Apparatus for ultrasonic welding of polymers and polymeric composites
Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.
1. An apparatus for ultrasonic welding of a workpiece of one or more components, the apparatus comprising:
a horn configured to contact the workpiece and to transmit energy to the workpiece, the horn comprising:
a shank, wherein the shank is cylindrical in shape;
a tip disposed at an end of the shank facing the workpiece, the tip having a face that has a tip radius so that the tip has a curved surface at the face, wherein the tip is shaped as a truncated spherical sector; and
a knurl on the face across the curved surface.
2. The apparatus of claim 1 , wherein the knurl is defined by a knurl angle and a knurl pitch.
3. The apparatus of claim 1 , wherein:
the shank has a horn radius (R);
the face has a tip radius (r);
the knurl has a knurl pitch (d);
the horn is defined by r/R=4-5 and d/R=0.09-0.13; and
the knurl has a knurl angle of 40-60 degrees.
4. The apparatus of claim 1 , wherein the tip radius defines the tip as a convex geometric structure that extends from the shank.
5. The apparatus of claim 1 , wherein:
the horn has a horn radius along the shank, and
wherein the knurl has a geometric structure proportional to the tip radius and to the horn radius.
6. The apparatus of claim 1 , wherein the horn has a horn radius along the shank, wherein a ratio of the tip radius to the horn radius is in a range of approximately 4 to approximately 5.
7. The apparatus of claim 1 , wherein the knurl comprises of a number of teeth arranged with a knurl pitch, wherein a ratio of the knurl pitch to the horn radius is in a range of approximately 0.09 to approximately 0.13.
8. The apparatus of claim 1 , wherein:
the knurl comprises of a number of teeth; and
each of the teeth has a knurl angle in a range of approximately 40 degrees to approximately 60 degrees.
9. The apparatus of claim 8 , wherein the knurl angle is measured from a side of a tooth to a plane that extends across the face perpendicular to a centerline of the horn.
10. The apparatus of claim 1 , wherein the workpiece comprises at least one of a polymeric composite material and a polymer material.
11. An apparatus for ultrasonic welding of a workpiece of one or more components, the apparatus comprising:
a horn configured to contact the workpiece and to transmit vibrational energy to the workpiece, the horn comprising:
a shank that has a transverse dimension;
a tip disposed at an end of the shank facing the workpiece, the tip having a face that has a tip radius, wherein the tip radius defines the tip as a convex geometric structure that extends from the shank; and
a knurl on the face,
wherein the transverse dimension comprises a horn radius along the shank, wherein a ratio of the tip radius to the horn radius is in a range of approximately 4 to approximately 5.
12. The apparatus of claim 11 , wherein the shank is cylindrical in shape, wherein the tip is shaped as a truncated spherical sector.
13. The apparatus of claim 11 , wherein:
the horn has a horn radius along the shank, and
wherein the convex geometric structure is defined proportional to the tip radius and to the horn radius.
14. The apparatus of claim 11 , wherein the tip radius and the knurl pitch are both optimized in size in relation to the horn radius.
15. The apparatus of claim 11 , wherein the knurl is comprised of a number of teeth arranged with a knurl pitch, wherein a ratio of the knurl pitch to the horn radius is in a range of approximately 0.09 to approximately 0.13.
16. The apparatus of claim 11 , wherein:
the knurl is comprised of a number of teeth; and
each of the teeth has a knurl angle in a range of approximately 40 degrees to approximately 60 degrees.
17. The apparatus of claim 16 , wherein the knurl angle is measured from a side of a tooth to a plane that extends across the face perpendicular to a centerline of the horn.
18. The apparatus of claim 11 , wherein:
the shank has a horn radius (R);
the face has a tip radius (r);
the knurl has a knurl pitch (d);
the horn is defined by r/R=4-5 and d/R=0.09-0.13; and
the knurl has a knurl angle of 40-60 degrees.
19. The apparatus of claim 11 , wherein:
the transverse dimension comprises a horn radius along the shank, wherein a ratio of the tip radius to the horn radius is in a range of approximately 4 to approximately 5;
the knurl comprises a number of teeth arranged with a knurl pitch, wherein a ratio of the knurl pitch to the horn radius is in a range of approximately 0.09 to approximately 0.13; and
each of the teeth has a knurl angle of approximately 40 degrees to approximately 60 degrees.
20. An apparatus for ultrasonic welding of a workpiece of one or more components, the apparatus comprising:
a horn configured to contact the workpiece and to transmit energy to the workpiece, the horn comprising:
a shank;
a tip disposed at an end of the shank facing the workpiece, the tip having a face; and
a knurl on the face, wherein:
the shank has a horn radius (R);
the face has a tip radius (r);
the knurl has a knurl pitch (d);
the horn is defined by r/R=4-5 and d/R=0.09-0.13; and
the knurl has a knurl angle of 40-60 degrees.