Suction Sonotrode Positioning for Space-Limited Ultrasonic Joining
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Solution Overview
Problem
Existing ultrasonic joining techniques require significant space for positioning tools, which can be a challenge when connecting multiple joining partners in limited spaces.
Innovation Solution
An ultrasonic joining arrangement that includes a sonotrode with a channel and a suction device, allowing for precise positioning and connection of joining partners by vibrating the sonotrode and using suction to align the second joining partner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If positioning tools are used to position second joining partners on a first joining partner, then positioning precision is improved, but the space requirement increases significantly
Solution Approach 1:
The patent combines the positioning function and the joining function into a single integrated tool. The positioning tool includes both positioning elements for aligning the second joining partner and a joining tool (ultrasonic welding tool) for connecting them, eliminating the need for separate positioning tools and reducing space requirements while maintaining positioning precision.
Solution Approach 2:
The positioning tool is designed with multi-functionality, serving both as a positioning device and as a joining device. The tool can perform alignment and positioning of the second joining partner, then subsequently perform the ultrasonic joining operation, making a single tool perform multiple functions that previously required separate tools.
2Reliability
If multiple second joining partners are connected successively using the same joining equipment, then connection reliability is improved, but the joining time increases
Solution Approach 1:
The positioning tool performs preliminary positioning and alignment of the second joining partner before the actual joining operation. By pre-positioning the component accurately, the tool ensures that subsequent joining operations can proceed immediately without repositioning or adjustment, maintaining reliability while reducing total joining time for multiple components.
Solution Approach 2:
The integrated positioning and joining tool allows for continuous operation where positioning and joining are performed in seamless succession. The tool transitions directly from positioning mode to joining mode without interruption, enabling continuous useful action when connecting multiple second joining partners to the first joining partner.
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 solution enables the creation of reliable mechanical and electrical connections with minimal space requirements, improving efficiency and precision in joining operations.
Implementation Method 1
a transducer (43) coupled to the sonotrode (42) and configured to vibrate the sonotrode (42)
Implementation Method 2
a suction device (410) coupled to a first one of the at least two openings (45) and configured to cause a second joining partner (20) to be sucked towards a second one of the at least two openings (45)
Data Source
Figure 1~2B
Figure 3~4B
Figure 4C~5B
AI summary
An ultrasonic joining arrangement comprises a first joining tool (40), the first joining tool (40) comprising a sonotrode (42), a transducer (43), and a suction device (410), wherein the transducer (43) is coupled to the sonotrode (42) and configured to vibrate the sonotrode (42), the sonotrode (42) comprises a channel (44) extending through the inside of the sonotrode (42), and having at least two openings (45) towards the outside of the sonotrode (42), and the suction device (410) is coupled to a first one of the at least two openings (45) and is configured to cause a second joining partner (20) to be sucked towards a second one of the at least two openings (45).