Bonding Horn and Clamper Alignment Using Mirror Hole Reflection
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Solution Overview
Problem
The existing bonding apparatuses face challenges in accurately aligning the clamper with the horn, leading to potential wire damage due to the soft nature of wires like gold, and the alignment process is operator-dependent, resulting in varying positioning accuracy.
Innovation Solution
An alignment method involving a mirror surface parallel to the bonding stage, where the mirror image of a teardrop-shaped second through hole is aligned with its center, and the clamper is adjusted to overlap the symmetry plane of the horn, ensuring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment method is used, then alignment can be completed, but positioning accuracy varies due to operator skill and alignment takes time
Solution Approach 1:
The patent uses a mirror to create an optical copy (mirror image) of the second through hole. This optical copy serves as a reference marker for alignment, replacing the need for manual measurement and positioning. The mirror image provides a visual guide that eliminates operator skill dependency and reduces alignment time while maintaining high positioning accuracy.
Solution Approach 2:
The mirror acts as an intermediary element between the operator and the alignment targets. Instead of directly measuring and aligning the through holes, the operator aligns the mirror image with the actual hole, using the mirror as a mediating tool that simplifies the alignment process and improves consistency.
2Ease of operation
If manual alignment is performed, then alignment can be achieved, but the process is complex and operator-dependent
Solution Approach 1:
By creating a mirror image copy of the second through hole, the patent transforms a complex manual measurement task into a simple visual alignment task. The operator only needs to align the mirror image with the actual hole, which is much easier and more consistent than traditional manual measurement methods.
Solution Approach 2:
The mirror image automatically provides the alignment reference without requiring external measurement tools or complex procedures. The system uses its own optical properties to generate the alignment guide, making the process self-service and eliminating operator skill dependency.
3Reliability
If the clamper center is off the capillary axis, then wire may be damaged, but ensuring precise alignment increases operation time
Solution Approach 1:
The mirror image of the second through hole serves as a precise alignment reference that ensures the clamper center is correctly positioned relative to the capillary axis. This visual copying method achieves accurate alignment quickly, protecting the wire without significantly increasing operation time.
Solution Approach 2:
The mirror is positioned in advance to create the mirror image reference before the alignment operation begins. This preliminary setup allows for quick and accurate alignment without requiring time-consuming measurements or adjustments during the actual wire handling process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for accurate and efficient alignment of the clamper with the horn, reducing the risk of wire damage and operator variability, thereby improving the alignment process.
Implementation Method 1
A mirror surface is disposed to be parallel to the bonding stage. A mirror image of the second through hole reflected on the mirror surface is aligned with a center of the second through hole
Data Source
AI summary
A bonding apparatus includes: a clamper able to clamp a wire between a pair of arms; a horn, in which a first through hole able to hold a capillary, and a second through hole adjacent to the first through hole and penetrating the horn in an up-down direction are further formed; and a bonding stage able to carry a workpiece. An alignment method for aligning a horn and a damper of a bonding apparatus with each other includes: disposing a mirror surface to be parallel to a bonding stage; aligning a mirror image of a second through hole reflected on the mirror surface with a center of the second through hole when the mirror surface is viewed through the second through hole; and aligning the damper based on a position of the mirror image and the horn.