Deformable electrical contacts with conformable target pads

Abstract

Deformable electrical contacts with conformable target pads for microelectronic assemblies and other applications are provided. A plurality of deformable electrical contacts on a first substrate may be joined to a plurality of conformable pads on a second substrate during die level or wafer level assembly of microelectronics, for example. Each deformable contact deforms to a degree that is related to the amount of joining pressure between the first substrate and the second substrate. The deformation process also wipes each respective conformable pad with the deformable electrical contact to create a fresh metal-to-metal contact for good conduction. Each conformable pad collapses as pressured by a compressible material to assume the approximate deformed shape of the electrical contact, providing a large conduction surface area, while also compensating for horizontal misalignment. Temperature can be raised to melt a dielectric, which encapsulates the electrical connections, equalizes gaps and variations between the two substrates, and permanently secures the two substrates together.