Bonding module pins to an electronic substrate
A method includes disposing a terminal pin on an electronic substrate with a base region of the terminal pin in contact with a circuit trace on an electronic substrate, and ultrasonically coupling the base region of the terminal pin to the circuit trace.
1. A terminal pin comprising:
a body region including a body having a length between a first end and a second end and a body width perpendicular to the length, the body being a cylindrical body including at least one shape feature that is compressible in a direction perpendicular to the length of the cylindrical body, the at least one shape feature including at least a groove disposed around the cylindrical body;
a tip region extending from the first end of the body along the length; and
a base region extending from the second end of the body along the length,
the base region including a flange having a flange width that is greater than the body width perpendicular to the length, the flange having a flat surface configured to be placed on a metal pad and configured to receive ultrasound energy to weld the base region to the metal pad,
the terminal pin configured to be received in a lumen of a probe tip of an ultrasonic welding device such that an end face of the probe tip is flush with the flange.
2. The terminal pin of claim 1 , wherein the body is disposed in a lumen of a probe tip of an ultrasonic welding device with an end face of the probe tip flush with the flange.
3. The terminal pin of claim 2 , wherein the flange is disposed on, and ultrasonically welded to, an electronic substrate.
4. The terminal pin of claim 2 , wherein the at least one shape feature includes an eye-of-needle structure disposed in the tip region of the terminal pin.
5. The terminal pin of claim 2 , wherein the at least one shape feature includes a chamfer transitioning from the body to the flange in the base region.
6. The terminal pin of claim 2 , wherein the body region includes a flat ribbon-like body, and wherein the at least one shape feature includes a chamfer transitioning from at least one lateral side of the flat ribbon-like body to the flange in the base region.
7. The terminal pin of claim 2 , wherein the at least one shape feature when compressed has a reduced diameter or width allowing the terminal pin to be inserted in the lumen of the ultrasonic welding device without resistance.
8. The terminal pin of claim 2 , wherein the at least one shape feature includes an eye-of-needle structure disposed in the body region of the terminal pin, the eye-of-needle structure having a width greater than a diameter of the lumen of the ultrasonic device.
9. The terminal pin of claim 2 , wherein the at least one shape feature includes a chamfer transitioning from the body of the terminal pin to the flange, the chamfer having a diameter greater than a diameter of the lumen of the ultrasonic device.
10. The terminal pin of claim 1 , wherein the body region includes a rod-like cylindrical body having a diameter in a range of about 0.4 mm millimeters to 2 millimeters.
11. The terminal pin of claim 10 , wherein the tip region includes an extension of the rod-like cylindrical body with a pointed end.
12. The terminal pin of claim 11 , wherein the extension of the rod-like cylindrical body in the tip region includes a grooves-and-ridges section having at least one circumferential groove and ridge.
13. The terminal pin of claim 1 , wherein the flange is one of a circular plate, an oval plate, or a rectangular plate.
14. The terminal pin of claim 13 , wherein the flange is one of the circular plate or the oval plate and has a diameter in a range of about 0.4 millimeters to 2.0 millimeters.
15. The terminal pin of claim 13 , wherein a chamfer transitions from the body to the flange at an angle in a range of about 20 degrees to 70 degrees.
16. The terminal pin of claim 15 , wherein the chamfer has a diameter at the flange that is greater than a diameter of the body by about 0.2 millimeters to 0.6 millimeters.
17. The terminal pin of claim 1 , wherein the tip region includes an eye-of-needle structure formed by providing a circular or oval hole in a flattened extension of a cylindrical body of the body region.
18. The terminal pin of claim 17 , wherein the eye-of-needle structure has a lateral width at its widest in a range of about 0.8 millimeters to 3.0 millimeters.
19. The terminal pin of claim 1 , wherein the body region includes structures of non-cylindrical shape including at least one of an S-shaped ribbon structure, a flat ribbon-like structure, or a double-eyelet eye-of-needle structure.
20. The terminal pin of claim 19 wherein the tip region includes an eye-of-needle structure formed by providing a circular or oval hole in an extension of a flat ribbon-like structure of the body region.