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the board s plated through-hole slightly upon insertion. This is the proverbial square pin in a round hole. The lead is tapered at its end to facilitate initial PTH insertion (see Fig. 49.2). Second is the square-pin variant sometimes referred to as the H section, which consists of a sculpted rectangle, an H in cross-section, whose corners are meant to deform (see Fig. 49.3). The third and most prevalent configuration is the collapsible pin known as eye-of-theneedle (EON) (see Fig. 49.4). Upon insertion and pressing into the PTH, the EON pin folds upon itself axially in a controlled manner, as depicted in Fig. 49.5. The plated through-hole barrel is slightly deformed from the mechanical interference of the press-fit pin against it. The resultant forces from the collapsed press-fit lead against the PTH barrel wall result in stable, long-term mechanical and electrical contact.

FIGURE 49.3 H -section press-fit pin. The sculpted cross-section of the pin allows the pin to deform slightly. This deformation along with some deformation of the PTH barrel upon insertion allows for reliable mechanical and electrical contact.

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Application of MEMS and microsystems in consumer products can be seen in optical switching and fibre-optic couplings, radiofrequency switches and tunable resonators (Figure 829) [4] High frequency circuits will benefit considerably from the advent of the RF-MEMS technology Electrical components such as inductors and tunable capacitors can be significantly improved compared to their integrated counterparts if they are made using MEMS and nanotechnology With the integration of such components, the performance of communication circuits will improve, while the total circuit area, power consumption and cost will be reduced In addition, the mechanical switch, as developed by several research groups, is a key component with a huge potential in various microwave circuits [7] Fig 829: An MEMS tunable bank [4] Motorola has introduced a pressure sensor to merge signal conditioning with mechanical sensing on a single chip The pressure sensor is well suited to be applied in microprocessor-based systems that have analogue to digital inputs [9]

MAX521 #1

FIGURE 49.5 As the EON pin is driven into the PTH barrel, its compliant section collapses inward upon itself. The resultant forces between the pin and the PTH barrel wall result in a stable, intimate mechanical and electrical contact.

Proper Loading The load necessary to apply a press-fit connector depends on a variety of factors, including pin design, pin material, pin size, pin surface finish (plating), PTH surface finish, plating thickness, pin and hole size, and the number of pins per connector. The connector manufacturer should provide the required loading per pin for each connector for proper insertion and connector seating.

Correct Design and Size Press-fit connector leads are designed to work within a tight range of PTH barrel diameters.The compliant pin normal force exerted against the PWB plated through-hole barrel wall must be maximized to anchor the connector into the PWB reliably, both for mechanical stability and electrical contact. The connector manufacturers will recommend proper PTH diameter and tolerances for their products. The resultant press-fit coupling is analogous to the solder joint. If the pin and barrel are sized properly and materials are appropriately finished, the anticipated joint life will be better than that of soldered assemblies. Also if the pin and barrel are sized correctly, the pin-to-barrel normal force will be high enough to form a gas-tight seal for long-term electrical and environmental contact reliability. The pin must be strong enough longitudinally to prevent buckling during the pressing operation. Pin normal forces must be optimized so as not to

damage the PTH barrel high enough for good contact, but light enough that the pin insertion will not damage the barrel or the PWB. 49.4.3 Reproducible Connector Press Since pressing force generally ranges from some 10s of grams to kilograms per lead, the mechanical advantage of a reproducible press machine is required for press-fit connector application.

The choice of materials in the manufacture of a microsystem is determined by microfabrication constraints Microelectronics use various conductors and insulators made from inorganic materials such as silicon, silicon dioxide, silicon nitride, aluminium, tungsten and certain polymers The microfabrication of MEMS extends beyond conventional microelectronics processes, and this allows

Base Material For purposes of affordability, mechanical integrity, electrical properties, and materials conservation, all electrical contacts, regardless of assembly methodology, are made from inexpensive base metals and plated with a minimum thickness of a more precious or more practical material. Many press-fit connectors have been made of beryllium-copper alloy, but due to beryllium dust toxicity, a factor in press-fit lead preparation, the switch to safer phosphor-bronze or other copper alloys has occurred throughout the industry.

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