Method for determining and / or calibrating the cutter height of a wedge bonding machine and related wedge bonding machine

Abstract

A method for determining a cutter height of a wedge bonding apparatus is provided, the method comprising: (a) lowering a wedge bonding tool towards a surface on a wedge bonding apparatus, (b) determining a first height measurement when the wedge bonding tool contacts the surface, (c) lowering a cutter of the wedge bonding apparatus relative to the wedge bonding tool, (d) determining a second height measurement when the cutter contacts the surface, and (e) determining a cutter height using the first height measurement and the second height measurement.

Description

[Technical field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Application No. 63 / 191,286, filed May 20, 2021, the contents of which are incorporated herein by reference. [Background technology]

[0002] The present invention relates to a method for determining and / or calibrating the cutter height of a wedge bonding machine, and to an associated wedge bonding machine.

[0003] Wire and ribbon bonding using wire bonding machines has been widely adopted in the semiconductor packaging industry and other industries requiring electrical interconnects. In connection with wire and ribbon bonding operations, various types of energy (e.g., ultrasonic energy, thermosonic energy, thermocompression energy, etc.) are used to bond the end of the wire / ribbon to a first bonding location. After a first bond is formed at the first bonding location, a length of the wire / ribbon is extended to a second bonding location, and then a second bond is formed at the second bonding location. A wire loop is a structure that includes at least a first bond and a second bond.

[0004] Exemplary conductive materials used for the wire / ribbon in conventional wire bonding (eg, ball bonding, wedge bonding, ribbon bonding, etc.) include aluminum, copper, and gold, among others. Summary of the Invention [Problem to be solved by the invention]

[0005] In wedge bonding and ribbon bonding operations, after a wire structure (e.g., a wire loop) is formed, a cutter tool ("cutter") may be used to cut the wire or ribbon. Such cutters have a relative height on the wedge bonding apparatus (e.g., with respect to the wedge bonding tool). This relative height may change, for example, due to wear and / or replacement of the cutter.

[0006] It is therefore desirable to provide an improved method for determining and / or calibrating the cutter height of a wedge bonding machine. [Means for solving the problem]

[0007] A method for determining a cutter height of a wedge bonding apparatus according to an exemplary embodiment of the present invention is provided, the method comprising: (a) lowering a wedge bonding tool towards a surface on a wedge bonding apparatus, (b) determining a first height measurement when the wedge bonding tool contacts the surface, (c) lowering a cutter of the wedge bonding apparatus relative to the wedge bonding tool, (d) determining a second height measurement when the cutter contacts the surface, and (e) determining a cutter height using the first height measurement and the second height measurement.

[0008] According to another exemplary embodiment of the present invention, there is provided a method for determining a cutter height of a wedge bonding apparatus, the method comprising: (a) lowering a wedge bonding tool toward a surface on the wedge bonding apparatus, the surface being integrated with a spring assembly, (b) determining a first height measurement when the wedge bonding tool contacts the surface, (c) compressing a spring portion of the spring assembly by further lowering the wedge bonding tool after the wedge bonding tool contacts the surface, (d) after step (c), raising the wedge bonding tool and the surface while stretching the spring portion until the cutter contacts the surface, (e) determining a second height measurement when the cutter contacts the surface, and (f) determining a cutter height using the first height measurement and the second height measurement.

[0009] According to another exemplary embodiment of the present invention, there is provided a method for determining a cutter height of a wedge bonding apparatus, the method comprising: (a) lowering a wedge bonding tool toward a surface on the wedge bonding apparatus, the surface being integrated with a spring assembly, (b) compressing a spring portion of the spring assembly by further lowering the wedge bonding tool after contact between the wedge bonding tool and the surface, (c) lowering the cutter relative to the wedge bonding tool and the surface until the cutter contacts the surface, and (d) determining a height measurement when the cutter contacts the surface.

[0010] According to another exemplary embodiment of the present invention, a method for determining a cutter height of a wedge bonding apparatus is provided, the method comprising the steps of: (a) relatively moving a wedge bonding tool and at least one surface on the wedge bonding apparatus; (b) determining a first height measurement when the wedge bonding tool contacts the surface; (c) moving a cutter of the wedge bonding tool and at least one of the surfaces relatively; (d) determining a second height measurement when the cutter contacts the surface; and (e) determining a cutter height using the first height measurement and the second height measurement.

[0011] According to another exemplary embodiment of the present invention, there is provided a method for determining a cutting profile of a cutter on a wedge bonding apparatus, the method comprising: (a) determining a cutter height of the wedge bonding apparatus; and (b) determining a cutting profile of a cutter on the wedge bonding apparatus using the cutter height determined in step (a).

[0012] According to another exemplary embodiment of the present invention, a wedge bonding apparatus is provided. Such a wedge bonding apparatus includes the elements referenced above in connection with the method for determining the cutter height of the wedge bonding apparatus. Such a wedge bonding apparatus may include any other elements referenced in this application, including, for example, a load cell for detecting contact between the wedge bonding tool (and / or cutter) and a surface, an electrical detection system for detecting electrical continuity between the wedge bonding tool (and / or cutter) and the surface, a spring assembly including the surface described herein, etc. [Brief description of the drawings]

[0013] The invention is best understood from the following detailed description read in conjunction with the accompanying drawings, in which: It is emphasized that, according to common practice, the various features of the drawings are not drawn to scale. Conversely, the dimensions of the various features have been arbitrarily increased or reduced for clarity. The drawings include the following figures: [Figure 1]FIG. 1 is a block side view of a wedge bonding apparatus useful for carrying out methods associated with various exemplary embodiments of this invention. [Figures 2A-2D] 2A-2D are a series of block diagrams illustrating a method for determining a cutter height for a wedge bonding apparatus in accordance with an exemplary embodiment of the present invention. [Figure 3A-3E] 3A-3E are a series of block diagrams illustrating another method for determining cutter height for a wedge bonding apparatus in accordance with an exemplary embodiment of the present invention. [Fig. 3F-3I] 3F-3I are a series of block diagrams illustrating yet another method for determining cutter height for a wedge bonding apparatus in accordance with an exemplary embodiment of the present invention. [Figure 4A-4D] 4A-4D are a series of block diagrams illustrating yet another method for determining cutter height for a wedge bonding apparatus in accordance with an exemplary embodiment of the present invention. [Figure 5A-5D] 5A-5D are a series of block diagrams illustrating a method for determining a cutting profile for a cutter on a wedge bonding apparatus according to an exemplary embodiment of the present invention. [Figure 6] 6, 7A-7B and 8 are flow diagrams illustrating various methods for determining cutter height for a wedge bonding apparatus according to various exemplary embodiments of the present invention. [Figure 7A] 6, 7A-7B and 8 are flow diagrams illustrating various methods for determining cutter height for a wedge bonding apparatus according to various exemplary embodiments of the present invention. [Figure 7B] 6, 7A-7B and 8 are flow diagrams illustrating various methods for determining cutter height for a wedge bonding apparatus according to various exemplary embodiments of the present invention. [Figure 8] 6, 7A-7B and 8 are flow diagrams illustrating various methods for determining cutter height for a wedge bonding apparatus according to various exemplary embodiments of the present invention. [Figure 9]FIG. 9 is a flow diagram illustrating a method for determining a cutting profile for a cutter on a wedge bonding apparatus in accordance with an exemplary embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] In accordance with certain exemplary embodiments of the present invention, a method is provided for determining and / or calibrating the cutter height on a wedge bonding apparatus (e.g., the relative cutter height of the cutter to the wedge bonding tool). By precisely knowing the cutter height (e.g., which changes when the cutter is changed on the wedge bonding apparatus), the wedge bonding apparatus can be operated (e.g., programmed) to adjust to the changed value of the cutter height.

[0015] Aspects of the invention relate to determining the cutter height when changing from a previous cutter to a new cutter on a wedge bonding machine (e.g., the cutter may be considered a consumable part). According to another aspect of the invention, the cutter height can be determined at some predetermined interval.

[0016] According to certain exemplary aspects of the present invention, instead of a combined value including the distance the cutter must travel to begin cutting into the wire / ribbon surface and the depth to which the cutter cuts into the wire / ribbon (which is adjusted with every cutter blade change), an exemplary method (e.g., cutter calibration method) of the present invention separates the distance into (i) the calibrated cutter height above the bond tool (height relative to the wire / ribbon location where the cut begins) and (ii) the actual cut depth into the wire / ribbon. Such an approach allows the cut depth value to be a variable independent of the cutter. Thus, the cut depth value can be adjusted as the cutter ages.

[0017] Exemplary aspects of the invention include using applied force and / or position feedback to calibrate the cutter during setup. Such an approach is applicable to both wire and ribbon cutting processes. Examples: (i) the bond tool followed by the cutter contacts a load cell - when contact is sensed the position of the cutter is read; (ii) the bond tool followed by the cutter contacts the hard surface using the motor current of the motion control system as a feedback mechanism; (iii) the bond tool followed by the cutter contacts the hard surface using the tracking error of the motion control system as a feedback mechanism. Of course, other methods are within the scope of the invention.

[0018] Aspects of the present invention provide simplified and automated cutter height measurement and / or calibration after cutter replacement, and further eliminate operator influence in determining cutter height.

[0019] Currently, cutter height related determinations are a manual process and rely heavily on operator intervention. The inventive methods described herein involve automating cutter height determinations.

[0020] As used herein, the term "cutter height" is the distance between the contact portion of the wedge bonding tool and the tip portion of the cutter. In certain figures herein, the cutter height is labeled "RCH" (relative cutter height). The cutter height can be considered as the relative height between the cutter and the wedge bonding tool. Exemplary ranges of cutter heights determined according to embodiments of the present invention are 100-2500 microns, and 100-2500 microns, 300-1500 microns, and 400-1200 microns. Of course, different cutter height ranges are contemplated.

[0021] According to certain aspects of the present invention, a cutter cutting profile can be determined, which can utilize the cutter height determined after a cutter change on the wedge bonding apparatus. The cut profile includes the amount of cut (e.g., cut depth) that is applied in a particular application. The cut profile can also include other factors such as time and force (e.g., cut depth vs. time, force applied during cut, etc.). Another value that can be used in conjunction with determining the cut profile is the height of the portion of the wire that extends below the bonding surface of the wedge tool (see, e.g., wire in FIGS. 5B-5D).

[0022] FIG. 1 illustrates a wedge bonding apparatus 100. As described herein and understood by one of ordinary skill in the art, certain elements illustrated in FIG. 1 are optional, and not all of the apparatus elements illustrated in FIG. 1 are included in each wedge bonding apparatus of the present invention within the scope of the present invention. The wedge bonding apparatus 100 includes a machine structure 102 (e.g., a workpiece support structure, or other structure) and a contact structure 104 on the machine structure 102. The contact structure 104 includes a surface 104e, which is configured for use in connection with height measurements related to various aspects of the present application. The contact structure 104 can be a substrate or workpiece configured to be wire bonded, or a different contact structure (e.g., a calibration station or a measurement station) specifically configured for use in connection with the present invention. The contact structure 104 can vary depending on the application (see, e.g., contact structure 104' in FIGS. 2A-2D, contact structure 104'' in FIGS. 3A-3E and 3F-3I, and contact structure 104'' in FIGS. 4A-4D).

[0023] In certain embodiments of the present invention, the contact structure 104 can include other exemplary elements, such as: a force (load) sensor 104a (e.g., for determining contact between the wedge bonding tool 106 and the surface 104e and / or for determining contact between the cutter 108 and the surface 104a); an electrical continuity detector 104b (e.g., for detecting completion of an electrical circuit including the wedge bonding tool 106 and the surface 104e, for determining contact therebetween and / or for detecting completion of an electrical circuit including the cutter 108 and the surface 104e); a spring assembly 104c (see, e.g., the spring portion 150 of the spring assembly shown in Figures 3A-3E and 3F-3I); and a contact structure motion system 104d (e.g., for moving the contact structure along the Z-axis, as in Figures 4B-4D). The wedge bonding apparatus 100 also includes a bond head assembly 110 that carries the wedge bonding tool 106 (including a working end 106a having a contact surface 106a1) and the cutter 108 (including a cutter tip 108a). The bond head assembly 110 is moved along a Z-axis of the wedge bonding apparatus 100 using a Z-axis motion system 114. The cutter 108 can also be moved along the Z-axis of the wedge bonding apparatus 100 using the Z-axis motion system 114. However, a cutter Z-axis motion system 116 can optionally be included for moving the cutter along the Z-axis (alternatively to or in addition to the use of the Z-axis motion system 114). The bond head assembly 110 includes a transducer 110a and one or more of the following: a force (load) sensor 110b (e.g., for determining contact between the wedge bonding tool 106 and the surface 104e and / or for determining contact between the cutter 108 and the surface 104e), an electrical continuity detector 110c (e.g., for sensing completion of an electrical circuit including the wedge bonding tool 106 and the surface 104e, for determining contact therebetween, and / or for sensing completion of an electrical circuit including the cutter 108 and the surface 104e to determine contact therebetween), a z-axis position detector 110d (e.g., a z-axis encoder for determining a height of a portion of the z-axis motion system), an overtravel Z-axis position detector 110e (e.g., a Z-axis encoder for determining a height of a portion of the overtravel mechanism of the Z-axis motion system), an overtravel mechanism 110f. As will be appreciated by those skilled in the art, the overtravel mechanism 110f provides for independent and constant movement of the cutter relative to the wedge bonding tool. For example, as described below, the overtravel mechanism 110f allows the cutter 108 to move downwardly independent of the wedge bonding tool 106, as shown between FIG. 2C and FIG. 2D. The overtravel mechanism 110f allows the wedge bonding tool 106 to move upwardly independent of the cutter 108, as shown between FIG. 3D and FIG. 3E. The overtravel mechanism 110f allows the wedge bonding tool 106 to move independently of the cutter 108, as shown between FIG. 3H and FIG. 3I. Additionally, the overtravel mechanism 110f allows the wedge bonding tool 106 to move upwardly independent of the cutter 108, as shown between FIG. 4C and FIG. 4D. The wedge bonding apparatus 100 also includes a computer 112 (representing one or more local or remote computing systems). The computer 112 communicates with elements of the Z-axis motion system 114 and the bond head assembly 110 for data collection and control. For example, the computer 112 receives information (e.g., from an encoder) related to Z-axis height measurements that are used to determine the height of the cutter.

[0024] 2A-2D are a series of block diagrams illustrating a method for determining the cutter height of the wedge bonding apparatus 100. As shown in FIG. 2A, the wedge bonding tool 106 (only tip portion 106a is shown in FIG. 2A) and cutter 108 are positioned above the surface 104e' of the contact structure 104'. Although not fully visible in FIG. 2A, the wedge bonding tool 106 defines a groove 106b having an apex 106b1 for receiving a wire. In FIG. 2B, the wedge bonding tool 106 is lowered (e.g., using the z-axis motion system 114) toward the surface 104e'. In FIG. 2C, the contact surface 106a1 of the wedge bonding tool 106 is in contact with the surface 104e'. At this point, a first height measurement (h1) is determined (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). The cutter 108 is then lowered relative to the wedge bonding tool 106 (e.g., using the Z-axis motion system 114 and overtravel mechanism 110f). For example, the overtravel mechanism 110f (see, e.g., FIG. 1) may allow the cutter 108 to be lowered after contact as shown in FIG. 2C. In FIG. 2D, the tip portion 108a of the cutter 108 contacts the surface 104e'. A second height measurement (h2) is determined at this point (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). Using h1 and h2, the height of the cutter can be determined.

[0025] In another example, the force applied by the Z-axis motion system 114 may be interrupted such that the spring force of the spring portion 150 pushes upward. In either case, the spring portion 150 extends until the tip portion 108a of the cutter 108 contacts the surface 104e'', as shown in FIG. 3E. A second height measurement (h2) is determined at this point (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). Using h1 and h2, the height of the cutter can be determined.

[0026] In the embodiment of Figures 3A-3E, a first height measurement and a second height measurement are determined and used to provide the cutter height. However, as shown in Figures 3F-3I, in certain implementations, it is possible to measure the cutter height using a single height measurement (e.g., because a measurement, such as an overtravel measurement, may begin at a known or zero reference value). With particular reference to Figure 3F, the wedge bonding tool 106 (only tip portion 106a is shown in Figure 3A) and cutter 108 are positioned on a surface 104e'' of the contact structure 104''. Although not fully visible in Figure 3F, the wedge bonding tool defines a groove 106b having an apex 106b1 for receiving a wire. In Figure 3F, a spring assembly (including a spring portion 150) is integrated with the surface 104e''. More specifically, the spring portion 150 is provided between the contact structure 104'' and the mechanical structure 102''. In FIG. 3G, the wedge bonding tool 106 is lowered (e.g., using the z-axis motion system 114) toward the surface 104e″. In FIG. 3H, the contact surface 106a1 of the wedge bonding tool 106 contacts the surface 104e″. At this time, the wedge bonding tool 106 is further lowered to compress the spring portion 150. The cutter 108 is then lowered relative to the wedge bonding tool 106 and surface 104e″ until the tip 108a of the cutter 108 contacts the surface 104e as shown in FIG. 3I. A height measurement (h1) is determined at this point (e.g., using a z-axis position detector 110d, such as an encoder or an overtravel encoder of the z-axis motion system). This height measurement can be considered the height of the cutter or can be used to derive the height of the cutter.

[0027] 4A-4D are a series of block diagrams illustrating a method for determining a cutter height of a wedge bonding apparatus 100, the wedge bonding apparatus including a contact structure motion system 104d (see, e.g., FIG. 1) for moving a contact structure 104'''. In FIG. 4A, a wedge bonding tool 106 (only a tip portion 106a is shown in FIG. 4A) and a cutter 108 are positioned on a surface 104e''' of the contact structure 104'''. Although not fully visible in FIG. 4, the wedge bonding tool 106 defines a groove 106b having an apex 106b1 for receiving a wire. In FIG. 4B, the contact structure 104''' is raised toward the wedge bonding tool 106 (e.g., using the contact structure motion system 104d). In FIG. 3C, the contact surface 106a1 of the wedge bonding tool 106 has a contact surface 104e'''. At this point, a first height measurement (h1) is determined (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). The contact structure 104''' is then further raised while in contact with the wedge bonding tool 106 (by the overtravel mechanism 110f). That is, the contact structure 104'' is further raised using the contact structure motion system 104d until the surface 104e''' contacts the tip portion 108a of the cutter 108 (as shown in FIG. 4D). A second height measurement (h2) is determined at this point (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). Using h1 and h2, the height of the cutter can be determined.

[0028] According to the present invention, the cutter height can be used in connection with a subsequent cutting operation on a wedge bonding apparatus (e.g., in connection with a cutter depth value). In a particular example, the cutter height can be used in connection with providing a cutting profile of the cutter on the wedge bonding apparatus. Figures 5A-5D show an exemplary method of determining such a cutting profile. Figure 5A shows that the cutter height is determined (e.g., as in Figures 2A-2D, Figures 3A-3E, Figures 3F-3I, Figures 4A-4D, or using any other method including methods within the scope of the present invention).

[0029] After the height of the cutter is determined, the wire 118 is engaged with the wedge bonding tool 106. In FIG. 5B, the wedge bonding tool 106 (only a tip portion 106a is shown in FIG. 5B) and the cutter 108 are positioned over the surface 120a of the structure 120. Although not fully shown in FIG. 5B, the wedge bonding tool 106 defines a groove 106b having an apex 106b1 for receiving the wire 118. In this position, the wire 118 engages with the wire bonding tool 106. In this position, a portion of the wire 118 extends below the contact surface 106a1 of the wedge bonding tool 106. The dimension of this portion of the wire 118 in FIG. 5B is labeled as hwire in FIG. 1. In FIG. 5C, the wedge bonding tool 106 is lowered (e.g., using the z-axis motion system 114) toward the surface 120a. In FIG. 5D, the wire 118 has a contact surface 120a. At this point a height measurement is determined (e.g., using a z-axis position detector 110d, such as an encoder of the z-axis motion system). This height measurement, and the cutter height (including at least a first height measurement and a second height measurement determined in conjunction with determining the cutter height), can be used to determine the cut profile. As will be appreciated by those skilled in the art, the structure 120 (including surface 120a) shown in Figures 5B-5D can be any structure (and corresponding surface) on a wedge bonding apparatus. Indeed, if desired, the structure 120 can be a contact structure 104 and surface 120a can be a contact surface 104e (see, e.g., Figure 1).

[0030] 6-8 are flow diagrams illustrating various exemplary methods for determining the cutter height of a wedge bonding apparatus according to the present invention. FIG. 8 is a flow diagram illustrating an exemplary method for determining the cutting profile of a cutter on a wedge bonding apparatus according to the present invention. As will be appreciated by those skilled in the art, certain steps included in the flow diagrams may be omitted and certain additional steps may be added, and the order of steps may be changed from the order shown, all within the scope of the present invention.

[0031] Referring now to FIG. 6, in step 600, the wire is disengaged from the wedge bonding tool. That is, if the wire is engaged with the wedge bonding tool (e.g., under the working end of the wedge bonding tool), the wire is removed from that position. In step 602, the bond head (e.g., carrying the wedge bonding tool and cutter) is moved (e.g., using its xyz motion system) to a test position. The test position can be, for example, any desired position on the wedge bonding apparatus. In step 604, the wedge bonding tool is lowered toward a surface on the wedge bonding apparatus (see, e.g., FIG. 2B). In step 606, a first height measurement is determined when the wedge bonding tool contacts the surface (see, e.g., determining height h1 in FIG. 2C). In step 608, the cutter is lowered relative to the wedge bonding tool, and in step 610, a second height measurement is determined when the cutter contacts the surface (see, e.g., determining height h2 in FIG. 2D). In step 612, the cutter height is determined using the first height measurement and the second height measurement (eg, by taking the difference between the first height measurement and the second height measurement).

[0032] Now referring to FIG. 7A, in step 700, the wire is removed from engagement with the wedge bonding tool. That is, if the wire is engaged with the wedge bonding tool (e.g., under the working end of the wedge bonding tool), the wire is removed from that position. In step 702, the bond head (e.g., carrying the wedge bonding tool and cutter) is moved (e.g., using its xyz motion system) to a test position. The test position can be, for example, any desired position on the wedge bonding apparatus. In step 704, the wedge bonding tool is lowered toward a surface integrated with a spring assembly on the wedge bonding apparatus (see, for example, FIG. 3B). In step 706, a first height measurement is determined when the wedge bonding tool contacts the surface (see, for example, determining height h1 in FIG. 3C). In step 706, a first height measurement is determined when the wedge bonding tool contacts the surface (see, for example, determining height h1 in FIG. 3C). In step 708, the spring portion of the spring assembly is compressed by further lowering the wedge bonding tool after contact between the wedge bonding tool and the surface (see, e.g., FIG. 3D). In step 710, after step 708, the wedge bonding tool and the surface are raised while extending the spring portion until the cutter contacts the surface. In step 712, a second height measurement is determined when the cutter contacts the surface (see, e.g., determining height h2 in FIG. 3E). In step 714, the cutter height is determined using the first height measurement and the second height measurement (e.g., by determining the difference between the first height measurement and the second height measurement).

[0033] Referring to FIG. 7B, in step 750, the wire is disengaged from the wedge bonding tool. That is, if the wire is engaged with the wedge bonding tool (e.g., under the working end of the wedge bonding tool), the wire is removed from that position. In step 752, the bond head (e.g., carrying the wedge bonding tool and cutter) is moved (e.g., using its xyz motion system) to a test position. The test position can be, for example, any desired position on the wedge bonding apparatus. In step 754, the wedge bonding tool is lowered toward a surface integrated with a spring assembly on the wedge bonding apparatus (e.g., see FIG. 3G, contact in FIG. 3H). In step 756, the spring portion of the spring assembly is compressed by further lowering the wedge bonding tool after contact between the wedge bonding tool and the surface (e.g., see FIG. 3I). In step 758, the cutter is lowered relative to the wedge bonding tool and the surface until the cutter contacts the surface (e.g., also see FIG. 3I). In step 760, a height measurement is determined when the cutter contacts the surface (see, for example, height h1 in FIG. 3I). This height measurement is used to determine the height of the cutter.

[0034] Referring to FIG. 8, in step 800, the wire is removed from engagement with the wedge bonding tool. That is, if the wire is engaged with the wedge bonding tool (e.g., under the working end of the wedge bonding tool), the wire is removed from that position. In step 802, the bond head (e.g., carrying the wedge bonding tool and cutter) is moved (e.g., using its xyz motion system) to a test position. The test position can be, for example, any desired position on the wedge bonding apparatus. In step 804, at least one of the wedge bonding tool and the surface is moved relative to one another (see the movement of the wedge bonding tool 106 in FIG. 2B or the movement of the surface 104e'' in FIG. 4B). In step 806, a first height measurement is determined when the wedge bonding tool contacts the surface (see, for example, the determination of height h1 in FIG. 2C or the determination of height h1 in FIG. 4C). In step 808, at least one of the cutter and the surface is moved relative to one another (see movement of cutter 108 in FIG. 2D or movement of surface 104e'' in FIG. 4D). In step 810, a second height measurement is determined when the cutter contacts the surface (e.g., see Determining height h2 in FIG. 2D or Determining height h2 in FIG. 4D). In step 812, the cutter height is determined using the first height measurement and the second height measurement (e.g., by finding the difference between the first height measurement and the second height measurement).

[0035] Referring to FIG. 9, in step 900, the wire is removed from engagement with the wedge bonding tool. That is, if the wire is engaged with the wedge bonding tool (e.g., under the working end of the wedge bonding tool), the wire is removed from that position. In step 902, the bond head (e.g., carrying the wedge bonding tool and cutter) is moved (e.g., using its xyz motion system) to a test position. The test position can be, for example, any desired position on the wedge bonding apparatus. In step 904, a cutter height is determined on the wedge bonding apparatus. The cutter height can be determined using any technique as desired (e.g., the method of FIGS. 2A-2D, the method of FIGS. 3A-3E, the method of FIGS. 3F-3I, the method of FIGS. 4A-4D). In step 906, a cut profile is determined using the cutter height determined in step 904. Additional steps can be added. For example, the portion of the wire that extends below the wedge bonding tool (see, e.g., Figures 5B-5D) can also be used in connection with determining the cut profile. In such a case, after step 904, the wire is engaged with the wedge bonding tool (e.g., positioned below the working end of the wedge bonding tool) - essentially reversing step 900. Next, the wedge bonding tool (with the wire engaged) is lowered toward the surface on the wedge bonding apparatus (see, e.g., Figure 5C). Next, a height measurement (e.g., height in Figure 5D) is determined when the wire contacts the surface - this height measurement provides information about hwire shown in Figure 5B. With this information, the process proceeds to step 906, where the cutter's cut profile is determined using the cutter's height (e.g., at least a first height measurement h1 and a second height measurement h2) and a third height measurement (h2) of the wire). More specifically, the cutter's height and the wire can be used to determine the cut profile.

[0036] As will be appreciated by those skilled in the art, various height measurements may be shown for a given structure, but are merely exemplary. For example, in FIG. 2C, height h1 is shown for the tip portion 108a of the cutter 108. Similarly, in FIG. 2D, height h2 is shown for the tip portion 108a of the cutter 108. However, these height measurements (i.e., h1 and h2) may be taken for various structures, so long as the results allow for the determination of the cutter height (e.g., the RCH shown in FIG. 2B).

[0037] As will be appreciated by those skilled in the art, the various height measurements described herein (e.g., h1, h2, hwire, etc.) may be determined using a variety of mechanisms. In one example, a z-axis position detector 110d may be used as shown in FIG. 1 (e.g., a Z-axis encoder in a Z-axis motion system). In another example, the various height measurements described herein may be determined using an over-travel z-axis position detector 110e as shown in FIG. 1 (e.g., an encoder in an over-travel mechanism).

[0038] Although various embodiments of the present invention are illustrated with respect to a wedge bonding tool that includes a groove (e.g., groove 106b) configured to receive a wire, it is understood that the present invention is applicable to any type of wedge bonding tool (including ribbon bonding tools) with or without a groove.

[0039] Although the invention has been illustrated and described herein with reference to specific embodiments, it is not intended that the invention be limited to the details shown, but rather various modifications of the details can be made within the scope of the claims and equivalents without departing from the invention.

Claims

1. 1. A method for determining a cutter height of a wedge bonding apparatus, comprising: (a) lowering a wedge bonding tool toward a surface on the wedge bonding apparatus; (b) determining a first height measurement when the wedge bonding tool contacts the surface; (c) lowering a cutter of the wedge bonding apparatus relative to the wedge bonding tool; (d) determining a second height measurement when the cutter contacts the surface; (e) determining a cutter height using the first height measurement and the second height measurement; The method according to claim 1,

2. 2. The method of claim 1, wherein the wedge bonding tool and the cutter are carried by a bond head assembly of the wedge bonding machine, and the bond head assembly is moved along a Z-axis of the wire bonding machine using a Z-axis motion system.

3. 3. The method of claim 2, wherein the wedge bonding tool is lowered in step (a) using the Z-axis motion system.

4. 3. The method of claim 2, The method of claim 1, wherein the cutter is lowered in step (c) using the Z-axis motion system.

5. 3. The method of claim 2, The method of claim 1, wherein the cutter is lowered in step (c) using a cutter motion system different from the Z-axis motion system.

6. 3. The method of claim 2, The method, wherein each of the first height measurement and the second height measurement is determined using an encoder of the Z-axis motion system.

7. 2. The method of claim 1, The method, wherein the bond head assembly includes an overtravel mechanism so that the cutter can be lowered in step (c) after contact of the wedge bonding tool in step (b).

8. 8. The method of claim 7, The method of claim 1, wherein the first height measurement is determined using an encoder of the over-travel mechanism.

9. 8. The method of claim 7, The method of claim 1, wherein the second height measurement is determined using an encoder of the over-travel mechanism.

10. 8. The method of claim 7, wherein each of the first height measurement and the second height measurement is determined using an encoder of the over-travel mechanism.

11. 2. The method of claim 1, The method, wherein the cutter height is determined by determining a difference between the first height measurement and the second height measurement.

12. 2. The method of claim 1, The method, wherein the cutter height is used for a subsequent cutting operation with the wedge bonding apparatus.

13. 2. The method of claim 1, The method of claim 1, wherein the cutter height is used in conjunction with a cutter depth value in the wedge bonding apparatus for subsequent cutting operations.

14. 2. The method of claim 1, The method is performed in conjunction with changing from a previous cutter to the cutter on the wedge bonding apparatus.

15. 2. The method of claim 1, The method, wherein the method is performed at predetermined intervals.

16. 2. The method of claim 1, The method of claim 1, wherein step (b) determines when the wedge bonding tool contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

17. 2. The method of claim 1, The method, wherein step (d) determines when the cutter contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

18. 1. A method for determining a cutter height for a wedge bonding apparatus, comprising: (a) lowering a wedge bonding tool toward a surface on the wedge bonding apparatus, the surface being integral with a spring assembly; (b) determining a first height measurement when the wedge bonding tool contacts the surface; (c) compressing a spring portion of the spring assembly by further lowering the wedge bonding tool after the wedge bonding tool contacts the surface; and (d) after step (c), raising the wedge bonding tool and the surface while extending the spring portion until the cutter contacts the surface; (e) determining a second height measurement when the cutter contacts the surface; (f) determining a cutter height using the first height measurement and the second height measurement; The method according to claim 1,

19. 20. The method of claim 18, wherein the wedge bonding tool and the cutter are carried by a bond head assembly of the wedge bonding machine, and the bond head assembly is moved along a Z-axis of the wire bonding machine using a Z-axis motion system.

20. 20. The method of claim 19, wherein the wedge bonding tool is lowered in step (a) using the Z-axis motion system.

21. 20. The method of claim 19, wherein the cutter is lowered in step (c) using the Z-axis motion system.

22. 20. The method of claim 19, wherein the cutter is lowered in step (c) using a cutter motion system different from the Z-axis motion system.

23. 20. The method of claim 19, wherein each of the first height measurement and the second height measurement is determined using an encoder of the Z-axis motion system.

24. 20. The method of claim 18, wherein the bond head assembly includes an overtravel mechanism.

25. 25. The method of claim 24, wherein the first height measurement is determined using an encoder on the over-travel mechanism.

26. 25. The method of claim 24, wherein the second height measurement is determined using an encoder on the over-travel mechanism.

27. 25. The method of claim 24, wherein each of the first height measurement and the second height measurement is determined using an encoder of the over-travel mechanism.

28. 20. The method of claim 18, wherein the cutter height is determined by determining a difference between the first height measurement and the second height measurement.

29. 20. The method of claim 18, wherein the cutter height is used for a subsequent cutting operation on the wedge bonding machine.

30. 20. The method of claim 18, wherein the cutter height measurement is used in conjunction with a cutter depth value in the wedge bonding apparatus for a subsequent cutting operation.

31. 20. The method of claim 18, wherein the method is performed in association with changing from a previous cutter to the cutter on the wedge bonding apparatus.

32. 20. The method of claim 18, wherein the method is performed at predetermined intervals.

33. 20. The method of claim 18, wherein step (b) includes determining when the wedge bonding tool contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

34. 20. The method of claim 18, wherein step (3) includes determining when the cutter contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis axial motion system characteristic.

35. 1. A method for determining a cutter height for a wedge bonding apparatus, comprising: (a) lowering a wedge bonding tool toward a surface on the wedge bonding apparatus, the surface being integral with a spring assembly; (b) compressing a spring portion of the spring assembly by further lowering the wedge bonding tool after contact between the wedge bonding tool and the surface; (c) lowering the cutter relative to the wedge bonding tool and the surface until the cutter contacts the surface; (d) determining a height measurement when the cutter contacts the surface; The method comprising:

36. 36. The method of claim 35, wherein the wedge bonding tool and the cutter are carried by a bond head assembly of the wedge bonding machine, and the bond head assembly is moved along a Z-axis of the wire bonding machine using a Z-axis motion system.

37. 37. The method of claim 36, wherein the wedge bonding tool is lowered in step (a) using the Z-axis motion system.

38. 37. The method of claim 36, wherein the cutter is lowered in step (c) using the Z-axis motion system.

39. 37. The method of claim 36, wherein the cutter is lowered in step (c) using a cutter motion system different from the Z-axis motion system.

40. 36. The method of claim 35, The method, wherein the bond head assembly includes an overtravel mechanism.

41. 41. The method of claim 40, The method, wherein the height measurement is determined using an encoder of the over-travel mechanism.

42. 36. The method of claim 35, The method, wherein the height measurements are used in a subsequent cutting operation with the wedge bonding machine.

43. 36. The method of claim 35, wherein the cutter height measurement is used in conjunction with a cutter depth value in the wedge bonding apparatus for a subsequent cutting operation.

44. 36. The method of claim 35, The method is performed in conjunction with changing from a previous cutter to the cutter on the wedge bonding apparatus.

45. 36. The method of claim 35, wherein the method is performed at predetermined intervals.

46. 36. The method of claim 35, wherein step (3) includes determining when the cutter contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

47. 1. A method for determining a cutter height for a wedge bonding apparatus, comprising: (a) moving a wedge bonding tool and at least one of the surfaces on the wedge bonding apparatus relative to one another; (b) determining a first height measurement when the wedge bonding tool contacts the surface; (c) moving a cutter of the wedge bonding apparatus and at least one of the surfaces relative to one another; (d) determining a second height measurement when the cutter contacts the surface; (e) determining a cutter height using the first height measurement and the second height measurement; The method according to claim 1,

48. 48. The method of claim 47, wherein the wedge bonding tool and the cutter are carried by a bond head assembly of the wedge bonding machine, and the bond head assembly is moved along a Z-axis of the wire bonding machine using a Z-axis motion system.

49. 49. The method of claim 48, wherein the wedge bonding tool is lowered in step (a) using the Z-axis motion system.

50. 49. The method of claim 48, wherein the surface is elevated in step (a) using a motion system.

51. 49. The method of claim 48, wherein the cutter is lowered in step (c) using the Z-axis motion system.

52. 49. The method of claim 48, wherein the cutter is lowered in step (c) using a cutter motion system different from the Z-axis motion system.

53. 49. The method of claim 48, wherein the surface is elevated in step (c) using a motion system.

54. 49. The method of claim 48, wherein each of the first height measurement and the second height measurement is determined using an encoder of the Z-axis motion system.

55. 49. The method of claim 48, wherein the bond head assembly includes an over-travel mechanism such that the cutter can be moved relative to the surface in step (c) after contact of the wedge bonding tool in step (b).

56. 56. The method of claim 55, wherein the first height measurement is determined using an encoder on the over-travel mechanism.

57. 56. The method of claim 55, wherein the second height measurement is determined using an encoder on the over-travel mechanism.

58. 56. The method of claim 55, wherein each of the first height measurement and the second height measurement is determined using an encoder of the over-travel mechanism.

59. 49. The method of claim 48, wherein the cutter height is determined by determining a difference between the first height measurement and the second height measurement.

60. 49. The method of claim 48, wherein the cutter height is used for a subsequent cutting operation with the wedge bonding machine.

61. 49. The method of claim 48, wherein the cutter height is used in conjunction with a cutter depth value in the wedge bonding apparatus in a subsequent cutting operation.

62. 49. The method of claim 48, wherein the method is performed in association with changing from a previous cutter to the cutter on the wedge bonding apparatus.

63. 49. The method of claim 48, wherein the method is performed at predetermined intervals.

64. 49. The method of claim 48, wherein step (b) includes determining when the wedge bonding tool contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

65. 49. The method of claim 48, wherein step (d) includes determining when the cutter contacts the surface using at least one of a load cell, an electrical continuity connection, and a Z-axis motion system characteristic.

66. 1. A method for determining a cutting profile for a cutter on a wedge bonding apparatus, comprising: (a) determining a cutter height of the wedge bonding apparatus; (b) determining a cutting profile for a cutter on the wedge bonding apparatus using the cutter height determined in step (a); and The method according to claim 1,

67. 67. The method of claim 66, further comprising determining a dimension of a wire that extends below a bonding surface of a wedge bonding tool, and step (b) comprises using the dimension in connection with determining the cut profile.

68. 67. The method of claim 66, wherein step (a) comprises: (a1) lowering a wedge bonding tool toward a surface of the wedge bonding apparatus; (a2) determining a first height measurement when the wedge bonding tool contacts the surface; (a3) lowering the cutter of the wedge bonding apparatus relative to the wedge bonding tool; (a4) determining a second height measurement when the cutter contacts the surface; (a5) determining a cutter height using the first height measurement and the second height measurement; and The method of claim 1,

69. 67. The method of claim 66, wherein step (a) comprises: (a1) moving a wedge bonding tool towards a surface on the wedge bonding apparatus, the surface being integral with a spring assembly; (a2) determining a first height measurement when the wedge bonding tool contacts the surface; (a3) compressing a spring portion of the spring assembly by further lowering the wedge bonding tool after contact between the wedge bonding tool and the surface; and (a4) after step (a3), raising the wedge bonding tool and the surface while stretching the spring portion until the cutter contacts the surface; (a5) determining a second height measurement when the cutter contacts the surface; (a6) determining a cutter height using the first height measurement and the second height measurement.

70. 67. The method of claim 66, wherein step (a) comprises: (a1) moving at least one of a wedge bonding tool and a surface on the wedge bonding apparatus relative to one another; (a2) determining a first height measurement when the wedge bonding tool contacts the surface; (a3) moving at least one of a cutter of the wedge bonding apparatus and the surface relative to one another; (a4) determining a second height measurement when the cutter contacts the surface; (a5) determining a cutter height using the first height measurement and the second height measurement; and The method of claim 1,

71. A wedge bonding apparatus comprising: a bond head assembly configured to carry a wire bonding tool and a cutter; a surface for determining the height of the cutter; A wedge bonding apparatus having:

72. 72. The wedge bonding apparatus of claim 71, wherein the surface is integral with a spring assembly for determining the height of the cutter.

73. 72. The wedge bonding apparatus of claim 71, A wedge bonding machine, wherein the surface is driven along a Z-axis of the wedge bonding machine in conjunction with determining the cutter height.

Images