Ladder assembly steps HFT PIXEL 1042009 1 ladder

Ladder assembly steps HFT PIXEL 1/04/2009 1 ladder fixture. SLDASM

ladder assembly with frame assembly frame full flex cable before cutting off ends 2

ladder exploded view cable bundle drivers kapton flex cable pixel chips adhesive composite backer adhesive wire bonds capacitors 3

order of assembly cable bundle drivers 7 kapton flex cable 1 pixel chips adhesive composite backer 6 adhesive 2 5 4 1 3 4

details of ladder sandwich, end view wire bonds capacitors Carbon composite recessed to give room for vacuum chuck backing of kapton and silicon while wire bonding adhesive extends past bonded element to avoid bulge due to adhesive pucker pixel chips soft acrylic adhesive flex kapton cable soft acrylic adhesive carbon composite ladder backing backer to sector beam adhesive 5

ladder assembly fixture vacuum distribution manifold ¾ ID tube connection to 1 gallon vacuum ballast tank 3/8 OD tube connection to vacuum release valve for hold down of the vacuum chucks 6

fixture parts (SLA) for bonding silicon chips v chuck chip. SLDPRT chip adhesive stop. SLDPRT chip stop. SLDPRT end drop chip. SLDPRT 7

fixture parts for bonding composite backer v chuck backer. SLDPRT backer adhesive stop. SLDPRT backer stop. SLDPRT end drop backer. SLDPRT 8

install chip vacuum chuck • install chip vacuum chuck against stops (arrow toward arrow) • open valve to vacuum lock down line. 9

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 10

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 11

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 12

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 13

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 14