Ultrasonic Horn Cross-Section for Directional Oscillation Control
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Solution Overview
Problem
Conventional horns used for ultrasonic bonding of electronic components fail to sufficiently suppress oscillation components other than those in the horizontal direction, leading to inefficient bonding processes.
Innovation Solution
A horn design with a cross-sectional area that maximizes in one direction and minimizes in another at specific positions corresponding to anti-nodes and nodes of a standing wave, combined with a horn holder positioned at nodes to suppress unwanted oscillations, allowing only horizontal oscillations to be effectively applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional horn is used for ultrasonic bonding, then the electronic component can be held and oscillated, but oscillation components other than the horizontal direction cannot be sufficiently suppressed
Solution Approach 1:
The horn cross-section is designed with non-uniform distribution where the first region (extending in the horizontal direction) has a larger sectional area and the second regions (extending in vertical directions) have smaller sectional areas. This local quality differentiation suppresses unwanted oscillation components while maintaining effective horizontal oscillations for bonding.
Solution Approach 2:
The horn cross-section employs asymmetric design with one first region and two second regions arranged such that the first region has maximum area at the anti-node position while the second regions have minimum area. This asymmetric area distribution creates directional oscillation control, suppressing vertical oscillation components while preserving horizontal oscillations.
2Object-generated harmful factors
If the horn cross-sectional area is optimized for horizontal oscillations, then unwanted oscillations are suppressed, but the structural complexity increases
Solution Approach 1:
The horn cross-sectional area parameters are systematically varied along its length, with the first region having maximum area at the anti-node position and the second regions having minimum area. This parameter optimization achieves oscillation suppression while maintaining manufacturable geometric forms.
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 effectively suppresses oscillations in directions other than the horizontal axis, ensuring efficient ultrasonic bonding by minimizing unwanted oscillations and enhancing the utilization of oscillation energy, thereby improving the bonding process.
Implementation Method 1
A horn to which oscillations are applied by an oscillator
Implementation Method 2
in a position corresponding to an anti-node of a standing wave of oscillations excited in the horn
Data Source
AI summary
A horn that can suppress oscillation components other than the component in the horizontal direction, a horn unit, and a bonding apparatus using same are provided. The horn has a cross-section variable section in which a cross section perpendicular to the lengthwise direction (X direction) thereof has a first region extending in the Z direction and a pair of second regions sandwiching the first region from Y direction. In the position P3 corresponding to an anti-node of a standing wave of oscillations excited in the horn, a sectional area S1 of the first region assumes a maximum and a sectional area S2 of the second region assumes a minimum. With a transition from the position P3 to the other positions corresponding to nodes, the sectional area S1 decreases and the sectional area S2 increases. As a result, oscillation components other than those in the X direction are suppressed.