WO2019070846A1 - Horn cooling configuration for ultrasonic welder - Google Patents

Horn cooling configuration for ultrasonic welder Download PDF

Info

Publication number
WO2019070846A1
WO2019070846A1 PCT/US2018/054152 US2018054152W WO2019070846A1 WO 2019070846 A1 WO2019070846 A1 WO 2019070846A1 US 2018054152 W US2018054152 W US 2018054152W WO 2019070846 A1 WO2019070846 A1 WO 2019070846A1
Authority
WO
WIPO (PCT)
Prior art keywords
cooling passage
horn
ultrasonic
converter
passage portion
Prior art date
Application number
PCT/US2018/054152
Other languages
French (fr)
Inventor
Clifford Byron MADDEN
Thomas Joseph Martin
Original Assignee
T.A. Systems, Inc.
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
Application filed by T.A. Systems, Inc. filed Critical T.A. Systems, Inc.
Publication of WO2019070846A1 publication Critical patent/WO2019070846A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
    • B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
    • B06B3/00—Methods or apparatus specially adapted for transmitting mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
    • B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
    • B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
    • B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
    • B06B1/06—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction
    • B06B1/0607—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction using multiple elements
    • B06B1/0611—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction using multiple elements in a pile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B23K20/106—Features related to sonotrodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
    • 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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • 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
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • 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
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/861—Hand-held tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/30—Organic material
    • B23K2103/42—Plastics

Definitions

  • Ultrasonic welders are commonly used to weld plastic components to one another.
  • a workpiece comprising multiple components are arranged on a support structure or fixture.
  • the components are clamped in place under pressure applied by a horn.
  • the horn is excited at high frequencies by a converter, which generates sufficient heat between the components to melt the materials together.
  • the horn heats up particularly with short cycle times.
  • the frequency of the heated horn will drift outside of its desired high frequency needed for welding.
  • elevated horn temperatures can cause loose welds due to improper forming of the molten plastic.
  • the horn may be cooled, for example, by directing cooling air onto the horn.
  • One typical arrangement uses a conduit arranged outside of the ultrasonic welding assembly with an end of the conduit directed at an exterior of the horn. In a production environment, this conduit may become bent or damaged.
  • an ultrasonic welder includes a converter having an end.
  • a first cooling passage portion extends from the converter through to the end.
  • a horn is mounted to the converter at the end.
  • the horn has a second cooling passage portion in fluid communication with the first cooling passage portion.
  • the converter includes a housing that has a mounting block and a cavity.
  • a piezoelectric assembly is arranged in the cavity and clamped to the mounting block. The mounting block provides the end.
  • the piezoelectric assembly includes a hole that receives a fastener that secures the piezoelectric assembly to the mounting block.
  • the fastener provides the first cooling passage portion in fluid communication with the cavity.
  • the housing has an inlet in fluid communication with the cavity.
  • the inlet is configured to receive pressurized fluid from an air source.
  • the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack.
  • a pressure plate is provided on the stack opposite the mounting plate.
  • the fastener extends through the pressure plate and the stack.
  • the horn includes a neck extending from a base that has a mounting surface abutting the end.
  • a fastening element secures the base to the end.
  • the fastening element provides the second cooling passage portion.
  • the fastening element may be a stud.
  • the second cooling passage portion extends from the fastening element toward a working surface that is provided on a terminal end of the neck opposite the base.
  • an exit is provided in the neck and in fluid communication with the second cooling passage portion.
  • the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
  • an ultrasonic horn in another exemplary embodiment, includes a neck extending from a base to a terminal end that provides a working surface.
  • the base provides a mounting surface that includes a fastening element.
  • a cooling passage extends from the neck to a fastening element terminal end. The cooling passage is configured to receive cooling fluid at the fastening element terminal end.
  • the fastening element may be a stud.
  • an exit is provided in the neck adjacent to the working surface and in fluid communication with the cooling passage.
  • the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
  • an ultrasonic converter in another exemplary embodiment, includes a housing having a mounting block and a cavity.
  • a cooling passage extends from the converter through to the mounting block.
  • a piezoelectric assembly is arranged in the cavity and clamped to the mounting block.
  • the mounting block provides the end configured to be secured to a horn.
  • the piezoelectric assembly includes a hole that receives a fastener that secures the piezoelectric assembly to the mounting block.
  • the fastener provides the cooling passage in fluid communication with the cavity.
  • the housing has an inlet in fluid communication with the cavity.
  • the inlet is configured to receive pressurized fluid from an air source.
  • the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack.
  • a pressure plate is provided on the stack opposite the mounting plate.
  • the fastener extends through the pressure plate and the stack.
  • Figure 1 is a perspective view of an example ultrasonic welder used in welding a workpiece.
  • Figure 2 is a cross-sectional view through the ultrasonic welder shown in Figure 1.
  • a workpiece 12 typically comprising multiple components arranged on a support structure or fixture 14.
  • the workpiece 12 has two or more components, which may be constructed of any suitable weldable material, such as plastic. Other materials may be welded as well.
  • the ultrasonic welder 10 includes a converter 18 to which a horn 16 is mounted.
  • the horn 16 includes a neck 16b extending from a base 16a to a terminal end that provides a working surface 16c configured to engage the workpiece 12.
  • a fillet provides a smooth transition between the base 16a and neck 16b.
  • the workpiece 12 is clamped between the support structure 14 by applying a force with the horn 16.
  • an air source 22 is fluidly connected to the converter 18 at an inlet 25.
  • the air source 22 may be shop air, but other cooling fluids may be used.
  • the converter 18 includes a housing 24 having a mounting block 28 and a cylindrical structure 29 that provides a cavity 27.
  • a piezoelectric assembly 26 which may be a stack of ceramic piezoelectric elements 26a-26e, is arranged within the cavity 27. Any suitable number of piezoelectric al elements may be used, depending upon the particular application. Wires from the electrical connector 19 transmit the electrical signal from the controller 20 to the piezoelectric assembly 26.
  • the mounting block 28 is provided at one end of the housing 24, and the piezoelectric assembly 26 is secured to the mounting block 28 by a fastener, such as clamping bolt 30.
  • a pressure plate 31 is provided on the stack, which transfers the load from the fastener 30 to the mounting block 28.
  • a hole extends through the piezoelectric assembly 26 and the pressure plate 31; the hole receives the fastener 30.
  • An aperture 36b is provided at one end of the mounting block 28.
  • a fastening element such as a threaded stud 32 is received in the aperture 36b, and the base 16a of the horn 16 is secured to the stud 32 at its mounting surface.
  • Air from the air source 22 is carried from the converter 18 to the horn 16 near its tip using an internal cooling passage provided by a first cooling passage portion (36a, 36b, collectively "36") in the converter 18 and a second cooling passage portion (38a, 38b, collectively "38”) in the horn 16.
  • the clamping bolt 30 includes a bore 36a extending therethrough from the cavity 27 to the aperture 36b to provide the first cooling passage portion 36.
  • a hole 38a is provided in the stud 32 to provide a segment of the second cooling passage portion 38, which is in fluid communication with the first cooling passage portion 36.
  • a passage 38b extends through the horn 16 to communicate fluid provided by the hole 38a to multiple radially extending channels 42, which terminate in exits 44 at an outer periphery of the horn's end.
  • the exits 44 are provided axially inwardly from the working surface 16c of the horn 16, which engages the workpiece 12. In this manner, the cooling fluid does not cool the workpiece directly, which would be counterproductive to generating heat sufficient weld the workpiece components to one another.
  • the base 16a may include notches 40 that receive a tool used to tighten and loosen the horn 16 relative to the mounting block 28. These notches 40 are shallow such that they do not intersect the second cooling passage portion 38. Thus, the base 16a is free from any cooling holes exiting its exterior surface.
  • the cooling passages used to cool the horn 16 are arranged entirely internally, which prevents damage to any plumbing that would otherwise be located in the work areas susceptible to damage. Moreover, the horn 16, which is designed for welding particular workpieces at particular frequencies, will not be impacted by plumbing that might be connected to the side of the horn.

Landscapes

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

Abstract

An ultrasonic welder includes a converter having an end. A first cooling passage portion extends from the converter through to the end. A horn is mounted to the converter at the end. The horn has a second cooling passage portion in fluid communication with the first cooling passage portion.

Description

HORN COOLING CONFIGURATION FOR ULTRASONIC WELDER
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to United States Provisional Application No. 62/567,313 which was filed on October 3, 2017, and is incorporated herein by reference.
BACKGROUND
[0002] Ultrasonic welders are commonly used to weld plastic components to one another. A workpiece comprising multiple components are arranged on a support structure or fixture. The components are clamped in place under pressure applied by a horn. The horn is excited at high frequencies by a converter, which generates sufficient heat between the components to melt the materials together.
[0003] During use in a production environment, the horn heats up particularly with short cycle times. The frequency of the heated horn will drift outside of its desired high frequency needed for welding. In addition, elevated horn temperatures can cause loose welds due to improper forming of the molten plastic. To address this problem, the horn may be cooled, for example, by directing cooling air onto the horn. One typical arrangement uses a conduit arranged outside of the ultrasonic welding assembly with an end of the conduit directed at an exterior of the horn. In a production environment, this conduit may become bent or damaged.
[0004] Another horn cooling arrangement has been proposed in which air is introduced into the side of the horn through a hole at the exterior of the horn's base. This additional structure on the horn will be subject to vibrations and undesired strain during welding operations. The external plumbing may also unpredictably affect the frequency at which the horn vibrates.
SUMMARY
[0005] In one exemplary embodiment, an ultrasonic welder includes a converter having an end. A first cooling passage portion extends from the converter through to the end. A horn is mounted to the converter at the end. The horn has a second cooling passage portion in fluid communication with the first cooling passage portion. [0006] In a further embodiment of the above, the converter includes a housing that has a mounting block and a cavity. A piezoelectric assembly is arranged in the cavity and clamped to the mounting block. The mounting block provides the end.
[0007] In a further embodiment of any of the above, the piezoelectric assembly includes a hole that receives a fastener that secures the piezoelectric assembly to the mounting block. The fastener provides the first cooling passage portion in fluid communication with the cavity.
[0008] In a further embodiment of any of the above, the housing has an inlet in fluid communication with the cavity. The inlet is configured to receive pressurized fluid from an air source.
[0009] In a further embodiment of any of the above, the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack. A pressure plate is provided on the stack opposite the mounting plate. The fastener extends through the pressure plate and the stack.
[0010] In a further embodiment of any of the above, the horn includes a neck extending from a base that has a mounting surface abutting the end. A fastening element secures the base to the end. The fastening element provides the second cooling passage portion.
[0011] In a further embodiment of any of the above, the fastening element may be a stud.
[0012] In a further embodiment of any of the above, the second cooling passage portion extends from the fastening element toward a working surface that is provided on a terminal end of the neck opposite the base.
[0013] In a further embodiment of any of the above, an exit is provided in the neck and in fluid communication with the second cooling passage portion.
[0014] In a further embodiment of any of the above, the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
[0015] In another exemplary embodiment, an ultrasonic horn includes a neck extending from a base to a terminal end that provides a working surface. The base provides a mounting surface that includes a fastening element. A cooling passage extends from the neck to a fastening element terminal end. The cooling passage is configured to receive cooling fluid at the fastening element terminal end.
[0016] In a further embodiment of the above, the fastening element may be a stud.
[0017] In a further embodiment of any of the above, an exit is provided in the neck adjacent to the working surface and in fluid communication with the cooling passage.
[0018] In a further embodiment of any of the above, the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
[0019] In another exemplary embodiment, an ultrasonic converter includes a housing having a mounting block and a cavity. A cooling passage extends from the converter through to the mounting block. A piezoelectric assembly is arranged in the cavity and clamped to the mounting block. The mounting block provides the end configured to be secured to a horn.
[0020] In a further embodiment of any of the above, the piezoelectric assembly includes a hole that receives a fastener that secures the piezoelectric assembly to the mounting block. The fastener provides the cooling passage in fluid communication with the cavity.
[0021] In a further embodiment of any of the above, the housing has an inlet in fluid communication with the cavity. The inlet is configured to receive pressurized fluid from an air source.
[0022] In a further embodiment of any of the above, the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack. A pressure plate is provided on the stack opposite the mounting plate. The fastener extends through the pressure plate and the stack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0024] Figure 1 is a perspective view of an example ultrasonic welder used in welding a workpiece.
[0025] Figure 2 is a cross-sectional view through the ultrasonic welder shown in Figure 1. DETAILED DESCRIPTION
[0026] An ultrasonic welder 10 is shown in Figure 1. A workpiece 12 typically comprising multiple components arranged on a support structure or fixture 14. The workpiece 12 has two or more components, which may be constructed of any suitable weldable material, such as plastic. Other materials may be welded as well.
[0027] The ultrasonic welder 10 includes a converter 18 to which a horn 16 is mounted. In the example shown in Figure 2, the horn 16 includes a neck 16b extending from a base 16a to a terminal end that provides a working surface 16c configured to engage the workpiece 12. A fillet provides a smooth transition between the base 16a and neck 16b.
[0028] Returning to Figure 1, the workpiece 12 is clamped between the support structure 14 by applying a force with the horn 16. A controller 20, which is connected to the ultrasonic welder 10 by an electrical connector 19, provides an electrical signal that excites the horn 16 at a desired high frequency and for a desired duration. The vibration generates heat at the interface between the components, melting the components to one another.
[0029] According to one disclosed embodiment, an air source 22 is fluidly connected to the converter 18 at an inlet 25. The air source 22 may be shop air, but other cooling fluids may be used.
[0030] Referring to Figure 2, the converter 18 includes a housing 24 having a mounting block 28 and a cylindrical structure 29 that provides a cavity 27. A piezoelectric assembly 26, which may be a stack of ceramic piezoelectric elements 26a-26e, is arranged within the cavity 27. Any suitable number of piezoelectric al elements may be used, depending upon the particular application. Wires from the electrical connector 19 transmit the electrical signal from the controller 20 to the piezoelectric assembly 26.
[0031] The mounting block 28 is provided at one end of the housing 24, and the piezoelectric assembly 26 is secured to the mounting block 28 by a fastener, such as clamping bolt 30. A pressure plate 31 is provided on the stack, which transfers the load from the fastener 30 to the mounting block 28. A hole extends through the piezoelectric assembly 26 and the pressure plate 31; the hole receives the fastener 30.
[0032] An aperture 36b is provided at one end of the mounting block 28. A fastening element such as a threaded stud 32 is received in the aperture 36b, and the base 16a of the horn 16 is secured to the stud 32 at its mounting surface. [0033] Air from the air source 22 is carried from the converter 18 to the horn 16 near its tip using an internal cooling passage provided by a first cooling passage portion (36a, 36b, collectively "36") in the converter 18 and a second cooling passage portion (38a, 38b, collectively "38") in the horn 16. To this end, the clamping bolt 30 includes a bore 36a extending therethrough from the cavity 27 to the aperture 36b to provide the first cooling passage portion 36. A hole 38a is provided in the stud 32 to provide a segment of the second cooling passage portion 38, which is in fluid communication with the first cooling passage portion 36. A passage 38b extends through the horn 16 to communicate fluid provided by the hole 38a to multiple radially extending channels 42, which terminate in exits 44 at an outer periphery of the horn's end. The exits 44 are provided axially inwardly from the working surface 16c of the horn 16, which engages the workpiece 12. In this manner, the cooling fluid does not cool the workpiece directly, which would be counterproductive to generating heat sufficient weld the workpiece components to one another.
[0034] The base 16a may include notches 40 that receive a tool used to tighten and loosen the horn 16 relative to the mounting block 28. These notches 40 are shallow such that they do not intersect the second cooling passage portion 38. Thus, the base 16a is free from any cooling holes exiting its exterior surface.
[0035] The cooling passages used to cool the horn 16 are arranged entirely internally, which prevents damage to any plumbing that would otherwise be located in the work areas susceptible to damage. Moreover, the horn 16, which is designed for welding particular workpieces at particular frequencies, will not be impacted by plumbing that might be connected to the side of the horn.
[0036] It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.
[0037] Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples. [0038] Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.

Claims

CLAIMS What is claimed is:
1. An ultrasonic welder comprising:
a converter having an end, and a first cooling passage portion extending from the converter through to the end; and
a horn mounted to the converter at the end, the horn having a second cooling passage portion in fluid communication with the first cooling passage portion.
2. The ultrasonic welder of claim 1, wherein the converter includes a housing having mounting block and a cavity, and a piezoelectric assembly is arranged in the cavity and clamped to the mounting block, the mounting block providing the end.
3. The ultrasonic welder of claim 2, wherein the piezoelectric assembly includes a hole that receives a fastener securing the piezoelectric assembly to the mounting block, the fastener providing the first cooling passage portion in fluid communication with the cavity.
4. The ultrasonic welder of claim 3, wherein the housing has an inlet in fluid communication with the cavity, the inlet is configured to receive pressurized fluid from an air source.
5. The ultrasonic welder of claim 3, wherein the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack, and a pressure plate is provided on the stack opposite the mounting plate, the fastener extends through the pressure plate and the stack.
6. The ultrasonic welder of claim 1, wherein the horn includes a neck extending from a base that has a mounting surface abutting the end, and a fastening element secures the base to the end, fastening element providing the second cooling passage portion.
7. The ultrasonic welder of claim 6, wherein the fastening element may be a stud.
8. The ultrasonic welder of claim 6, wherein the second cooling passage portion extends from the fastening element toward a working surface provided on a terminal end of the neck opposite the base.
9. The ultrasonic welder of claim 8, wherein an exit is provided in the neck and in fluid communication with the second cooling passage portion.
10. The ultrasonic welder of claim 9, wherein the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
11. An ultrasonic horn comprising:
a neck extending from a base to a terminal end providing a working surface, the base providing a mounting surface including a fastening element, and a cooling passage extends from the neck to a fastening element terminal end, the cooling passage configured to receive cooling fluid at the fastening element terminal end.
12. The ultrasonic horn of claim 11, wherein the fastening element may be a stud.
13. The ultrasonic horn of claim 11 , wherein an exit is provided in the neck adj acent to the working surface and in fluid communication with the cooling passage.
14. The ultrasonic horn of claim 9, wherein the base is free from any cooling holes exiting an exterior surface of the base that are in fluid communication with the second cooling passage portion.
15. An ultrasonic converter comprising:
a housing having mounting block and a cavity, a cooling passage extends from the converter through to the mounting block, and a piezoelectric assembly is arranged in the cavity and clamped to the mounting block, the mounting block providing the end configured to be secured to a horn.
16. The ultrasonic converter of claim 15, wherein the piezoelectric assembly includes a hole that receives a fastener securing the piezoelectric assembly to the mounting block, the fastener providing the cooling passage in fluid communication with the cavity.
17. The ultrasonic converter of claim 16, wherein the housing has an inlet in fluid communication with the cavity, the inlet is configured to receive pressurized fluid from an air source.
18. The ultrasonic converter of claim 16, wherein the piezoelectric assembly includes multiple piezoelectric elements arranged in a stack, and a pressure plate is provided on the stack opposite the mounting plate, the fastener extends through the pressure plate and the stack.
PCT/US2018/054152 2017-10-03 2018-10-03 Horn cooling configuration for ultrasonic welder WO2019070846A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201762567313P 2017-10-03 2017-10-03
US62/567,313 2017-10-03

Publications (1)

Publication Number Publication Date
WO2019070846A1 true WO2019070846A1 (en) 2019-04-11

Family

ID=65995145

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2018/054152 WO2019070846A1 (en) 2017-10-03 2018-10-03 Horn cooling configuration for ultrasonic welder

Country Status (1)

Country Link
WO (1) WO2019070846A1 (en)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030066863A1 (en) * 2001-10-10 2003-04-10 Skogsmo Jan Birger Sonotrode for ultrasonic welding apparatus
US20040124745A1 (en) * 2002-09-23 2004-07-01 Goodson J. Michael Sleeved ultrasonic transducer
US20080000944A1 (en) * 2006-06-30 2008-01-03 T.A. Systems Inc. Ultrasonic welder having motor drive assembly integrated with transducer housing
US20100147466A1 (en) * 2007-03-02 2010-06-17 Compania Espanola De Ulltrasonidos, Sa Ultrasonic head and transducer for ultrasonic soldering of plastics
FR3053909A3 (en) * 2016-07-12 2018-01-19 Compania Espanola De Ultrasonidos SONOTRODE WITH COOLING SYSTEM

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030066863A1 (en) * 2001-10-10 2003-04-10 Skogsmo Jan Birger Sonotrode for ultrasonic welding apparatus
US20040124745A1 (en) * 2002-09-23 2004-07-01 Goodson J. Michael Sleeved ultrasonic transducer
US20080000944A1 (en) * 2006-06-30 2008-01-03 T.A. Systems Inc. Ultrasonic welder having motor drive assembly integrated with transducer housing
US20100147466A1 (en) * 2007-03-02 2010-06-17 Compania Espanola De Ulltrasonidos, Sa Ultrasonic head and transducer for ultrasonic soldering of plastics
FR3053909A3 (en) * 2016-07-12 2018-01-19 Compania Espanola De Ultrasonidos SONOTRODE WITH COOLING SYSTEM

Similar Documents

Publication Publication Date Title
US7959054B2 (en) Device for processing workpieces using ultrasound
CA3042636C (en) Linear friction welding apparatus and method
US20200282492A1 (en) Method for ultrasonic welding
US20180185956A1 (en) Device for welding components by means of ultrasound
JP2020518463A (en) Insert for assembling a first member and a second member by electric resistance welding, and an assembly method using the insert
US10384297B2 (en) Method and device for joining a composite sheet metal component to a functional element
US9505061B2 (en) Chuck
JP2003522650A (en) Inflatable fastening device
US20140326781A1 (en) Linear Friction Welding Method
CN102615420A (en) Manufacturing method of valve seat assembly
WO2019070846A1 (en) Horn cooling configuration for ultrasonic welder
US20220088701A1 (en) Ultrasonic sonotrode with workpiece clamping tool
KR101374560B1 (en) Projection welding electrode
JP3503496B2 (en) Ultrasonic bonding method
US20190143441A1 (en) Joining head and joining device with reduced interfering contour
EP3252319B1 (en) Method of assembling a piston-cylinder group through low temperature welding
JP2016539018A (en) Breaking and splitting device
KR200449675Y1 (en) Hydraulic chuck for fixing cutting tool
US20230356304A1 (en) Expansion clamping device and method of making same
JP3121114U (en) Steel with fixed nuts
KR101799797B1 (en) Stud welding method
US10758995B2 (en) Electrode chip attachment device
JP2005007565A (en) Driving machine
CN110653469B (en) Joining device and joining method
KR20200063218A (en) Fastening method

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 18864441

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 18864441

Country of ref document: EP

Kind code of ref document: A1