Module Production

T. Bowcock

Substrates

• Twist problem– Further understanding of the warp/weft and layup problem

• Chirality of the twist– Looks like it can be controlled

• It looks like it is a function of the 45°layer.

– The current layup is good ~0.5° (Limit about 3°)

• Pressure identified as part of problem– Reproduce twist at Liverpool by increasing pressure >90psi– Note nominal maximum pressure ~300psi

• Determine the CF/Epoxy ratios– For our modules ~ 9.9g/Weight (module)– Should be approx 60-68% CF by weight.

• PAC still quotes at 10/week.

K-05

• (Re)-Processing almost complete– Last batch were untestable through

overetching

• Circuits should be ready to laminate next week at Stevenage

Pitch Adaptors

• All pitch adaptors sent back to CERN for plasma cleaning

• Current ones not testable– 2 controls done in old pa’s– Damage/deposit on needle

Sensors

• 8 arrived at Liverpool– Currents ~uA and 0<0.5% percent strips bad.– One with no bad strips

• “Perfect” cutting

• 2 returned to Micron for remeasurement (3 others high in dB)– One recleaned at Micron did not change

current

Sensor Testing Problem

• On new batch of sensors on some detectors measure substantially higher current than micron

• Complete halt and check for damage to sensors– Inspection of old sensors– Running tests with mechanicals– Tests with “quartz”

• Repeat of tests using chuck/kapton– Currents confirmed

Sensor Testing

• Limited evidence of microscopic liquid from vacuum holes

• Hypothesis that the jigs were contaminating the sensors (Noryl)

• 2nd and 3rd tier of cleaning of jigs• Tests underway• 8 Pairs of new (cleaner) jigs under

construction for Liverpool and Micron– Acetal rather than Noryl

Bonding & Jigs

• Now have 4 double sided bonding jigs– 1 for backend– 2 for frontend– 1 for laser system

• 2 handling frames created (expect about 10 at the end)

Module Production

• Feet and Bases still in production

• Paddle Moulds (3 off) still to be made

Testing Equipment

• Laser rig plate finalized and submitted

• Thermograph equipment designed (to be reviewed)

• Gluing equipment expect to start the metrology and programming next week

Summary

• K-05 circuits close to delivery• Twist story still approx 2 weeks from resolution

– Living with the twist?

• Pitch adaptor problems again. Need cleaning?• Sensor testing issues uncovered

– Micron results look OK

• All mechanics except the thermograph system and the final paddle-hybrid assembly (twist) ready by July.

Timeline

• No prototype modules will be completed until end Aug 05 based on current status of K-05 and twist (guesstimate)– 4 double sided modules

• Look for “real” production start ~ Oct ‘05