Coated Ultrasonic Transducer Surfaces to Reduce Wire Bonding Galling
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Solution Overview
Problem
Conventional ultrasonic transducers used in wire bonding machines suffer from significant wear and galling issues due to the static and dynamic interaction between the transducer's tool clamp and the wire bonding tool, leading to reduced lifespan and performance.
Innovation Solution
The surface of the ultrasonic transducer is processed, typically coated with materials like titanium nitride, diamond-like carbon, or tungsten disulfide, to reduce friction and increase hardness, creating a processed area that minimizes wear and galling by acting as a galling inhibitor or surface hardener, thereby extending the transducer's lifetime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional ultrasonic transducer surfaces are used without processing, then the transducer structure remains simple and manufacturing is easier, but wear and galling occur at high rates reducing transducer lifetime
Solution Approach 1:
The patent applies composite material principles by combining the base transducer body material (typically titanium or stainless steel) with surface coating materials (such as diamond-like carbon, titanium nitride, or tungsten disulfide). This creates a composite structure where the bulk material provides mechanical strength and the surface coating provides wear and galling resistance, thereby extending transducer lifetime while maintaining manufacturing feasibility through established coating processes.
Solution Approach 2:
The patent changes the surface parameters of the transducer by applying coatings that modify surface hardness, friction coefficient, and chemical reactivity. These parameter changes transform the surface properties to resist wear and galling without fundamentally altering the transducer's overall structure or manufacturing process, thus extending lifetime with minimal added complexity.
2Reliability
If the transducer surface is left unprocessed, then manufacturing costs and process time are lower, but the work tool becomes expensive relative to the transducer and wear occurs rapidly
Solution Approach 1:
The patent applies local quality principles by processing only the specific surface areas of the transducer that are subject to wear and galling during operation. Rather than treating the entire transducer, the coating is applied selectively to the contact surfaces where the wire bonding tool interfaces with the transducer, providing wear resistance exactly where needed while minimizing additional process complexity and cost.
3Productivity
If no surface processing is applied, then the manufacturing process is simpler and faster, but galling occurs between the transducer and wire bonding tool reducing operational reliability
Solution Approach 1:
The patent effectively makes the work tool disposable or replaceable while protecting the expensive transducer through surface coating. By applying wear-resistant coatings to the transducer, the design accepts that the cheaper work tool will wear and need replacement, while the coated transducer maintains its serviceability and performance over extended periods, thereby improving operational efficiency with minimal impact on manufacturing simplicity.
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
The processed surface area reduces wear and galling, leading to improved performance and extended lifespan of the ultrasonic transducers by shifting the wear component from the expensive transducer to the inexpensive work tool, thus enhancing the transducer's durability and operational efficiency.
Implementation Method 1
The processed area has a changed condition at the surface of the transducer body... to reduce friction and increase hardness, creating a processed area that minimizes wear and galling by acting as a galling inhibitor or surface hardener
Data Source
AI summary
An ultrasonic transducer system is provided. The ultrasonic transducer system includes a transducer body, wherein at least a portion of a surface of the transducer body includes a processed area. The processed area has a changed condition at the surface of the transducer body.