Amp LLC

The Whitaker Corporation

Michael J McKee

Joseph M Pawlikowski

Homer E Henschen

David T Shaffer

Ernest L Beinhaur

William E Zelko

Richard L Schaeffer, Jr

William D Miknis

Homer E Henschenp

Alexander M Sharpe

A grid array 10 of terminals 20 secured with a fusible electrically conductive material 34 usable in conjunction with a source of constant amplitude high frequency alternating current of known frequency is formed by the steps of: selecting a plurality of terminals 20 having a thin magnetic layer 30 defined thereon, transforming the terminal into a Curie point heater, each terminal 20 including a first connecting section 24 having a fusible electrically conductive material 34 disposed thereon; releasably holding each of the terminals 20 precisely positioned within an array 22 corresponding to an array 14 of circuit termini 16 of a circuit bearing article 12 such that each of the first connecting sections 24 of the terminals 20 is substantially in physical engagement with a corresponding circuit terminus 16; interposing an electrical conductor 60 connected to the source of alternating current among and adjacent each terminal 20 positioned within the array 22; subjecting each heater body to said constant current of known frequency, the heater body resultingly generating and transferring sufficient thermal energy to melt the fusible material 34 thereby electrically and mechanically interconnecting the terminals 20 to the respective circuit termini 16; and releasing the terminals 20.

Method of making a pin grid array and terminal for use therein

The jumper cable assembly 10 in accordance with the invention includes at least a first layer 12 of insulating film, an array of electrical conductors 20, each having first and second connecting portions 22,24 at opposed ends thereof and a fusible electrically conductive material disposed on the connecting portions 22,24. Each conductor 20 is formed from a first conductive layer 26 having high electrical resistance and high magnetic permeability, and a second conductive layer 28 integrally joined thereto, the second layer having low electrical resistance and minimal magnetic permeability. Each of the conductors 20 defines a heater body. Upon disposing the corresponding arrays of the first and second connecting portions 22,24 over corresponding contact pads 54,64 of the first and second electrical articles 50,60 and upon subjecting the heater bodies to the constant current of known frequency, each heater body generates and transfers sufficient thermal energy to the connecting portions to melt the fusible material thereby effecting electrical and mechanical interconnection.

Device for electrically interconnecting contact arrays

Soldering of surface mount connector terminals to contact pads on a circuit board is facilitated by configuring the terminals and their solder tails as spaced integrally-formed projections of a selectively actuable heater. Thermal energy developed in the heater is conducted along the projections to the solder tails to melt fusible conductive material (e.g., solder, at the connection sites). After cooling, the projections are severed from the heater. The terminals, which are formed at the distal ends of the projections, are typically supplied partially inserted in respective terminal-receiving passages of the connector housing. After the soldering operation, the terminals are fully inserted into the passages. The heater is preferably a self-regulating heater in the form of a copper substrate having a skin layer of magnetically permeable, high resistance material. An alternating current of constant amplitude and high frequency is passed through the heater and concentrated in the skin layer at temperatures below the Curie temperature of the skin layer material. At higher temperatures the current is distributed through the lower resistance substrate to limit further heating. During the time interval required for the surface layer to reach its Curie temperature, the resistive power dissipation creates thermal energy that is conducted to the solder tails.

Surface mount technology breakaway self regulating temperature heater

A connector (10) having one or more arrays of elongate cantilever beam arms (22) of contacts (20) can have contact sections (26) on free ends (24) thereof soldered to respective traces (94) of a circuit element (90), by securing a lead frame (50) to free ends (24) which includes a corresponding plurality of fingers (56) extending from a carrier strip (52). On the finger ends (58) are affixed preforms (80,82) 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 (20), and in a remote location later subjected to RF current to reflow solder preform (82) to join contact sections (26) to traces (94).

Method of assembling a connector to a circuit element and soldering lead

A self-regulating heater includes an electrically-conductive substrate (11), having a magnetic surface layer (13) of one skin depth, folded 180 degrees to define two heater sections joined by a fold section. The magnetic material has a considerably higher resistance than the substrate material. The surface of the two sections clad with the surface layer are in closely spaced parallel relation and connected in series by the fold section (23) such that a constant amplitude alternating energizing current flows in opposite directions through the two sections at any instant of time to thereby establish an electric field between the two heaters. The field concentrates current flow at the two facing surfaces. Depth of the current is determined by the skin effect phenomenon and increases significantly at temperatures above the Curie temperature of the magnetic material.

Generating electromagnetic fields in a self regulating temperature

Spaced contact pads (23,43,83,84) on a printed circuit board (19,45,85) are soldered to respective spaced contacts (21,41,51,81,82) in a cable (230,50) or connector assembly (40,80) by means of respective spaced connecting members (15,48,57,70,92,94,96,98,100,102,104,106) interposed between contacts to be soldered. The connecting members are typically electrically and thermally conductive finger-like projections formed as part of a heater body (10,60,55,47,91) and are readily severably from the heater body after soldering to thereby remain part of the final solder connection. A presecribed amount of fusible material (e.g., solder) is pre-deposited on the connecting members and/or contacts and is melted when the heater is actuated. The heater body may be a self-regulating heater in the form of a copper substrate (11,61,65) having a thin surface layer (13, 63,67) of magnetically permeable, high resistance alloy. An alternating current of constant amplitude and high frequency is passed through the heater body 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 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 are positioned and configured as necessary to reach their respective connection sites.

Self regulating temperature heater with thermally conductive extensions

Simultaneous solder connections of multiple electrical terminals to respective electrical leads is achieved by conducting thermal energy from an actuable heater body (10,40,50,60,70) to the multiple connection sites via the terminals (20,21,45) themselves, the terminals being formed integrally with the heater body. The terminals are scored, perforated, etc., to facilitate severence from the heater body after soldering. The preferred heater body takes the form of a copper substrate (17,27,41,51,61) having a skin depth surface layer (19,29,43,53,63,65) of magnetically-permeable, high resistance alloy. Alternating current of constant amplitude and high frequency is passed through the heater body and concentrated in the surface layer at temperatures below the Curie temperature of the alloy. For higher temperatures the current is distributed through the lower resistance substrate 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 solder that is pre-deposited on the terminals and/or leads.

Self regulating temperature heater carrier strip

A heater (20,40,50,70,80) is secured to or embedded in a circuit board (10,30,75,86) and is selectively energizable by current to melt solder in a connection or disconnection operation. The heater is spaced from circuit board contact pads (13,34) by circuit board structure material that transmits the generated thermal energy to the contact pads to melt solder or other fusible material. The heater is a self-regulating heater in the form of a copper substrate having a thin surface layer of magnetically permeable, high resistance material. An alternating current of constant amplitude and high frequency is passed through the heater and 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 to limit further heating. A current return path (21,43,53,73,85) or bus is disposed in closely-spaced parallel relation to the surface layer and establishes an electric field between the substrate and the return bus to bias current in the substrate toward the surface layer. The return bus may be embedded in the circuit board or provided as part of external tooling employed to deliver energizing current.

Self regulating temperature heater as an integral part of a printed

A heater bar assembly intended for use in a soldering apparatus or the like has a laminated self-regulating Curie effect heater mounted on a rigid support member. The heater is rapidly heated in use up to its Curie temperature and maintained at that temperature during a soldering operation so that overheating does not occur and, on the other hand, cold joints are avoided. The heater is slightly resilient, or deformable, so that when it is brought into contact with the wires, it is deformed by the wires thereby increasing the area of contact with the wires. A complete integrated soldering apparatus incorporating the heater bar assembly is also described.

Heating apparatus having Curie effect heater

A self-redulanting heater includes an electrically-conductive substrate (11), having a magnetic surface layer (13) of one skin depth, folded 180 degrees to define two heater sections joined by a fold section. The magnetic material has a considerably higher resistance than the substrate material. The surfaces of the two sections clad with the surface layer are in closely spaced parallel relation and connected in series by the fold section (23) such that a constant amplitude alternating energizing current flows in opposite directions through the two sections at any instant of time to thereby establish an electric field between the two heaters. The field concentrates current flow at the two facing surfaces. Depth of the current is determined by the skin effect phenomenon and increases significantly at temperatures above the Curie temperature of the magnetic material.

A strap comprised of a layer of magnetic material on a layer of nonmagnetic conductive metal comprises a self-regulating heater, which is wrapped around a length of heat recoverable tubing disposed around a terminal being terminated to a conductor wire, or a pair of wires being spliced. When energized, the strap generates thermal energy melting solder of a preform within the tubing, terminating the terminal to the wire, or the two wires together, and sealing the termination simultaneously. A plurality of terminals in a connector housing include solder tails extending rearwardly from the housing so that respective wire ends may be placed therealong within solder preforms within heat recoverable tubing therearound. A strap comprising a self-regulating temperature source is wrapped around the array of solder tails and wire ends and is energized to solder the array and seal the terminations. A high frequency alternating current induced in or transmitted to the magnetic layer of the strap causes the strap to generate thermal energy sufficient to melt the solder and shrink the tubing. The strap may have several layers and may be shapable to conform to the outer surfaces of the heat recoverable tubing lengths. A strap may seal an open end of a length of heat recoverable tubing having a sealant preform therewithin, when wrapped therearound and energized.

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New Cumberland, PA, United States of America

Michael J McKee