Ultrasonic Tool Recess Layout for Laser-Assisted Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultrasonic tools for laser-assisted bonding and welding face challenges in coupling the laser beam effectively, leading to contamination, improper heating, and safety hazards due to uncontrollable reflections.
Innovation Solution
The ultrasonic tool features a pocket-shaped or blind-hole-like recess on its outer surface, allowing the laser beam to be directed externally onto the tool, which is heated precisely at the connection point, preventing contamination and unsafe reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the laser beam is coupled into a longitudinal recess extending along the tool's length, then the laser can be supplied to the joining contact surface, but the positioning of the laser generator becomes difficult and the tool changes become complex
Solution Approach 1:
The recess is positioned specifically in the end region of the tool rather than extending along the entire length, segmenting the laser interaction zone to simplify positioning and tool changing operations while maintaining effective laser coupling at the joining contact surface
2Temperature
If the laser beam strikes the joining component directly, then heating can be applied, but vapors and particles are generated causing contamination
Solution Approach 1:
The ultrasonic tool acts as an intermediary between the laser beam and the joining component. The laser heats the tool in the end region, which then transfers heat to the joining component through contact, avoiding direct laser-stcomponent interaction that would generate harmful vapors and particles
3Temperature
If the laser beam is directed through a longitudinal recess, then the joining component can be heated, but reflections may cause damage to components or operators
Solution Approach 1:
The harmful reflection pathway is extracted and eliminated by positioning the recess in the end region rather than having it extend through the joining contact surface, allowing the laser to heat the tool without creating uncontrolled reflections toward operators or components
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 simplifies laser positioning, ensures precise heating, and reduces the risk of damage to components and operators by controlling laser reflections, enhancing the efficiency and safety of ultrasonic bonding and welding processes.
Implementation Method 1
the laser beam is directed onto the recess formed on the ultrasonic tool in such a way that the laser beam preferably hits the ultrasonic tool completely or predominantly within the recess and that the laser beam particularly preferably hits the recess base facing the connecting contact surface of the ultrasonic tool
Implementation Method 2
The ultrasonic tool is excited to vibrations, such as torsional, bending, or longitudinal vibrations, via the transducer, which typically uses piezoelectric transducers as vibration exciters
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to an ultrasonic tool (1) comprising a first end face (2) and a second end face (3, 3') which is opposite the first end face (2), as well as a tool casing surface (4) connecting the first end face (2) and the second end face (3, 3'), wherein the ultrasonic tool (4) is elongated in a longitudinal direction (5) of the tool, wherein at least the first end face (2') is formed as a connecting contact surface (2, 3') which is arranged for pressing the ultrasonic tool (1) against a connecting component, wherein the ultrasonic tool (1) has an end region (6) comprising the connecting contact surface (2, 3') and which extends from the connecting contact surface (2, 3') in the longitudinal direction (5) of the tool over 15 mm, but at most one third of a length (L) of the ultrasonic tool (1) in the direction of the opposite end face (2, 3, 3'), and wherein in the end region (6) on the tool casing surface (4), a pocket-shaped and/or blind-hole like recess (9) with a recess cover surface (3) and a recess base (14) facing the connecting contact surface (2, 3') is formed. The invention also relates to an ultrasonic connection device for ultrasonic welding and/or ultrasonic bonding with the ultrasonic tool (1).