Tin fusion joining for robust integration of electrical components with axial leads
AssigneeGM Global Technology Operations LLC
InventorEvan J. Dawley
Life of this patent
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Abstract
A method of joining a first tin-plated electrical component to a second tin-plated electrical component, and components joined to exhibit reduced stress levels at the joined location. The method includes defining a pocket in the second component that is shaped to accept a portion of the first component, placing the portion of the first component substantially within the pocket to define an interfacial region, and using a resistance welder to both form a solid-state diffusion bond along at least a portion of the interfacial region and fill a substantial remainder of the interfacial region with melted tin plating from one or both of the first and second components.
Claims17
A method of joining a first tin-plated electrical component to a second tin-plated electrical component, the method comprising:
- defining a pocket in the second component that is shaped to accept a portion of the first component therein;
- placing the portion of the first component substantially within the pocket to define an interfacial region thereby;
- and
- forming a solid-state diffusion bond along at least a portion of the interfacial region such that at least a portion of the tin plating of both the first and second components melts to substantially fill at least another portion of the interfacial region, the forming taking place such that a reduction in a cross-sectional dimension of the portion of the first electrical component is less than if the forming did not take place in the pocket,
- wherein the reduction in the cross-sectional dimension of the portion of the first electrical component results in a truncated circle having a generally planar surface opposite a generally rounded surface, the generally rounded surface is disposed within the pocket, and the generally planar surface is parallel to an opening of the pocket.
A method of joining a first tin-plated electrical component to a second tin-plated electrical component, the method comprising:
- defining a pocket in the second component that is shaped to accept a portion of the first component therein;
- placing the portion of the first component substantially within the pocket to define an interfacial region thereby;
- and
- using a resistance welder to (a) form a solid-state diffusion bond along at least a portion of the interfacial region and (b) fill a substantial remainder of the interfacial region with melted tin plating from at least one of the first and second components,
- wherein the joining takes place such that a reduction in a cross-sectional dimension of the portion of the first electrical component is less than if the forming did not take place in the pocket, and
- wherein the reduction in the cross-sectional dimension of the portion of the first electrical component results in a truncated circle having a generally planar surface opposite a generally rounded surface, the generally rounded surface is disposed within the pocket, and the generally planar surface is parallel to an opening of the pocket.
A method of resistance welding a first tin-plated electrical component to a second tin-plated electrical component, the method comprising:
- placing an electrical lead that extends from the first component substantially within a pocket formed in the second component such that an interfacial region is defined thereby;
- and
- using a resistance welder to (a) form a solid-state diffusion bond along at least a portion of the interfacial region and (b) fill a substantial remainder of the interfacial region with melted tin plating from at least one of the first and second components,
- wherein forming the solid-state diffusion bond provides a reduction in a cross-sectional dimension of the portion of the first electrical component that is less than if the forming did not take place in the pocket, and
- wherein the reduction in the cross-sectional dimension of the portion of the first electrical component results in a truncated circle having a generally planar surface opposite a generally rounded surface, the generally rounded surface is disposed within the pocket, and the generally planar surface is parallel to an opening of the pocket.
Dependencies are inferred from the claim text.