CN-115697615-B - Ultrasonic welding system, method of use thereof, and related workpieces including welded conductive pins

Abstract

An ultrasonic welding system is provided. An ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a welding head assembly including an ultrasonic transducer carrying a sonotrode. The ultrasonic welding system also includes a conductive pin supply configured to provide a plurality of conductive pins for welding with the sonotrode.

Inventors

• T.J. Kobertite
• R.J. McCartney
• O. Nyayes

Assignees

• 库利克和索夫工业公司

Dates

Publication Date

20260512

Application Date

20210528

Priority Date

20200603

Claims (20)

1. 1. An ultrasonic welding system, comprising: a support structure configured to support a workpiece; a bond head assembly including an ultrasonic transducer carrying a sonotrode, and A conductive pin supply configured to provide a plurality of conductive pins for soldering with the sonotrode, Wherein the bond head assembly defines a keyed feature configured to align with a corresponding feature of the conductive lead such that the conductive lead held by the bond head assembly is properly aligned with respect to the sonotrode.
2. 2. The ultrasonic welding system of claim 1, wherein the welding head assembly is configured to move along a plurality of distinct axes of motion.
3. 3. The ultrasonic welding system of claim 2, wherein the plurality of distinct axes of motion comprises an x-axis, a y-axis, and a z-axis.
4. 4. The ultrasonic welding system of claim 2, wherein the plurality of distinct axes of motion comprises a theta axis.
5. 5. The ultrasonic welding system of claim 1, wherein the sonotrode of the bond head assembly is configured to withdraw a conductive pin from the conductive pin supply, and the bond head assembly is configured to carry the withdrawn conductive pin toward a workpiece and ultrasonically weld the conductive pin to the workpiece.
6. 6. The ultrasonic welding system of claim 5, wherein the sonotrode defines a vacuum channel for retrieving conductive pins from the conductive pin supply.
7. 7. The ultrasonic welding system of claim 1, wherein the bond head assembly comprises a clamp mechanism configured to withdraw a conductive pin from the conductive pin supply, and the bond head assembly is configured to carry the withdrawn conductive pin toward a workpiece and ultrasonically weld the conductive pin to the workpiece.
8. 8. The ultrasonic welding system of claim 7, wherein the clamp grabber mechanism comprises a movable arm configured to move between (i) an open position for engaging a conductive pin and (ii) a closed position for holding the conductive pin in a position for movement toward a workpiece.
9. 9. The ultrasonic welding system of claim 8, wherein the movable arm aligns the conductive pin with an ultrasonic weld in a closed position.
10. 10. The ultrasonic welding system of claim 7, wherein the clamp grabber mechanism comprises a movable arm configured to move between (i) an open position for engaging a conductive pin and (ii) a closed position for holding the conductive pin in a position for movement toward a workpiece, wherein the movable arm aligns the conductive pin with an ultrasonic welding line in the closed position.
11. 11. The ultrasonic welding system of claim 1, further comprising a pick tool configured to remove a conductive pin from the conductive pin supply, the removed conductive pin being transferred to a bond head assembly for welding to a workpiece.
12. 12. The ultrasonic welding system of claim 1, wherein the sonotrode is configured for welding a conductive pin to a workpiece, and for welding a power terminal to a workpiece.
13. 13. The ultrasonic welding system of claim 1, wherein the sonotrode comprises a first region configured to contact a conductive pin for welding to a workpiece and a second region configured to contact a power terminal for welding to a workpiece.
14. 14. The ultrasonic welding system of claim 1, further comprising a second weld head assembly comprising a second ultrasonic transducer carrying a second ultrasonic weld pole, the second weld head assembly configured to weld a power terminal to a workpiece.
15. 15. A method of operating an ultrasonic welding system, the method comprising the steps of: supporting a workpiece on a support structure of an ultrasonic welding system, and Welding conductive pins from a conductive pin supply of an ultrasonic welding system to a workpiece using an ultrasonic welding pole of a welding head assembly of the ultrasonic welding system, the conductive pin supply including a plurality of conductive pins, Wherein the bond head assembly defines a keyed feature configured to align with a corresponding feature of the conductive lead such that the conductive lead held by the bond head assembly is properly aligned with respect to the sonotrode.
16. 16. The method of claim 15, wherein the welding head assembly is configured to move along a plurality of distinct axes of motion of an ultrasonic welding system.
17. 17. The method of claim 16, wherein the plurality of distinct axes of motion includes an x-axis, a y-axis, and a z-axis.
18. 18. The method of claim 16, wherein the plurality of distinct axes of motion comprises a theta axis.
19. 19. The method of claim 15, wherein prior to the soldering step, the method further comprises the steps of (i) retrieving conductive pins from the conductive pin supply using a sonotrode of a soldering tip assembly, and (ii) carrying the retrieved conductive pins toward the workpiece using a soldering tip assembly.
20. 20. The method of claim 19, wherein the sonotrode defines a vacuum channel for retrieving conductive pins from the conductive pin supply.

Description

Ultrasonic welding system, method of use thereof, and related workpieces including welded conductive pins Cross Reference to Related Applications The present application claims the benefit of U.S. provisional patent application No. 63/034,345 filed on 6/3 of 2020, the contents of which are incorporated herein by reference. Technical Field The present invention relates to ultrasonic welding, and more particularly to an improved system and method for performing ultrasonic welding operations, including conductive pin welding. Background Ultrasonic energy is widely used in forming interconnections between two or more materials. For example, wire bonding machines (e.g., ball bonding machines, wedge bonding machines, ribbon bonding machines, etc.) are used to bond wires or ribbons to a bonding location. However, the wire bonds employ relatively low energy levels (e.g., welding force, ultrasonic energy, etc.). An exemplary wire bonding machine is marketed by Kulicke and Soffa Industries, inc. Some applications involve the coupling of materials other than wires. Welding has been considered for such applications. Ultrasonic welding is also a widely used technique. Ultrasonic welding may use an ultrasonic transducer (e.g., carrying a sonotrode) to convert electrical energy into mechanical movement/scrubbing (e.g., linear movement/scrubbing, torsional movement/scrubbing, etc.). However, existing ultrasonic welding techniques and equipment are limited in providing solutions that can meet market demands in terms of cost, operating efficiency, flexibility, portability, and related factors. International publication No. 2018/187364 (titled "Ultrasonic WELDING SYSTEMS AND Methods of Using the Same"), assigned to Kulicke and Soffa Industries, inc, incorporated by reference in its entirety, relates to improvements in Ultrasonic welding technology. In connection with ultrasonic welding, including ultrasonic pin welding, where such pins are typically solder and/or press fit into a power module, improvements are still needed. Accordingly, it is desirable to improve ultrasonic welding techniques, including ultrasonic pin welding. Disclosure of Invention According to another exemplary embodiment of the present invention, an ultrasonic welding system is provided. An ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a welding head assembly including an ultrasonic transducer carrying a sonotrode. The ultrasonic welding system also includes a conductive pin supply configured to provide a plurality of conductive pins for welding with the sonotrode. According to yet another exemplary embodiment of the present invention, a method of operating an ultrasonic welding system is provided. The method includes the steps of (a) supporting a workpiece on a support structure of an ultrasonic welding system, and (b) welding conductive pins from a conductive pin supply of the ultrasonic welding system to the workpiece with a sonotrode of a weld head assembly of the ultrasonic welding system, the conductive pin supply including a plurality of conductive pins. According to yet another exemplary embodiment of the present invention, a workpiece is provided. The workpiece includes a substrate and conductive pins ultrasonically welded to the substrate. Drawings The invention is best understood from the following detailed description when read in connection with the accompanying drawing figures. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures: FIG. 1 is a block diagram side view of an ultrasonic welding system according to an exemplary embodiment of the present invention; FIG. 2A is a block diagram side view of another ultrasonic welding system according to another exemplary embodiment of the present invention; FIG. 2B is a perspective view of an end portion of a sonotrode of the ultrasonic welding system of FIG. 2B; FIG. 2C is a side view of a conductive pin from the conductive pin supply of the ultrasonic welding system of FIG. 2B; FIG. 3A is a block diagram side view of yet another ultrasonic welding system in accordance with yet another exemplary embodiment of the present invention; 3B-3C are side block views illustrating removal of a conductive pin from a conductive pin supply using the ultrasonic welding system of FIG. 3A; FIG. 3D is a side view of a conductive pin from the conductive pin supply of the ultrasonic welding system of FIG. 3A; FIG. 4 is a block diagram side view of yet another ultrasonic welding system in accordance with yet another exemplary embodiment of the present invention; FIG. 5 is a block diagram side view of yet another ultrasonic welding system in accordance with yet another exemplary embodiment of the present invention; FIGS. 6A-6G are dif