BackToBasics: Wire Bonding in PCBs

You would have seen those black blobs in PCBs in those cheap mass-manufactured toys. It’s called a Chip on Board(COB).

COBs are placed on the PCBs via Wire Bonding. Wire bonding is a solid-phase welding process that joins a thin wire and pad surface. Now a COB is usually a chip with just the bare silicon die with exposed metal pads. This means that the plastic packaging that you find in most ICs which makes it a packaging style of QFN, TFQP, etc is missing. The metal pads on the die are connected via wire bonding directly to the PCB pads. Pour some black epoxy for strength and there you have a full COB on a PCB. It always need not be black epoxy, for SMD RGB LEDs if you look carefully you will see wire bonding used to connect the die to the package, and then the clear epoxy is poured to act as a lens to focus light.

Wire bonding can be done using Gold, Copper, or Aluminium wires based on requirements with Gold having good conductivity, resistance to oxidation, and good malleability to create strong bonds. But they are expensive. Copper or Aluminium is used when price is a concern. The wires are extremely thin with diameters in 10s of micrometers. To bond the wire on the pad you have different techniques like thermocompression bonding(using high heat and pressure to bond), ultrasonic bonding(Ultrasonic vibration to excite the spot to bond), or thermosonic(which is a combination of the above two methods).

Now Why wirebond on PCBs? Why not just use the chip as it is with the plastic package and solder it? The answer lies in the cost. For extremely large volume manufacturing, you can get the manufacturer to just give you the bare dies at a much cheaper cost than that with a package. Now wirebonding + die is cheaper than having a package. This is the reason why you see them a lot in dirt-cheap products. Another reason is that the actual die is usually much smaller than the plastic package, so for extremely small products it makes sense to do die + wirebonding to save a few mm of space in the PCB area.

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TechExplained: The Black Dots on the Windshields

I was flying a couple of times this week and got a window seat on the flight. When gazing out at the world below I noticed something similar I had to work on for a project some time back. Ever wondered why you see a black coating around the edges of plane windows or even on car windshields? The interesting part is not the black border, but the series of black dots around its periphery. It’s a little-known fact I thought I’d share with you all.



These black dots, are known as the “frits”. The frit is a ceramic/enamel paint that is baked into the glass edges at high temperatures. It’s incredibly tough and cannot be scraped off or damaged by UV rays. The black band in the frit helps the windshield glass stick to the window frame and hides the black adhesive used to stick the glass panel. It protects the adhesive from UV exposure and makes the adhesive last longer.

Now why do you need a black dot matrix all around it? You might also notice that the dots become less dense as they move inwards. It’s just a clever mechanism to distribute heat evenly from the edges while the glass is bent into shape. Less dense means, a smoother temperature gradient and you won’t have a sharp edge for the temperature gradient for the glass to crack at that edge. Dots are just a way to keep that gradient. Remember more black color always absorbs more heat.

So, the next time you see those black dots, you’ll know they’re not just for decoration. Tiny engineering details make all the difference!

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