Photo 1 Bonding with slit horn tip

The connector ( a component that provide conduction between wires and electronic components), has a metal contact area.

Corrosion/oxidation, poor soldering, and whiskers are among the defects that cause poor conductivity, insulation, and poor contact of connectors. Recently, bonding with gold plating and solderless bonding have undergone testing to in order to reduce the above defects.

When using LINK-US’s ultrasonic bonding technology using complex vibrations to bond stranded wire, since folding back does not occur due to elliptical or circular vibration trajectories, and there is no direction in the bond, vibrational energy is transferred in all directions of the XYZ axes, making it possible to bulk wires together and bond them to the lower plate material. Bulking wires at the same time as the bond reduces wire inconsistencies that can occur during bonding of stranded wire.
In addition, high-efficiency non-invasive bonding is possible, and since no folding back occurs with vibration, wire breaks can be suppressed, preventing breakage of bonds.

Photo 2. Photo after bonding (enlarged with a microscope)

Bonding tests were carried out using the following workpiece and test conditions for bonded connectors. Having no folded back vibration trajectories allowed for low-energy, non-intrusive bonding for the workpieces used in this test as well.
Additionally, the horn tip (consumable) was bonded without breaking it even with its long and narrow dimensions as shown in Photo 1.

Photo 3. Photo after tensile test (enlarged with a microscope)

A tensile test was performed after the above bonding test. The results of the tensile strength are as follows: In conclusion, bonding was successful without wire breaks in bond ends, and with the bulking of wires.
Due to the strength of the base metal being 35N and unmeasurable using a tensile test machine, we were able to obtain a bonding strength almost equal to the strength of the base metal as the base metal fracture was confirmed after removing it by hand.

If the bond between the wire and plate material used in the connector also uses complex vibrations, a slit horn tip with a geometry suitable for the workpiece can be used for low energy and non-invasive bonding.

Our horn tips can be designed to match your workpiece's geometry.
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