post delivery system comprising a positioning means for positioning solder posts comprising a continuous r generally rec-tangular frame 190 and a plurality of solder posts 192.
The frame 190 is preferably continuous across the inner periphery thereof and comprises a thin sheet of solder from which the solder posts 192 extend generally normal thereto. In this embodiment the frame 190 is capable of being discontinuous upon heating the frame or thin sheet of solder since the solder is capable of flowing to supplement the solder posts 192. In this embodiment the securing portion of the positioning means is the integral connection of the solder posts I92 and the sheet 190.
Also illustrated in Figure 19 is the die 194 shown in pbantom illustrating apparatus which is capable of ~abricating the solder delivery system.
Specifically, it can be seen that a sheet of fuseable material or solder may be placed in the lower part of the die and hit with the upper part of the die resulting in the formed solder posts 192 connected and capable of being delivered by the remaining attached flash forming the thin shee~ of solder for positioning means 190. It is understood that that starting sheet of material may include a thin copper mesh or other filler that will give integrity to the construction but which will disappear from the sheet 190 upon heating.

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Figure 20 illustrates yet another embodiment of the instan~ invention wherein the solder delivery system comprises a positioning means 196 for positioning solder posts, the positioning means having a plurality of openings ~98 therethrough and further including a plurality of solder posts with one post per opening, the posts comprising solder paste 200 which ~ills the openings 198 to define individual solder posts. In this embodiment, the solder paste 120 is extruded into the openings lg8 by wiping the ~older paste across the surface of the positioning means lg6 by wiping means 202.
Figure 21 illustrates an alternative approach to fabrication of the delivery system wherein the positioning means 204 and the solder paste 206 are co~extruded in one direction to define a continuous composite, the composite being sliced through at an angle perpendicular to the direction of co-extrusion to define an individual solder delivery system shown generally at 208. Solder paste used to fabricate the embodiments of Figures 20 and 21 may be made from a solder and spherical and/or angular wettable, conductive, high melting ~iller particles forming a paste having a percentage of solder filler, resin, flux and other materials as desired. For all of the embodiments of the instant invention suitable joint-~orming material in the form of filled solder composition, paste or supported solder which will retain its shape upon the solder melting and reflowing arew within the scope of the instant invention. As used herein by the term "filled solder" and solder paste are discussed the commonly assigned published U.K. application Ser. No. GB 2,142,568A.

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Figure 22 illustrates method and apparatus for fabricating a preleaded chip carrier package 210, the method comprising the steps of providing a reusable solder post delivery system de~ined by a mold 212, having a chip carrier package securing portion 21~ in one side thereof, and having openings 216 therethrough for solder posts extending from a securing portion 214 to the other side of the mold Z12, as seen in Figure 22A;
inserting a chip carrier package 218 in the portion 214; inserting solder posts 220 through the openings 216 into contact with the cbip carrier package 218 (as can be seen in Figure 22B wherein the mold 212 has been turned over, as noted by the directional arrow);
clamping the solder posts 220 and the chip carrier package with respect to the mold 212 (as can be seen in Figure 22C) while reflowing the solder posts to secure the solder posts 220 to the carrier package 218; and finally removing the mold to produce the prele~ded chip carrier package (as can be seen in Figure 22D). The above apparatus may be made disposable by using --dissolvable material such as water soluble aluminum for mold 212. Aluminum rasists being soldered to and is structurally reli.able for the intended application.
Figures 23 and 24 illustrate another embodi-ment of a solder post delivery system of an heat-activated mechanically removable positioning means for solder posts. Specifically, there is disclosed a posi-tioning means 222 for positioning solder posts 224, the positioning means being generally planar and having a plurality of openings 226 therethrough, the positioning means being made from a heat-recoverable polymeric material and the positioning means having a first dimension, as ~een in ' ~: . :' ~: .
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Figure 23, including a first thickness wherein the openings have a first diameter and the positioning means having a second dimension as seen in Figure 24, including a smaller, second thickness and wherein the openings have a smaller second diameter. The plurality of solder posts 224 with one posts per opening are secured by a force fit within the openings when the openings are at the smaller, second diameter. It can be appreciated that when the openings are at the first diameter the solder posts are released, the positioning means being capable of going ~rom the second dimension to the first dimension upon application of heat.

In the embodiment of Figures 23 and 24 a flat sheet of radiation cross~linked polymer is punched in the desired pattern and the opening diameter is larger than the column diameter of the solder posts. The positioning means is then pressed while above the melt point to decrease the opening diameter while the opening spacing is maintained. The positioning means is then cooled and the smaller opening dimension is set temporarily. The solder posts are then inserted as seen in Figure 24. During khe heating of the system and the reflow of the solder, the positioning means returns to its original shape and dimension as seen in Figure 23. It is then possible for the positioning means 222 to be easily removed mechanically. Suitable heat recoverable materials such as polyethylene, Kynar (a trademark) and other materials are well known as well as the cross-linking technology use~ul to elevate the melting point of the polymeric materials above that of the fusible solder posts.

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Figure 25 illustrates an embodiment of the instant invention in the form of a solder clip delivery system. In this embodiment a sheet of flexible, non-solderable material, such as plastic, is prepared to have flat, thin traces of solderable metal such as copper deposited in given arrays on one surface. Solder is then placed on the metal. The ass~-mbly is formed to bend the metal into a shape so that the solder coated surface faces outward so that portions of the surface are parallel with each other. This assembly is placed between a chip carrier package having matching solderable pads and a corresponding substrate having like pads. The application of heat flows the solder, causing the permanent joint to be made between the chip carrier pads and the substrate. The act of heating preferably loosens the bond between the material under the metal and this material may be pulled out and removed, if des~red, increasing the durability of the joints and allowing them to flex more freely. A similar structure may be fabricated by adhering a thin metal layer over an insulated centerpiece and subse~lently trimming the metal layer and center piece at the edges thereof to create outwardly extending conductive items which become clips. This structure will be discussed later with respect to Figure 35.

Figure 25 is a perspective view of a complete device shown generally at 228 wherein 230 is the positioning means for positioning the solder clips and comprises a generally rectangular frame having top surface 232 and bottom surface 234 and having an inner and outer periphery, the inner periphery of the frame having portions having a solderable metal deposited thereon and having solder plated on the metal to . . .

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~ ;, 2 define individual solder clips 236. The rectangular frame may be cut as noted in phantom at 237 to remove the frame as will become apparent from the Eollowing.
Figure 26 i~ a partial cross~sectional view of a solder clip 236 shown in phantom. The figure illustrates how the clip is formed wherein the posi-tioning means 234 referred to as the frame has had solderable metal 238 deposited thereon and has solder 240 plated on the metal to define the individual solder clip .
Figure 27 shows a cross-section similar to Figure 26 wherein a chip carrier package 242 is posi-tioned above the solder clip delivexy system 228 which is, in turn, positioned above the substrate pads 244.
Figure 28 illustrates the parts in position a~ter the application of heat wherein the solder 240 flows and joins the metal 238 to the chip carrier 242 and the substrate pads 244. As mentioned earlier, the delivery material referred to as the positioning means 234 may be pulled away from the metal strips and discarded. Thus, it can be seen that the frame 34 is capable of being detached from the clips when heat is applied to the clips, the heat melting the solder to cause a permanent joint between the metal and the com-ponent to be connected in loosening the frame from metal. It likewise can be seen that the inner periphery of the frame, having the portions of solderable metal deposited thereon project inwardly and are fingerlike portions having the metal deposited on the top surface thereof, the portions being bent out of the plane of the surface to form a generally C-shaped solder clip.

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Figure 29 illustrates a method of fabrication wherein the frame is defined by two parallel layers 246 and 248, each layer having portions projecting from only two opposite sides thereof and the layers being oriented at right angles to each other so that the portions project inwardly from all sides of the frame when the layers are brought together. In other words, the two opposed rows of termination strips are combined at 90 angles to each other and once formed into the pxeferred C-shapes will have pads alosely adjoining in the corners. Item 250, in Figure 29, and item 252, in Figure 25, are optional plating busses for the attachment of a current source to improve metal deposition as is known to one skilled --in the art. Such an optional plating buss is removed a~ter plating is accomplished. A conductive polymer may be used instead of a plating buss 250 in Figure 29, 252 in Figure 25 and yet to be described 262 in Figure 30. The conductive polymer frame members provide an integral current return path ~or the electro deposition of the metals to make the clips.

Figures 30 and 31 illustrate a variation in the solder clip delivery system described above wherein the solderable.
metal 252, as seen in the cross-sectional view of Figure 31, taken along section lines 31-31 of Figure 30, is deposited along the inner periphery 254 and the top surface 256 and the bottom surface 258 in a spaced-apart fashion, as seen in Figure 30, to define C-shaped configurations upon which the solder is plated to define individual solder clips 260. In Figure 30, areas 262 are plating busses which may ba punched out prior to the use of the device. In the embodiments of Figures 30 and 31 everything is similar in arrangement in function to the formed clips described with respect to .. . .

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Figures 25- 29, except that the solder clad opposed C-shaped solder clips are fa~ricated around the edge of positioning means, the opposed sides and adjoining edges are sensitized by chemical and other well known processes to form a site for metal deposition. Doing so in a direct way allows for much finer features to be created and it also permits the features to be formed closer together. Figure 30 also illustrates how nested rows of solder clips may be fabricated.
Figures 32-34 illustrate yet another chip carrier joining device using solder-clad deposited metal over an insulative supporting structure, several of which may be arranged to form an array. In this embodiment, the supporting structure may be removed by heat recovery from the supporting structure or by chemical means. Removal of the supporting means facilitates inspection and improved flexibility of the joints. Specifically, there is disclosed a solder ring delivery system shown generally at 264, comprising a positioning means for positioning solder rings 266, the positioning means including a plurality of diametrically heat-recoverable rods 268, the rods being adjacent to each other in spaced parallel relationships. It is also within the scope of the invention to use tubes and it is understood that the term "rod" as used herein includes tubing. The dalivery system includes a plurality of solder rings 266 positioned about the rod, the rods having surface portions about the rods, upon which a solderable metal has been deposited and having solder plated on the metal, the metal and the solder defining the individual solder rings 266. The rods 268 are preferably diametrically shrinkable upon application of heat and are therefore capable of being removed.

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The heat-shrinkable tube or rod may be plated or clad with rings of similar coated metal. The rod may al30 be chemically dissolvable. In either case, the rod or tube is used to position the rings in place between the chip carrier pads and the substrate pads.
~ter application of haat to join the pads to~ether by means of soldering, as seen in Figure 34, the rods are removed. Absence of the rods again permits joint inspection. Absence of the supporting rod also permits the rings to flex more freely, increasing the durabi-lity of the joints during heat cycling and mechanical flexing.
If a tube is used, it may be conventional heat-shrinkable material which contracts radially during application of heat. If a rod is used, it may be foamed so that upon heating it collapses to a smaller diameter. Ir the rod is chemically removed, it is fabricated from a material which permits chemical fabrication of the solder-clad rings.
The ringed rods can be fabrica~ed in a con-tinuous process. The rod is photochemically (or the like) sensitized to receive an electrolytic deposit of metal. A plating buss wire 270 is pressed into contact with the sensitized areas. Electrical plating then builds the required metal thickness. Tin or other suitable solderable metals are added in turn. The plated buss wire is peeled off and discarded. The electroplated tin and lead may be reflowed by select infrared or radio-frequency methods so as not to shrink the rod. Conductive polymer may be used ins~ead of conventional material for the rod or tube to perform tWO functions. In the first instance it may eliminate the need for a buss wire 270 or the like during plating. In the second instance, it may become ~ ~3~

hot enouqh to recover (shrink) if sufficient current is applied.
Alternate ringed rods 26~ and unringed rods or insulators 272 are grouped together in arrays to match given pad-to-pad geometries. The group may be held together with tape 274 or the like. After heating the tape 274 may be used to remove all of the rods at once.
Figure 32 illustrates ring rods 268, separated by unringed rods 272. Figure 33 illustrates the same relationship for application of heat. Figure 34 illustrates the array after application of heat and after the solder-cladding 266a has joined opposing pads. The rods 268 and 272 have been reduced in diameter because of their plastic memory.
lS Figure 35A referred to earlier shows a thin metal frame 276 having a square hole therethrough so as to overlap a thin, insulative (non-metal, nonconductive, semi-rigid) center piece 278. The two items are then adhered together permanently to form a laminated structure.
Portions of frame 276 and center piece 278 are cut away to produce a plurality of outwardly extending metal projections 280 as seen in Figure 35B and may be further bent into a "C" shape to interface and to be soldered to conductive pads of a device to be connected Snot shown).
Partial cross-sectional view Figure 35C, taken alon~ section lines C-C, illustrates the item 280. Partial cross-sectional view Figure 35D, taken along secton lines D-D, illustrates the finished "C" shape.

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Claims (24)

1. A solder post delivery system comprising:

a positioning means for positioning solder posts, said positioning means being elongated along a longitudinal axis, said positioning means having a plurality of longitudinally spaced openings therethrough, each of said openings having a top and a bottom generally parallel to said longitudinal axis wherein said positioning means is folded along a line generally parallel to the tops and bottoms of said openings providing unobstructed access to said solder posts; an elongated and flexible backing means having at least one adhesive surface, said backing means connected to said positioning means by said surface and to solder posts to be positioned through said openings; and a plurality of solder posts positioned by said openings and held therein by said backing means, said positioning means capable of being bent with respect to said longitudinal axis to align the ends of said solder posts with respect to electrical components to be interconnected.

2. A delivery system as in claim 1 wherein longitudinal ends of said positioning means are closed into a loop which is capable of being curved outwardly to conform to a geometric configuration and is capable of being retained in said configuration for interconnection of said solder posts.

3. A delivery system as in claim 2 wherein said loop is capable of being bent from a generally circular cross-section to a generally rectangular cross-section.

4. A delivery system as in claim 1 wherein said backing means includes an adhesive surface on both sides thereof, said positioning means capable of being placed against external support and being retained in position by said backing means.

5. A delivery system in claim 1 wherein said positioning means is folded along a line passing generally midway between the tops and bottoms of said openings providing unobstructed access to said solder posts, said backing means extending beyond at least one longitudinal periphery of said positioning means to provide a surface for securing said positioning means.

6. A delivery system as in claim 1 wherein said positioning means is folded along lines coincident with the tops and bottoms, respectively, of said openings to form a U-shaped cross-section having top and bottom flanges that extend transversely at right angles to said longitudinal axis.

7. A delivery system as in claim 6 wherein at least one of said flanges is provided with at least one notch, said adhesive surface of said backing means being exposed through said notch.

8. A delivery system as in claim 7 further including cover means in removable contact with said exposed adhesive surface to protect said surface before installation of said system.

9. A delivery system as in claim 6 wherein said flanges are cut transversely to allow said positioning means to be bent.

10. A delivery system as in claim 1 wherein said positioning means is folded along a line coincident with tops of said openings to form an L-shaped cross-section having a top flange that extends transversely at a right angle to said longitudinal axis, said backing means conforming to said top flange to provide an adhesive surface capable of securing said positioning means with respect to a substrate.

11. A delivery system as in claim 10 wherein said flange is cut transversely to allow said positioning means to be bent.

12. A delivery system as in claim 10 wherein said flange includes at least one window opening therethrough, said adhesive surface being exposed through said window opening.

13. A delivery system as in claim 12 further including cover means in removable contact with said exposed adhesive surface to protect said surface before installation of the system.

14. A delivery system as in claim 1 wherein at least two of said openings are empty and said positioning means is folded transversely with respect to said longitudinal axis between said two openings, said adhesive surface of said backing means extending through each of said two openings to contact itself to define a tab and a corner for said positioning means.

15. A solder post delivery system comprising:

a positioning means for positioning solder posts, said positioning means including at least three layers of sheet-like material, each of said layers having a plurality of openings therethrough, the openings in each layer being in general axial alignment with the openings in the other layers, said openings being capable of being slightly misaligned by movement of the layers with respect to each other; and a plurality of solder posts, one solder post being positioned in each generally aligned opening and being secured therein by a force fit created by said slight misalignment.

16. A system as in claim 15 wherein said positioning means is slit through said layers and said layers are bent slightly out of the plane of said layers to define abutment means for contact and alignment of electrical components to be interconnected by the system.

17. A solder post delivery system comprising:

a positioning means for positioning solder posts comprising a continuous frame having an inner and outer periphery, said frame capable of being discontinuous, said positioning means having securing portions which are capable of removably securing solder posts thereto when said frame is continuous and which are capable of releasing solder posts that may be secured thereto when said frame is discontinuous:
and a plurality of solder posts in contact with said securing portions of said positioning means: and wherein said frame has a generally U-shaped cross-section having top and bottom flanges and a securing portion on the inner periphery of said frame comprising a plurality of spaced openings, each of said openings extending across the width of said inner periphery and into said top and bottom flange, each of said solder posts being positioned and held within one of said openings by contact with the edges of each of said openings.

18. A solder post delivery system comprising:

a positioning means for positioning solder posts comprising a continuous frame having an inner and outer periphery, said frame capable of being discontinuous, said positioning means having securing portions which are capable of removably securing solder posts thereto when said frame is continuous and which are capable of releasing solder posts that may be secured thereto when said frame is discontinuous;
and a plurality of solder posts in contact with said securing portions of said positioning means; and wherein the inner periphery of said frame is contoured to provide spaced securing portions thereof that are complementary to said solder posts to secure said solder posts thereto, said frame having corners, said frame being discontinuous at one of said corners of said frame including separate removable fastening means to hold said corner together, said other corners being bendable in hinge-like fashion to open said frame with respect to said solder posts to release said solder posts from said securing portions.

19. A solder delivery system comprising:

a positioning means for positioning solder posts, said positioning means having a plurality of openings therethrough; and a plurality of solder posts with one post per opening, said posts comprising solder paste which fills said openings to define individual solder posts; and wherein said positioning means and said solder paste are co-extruded in one direction to define a continuous composite, said composite being sliced through at an angle perpendicular to the direction of co-extrusion to define an individual solder delivery system.

20. A solder post delivery system comprising:

a positioning means for positioning solder posts, said positioning means being generally planar and having a plurality of openings therethrough, said positioning means being made from a heat-recoverable polymeric material, said positioning means having a first dimension including a first thickness wherein said openings have a first diameter, said positioning means having a second dimension including a smaller, second thickness wherein said openings have a smaller second diameter; and a plurality of solder posts with one post per opening, said posts secured by a force fit within said openings when said openings are at said second diameter and being released when said openings are at said first diameter, said positioning means capable of going from said second dimension to said first dimension upon application of heat.

21. A solder clip delivery system comprising:

a positioning means for positioning solder clips comprising a frame having top and bottom surfaces and an inner and an outer periphery, said inner periphery of said frame having portions having a solderable metal deposited thereon and having solder plated on said metal, to define individual solder clips; and wherein said frame is capable of being detached from said clips when heat is applied to said clips, heat melting said solder to cause a permanent joint between the metal and the component to be connected and loosening the frame from said metal.

22. A solder clip delivery system comprising:

a positioning means for positioning solder clips comprising a frame having top and bottom surfaces and an inner and an outer periphery, said inner periphery of said frame having portions having a solderable metal deposited thereon and having solder plated on said metal, to define individual solder clips; and wherein said portions are inwardly projecting finger-like portions having metal deposited on the top surface thereof, said portions being bent out of the plane of said surface to form a generally C-shaped solder clip.

23. A delivery system as in claim 22 wherein said frame is defined by two parallel layers, each layer having portions projecting Prom only two opposed sides thereof, said layers being oriented at right angles to each other so that portions project inwardly from all sides of the frame.

24. A solder ring delivery system comprising:

a positioning means for positioning solder rings, said positioning means including a plurality of diametrically heat-recoverable rods, said rods being adjacent to each other in general spaced parallel relationship; and a plurality of solder rings positioned about said rods, said rods having surface portions about said rods upon which a solderable metal has been deposited and having solder plated on said metal, said metal and solder defining said solder rings, said rods being diametrically shrinkable upon application of heat and capable of being removed.