Ultrasonic Tool Absorption Surface for Laser-Assisted Bonding
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Solution Overview
Problem
Conventional ultrasonic tools face difficulties in coupling a laser beam due to structural and spatial conditions, leading to contamination and damage from vapor formation and particle release during laser-supported ultrasonic bonding or welding.
Innovation Solution
The ultrasonic tool features a surface-structured absorption surface in the end region, designed to absorb and diffuse the laser beam, preventing specular reflection and enhancing energy absorption, thus reducing contamination and damage while facilitating efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a longitudinal recess is used to couple the laser beam into the ultrasonic tool, then the laser beam can be directed to the end region, but coupling the laser beam and replacing the ultrasonic tool becomes difficult due to structural and spatial conditions
Solution Approach 1:
The invention extracts the laser beam coupling function from the longitudinal recess structure and implements it through a surface-structured absorption surface on the tool cover surface. This allows the laser beam to be absorbed and converted to thermal energy directly at the tool's exterior surface, eliminating the need for complex internal recess structures while maintaining the heating function.
Solution Approach 2:
The invention replaces the mechanical coupling structure (longitudinal recess) with an optical absorption structure (surface-structured absorption surface). The complex mechanical geometry required for laser beam coupling is substituted by a surface treatment that directly absorbs laser energy, simplifying the overall tool structure.
2Temperature
If the laser beam impinges on the connecting component, then heating can be achieved, but vapors form or particles are released causing contamination
Solution Approach 1:
The ultrasonic tool with the surface-structured absorption surface acts as an intermediary between the laser beam and the connecting component. The laser beam first heats the tool's absorption surface, which then transfers thermal energy to the connecting component through contact. This indirect heating path prevents direct laser-material interaction that would cause vaporization and contamination.
Solution Approach 2:
The invention converts the potentially harmful direct laser impingement on the connecting component into a beneficial indirect heating process. By absorbing the laser energy on the tool's absorption surface and transferring it thermally to the connecting component, the process achieves heating while avoiding the harmful effects of direct laser-material interaction such as vapor formation and particle release.
3Loss of energy
If a specular reflection occurs from the tool surface, then laser energy is reflected away, but surrounding components and personnel are damaged
Solution Approach 1:
The invention applies a localized surface structure to specific regions of the tool (the absorption surface) that selectively absorbs laser energy. This local quality change creates a zone of high laser energy absorption that converts optical energy to thermal energy, preventing specular reflection and redirecting the energy into useful heating while protecting surrounding components and personnel from laser damage.
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 surface-structured absorption surface improves the ultrasonic tool's suitability for laser-supported bonding/welding by minimizing reflection and contamination, ensuring rapid and uniform heating with reduced risk of damage to components and personnel.
Implementation Method 1
a first partial surface of the tool cover surface is formed as a surface-structured absorption surface... ensures, on the one hand, that a laser beam directed at it can be substantially absorbed
Implementation Method 2
the surface-structured absorption surface can be designed as a beam trap for an incident laser beam in such a way that the laser beam impinging on the absorption surface is reflected several times on the absorption surface and is always absorbed proportionately
Implementation Method 3
which in particular has piezoelectric transducers as vibration exciters
Implementation Method 4
The ultrasonic tool is excited to vibrations, for example to torsional vibrations, bending vibrations or longitudinal vibrations
Data Source
AI summary
An ultrasonic tool comprising a first end face and a second end face, which is opposite the first end face, as well as a tool cover surface connecting the first end face and the second end face, wherein the ultrasonic tool is elongated in a longitudinal direction of the tool, wherein at least the first end face is formed as a connecting contact surface, which is arranged for pressing the ultrasonic tool against a connecting component, and wherein the ultrasonic tool comprises an end region comprising the connecting contact surface, which extends from the connecting contact surface in the longitudinal direction of the tool over 15 mm, but at most extends one third of the length of the ultrasonic tool in the direction of the opposite end face, and wherein in the end region, a first partial surface of the tool cover surface is formed as a surface-structured absorption surface.