Ultrasonic Bonding Tool Asymmetric Fitting Design
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Solution Overview
Problem
Conventional ultrasonic bonding tools experience position aberration and impaired vibration characteristics due to insufficient clearance between male and female fitting parts, leading to suboptimal adhesion layer thickness and compromised flatness of the electronic component holding face, which affects the quality of ultrasonic joining.
Innovation Solution
A bonding tool design featuring a horn with a trapezoidal male fitting part and groove, where the male fitting part is a ridge with a larger top face width than the bottom face, and the adhesion layer thickness is optimized to ensure proper vibration transmission and absorption, using a brazing material with a higher Young's modulus than the adhesion layer, and a manufacturing method involving a thermostatic bath for forming the adhesion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sufficient clearance is ensured between male fitting part and female fitting part to facilitate fitting, then ease of manufacture is improved, but position aberration occurs during pressurization leading to impaired vibration characteristics
Solution Approach 1:
The invention applies asymmetry by making the top face width of the male fitting part larger than the bottom face width, creating a tapered shape. This asymmetric geometry allows the fitting parts to align properly during pressurization while maintaining sufficient clearance for easy fitting, thereby resolving the contradiction between ease of manufacture and vibration characteristics.
2Strength
If adhesion layer thickness is increased to improve bonding strength, then strength is improved, but flatness of electronic component holding face is impaired
Solution Approach 1:
The invention applies local quality by optimizing the adhesion layer thickness distribution - the top face has a larger thickness for bonding strength, while the side faces have smaller thicknesses to maintain flatness. This localized variation in thickness resolves the contradiction between strength and manufacturing precision.
3Ease of manufacture
If male fitting part width is reduced to ensure clearance, then ease of manufacture is improved, but adhesion layer thickness becomes non-uniform
Solution Approach 1:
The tapered asymmetric shape of the male fitting part (larger top face, smaller bottom face) allows the top face to maintain sufficient width for uniform adhesion layer formation, while the overall geometry ensures adequate clearance for easy fitting. This resolves the contradiction between ease of manufacture and adhesion layer thickness uniformity.
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 design enhances the quality of ultrasonic joining by maintaining preferable vibration characteristics and improving the homogeneity of ultrasonic vibration transmission, reducing the risk of flatness impairment and position aberration, thus enabling higher-quality bonding of electronic components to circuit boards.
Implementation Method 1
an ultrasonic vibrator 52, and an electronic component holding part 53 which holds the electronic component 8... allowing an electronic component 8 to vibrate by an ultrasonic vibrator 52... the electronic component to vibrate by ultrasonic vibration so as to join electrically an electrode
Implementation Method 2
since the rigidity of the adhesion layer 516 is lower than the rigidity of the horn 51... the swell of the horn 51 is absorbed by the adhesion layer 516... Young's modulus of a material that constitutes the horn is larger than Young's modulus of a material that constitutes the adhesion layer
Implementation Method 3
a brazing material arranging step of arranging a brazing material for forming the adhesion layer 516 between the male fitting part 532 and the female fitting part 5151... forming the adhesion layer by heating the male fitting part 532 and the female fitting part 5151
Data Source
AI summary
In some cases, it is difficult to carry out ultrasonic joining of high quality with a conventional bonding tool. A bonding tool includes: a horn that transmits an ultrasonic vibration; an ultrasonic vibrator that is provided at one end of the horn, and generates the ultrasonic vibration; and an electronic component holding part that holds an electronic component, wherein the electronic component holding part has a male fitting part in a shape of a tapering-off, and an electronic component holding face that holds the electronic component on an opposite side to the male fitting part, a female fitting part in a shape according to a shape of the male fitting part is formed in a predetermined face of the horn, and the male fitting part is fitted into the female fitting part via an adhesion layer.