Response surface methodology is used to characterize a state-of-the-art wire bonder with a bottleneck capillary for fine pitch bonding. Regression analysis generates mathematical models to plot 3-D charts and contour charts of ball size and ball shear force as a function of wire bond parameters. A procedure is described to use contour charts to optimize bonding parameters. Bonding windows are identified by using bonding specification requirements and material/process constraints as boundary conditions.
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