Ultrasonic Weld Head Positioning for Faster Multi-Point Bonding
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Solution Overview
Problem
Existing ultrasonic welding technologies are limited in cost-effectiveness, operational efficiency, flexibility, and portability, failing to meet market demands for efficient volume production and diverse applications.
Innovation Solution
An ultrasonic welding system with a moveable weld head assembly and sonotrode capable of operating at a bond force of 5-500 kg and a sonotrode tip motion amplitude of 5-150 microns, allowing for versatile welding operations across various materials and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing ultrasonic welding technology is used, then welding capability is provided, but operational efficiency and productivity are limited
Solution Approach 1:
The weld head assembly is made movable along multiple horizontal axes (X, Y, and Z axes) rather than being fixed, allowing dynamic positioning and adjustment during welding operations. This enables the system to adapt to different workpiece configurations and welding locations, significantly improving operational efficiency and productivity while reducing overall welding cycle time through automated repositioning capabilities
2Adaptability or versatility
If existing ultrasonic welding technology is used, then welding capability is provided, but flexibility and adaptability are limited
Solution Approach 1:
The weld head assembly is designed with multi-axis movement capability (X, Y, Z axes) that enables a single device to perform multiple welding functions and accommodate various workpiece types including power modules, battery modules, and lead frames. This universal design approach increases adaptability and versatility without proportionally increasing system complexity, as the same movable assembly serves diverse welding applications
3Ease of manufacture
If existing ultrasonic welding technology is used, then welding capability is provided, but cost-effectiveness is limited
Solution Approach 1:
The movable weld head assembly along multiple horizontal axes enables automated positioning and welding operations, which increases volume production efficiency. This dynamic capability allows the system to handle diverse applications without requiring multiple dedicated welding stations, thereby improving cost-effectiveness through consolidated equipment that achieves high productivity across various production volumes
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 system enhances operational efficiency and flexibility, enabling efficient volume production and adaptable welding solutions for diverse applications, including power modules, battery modules, and lead frames, while improving cost-effectiveness.
Implementation Method 1
Ultrasonic energy is widely used in forming interconnections between two or more materials... generate ultrasonic vibration (amplitude: 10-70 μm) in a horizontal direction
Implementation Method 2
Ultrasonic welding is also a widely used technology... welding a first portion of the workpiece to a second portion of the workpiece using a weld head assembly including an ultrasonic converter carrying a sonotrode
Data Source
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Figure 3A
AI summary
An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The weld head assembly is moveable along a plurality of substantially horizontal axes. The sonotrode is configured to operate during a welding operation at a bond force of between 5-500 kg, and with a sonotrode tip motion amplitude of between 5-150 microns.