Abstract: A system includes a first horn, a first ultrasonic transducer, a second horn, a second ultrasonic transducer, a memory, and a controller. The first horn includes a first part-interfacing surface. The second horn includes a second part-interfacing surface and is positioned relative to the first horn such that a part to be welded can be positioned between the first and second part-interface surfaces. The controller is configured to cause a first ultrasonic energy to be applied through the first horn via the first transducer to cause the first part-interfacing surface to vibrate, cause the first horn to move in a first direction at a first time, cause a second ultrasonic energy to be applied through the second horn via the second transducer to cause the second part-interfacing surface to vibrate, and cause the second horn to move in a second direction at the first time.

Abstract: A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Abstract: A system includes a first horn, a first ultrasonic transducer, a second horn, a second ultrasonic transducer, a memory, and a controller. The first horn includes a first part-interfacing surface. The second horn includes a second part-interfacing surface and is positioned relative to the first horn such that a part to be welded can be positioned between the first and second part-interface surfaces. The controller is configured to cause a first ultrasonic energy to be applied through the first horn via the first transducer to cause the first part-interfacing surface to vibrate, cause the first horn to move in a first direction at a first time, cause a second ultrasonic energy to be applied through the second horn via the second transducer to cause the second part-interfacing surface to vibrate, and cause the second horn to move in a second direction at the first time.

Abstract: The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.

Abstract: A system includes a first horn, a first ultrasonic transducer, a second horn, a second ultrasonic transducer, a memory, and a controller. The first horn includes a first part-interfacing surface. The second horn includes a second part-interfacing surface and is positioned relative to the first horn such that a part to be welded can be positioned between the first and second part-interface surfaces. The controller is configured to cause a first ultrasonic energy to be applied through the first horn via the first transducer to cause the first part-interfacing surface to vibrate, cause the first horn to move in a first direction at a first time, cause a second ultrasonic energy to be applied through the second horn via the second transducer to cause the second part-interfacing surface to vibrate, and cause the second horn to move in a second direction at the first time.

Abstract: An ultrasonic welding system. The system includes an ultrasonic transducer assembly having a horn and a first transducer and a second transducer arranged to impart ultrasonic energy into the horn. The horn has a first part-interfacing surface and a second part-interfacing surface opposite the first part-interfacing surface. An actuator assembly is operatively coupled to the ultrasonic transducer assembly and configured to cause rotation of the horn. A controller is configured to: cause the actuator assembly to rotate the horn so that the first part-interfacing surface applies the ultrasonic energy to a first part along an entire length of the first part-interface surface while a first ultrasonic energy is applied through the horn via the first transducer to cause the first part-interfacing surface to vibrate back and forth along its entire length as the first ultrasonic energy is applied by the first transducer to the horn.

Abstract: The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.

Abstract: An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part.

Abstract: An ultrasonic systems and methods for sealing complex interfaces or for metal forming. Complex interfaces, such as a Gable top, have multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. An example system includes two ultrasonic horns arranged opposite a gap between which the interface is provided. The frequency and phase of the ultrasonic energy are synchronized as the energy is applied simultaneously while the interface is pressed between a jaw and the energy is applied to both sides of the interface. Another example system includes two ultrasonic transducers synchronized in frequency and phase and used to vibrate a horn mechanically to facilitate a sealing or welding interface or to assist in a metal-forming process.

Abstract: A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Abstract: An ultrasonic welding system. The system includes an ultrasonic transducer assembly having a horn and a first transducer and a second transducer arranged to impart ultrasonic energy into the horn. The horn has a first part-interfacing surface and a second part-interfacing surface opposite the first part-interfacing surface. An actuator assembly is operatively coupled to the ultrasonic transducer assembly and configured to cause rotation of the horn. A controller is configured to: cause the actuator assembly to rotate the horn so that the first part-interfacing surface applies the ultrasonic energy to a first part along an entire length of the first part-interface surface while a first ultrasonic energy is applied through the horn via the first transducer to cause the first part-interfacing surface to vibrate back and forth along its entire length as the first ultrasonic energy is applied by the first transducer to the horn.

Abstract: A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Abstract: An ultrasonic systems and methods for sealing complex interfaces or for metal forming. Complex interfaces, such as a Gable top, have multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. An example system includes two ultrasonic horns arranged opposite a gap between which the interface is provided. The frequency and phase of the ultrasonic energy are synchronized as the energy is applied simultaneously while the interface is pressed between a jaw and the energy is applied to both sides of the interface. Another example system includes two ultrasonic transducers synchronized in frequency and phase and used to vibrate a horn mechanically to facilitate a sealing or welding interface or to assist in a metal-forming process.

Abstract: A laser welding method and system for joining portions of first and second workpieces of thermoplastic material that is partially permeable to a laser beam but absorbs radiation from the laser beam. The first and second workpieces, which are made of material that absorbs radiation from a laser beam, are clamped together. A mask is placed on a first surface of the first workpiece, the first surface being opposite the surface engaging the second workpiece. The mask is impermeable to a laser beam and forms a slot for passing a laser beam to the portion of the first surface of the upper workpiece exposed by the slot, so that heating and melting of the material of the workpieces is limited to the width of the slot. A laser beam is directed onto the slot and moved in a manner to illuminate the slot to melt and join the workpieces.

Abstract: An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part.

Abstract: A system for providing power to more than one ultrasonic welding probe from M power supplies includes N multipoint units and a base. Each of the N multipoint units includes: a housing, a plurality of analog or digital inputs configured to carry distance information regarding probe distance of a plurality of ultrasonic welding probes, a dedicated high voltage input connector connectable via a high voltage cable to a dedicated high voltage output connector of one of the M power supplies, and a microcontroller. The microcontroller is configured to: direct power from the dedicated high voltage input connector to a corresponding one of the plurality of ultrasonic welding probes, and sample the distance information of the plurality of ultrasonic welding probes at a rate of at least once per millisecond. The base houses the M power supplies, wherein M and N are both integers greater than or equal to 1.

Abstract: The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.

Abstract: An ultrasonic system and method for sealing a complex interface, such as a Gable top, having multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. The system includes two ultrasonic horns arranged opposite a gap between which the interface is provided. The frequency and phase of the ultrasonic energy are synchronized as the energy is applied simultaneously while the interface is pressed between a jaw and the energy is applied to both sides of the interface. Only one application of the frequency- and phase-synchronized ultrasonic energy is required to hermetically seal all the layers of the interface together.

Abstract: The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.

Abstract: An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part.