Cantilever Ultrasonic Bonding Head With Counterforce Restraint
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Solution Overview
Problem
Conventional ultrasonic bonding devices are too large and interfere with ultrasonic vibrations due to holding the ultrasonic horn on both sides, making them impractical for bonding applications like glass boards and flexible printed circuits.
Innovation Solution
An ultrasonic bonding head with a vibrator unit held in a cantilever manner, featuring a press part at the tip and a restraint portion that contacts the vibrator unit at a counterforce dispersion position, allowing for increased ultrasonic vibration and downsized device design, while preventing deformation and maintaining high pressure for effective bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the ultrasonic horn is held from both sides to increase ultrasonic vibration, then the ultrasonic vibration is enhanced, but the device becomes large and complex
Solution Approach 1:
The holder is designed to hold only one side of the ultrasonic horn in a cantilever manner, creating an asymmetric structure that reduces device complexity and size while maintaining ultrasonic vibration effectiveness. This eliminates the need for symmetric dual-side holding mechanisms.
Solution Approach 2:
The restraint portion is positioned at a specific location along the longitudinal axis of the ultrasonic horn, distributing counterforce in a spatial arrangement that prevents deformation without requiring additional holding points that would increase device size. The restraint portion contacts the horn at an optimized position to provide structural support in the third dimension.
2Stress or pressure
If the pressurizing force is increased to improve bonding pressure, then bonding quality improves, but the vibrator unit deforms due to counterforce
Solution Approach 1:
The restraint portion acts as an intermediary element that mediates the counterforce generated during pressurizing. It provides an intermediate support point that absorbs and distributes the reaction force, preventing direct transmission of deformation to the vibrator unit while allowing high bonding pressure to be applied.
Solution Approach 2:
The position of the restraint portion along the longitudinal axis is optimized to change the structural parameters of the vibrator unit system. By positioning it at a specific location, the counterforce dispersion is maximized, allowing higher pressurizing forces to be applied without exceeding deformation thresholds.
3Device complexity
If the holder structure is simplified to downsize the device, then device size is reduced, but ultrasonic vibration may be disturbed
Solution Approach 1:
The holder is designed with multi-functionality: it provides the primary cantilever support for the ultrasonic horn while also incorporating the restraint portion that prevents deformation during pressurizing. This single structural element performs multiple functions that would otherwise require separate components, maintaining reliability while reducing device size.
Solution Approach 2:
The restraint portion is pre-positioned at the optimized location along the ultrasonic horn before bonding operations begin. This preliminary structural arrangement ensures that when pressurizing forces are applied, the counterforce is already distributed through the restraint portion, preventing vibration disturbance during the actual bonding 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 design enhances ultrasonic bonding by increasing vibration amplitude, allowing for wider bonding areas and reliable connections, even with small wiring pitch intervals, and supports bonding of flat members with large widths.
Implementation Method 1
a vibrator unit including a press part formed at a tip of the vibrator unit in a longitudinal axis thereof and configured to press a bonding scheduled part to be bonded
Implementation Method 2
a pressurizing shaft connected with the holder and configured to transmit a force of pressing the press part against the bonding scheduled part so that the vibrator unit moves along a perpendicular axis substantially perpendicular to the longitudinal axis
Data Source
AI summary
An ultrasonic bonding head includes a vibrator unit, a holder, and a pressurizing shaft. The vibrator unit includes a press part formed at a tip of the vibrator unit in a longitudinal axis thereof and configured to press a bonding scheduled part to be bonded. The holder holds a base of the vibrator unit in a cantilever manner so that the tip is a free end. The pressurizing shaft is connected with the holder and transmits a force of pressing the press part against the bonding scheduled part so that the vibrator unit moves substantially perpendicularly to the longitudinal axis. The holder is provided with a restraint portion. The restraint portion contacts with the vibrator unit at a counterforce dispersion position located between a main hold position for holding the vibrator unit by the holder and the free end.