Ultrasonic Horn Tip Geometry for Stable Bonding Attachment
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Solution Overview
Problem
Conventional ultrasonic bonding devices require complex and costly fabrication of holes in the horn for reliable tip attachment, and screw loosening occurs during bonding due to resonance issues, affecting bonding accuracy.
Innovation Solution
A horn tip with a bottom plate and vertically protruding bonding part, where the bonding part's length to thickness ratio is ≤1.5, allowing for reliable screw fixation and differentiation of natural frequencies to prevent resonance, and a groove on the bottom plate to reduce frictional heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple through-holes are formed in the ultrasonic horn for reliable tip attachment, then attachment reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The horn tip is divided into functionally distinct parts: a bottom plate part for attachment and a bonding part for workpiece bonding. This segmentation allows the attachment features (through-holes) to be concentrated in the bottom plate part, simplifying the overall horn design while maintaining reliable attachment capability.
Solution Approach 2:
The bottom plate part is designed with through-holes pre-positioned for screw attachment before the actual bonding operation. This preliminary configuration of attachment features ensures reliable fixation without requiring complex post-processing or additional manufacturing steps.
2Length of moving object
If the tip member length is increased for better bonding reach, then bonding capability is improved, but resonance with the ultrasonic horn occurs affecting stability
Solution Approach 1:
The length-to-thickness ratio of the bonding part is controlled to be 1.5 or less. By adjusting these dimensional parameters, the natural frequency of the horn tip is differentiated from the ultrasonic horn's frequency, preventing resonance and ensuring stable bonding operations.
Solution Approach 2:
The thickened part is provided at the junction between the bottom plate part and bonding part to preemptively counteract potential wobbling or instability. This structural reinforcement prevents resonance-induced instability before it can affect bonding accuracy.
3Adaptability or versatility
If the bonding part protrudes longer for better workpiece access, then bonding versatility is improved, but the bonding part wobbles during operation
Solution Approach 1:
The horn tip features non-uniform thickness distribution: the bottom plate part has sufficient thickness for stable attachment, the bonding part has controlled thickness for versatility, and the thickened part provides localized reinforcement at the junction. This local quality variation optimizes both versatility and stability.
Solution Approach 2:
The thickened part is strategically positioned to prevent wobbling of the bonding part during operation. This preemptive structural reinforcement ensures stability without compromising the bonding part's ability to access various workpiece configurations.
4Strength
If the contact area between horn tip and ultrasonic horn is increased for better attachment, then attachment strength is improved, but frictional heat generation increases
Solution Approach 1:
The horn tip is segmented into a bottom plate part for attachment and a bonding part for operation. This segmentation concentrates the attachment function in the bottom plate part with optimized contact area, while the bonding part maintains minimal interference with the ultrasonic horn surface, reducing frictional heat generation.
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 solution enables stable and accurate ultrasonic bonding by ensuring reliable attachment and minimizing resonance-induced issues, improving bonding accuracy and reducing frictional heat.
Implementation Method 1
a horn tip used to bond workpieces by ultrasonic bonding
Implementation Method 2
frictional heat due to ultrasonic vibration increases
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A horn tip that can be easily and reliably attached to an ultrasonic bonding device and stably operates during bonding is provided. A horn tip 6 includes a bottom plate part 6a and a bonding part 6b, the bottom plate part 6a being provided with a plurality of through-holes 61 and 62 for attachment to an ultrasonic LT horn 4, the bonding part 6b protruding vertically from the bottom plate part 6a. A ratio h/w of a length h of the bonding part 6b from an upper surface side of the bottom plate part 6a to a thickness w of the bonding part 6b is equal to or smaller than 1.5.