US20130299559A1 - Ultrasonic bonding systems and methods of using the same - Google Patents
Ultrasonic bonding systems and methods of using the same Download PDFInfo
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- US20130299559A1 US20130299559A1 US13/941,922 US201313941922A US2013299559A1 US 20130299559 A1 US20130299559 A1 US 20130299559A1 US 201313941922 A US201313941922 A US 201313941922A US 2013299559 A1 US2013299559 A1 US 2013299559A1
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- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
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- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
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- H—ELECTRICITY
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- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/74—Apparatus for manufacturing arrangements for connecting or disconnecting semiconductor or solid-state bodies
- H01L24/78—Apparatus for connecting with wire connectors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
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- H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
- H01L31/1876—Particular processes or apparatus for batch treatment of the devices
- H01L31/188—Apparatus specially adapted for automatic interconnection of solar cells in a module
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- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
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- H01L2224/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
- H01L2224/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
- H01L2224/45001—Core members of the connector
- H01L2224/4501—Shape
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- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
- H01L2224/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
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- H01L2224/45099—Material
- H01L2224/451—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof
- H01L2224/45117—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof the principal constituent melting at a temperature of greater than or equal to 400°C and less than 950°C
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- H01L2224/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
- H01L2224/85—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a wire connector
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- H01L2224/80—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected
- H01L2224/85—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a wire connector
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- H01L24/42—Wire connectors; Manufacturing methods related thereto
- H01L24/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
- H01L24/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
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- H01L2924/0001—Technical content checked by a classifier
- H01L2924/00014—Technical content checked by a classifier the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- ultrasonic bonding e.g., wire bonding, ribbon bonding, etc.
- ribbon bonding machines are used to form ribbon interconnections between respective locations to be electrically interconnected such as is disclosed in U.S. Pat. No. 7,745,253, the contents of which are herein incorporated by reference in their entirety.
- an upper terminal end of a bonding tool is typically engaged in an ultrasonic transducer which causes the bonding tool to vibrate during bonding.
- Ultrasonic bonding typically uses relative motion between (1) the bonding material and (2) a bonding location to form a bond therebetween.
- soldering In providing electrical interconnection in solar substrate applications (e.g., crystalline silicon solar cells, thin film solar cells, etc.) techniques such as soldering or conductive adhesive are used to electrically connect adjacent cells. Certain types of solar substrates (e.g., crystalline silicon solar cells) utilize such connections on the top and bottom of the substrate. Such soldering processes have limitations such as cost, reliability, yield, compliance with lead free requirements, and complexity.
- a method of bonding a workpiece includes the step of supporting a workpiece with a support structure during a bonding operation.
- the method further includes the steps of bonding an upper bonding material to an upper side of the workpiece using an upper bonding tool positioned above the workpiece, and bonding a lower bonding material to a lower side of the workpiece using a lower bonding tool positioned below the workpiece.
- an ultrasonic ribbon bonding machine includes a support structure configured to support a solar substrate during a ribbon bonding operation.
- the ultrasonic ribbon bonding machine further includes an upper ribbon bonding tool positioned above the support structure and configured for bonding a first conductive ribbon to an upper side of the solar substrate, and a lower ribbon bonding tool positioned below the support structure and configured for bonding a second conductive ribbon to a lower side of the solar substrate.
- a method of bonding a solar substrate includes the step of supporting a solar substrate with a support structure during a bonding operation.
- the method further includes the steps of bonding a first conductive ribbon to an upper side of the solar substrate using an upper ribbon bonding tool positioned above the solar substrate, and bonding a second conductive ribbon to a lower side of the solar substrate using a lower ribbon bonding tool positioned below the solar substrate.
- FIG. 1 is a side sectional block diagram view of a substrate with respective bonding tools over an upper side and under a lower side in accordance with an exemplary embodiment of the present invention
- FIG. 4A is a plan block diagram view of a substrate during bonding with multiple upper and lower bonding tools according to an exemplary embodiment of the present invention
- FIGS. 4F-4G are plan block diagram views of a substrate during bonding with upper bonding tools carried together, with FIG. 4G showing formed bonds, according to an exemplary embodiment of the present invention
- FIG. 5 is a side sectional block diagram view of a substrate bonding system having upper and lower apertured substrate pressing elements in accordance with an exemplary embodiment of the present invention
- FIGS. 7A-7B are respective perspective block diagram view of a series of three electrically interconnected solar substrates, and a simplified side view thereof, according to an exemplary embodiment of the present invention.
- the ultrasonic bonding systems may be, for example: (1) ball bonding systems for forming wire interconnections and related structures (e.g., wire loops); (2) wedge wire bonding systems for forming wire interconnections and related structures (e.g., wire loops); and (3) ribbon bonding systems (e.g., wedge ribbon bonding systems) for forming ribbon interconnections using materials such as aluminum ribbon material, aluminum-copper clad ribbon material, amongst others.
- the workpiece may not need to be flipped over to form the lower side bonds (e.g., ribbon bonds). This results in less handling of the workpiece (and therefore a lower cost of handling equipment), and a reduced potential for damage to the workpiece.
- FIG. 1 illustrates a block diagram view of an exemplary ultrasonic bonding system including support structure 110 supporting workpiece 100 .
- Workpiece 100 may be a substrate (e.g., a leadframe carrying one or more semiconductor die), a solar substrate (e.g., a solar cell), amongst others.
- Support structure 110 may be any appropriate structure for supporting the given workpiece such as, for example, a heat block, an anvil, a vacuum chuck, amongst others. Such a support structure may be included in an indexing system, similar to such systems used on die or wire bonding equipment.
- Upper bonding tool 140 is positioned above support structure 110 /workpiece 100 and is configured to bond an upper bonding material (not shown) to upper side 102 of workpiece 100 .
- FIG. 2A illustrates upper bonding tool 240 (for bonding upper bonding material 220 to upper surface 202 of workpiece 200 ) and lower bonding tool 260 (for bonding lower bonding material 222 to lower surface 204 of workpiece).
- Tools 240 and 260 are spaced apart from one another in a horizontal plane (e.g., the XY plane in accordance with the legend). If desired, the bonding sequences may be configured such that the respective tools 240 , 260 never bond directly above one another simultaneously.
- Other elements not shown in FIG. 2A may include pressing elements above/below the respective tools 240 , 260 for support before, during, and/or after bonding. Depending upon the configuration such pressing elements may be omitted.
- FIG. 2B illustrates upper bonding tool 240 (for bonding upper bonding material 220 to upper side 202 of workpiece 200 ) opposing lower bonding tool 260 (for bonding lower bonding material 222 to lower side 204 of workpiece 200 ).
- face 242 of upper bonding tool 240 is substantially directly above face 262 of lower bonding tool 260 .
- upper bonding tool 240 may be used for support during bonding using lower bonding tool 260
- lower bonding tool 260 may be used for support during bonding using upper bonding tool 240 .
- the tools may be aligned/rotated to at any desired angle (e.g., zero degrees, 90 degrees, etc.) with respect to one another.
- FIGS. 2C-2E illustrate exemplary configurations of upper and lower bonding tools 240 , 260 during a bonding operation and illustrate mutual support between upper and lower bonding tools 240 , 260 during respective upper and lower bond formation.
- FIG. 2C illustrates sequential such upper and lower bond formation
- FIG. 2D illustrates simultaneous, in-phase upper and lower bond formation
- FIG. 2E illustrates simultaneous, out-of-phase upper and lower bond formation.
- FIG. 2D illustrates substantially simultaneous, in-phase upper and lower bond formation by opposing upper and lower bonding tools 240 , 260 .
- Upper bonding tool 240 vibrates as at 244 to form the upper bond
- lower bonding tool 260 vibrates as at 264 to form the lower bond, such that upper bonding tool 240 and lower bonding tool 260 vibrate in-phase.
- This in-phase vibration is shown schematically by upper and lower bonding tool arrows 244 , 264 pointing in the same direction (to the left as illustrated).
- bonding tools 240 , 260 may (or may not) be supported by a common transducer/bond head assembly (not shown).
- Such out-of-phase vibration of the opposing upper and lower bonding tools 240 , 260 may assist in better bond formation because the relative motion between bonding tools may dampen or reduce movement of workpiece 200 that may have been induced by upper and lower bonding tools 240 , 260 , thereby increasing or maximizing relative motion between the bonding tools and the workpiece.
- FIG. 3 illustrates bonding of workpiece 300 using upper and lower bonding tools 340 , 360 spaced apart from one another in a horizontal plane (e.g., the XY plane as shown by the legend).
- Upper terminal end 350 of upper bonding tool 340 is engaged in upper transducer 352 , and upper transducer 352 is supported by upper bond head assembly 354 of an upper bonding system.
- Lower terminal end 370 of lower bonding tool 360 is engaged in lower transducer 372 , and lower transducer 372 is supported by lower bond head assembly 374 of an upper bonding system.
- FIGS. 4A-4B illustrate workpiece 400 being bonded with multiple upper and lower bonding tools according to certain exemplary embodiments of the present invention.
- FIG. 4A illustrates two upper bonding tools 440 a, 440 b with their respective upper terminal ends engaged in transducers 452 a, 452 b, where upper transducers 452 a, 452 b are supported by respective upper bond head assemblies 454 a, 454 b of an upper bonding system(s).
- the lower terminal ends of respective lower bonding tools 460 a, 460 b are engaged in lower transducers 472 a, 472 b, where lower transducers 472 a, 472 b are supported by respective lower bond head assemblies 474 a, 474 b of a lower bonding system(s).
- Upper bonding tools 440 a, 440 b are configured to bond upper bonding materials to respective conductive regions 456 a, 456 b of upper side 402 of workpiece 400 .
- Lower bonding tools 460 a, 460 b are configured to bond lower bonding materials to respective conductive regions 476 a, 476 b of lower side 404 of workpiece 400 .
- Each set of bonding tools 440 a, 440 b; 460 a, 460 b may act in concert, or either or both sets may act independently during the bonding processes.
- FIG. 4B illustrates another bonding system similar to that shown in FIG. 4A (with the same numbering of elements except as specified).
- upper bonding tools 440 a, 440 b are carried by upper bond head assemblies 454 a, 454 b , respectively, which are physically connected to one another by coupling structure 458 ; and
- the lower bonding tools 460 a, 460 b are carried by lower bond head assemblies 474 a, 474 b, respectively, which are physically connected to one another by coupling structure 478 .
- each pair of bond head assemblies/bonding tools is coupled for movement together in at least one direction.
- more than two bonding tools may be connected together as desired in the given application.
- certain workpieces may include bonding locations with a predetermined spacing.
- FIG. 7A illustrates workpiece 700 (e.g., solar substrate 700 ) including two bonding locations (e.g., busbars 782 ) on upper surface 702 , where busbars 782 have a predetermined spacing between each other.
- a bonding material e.g., a ribbon material
- the number of bonding tools may equal the number of bonding locations (e.g., busbars of a solar substrate) to be bonded.
- These multiple bonding tools may be independently moveable with respect to one another (e.g., as in FIG. 4A ) or may be carried together for movement in at least one direction (e.g., as in FIG. 4B ).
- the spacing of the bonding tools may be provided to match the spacing of the conductive regions (e.g., busbars on a solar substrate).
- the spacing between the bonding tools may be configured to equal the spacing between busbars 782 (e.g., see FIG. 7A ).
- the bonding tools may move to a first XY location using an XY table of the bonding machine where a first XY location corresponds to an XY position of the desired bonded locations. Then, the upper bonding tools may be lowered (and/or the lower bonding tools may be raised) (e.g., along the Z-axis) until each of the bonding tools contacts a respective bonding material (e.g., the ribbon material). The bonding tools bond the bonding material to the respective bonding locations (e.g., bond a portion of ribbon material to a respective area of a busbar).
- a respective bonding material e.g., the ribbon material
- the upper bonding tools may be raised (and/or the lower bonding tools may be lowered) and moved to another XY location for forming another bonded portion along the length of the ribbon materials (e.g., forming another bonded portion along the length of the ribbon material to the corresponding busbar (e.g., see FIGS. 4D-4E , discussed below)).
- Such a process may be repeated until the desired number of bonded portions are formed between a given length of bonding material (e.g., a ribbon material) and a respective bonding location (e.g., a busbar of a solar substrate).
- FIG. 4C illustrates another bonding system similar to that shown in FIG. 4B (with the same numbering of elements except as specified) except that in FIG. 4C , lower bonding locations 476 a, 476 b oppose (or are substantially under) respective upper bonding locations 456 a, 456 b.
- respective upper and lower bonding tools 440 a, 440 b; 460 a, 460 b may provide support for each other during their respective bond formation processes (e.g., see FIGS. 2B-2E ), if desired.
- FIGS. 4D-4E illustrate a pair of bonding tools forming ribbon bonds on upper bonding locations (e.g., busbars) of a workpiece (e.g., a solar substrate) in accordance with an exemplary embodiment of the present invention.
- the formation of lower bonds on the lower surface of the workpiece is not illustrated for simplicity and ease of understanding.
- FIG. 4D illustrates workpiece 400 (e.g., solar substrate 400 ) having a pair of busbars 456 a, 456 b on its upper surface 402 .
- a pair of conductive ribbons 442 a, 442 b is positioned on respective busbars 456 a, 456 b and is generally aligned therewith.
- Ribbon bonding tools 440 a ′, 440 b ′ have their respective upper terminal ends engaged in transducers 452 a ′, 452 b ′, and transducers 452 a ′, 452 b ′ are supported by respective upper bond head assemblies 454 a ′, 454 b ′. Ribbon bonding tools 440 a ′, 440 b ′ are carried by bond head assemblies 454 a ′, 454 b ′, respectively, that are connected to one another by coupling structure 458 ′.
- FIG. 4E illustrates the ribbon bonding system of FIG. 4D (with the same numbering of elements except as specified) during formation of ribbon bonds (between ribbons 442 a, 442 b and underlying busbars 456 a, 456 b ).
- Three ribbon bond pairs 480 a, 480 b; 482 a, 482 b; 484 a, 484 b are illustrated.
- the vibration of ribbon bonding tools 440 a ′, 440 b ′ scrub against respective ribbons 442 a, 442 b to form ribbon bond pairs 480 a, 480 b; 482 a, 482 b; 484 a, 484 b.
- Bonding tools 440 a ′, 440 b ′ may continue downwardly in FIG. 4E forming additional ribbon bonds at the spaced intervals as shown to securely bond respective ribbons 442 a, 442 b to busbars 456 a, 456 b on workpiece 400 (e.g., solar substrate 400 ).
- Ribbon bonding tools 440 a ′, 440 b ′ would typically scrub along the length of ribbons 442 a, 442 b (i.e., in the X-axis direction in FIG. 4E ).
- bonding tools in any of the exemplary embodiments illustrated and described herein may scrub in any direction in accordance with the present invention.
- FIGS. 4F-4G illustrate a pair of bonding tools (carried together) in tandem forming ribbon bonds on upper bonding locations (e.g., busbars) of a workpiece (e.g., a solar substrate) in accordance with an exemplary embodiment of the present invention (with the same numbering of elements except as specified).
- bonding tools 430 a, 430 b are configured to scrub/vibrate in a direction substantially perpendicular to the length of the ribbons 432 a, 432 b (i.e., along the Y-axis direction in FIGS. 4F-4G ).
- Bonding tools 430 a , 430 b (positioned over conductive ribbons 432 a, 432 b ) have their respective upper terminal ends engaged in transducers 422 a, 422 b which are in turn supported by respective upper bond head assemblies 424 a, 424 b.
- Transducers 422 a, 422 b induce bonding tools 430 a, 430 b to vibrate in the Y-axis direction to form ribbon bonds.
- FIG. 4G illustrates the ribbon bonding system of FIG. 4F during formation of exemplary ribbon bonds, that is, two ribbon bond pairs 490 a, 490 b; 492 a, 492 b as illustrated.
- Ribbon bonding tools 430 a, 430 b scrub against ribbons 432 a, 432 b to form the ribbon bond pairs.
- Coupled bonding tools 430 a, 430 b may continue to move downwardly in FIG. 4G (along the X-axis) forming additional ribbon bonds at the spaced intervals as shown to securely bond respective ribbons 432 a, 432 b to busbars 426 a, 426 b on solar substrate 410 . While a pair of coupled bonding tools 430 a, 430 b are illustrated in FIG.
- alternative configurations are contemplated (e.g., a single bonding tool scrubbing along the Y-axis, more than two bonding tools carried together, multiple bonding tools carried together using alternative structural configurations).
- the bonding tools may operate (e.g., applying ultrasonic energy, applying bond force, etc.) together or independently.
- Other examples of such alternative structural configurations for carrying multiple bonding tools (and multiple transducers) include: (1) an arrangement where the coupling mechanism for carrying the transducers (and bonding tools) is positioned between the transducers such that the transducers point away from one another; and (2) an arrangement where a coupling mechanism for carrying the transducers (and bonding tools) is positioned such that they face one another.
- FIG. 5 illustrates a side sectional block diagram view of a substrate bonding system having upper and lower apertured substrate pressing elements in accordance with an exemplary embodiment of the present invention.
- Upper bonding material 556 is bonded to upper side 502 of workpiece 500
- lower bonding material 576 is bonded to lower side 504 of workpiece 500 .
- Support structure 510 e.g., workholder 510
- supports workpiece 500 e.g., solar substrate 500
- defines a plurality of lower apertures 512 spaced by a plurality of lower pressing elements 562 defined by support structure 510 .
- Apertures 512 expose lower portions 514 of lower bonding material 576 .
- a plurality of vacuum ports 548 within support structure 510 , and adjacent lower bonding material 576 may create a downward vacuum pull against lower bonding material 576 (and/or lower side 504 of workpiece 500 ) to retain substrate 500 against support structure 510 .
- Lower bonding tool pressing member 578 (illustrated adjacent lower bonding tool 560 within aperture 512 ) is supported by the lower bond head assembly (not shown) and may be moveable with respect to the lower bond head assembly independent of lower bonding tool 560 .
- Pressing member 578 presses against lower bonding material 576 proximate lower bonding tool 560 during removal of bonding tool 560 from material 576 (e.g., after a bonding operation), thereby reducing the potential for lower bonding tool 560 to peel away or otherwise damage lower bonding material 576 and/or a portion of workpiece 500 after bonding, because of tool 560 sticking to bonding material 576 .
- Lower terminal end 570 of lower bonding tool 560 is engaged in lower transducer 572 which induces lower bonding tool 560 to vibrate during a bonding process.
- Upper pressing member 542 (e.g., a clamping member for securing workpiece 500 against support structure 510 ) overlies upper bonding material 556 , and includes a plurality of upper apertures 544 (separated by a plurality of upper pressing elements 516 defined by upper pressing member 542 ). Apertures 544 expose upper portions 546 of upper bonding material 556 .
- Upper bonding tool pressing member 558 (illustrated adjacent upper bonding tool 540 within aperture 544 ) is supported by the upper bond head assembly (not shown) and is moveable with respect to the upper bond head assembly independent of upper bonding tool 540 . Such a pressing member(s) may also be supported by (or integrated with), for example, a workholder of the bonding system.
- Pressing member 558 presses against upper bonding material 556 proximate upper bonding tool 540 during removal of bonding tool 540 from material 556 (e.g., after a bonding operation), thereby reducing the potential for upper bonding tool 540 to peel away or otherwise damage upper bonding material 556 and/or a portion of workpiece 500 after bonding, because of tool 540 sticking to bonding material 556 .
- Upper terminal end 550 of upper bonding tool 540 is engaged in upper transducer 552 which induces upper bonding tool 540 to vibrate during a bonding process.
- Upper and lower bonding tools 540 , 560 may form bonds within respective upper and lower apertures 544 , 512 and may then move to another (adjacent) aperture 544 , 512 as indicated by the respective sets of three arrows, and form bonds within those apertures, etc.
- a plurality of upper pressing elements 516 oppose lower apertures 512 and may serve to support lower bonding tool 560 while bonding in a plurality of lower apertures 512 .
- a plurality of lower pressing elements 562 oppose upper apertures 544 and may serve to support upper bonding tool 540 while bonding in a plurality of upper apertures 544 .
- workpiece 500 may be indexed and aligned into its proper location shown in FIG. 5 using any of a number of alignment structures such as, for example, locating pins, gripper mechanisms, pusher mechanisms, puller mechanisms.
- alignment structures such as, for example, locating pins, gripper mechanisms, pusher mechanisms, puller mechanisms.
- respective bonding materials 556 , 576 ) have been provided on opposing sides of workpiece 500 prior to securing (between support structure 510 and upper pressing member 542 ) and subsequent bonding.
- bonding materials e.g., ribbon materials
- bonding materials 556 , 576 may be fed into their position on either side of workpiece 500 (e.g., prior to being secured in position) using any of a number of techniques, including, for example, manual placement, spool feeding, amongst others.
- Upper pressing element 616 is positioned over lower bonding tool 660 to oppose and support (as at downward force arrow 618 ) lower bonding tool 660 during formation of a lower bond of exposed portion 614 of lower bonding material 676 to workpiece 600 .
- Upper pressing element 616 may be supported by (or integrated into) various structures not shown, for example, an upper bond head assembly, a workholder of the bonding system (e.g., as in FIG. 5 ), a separate structure of the bonding system (e.g., such that the upper pressing element(s) aligns with, and follows, the lower bonding tool from bond location to bond location), amongst others. While a single upper pressing element 616 is shown in FIGS. 6A-6B , it is understood that a plurality of upper pressing elements (which may be actuated individually or together, and which may be carried individually or carried by a common support structure) may be provided for bonding of a given workpiece.
- FIG. 6B illustrates lower bonding tool pressing member 678 proximate the tip of lower bonding tool 660 , within aperture 612 and contacting lower bonding material 676 at/proximate the lower bond site.
- Lower bonding tool pressing member 678 may be supported by the lower bond head assembly (not shown) and may be moveable with respect to the lower bond head assembly independent of lower bonding tool 660 .
- Lower bonding tool pressing member 678 presses against material 676 proximate bonding tool 660 during removal of bonding tool 660 from material 676 (e.g., after or towards the end of a bonding operation), thereby reducing the potential for bonding tool 660 to peel away or otherwise damage bonding material 676 and/or a portion of workpiece 600 after bonding, because of tool 660 sticking to bonding material 676 .
- lower bonding tool 660 is shown forming a lower bond with opposing/supporting upper pressing element 616 in FIGS. 6A-6B
- an analogous upper bonding tool may form an upper bond with an analogous opposing/supporting lower pressing element within the teachings of the present invention.
- FIGS. 7A-7B are perspective and side block diagram views of three ribbon bonded solar substrates in accordance with an exemplary embodiment of the present invention.
- an upper conductive ribbon ( 756 ′) of a bonded solar substrate ( 780 ′) extends from one end of the solar substrate ( 780 ′) to its other end and then continues to the lower side ( 704 ) of an adjacent bonded solar substrate ( 780 ) to become that adjacent solar substrate's ( 780 ) lower conductive ribbon ( 776 ). It is noted that several solar substrates may be electrically interconnected as illustrated, with each end substrate being configured for electrical interconnection to other elements as desired in the chosen application.
- bonds may be formed on the first (upper) and second (lower) sides of a workpiece without flipping the workpiece.
- a first (upper) bonding operation to bond a first (upper) bonding material to a first (upper) side of a workpiece may be conducted at the same time as a second (lower) bonding operation to bond a second (lower) bonding material to a second (lower) side of a workpiece.
- an upper bonding process may be completed before a lower bonding process begins, and vice-versa.
- the same bonding tool/bond head assembly/bonding system may be used to form the bonds on the upper surface of a workpiece as well as the lower side of the workpiece, and vice-versa.
- a first bond formation on the first side may occur: a) at the same time as a second bond is formed on the second side; b) at least partially concurrently with formation of a second bond on the second side; or c) sequentially with formation of a second bond on the second side.
- the first bond formation may occur: a) oppositely the second bond formation (i.e., the upper and lower bonding tools are positioned on opposite sides of the substrate opposing each other such as in FIGS. 2B-2E ); or b) offset from the second bond formation (i.e., such as in FIG. 2A ).
- Certain of the exemplary embodiments of the present invention disclosed herein include multiple bonding tools for bonding on a side of a workpiece (e.g., an upper side, a lower side), where each of the bonding tools includes a respective ultrasonic transducer.
- a single transducer may carry (and/or excite) a number of bonding tools.
- the multiple bonding tools may bond the bonding material to the respective bonding locations simultaneously if desired through the actuation of the single transducer.
- the workpiece includes two busbars on the upper surface of the workpiece (as in FIGS.
- a single transducer may carry two bonding tools that are spaced to match the spacing of the two busbars.
- more than two bonding tools may be carried by the transducer.
- such an arrangement (a single transducer carrying multiple bonding tools) may be utilized on the upper side of the workpiece and/or the lower side of the workpiece.
- transducer design issues e.g., locations of nodes, anti-nodes, direction of scrub, etc
- the present invention contemplates embodiments where one transducer (engaged with one bonding tool) is used to form bonds at a plurality of locations simultaneously using multiple bonding tools.
- the plurality of locations may include a plurality of locations on one side of the workpiece, or a location(s) on multiple sides (e.g., both an upper side and a lower side) of a workpiece, etc.
- a bonding tool (engaged with an ultrasonic transducer) which contacts a bonding material on one side of a workpiece (e.g., an upper side) may excite the bonding system such that a second bonding tool (e.g., which contacts the bonding material at a different location on the same side of the workpiece, or on the opposite side of the workpiece such as the lower side) forms a bond between the bonding material and a bonding location without the second bonding tool being engaged in an ultrasonic transducer.
- a second bonding tool e.g., which contacts the bonding material at a different location on the same side of the workpiece, or on the opposite side of the workpiece such as the lower side
- more than two (i.e., multiple) bonding tools could be utilized in such a system where the excitation generated by a single transducer is used to form bonds using the multiple bonding tools.
- the process may be optimized such as by controlling the length of the bonding tools in order to obtain the desired vibration/scrubbing (e.g., vibration by different bonding tools in or out of phase with one another).
- one or more of the bonding tools may be non-conventional bonding tools.
- a portion of a workpiece support structure in contact with a bonding material may be used to form a bond in a system excited by a distinct ultrasonic transducer.
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Abstract
Description
- This application is a continuation of U.S. patent application Ser. No. 13/578,740 filed on Aug. 13, 2012, which claims the benefit of International Patent Application No. PCT/US2011/034411 filed Apr. 29, 2011, which claims the benefit of U.S. Provisional Application No. 61/329,697 filed on Apr. 30, 2010, the content of all of which is incorporated herein by reference.
- The present invention relates to ultrasonic bonding operations, and more particularly, to bonding systems for solar cells or the like.
- In the processing and packaging of semiconductor devices, ultrasonic bonding (e.g., wire bonding, ribbon bonding, etc.) continues to be a widely used method of providing electrical interconnection between locations within a package. For example, ribbon bonding machines are used to form ribbon interconnections between respective locations to be electrically interconnected such as is disclosed in U.S. Pat. No. 7,745,253, the contents of which are herein incorporated by reference in their entirety. In ultrasonic bonding, an upper terminal end of a bonding tool is typically engaged in an ultrasonic transducer which causes the bonding tool to vibrate during bonding. Ultrasonic bonding typically uses relative motion between (1) the bonding material and (2) a bonding location to form a bond therebetween. Ultrasonic wedge wire and ribbon bonding are typically low temperature (i.e., room temperature) bonding processes (although heat may be used if desired). In contrast, ultrasonic ball bonding often uses heat wherein the ultrasonic process may then be referred to as thermosonic.
- In providing electrical interconnection in solar substrate applications (e.g., crystalline silicon solar cells, thin film solar cells, etc.) techniques such as soldering or conductive adhesive are used to electrically connect adjacent cells. Certain types of solar substrates (e.g., crystalline silicon solar cells) utilize such connections on the top and bottom of the substrate. Such soldering processes have limitations such as cost, reliability, yield, compliance with lead free requirements, and complexity.
- Thus, it would be desirable to provide improved ultrasonic bonding systems and methods of use.
- According to an exemplary embodiment of the present invention, an ultrasonic bonding machine is provided. The ultrasonic bonding machine includes a support structure configured to support a workpiece during a bonding operation. The ultrasonic bonding machine further includes an upper bonding tool positioned above the support structure and configured for bonding an upper bonding material to an upper side of the workpiece, and a lower bonding tool positioned below the support structure and configured for bonding a lower bonding material to a lower side of the workpiece.
- According to another exemplary embodiment of the present invention, a method of bonding a workpiece is provided. The method includes the step of supporting a workpiece with a support structure during a bonding operation. The method further includes the steps of bonding an upper bonding material to an upper side of the workpiece using an upper bonding tool positioned above the workpiece, and bonding a lower bonding material to a lower side of the workpiece using a lower bonding tool positioned below the workpiece.
- According to another exemplary embodiment of the present invention, an ultrasonic ribbon bonding machine is provided. The ultrasonic ribbon bonding machine includes a support structure configured to support a solar substrate during a ribbon bonding operation. The ultrasonic ribbon bonding machine further includes an upper ribbon bonding tool positioned above the support structure and configured for bonding a first conductive ribbon to an upper side of the solar substrate, and a lower ribbon bonding tool positioned below the support structure and configured for bonding a second conductive ribbon to a lower side of the solar substrate.
- According to another exemplary embodiment of the present invention, a method of bonding a solar substrate is provided. The method includes the step of supporting a solar substrate with a support structure during a bonding operation. The method further includes the steps of bonding a first conductive ribbon to an upper side of the solar substrate using an upper ribbon bonding tool positioned above the solar substrate, and bonding a second conductive ribbon to a lower side of the solar substrate using a lower ribbon bonding tool positioned below the solar substrate.
- The invention is best understood from the following detailed description when read in connection with the accompanying drawing. 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 drawing are the following figures:
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FIG. 1 is a side sectional block diagram view of a substrate with respective bonding tools over an upper side and under a lower side in accordance with an exemplary embodiment of the present invention; -
FIGS. 2A-2E are side sectional block diagram views of bonding tool positions and configurations according to various exemplary embodiments of the present invention; -
FIG. 3 is a plan block diagram view of a substrate during bonding with upper and lower bonding tools according to an exemplary embodiment of the present invention; -
FIG. 4A is a plan block diagram view of a substrate during bonding with multiple upper and lower bonding tools according to an exemplary embodiment of the present invention; -
FIGS. 4B-4C are plan block diagram views of a substrate during bonding with respective upper bonding tools carried together, and lower bonding tools coupled for movement together, according to exemplary embodiments of the present invention; -
FIGS. 4D-4E are plan block diagram views of a substrate during bonding with upper bonding tools carried together, withFIG. 4E showing formed bonds, according to an exemplary embodiment of the present invention; -
FIGS. 4F-4G are plan block diagram views of a substrate during bonding with upper bonding tools carried together, withFIG. 4G showing formed bonds, according to an exemplary embodiment of the present invention; -
FIG. 5 is a side sectional block diagram view of a substrate bonding system having upper and lower apertured substrate pressing elements in accordance with an exemplary embodiment of the present invention; -
FIGS. 6A-6B are respective end and side sectional block diagram views of bonding system elements according to an exemplary embodiment of the present invention; and -
FIGS. 7A-7B are respective perspective block diagram view of a series of three electrically interconnected solar substrates, and a simplified side view thereof, according to an exemplary embodiment of the present invention. - According to various exemplary embodiments of the present invention, ultrasonic bonding systems (and related processes) are provided for bonding to an upper side and a lower side of a workpiece. More specifically, an upper bonding tool is provided for bonding a bonding material to an upper side of the workpiece, and a lower bonding tool is provided for bonding a bonding material to a lower side of the workpiece. Bonding operations of the upper and lower bonding tools may (or may not) be simultaneous. The workpiece may be any type of device configured for bonding on an upper side and a lower side. The ultrasonic bonding systems may be, for example: (1) ball bonding systems for forming wire interconnections and related structures (e.g., wire loops); (2) wedge wire bonding systems for forming wire interconnections and related structures (e.g., wire loops); and (3) ribbon bonding systems (e.g., wedge ribbon bonding systems) for forming ribbon interconnections using materials such as aluminum ribbon material, aluminum-copper clad ribbon material, amongst others.
- An exemplary workpiece is a semiconductor device such as a semiconductor die (or a plurality of die) supported by a leadframe strip. One specific exemplary workpiece includes a leadframe strip with semiconductor die(s) attached on both an upper and lower side (e.g., power semiconductor devices such as MOSFETs). Another specific exemplary workpiece is a solar substrate (e.g., solar cell) such as a crystalline silicon solar cell. The present invention has specific advantages in solar substrate applications where it is desirable to form electrical interconnections on both an upper and a lower side of the workpiece. In embodiments of the present invention including a bonding tool(s) for bonding an upper side of the workpiece as well as a bonding tool(s) for bonding a lower side of the workpiece, the workpiece may not need to be flipped over to form the lower side bonds (e.g., ribbon bonds). This results in less handling of the workpiece (and therefore a lower cost of handling equipment), and a reduced potential for damage to the workpiece.
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FIG. 1 illustrates a block diagram view of an exemplary ultrasonic bonding system includingsupport structure 110 supportingworkpiece 100.Workpiece 100 may be a substrate (e.g., a leadframe carrying one or more semiconductor die), a solar substrate (e.g., a solar cell), amongst others.Support structure 110 may be any appropriate structure for supporting the given workpiece such as, for example, a heat block, an anvil, a vacuum chuck, amongst others. Such a support structure may be included in an indexing system, similar to such systems used on die or wire bonding equipment.Upper bonding tool 140 is positioned abovesupport structure 110/workpiece 100 and is configured to bond an upper bonding material (not shown) toupper side 102 ofworkpiece 100.Lower bonding tool 160 is positioned belowsupport structure 110/workpiece 100 and is configured to bond a lower bonding material (not shown) tolower side 104 ofworkpiece 100 through openings (not shown) in the support structure. Upper andlower bonding tools lower bonding tools -
FIGS. 2A-2E illustrate the positions and configurations of upper and lowerultrasonic bonding tools lower bonding materials lower surfaces workpiece 200 in accordance with various exemplary embodiments of the present invention. -
FIG. 2A illustrates upper bonding tool 240 (for bondingupper bonding material 220 toupper surface 202 of workpiece 200) and lower bonding tool 260 (for bondinglower bonding material 222 tolower surface 204 of workpiece).Tools respective tools FIG. 2A may include pressing elements above/below therespective tools -
FIG. 2B illustrates upper bonding tool 240 (for bondingupper bonding material 220 toupper side 202 of workpiece 200) opposing lower bonding tool 260 (for bondinglower bonding material 222 tolower side 204 of workpiece 200). For example, face 242 ofupper bonding tool 240 is substantially directly aboveface 262 oflower bonding tool 260. In this arrangement,upper bonding tool 240 may be used for support during bonding usinglower bonding tool 260, andlower bonding tool 260 may be used for support during bonding usingupper bonding tool 240. In an example ribbon bonding application using a ribbon bonding tool having a rectangular face, the tools may be aligned/rotated to at any desired angle (e.g., zero degrees, 90 degrees, etc.) with respect to one another. -
FIGS. 2C-2E illustrate exemplary configurations of upper andlower bonding tools lower bonding tools FIG. 2C illustrates sequential such upper and lower bond formation,FIG. 2D illustrates simultaneous, in-phase upper and lower bond formation, andFIG. 2E illustrates simultaneous, out-of-phase upper and lower bond formation. - “In-phase” as used herein refers to vibration of the upper and lower bonding tools together in the same direction, that is, they vibrate/scrub in the same direction at substantially the same time, that is, substantially synchronized with one another (e.g., the tools remain substantially one over the other during bonding as illustrated in
FIG. 2D ). “Out-of-phase” as used herein refers to vibration of the bonding tools that are not in-phase, and may include vibration/scrub in substantially opposite directions with respect to one another, that is, substantially asynchronous vibration. That is, when an upper bonding tool is moving to the right, the lower bonding tool is moving to the left and vice versa. -
FIG. 2C illustrateslower bonding tool 260 providing support during bonding byupper bonding tool 240.Upper bonding tool 240 vibrates as at 244 (e.g., induced by connection to an upper transducer of an upper ultrasonic bond head assembly, not shown) to form an upper bond, whilelower bonding tool 260 which provides support for the upper bond formation may (or may not, as desired) remain substantially static). Once the upper bond is formed,upper bonding tool 240 may cease vibration and remain substantially static to support formation of a lower bond by vibrating lower bonding tool 260 (e.g., induced to vibrate through a connection to a lower transducer of lower ultrasonic bond head assembly, not shown). It is noted that this sequence of upper and lower bond formation may be reversed. Of course, more than one upper bond may be formed using the upper bonding tool 240 (using thelower bonding tool 260 as a support) before switching to formation of lower bonds using the lower bonding tool 260 (using theupper bonding tool 240 as a support). -
FIG. 2D illustrates substantially simultaneous, in-phase upper and lower bond formation by opposing upper andlower bonding tools Upper bonding tool 240 vibrates as at 244 to form the upper bond, whilelower bonding tool 260 vibrates as at 264 to form the lower bond, such thatupper bonding tool 240 andlower bonding tool 260 vibrate in-phase. This in-phase vibration is shown schematically by upper and lowerbonding tool arrows lower bonding tools bonding tools -
FIG. 2E illustrates substantially simultaneous, out-of-phase upper and lower bond formation by opposing upper andlower bonding tools Upper bonding tool 240 vibrates as at 244 to form the upper bond, whilelower bonding tool 260 vibrates as at 266 to form the lower bond, such thatupper bonding tool 240 andlower bonding tool 260 vibrate out-of-phase. This out-of-phase vibration (e.g., 180 degrees out of phase with one another) is shown schematically by upperbonding head arrow 244 pointing in the left direction and lowerbonding head arrow 266 pointing in the right direction. Such out-of-phase vibration of the opposing upper andlower bonding tools workpiece 200 that may have been induced by upper andlower bonding tools - It is noted that in the following exemplary embodiments illustrated in FIGS. 3 and 4A-4C, certain portions of lower structures/elements (such as a portions of a lower bonding tool transducer) are generally shown in dashed lines to indicate that they are masked by a workpiece or the like.
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FIG. 3 illustrates bonding ofworkpiece 300 using upper andlower bonding tools terminal end 350 ofupper bonding tool 340 is engaged inupper transducer 352, andupper transducer 352 is supported by upperbond head assembly 354 of an upper bonding system. Lowerterminal end 370 oflower bonding tool 360 is engaged inlower transducer 372, andlower transducer 372 is supported by lowerbond head assembly 374 of an upper bonding system. - As illustrated,
upper bonding tool 340 andlower bonding tool 360 may bond bothupper side 302 andlower side 304, respectively, ofworkpiece 300 during a bonding operation.Upper bonding tool 340 is configured to bond a bonding material (e.g., a wire, a conductive ribbon, etc., not shown) toconductive regions busbars upper side 302 ofworkpiece 300.Lower bonding tool 360 is configured to bond a bonding material toconductive regions lower side 304 ofworkpiece 300. Upper and lower conductive regions of a given workpiece may be staggered (as shown inFIG. 3 ), or may oppose each other. Further, in certain applications, the entire lower surface of the workpiece may be conductive while the upper surface may include conductive regions (e.g., busbars on an upper surface of a solar substrate), or vice-versa. -
FIGS. 4A-4B illustrateworkpiece 400 being bonded with multiple upper and lower bonding tools according to certain exemplary embodiments of the present invention.FIG. 4A illustrates twoupper bonding tools transducers upper transducers bond head assemblies lower bonding tools lower transducers lower transducers bond head assemblies Upper bonding tools conductive regions upper side 402 ofworkpiece 400.Lower bonding tools conductive regions lower side 404 ofworkpiece 400. Each set ofbonding tools - While it is contemplated that there may be more than two multiple bonding tools on each side of
workpiece 400, there may also be multiple bonding tools on one side ofworkpiece 400, and only one bonding tool on the other side ofworkpiece 400, and there may also be unequal numbers of multiple bonding tools on either sides ofworkpiece 400. Of course, it is understood that the use of multiple bonding tools on the upper and/or lower sides of the workpiece may reduce bonding time of the workpiece, and may simplify certain aspects of the design of the bonding system. -
FIG. 4B illustrates another bonding system similar to that shown inFIG. 4A (with the same numbering of elements except as specified). InFIG. 4B : (1)upper bonding tools bond head assemblies coupling structure 458; and (2) thelower bonding tools bond head assemblies coupling structure 478. Thus, each pair of bond head assemblies/bonding tools is coupled for movement together in at least one direction. Of course, more than two bonding tools (e.g., including bond head assemblies) may be connected together as desired in the given application. Further, bonding tool pairs 440 a, 440 b; 460 a, 460 b may be carried by a common structure that is different than couplingstructures 458, 478 (e.g., a coupling structure different from one that connects respective bond head assemblies, etc.). - It is understood that certain workpieces (e.g., solar substrates/cells) may include bonding locations with a predetermined spacing. For example,
FIG. 7A (described below) illustrates workpiece 700 (e.g., solar substrate 700) including two bonding locations (e.g., busbars 782) onupper surface 702, wherebusbars 782 have a predetermined spacing between each other. It is desired to bond a bonding material (e.g., a ribbon material) to each ofbonding locations 782, and as such, it may be desirable to provide a bonding system that includes multiple bonding tools configured to bond the bonding material to the bonding location simultaneously. In one example, the number of bonding tools may equal the number of bonding locations (e.g., busbars of a solar substrate) to be bonded. - These multiple bonding tools may be independently moveable with respect to one another (e.g., as in
FIG. 4A ) or may be carried together for movement in at least one direction (e.g., as inFIG. 4B ). In a case where the multiple bonding tools are carried together, the spacing of the bonding tools may be provided to match the spacing of the conductive regions (e.g., busbars on a solar substrate). For example, the spacing between the bonding tools may be configured to equal the spacing between busbars 782 (e.g., seeFIG. 7A ). In such an example, the bonding tools (e.g., driven by a single bond head, driven by multiple bond heads, etc.) may move to a first XY location using an XY table of the bonding machine where a first XY location corresponds to an XY position of the desired bonded locations. Then, the upper bonding tools may be lowered (and/or the lower bonding tools may be raised) (e.g., along the Z-axis) until each of the bonding tools contacts a respective bonding material (e.g., the ribbon material). The bonding tools bond the bonding material to the respective bonding locations (e.g., bond a portion of ribbon material to a respective area of a busbar). Then, the upper bonding tools may be raised (and/or the lower bonding tools may be lowered) and moved to another XY location for forming another bonded portion along the length of the ribbon materials (e.g., forming another bonded portion along the length of the ribbon material to the corresponding busbar (e.g., seeFIGS. 4D-4E , discussed below)). Such a process may be repeated until the desired number of bonded portions are formed between a given length of bonding material (e.g., a ribbon material) and a respective bonding location (e.g., a busbar of a solar substrate). -
FIG. 4C illustrates another bonding system similar to that shown inFIG. 4B (with the same numbering of elements except as specified) except that inFIG. 4C ,lower bonding locations upper bonding locations lower bonding tools FIGS. 2B-2E ), if desired. -
FIGS. 4D-4E illustrate a pair of bonding tools forming ribbon bonds on upper bonding locations (e.g., busbars) of a workpiece (e.g., a solar substrate) in accordance with an exemplary embodiment of the present invention. The formation of lower bonds on the lower surface of the workpiece is not illustrated for simplicity and ease of understanding.FIG. 4D illustrates workpiece 400 (e.g., solar substrate 400) having a pair ofbusbars upper surface 402. A pair ofconductive ribbons respective busbars Ribbon bonding tools 440 a′, 440 b′ have their respective upper terminal ends engaged intransducers 452 a′, 452 b′, andtransducers 452 a′, 452 b′ are supported by respective upperbond head assemblies 454 a′, 454 b′.Ribbon bonding tools 440 a′, 440 b′ are carried bybond head assemblies 454 a′, 454 b′, respectively, that are connected to one another bycoupling structure 458′.Ribbon bonding tools 440 a′, 440 b′ are positioned onconductive ribbons respective transducers 452 a′, 452 b′ to form ribbon bonds. -
FIG. 4E illustrates the ribbon bonding system ofFIG. 4D (with the same numbering of elements except as specified) during formation of ribbon bonds (betweenribbons underlying busbars ribbon bonding tools 440 a′, 440 b′ scrub againstrespective ribbons Bonding tools 440 a′, 440 b′ (carried together) may continue downwardly inFIG. 4E forming additional ribbon bonds at the spaced intervals as shown to securely bondrespective ribbons busbars Ribbon bonding tools 440 a′, 440 b′ would typically scrub along the length ofribbons FIG. 4E ). However, bonding tools (in any of the exemplary embodiments illustrated and described herein) may scrub in any direction in accordance with the present invention. -
FIGS. 4F-4G illustrate a pair of bonding tools (carried together) in tandem forming ribbon bonds on upper bonding locations (e.g., busbars) of a workpiece (e.g., a solar substrate) in accordance with an exemplary embodiment of the present invention (with the same numbering of elements except as specified). In contrast to the embodiment illustrated inFIGS. 4D-4E ,bonding tools ribbons FIGS. 4F-4G ). - Specifically,
FIG. 4F illustratesribbon bonding tools coupling structures 428.Tools FIG. 4G ) onbusbars upper side 412 of solar substrate 410 (the formation of bonds on the lower surface ofsolar substrate 410 is not shown for simplicity).Ribbons respective busbars Bonding tools conductive ribbons transducers bond head assemblies Transducers bonding tools -
FIG. 4G illustrates the ribbon bonding system ofFIG. 4F during formation of exemplary ribbon bonds, that is, two ribbon bond pairs 490 a, 490 b; 492 a, 492 b as illustrated.Ribbon bonding tools ribbons bonding tools FIG. 4G (along the X-axis) forming additional ribbon bonds at the spaced intervals as shown to securely bondrespective ribbons busbars solar substrate 410. While a pair of coupledbonding tools FIG. 4G , alternative configurations are contemplated (e.g., a single bonding tool scrubbing along the Y-axis, more than two bonding tools carried together, multiple bonding tools carried together using alternative structural configurations). Of course, the bonding tools may operate (e.g., applying ultrasonic energy, applying bond force, etc.) together or independently. Other examples of such alternative structural configurations for carrying multiple bonding tools (and multiple transducers) include: (1) an arrangement where the coupling mechanism for carrying the transducers (and bonding tools) is positioned between the transducers such that the transducers point away from one another; and (2) an arrangement where a coupling mechanism for carrying the transducers (and bonding tools) is positioned such that they face one another. -
FIG. 5 illustrates a side sectional block diagram view of a substrate bonding system having upper and lower apertured substrate pressing elements in accordance with an exemplary embodiment of the present invention.Upper bonding material 556 is bonded toupper side 502 ofworkpiece 500, andlower bonding material 576 is bonded tolower side 504 ofworkpiece 500. Support structure 510 (e.g., workholder 510) supports workpiece 500 (e.g., solar substrate 500), and defines a plurality of lower apertures 512 (separated by a plurality of lowerpressing elements 562 defined by support structure 510).Apertures 512 exposelower portions 514 oflower bonding material 576. A plurality ofvacuum ports 548 withinsupport structure 510, and adjacentlower bonding material 576, may create a downward vacuum pull against lower bonding material 576 (and/orlower side 504 of workpiece 500) to retainsubstrate 500 againstsupport structure 510. Lower bonding tool pressing member 578 (illustrated adjacentlower bonding tool 560 within aperture 512) is supported by the lower bond head assembly (not shown) and may be moveable with respect to the lower bond head assembly independent oflower bonding tool 560. Pressingmember 578 presses againstlower bonding material 576 proximatelower bonding tool 560 during removal ofbonding tool 560 from material 576 (e.g., after a bonding operation), thereby reducing the potential forlower bonding tool 560 to peel away or otherwise damagelower bonding material 576 and/or a portion ofworkpiece 500 after bonding, because oftool 560 sticking tobonding material 576. Lowerterminal end 570 oflower bonding tool 560 is engaged inlower transducer 572 which induceslower bonding tool 560 to vibrate during a bonding process. - Upper pressing member 542 (e.g., a clamping member for securing
workpiece 500 against support structure 510) overliesupper bonding material 556, and includes a plurality of upper apertures 544 (separated by a plurality of upperpressing elements 516 defined by upper pressing member 542).Apertures 544 exposeupper portions 546 ofupper bonding material 556. Upper bonding tool pressing member 558 (illustrated adjacentupper bonding tool 540 within aperture 544) is supported by the upper bond head assembly (not shown) and is moveable with respect to the upper bond head assembly independent ofupper bonding tool 540. Such a pressing member(s) may also be supported by (or integrated with), for example, a workholder of the bonding system. Pressingmember 558 presses againstupper bonding material 556 proximateupper bonding tool 540 during removal ofbonding tool 540 from material 556 (e.g., after a bonding operation), thereby reducing the potential forupper bonding tool 540 to peel away or otherwise damageupper bonding material 556 and/or a portion ofworkpiece 500 after bonding, because oftool 540 sticking tobonding material 556. Upperterminal end 550 ofupper bonding tool 540 is engaged inupper transducer 552 which inducesupper bonding tool 540 to vibrate during a bonding process. Upper andlower bonding tools lower apertures aperture pressing elements 516 opposelower apertures 512 and may serve to supportlower bonding tool 560 while bonding in a plurality oflower apertures 512. Similarly, a plurality of lowerpressing elements 562 opposeupper apertures 544 and may serve to supportupper bonding tool 540 while bonding in a plurality ofupper apertures 544. - As will be appreciated by those skilled in the art,
workpiece 500 may be indexed and aligned into its proper location shown inFIG. 5 using any of a number of alignment structures such as, for example, locating pins, gripper mechanisms, pusher mechanisms, puller mechanisms. As shown inFIG. 5 (and applicable to other embodiments of the present invention, as desired) respective bonding materials (556, 576) have been provided on opposing sides ofworkpiece 500 prior to securing (betweensupport structure 510 and upper pressing member 542) and subsequent bonding. The presence of the bonding materials (e.g., ribbon materials) on opposing sides ofworkpiece 500 prior to and during bonding substantially reduces the potential for damage to delicate structures ofworkpiece 500 because the bonding materials act as buffers betweenworkpiece 500 andsupport structure 510 and upper pressingmember 542.Bonding materials -
FIGS. 6A-6B illustrate respective end and side sectional block diagram views of a lower bonding tool forming a bond opposed by an upper workpiece pressing element to provide support for the lower bonding tool in accordance with an exemplary embodiment of the present invention.FIG. 6B is a view taken alongline 6B-6B ofFIG. 6A . As shown in each ofFIGS. 6A-6B ,support structure 610 supportsworkpiece 600.Upper bonding material 656 overliesupper surface 602 ofworkpiece 600 andlower bonding material 676 contactslower surface 604 ofworkpiece 600.Lower bonding tool 660 extends through one of a plurality of support structure apertures 612 (of support structure 610) to contact one of a plurality of exposedportions 614 oflower bonding material 676. Upperpressing element 616 is positioned overlower bonding tool 660 to oppose and support (as at downward force arrow 618)lower bonding tool 660 during formation of a lower bond of exposedportion 614 oflower bonding material 676 toworkpiece 600. Upperpressing element 616 may be supported by (or integrated into) various structures not shown, for example, an upper bond head assembly, a workholder of the bonding system (e.g., as inFIG. 5 ), a separate structure of the bonding system (e.g., such that the upper pressing element(s) aligns with, and follows, the lower bonding tool from bond location to bond location), amongst others. While a single upperpressing element 616 is shown inFIGS. 6A-6B , it is understood that a plurality of upper pressing elements (which may be actuated individually or together, and which may be carried individually or carried by a common support structure) may be provided for bonding of a given workpiece. - While not shown in
FIG. 6A for simplicity,FIG. 6B illustrates lower bondingtool pressing member 678 proximate the tip oflower bonding tool 660, withinaperture 612 and contactinglower bonding material 676 at/proximate the lower bond site. Lower bondingtool pressing member 678 may be supported by the lower bond head assembly (not shown) and may be moveable with respect to the lower bond head assembly independent oflower bonding tool 660. Lower bondingtool pressing member 678 presses againstmaterial 676proximate bonding tool 660 during removal ofbonding tool 660 from material 676 (e.g., after or towards the end of a bonding operation), thereby reducing the potential forbonding tool 660 to peel away or otherwisedamage bonding material 676 and/or a portion ofworkpiece 600 after bonding, because oftool 660 sticking tobonding material 676. It is noted that whilelower bonding tool 660 is shown forming a lower bond with opposing/supporting upperpressing element 616 inFIGS. 6A-6B , an analogous upper bonding tool may form an upper bond with an analogous opposing/supporting lower pressing element within the teachings of the present invention. - Solar substrates (e.g., solar cells) sometimes utilize electrical connections on an upper side and a lower side of each substrate. Such connections may include (1) connections between adjacent solar substrates, and (2) connections between a solar substrate(s) and an external circuit such as a collection circuit.
FIGS. 7A-7B are perspective and side block diagram views of three ribbon bonded solar substrates in accordance with an exemplary embodiment of the present invention. -
FIGS. 7A-7B illustrate a series of three electrically interconnected and bonded solar substrates according to an exemplary embodiment of the present invention.FIG. 7A illustrates bondedsolar substrates solar substrate workpieces conductive ribbons upper busbars upper surfaces respective workpieces conductive ribbons lower surfaces workpieces conductive ribbons conductive ribbons 756′, 756″, 756′″). As more clearly illustrated inFIG. 7B (with the same numbering of elements except as specified), an upper conductive ribbon (756′) of a bonded solar substrate (780′) extends from one end of the solar substrate (780′) to its other end and then continues to the lower side (704) of an adjacent bonded solar substrate (780) to become that adjacent solar substrate's (780) lower conductive ribbon (776). It is noted that several solar substrates may be electrically interconnected as illustrated, with each end substrate being configured for electrical interconnection to other elements as desired in the chosen application. - It is noted that in the exemplary embodiments of the present invention disclosed herein, and in accordance with the teachings of the present invention, bonds may be formed on the first (upper) and second (lower) sides of a workpiece without flipping the workpiece. During one or more exemplary bonding operations disclosed herein, a first (upper) bonding operation to bond a first (upper) bonding material to a first (upper) side of a workpiece may be conducted at the same time as a second (lower) bonding operation to bond a second (lower) bonding material to a second (lower) side of a workpiece. Further, an upper bonding process may be completed before a lower bonding process begins, and vice-versa. The same bonding tool/bond head assembly/bonding system may be used to form the bonds on the upper surface of a workpiece as well as the lower side of the workpiece, and vice-versa. A first bond formation on the first side may occur: a) at the same time as a second bond is formed on the second side; b) at least partially concurrently with formation of a second bond on the second side; or c) sequentially with formation of a second bond on the second side. Further, the first bond formation may occur: a) oppositely the second bond formation (i.e., the upper and lower bonding tools are positioned on opposite sides of the substrate opposing each other such as in
FIGS. 2B-2E ); or b) offset from the second bond formation (i.e., such as inFIG. 2A ). - Certain of the exemplary embodiments of the present invention disclosed herein include multiple bonding tools for bonding on a side of a workpiece (e.g., an upper side, a lower side), where each of the bonding tools includes a respective ultrasonic transducer. However, the present invention is not limited to such an arrangement. For example, a single transducer may carry (and/or excite) a number of bonding tools. In such an arrangement, the multiple bonding tools may bond the bonding material to the respective bonding locations simultaneously if desired through the actuation of the single transducer. As a specific example, if the workpiece includes two busbars on the upper surface of the workpiece (as in
FIGS. 4A-4G ), then a single transducer may carry two bonding tools that are spaced to match the spacing of the two busbars. Of course, more than two bonding tools may be carried by the transducer. Further, such an arrangement (a single transducer carrying multiple bonding tools) may be utilized on the upper side of the workpiece and/or the lower side of the workpiece. Of course, transducer design issues (e.g., locations of nodes, anti-nodes, direction of scrub, etc) may be considered in the actual design of a transducer carrying multiple bonding tools, as will be appreciated by one skilled in the art. - Further, a hybrid bond tool may be utilized which includes a plurality of bonding contacts (e.g., where the bonding contacts are portions of the bonding tool that contact the bonding material during bonding). Such bonding contacts may be used to form bonds at different locations simultaneously, or separately, as desired. The different locations may be a plurality of bonding locations on one side of a workpiece, or a plurality of bonding locations including at least one location on each of multiple sides (e.g., an upper and lower side) of the workpiece.
- As provided above, the present invention contemplates embodiments where one transducer (engaged with one bonding tool) is used to form bonds at a plurality of locations simultaneously using multiple bonding tools. The plurality of locations may include a plurality of locations on one side of the workpiece, or a location(s) on multiple sides (e.g., both an upper side and a lower side) of a workpiece, etc. For example, a bonding tool (engaged with an ultrasonic transducer) which contacts a bonding material on one side of a workpiece (e.g., an upper side) may excite the bonding system such that a second bonding tool (e.g., which contacts the bonding material at a different location on the same side of the workpiece, or on the opposite side of the workpiece such as the lower side) forms a bond between the bonding material and a bonding location without the second bonding tool being engaged in an ultrasonic transducer. Of course, more than two (i.e., multiple) bonding tools could be utilized in such a system where the excitation generated by a single transducer is used to form bonds using the multiple bonding tools. Furthermore, the process may be optimized such as by controlling the length of the bonding tools in order to obtain the desired vibration/scrubbing (e.g., vibration by different bonding tools in or out of phase with one another). Further still, one or more of the bonding tools may be non-conventional bonding tools. In one specific example, a portion of a workpiece support structure in contact with a bonding material may be used to form a bond in a system excited by a distinct ultrasonic transducer.
- Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
Claims (68)
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US13/941,922 US8573468B1 (en) | 2010-04-30 | 2013-07-15 | Ultrasonic bonding systems and methods of using the same |
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US13/941,922 US8573468B1 (en) | 2010-04-30 | 2013-07-15 | Ultrasonic bonding systems and methods of using the same |
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US8544717B2 (en) | 2013-10-01 |
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