Ultrasonic welding and related techniques for luggage
The techniques described herein relate to ultrasonic welding and related techniques for luggage. In some embodiments, a method of manufacturing a luggage component is provided that includes orienting a first component adjacent to a second component, wherein a first surface of the first component adjacent a second surface of the second component comprises a flat portion with one or more protrusions extending from the flat portion, and applying, via a horn sized to receive the first component, an ultrasonic vibration to melt the one or more protrusions to ultrasonically weld the first component to the second component.
1 . A method of manufacturing a luggage component, the method comprising:
orienting a first component adjacent to a second component, wherein a first surface of the first component adjacent a second surface of the second component comprises a flat portion with one or more protrusions extending from the flat portion; and
applying, via a horn comprising a recess sized to receive the first component, an ultrasonic vibration to melt the one or more protrusions to ultrasonically weld the first component to the second component.
2 . The method of claim 1 , wherein the first component comprises a loop boss.
3 . The method of claim 1 , wherein the first component comprises a trolley bracket.
4 . The method of claim 1 , wherein the second component comprises a polycarbonate plastic.
5 . The method of claim 1 , wherein the applying of the ultrasonic vibration comprises a weld time between 0.3 seconds and 2 seconds.
6 . The method of claim 1 , further comprising holding the first component in place for a cooling time between 1 second and 2 seconds.
7 . The method of claim 1 , wherein the one or more protrusions comprise a first number of protrusions on a first side of the first component and a second number of protrusions on a second side of the first component.
8 . The method of claim 1 , wherein an arrangement of the one or more protrusions is around an outer perimeter of a rectangular shape.
9 . The method of claim 1 , wherein the applying of the ultrasonic vibration flattens the one or more protrusions.
10 . The method of claim 1 , further comprising retracting the horn from the first component and the second component.
11 . The method of claim 1 , wherein the horn is configured to make an orthogonal contact with the first component relative to the first surface.
12 . The method of claim 1 , wherein a cross section of the one or more protrusions is triangular.
13 . The method of claim 1 , wherein the first surface is completely flat surrounding the one or more protrusions on the first surface.
14 . The method of claim 3 , wherein a cross section of the one or more protrusions is triangular.
15 . A luggage component, comprising:
a first component adjacent to a second component, the first component comprising a first surface adjacent a second surface of the second component; and
an interface comprising the second surface of the second component and a first portion of the first surface welded to the second surface of the second component,
wherein the second surface is substantially flat proximate the first surface, and the interface comprises a melted portion that is formed by melting one or more protrusions on the first surface of the first component.
16 . The luggage component of claim 15 , wherein the first portion of the first surface welded to the second surface comprises a flat surface.
17 . The luggage component of claim 16 , wherein the first surface is completely flat surrounding the one or more protrusions on the first surface.
18 . The luggage component of claim 15 , wherein an arrangement of the melted portion is a rectangular shape.