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1
Ladder assembly stepsHFT PIXEL
1/04/2009
ladder fixture.SLDASM
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ladder assembly with frame
assembly frame
full flex cable beforecutting off ends
3
ladder exploded viewcable bundle
drivers
pixel chips
adhesive
wire bonds
capacitors
adhesive
composite backer
kapton flex cable
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order of assembly
cable bundle
drivers
pixel chips
adhesive
adhesive
composite backer
kapton flex cable
1
12
6
5
3
4
7
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
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ladder assembly fixture
3/8 OD tube connection tovacuum
¾ ID tube connection to1 gallon vacuum ballast tank
vacuum release valve forhold down of the vacuum chucks
vacuum distribution manifold
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fixture parts (SLA) for bonding silicon chips
v chuck chip.SLDPRT
chip adhesive stop.SLDPRT
chip stop.SLDPRT
end drop chip.SLDPRT
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fixture parts for bonding composite backer
v chuck backer.SLDPRT
backer adhesive stop.SLDPRT
backer stop.SLDPRT
end drop backer.SLDPRT
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install chip vacuum chuck
• install chip vacuum chuck against stops (arrow toward arrow)
• open valve to vacuum lock down line.
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attach chip adhesive to kapton cable
• install “adhesive stop” 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 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
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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
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backer adhesive to kapton cable
• install “adhesive stop” 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
13
attach backer to kapton cable
• position and lock down backer stop
• 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
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attach chips to kapton cable
• switch to chip vacuum chuck• position and lock down chip stop• butt chips one at time against chip
stop 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
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