Ultrasonic welding system and ultrasonic welding electrode for ultrasonic welding system

Abstract

The utility model provides an ultrasonic welding electrode which is configured to be used in an ultrasonic welding system. The sonotrode includes a body portion terminating in a tip portion, the tip portion including a working surface. The working surface defines an aperture configured to retain a conductive stitch during an ultrasonic welding process. The working surface also defines a plurality of rectilinear recesses. Each of the plurality of rectilinear recesses follows a path that does not intersect the aperture.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefits of U.S. Provisional Application No. 63 / 565,931, filed March 15, 2024, and U.S. Provisional Application No. 63 / 669,740, filed July 11, 2024, the contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to ultrasonic welding, and more particularly to an improved ultrasonic welding electrode for use in ultrasonic welding systems (such as ultrasonic welding systems for welding conductive pins). Background Technology

[0004] Ultrasonic energy is widely used to form interconnects between two or more materials. For example, wire bonders (e.g., ball bonders, wedge bonders, strip bonders) are used to bond leads or strips to a bonding location. Wire bonding / joining utilizes relatively low levels of energy (e.g., bond force, ultrasonic energy, etc.). An exemplary wire bonder is sold by Kulickeand Soffa Industries, Inc., Ford, Washington, Pennsylvania.

[0005] Specific applications involve joining materials other than leads. Welding has been considered for such applications. Ultrasonic welding is also a widely used technique. Ultrasonic welding can use an ultrasonic transducer (e.g., a carrier ultrasonic welding electrode) to convert electrical energy into mechanical motion / scratching (e.g., linear motion / scratching, torsional motion / scratching, etc.). However, existing ultrasonic welding technologies and equipment are limited in their ability to provide solutions that meet market demands in terms of cost, operational efficiency, flexibility, portability, and related factors.

[0006] The following U.S. patents assigned to Kulicke and Soffa Industries are: U.S. Patent No. 10,882,134 (titled "Ultrasonic Welding Systems and Methods of Using the Same"), U.S. Patent No. 11,364,565 (titled "Ultrasonic Welding Systems and Methods of Using the Same"), U.S. Patent No. 11,850,676 (titled "Ultrasonic Welding Systems, Methods of Using the Same, and Related Workpieces Including Welded Conductive Pins"), U.S. Patent No. 12,070,814 (titled "Ultrasonic Welding Systems, Methods of Using the Same, and Related Workpieces Including Welded Conductive Pins"), and U.S. Patent Application Publication No. 2024 / 0359255 (titled "Ultrasonic Welding Systems, Methods of Using the Same, and Related Workpieces Including Welded Conductive Pins"). The following patents, namely U.S. Patent Application Publication No. 2024 / 0351132 (titled “Ultrasonic Welding Systems for Conductive Pins, and Related Methods”) and International Patent Publication No. WO2024 / 0220203 (titled “Ultrasonic Welding Systems, Sonotrodes and Conductive Pins for Such Systems, and Related Methods and Workpieces”), relate to improvements in ultrasonic welding technology and are incorporated herein by reference in their entirety.

[0007] Further improvements are still needed for specific applications of ultrasonic welding, including ultrasonic pin welding. For example, in ultrasonic pin welding, the unwelded material of the conductive pin can form undesirable "whiskers" (e.g., long strands of unwelded material), which can cause short circuits in the workpiece. Therefore, it is desirable to provide improved ultrasonic welding electrodes and ultrasonic welding systems incorporating such electrodes, configured for use in conjunction with ultrasonic pin welding. Utility Model Content

[0008] According to an exemplary embodiment of the present invention, an ultrasonic welding electrode configured for use in an ultrasonic welding system is provided. The ultrasonic welding electrode includes a body portion terminating at a tip, the tip portion including a working surface. The working surface defines an aperture configured to hold conductive pins during the ultrasonic welding process. The working surface also defines a plurality of linear recesses. Each of the plurality of linear recesses follows a path that does not intersect with the aperture.

[0009] According to other embodiments of the present invention, the ultrasonic welding electrode described in the preceding paragraph may have any one or more of the following features: each of a plurality of straight recesses extends across a working surface; the plurality of straight recesses collectively define a star-shaped pattern; the plurality of straight recesses collectively define a plurality of V-shaped patterns surrounding a peripheral portion of the working surface; the working surface includes a smooth portion, and the plurality of straight recesses are disposed around a peripheral portion of the working surface; the working surface also defines an annular recess between the edge of the hole and the working surface; the body portion and the tip portion are formed from a single piece of material; the body portion and the tip portion are separate pieces coupled together; the tip portion includes a chamfered portion between the working surface and the terminating end of the ultrasonic welding electrode; and / or the chamfered portion is configured to align the conductive pins relative to the hole in conjunction with the ultrasonic welding process.

[0010] According to another exemplary embodiment of the present invention, an ultrasonic welding electrode configured for use in an ultrasonic welding system is provided. The ultrasonic welding electrode includes a body portion terminating at a terminal portion, the terminal portion including a working surface. The working surface defines an aperture configured to retain conductive pins during the ultrasonic welding process. The working surface defines an annular recess between the aperture and an edge of the working surface.

[0011] According to other embodiments of the present invention, the ultrasonic welding electrode described in the preceding paragraph may have any one or more of the following features: the working surface includes a rough portion; the working surface includes a patterned portion; the working surface includes a plurality of recesses; the plurality of recesses are a plurality of straight grooves; the plurality of straight grooves are arranged in a certain pattern; the body portion and the tip portion are formed from a single piece of material; the body portion and the tip portion are separate pieces coupled together; the tip portion includes a chamfered portion between the working surface and the terminating end of the ultrasonic welding electrode; and / or the chamfered portion is configured to align the conductive pins relative to the hole in conjunction with the ultrasonic welding process.

[0012] According to another exemplary embodiment of the present invention, an ultrasonic welding electrode configured for use in an ultrasonic welding system is provided. The ultrasonic welding electrode includes a body portion terminating at a terminal portion, the terminal portion including a working surface. The working surface defines an aperture configured to hold conductive pins during the ultrasonic welding process. The ultrasonic welding electrode defines a cavity adjacent to the working surface. The cavity is defined by the working surface and peripheral walls. The pin tips of the conductive pins are configured to be received by the cavity.

[0013] According to other embodiments of the present invention, the ultrasonic welding electrode described in the preceding paragraph may have any one or more of the following features: a peripheral wall is a circular wall surrounding a working surface; the peripheral wall extends perpendicularly from the working surface; the peripheral wall is configured to mitigate (e.g., reduce, prevent) material outflow generated by the ultrasonic welding process; the working surface includes a rough portion; the working surface includes a patterned portion; the working surface includes a plurality of straight grooves; the plurality of straight grooves are arranged in a pattern; the working surface includes a plurality of protrusions; the plurality of protrusions are laser-etched protrusions; the plurality of protrusions are arranged in a plurality of concentric rings, each of the plurality of concentric rings including a portion of the plurality of protrusions; the body portion and the terminal portion are formed from a single piece of material; the body portion and the terminal portion are separate pieces coupled together; the peripheral wall is a chamfered wall between the working surface and the terminating end of the ultrasonic welding electrode; and / or the chamfered wall is configured to align the conductive pins relative to the hole in conjunction with the ultrasonic welding process.

[0014] According to other embodiments of the present invention, an ultrasonic welding system is provided, which includes the features described in the preceding six paragraphs and the features disclosed in this application (e.g., a support structure configured to support a workpiece, a welding head assembly including an ultrasonic transducer for carrying an ultrasonic welding electrode, etc.) and / or any combination of other features within the scope of the present invention. Attached Figure Description

[0015] The present invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It should be emphasized that, by convention, the various features in the drawings are not drawn to scale. Instead, for clarity, the dimensions of the various parts have been arbitrarily expanded or reduced. The drawings include the following illustrations:

[0016] Figures 1A to 1B This is a cross-sectional block diagram side view of various parts of the ultrasonic welding electrode related to ultrasonic welding operations according to various exemplary embodiments of the present invention.

[0017] Figures 1C to 1E This is based on various exemplary embodiments of the present invention. Figures 1A to 1BEnd view of the working surface of the ultrasonic welding electrode, including various alternative working surfaces;

[0018] Figures 2A to 2B This is a cross-sectional block diagram side view of various parts of the ultrasonic welding electrode related to ultrasonic welding operations according to various exemplary embodiments of the present invention.

[0019] Figures 2C to 2D This is based on various exemplary embodiments of the present invention. Figures 2A to 2B End view of the working surface of the ultrasonic welding electrode, including various alternative working surfaces;

[0020] Figure 3A This is a cross-sectional block side view of a portion of an ultrasonic welding electrode related to an ultrasonic welding operation, according to an exemplary embodiment of the present invention.

[0021] Figure 3B yes Figure 3A A detailed cross-sectional block diagram side view of a portion of an ultrasonic welding electrode;

[0022] Figure 3C This is an exemplary embodiment of the present invention, including a replacement working surface. Figure 3A End view of the ultrasonic welding electrode;

[0023] Figure 3D This is a perspective view of the distal portion of another ultrasonic welding electrode in relation to an ultrasonic welding operation, according to an exemplary embodiment of the present invention.

[0024] Figure 3E yes Figure 3D An end view of the distal portion of an ultrasonic welding electrode;

[0025] Figure 3F yes Figure 3E A detailed view of a portion;

[0026] Figure 3G This is a perspective view of the distal portion of another ultrasonic welding electrode in relation to an ultrasonic welding operation, according to an exemplary embodiment of the present invention.

[0027] Figure 3H yes Figure 3G An end view of the distal portion of the ultrasonic welding electrode; and

[0028] Figure 4 According to various exemplary embodiments of the present invention, it includes an ultrasonic welding electrode (e.g., is) Figures 1A to 1E , Figures 2A to 2D and Figures 3A to 3H A block diagram side view of an ultrasonic welding system (one or more of the ultrasonic welding electrodes shown). Detailed Implementation

[0029] This document describes an ultrasonic welding electrode used in conjunction with an ultrasonic welding system (e.g., configured to ultrasonically weld conductive pins to a workpiece, for example, by a torsional motion). Specific exemplary embodiments of the ultrasonic welding electrode disclosed herein offer particular advantages in mitigating unwelded material (e.g., of conductive pins) generated during specific ultrasonic welding operations (e.g., pin welding operations). In certain applications, unwelded material can form undesirable “whiskers,” which can be described as strands (e.g., long strands) of unwelded material generated during ultrasonic welding operations. Such “whiskers” can lead to undesirable results, such as causing short circuits in the welded workpiece and / or nearby electronic components (e.g., semiconductor elements). According to specific exemplary embodiments of the present invention, an ultrasonic welding electrode is provided that reduces excess weld material (which can typically form undesirable “whiskers”) (e.g., by capturing with an annular recess, capturing with a peripheral wall, minimizing the length of any whiskers, and / or any whiskers within the weld portion substantially encompassing the conductive pins).

[0030] As used herein, the term "conductive pin" is intended to refer to any conductive structure intended to be welded (e.g., ultrasonically welded) to a workpiece. A conductive pin may have a free end (after welding to the workpiece), and the body portion of the conductive pin may extend substantially vertically from the "welded" end to the free end. The cross-section of a conductive pin may be circular, square, rectangular, or have any desired cross-section. The term conductive pin should also be interpreted as including conductive sockets or sleeves (e.g., having a tubular shape such as a rivet) wherein the conductive socket / sleeve is ultrasonically welded to the workpiece and configured to receive another conductive element.

[0031] As used herein, “periphery” is intended to be interpreted broadly as meaning, for example, the outer boundary or surface of an ultrasonic welding electrode, or at or near such a boundary or surface. Similarly, “circumference” and “circumferential” are intended to refer to the perimeter of a shape, such as a circle, ellipse, rectangle, and / or any other geometry.

[0032] As used herein, “ring” is intended to be interpreted broadly as a circular shape (e.g., circle, ring, annular shape, toroidal, ellipse, oval, etc.) surrounding a point (e.g., a hole). It should be understood that, in certain embodiments, within the scope of this invention, any other polygon and / or geometry surrounding a central point may be referred to as “ring”.

[0033] Now refer to the attached diagram, Figure 1A The diagram shows a configuration for use in an ultrasonic welding system (e.g., Figure 4This is a portion of an ultrasonic welding electrode 100 of an ultrasonic welding system 400. The ultrasonic welding electrode 100 is shown in conjunction with an ultrasonic welding operation, wherein conductive pins 104 are welded to a workpiece 106 (e.g., a substrate, semiconductor device, power module, etc.) supported by a support structure 120 (e.g., the ultrasonic welding system). The ultrasonic welding electrode 100 is configured to ultrasonically weld the conductive pins 104 to the workpiece 106 during a welding process / procedure (e.g., an ultrasonic welding process, an ultrasonic welding operation, etc.). The conductive pins 104 are shown as including a body portion 104a and a head portion 104b. The ultrasonic welding electrode 100 includes a body portion 102, which includes a tip portion 102a, wherein the tip portion 102a includes a working surface 102b. The working surface 102b defines an edge 102d (e.g., a circumferential edge, an annular edge, etc.) and also (at least partially) defines a hole 102c. Hole 102c (and / or body portion 102a) is configured to retain conductive pin 104 during the ultrasonic welding process (e.g., by providing sufficient space for conductive pin 104 during the ultrasonic welding process).

[0034] Figure 1B A portion of an ultrasonic welding electrode 100' (including a body portion 102' terminating at a terminal portion 102a') is shown, the ultrasonic welding electrode being configured for use in an ultrasonic welding system (e.g., Figure 4 The ultrasonic welding system 400). The ultrasonic welding electrode 100' is similar to... Figure 1A The ultrasonic welding electrode 100, in addition to the ultrasonic welding electrode 100' including a terminal portion 102a' replacing the terminal portion 102a, also includes a hole 102c' and an edge 102d' replacing the hole 102c and the edge 102d. It should be understood that the same reference numerals denote the same elements. The terminal portion 102a' includes a working surface 102b', a chamfered portion 102e (e.g., a tapered portion, a rounded portion, etc.), and a terminating end 102f (e.g., a surface parallel to the working surface 102b', a non-contact portion, a portion surrounding at least a portion of the conductive pin 104, etc.). The chamfered portion 102e is shown between the working surface 102b' and the terminating end 102f. As shown, when the ultrasonic welding electrode 100' is used to weld the conductive pin 104, the portion of the head portion 104b that contacts the chamfered portion 102e deforms (e.g., is crushed). The chamfered portion 102e can be configured to align the conductive pin 104 relative to the hole 102c' in conjunction with the ultrasonic welding process (e.g., in the presence of a vacuum section in the ultrasonic welding electrode, the pin can become aligned by engaging with the peripheral wall). The chamfered portion 102e provides specific benefits when used in conjunction with ultrasonic welding operations, such as: providing a centering function (e.g., alignment) when engaging the conductive pin 104 with the ultrasonic welding electrode 100'; providing a function for collecting excess material (e.g., "whiskers"); and so on.

[0035] It should be understood that Figures 1A to 1B The possible occurrences have been omitted. Figures 1C to 1E Specific elements in the text. For example, elements omitted. Figure 1D The annular recess 102b2a, although such a component can be applied to Figures 1A to 1B The example shown.

[0036] Figures 1C to 1E Working surfaces, namely working surface 102b1, working surface 102b2, and working surface 102b3, which can be disposed on embodiments of ultrasonic welding electrode 100 and / or ultrasonic welding electrode 100', are shown respectively. It should be understood that certain repeated or redundant reference numerals may be omitted for clarity.

[0037] For details, please refer to the following: Figure 1C The diagram shows a working surface 102b1. The working surface 102b1 defines a plurality of linear recesses 102b1n (thirty-two (32) linear recesses 102b1n are shown in the exemplary illustration). Each of the plurality of linear recesses 102b1n (e.g., a plurality of grooves) follows a path (e.g., a straight path) that does not intersect with holes 102c, 102c'. Although each of the plurality of linear recesses 102b1n is shown as substantially tangent to holes 102c, 102c', it should be understood that each of the plurality of linear recesses 102b1n can be positioned anywhere (e.g., not tangent to holes 102c, 102c') as long as the path of each of the plurality of linear recesses 102b1n does not intersect with holes 102c, 102c'.

[0038] exist Figure 1C In the illustrated embodiment, each of the plurality of straight recesses 102b1n extends across the working surface 102b1. The plurality of straight recesses 102b1n collectively define a star-shaped polygon (e.g., a regular star-shaped polygon) and / or a star pattern. It should be understood that, in certain embodiments, the plurality of recesses disposed on the working surface may not be straight (e.g., wherein the path of each recess is defined by a curve or parabola that does not intersect with the holes 102c, 102c').

[0039] Now for reference Figure 1D The diagram shows a working surface 102b2. Working surface 102b2 is similar to working surface 102b1 in many respects. Working surface 102b2 defines a plurality of straight recesses 102b2n (note that specific reference numerals are omitted for clarity). Working surface 102b2 also defines holes 102c, 102c' and the outer edges of working surface 102b2 (e.g., ...). Figure 1A Edge 102d, Figure 2BThe annular recess 102b2a is defined near the peripheral portion 110 between the edges 102d' and 102d'.

[0040] Now for reference Figure 1E The diagram shows a working surface 102b3. The working surface 102b3 defines a plurality of linear recesses 102b3n (note that specific reference numerals are omitted for clarity). Each of the plurality of linear recesses 102b3n may be a groove.

[0041] Each of the plurality of straight recesses 102b3n follows a path that does not intersect with holes 102c, 102c′ (e.g., a straight path of an extended straight recess 102b3n). As shown, the plurality of straight recesses 102b3n includes a plurality of angular shapes 108n disposed around the peripheral portion 110 of the working surface 102b3. Each of the plurality of angular shapes 108n is shown as a “V” pattern. Thus, a plurality of fan-shaped patterns 112n (e.g., wedge shapes) are disposed around the peripheral portion 110 of the working surface 102b3. The working surface 102b3 includes a smooth portion 114 (where the plurality of straight recesses 102b3n are disposed around the peripheral portion 110). It should be understood that the smooth portion 114 can be rough, which may be appropriate in ultrasonic welding applications. The smooth portion 114 can be defined as an area without any straight recesses.

[0042] In a particular embodiment, the working surface 102b3 may also define another recess, such as an annular recess, between the holes 102c, 102c' and the outer edges (e.g., edges 102d, 102d') of the working surface 102b3 (e.g., see [link to relevant documentation]). Figure 1D (102b2a) of annular recess.

[0043] exist Figure 1E In an exemplary embodiment, the plurality of straight recesses 102b3n are discontinuous (e.g., extending from one end / edge of the working surface 102b3 to the other end / edge of the working surface 102b3). Although Figures 1C to 1E The straight recessed portion is shown as a straight line or line segment, but the present invention is not limited thereto. For example, it is conceivable that curves (e.g., curve segments, curves, ellipses, parabolas, etc.) that do not pass through holes 102c and 102c' can be used in certain embodiments. In addition, other recessed portions, such as circular recessed portions, serrated recessed portions, etc., are conceivable.

[0044] Now for reference Figure 2A This illustrates a configuration for use in an ultrasonic welding system (e.g., Figure 4A portion of the ultrasonic welding electrode 200 of the ultrasonic welding system 400 (including the body portion 202 terminating at the tip portion 202a). The ultrasonic welding electrode 200 is substantially similar to the ultrasonic welding electrode 100 (where identical elements have the same reference numerals or reference numerals beginning with "2" instead of "1"), except that the ultrasonic welding electrode 200 includes an annular recess 202b2a. Figures 1A to 1E The description of such components applies to the ultrasonic welding electrode 200 (unless otherwise explicitly or implicitly indicated) and is therefore omitted for brevity. The body portion 202 defines the working surface 202b, the hole 202c, and the edge 202d.

[0045] Now for reference Figure 2B This illustrates a configuration for use in an ultrasonic welding system (e.g., Figure 4 A portion of the ultrasonic welding electrode 200' of the ultrasonic welding system 400 (including the body portion 202' terminating at the tip portion 202a'). Except that the ultrasonic welding electrode 200' includes an annular recess 202b2a, the ultrasonic welding electrode 200' is substantially similar to the ultrasonic welding electrode 100' (or the reference numerals beginning with "2" instead of "1"). Figures 1A to 1E The description of such components applies to the ultrasonic welding electrode 200' (unless otherwise explicitly or implicitly indicated) and is therefore omitted for brevity. The body portion 202' defines the working surface 202b', the hole 202c', the edge 202d', the chamfered portion 202e, and the terminating end 202f (e.g., the surface parallel to the working surface 202b', the non-contact portion, the portion surrounding at least a portion of the conductive pin 104, etc.).

[0046] Figures 2C to 2D Working surfaces, namely working surface 202b1 and working surface 202b3, that can be disposed on embodiments of ultrasonic welding electrode 200 and / or ultrasonic welding electrode 200' are shown respectively. It should be understood that certain repeated or redundant reference numerals may be omitted for clarity.

[0047] Now for reference Figure 2C The diagram illustrates a working surface 202b1. The working surface 202b1 defines an annular recess 202b2a between holes 202c, 202c' and the outer edges (e.g., edges 202d, 202d') of the working surface 202b1. The working surface 202b1 includes a patterned portion 202b2, which includes a plurality of recesses 202b2n. In a particular embodiment, the plurality of recesses 202b2n are a plurality of straight grooves arranged in a pattern (e.g., a grid pattern, a diamond pattern, a "waffle" pattern, etc.).

[0048] In certain embodiments, a rough portion may be used instead of (and / or except for) the patterned portion 202b2. Such embodiments are... Figure 2D As shown in the image. Figure 2D A working surface 202b3 including a rough portion 202b4 is shown. In a particular embodiment, at least a portion of the rough portion 202b4 will have an average surface roughness between: 0.01 μm and 100 μm; 0.05 μm and 5 μm; and / or 0.1 μm and 1 μm.

[0049] refer to Figures 2C to 2D It should be understood that the described working surface applies to the region from the annular recess 202b2a to the holes 202c, 202c'. The region radially outward from the annular recess 202b2a can vary based on specific embodiments, as shown by the dashed circle.

[0050] Now for reference Figure 3A This illustrates a configuration for use in an ultrasonic welding system (e.g., Figure 4 This is part of the ultrasonic welding electrode 300 of the ultrasonic welding system 400. The ultrasonic welding electrode 300 is similar in certain respects to ultrasonic welding electrodes 100, 100', 200, and 200', wherein the same elements have the same reference numerals (or reference numerals beginning with "3" instead of "1" or "2"). Combined Figures 1A to 1E and Figures 2A to 2D The description of such components applies to ultrasonic welding electrode 300 (unless otherwise explicitly or implicitly indicated) and is therefore omitted for the sake of brevity.

[0051] The ultrasonic welding electrode 300 is configured to ultrasonically weld conductive pins 104 to a workpiece 106 during a welding process (e.g., an ultrasonic welding process). The conductive pins 104 are shown as including a body portion 104a and a head portion 104b. The ultrasonic welding electrode 300 includes a body portion 302 terminating at a tip portion 302a, wherein the tip portion 302a includes a working surface 302b. The tip portion 302a defines a peripheral wall 302e (e.g., an inner circumferential edge) and also defines a hole 302c. The hole 302c (and / or the body portion 302) is configured to retain the conductive pins 104 during the ultrasonic welding process.

[0052] An ultrasonic welding electrode 300 defines a cavity 302h adjacent to (e.g., perpendicular to) a working surface 302b. The cavity 302h is defined (at least partially) by the working surface 302b and a peripheral wall 302e (e.g., including one or more annular edges). A head portion 104b (e.g., a pin head) of a conductive pin 104 may be configured to be received by the cavity 302h (e.g., configured such that the head portion 104b fits within the dimensions of the cavity 302h). A terminal portion 302a includes a circumferential portion 302g (e.g., a substantially annular element) extending radially outward from the working surface 302b, wherein the circumferential portion 302g is partially defined by a peripheral wall 302e, an edge 302d, and a termination end 302f. The cavity 302h, the peripheral wall 302e, and / or the circumferential portion 302g are configured to mitigate the outflow of material 316 (e.g., material removed from the conductive pin 104, whisker-forming material, metal fragments, etc.) generated during the formation of the weld.

[0053] More specifically, the circumferential portion 302g (including the peripheral wall 302e) can serve as a structural barrier to mitigate the growth of whiskers. Whiskers can be accommodated by using the ultrasonic welding electrode 300, including the circumferential portion 302g surrounding the head portion 104b of the conductive pin 104.

[0054] Now for reference Figure 3B A detailed view of a portion of the ultrasonic welding electrode 300 is shown. As shown, the cavity 302h, peripheral wall 302e, and / or circumferential portion 302g are configured (e.g., via a protruding length “L” extending from a portion of the working surface 302b) to reduce the flow of material 316 from the weld portion formed during the welding process (e.g., the ultrasonic welding process). Thus, in a particular embodiment, the working surface 302b may define any friction-inducing features sufficient for ultrasonic welding operations (e.g., besides...). Figure 3C The patterned portion 302b1 shown is outside of or replaces the patterned portion.

[0055] The working surface 302b of the ultrasonic welding electrode 300 can have any of a variety of configurations as needed (e.g., including straight recesses, patterned portions, rough portions, smooth portions, etc.). Now refer to Figure 3CThe example shown illustrates, in more detail, the working surface 302b' of the ultrasonic welding electrode 300 (e.g., an exemplary embodiment of the working surface 302b). The working surface 302b' includes a patterned portion 302b1. In a particular embodiment, the working surface 302b' may include a plurality of recesses 302b1n (e.g., a plurality of linear grooves). The plurality of recesses 302b1n (e.g., linear grooves) may be arranged in a pattern (e.g., a grid pattern). It should be understood that the plurality of recesses 302b1n (e.g., linear grooves) may be arranged in any pattern (e.g., rectangular, rhomboid, pyramidal, or any other pattern). In a particular embodiment, the working surface 302b may include a roughened portion instead of (at least a portion of) the patterned portion 302b1 (e.g., see [reference needed]). Figure 2D The rough part (202b4).

[0056] Now for reference Figures 3D to 3F The example shown illustrates the working surface 302b of an ultrasonic welding electrode 300′ (e.g., an exemplary embodiment of the ultrasonic welding electrode 300). Figure 3A An exemplary embodiment of the working surface 302b). The ultrasonic welding electrode 300' is similar to the ultrasonic welding electrode 300 in many respects, wherein the same elements have the same reference numerals. In the illustrated embodiment, the terminating end 302f' is significantly larger / wider than the terminating end 302f of the ultrasonic welding electrode 300, which may be useful in certain applications (e.g., providing additional torsional strength / stiffness for the ultrasonic welding electrode 300'). The working surface 302b" includes a plurality of protrusions 320 (e.g., pyramidal protrusions, serrated protrusions, or any other desired shape) and cavities between the protrusions, which are disposed between the peripheral walls 302e' and the holes 302c' of the cavity 302h'. The plurality of protrusions 320 may be formed, for example, using a laser (e.g., by laser scribing, etc.). Figures 3D to 3F In the illustrated embodiment, a plurality of protrusions 320 are arranged in a plurality of concentric rings 320a, 320b, and 320c. Although three concentric rings 320a, 320b, and 320c are shown, any number of concentric rings may be provided. Gap (e.g., valley) is shown between adjacent protrusions in the plurality of protrusions 320. Figure 3F As shown, gap 320a' is disposed between adjacent protrusions of a plurality of protrusions 320 in concentric ring 320a, while gap 320b' is disposed between adjacent protrusions of a plurality of protrusions 320 in concentric ring 320b, and so on. Based on (i) the placement of the protrusions of the plurality of protrusions 320 in concentric ring 320a and (ii) the placement of the protrusions of the plurality of protrusions 320 in concentric ring 320b, gap 320a' is offset from gap 320b'. Therefore, the plurality of protrusions 320 in one concentric ring (e.g., concentric ring 320a) are offset from the protrusions in adjacent concentric rings (e.g., concentric ring 320b).

[0057] Furthermore, according to specific embodiments of this utility model (including...) Figures 3D to 3F In the embodiment shown, the size of each of the plurality of protrusions 320 can increase as they are further away from the center of the working surface 302b” (e.g., further away from the hole 302c'). Reference Figures 3D to 3F The protrusions 320 in concentric ring 320b are larger than the protrusions in concentric ring 320c, and the protrusions 320 in concentric ring 320a are larger than the protrusions in concentric ring 320b.

[0058] Now for reference Figures 3G to 3H This shows a portion of the ultrasonic welding electrode 300”. The ultrasonic welding electrode 300” is substantially similar to the ultrasonic welding electrode 300’, except that a peripheral wall 302e” (e.g., a chamfered wall) is used instead of the peripheral wall 302e’, wherein the peripheral wall 302e” is angled (e.g., chamfered, tapered, etc.). Due to the angle of the peripheral wall 302e”, the area of ​​the terminating end 302f” of the ultrasonic welding electrode 300” is smaller than the area of ​​the terminating end 302f′ of the ultrasonic welding electrode 300’. The peripheral wall 302e” (e.g., a chamfered wall) can be configured to align the conductive pins (e.g., conductive pins 104) relative to the hole 302c” in conjunction with the ultrasonic welding process (e.g., in the case of a vacuum portion in the ultrasonic welding electrode, the pins can become aligned by engaging with the peripheral wall). The ultrasonic welding electrode 300” is shown as including a plurality of protrusions 320’ disposed between the peripheral wall 302e” and the hole 302c” of the cavity 302h”. The working surface 302b” of the ultrasonic welding electrode 300” is substantially similar to the working surface 302b’ of the ultrasonic welding electrode 300’.

[0059] Now for reference Figure 4 An ultrasonic welding system 400 is shown. The ultrasonic welding system 400 includes a support structure 120 configured to support one or more workpieces 106. The ultrasonic welding system 400 is shown as including an input workpiece supplier 106a (e.g., a carrier such as a magazine handler for carrying multiple workpieces) configured to carry and / or supply one or more workpieces 106, an output workpiece supplier 106b for receiving one or more workpieces 106, and a material handling system 430 configured to move the workpieces 106 between the input workpiece supplier 106a and the output workpiece supplier 106b.

[0060] The ultrasonic welding system 400 may include a vacuum unit 426 (including a vacuum conduit 426a) to extract conductive pins 104 from a conductive pin supplier (not shown). It should be understood that alternative conductive pin handling configurations (e.g., using clamping mechanisms, magnetic handling mechanisms, etc.) are contemplated within the scope of this invention. In certain applications, a camera 428 may be used to position the ultrasonic welding system 400 in conjunction with the pickup or placement of the conductive pins 104.

[0061] The ultrasonic welding system 400 includes a welding head assembly 418, which is configured along the x-axis, y-axis, z-axis and / or θ-axis of the ultrasonic welding system 400. (Axis) movement. It should be understood that not all of these axes of motion are necessary in every application. The welding head assembly 418 includes an ultrasonic transducer 422 configured to carry an ultrasonic welding electrode. More specifically, the ultrasonic welding system 400 utilizes an ultrasonic welding electrode including a body portion terminating at a working surface, wherein the working surface defines a hole configured to hold conductive pins during the ultrasonic welding process.

[0062] The ultrasonic welding electrode included in the ultrasonic welding system 400 can be any ultrasonic welding electrode within the scope of this invention, including but not limited to ultrasonic welding electrode 100 (e.g., ultrasonic welding electrode 100'), ultrasonic welding electrode 200 (e.g., 200'), ultrasonic welding electrode 300 (e.g., 300', 300") and / or any other ultrasonic welding electrode configured for use in the ultrasonic welding system 400.

[0063] It should be understood that the control system 424 can be programmed to perform the welding operation in conjunction with a given ultrasonic welding electrode used in a particular welding operation. For example, specific USG, amplitude, frequency, and / or motion profiles can be used for a particular ultrasonic welding electrode.

[0064] Various embodiments of the present invention described herein include straight recesses (e.g., such as...). Figures 1C to 1E , Figure 2C and Figure 3C (The straight recessed portion in the middle). The depth of this straight recessed portion can be, for example, between 1-1000 micrometers; between 20-500 micrometers; or between 50-100 micrometers, etc. The width of this straight recessed portion can be, for example, between 1-2000 micrometers; between 20-1000 micrometers; or between 50-200 micrometers, etc.

[0065] The various embodiments of the present invention described herein include annular recesses (e.g., such as...). Figure 1D , Figure 2A , Figure 2B , Figure 2C , Figure 2D(The annular recess in the middle). The depth of this annular recess can be, for example, between 1-1500 micrometers; between 20-600 micrometers; or between 50-200 micrometers, etc. The width of this annular recess can be, for example, between 1-2000 micrometers; between 20-1000 micrometers; or between 50-300 micrometers, etc.

[0066] Various embodiments of this invention include a chamfered portion (e.g., a chamfered section, a peripheral wall, etc.) included as part of the terminal portion. The chamfered portion defines an angle relative to a horizontal plane of the working surface. Exemplary ranges of the angle of the chamfered portion (and the angled peripheral wall) may be, for example, between 20° and 70°; between 30° and 60°; and between 40° and 50°. A given range may be selected based on the application (e.g., an application requiring alignment of the ultrasonic welding electrode with the conductive pin).

[0067] Various ultrasonic welding electrodes within the scope of this invention (including many ultrasonic welding electrodes described herein) include a body portion terminating at a terminal portion. The body portion and the terminal portion may be formed from a single piece of material (e.g., steel, stainless steel, metal alloy, etc.). Alternatively, the body portion and the terminal portion may be separate pieces coupled together (e.g., by brazing or other techniques) (e.g., see [link to relevant documentation]). Figure 1A , Figure 1B , Figure 2A , Figure 2B and Figure 3A (The relevant body portion and the terminal portion are separated by dashed lines in each of the examples). Regarding embodiments where the body portion and the terminal portion are separate pieces, examples of materials for the body portion include: steel; stainless steel; metal alloys, etc., and examples of materials for the terminal portion include: ceramic; steel; carbide materials; and / or metal alloys.

[0068] This invention relates to including various features (e.g., straight recesses, annular recesses, protrusions, etc.) at the distal portion of an ultrasonic welding electrode. These features can be formed in the distal portion using any of a variety of techniques such as laser marking, laser irradiation, and electrical discharge machining.

[0069] Although the present invention has been illustrated and described herein with reference to specific embodiments, it is not intended to be limited to the details shown. Rather, various modifications may be made to the details within the scope and equivalents of the claims without departing from the present invention.

Claims

1. An ultrasonic horn configured for use in an ultrasonic welding system, the ultrasonic horn comprising: including: a body portion terminating at a tip portion, the tip portion including a working surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the working surface further defining a plurality of linear recesses, each of the plurality of linear recesses following a path that does not intersect the hole.

2. The ultrasonic horn of claim 1, wherein, each of the plurality of linear recesses extends across the working surface.

3. The ultrasonic horn of claim 1, wherein, the plurality of linear recesses collectively define a star pattern.

4. The ultrasonic horn of claim 1, wherein, the plurality of linear recesses collectively define a plurality of V-shaped patterns around a perimeter portion of the working surface.

5. The ultrasonic horn of claim 1 wherein, the working surface includes a smooth portion, and wherein the plurality of linear recesses are disposed around the perimeter portion of the working surface.

6. The ultrasonic horn of claim 1, wherein, the working surface further defines an annular recess between the hole and an edge of the working surface.

7. The ultrasonic horn of claim 1 wherein, the body portion and the tip portion are formed from a unitary piece of material.

8. The ultrasonic horn of claim 1, wherein, the body portion and the tip portion are separate pieces that are coupled together.

9. The ultrasonic horn of claim 1, wherein, the tip portion includes a chamfered portion between the working surface and a terminating end of the ultrasonic horn.

10. The ultrasonic horn of claim 9, wherein, the chamfered portion is configured to align the conductive pin relative to the hole in conjunction with the ultrasonic welding process.

11. An ultrasonic horn configured for use in an ultrasonic welding system, the horn comprising: including: a body portion terminating at a tip portion, the tip portion including a working surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the working surface further defines an annular recess between the hole and an edge of the working surface.

12. The ultrasonic horn of claim 11, wherein, the working surface includes a roughened portion.

13. The ultrasonic horn of claim 11, wherein: the working surface includes a patterned portion.

14. The ultrasonic horn of claim 11, wherein, the working surface includes a plurality of recesses.

15. The ultrasonic horn of claim 14, wherein: the plurality of recesses are a plurality of linear grooves.

16. The ultrasonic horn of claim 15, wherein: the plurality of linear grooves are arranged in a pattern.

17. The ultrasonic horn of claim 11, wherein, the body portion and the tip portion are formed from a unitary piece of material.

18. The ultrasonic horn of claim 11, wherein, the body portion and the tip portion are separate pieces that are coupled together.

19. The ultrasonic horn of claim 11, wherein, the tip portion includes a chamfered portion between the working surface and a terminating end of the ultrasonic horn.

20. The ultrasonic horn of claim 19, wherein, the chamfered portion is configured to align the conductive pin relative to the hole in conjunction with the ultrasonic welding process.

21. An ultrasonic horn configured for use in an ultrasonic welding system, the horn comprising: including: a body portion terminating at a tip portion, the tip portion including a working surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the ultrasonic horn defines a cavity adjacent to the working surface, the cavity defined by the working surface and a perimeter wall, whereby a pin head of the conductive pin is configured to be received by the cavity.

22. The ultrasonic horn of claim 21, wherein: the perimeter wall is a circular wall around the working surface.

23. The ultrasonic horn of claim 22, wherein: the perimeter wall extends perpendicularly from the working surface.

24. The ultrasonic horn of claim 22, wherein: the perimeter wall is configured to mitigate outflow of material resulting from the ultrasonic welding process.

25. The ultrasonic horn of claim 21, wherein: the working surface includes a roughened portion.

26. The ultrasonic horn of claim 21, wherein: the working surface includes a patterned portion.

27. The ultrasonic horn of claim 21, wherein: the working surface includes a plurality of linear grooves.

28. The ultrasonic horn of claim 27, wherein: the plurality of linear grooves are arranged in a pattern.

29. The ultrasonic horn of claim 21, wherein: the working surface includes a plurality of protrusions.

30. The ultrasonic horn of claim 29, wherein: the plurality of protrusions are laser-scored protrusions.

31. The ultrasonic horn of claim 29, wherein: the plurality of protrusions are arranged in a plurality of concentric rings, each of the plurality of concentric rings including a portion of the plurality of protrusions.

32. The ultrasonic horn of claim 21, wherein: the body portion and the tip portion are formed from a unitary piece of material.

33. The ultrasonic horn of claim 21, wherein: The body portion and the tip portion are separate pieces that are coupled together.

34. The ultrasonic horn of claim 21, wherein: The perimeter wall is a chamfered wall between the work surface and a terminal end of the ultrasonic horn.

35. The ultrasonic horn of claim 34, wherein: The chamfered wall is configured to align the conductive pin relative to the hole in connection with the ultrasonic welding process.

36. An ultrasonic welding system characterized by, Comprising: a support structure configured for supporting a workpiece; and a horn assembly including an ultrasonic transducer carrying an ultrasonic horn configured for use in the ultrasonic welding system, the ultrasonic horn including a body portion terminating in a tip portion, the tip portion including a work surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the work surface further defining a plurality of linear recesses, each of the plurality of linear recesses following a path that does not intersect the hole.

37. An ultrasonic welding system characterized by, Comprising: a support structure configured for supporting a workpiece; and a horn assembly including an ultrasonic transducer carrying an ultrasonic horn configured for use in the ultrasonic welding system, the ultrasonic horn including a body portion terminating in a tip portion, the tip portion including a work surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the work surface defining an annular recess between the hole and an edge of the work surface.

38. An ultrasonic welding system characterized by, Comprising: a support structure configured for supporting a workpiece; and a horn assembly including an ultrasonic transducer carrying an ultrasonic horn configured for use in the ultrasonic welding system, the ultrasonic horn including a body portion terminating in a tip portion, the tip portion including a work surface defining a hole configured to hold a conductive pin during an ultrasonic welding process, the ultrasonic horn defining a chamber adjacent to the work surface, the chamber defined by the work surface and a perimeter wall, whereby a pin head of the conductive pin is configured to be received by the chamber.

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