WO2001000388A1 - Appareil de soudage a ultrasons - Google Patents

Appareil de soudage a ultrasons Download PDF

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Publication number
WO2001000388A1
WO2001000388A1 PCT/US2000/017429 US0017429W WO0100388A1 WO 2001000388 A1 WO2001000388 A1 WO 2001000388A1 US 0017429 W US0017429 W US 0017429W WO 0100388 A1 WO0100388 A1 WO 0100388A1
Authority
WO
WIPO (PCT)
Prior art keywords
ultrasound
weld
weldable material
region
welding
Prior art date
Application number
PCT/US2000/017429
Other languages
English (en)
Inventor
Peter T. Lee
Andrew Kelley, Iii
Original Assignee
Virtual Ink Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/340,747 external-priority patent/US6217686B1/en
Application filed by Virtual Ink Corporation filed Critical Virtual Ink Corporation
Priority to AU56365/00A priority Critical patent/AU5636500A/en
Publication of WO2001000388A1 publication Critical patent/WO2001000388A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/36—Bending and joining, e.g. for making hollow articles
    • B29C53/38—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges
    • B29C53/40—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of definite length, i.e. discrete articles
    • B29C53/42—Bending and joining, e.g. for making hollow articles by bending sheets or strips at right angles to the longitudinal axis of the article being formed and joining the edges for articles of definite length, i.e. discrete articles using internal forming surfaces, e.g. mandrels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4324—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making closed loops, e.g. belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/49—Internally supporting the, e.g. tubular, article during joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7852—Holding or clamping means for handling purposes using electrostatic forces to hold at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges

Definitions

  • the present invention relates to an ultrasound welding component for welding an ultrasound weldable material into a loop and more particularly for welding an ultrasound transmitting material into a loop shaped ultrasound transducer.
  • Ultrasound welding refers to the technique of using sonic or ultrasonic vibrations to form a weld between ultrasound weldable materials.
  • a typical ultrasound welding system includes an ultrasound welding tool for producing the sonic or ultrasonic vibrations and a surface where the ultrasound weldable materials are positioned. In operation of the system, the ultrasound welding tool is used to compress the ultrasound weldable materials against the surface. This compression generally results in the formation of an ultrasound weld between the sections of ultrasound weldable material which were compressed against the surface.
  • the component includes a weld region about which an ultrasound weldable material may be wrapped.
  • the weld region includes a weld zone consisting of recesses positioned on opposing sides of a weld area.
  • the recesses and weld area have widths selected such that an ultrasound source compressing overlapping sections of the ultrasound weldable material against the weld area forms a weld having a width which is narrower than a sum of the widths of the recesses and the weld area.
  • the component also includes a mechanism which immobilizes the ultrasound weldable material relative to the weld zone.
  • the component includes a weld region about which an ultrasound weldable material may be wrapped, the weld region including a geometric configuration; and a weld zone forming a portion of the weld region, the weld zone having an elliptical curvature.
  • the component includes a weld region about which an ultrasound weldable material may be wrapped; and a weld zone forming a portion of the weld region, the weld zone being adjacent to overlapping sections of the ultrasound weldable material, the weld zone having a geometric configuration selected to cause the ultrasound weldable material to develop a more circular cross-section after removal of an ultrasound source.
  • the geometric configuration is elliptical in shape.
  • the invention also relates to ultrasound welding apparatuses which include an ultrasound welding component according to the present invention.
  • the welding component also includes a mechanism which immobilizes the ultrasound weldable material relative to the weld zone.
  • the ultrasound welding apparatus further includes an ultrasound source positionable opposite the weld area.
  • the ultrasound welding apparatus includes a weld region about which an ultrasound weldable material may be looped; a weld zone forming a portion of the weld region; and a hard-stop aligned to stop an ultrasound source at a predetermined height above the weld zone.
  • the invention also relates to methods for forming a weld in an ultrasound weldable material.
  • the method includes providing a welding component having a weld region with a weld zone consisting of recesses positioned on opposing sides of a weld area.
  • the method also includes wrapping the ultrasound weldable material around the weld region with sections of the ultrasound weldable material overlapping one another adjacent to the weld area and contacting the overlapping sections of the ultrasound weldable material with an ultrasound source.
  • the method includes providing a welding component with a weld region having a weld zone, the weld zone having an elliptical curvature; wrapping the ultrasound weldable material into a loop about the weld region with sections of the ultrasound weldable material overlapping one another adjacent to the weld zone; and applying an ultrasound source to the overlapping sections.
  • the method includes looping an ultrasound weldable material on a weld region of an ultrasound welding component to form overlapping sections of the ultrasound weldable material adjacent to a weld zone of the weld region; delivering an ultrasound source to the overlapping sections to form a weld using an ultrasound source, wherein a separation between the weld zone and the ultrasound source during welding is controlled by a hard-stop.
  • a method for forming a weld on an ultrasound weldable material.
  • the method includes providing a welding component with a weld region having a weld zone, where the weld zone has an elliptical curvature.
  • the method includes wrapping the ultrasound weldable material into a loop about the weld region with sections of the ultrasound weldable material overlapping one another adjacent to the weld zone.
  • the method also includes applying an ultrasound source to the overlapping sections, and causing the loop of the ultrasound weldable material to become more circular by removing the ultrasound source being applied to the overlapping sections.
  • a method for forming a weld on an ultrasonic weldable material includes looping an ultrasound weldable material on a weld region of an ultrasound welding component to form overlapping sections of the ultrasound weldable material adjacent to a weld zone of the weld region.
  • the method further includes delivering an ultrasound source to the overlapping sections, where the ultrasound source reduces a thickness of the overlapping sections.
  • the method further includes providing a hard-stop on the ultrasound welding component to stop the ultrasound source from reducing the thickness of the overlapping sections once the thickness of the overlapping sections is reduced to a differential height of the hard-stop relative to the weld zone.
  • Figure 1A is a perspective view of a welding component which includes a weld region.
  • Figure IB is a cross section of the welding component illustrated in Figure 1A.
  • Figures 2 A-2G illustrate a method for using a welding component.
  • Figure 2B illustrates a band of material wrapped entirely around a weld region of a welding component.
  • Figure 2C is a sideview of a band of material w ⁇ apped around a weld region such that one section of the band of material overlaps another section of the band of material.
  • Figure 2G illustrates a loop of ultrasound weldable material being removed from the welding component.
  • Figure 3 is a cross section of a welding component looking along the longitudinal axis of the welding component.
  • Figure 4A illustrates a welding collar which is removable from an operating end of the welding component.
  • Figure 5B illustrates a welding component with a welding collar positioned in a receiving trench.
  • Figure 6 A is a cross section of a welding component having a receiving trench and a welding collar having a coupling side positioned within the receiving trench.
  • Figure 6B is a cross section of the welding collar having a weld zone and a coupling side.
  • the outer diameter of the coupling side is the same size as the diameter of the weld zone.
  • Figure 6C is a cross section of the welding collar having a weld zone and a coupling side. The outer diameter of the coupling side is smaller than the diameter of the weld zone.
  • FIG. 8A illustrate the weldable material looped or wrapped around the weld region of the component, with the ultrasound source to be applied.
  • FIG. 8B illustrates the weldable material being welded in a hot state, under an embodiment of the invention.
  • FIG. 8C illustrate the loop of weldable material removed from the weld region and formed into a loop having a substantially circular cross-section.
  • FIGS. 9A-9C illustrate use of an ultrasound source with the hard-stop of the component of FIG. 7, under an embodiment of the invention.
  • FIG. 9A illustrates the ultrasound source being applied to overlapping sections of weldable material wrapped around the weld region of the ultrasound welding component.
  • FIG. 9B illustrate the ultrasound source beginning deformation of the weldable material.
  • FIG. 9C illustrate the ultrasound source being stopped from further deformation of the weldable material by the hard-stop.
  • the present invention relates to welding components, apparatuses, and methods for operating welding components.
  • the welding component includes a weld region with a weld zone consisting of a weld area.
  • a piece of an ultrasound weldable material may be wrapped around the weld region such that sections of the ultrasound weldable material overlap one another adjacent to the weld area.
  • the welding component can also include an attachment mechanism for immobilizing the ultrasound weldable material with the overlapping sections adjacent to the weld area.
  • an ultrasound source is used to compress the overlapping sections against the weld area. This compression can generate sufficient energy to form a weld within the overlapping sections which are adjacent to the weld area. Since the weld is formed in the overlapping sections of the band, the band is formed into a loop.
  • recesses are provided on opposing sides of the weld area to prevent the ultrasound source from compressing the ultrasound weldable material adjacent the weld area.
  • the recesses By using the recesses to limit the amount of material that is compressed, the size of the weld that is formed can be controlled.
  • the present invention makes it possible to form smaller welds.
  • the welds formed typically have a width that is smaller than the combined widths of the recesses and the weld area.
  • the loop shaped ultrasound transducers used with transcription systems are frequently formed by welding together overlapping sections of a band of an ultrasound transmitting material. If the weld is not formed properly, the weld can cause non-uniform transmission of ultrasound signals from different positions around the stylus. This non-uniform ultrasound transmission causes the position determined for the stylus to be a function of the angular orientation of the stylus relative to the detectors. Because a stylus is frequently rotated as it is used, this effect is not desirable. However, the effect can be reduced by using the welding component of the present invention to weld a band of an ultrasound transmitting material into a loop having a narrow weld.
  • One type of ultrasound weldable material that is suitable for use with the present invention is PVDF.
  • PVDF is known to emit ultrasound signals in response to application of a potential. Accordingly, a band of PVDF is ideal for forming the loop shaped ultrasound transducer for a transcription system.
  • the perimeter of a loop created according to the present inventor can be controlled by selecting the size of the component used. Since the band of material is wrapped around the weld region before the band is welded into a loop, the perimeter of the loop formed are similar to the perimeter of the ultrasound welding component adjacent of the weld region. Accordingly, small perimeter loops can be created with an ultrasound welding component having a weld region with a small perimeter. Since loop shaped ultrasound transducers used with transcription systems frequently have small perimeters, the ultrasound welding component of the present invention is ideal for creation of these small perimeter loops.
  • FIG. 1A illustrates a welding component 10 according to the present invention.
  • the component includes a rigid body 12 with a mounting region 14 having one or more flat sections 16 for mounting the component 10 in a clamping device.
  • the clamping device can be coupled with the flat sections 16 so as to prevent the component 10 from rotating within the clamping device.
  • Suitable materials for construction of the welding component include, but are not limited to, iron and steel.
  • the component 10 also includes a weld region 18 about which a band of ultrasound weldable material can be wrapped.
  • the weld region includes a weld zone 19 consisting of a plurality of recesses 20 positioned on opposing sides of a weld area 22.
  • the weld region 18 also includes a plurality of vacuum ports 24 positioned on opposing sides of the weld area 22.
  • the vacuum ports 24 preferably have a diameter between 0.01 and 0.03 inches.
  • Figure IB is a cross section of the component 10 illustrated in Figure 1 A.
  • the vacuum ports 24 on the weld region 18 are in fluid communication with a lumen 26 extending through the longitudinal length of the component 10.
  • the lumen 26 can be coupled with a vacuum source which can be used to draw a vacuum through the vacuum ports 24.
  • the vacuum pulled through the vacuum ports 24 can be used to immobilize a band of material relative to the weld region 18.
  • FIGs 2A-2G illustrate a method for using the component 10.
  • a vacuum is drawn through the lumen 26 within the component 10 and a band 28 of ultrasound weldable material is wrapped around the weld region 18 of the component 10.
  • Suitable ultrasound weldable materials include, but are not limited to, PVDF.
  • the band 28 is positioned on the weld region 18 so a section of the band 28 extends over the weld area 22.
  • the band 28 is then wrapped around the weld region 18 so the band 28 covers the vacuum ports 24 positioned to one side of the weld area 22.
  • the vacuum pulled through the vacuum ports 24 immobilizes the band 28 relative to the weld area 22.
  • the band 28 is kept in contact with a weld region edge 30 to ensure correct placement of the band 28 relative to the weld region 18.
  • the band 28 is eventually wrapped around the weld region 18 so it covers the vacuum ports 24 on both sides of the weld area 22.
  • the vacuum pulled through the vacuum ports 24 immobilizes the band 28 relative to the weld region 18.
  • Other suitable attachment mechanisms include, but are not limited to, electrostatic mechanisms, releasable adhesives, contact strips, and other high friction materials.
  • the attachment mechanism can also be a function of the material to be welded. For instance, when the material has a metal component 10, the attachment mechanism can be magnets positioned around the weld zone 18.
  • FIG. 2C is a sideview of the component 10 looking down the longitudinal axis of the component 10 of Figure 2B as illustrated by the arrow labeled A. Sections of the band 28 overlap one another adjacent to the weld area 22. Similarly, sections of the band 28 overlap one another adjacent to the recesses 20.
  • FIGS 2D and 2E illustrate an ultrasound source 34 compressing overlapping sections of the band 28 which are adjacent to the weld area against the weld area.
  • the weld area 22 supports the adjacent overlapping sections of the band 28 during the compression. This support creates a pinch point 32 at the closest point between the ultrasound source 34 and the weld area 22. The maximum compression occurs at this pinch point 32 and decreases moving away from the pinch point 32. The compression generates enough energy within and around the pinch point 32 to form a weld 35 within the overlapping sections of the band 28 which are adjacent to the weld area 22.
  • overlapping sections of the band 28 are also positioned adjacent to the recesses 20.
  • the size of the recesses 20 are selected to reduce the support provided to the adjacent overlapping sections during compression of the overlapping sections adjacent to the weld area 22.
  • the reduced support yields a reduced amount of energy generation within the overlapping sections adjacent to the recesses 20 as compared to the energy generation within the overlapping sections adjacent to the weld area 22.
  • the reduced energy generation limits the formation of the weld 35 within the overlapping sections which are adjacent to the recesses 20.
  • the weld 35 is primarily formed in the overlapping sections which are adjacent to the weld area 22 although portions of the weld 35 can be formed in the overlapping sections adjacent to the recesses 20. Because the weld 35 is primarily formed in the overlapping sections adjacent to the weld area 22, the weld 35 has a geometry which is similar to the geometry of the weld area 22.
  • the geometry of the weld area 22 can be altered in order to alter the geometry of the weld 35.
  • the weld 35 is preferably small to prevent the weld 35 from affecting the transmitting characteristics of the ultrasound transmitting material.
  • the small weld is provided by using a welding component 10 with a narrow weld area 22.
  • Suitable ultrasound sources 64 include, but are not limited to, an ultrasound hammer configured to vibrate at 20, 40, and 60 kHz. As illustrated, the direction of vibration is preferably perpendicular to the plane of the band 28 at the pinch point 32.
  • the ultrasound source 34 can be handheld.
  • an ultrasound welding apparatus can have a structure which includes both the ultrasound source 34 and the component 10 as illustrated in Figure 2F.
  • the structure is designed so the ultrasound source 34 can be mechanically moved relative to the band 28 of ultrasound weldable material. Accordingly, the ultrasound source 34 can be moved into and out of contact with the band 28 of material with the force, direction and duration required to form the ultrasound weld 35.
  • the apparatus can be computer controlled to minimize the amount of operator error associated with creating the weld 35.
  • the loop can be removed from the weld region 18 as illustrated in Figure 2G.
  • the loop can have one or more tag ends 86 extending beyond the weld. These tag ends can be removed with a cutting technique which is appropriate for the ultrasound weldable material.
  • the length of the material is selected such that tag ends are not formed, thereby obviating a removal step.
  • the features of the weld region 18 are selected so the weld has a geometry which is similar to the geometry of the weld area.
  • Figure 3 illustrates the features of the weld region in a cross sectional view of a component 10 looking down the longitudinal length of the component 10 at the point labeled A in Figure 1.
  • the weld region has a perimeter labeled P.
  • the perimeter of the weld region is preferably less than 1.75 inches, more preferably between 0.75 and 1.75 inches, and most preferably between 1 and 1.75 inches.
  • the weld area has a surface 36 labeled S.
  • the surface 36 is preferably curved. Examples of curved surfaces include, but are not limited to, elliptical and circular.
  • the weld area may have an angular width labeled ⁇ .
  • An increased angular width ⁇ results in an increased weld area 22 and accordingly a wider weld.
  • the angular width, ⁇ is preferably less than about 0.1 degrees and more preferably between about 0.01 and 0.1 degrees and most preferably between about 0.03 and 0.06 degrees.
  • the weld area can also have an width labeled W WA .
  • the width W WA is preferably less than 0.03 includes, preferably between 0.005 and 0.03 inches and more preferably between 0.005 and 0.015 inches.
  • the width of the weld area, W WA is decreased.
  • the recesses 20 have an angular width labeled ⁇ .
  • the angular width, ⁇ is preferably less than about 0.3 degrees, more preferably between 0.1 and 0.3 degrees, most preferably 0.25 degrees.
  • the recesses also have a width labeled W R .
  • the width, W R is preferably less than about 0.05 inches, more preferably between 0.02 and 0.05 inches, and most preferably between 0.02 and 0.04 inches.
  • the weld region 18 can be integral with the rigid body 12 or can be included on a welding collar 37 which slides over the rigid body 12 as illustrated in Figure 4 A.
  • the rigid body 12 can also include vacuum ports 24. These vacuum ports 24 are aligned with the vacuum ports 24 on the welding collar 37 when the welding collar 37 is positioned on the rigid body 12.
  • a fastener such as a set screw 38, can be engaged to retain the welding collar 37 in place on the rigid body 12.
  • An alternative fastener can include complementary threads on both the welding collar 37 and the rigid body 12. These complementary threads can be used to screw the welding collar 37 on and off the rigid body 12.
  • the recesses 20 can be indentations in the welding collar 37 or can be apertures extending through the welding collar 37. Because the recesses 20 can be formed in the welding collar 37, the recesses 20 do not need to be formed in the rigid body 12. As a result, a number of different welding collars 37 can be used with a single rigid body 12. These welding collars 37 can have different perimeters for forming loops of different sizes. Further, different welding collars 37 can have weld areas 22 with different sizes. Since the weld formed with the component 10 has a geometry which is similar to the geometry of the weld area 22, a single rigid body 12 can be used with different welding collars 37 to provide different geometry welds.
  • FIG. 5A and 5B An alternative component 10 which can be used to provide a weld area 22 with a consistent shape adjacent to the weld region edge 30 is illustrated in Figures 5A and 5B.
  • the weld region edge 30 includes a receiving trench 48 configured to receive the abutting side 40 of a welding collar 37 positioned on the rigid body 12.
  • the receiving trench 48 can be deep enough to engulf the closed ends as illustrated in Figure 5B. Enclosure of these ends allows the weld area 22 to maintain a geometry adjacent to the weld region edge 30 which is consistent with the geometry of the remaining portions of the weld area 22.
  • Figure 6 A provides a cross section of a component 10 with a welding collar 37 positioned on the rigid body 12.
  • the abutting side 40 of the welding collar 37 has a coupling side 50 with a geometry which is complementary to the geometry of the receiving trench 48. These complementary geometries permit the coupling side 50 to be positioned within the receiving trench 48.
  • the coupling side 50 can have an external side 52 which sits flush with the weld region edge 30 when the coupling side 50 is positioned within the receiving trench 48. As a result, the external side 52 of the coupling side 50 becomes a part of the weld region edge 30.
  • the weld area 22 can have any number of geometries including curved, zigzagged and other irregular geometries.
  • the component 10 is not limited to welding pieces of material into loops as discussed above.
  • the component 10 can be used to weld two different pieces of material together.
  • the components, apparatuses and methods according to the present invention can be used to form ultrasound welds in materials to be used in applications other than ultrasound transducers and transcription systems.
  • the geometry of the weld region is used to cause a loop of ultrasound weldable material to be formed which has a more circular cross-section.
  • the weld region has an elliptical shape which fosters this desired result.
  • the welding component includes a weld region about which an ultrasound weldable material is wrapped.
  • the weld component may or may not have recesses.
  • a weld zone is provided on the weld region adjacent to where overlapping sections of the weldable material are to be welded together. An ultrasound source is applied to weld the overlapping sections of the weldable material together.
  • the ultrasound source heats the weldable material. Once the ultrasound source is removed, the weldable material cools and changes shape. When the ultrasound source is applied, the weld region is shaped so as to allow the weldable material to subsequently cool and form a loop with a more circular cross-section.
  • a method for forming a weld on an ultrasound weldable material includes providing a weld region having a weld zone with an elliptical curvature.
  • the elliptical curvature includes any arc-length having a curve that can be characterized by more than one radius of curvature.
  • the weld zone may form an arc-length portion of the weld region where end points of the arc-length each have a radius of curvature that is different than a radius of curvature of a point intermediate to the end points.
  • the weld region includes an elliptical cross-section, and the weld zone is an arc-length forming a peripheral surface of the weld region.
  • the weldable material is wrapped into a loop about the weld region, with overlapping sections of the weldable material being formed adjacent to the weld zone.
  • the ultrasound source is then applied to the overlapping sections.
  • the loop of the weldable material is caused to become more circular when the ultrasound source is removed from weldable material. This may be accomplished by allowing the weldable material to cool after the ultrasound source is removed.
  • a hard stop is used to control the thickness of ultrasound welds that are formed. It is noted that the recesses described in Section 1 , the elliptical cross section described in Section 2, and hard stop described in this section may each be used alone or in different combinations with each other.
  • an ultrasound welding apparatus which includes a weld region about which weldable material is looped.
  • the weldable material is deformable with the application of the ultrasound source.
  • the apparatus includes a weld zone that forms a portion of the weld region.
  • the weld zone is adjacent to the overlapping sections of the weldable material.
  • the apparatus also includes a hard-stop.
  • the hard-stop is positioned adjacent to the weld zone to control the positioning of the ultrasound source relative to the weldable material. This allows welds of controlled thicknesses to be formed, the thicknesses being governed by the relative height of the hard-stop to the weld zone.
  • a method for forming a weld on an ultrasound weldable material which includes looping an ultrasound weldable material on a weld region of an ultrasound welding component to form overlapping sections of the ultrasound weldable material adjacent to a weld zone of the weld region; and delivering an ultrasound source to the overlapping sections to form a weld using an ultrasound source, wherein a separation between the weld zone and the ultrasound source during welding is controlled by a hard-stop
  • FIG. 7 is a welding component 110.
  • the welding component 110 includes a mounting region 114, including a flat section 116.
  • the flat section 116 is used to clamp the weld component to the ultrasound source 28 (FIG. 2D).
  • the mounting region 114 includes a hard-stop 150 and a weld region 118.
  • Hard-stop 150 is a flat surface positioned adjacent to the weld region 118.
  • the weld region 118 of welding component 1 10 may have an elliptical cross-section.
  • the weld region 118 includes a rigid body 112 extending from a front face 103 of the mounting section 114.
  • the front face 103 forms a shoulder on weld region 118.
  • weldable material 140 When weldable material 140 is wrapped about the weld region 118, the weldable material may be easily aligned along rigid body 112 by pushing the weldable material against the front face 103.
  • the elliptical cross-section of the weld region 118 includes characteristics of a short radius a, and a long radius b.
  • a plurality of vacuum ports 124 may be distributed on the weld region 118.
  • the vacuum ports 124 extend to a lumen in which a vacuum source may be applied.
  • a vacuum force may be extended through the vacuum ports 124 to retain the ultrasound weldable material against the weld region 118.
  • the vacuum ports release an audible differential when the weldable material 140 is wrapped around the weld region.
  • the vacuum ports 124 are disposed so that if the weldable material 140 is pushed completely against the front face 103, all of vacuum ports 124 are covered. If the weldable material is not pushed completely against the front face 103, the audible difference is detectable.
  • weld zone 119 includes an elliptical curvature with a tangential plane that is parallel with hard-stop 150.
  • the weld region 118 includes an elliptical cross-section to define the curvature of the weld zone 119.
  • the hard-stop 150 is positioned slightly above the weld zone, that height difference controlling the resulting thickness of the weld.
  • the height difference is preferably about the thickness of the weldable material. In one embodiment, the height difference is 0.001 inches.
  • FIGS. 8A-8C illustrate a process by which the elliptical geometric configuration of the weld region 118 can be used to form a circular loop of ultrasound weldable material 140.
  • weldable material 140 is wrapped about the weld region 118 so as to form a loop having a substantially elliptical cross-section.
  • the overlapping sections 132 are radially aligned with weld zone 119.
  • the ultrasound source is applied to the overlapping sections 132.
  • the weldable material 140 is heated.
  • the portion of the weldable material 140 that is melted is with the weld zone 119.
  • FIG. 8B the loop of ultrasound weldable material 140 is removed from the weld region 118.
  • FIG. 8C illustrates the loop of weldable material after it has cooled.
  • the re-solidified weldable material shrinks to form the weld 144.
  • the formation of weld 144 alters the geometric configuration from when the loop of weldable material was first wrapped about the weld region 118.
  • the weld region's characteristic elliptical properties are selected so that the resulting loop of weldable material in the cool state has a substantially circular cross-section.
  • the radius of curvature of the resulting loop of weldable material is approximately uniform across the loop of weldable material 140.
  • FIGS. 9A-9C illustrate an embodiment in which hard-stop 150 controls the extend of deformation of weldable material 140 over weld zone 119.
  • the hard-stop 150 is a laterally adjacent to weld zone 119.
  • the hard-stop 150 forms a stepped configuration with respect to the portion of the weld region 118 representing the weld zone 119.
  • the distance between tangential planes of the hard-stop 150 and the weld zone 119 corresponds to a designated separation or height h.
  • a separation or height between the weld zone 119 and the hard-stop 150 also refers to the designated thickness h of the stepped configuration.
  • the designated thickness h is the thickness of one layer of the weldable material. This thickness may range between 0.0008" and 0.0012", and preferably about 0.001".
  • FIG. 9A is a front view of ultrasonic welding component 110, illustrating the ultrasound source 28 being lowered onto overlapping sections of the weldable material 140. The overlapping sections are positioned on the weld zone 119.
  • hard-stop 150 include ensuring that weldable material is welded so as to deform into an optimal thickness.
  • the optimal thickness corresponds to a thickness of one layer of the weldable material. Therefore, with overlapping sections, two layers of weldable material are welded to have a thickness corresponding to one layer of weldable material. Because the thickness of one layer of weldable material is about 0.001", the settings of most other welding machines is not consistent or accurate enough to achieve the 0.001".
  • embodiments of the invention provide that the minimum separation or height h of the hard-stop relative to the weld zone 119 may be manufactured to be approximately 0.001". This allows subsequent welding processes to always produce overlapping sections that are welded together to have a thickness of one layer of weldable material. This is possible because the machining tolerances for forming the hard-stop to include the designated thickness h from the weld zone 119 is much more accurate than position settings on a device including an ultrasound source 28.
  • An ultrasound welding component having a cylindrically shaped weld region with a radius of 0.225 inches was used in conjunction with a 40 kHz ultrasound hammer to weld a band of PVDF into an loop shaped ultrasound transducer.
  • the welding component had a weld area with a width of 0.1 inches (0.05 degrees) and recesses on opposing sides of the weld area with a width of 0.3 inches (0.15 degrees).
  • the ultrasound hammer was used to compress overlapping sections of the PVDF band against the weld area for 0.3 seconds to produce a loop of PVDF material having a weld with a width of about 0.1 inches.
  • the weld region 118 includes an elliptical cross- section having a short radius a measuring 0.394", and a long radius b measuring 0.500".
  • the ultrasound welding source welds overlapping sections of a loop of weldable material such as PVDF. After welding is complete, the resulting circular cross-section of the loop has a diameter of approximately 0.450".
  • the contraction properties of the weldable material 140 may be used to alter the geometric configuration of the weldable material into a desired shape.
  • the geometric configuration of the weld region 118 may be elliptical, oval or another shape.
  • the weldable material 140 may be made to have a different short and long radii.
  • the weldable material 140 may be made to have an elliptical but more circular cross-section than weld region 118.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un composant de soudage à ultrasons (118). Un mode de réalisation du composant comprend une zone de soudage autour de laquelle un matériau soudable à ultrasons (140) peut être enveloppé dans une boucle. La région de soudage présente une section transversale elliptique et une zone de soudure comportant des évidements situés sur les côtés opposés de la zone de soudure. La configuration de la région de soudure permet à la boucle de matériau soudable de développer une forme plus circulaire que la section transversale elliptique de la région de soudure.
PCT/US2000/017429 1999-06-28 2000-06-23 Appareil de soudage a ultrasons WO2001000388A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU56365/00A AU5636500A (en) 1999-06-28 2000-06-23 Ultrasound welding apparatus

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US09/340,747 US6217686B1 (en) 1999-06-28 1999-06-28 Ultrasound welding apparatus
US09/340,747 1999-06-28
US57238900A 2000-05-16 2000-05-16
US09/572,389 2000-05-16

Publications (1)

Publication Number Publication Date
WO2001000388A1 true WO2001000388A1 (fr) 2001-01-04

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AU (1) AU5636500A (fr)
WO (1) WO2001000388A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4123312A (en) * 1976-09-24 1978-10-31 Automation Industrielle Sa Apparatus for producing collapsible containers
US4366016A (en) * 1981-06-25 1982-12-28 Owens-Illinois, Inc. Method and apparatus for producing a plastic sleeve
US4959109A (en) * 1986-03-27 1990-09-25 Xerox Corporation Apparatus and process for preparing belts
EP0409021A2 (fr) * 1989-07-21 1991-01-23 Kmk Lizence Ltd. Appareil et procédé pour la fabrication de corps tubulaires
US5205807A (en) * 1990-08-15 1993-04-27 Philip Morris Incorporated Apparatus and method for forming hinged top cigarette box

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4123312A (en) * 1976-09-24 1978-10-31 Automation Industrielle Sa Apparatus for producing collapsible containers
US4366016A (en) * 1981-06-25 1982-12-28 Owens-Illinois, Inc. Method and apparatus for producing a plastic sleeve
US4959109A (en) * 1986-03-27 1990-09-25 Xerox Corporation Apparatus and process for preparing belts
EP0409021A2 (fr) * 1989-07-21 1991-01-23 Kmk Lizence Ltd. Appareil et procédé pour la fabrication de corps tubulaires
US5205807A (en) * 1990-08-15 1993-04-27 Philip Morris Incorporated Apparatus and method for forming hinged top cigarette box

Also Published As

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AU5636500A (en) 2001-01-31

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