Patent ID: 7909228

Claim:
A method of ultrasonically bonding a flexible conductive ribbon material, the method comprising the steps of: (a) providing a bonding tool having a bond foot, the bond foot defining a plurality of protrusions extending from a surface of the bond foot, the bond foot also defining a plurality of grooves between the protrusions, the grooves having a depth defined by the protrusions and the surface, the depth of the grooves being at least 100 μm, a width of the grooves at an end of the bonding tool being greater than a width of the protrusions at the end of the bonding tool; (b) forming a bond between a flexible conductive ribbon material and an underlying surface, the step of forming the bond including depressing the bonding tool into the flexible conductive ribbon material to a depth that exceeds the depth of the grooves; (c) feeding a length of the flexible conductive ribbon material, that is continuous with the bond between the flexible conductive ribbon material and the underlying surface, toward a bonding location; and (d) forming a bond between the flexible conductive ribbon material and the bonding location.