Ultrasonic Joining Tool Temperature Control Between Successive Welds

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Solution Overview

Problem

Ultrasonic joining techniques face challenges in maintaining consistent process conditions during successive operations, leading to variations in connection quality due to unintentional changes in process parameters, such as temperature, which affect the reliability of mechanical and electrical connections between joining partners.

Innovation Solution

The method involves using a second joining tool with a temperature unit that actively cools or heats during intermediate time intervals between successive ultrasonic joining operations to maintain consistent temperature and process conditions, ensuring reliable connections by adjusting the temperature of the second joining tool before each operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple ultrasonic joining operations are performed in direct succession using the same joining equipment, then productivity is improved, but process parameters such as temperature change unintentionally, leading to decreased connection quality

Engineering Contradiction:

Improvenumber of joining operations per unit timeVSAvoidconnection quality consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary actions during intermediate time intervals by actively cooling or heating the second joining tool to restore its temperature to a predetermined value before the next joining operation, preventing temperature-related variations in connection quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system monitors the temperature of the second joining tool and uses this feedback information to control the cooling or heating process, ensuring the tool reaches the optimal temperature range before each joining operation to maintain consistent connection quality

Inventive Principle:

Principle #23Feedback

2Object-affected harmful factors

If the second joining tool is allowed to cool passively between operations, then temperature-related harmful effects are reduced, but the time required between operations increases, reducing productivity

Engineering Contradiction:

Improvetemperature-related variations in connection qualityVSAvoidcycle time between joining operations

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The system replaces passive thermal conduction cooling with an active cooling system that uses a cooling medium (such as gas or liquid) to rapidly remove heat from the second joining tool, significantly reducing the time required to cool between operations while maintaining connection quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the cooling parameter from passive environmental cooling to active controlled cooling by introducing a cooling medium with adjustable flow rate and temperature, enabling precise control over the cooling process to optimize both connection quality and productivity

Inventive Principle:

Principle #35Parameter changes

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 approach maintains consistent process conditions throughout multiple ultrasonic joining operations, enhancing the reliability and consistency of connections formed, while reducing the overall time required for the process by preventing temperature-related variations.

Implementation Method 1

applying high-frequency ultrasonic vibrations to the joining partners

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

at least one of actively cooling and heating the second joining tool

Methodology Applied

Scientific EffectActive cooling: Cooling

Implementation Method 3

at least one of actively cooling and heating the second joining tool

Methodology Applied

Scientific EffectActive heating: Heating

Data Source

PatentUS11318688B2Ultrasonic joining method and arrangement

Publication Date: 2022.05.03 INFINEON TECHNOLOGIES AG

AI summary

A method for joining at least two joining partners includes performing a plurality of ultrasonic joining operations in direct succession, wherein performing an individual ultrasonic joining operation includes, with a second joining tool, applying pressure to a second joining partner arranged adjacent to a first joining partner, thereby pressing the second joining partner against the first joining partner, and, with the second joining tool, applying high-frequency ultrasonic vibrations to the joining partners. The method further includes, during at least one intermediate time interval between two directly successive ultrasonic joining operations, at least one of actively cooling and heating the second joining tool.