An ultrasonic horn and ultrasonic welding system for ultrasonic welding of a conductive pin to a workpiece

Abstract

The utility model provides a kind of for the ultrasonic welding electrode for ultrasonic welding electrically conductive pin to workpiece.Ultrasonic welding electrode includes the body portion being configured as coupling to ultrasonic transducer.The body portion terminates at tip portion, and tip portion defines mating feature, which is configured to mate with corresponding mating feature of base portion of electrically conductive pin.Through the cooperation of mating feature and the corresponding mating feature of base portion, electrically conductive pin is oriented in predetermined configuration.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 725,093, filed November 26, 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 used in ultrasonic welding systems, such as ultrasonic welding systems for soldering conductive leads. Background Technology

[0004] Ultrasonic welding is a technique used to join conductive components. Ultrasonic welding can use an ultrasonic transducer (e.g., a welding electrode) to convert electrical energy into mechanical motion / scrubbing (e.g., linear motion / scrubbing, torsional motion / scrubbing, etc.). U.S. Patent Nos. 10,882,134 and 11,364,565, assigned to Kulicke and Soffa Industries (each entitled “ULTRASONIC WELDING SYSTEMS AND METHODS OF USING THE SAME”), relate to improvements in ultrasonic welding techniques and are incorporated herein by reference in their entirety.

[0005] The specific application of ultrasonic welding technology involves ultrasonic pin welding (where such pins are typically soldered and / or press-fitted into power modules). U.S. Patent No. 11,285,561 (titled "ULTRASONIC WELDING SYSTEMS AND METHODS OF USING THE SAME"), U.S. Patent No. 11,504,800 (titled "ULTRASONIC WELDING SYSTEMS AND METHODS OF USING THE SAME"), U.S. Patent No. 11,958,124 (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"), and U.S. Patent No. 12,070,814 (titled "ULTRASONIC WELDING SYSTEMS, METHODS OF USING THE SAME, AND RELATED WORKPIECES") U.S. Patent No. 12,377,489 (titled "ULTRASONIC WELDING SYSTEMS, METHODS OF USING THE SAME, AND RELATED WORKPIECES INCLUDING WELDED CONDUCTIVE PINS"), U.S. Patent No. 12,377,489 (titled "ULTRASONIC WELDING SYSTEMS FOR CONDUCTIVE PINS, AND RELATED METHODS"), U.S. Patent Application Publication No. 2025 / 0332654 (titled "ULTRASONIC WELDING SYSTEMS FOR CONDUCTIVE PINS, AND RELATED METHODS"), and U.S. Patent Application Publication No. 2025 / 0187103 (titled "CONDUCTIVE PINS, POWER MODULES, ULTRASONIC WELDING SYSTEMS, AND METHODS OF USING THE SAME"), U.S. Patent Application Publication No. 2025 / 0187103 (titled "CONDUCTIVE PINS, POWER MODULES, ULTRASONIC WELDING SYSTEMS, AND METHODS OF USING THE SAME"), SAME), International Patent Application Publication No.WO2024 / 220203 (titled "ULTRASONIC WELDING SYSTEMS, SONOTRODES AND CONDUCTIVE PINS FOR SUCH SYSTEMS, AND RELATED METHODS AND WORKPIECES") and U.S. Patent Application Publication No. 2025 / 0289074 ("ULTRASONIC WELDING SYSTEMS, AND SONOTRODES FOR ULTRASONIC WELDING SYSTEMS"), each assigned to Kulicke and Soffa Industries, Inc., relate to improvements in ultrasonic welding techniques related to conductive pins, and are also incorporated herein by reference in their entirety.

[0006] In practice, ultrasonic welding electrodes can be used to pick up conductive leads before ultrasonically welding them to a workpiece. During pickup and / or ultrasonic welding, the conductive leads may become misaligned and / or misoriented with respect to the ultrasonic welding electrode. Therefore, it is desirable to provide an improved ultrasonic welding electrode and an ultrasonic welding system incorporating such an electrode, configured for use in conjunction with ultrasonic lead welding. Utility Model Content

[0007] According to an exemplary embodiment of the present invention, an ultrasonic welding electrode is provided for ultrasonically welding conductive pins to a workpiece. The ultrasonic welding electrode includes a body portion configured to be coupled to an ultrasonic transducer. The body portion terminates at a terminal portion defining a mating feature configured to mate with a corresponding mating feature of a base portion of the conductive pin. Through the mating of the terminal portion-defined mating feature with the corresponding mating feature of the base portion, the conductive pin is oriented in a predetermined configuration.

[0008] According to another exemplary embodiment of the present invention, an ultrasonic welding system is provided. The ultrasonic welding system includes a support structure configured to support a workpiece and a welding head assembly. The welding head assembly includes an ultrasonic transducer and an ultrasonic welding electrode carried by the ultrasonic transducer. The ultrasonic welding electrode includes a terminal portion defining a mating feature configured to mate with a corresponding mating feature of a base portion of a conductive pin. Through the mating of the mating feature defined by the terminal portion with the corresponding mating feature of the base portion, the conductive pin is oriented in a predetermined configuration.

[0009] According to other embodiments of the present invention, the ultrasonic welding electrode and / or ultrasonic welding system described immediately following the preceding two paragraphs may have any one or more of the following features: a mating feature defined by the distal portion includes an orifice configured to mate with a corresponding mating feature of the base portion in shape; a conductive pin defines a hole at a position along its length, a predetermined configuration relating to the orientation of the hole; the conductive pin is an "L"-shaped conductive pin, a predetermined configuration relating to the orientation of the "L"-shaped conductive pin; the conductive pin is a power terminal configured for ultrasonic welding in a power module; the ultrasonic welding electrode is configured to weld the conductive pin to the workpiece using linear / straight-line motion; the mating feature defined by the distal portion includes a chamfered portion configured to guide the conductive pin to an alignment position with respect to the ultrasonic welding electrode; and the ultrasonic welding electrode is configured to weld the conductive pin to the workpiece using torsional motion.

[0010] According to another exemplary embodiment of the present invention, an ultrasonic welding electrode is provided for ultrasonically welding conductive pins to a workpiece. The ultrasonic welding electrode includes a body portion configured to be coupled to an ultrasonic transducer. The body portion terminates at a terminal portion. The terminal portion is configured to receive the conductive pins. The ultrasonic welding electrode also includes an alignment mechanism configured to align the conductive pins within a hole in the ultrasonic welding electrode.

[0011] According to another exemplary embodiment of the present invention, an ultrasonic welding system is provided. The ultrasonic welding system includes a support structure configured to support a workpiece. The ultrasonic welding system also includes a welding head assembly, the welding head assembly including an ultrasonic transducer. The ultrasonic welding system further includes an ultrasonic welding electrode carried by the ultrasonic transducer. The ultrasonic welding electrode includes a distal portion. The distal portion is configured to receive conductive pins. The ultrasonic welding electrode also includes an alignment mechanism configured to align the conductive pins within a hole in the ultrasonic welding electrode.

[0012] According to other embodiments of the present invention, the ultrasonic welding electrode and / or ultrasonic welding system described immediately following the preceding two paragraphs may have any one or more of the following features: an alignment mechanism including a first alignment tool for aligning conductive pins; an alignment mechanism including a second alignment tool for aligning conductive pins, the first alignment tool being disposed adjacent to a first lateral orifice of the ultrasonic welding electrode, and the second alignment tool being disposed adjacent to a second lateral orifice of the ultrasonic welding electrode; the first and second alignment tools being configured to be supplied with ultrasonic energy during pin alignment operations; the first and second alignment tools being configured to vibrate during pin alignment operations; the first and second alignment tools being spring-based alignment tools; the alignment mechanism being an alignment tool disposed within an orifice of the ultrasonic welding electrode, the alignment tool defining an alignment orifice configured to receive the upper tip of the conductive pin; and the conductive pin defining an orifice at a position along its length, the alignment mechanism aligning the conductive pin within the orifice by engaging with the orifice.

[0013] According to another exemplary embodiment of the present invention, a method for operating an ultrasonic welding system is provided. The method includes the steps of: (a) providing a conductive pin to an ultrasonic welding electrode of the ultrasonic welding system, the ultrasonic welding electrode including a body portion terminating at a terminal portion, the terminal portion defining a mating feature configured to mate with a corresponding mating feature of a base portion of the conductive pin; and (b) orienting the conductive pin in a predetermined configuration about the ultrasonic welding electrode by mates the mating feature defined by the terminal portion with the corresponding mating feature of the base portion.

[0014] According to other embodiments of the present invention, the method of operating the ultrasonic welding system described in the preceding paragraph may have any one or more of the following features: step (a) includes picking up a conductive pin using an ultrasonic welding electrode; the ultrasonic welding electrode picking up the conductive pin using a vacuum source; step (b) includes using a vacuum source coupled to the ultrasonic welding electrode, wherein the vacuum source assists in orienting the conductive pin in the predetermined configuration; further including step (c) after step (b) ultrasonically welding the conductive pin to a workpiece; step (c) includes ultrasonically welding the conductive pin to the workpiece using torsion welding; wherein step (c) includes using linear welding to weld the conductive pin to the workpiece. An electrical pin is ultrasonically welded to the workpiece; the mating feature defined by the distal portion includes an orifice configured to mate with a corresponding mating feature of the base portion in shape; the conductive pin defines an orifice along its length, the predetermined configuration relating to the orientation of the orifice; the conductive pin is an "L"-shaped conductive pin, the predetermined configuration relating to the orientation of the "L"-shaped conductive pin; the conductive pin is a power terminal configured for ultrasonic welding in a power module; and the mating feature defined by the distal portion includes a chamfered portion configured to guide the conductive pin to an alignment position with respect to the ultrasonic welding electrode.

[0015] According to another exemplary embodiment of the present invention, a method for operating an ultrasonic welding system is provided. The method includes the steps of: (a) providing a conductive pin to an ultrasonic welding electrode of the ultrasonic welding system, the ultrasonic welding electrode including a body portion terminating at a terminal portion, the terminal portion receiving the conductive pin; and (b) aligning the conductive pin within an orifice of the ultrasonic welding electrode at the terminal portion using an alignment mechanism.

[0016] According to other embodiments of the present invention, the method of operating the ultrasonic welding system immediately following the preceding paragraph may have any one or more of the following features: step (a) includes picking up a conductive pin using an ultrasonic welding electrode; the ultrasonic welding electrode picks up the conductive pin using a vacuum source; further includes step (c) of ultrasonically welding the conductive pin to a workpiece after step (b); step (c) includes ultrasonically welding the conductive pin to the workpiece using torsion welding; wherein step (c) includes ultrasonically welding the conductive pin to the workpiece using linear welding; the alignment mechanism includes a first alignment tool for aligning the conductive pin; the alignment mechanism includes a second alignment tool for aligning the conductive pin, the first alignment tool being disposed adjacent to a first lateral orifice of the ultrasonic welding electrode, and the second alignment tool being adjacent to a second lateral orifice of the ultrasonic welding electrode. The orifice setting; the first alignment tool and the second alignment tool are configured to be supplied with ultrasonic energy during pin alignment operation; the first alignment tool and the second alignment tool are configured to vibrate during pin alignment operation; the first alignment tool and the second alignment tool are spring-based alignment tools; the alignment mechanism is an alignment tool disposed within the orifice of the ultrasonic welding electrode, the alignment tool defining an alignment orifice, the alignment orifice being configured to receive the upper tip of the conductive pin; the conductive pin defines the orifice along its length, and step (b) includes aligning the conductive pin within the orifice of the ultrasonic welding electrode such that the orifice is arranged in a predetermined configuration; and the conductive pin is an "L"-shaped conductive pin, wherein step (b) includes aligning the conductive pin within the orifice such that the "L"-shaped conductive pin is arranged in a predetermined configuration. Attached Figure Description

[0017] The present invention can be 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 to scale. Instead, for clarity, the dimensions of the various features have been arbitrarily enlarged or reduced. The drawings include the following illustrations: Figure 1 This is a block diagram of an ultrasonic welding system according to various exemplary embodiments of the present invention; Figures 2A to 2F These are cross-sectional side and top views of an ultrasonic welding electrode and conductive pins including an alignment mechanism, according to an exemplary embodiment of the present invention. Figures 3A to 3B According to another exemplary embodiment of the present invention, it includes an alignment mechanism and Figures 2A to 2F A cross-sectional side view of another ultrasonic welding electrode of the conductive pin; Figure 4 This is according to another exemplary embodiment of the present invention. Figures 2A to 2F ultrasonic welding electrodes and Figures 2A to 2F A cross-sectional side view of the conductive pin; Figure 5A According to another exemplary embodiment of the present invention, it includes an alignment mechanism and Figures 2A to 2F A cross-sectional side view of another ultrasonic welding electrode of the conductive pin; Figure 5B yes Figure 5A A bottom view of the ultrasonic welding electrode; Figure 5C Is with Figure 5A A portion of the ultrasonic welding electrode related Figure 5A Top view of the conductive pins; Figure 6A This is a cross-sectional side view of another ultrasonic welding electrode and another conductive pin according to another exemplary embodiment of the present invention; Figure 6B yes Figure 6A A bottom view of the ultrasonic welding electrode; Figure 6C yes Figure 6A Top view of the conductive pins; Figure 7A This is a cross-sectional side view of another ultrasonic welding electrode and another conductive pin according to another exemplary embodiment of the present invention; Figure 7B yes Figure 7A A bottom view of the ultrasonic welding electrode; Figure 7C yes Figure 7A Top view of the conductive pins; Figures 8A to 8B This is a cross-sectional side view of another ultrasonic welding electrode and another conductive pin according to another exemplary embodiment of the present invention; Figures 8C to 8D yes Figures 8A to 8B Top view of the conductive pins; Figure 8E yes Figures 8A to 8B A bottom view of the ultrasonic welding electrode; Figures 9A to 9B This is a cross-sectional side view of another ultrasonic welding electrode and another conductive pin according to another exemplary embodiment of the present invention; Figures 9C to 9D yes Figures 9A to 9B Top view of the conductive pins; Figure 9E yes Figures 9A to 9B A bottom view of the ultrasonic welding electrode; Figure 10A This is a cross-sectional side view of another ultrasonic welding electrode and another conductive pin according to another exemplary embodiment of the present invention; Figure 10B yes Figure 10A A bottom view of the ultrasonic welding electrode; Figure 10Cyes Figure 10A A top view of the conductive pins; and Figures 11 to 12 This is a flowchart of various methods for operating an ultrasonic welding system according to various exemplary embodiments of the present invention. Detailed Implementation

[0018] Specific conductive pins are ideally soldered to a workpiece in a predetermined configuration. For example, conductive pins that define "holes" along their length (sometimes called "fisheye" pins) are sometimes soldered to a workpiece. After assembling the power module, these fisheye pins can be used for appropriate soldering setups. These fisheye pins can be press-fitted into feature structures on the PCB board. Therefore, the configuration of conductive pins when soldering to a workpiece is important.

[0019] In cases where the orientation of the fisheye pin and / or other conductive pins (e.g., "directional" conductive pins) is related to the orientation of the conductive pins, specific embodiments of the present invention provide an ultrasonic welding electrode that properly orients / aligns the conductive pins during (and / or after) pickup of the conductive pins by the ultrasonic welding electrode. Accordingly, when the conductive pins are ultrasonically welded to a workpiece, orientation, alignment, and / or directionality of the conductive pins (e.g., in the XY plane of the ultrasonic welding system) can be provided.

[0020] Now refer to the attached diagram, Figure 1An ultrasonic welding system 100 is shown. The ultrasonic welding system 100 includes an input workpiece supplier 102 for providing workpieces 102a1, wherein the input workpiece supplier 102 can be configured to carry multiple workpieces 102a1 (e.g., the input workpiece supplier 102 can be a carrier such as a magazine handler for carrying multiple workpieces 102a1, or other supply structures suitable for specific workpieces, etc.). Exemplary workpieces 102a1 carried by the input workpiece supplier 102 include power modules, components of power modules, lead frames, battery modules, etc. Workpieces 102a1 (via any desired transport assembly that may be included in the material handling system 104, such as a clamping assembly) are provided from the input workpiece supplier 102 to the material handling system 104. The material handling system 104 moves the workpieces 102a1 (e.g., using a conveyor assembly, using a clamping assembly, etc.) from the input workpiece supplier 102 to a support structure 106. Support structure 106 supports the workpiece (e.g., workpiece 102a1, clamped workpiece 102a2, etc.) during the welding operation. After the welding operation (described below with respect to weld head assembly 112), the now-welded workpiece 102a3 is moved from a portion of the material handling system 104 downstream of support structure 106 (e.g., using a conveyor assembly, using a clamping assembly, etc.) to output workpiece supplier 110. Output workpiece supplier 110 is configured to receive the welded workpiece 102a3 after being processed by weld head assembly 112. Output workpiece supplier 110 may be a carrier, such as a cassette transporter for carrying multiple welded workpieces 102a3, or another supply structure suitable for dedicated workpieces.

[0021] The ultrasonic welding system 100 includes a welding head assembly 112. The welding head assembly 112 includes an ultrasonic transducer 112b that carries ultrasonic welding electrodes 116 (e.g., ultrasonic welding electrodes 216, 216', 516, 616, 716, 816, 916, and 1016) and is movable along multiple substantially horizontal axes (e.g., X-axis, Y-axis, etc.). The ultrasonic welding electrodes 116 include a body portion 116a terminating in a terminal portion 116b (e.g., terminal portion 216b, 516b, 616b, 716b, 816b, 916b, and 1016b).

[0022] exist Figure 1 In the example shown, the welding head assembly 112 is configured to move along the X and Y axes of the ultrasonic welding system 100. Figure 1 In the example shown, the welding head assembly 112 is also configured along the Z-axis of the ultrasonic welding system 100 and around the ultrasonic welding system 100. axis( (Axis) movement. Not all of these axes of motion are required in every application. Using the axes of motion of the welding head assembly 112, the ultrasonic welding electrode 116 can be moved relative to the clamped workpiece 102a2 (clamp not shown) to the appropriate welding position. A camera 114 of the ultrasonic welding system 100 is also provided (where the camera may optionally be carried by the welding head assembly 112, or may be carried by another component of the ultrasonic welding system 100) for imaging operations related to alignment between the ultrasonic welding electrode 116 and the clamped workpiece 102a2, alignment of the components of the clamped workpiece 102a2 itself, and optical inspection of the weld after the welding operation.

[0023] Various types of workpieces can be welded using the ultrasonic welding system 100 (or other systems within the scope of this invention). Exemplary workpieces include power modules, lead frames, and battery modules.

[0024] According to this invention, various types of ultrasonic motion can be applied to conductors (e.g., conductive pins, signal connectors, conductive terminals, power terminals, etc.). For example, an ultrasonic welding electrode can be configured to weld the conductor to a workpiece using at least one of linear ultrasonic motion and torsional ultrasonic motion.

[0025] Some of these workpieces are configured to receive conductive pins. As used herein, the term "conductive pin" is a conductive structure intended to be soldered to a workpiece. A conductive pin may have a free end (after soldering to the workpiece), and the body portion of the conductive pin may extend substantially vertically from the "soldering" end to the free end. The cross-section of a conductive pin may be circular, square, rectangular, or have any desired cross-section. Conductive pins described herein may be "L-shaped" pins, "fisheye" pins, etc. The term conductive pin should also be interpreted as including conductive sockets or sleeves (e.g., tubular shapes) wherein the conductive socket / sleeve is ultrasonically soldered to the workpiece and configured to receive another conductive element. In a particular embodiment, a conductive pin may be a power terminal configured for ultrasonic soldering in a power module.

[0026] According to a specific exemplary embodiment of the present invention, the ultrasonic welding system 100 includes a conductive pin supplier 108 configured to provide a plurality of conductive pins 208 (e.g., although conductive pins 208 are shown, the conductive pin supplier 108 may include any pins within the scope of the present invention, such as conductive pins 608, 708, 808, 908, and 1008) for welding using an ultrasonic welding electrode 116. Exemplary configurations of the conductive pin supplier include: a grid arrangement (including columns and rows of conductive pins oriented in a manner conducive to easy pickup), a bowl feeder, a hopper, a spool, etc. Alternative configurations are contemplated. The conductive pin supplier 108 may be configured to operate in conjunction with a buffer system such that pins are fed through a staging area, ready to be picked up for welding.

[0027] The ultrasonic welding system 100, including the conductive pin supplier 108 and the ultrasonic welding electrode 116, can take various forms. More specifically, different configurations of the conductive pin supplier 108, different configurations of the ultrasonic welding electrode 116, etc., are conceivable. Exemplary configurations are shown and described herein.

[0028] Now for reference Figures 2A to 2F An ultrasonic soldering electrode 216 is shown for ultrasonically soldering conductive pin 208 to a workpiece. The ultrasonic soldering electrode 216 includes a body portion configured to couple to an ultrasonic transducer 112b (e.g., see [reference needed]). Figure 1 The body portion 116a of the ultrasonic welding electrode 216 terminates at a tip portion 216b. The tip portion 216b is configured to receive a conductive pin 208. For example, the tip portion 216b defines an aperture 216b1 for receiving the conductive pin 208. The tip portion 216b defines a working surface 216b2 for interacting with the base portion 208a of the conductive pin 208.

[0029] The distal portion 216b is shown as including lateral apertures 216b3 and 216b4. Lateral apertures 216b3 and 216b4 are configured such that an alignment tool (e.g., a directional pin) of the alignment mechanism can be disposed within lateral apertures 216b3 and 216b4 to align the conductive pin 208 within the aperture 216b1 of the ultrasonic welding electrode 216.

[0030] A conductive pin 208 is shown disposed within an ultrasonic welding electrode 216 (e.g., under vacuum using a vacuum source), such that the surface of a base portion 208a contacts the working surface 216b2 of the ultrasonic welding electrode 216. The conductive pin 208 includes a base portion 208a coupled to an elongated portion 208b. The conductive pin 208 defines an aperture 208c1 at a position along its length. Figure 2AIn the example shown, the hole 208c1 is defined by the upper end 208c of the conductive pin 208.

[0031] Now for reference Figure 2B The diagram shows a top view of the conductive pin 208 (the ultrasonic welding electrode 216 is not shown for clarity).

[0032] Now for reference Figures 2C to 2D The image shows an alignment mechanism 218 for the ultrasonic solder electrode 216. The alignment mechanism 218 is configured to align the conductive leads 208 within an aperture 216b1 by engaging with an aperture 208c1 (and / or a terminal portion 208c). The alignment mechanism 218 includes alignment tools 218a and 218b for aligning the conductive leads 208. Alignment tool 218a is disposed within a lateral aperture 216b3 of the ultrasonic solder electrode 216. Alignment tool 218b is disposed within a lateral aperture 216b4 of the ultrasonic solder electrode 216.

[0033] As shown, alignment tools 218a and 218b are brought into contact with the distal portion 208c of the conductive pin 208. In a particular embodiment, alignment tools 218a and 218b are configured to be supplied with ultrasonic energy (e.g., USG from ultrasonic transducer 112b) during pin alignment operations. In a particular embodiment, alignment tools 218a and 218b are configured to vibrate during pin alignment operations (e.g., using piezoelectric stacked actuators).

[0034] Now for reference Figures 2E to 2F The alignment mechanism 218 of the ultrasonic solder electrode 216 is shown as pushing through a hole 208c1 through the conductive pin 208, thereby rotating (e.g., ~90°), orienting, and aligning the conductive pin 208. Accordingly, the ultrasonic solder electrode 216 and / or the alignment mechanism 218 have been shown to orient the conductive pin 208 in a desired (e.g., predetermined) orientation.

[0035] Now for reference Figures 3A to 3B The ultrasonic welding electrode 216' is shown. The ultrasonic welding electrode 216' is substantially the same as the ultrasonic welding electrode 216, except that it includes an alignment mechanism 218' instead of the alignment mechanism 218 of the ultrasonic welding electrode 216. For clarity, repeated reference numerals have been omitted, and additional reference numerals have been added. Figure 1 Relevant specific reference numerals. The alignment mechanism 218' includes a spring-based alignment tool 218'a and a spring-based alignment tool 218'b (e.g., using a leaf spring). See details. Figure 3A When the conductive pin 208 is misaligned, the spring-based alignment tools 218'a and 218'b are compressed / bent. See details. Figure 3BWhen the conductive pin 208 is rotated, aligned and oriented, the spring-based alignment tool 218'a and the spring-based alignment tool 218'b are not compressed / straightened.

[0036] Now for reference Figure 4 This illustrates the ultrasonic welding electrode 216 used in conjunction with the alignment mechanism 218''. The alignment mechanism 218'' and... Figures 3A to 3B The alignment mechanism 218' is substantially the same as that of the ultrasonic welding electrode, except that the alignment mechanism 218' is not entirely supported by the ultrasonic welding electrode; instead, the alignment mechanism 218'' (including the spring-based alignment tool 218''a and the spring-based alignment tool 218''b) is supported by the ultrasonic transducer 112b of the welding head assembly 112. Therefore, it is clear that the alignment mechanism within the scope of this invention can be supported by any part of the welding head assembly 112. For clarity, repeated reference numerals have been omitted, and additional reference numerals have been added to the design. Figure 1 Related specific figure labels.

[0037] Combination Figures 2A to 2F , Figures 3A to 3B and Figure 4 Additional exemplary aspects (and uses) of the alignment tool (e.g., a directional pin) shown and described can be described as follows. After a conductive pin is introduced into an ultrasonic welding electrode (e.g., by vacuum), the alignment tool (e.g., a directional pin) can be pressed against a portion of the defined aperture (“fisheye”) of the conductive pin. Energy (e.g., ultrasonic energy, vibration, etc.) can be applied to the ultrasonic welding electrode to properly oriented the conductive pin using the alignment tool (e.g., the directional pin). After the conductive pin is properly oriented, it is welded to the workpiece. The ultrasonic welding electrode can then be lifted (e.g., after releasing the alignment tool) to retrieve another conductive pin. The alignment tool can be released before or after ultrasonically welding the conductive pin to the workpiece. The alignment tool (e.g., the directional pin) may not contact the ultrasonic welding electrode during operation and may have a rounded tip to assist in orienting the conductive pin and avoid excessive wear.

[0038] Alignment tools (e.g., directional pins) can be actuated by electric, pneumatic, air, piezoelectric, solenoid, electric motor, or any other means sufficient for the process. Alignment tools (e.g., directional pins) can be formed from hard and durable engineered materials, metals, ceramics, or combinations thereof, such as tungsten carbide. Alignment tools (e.g., directional pins) can have a durable coating or a special tip section made of a material different from the rest of the alignment tool.

[0039] Although the attached diagram shows Figures 2A to 2F , Figures 3A to 3B and Figure 4 Each of the two alignment tools is present, but the present invention is not limited thereto. A single alignment tool or more than two alignment tools are contemplated.

[0040] In a particular embodiment, ultrasonic transducer 112b can be used to provide ultrasonic energy to alignment tools (e.g., alignment tools 218a, 218b, 218'a, 218'b, 218''a, 218''b) of alignment mechanisms (e.g., alignment mechanisms 218, 218''a, 218''b) to facilitate the orientation / rotation of conductive pin 208 (e.g., to facilitate the interconnection of the alignment tool and the hole 208c1 of the upper end 208c of conductive pin 208 to help overcome friction, etc., caused by misalignment).

[0041] Now for reference Figure 5A This illustrates an ultrasonic welding electrode 516 for ultrasonically welding conductive pin 208 to a workpiece. The ultrasonic welding electrode 516 includes a body portion configured to couple to an ultrasonic transducer 112b (see, for example, [link to previous section]). Figure 1 The body portion 116a of the ultrasonic welding electrode 516 terminates in a terminal portion 516b. The terminal portion 516b is configured to receive a conductive pin 208. For example, the terminal portion 516b defines an aperture 516b1 for receiving the conductive pin 208. The aperture 516b1 may have more than one diameter along the length of the ultrasonic welding electrode 516 to accommodate different components (e.g., conductive pin 208, alignment mechanism, alignment tool, etc.). In the illustrated embodiment, the aperture 516b1 has: a first diameter configured to receive the conductive pin (e.g., conductive pin 208); and a second diameter configured to receive a portion of an alignment mechanism (e.g., alignment tool 518a). The terminal portion 516b defines a working surface 516b2 for interacting with the base portion 208a of the conductive pin 208.

[0042] The ultrasonic soldering electrode 516 includes an alignment mechanism 518. The alignment mechanism 518 includes an alignment tool 518a for aligning the conductive leads 208. The alignment tool 518a is disposed within an aperture 516b1 of the ultrasonic soldering electrode 516. The alignment tool 518a defines an alignment aperture 518b (e.g., as shown in the image). Figure 5C The gaps, spaces, openings, etc. shown are configured to receive the upper end 208c of the conductive pin 208.

[0043] Now for reference Figure 5B The image shows a bottom view of the ultrasonic welding electrode 516. Now refer to... Figure 5C The image shows a top view of a conductive pin 208 that interacts with a portion of the alignment tool 518a.

[0044] When the conductive pin 208 is provided to the ultrasonic soldering electrode 516 (e.g., the ultrasonic soldering electrode 516 uses a vacuum provided by a vacuum source to pick up the conductive pin 208), the alignment tool 518a interacts with the upper portion (e.g., the upper tip 208c) of the conductive pin 208, causing the conductive pin 208 to be oriented in a predetermined configuration. In the illustrated embodiment, the alignment tool 518a includes a first flange portion 518a1 and a second flange portion 518a2. The first flange portion 518a1 and the second flange portion 518a2 are disposed on opposite sides of the conductive pin 208 to orient the conductive pin 208 (e.g., at least a portion of the conductive pin 208, such as the upper tip 208c, can be described as being "clamped" between the first flange portion 518a1 and the second flange portion 518a2). In a particular embodiment, an ultrasonic transducer 112b may be used to provide ultrasonic energy to the alignment tool 518a to assist in orienting / rotating the conductive pin 208 (e.g., to assist in the interconnection of the alignment tool 518a and the upper end 208c of the conductive pin 208 to help overcome friction caused by misalignment, etc.).

[0045] Specific embodiments of this invention relate to mating features of the distal portion of an ultrasonic welding electrode that interact with corresponding mating features of the base portion of a conductive pin. As used herein, a “matting feature” refers to a shape, structure, or feature configured to orient a conductive pin in a predetermined configuration. For example, a predetermined configuration may involve arranging “holes” of fisheye pins such that they face a predetermined direction (e.g., at an angle in the predetermined direction). In another example, a predetermined configuration may involve arranging “L”-shaped pins such that they face a predetermined direction (e.g., at an angle in the predetermined direction).

[0046] although Figures 6A to 6C , Figures 7A to 7C , Figures 8A to 8E , Figures 9A to 9E and / or Figures 10A to 10C The various embodiments illustrated show flat or planar mating features (e.g., including chamfered mating features), but it should be understood that mating features may include curved surfaces (e.g., concave dome shapes, semi-elliptical shapes, groove shapes, conical shapes, etc.) to facilitate alignment of the mating features of the distal portion of the ultrasonic welding electrode with the corresponding mating features of the base portion of the conductive pin. It should be understood that the specific mating features described herein can be used in conjunction with vibrational energy (e.g., ultrasonic energy) and vacuum to mitigate and improve misalignment between the mating features (e.g., the distal portion of the ultrasonic welding electrode) and the corresponding mating features (e.g., the base portion of the conductive pin) before ultrasonically welding the conductive pin to the workpiece.

[0047] Now for reference Figure 6AThis illustrates an ultrasonic solder electrode 616 for ultrasonically soldering conductive pin 608 to a workpiece. The ultrasonic solder electrode 616 includes a body portion configured to couple to an ultrasonic transducer 112b (see, for example, [link to previous section]). Figure 1 The body portion 116a of the ultrasonic welding electrode 616 terminates at a tip portion 616b. The tip portion 616b is configured to receive a conductive pin 608. For example, the tip portion 616b defines an aperture 616b1 for receiving the conductive pin 608. The tip portion 616b defines a working surface 616b2 for interacting with the base portion 608a of the conductive pin 608. The tip portion 616b defines a mating feature 616b5 configured to mate with a corresponding mating feature 608a1 of the base portion 608a.

[0048] A conductive pin 608 is shown disposed within an ultrasonic soldering electrode 616 (e.g., under vacuum using a vacuum source) such that the surface of a base portion 608a contacts the working surface 616b2 of the ultrasonic soldering electrode 616. The conductive pin 608 includes a base portion 608a coupled to an elongated portion 608b. The conductive pin 608 includes an upper tip 608c defining a hole 608c1. The conductive pin 608 is oriented in a predetermined configuration by the engagement of a mating feature 616b5 of the ultrasonic soldering electrode 616 with a corresponding mating feature 608a1 of the base portion 608a. Although the mating feature 616b5 of the ultrasonic soldering electrode 616 is shown with a small gap (e.g., not flush) with the mating feature 608a1 of the base portion 608a, this gap is provided only for illustrative purposes; it should be understood that the mating features 616b5 and 608a1 are sufficiently close along their respective peripheries to provide proper alignment of the conductive pin 608.

[0049] Now for reference Figure 6B The image shows a bottom view of the ultrasonic welding electrode 616. Now refer to... Figure 6C The diagram shows a top view of conductive pin 608. In the illustrated embodiment, mating features 616b5 and 608a1 are substantially elliptical in shape and have similar (although different) dimensions.

[0050] Now for reference Figure 7A An ultrasonic soldering electrode 716 is shown for ultrasonically soldering conductive pin 708 to a workpiece. The ultrasonic soldering electrode 716 includes a body portion configured to couple to an ultrasonic transducer 112b (e.g., see [reference needed]). Figure 1The body portion 116a of the ultrasonic welding electrode 716 terminates at a tip portion 716b. The tip portion 716b is configured to receive a conductive pin 708. For example, the tip portion 716b defines an aperture 716b1 for receiving the conductive pin 708. The tip portion 716b defines a working surface 716b2 for interacting with the base portion 708a of the conductive pin 708. The tip portion 716b defines a mating feature 716b5 configured to mate with a corresponding mating feature 708a1 of the base portion 708a of the conductive pin 708.

[0051] A conductive pin 708 is shown disposed within an ultrasonic soldering electrode 716 (e.g., under vacuum using a vacuum source) such that the surface of a base portion 708a contacts the working surface 716b2 of the ultrasonic soldering electrode 716. The conductive pin 708 includes a base portion 708a coupled to an elongated portion 708b. The conductive pin 708 includes an upper tip 708c defining a hole 708c1. The conductive pin 708 is oriented in a predetermined configuration by the engagement of a mating feature 716b5 of the ultrasonic soldering electrode 716 with a corresponding mating feature 708a1 of the base portion 708a. Although the mating feature 716b5 of the ultrasonic soldering electrode 716 is shown with a small gap (e.g., not flush) with the mating feature 708a1 of the base portion 708a, this gap is provided only for illustrative purposes; it should be understood that the mating features 716b5 and 708a1 are sufficiently close along their respective peripheries to provide proper alignment of the conductive pin 708.

[0052] Now for reference Figure 7B The image shows a bottom view of the ultrasonic welding electrode 716. Now refer to... Figure 7C The diagram shows a top view of conductive pin 708. In the illustrated embodiment, mating features 716b5 and 708a1 are substantially elliptical in shape and have similar (albeit different) dimensions. Figures 6A to 6C compared to, Figures 7A to 7C The main difference between the embodiments shown is that the feature that is not the bottommost feature (i.e., see conductive pin 608) is not... Figures 6A to 6C Compared to the mating portion 608a1 on the bottommost feature, the mating feature of the conductive pin is the bottommost portion of the conductive pin (i.e., Figures 7A to 7C ).

[0053] Although conductive pins 208, 608, and 708 can be understood as assemblies of various materials (e.g., rivets, conductive sleeves, elongated pin bodies, etc.), wherein the corresponding elongated portions are generally cylindrical, the present invention is not limited thereto. For example, a conductive pin can be a monolithic material (e.g., a bent conductive material), wherein the cross-section of such a conductive pin can be generally rectangular (e.g., see conductive pins 808, 908, 1008, etc.).

[0054] Now for reference Figures 8A to 8B This illustrates an ultrasonic welding electrode 816 for ultrasonically welding conductive leads 808 (e.g., "L"-shaped conductive leads) to a workpiece. The ultrasonic welding electrode 816 includes a body portion configured to be coupled to an ultrasonic transducer 112b (e.g., see [link to original document]). Figure 1 The body portion 116a of the ultrasonic welding electrode 816 terminates at a tip portion 816b. The tip portion 816b is configured to receive a conductive pin 808. For example, the tip portion 816b defines an aperture 816b1 for receiving the conductive pin 808. The tip portion 816b defines a working surface 816b2 for interacting with the base portion 808a of the conductive pin 808. The tip portion 816b defines a mating feature 816b5 configured to mate with a corresponding mating feature 808a1 of the base portion 808a of the conductive pin 808.

[0055] A conductive pin 808 is shown disposed within an ultrasonic welding electrode 816 (e.g., under vacuum using a vacuum source), such that the surface of a base portion 808a contacts the working surface 816b2 of the ultrasonic welding electrode 816. The conductive pin 808 includes a base portion 808a coupled to an elongated portion 808b. The conductive pin 808 includes an upper tip 808c defining a hole 808c1. The conductive pin 808 is oriented in a predetermined configuration by the engagement of a mating feature 816b5 of the ultrasonic welding electrode 816 with a corresponding mating feature 808a1 of the base portion 808a.

[0056] Now for reference Figures 8C to 8D The image shows a top view of conductive pin 808 (the dimensions are arbitrarily enlarged for clarity). Now refer to... Figure 8E The image shows a bottom view of the ultrasonic welding electrode 816.

[0057] Now for reference Figures 9A to 9B This illustrates an ultrasonic welding electrode 916 for ultrasonically welding conductive leads 908 (e.g., "L"-shaped conductive leads) to a workpiece. The ultrasonic welding electrode 916 includes a body portion configured to be coupled to an ultrasonic transducer 112b (e.g., see [link to original document]). Figure 1The body portion 116a of the ultrasonic welding electrode 916 terminates at a tip portion 916b. The tip portion 916b is configured to receive a conductive pin 908. For example, the tip portion 916b defines an aperture 916b1 for receiving the conductive pin 908. The tip portion 916b defines a working surface 916b2 for interacting with the base portion 908a of the conductive pin 908. The tip portion 916b defines a mating feature 916b5 (e.g., a chamfered portion, a rounded portion, a fillet portion, etc.) configured to mate with a corresponding mating feature 908a1 of the base portion 908a of the conductive pin 908. It should be understood that although the mating feature 916b5 is shown as including a single chamfer size, combinations of chamfer sizes (e.g., large or shallow chamfers adjacent to smaller or steeper chamfers) can be used to help orient the conductive pin 908 when used with a vacuum. The mating feature 916b5 (defined by the terminal portion 916b) includes a chamfered portion configured to guide the conductive pin 908 to an alignment position with respect to the ultrasonic welding electrode 916. For example, when a vacuum is drawn through the orifice 916b1, a portion of the conductive pin 908 (e.g., the corresponding mating feature 908a1 of the base portion 908a, the edge of the base portion 908a) can be pulled against the chamfered portion to orient and / or position the conductive pin 908 within the orifice 916b1.

[0058] A conductive pin 908 is shown disposed within an ultrasonic welding electrode 916 (e.g., under vacuum using a vacuum source), such that the surface of a base portion 908a contacts the working surface 916b2 of the ultrasonic welding electrode 916. The conductive pin 908 includes a base portion 908a coupled to an elongated portion 908b. The conductive pin 908 includes an upper tip 908c. The conductive pin 908 is oriented in a predetermined configuration by the engagement of a mating feature 916b5 of the ultrasonic welding electrode 916 with a corresponding mating feature 908a1 of the base portion 908a.

[0059] Now for reference Figures 9C to 9D The diagram shows a top view of conductive pin 908 (the dimensions are arbitrarily enlarged for clarity). Now refer to... Figure 9E The image shows a bottom view of the ultrasonic welding electrode 916. Figures 9A to 9E The embodiments shown are particularly suitable for linear ultrasonic welding.

[0060] Now for reference Figure 10A An ultrasonic welding electrode 1016 is shown for ultrasonically welding conductive pin 1008 to a workpiece. The ultrasonic welding electrode 1016 includes a body portion configured to couple to an ultrasonic transducer 112b (see, for example, [link to previous section]). Figure 1The body portion 116a of the ultrasonic welding electrode 1016 terminates at a tip portion 1016b. The tip portion 1016b is configured to receive a conductive pin 1008. For example, the tip portion 1016b defines an aperture 1016b1 for receiving the conductive pin 1008. The tip portion 1016b defines a working surface 1016b2 for interacting with the base portion 1008a of the conductive pin 1008. The tip portion 1016b defines a mating feature 1016b5 configured to mate with a corresponding mating feature 1008a1 of the base portion 1008a of the conductive pin 1008.

[0061] A conductive pin 1008 is shown disposed within an ultrasonic welding electrode 1016 (e.g., under vacuum using a vacuum source), such that the surface of a base portion 1008a contacts the working surface 1016b2 of the ultrasonic welding electrode 1016. The conductive pin 1008 includes a base portion 1008a coupled to an elongated portion 1008b. The conductive pin 1008 includes an upper tip 1008c defining a hole 1008c1. The conductive pin 1008 includes a stress-relieving portion 1008d. The conductive pin 1008 is oriented in a predetermined configuration by the engagement of a mating feature 1016b5 of the ultrasonic welding electrode 1016 with a corresponding mating feature 1008a1 of the base portion 1008a.

[0062] Now for reference Figure 10B The image shows a bottom view of the ultrasonic welding electrode 1016. Now refer to... Figure 10C The diagram shows a top view of the conductive pin 1008 (the dimensions are arbitrarily enlarged for clarity).

[0063] As those skilled in the art will understand, in the accompanying drawings (e.g., in...) Figures 6A to 6C , Figures 7A to 7C , Figures 8A to 8E , Figures 9A to 9E as well as Figures 10A to 10C The shape of the corresponding mating features for the ultrasonic welding electrode and base portion has been simplified. It should be understood that, in order for the corresponding mating features to perform the function of orienting the conductive pins in a desired predetermined configuration, the mating features may have curvature and other features not shown herein.

[0064] Figures 11 to 12 This is a flowchart illustrating various methods of operating an ultrasonic welding system. As will be understood by those skilled in the art, specific steps included in the flowchart may be omitted; specific additional steps may be added; and the order of the steps may be changed from the order shown, all of which are within the scope of this invention.

[0065] Now for reference Figure 11This illustrates a method of operating an ultrasonic welding system (e.g., ultrasonic welding system 100). In step 1100, conductive leads (e.g., conductive leads 608, 708, 808, 908, and 1008) are provided to ultrasonic welding electrodes (e.g., ultrasonic welding electrodes 616, 716, 816, 916, and 1016) of the ultrasonic welding system. The ultrasonic welding electrode includes a body portion (e.g., body portion 116a) terminating in a terminal portion (e.g., terminal portion 116b, terminal portion 616b, terminal portion 716b, terminal portion 816b, terminal portion 916b, and terminal portion 1016b). The distal portion defines mating features (e.g., mating features 616b5, 716b5, 816b5, 916b5, and 1016b5), which are configured to mate with corresponding mating features (e.g., mating features 608a1, 708a1, 808a1, 908a1, and 1008a1) of the base portions of the conductive pin (e.g., base portions 608a, 708a, 808a, 908a, and 1008a1). At step 1102, the conductive pin is oriented with respect to the ultrasonic welding electrode in a predetermined configuration through the mating of the mating features with the corresponding features of the base portions. At step 1104, the conductive pin is ultrasonically welded (e.g., using torsional motion, linear motion, etc.) to the workpiece after step 1102.

[0066] Now for reference Figure 12 This illustrates a method for operating an ultrasonic welding system. At step 1200, a conductive pin (e.g., conductive pin 208) is provided to an ultrasonic welding electrode (e.g., ultrasonic welding electrode 116, ultrasonic welding electrode 216, ultrasonic welding electrode 216', ultrasonic welding electrode 516) of the ultrasonic welding system. The ultrasonic welding electrode includes a body portion (e.g., body portion 116b) terminating at a terminal portion (e.g., terminal portion 216b, terminal portion 516b). The terminal portion receives the conductive pin. At step 1202, the conductive pin is aligned within an orifice at the terminal portion of the ultrasonic welding electrode using alignment mechanisms (e.g., alignment mechanisms 218, alignment mechanisms 218', alignment mechanisms 218'', alignment mechanism 518). At step 1204, after step 1202, the conductive pin is ultrasonically welded (e.g., using torsional motion, linear motion, etc.) to a workpiece.

[0067] Although this invention has been described and illustrated 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 implications of the equivalents of the claims without departing from the invention.

Claims

1. An ultrasonic welding electrode for ultrasonically welding conductive leads to a workpiece, characterized in that, The ultrasonic welding electrode includes: The body portion, which is configured to be coupled to the ultrasound transducer, The body portion terminates at a terminal portion, the terminal portion defining a mating feature configured to mate with a corresponding mating feature of the base portion of the conductive pin, wherein the conductive pin is oriented in a predetermined configuration by mates the mating feature defined by the terminal portion with the corresponding mating feature of the base portion.

2. The ultrasonic welding electrode according to claim 1, characterized in that, The mating feature defined by the distal portion includes an orifice configured to mate with the shape of a corresponding mating feature of the base portion.

3. The ultrasonic welding electrode according to claim 1, characterized in that, The conductive pin defines a hole at a position along its length, and the predetermined configuration is related to the orientation of the hole.

4. The ultrasonic welding electrode according to claim 1, characterized in that, The conductive pin is an "L"-shaped conductive pin, and the predetermined configuration is related to the orientation of the "L"-shaped conductive pin.

5. The ultrasonic welding electrode according to claim 1, characterized in that, The conductive pins are power terminals configured for ultrasonic welding in the power module.

6. The ultrasonic welding electrode according to claim 1, characterized in that, The ultrasonic welding electrode is configured to weld the conductive pin to the workpiece using a torsional motion.

7. The ultrasonic welding electrode according to claim 1, characterized in that, The ultrasonic welding electrode is configured to weld the conductive pin to the workpiece using linear motion.

8. The ultrasonic welding electrode according to claim 1, characterized in that, The mating feature defined by the distal portion includes a chamfered portion configured to guide the conductive pin to an alignment position with respect to the ultrasonic welding electrode.

9. An ultrasonic welding system, characterized in that, include: A support structure configured to support a workpiece; Welding head assembly, the welding head assembly including an ultrasonic transducer; as well as An ultrasonic welding electrode, carried by the ultrasonic transducer, includes a terminal portion defining a mating feature configured to mate with a corresponding mating feature of a base portion of a conductive pin, wherein the conductive pin is oriented in a predetermined configuration by the mating feature mates with the corresponding feature of the base portion.

10. An ultrasonic welding electrode for ultrasonically welding conductive leads to a workpiece, characterized in that, The ultrasonic welding electrode includes: The body portion, configured to be coupled to an ultrasonic transducer, terminates at a terminal portion configured to receive the conductive pin; and An alignment mechanism configured to align the conductive pins within the orifice of the ultrasonic welding electrode.

11. The ultrasonic welding electrode according to claim 10, characterized in that, The alignment mechanism includes a first alignment tool for aligning the conductive pins.

12. The ultrasonic welding electrode according to claim 11, characterized in that, The alignment mechanism includes a second alignment tool for aligning the conductive pins, wherein the first alignment tool is disposed adjacent to a first lateral aperture of the ultrasonic welding electrode, and wherein the second alignment tool is disposed adjacent to a second lateral aperture of the ultrasonic welding electrode.

13. The ultrasonic welding electrode according to claim 12, characterized in that, The first alignment tool and the second alignment tool are configured to be supplied with ultrasonic energy during pin alignment operations.

14. The ultrasonic welding electrode according to claim 12, characterized in that, The first alignment tool and the second alignment tool are configured to vibrate during pin alignment operations.

15. The ultrasonic welding electrode according to claim 12, characterized in that, The first alignment tool and the second alignment tool are spring-based alignment tools.

16. The ultrasonic welding electrode according to claim 10, characterized in that, The alignment mechanism is an alignment tool disposed within the orifice of the ultrasonic welding electrode, the alignment tool defining an alignment orifice configured to receive the upper tip of the conductive pin.

17. The ultrasonic welding electrode according to claim 10, characterized in that, The conductive pin defines a hole at a position along its length, and the alignment mechanism aligns the conductive pin within the hole by engaging with the hole.

18. An ultrasonic welding system, characterized in that, include: A support structure configured to support a workpiece; Welding head assembly, the welding head assembly including an ultrasonic transducer; An ultrasonic welding electrode carried by the ultrasonic transducer, the ultrasonic welding electrode including a terminal portion configured to receive a conductive pin, the ultrasonic welding electrode including an alignment mechanism configured to align the conductive pin within an orifice of the ultrasonic welding electrode.

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