Horn for an ultrasonic welding process

1. A horn for a ultrasonic welding apparatus, the horn comprising:

a body having an outer diameter surface; and

a convex welding tip having a first curved surface and a second curved surface, wherein a peak curvature point is defined by the second curved surface, a base curvature point is defined at an intersection between the outer diameter surface and the first curved surface, and an inner diameter is defined at an intersection between the first curved surface and the second curved surface, and wherein a first depth is defined between the peak curvature point and the base curvature point, a second depth is defined between the peak curvature point and the inner diameter, and a third depth is defined between the base curvature point and the inner diameter, and wherein the second depth and the third depth, combined, equal the first depth.

2. The horn of claim 1 , wherein the first depth is less than 1 mm.

3. The horn of claim 1 , wherein the first curved surface defines a first dome-shaped welding surface and the second curved surface defines a second dome-shaped welding surface.

4. The horn of claim 1 , wherein the inner diameter is concentric with the outer diameter surface.

5. A method for joining workpieces, comprising:

providing the workpieces in a stacked arrangement;

providing a robotic tool having an ultrasonic welding device at a distal end thereof, the ultrasonic welding device including a horn having a body with an outer diameter and a convex tip, wherein the convex tip has a first curved surface and a second curved surface, wherein a peak curvature point is defined by the second curved surface, a base curvature point is defined at an intersection between the outer diameter and the first curved surface, and an inner diameter is defined at an intersection between the first curved surface and the second curved surface, and wherein a first depth is defined between the peak curvature point and the base curvature point, a second depth is defined between the peak curvature point and the inner diameter, and a third depth is defined between the base curvature point and the inner diameter, and wherein the second depth and the third depth, combined, equal the first depth;

moving the distal end of the robotic tool to a first location adjacent a surface of the workpieces such that the horn of the ultrasonic welding device contacts the workpieces at the first location at a first angle from perpendicular; and

generating a vibration energy by the ultrasonic welding device that propagates through the horn to the workpieces.

6. The method of claim 5 , wherein the inner diameter is concentric with the outer diameter.

7. The method of claim 5 , further comprising:

moving the distal end of the robotic tool to a second location adjacent the surface of the workpieces such that the horn of the ultrasonic welding device contacts the workpieces at the second location at a second angle from perpendicular.

8. The method of claim 7 , wherein the first angle and the second angle are less than seven degrees from normal.

9. A horn for an ultrasonic welding apparatus, the horn comprising:

a body having an outer diameter surface; and

a convex tip having a first radial surface and a second radial surface, wherein the first radial surface and the second radial surface intersect at an inner diameter that is concentric with the outer diameter surface, wherein a peak curvature point is defined by the second radial surface and a base curvature point is defined at an intersection between the outer diameter surface and the first radial surface, and wherein a first depth is defined between the peak curvature point and the base curvature point, a second depth is defined between the peak curvature point and the inner diameter, and a third depth is defined between the base curvature point and the inner diameter, and wherein the second depth and the third depth, combined, equal the first depth.

10. The horn of claim 9 , wherein the first depth is less than 1 mm.

11. The horn of claim 9 , wherein the convex tip is configured to engage a workpiece at a workpiece surface with at least a portion of both the first radial surface and the second radial surface.