Abstract:
The invention provides a composition (3) comprising: (i) a ferrofluid comprising a colloidal suspension (4) of ferromagnetic particles in a non-magnetic carrier liquid, and (ii) a plurality of electrically-conductive particles (5) having substantially uniform sizes and shapes, dispersed in the ferrofluid. Various types of substantially non-magnetic electrically-conductive particles (5) are described. Application of a substantially uniform magnetic field by magnet means (8) to the composition (3) causes the electrically-conductive particles (5) to form a regular pattern (9). The composition is used for providing anisotropic conductive pathways (9a, 9b) between two sets of conductors (2a, 2b; 7a, 7b) in the electronics industry. The composition may be a curable adhesive composition which bonds the conductors. Alternatively or in addition the electrically-conductive particles may have a latent adhesive property e.g. the particles may be solder particles. The ferrofluid may be a colloidal suspension of ferromagnetic particles in a liquid monomer.
Abstract:
The present invention provides a variety of interrelated methods of coating non-random and ordered arrays of particles, as well as films containing such arrays. The present invention also relates to the coated non-random and ordered arrays of particles and films prepared therefrom. The coated non-random and ordered arrays are obtained by the use of ferrofluid compositions which may be curable. The arrays and films may contain electrically-conductive particles useful in electronic applications for effecting contact between conductors.
Abstract:
Electronic devices having at least two components (53,55) with mating contact pads (52,54) are provided with high-aspect-ratio solder joints between the mating pads. These joints are formed by placing a composite solder medium (51) containing solder wires (56) in an electrically insulating matrix (57) such that at least two solder wires (56) are in contact with the mating pads (52,54), and fusing the wires (56) to the pads. The insulating matrix (57) with remainder of solder wires (56) is then optionally removed from between the said at least two components (53,55). The composite solder medium (51) is formed by preparing an elongated body of solder wires in an insulating matrix and cutting off slices of the composite solder medium, the solder wires having a high-aspect-ratio of length to their diameter. Alternatively sheets of the composite solder medium are prepared by magnetically aligning solder coated magnetic particles into columns arranged transverse of an insulating matrix and heating sufficiently to fuse the solder in each column into a continuously conducting solder path.
Abstract:
A connector (10) having one or more arrays of elongate cantilever beam arms (22) of contacts can have contact sections (26) on free ends thereof soldered to respective traces of a circuit element, by securing a lead frame (50) to the free ends which includes a corresponding plurality of fingers (56) extending from a carrier strip (52). On the finger ends are affixed preforms of solder; on the carrier strip (52) is defined a thin magnetic layer, transforming the brass carrier strip into a Curie point heater. When the carrier strip is subjected to RF current, it generates thermal energy which melts the solder preforms to join the fingers first to the contact sections (26) of the connector contacts, and in a remote location later subjected to RF current to reflow the solder preform to join contact sections (26) to the circuit element traces.
Abstract:
A connector (10) having one or more arrays of elongate cantilever beam arms (22) of contacts can have contact sections (26) on free ends thereof soldered to respective traces of a circuit element, by securing a lead frame (50) to the free ends which includes a corresponding plurality of fingers (56) extending from a carrier strip (52). On the finger ends are affixed preforms of solder; on the carrier strip (52) is defined a thin magnetic layer, transforming the brass carrier strip into a Curie point heater. When the carrier strip is subjected to RF current, it generates thermal energy which melts the solder preforms to join the fingers first to the contact sections (26) of the connector contacts, and in a remote location later subjected to RF current to reflow the solder preform to join contact sections (26) to the circuit element traces.
Abstract:
Spaced contact pads (23) on a printed circuit board (19) are soldered to respective spaced contacts (21) in a cable or connector assembly by means of respective spaced connecting members (15) interposed between contacts (21) to be soldered. The connecting members (15) are typically electrically and thermally conductive finger-like projections formed as part of a heater body (10) and are readily severable from the heater body (10) after soldering to thereby remain part of the final solder connection. A prescribed amount of fusible material (e.g., solder) is pre-deposited on the connecting members (15) or contacts (21) and is melted when the heater is actuated. The heater body (10) may be a self-regulating heater in the form of a copper substrate (11) having a thin surface layer (13) of magnetically permeable, high resistance alloy. An alternating current of constant amplitude and high frequency is passed through the heater body (10) and is concentrated in the surface layer at temperatures below the surface layer Curie temperature. At higher temperatures the current is distributed through the lower resistance substrate (11) to limit further heating. During the time interval required for the surface layer to reach its Curie temperature, the resistive power dissipation creates sufficient thermal energy to melt the pre-deposited solder. The connecting members (15) are positioned and configured as necessary to reach their respective connection sites.
Abstract:
A self-heating and self-soldering bus bar for use in many applications. The pins of the bus bar are quickly and directly heated to a predetermined autoregulated temperature without significantly raising the temperature of the body of the bus. Thusly a bus bar may be mounted while maintaining thermal balance and mechanical integrity of all wotk pieces. The present invention avoids the problems normally associated with excess thermal expansion experienced when a bus bar is heated incidental to the heating of its contact points. A majority of this incidental heating is eliminated by direct quick heating of the mounting pins.