Mounting terminal pins in substrates

Abstract: An electronic device (22) includes a flat flexible dielectric substrate (28) which is less than 1.27mm (0.050 inch) thick and has a generally round hole (30) of a given diameter. A ductile conductive film (32) is deposited on the substrate in an area at least about the hole. A generally round terminal pin (24) is inserted into the hole in the substrate in contact with the conductive film. The pin has a given diameter greater than that of the hole. The difference between the diameter of the pin and the diameter of the hole is on the order of 5% to 50% of the diameter of the hole.

Description: Field of the Invention This invention relates to an electrical or electronical interconnection device according to the preamble of claim 1. In such device a terminal pin is electrically coupled in a hole of a flat flexible substrate. Background of the Invention A device according to the preamble of claim 1 is known from US-A 4 970 624. A flat flexible dielectric substrate having a conductive film on it is punctured to make a hole in it. Such punctured hole normally is not a round hole of a given diameter, anyway, it will produce inwardly directed forces onto the terminal pin. For producing a sufficient electrical and mechanical connection between the terminal pin and the flat flexible circuit, a conductive adhesive is deposited on the conductive film before being punctured by the terminal pin. Although such electrical connections generally serve their intended purposes, the use of solder materials, conductive adhesives, Z-axis epoxy and other similar materials require secondary operations to establish conductivity between the terminal pin and the flat conductor on the flat flexible substrate. In addition to the time and expense of the secondary operations, the materials, themselves, are relatively expensive. A circuit board comprising a substantially rigid board and a separately formed flexible sheet is known from EP A 0 303 485, wherein a pin is urged through an electrically conductive strip or pad on the flexible sheet so that a pierced hole will be produced where electrical contact is made to the pin. It is considered to use a special punching pin or pins to form the hole or holes prior to insertion of the contact pin or pins. There is no mention of the hole being round and a particular difference in diameter between hole and terminal pin be observed. It is already known to make a hole through a stack of flexible printed circuit boards by means of a metal tube (GB-A 1 142 160). A rigid conductor is passed through these punched holes and a part of the pad is bent into the hole. The conductor is then jointed to the pad by means of solder. A multilayer printed circuit board assembly is known from GB-A-1,134,376. A rigid pin is passed through aligned holes of a stack of circuit boards, each having conductor lands around the holes. Each individual board is typically 0.1 mm thick bearing a 70 µm thick conductor layer. When the pins are forced through the holes, which are smaller in diameter, some material of the conductor land is shown to be drawn into the entrance end of the hole to obtain a high contacting pressure between the pin and the ring of each hole of approximately 2 kg. The exit end of the hole is not deformed. Summary of Invention The present invention is designed for eliminating the need for solder or other conductive materials in a device according to the preamble of claim 1. With invention, a new and improved system for mounting terminal pins, in flat flexible circuitry, is provided. The invention is defined in claim 1. With invention, an electrical connection is directly established between the terminal pin and the flat conductor on the flat flexible substrate, by having similar metal interface between the pin and the flat conductor and by controlling various parameters of the pin and the substrate. The substrate is a flat flexible dielectric substrate less than 1.27mm (0.050 inch) thick and has a generally round prepunched hole of a given diameter. A ductile conductive film is deposited on the substrate in an area at least about the hole. A generally round terminal pin is inserted into the hole in the substrate in contact with the conductive film. The pin has a given diameter greater than that of the hole. The difference between the diameter of the pin and the diameter of the hole is on the order of 5% to 50% of the diameter of the hole. These parameters establish a good connection between the pin and the conductive film on the flexible substrate, i.e. a controlled meniscus is created by the flexible substrate and the ductile conductive film around the terminal pin which established a particular interference between the flat flexible circuit and the terminal pin. The substrate preferably is fabricated of a material such as polyamide, although such other materials as polyester and the like are appropriate. The ductile conductive film may be of copper material or conductive thick film material. A preferred feature of the invention is that the terminal pin and the ductile conductive film both be plated with a common plating material. In one embodiment of the invention, the plating material is a tin/lead alloy. Another feature of the invention involves the application of a lubricant to the terminal pin. Such a lubricant will prevent or at least reduce what is called "fretting" corrosion. In other words, when two metals rub together, they tend to create oxides which the lubricant will reduce. When using tin-lead interfaces, a polyphenol ether lubricant can be used. Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings. Brief Description of the Drawings The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: FIGURE 1 is a section through the interconnection between a terminal pin and a flat flexible circuit according to the prior art; and FIGURE 2 is a section through the interconnection between a terminal pin and a flat flexible circuit according to the invention. Detailed Description of the Preferred Embodiment Referring to the drawings in greater detail, and first to Figure 1, an electronic device or electrical interconnection, generally designated 10, between a generally round terminal pin 12 and a flat flexible circuit, generally designated 14, is illustrated according to a known prior art system. Specifically, Figure 1 represents a system as disclosed in the aforementioned U.S. Patent No. 4,970,624. More particularly, in the prior art system of Figure 1, the flat flexible circuit 14 includes a flat flexible dielectric substrate 16 having a ductile conductive film 18 thereon. The flat conductor or film 18 may be of a copper material with a tin/lead plating on one side thereof (i.e. the side which engages terminal pin 12). Substrate 16 is precut with slits to facilitate insertion of terminal pin 12 through the flat flexible circuit in the direction of arrow "A" to the position shown in Figure 1. A Z-axis conductive epoxy 20 either is applied to terminal pin 12 prior to insertion through the flat flexible circuit, or the epoxy is deposited on film 18 in an area about the penetration point of the terminal pin prior to insertion of the pin. After assembly, epoxy 20 is cured and rigidified at the interface area between terminal pin 12 and conductive film 18, as shown. Although the prior art illustration of Figure 1 and the above description thereof is representative only, such systems require secondary operations, whether employing conductive epoxy, other adhesives or conventional solder material. The secondary operations include applying the material as well as subsequently curing the epoxy or reflowing the solder. The present invention completely eliminates these expensive and time consuming secondary operations, as will be understood from the following detailed description. In particular, referring to Figure 2, an electronic device, generally designated 22, is illustrated for establishing an electrical connection between a generally round terminal pin 24 and a flat flexible circuit, generally designated 26. The flat flexible circuit includes a flat dielectric substrate 28 which initially is provided with a prepunched, generally round hole 30 of a given diameter. Substrate 28 is less than 1.27mm (0.050 inch) thick. A ductile conductive film or flat conductor 32 is deposited on substrate 28 in an area at least about hole 30. When used herein and in the claims hereof, the term "round" to describe the cross-sectional configuration of terminal pin 24 and the configuration of hole 30 is not meant to be limited to a precise circular pin or hole. For instance, an elliptical pin may be inserted in a corresponding elliptial hole as long as the minor and major axes of the two elliptical configurations are aligned. In addition, although Figure 1 shows only a single pin inserted into a single hole, the invention is applicable in multi-circuit electronic devices including a plurality of pins inserted individually or simultaneously into a corresponding plurality of holes in flat flexible circuit 26. The invention contemplates that both terminal pin 24 and conductive film 32 be plated with a particular conductive material. For instance, conductive film 32 may be of copper material and be plated with a tin/lead alloy. Correspondingly, terminal pin 24 is plated with a similar tin/lead alloy, preferably to form a similar metal interface. Of course, other alloys, such as tin/nickel alloy, can be used. Another preferred feature of the invention is to apply a lubricant to terminal pin 24 prior to inserting the pin into the hole in the flat flexible circuit. The lubricant is shown schematically by dotted lines, at 34. The lubricant eliminates or at least reduced "fretting corrosion" which is created by oxides formed when two metals rub together. With a tin/lead interface, an appropriate lubricant would be a polyphenol ether. The lubricant also eases the insertion of the pin in the direction of arrow "B", as well as minimizing skiving or flaking of the plating material. As stated above, flat flexible dielectric substrate 28 is less than 1.27mm (0.050 inch) thick. The substrate may be of various materials, but a polyamide material marketed by DuPont Corporation under the trademark KAPTON has proven effective. Other materials, such as a polyester material marketed under the trademark MYLAR also could be used. Hole 30 in the flat flexible substrate is preformed, such as being prepunched, in order to prevent the substrate material from tearing or "running" when a pin of a diameter larger than the diameter of the hole is inserted into the hole. The invention contemplates the use of a principle which may be called a "controlled meniscus", as indicated at 36 in Figure 2. In other words, in order to eliminate the use of solder, epoxies and the like, a particular interference is established between terminal pin 24 and flat flexible circuit 26 in curved area 36 which, in essence, is a deformed peripheral area of the circuit which applies normal forces to the terminal pin in the direction of arrows "C" when the pin is inserted in the direction of arrow "B". It has been found that this area and the interference forces are controlled by controlling the relative diameters of terminal pin 24 and hole 30. In actual practice, it has been found that good electrical connections can be maintained when the difference between the diameter of terminal pin 24 and the diameter of hole 30 is on the order of 5% to 50% of the diameter of the hole. This could be termed the "interference" parameter. In actual practice, using this relationship, the following experimental results have been found: Pin Diameter (x) Hole Diameter (y) Interference x-y 2.032mm (.080 inch) 1.575mm (.062 inch) 29% y 1.524mm (.060 inch) 1.27mm (.050 inch) 20% 1.016mm (.040 inch) .071mm (.028 inch) 43% 1.016mm (.040 inch) .787mm (.031 inch) 29% 1.016mm (.040 inch) .889mm (.035 inch) 14% 1.016mm (.040 inch) .965mm (.038 inch) 5% These interference levels were maintained with substrate 28 being a polyamide film of either 0.127mm (0.005 inch) thick or 0.05mm (0.002 inch) thick, and with a 28.35 grams (one ounce) copper film 32 having a tin/lead plating. By maintaining parameters similar to that outlined above, it has been found that secondary operations such as soldering the terminal pin to the flat conductor of the flat flexible circuit, or using epoxy or other adhesives between the pin and the flexible circuit can be completely eliminated and still maintain a good electrical connection between the pin and the flat conductor of the flexible circuit.

Claims: An electrical or electronical interconnection device (22) for establishing a connection between a generally round terminal pin (24) and a flat flexible circuit (26), comprising: a flat flexible dielectric substrate (28) having a hole (30) in it; a ductile conductive film (32) on the substrate (28) in an area at least about said hole (30); wherein said terminal pin (24) is inserted into the hole (30) in the substrate (28) in contact with the conductive film (32), characterized in that i) said flat flexible dielectric substrate (28) is less than 1.27 mm (0.050 inch) thick, said hole (30) in it is generally round and being a prepunched hole of a given diameter; ii) said terminal pin (24) has a given diameter greater than that of the hole (30); iii) said electrical or electronical interconnection device establishes an electrical connection directly between the terminal pin (24) and the ductile conductive film (32) without the use of solder or conductive adhesives; and iv) the difference between the diameter of the pin (24) and the diameter of the hole (30) is a particular difference in the order of 5% to 50% of the diameter of the hole according to the controlled meniscus principle, and a particular interference is established between terminal pin (24) and flat flexible circuit (26). The device of claim 1, wherein said substrate (28) is fabricated of polyamide material. The device of claim 1, wherein said substrate (28) is fabricated of polyester material. The device of any of claims 1 to 3, wherein said ductile conductive film (32) is plated with a conductive material. The device of any of claims 1 to 4, wherein said terminal pin (24) is plated with a conductive material. The device of claim 4 and 5, wherein said ductile conductive film (32) and said terminal pin (24) are plated with a common conductive plating material. The device of any of claims 1 to 6, wherein said ductile conductive film (32) is fabricated of copper. The device of any of claims 4 to 7, wherein said ductile conductive film (32) is plated with a tin/lead alloy. The device of any of claims 5 to 8, wherein said terminal pin (24) is plated with a tin/lead alloy. The device of any of claims 1 to 9 including a lubricant (34) applied to the terminal pin (24). The device of claim 10, wherein the lubricant (34) is at least in the area of contact to the conductive film (32). The device of any of claims 1 to 11, wherein said ductile conductive film (32) is of a conductive thick film material.

Inventors: FUERST ROBERT M, KREHBIEL FRED LOVE, FUERST, ROBERT M., KREHBIEL, FRED LOVE
Applicants: MOLEX INC, MOLEX INCORPORATED
Application year: 1995
Main classification: H01R12
IPC codes: H05K3, H01R13, H05K1, H01R12