System for populating a circuit board with semiconductor chips

1. A system for populating a circuit board with a three dimensional array of semiconductor chips comprising:

a) a plurality of chip carriers attachable to a circuit board with space for a chip to be positioned directly on said circuit board beneath each chip carrier as well as for positioning a chip on top of said chip carrier to thereby create a three dimensional array of chips on said circuit board; and

b) a pallet for holding and moving said plurality of chip carriers during a circuit board assembly process, said pallet having a matrix of chambers in a frame form with the chambers being open at least at a top side of said pallet, each chamber being formed to hold a chip carrier during the circuit board assembly process, said chip carriers being positioned in each of said chambers of the pallet with a top, chip receiving side, of said chip carrier facing out from the top of said pallet to thereby make said top side of said chip carrier accessible during the circuit board assembly process.

2. The system of claim 1 further including a protective barrier to protect said chip carriers from unintended alteration during said assembly process.

3. The system of claim 2 wherein: a) said chambers of said pallet are also open at a bottom side of said pallet and said protective barrier comprises a plurality of abutments around the outside top periphery of each of said chambers, said chip carriers having retaining flanges to allow them to rest in a chamber on said pallet and not fall through and said abutments being positioned such that when a chip carrier is in said chamber its top is below the top of said abutments and is thereby protected by said abutments from unintentional alteration; and

b) said system further comprising a print fixture pedestal having a matrix like array of raised portions with the matrix array of raised portions being positioned and formed such that each raised portion corresponds to a chamber of said pallet so that when said print fixture pedestal is positioned under said pallet with said raised portions facing said pallet each raised portion fits into the bottom opening of an adjacent chamber, a circumference of said raised portion being less than the inside circumference of said chamber so that a top surface of said raised portion can positioned up against the bottom surface of a chip carrier in said chamber and securely but detachably hold said chip carrier during a circuit board assembly process.

4. The system of claim 3 wherein said raised portions each have an aperture at its top side which abuts against the bottom side of a chip carrier positioned in said chamber so tat a vacuum can be created between said raised portion and said chip carrier to securely but detachably hold said chip carrier during a Stenciling process.

5. The system of claim 3 wherein said print fixture pedestal during said circuit board assembly process is attached to a moving and positioning mechanism during said circuit board assembly process so that it can be positioned under said pallet with chip carriers to securely hold said chip carriers during a stenciling step and properly position said chip carriers during said stenciling step and assure that said chip carriers disengage at the completion of said stenciling step.

6. The system of claim 1 further including a mechanism to move and position said pallet during said assembly process so that said plurality of chip carriers held by said pallet can be prepared to receive a chip during said assembly process and easily accessed, removed from said pallet and positioned on said circuit board over chips positioned directly on said circuit board with chips positioned on each chip carrier to thereby create a three dimensional array of chips on said circuit board.