Ultrasonic Joining Tool Temperature Cycling 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 affects the reliability of mechanical and electrical connections.
Innovation Solution
Incorporating a temperature unit in the second joining tool that actively heats or cools the tool during intermediate time intervals between successive joining operations, while remaining inactive during the operations themselves, to maintain consistent temperature and process conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple ultrasonic joining operations are performed in direct succession using the same joining tool, then productivity is improved, but the temperature of the joining tool changes between operations causing variations in process parameters and connection quality
Solution Approach 1:
The patent implements periodic cooling cycles between ultrasonic joining operations. A cooling device is activated during intermediate time intervals between successive joining operations to reduce the temperature of the joining tool. This periodic action maintains temperature within a controlled range, ensuring consistent process parameters and connection quality across multiple operations while allowing high-speed successive joining.
2Manufacturing precision
If the joining tool temperature is actively controlled between operations, then connection quality consistency is improved, but device complexity increases due to additional temperature control systems
Solution Approach 1:
The patent introduces a cooling device as an intermediary element between the ultrasonic generator and the joining tool. This cooling device includes a cooling medium supply line that delivers cooling fluid to the joining tool during intermediate time intervals. The cooling device acts as a mediator to control temperature without interfering with the ultrasonic joining process itself, maintaining manufacturing precision while adding minimal structural complexity.
3Temperature
If cooling is applied during joining operations, then temperature control is improved, but the joining process is disrupted affecting connection quality
Solution Approach 1:
The cooling device is designed to operate periodically rather than continuously. It is activated specifically during intermediate time intervals between ultrasonic joining operations and is deactivated during the actual joining process. This periodic operation allows temperature control without disrupting the mechanical bonding process, ensuring both temperature management and connection quality.
Solution Approach 2:
The ultrasonic joining process maintains continuous useful action during the joining operations, while the cooling function is applied continuously but only during intermediate intervals. This separation ensures that the joining process is not interrupted, and the cooling action complements rather than interferes with the primary joining function, maintaining both temperature control and connection reliability.
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 ensures consistent process conditions across multiple joining operations, enhancing the reliability and consistency of the connections formed, thereby improving the overall quality of ultrasonic joining processes.
Implementation Method 1
The second joining tool (42) is heated or cooled by means of a temperature unit (421), which is inactive during each of the plurality of ultrasonic joining operations
Implementation Method 2
The second joining tool (42) is heated or cooled by means of a temperature unit (421), which is inactive during each of the plurality of ultrasonic joining operations
Implementation Method 3
with the second joining tool (42), applying high-frequency ultrasonic vibrations to the joining partners
Data Source
Figure 1~2
Figure 3~4
Figure 5A~6
AI summary
The present application relates to a method of and an arrangement for joining at least two joining partners (10, 20) comprises performing a plurality of ultrasonic joining operations in direct succession, wherein performing an ultrasonic joining operation comprises, with a second joining tool (42), applying pressure to a second joining partner (20) that is arranged adjacent to a first joining partner (10), thereby pressing the second joining partner (20) against the first joining partner (10), and, with the second joining tool (42), applying high-frequency ultrasonic vibrations to the joining partners (10, 20). The method further comprises, 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 (42).