Patents by Inventor Scott Caldwell

Scott Caldwell has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10730141
    Abstract: Plastic parts are welded in a laser welding system. An infrared laser source in a laser chamber is controlled by a controller using closed-loop feedback control with a corrected feedback signal that is compensated for background infrared radiation in the laser chamber. Prior to the infrared laser source being turned on, the controller senses with the optical sensor an intensity of background infrared radiation in the laser chamber. Once the laser is on, the controller senses with the optical sensor an intensity of infrared laser radiation in the laser chamber. The controller calculates the corrected feedback signal by subtracting the intensity of the background infrared radiation sensed when the infrared laser source was off from the intensity of the infrared laser radiation sensed when the infrared laser source is on.
    Type: Grant
    Filed: March 2, 2018
    Date of Patent: August 4, 2020
    Assignee: Branson Ultrasonics Corporation
    Inventor: Scott Caldwell
  • Publication number: 20200198254
    Abstract: Sensors incorporated within a waveguide detect a laser light output from at least a laser delivery optical fiber to provide in situ feedback of the laser light intensity detected by the sensor. The sensors may detect laser light directly from the laser delivery optical fiber or as reflected back from a plurality of work pieces during a weld cycle. In various aspects, the feedback provided from the sensors is used to control the laser light intensity or to alert an operator that the laser light intensity is below a predetermined parameter.
    Type: Application
    Filed: May 23, 2018
    Publication date: June 25, 2020
    Applicant: Branson Ultrasonics Corporation
    Inventors: Scott CALDWELL, Sean TRIMBY, Raul PASOLS
  • Publication number: 20200189204
    Abstract: Plastic parts are welded with a true 3D volumetric weld using intersecting multi-beam trace laser welding in which a plurality of spot laser beams having the same wavelength are directed to the so that the laser beams intersect each other at a point along a weld path within one of the plastic parts at an angle in an intersection angle range between ten degrees and ninety degrees. The plurality of laser beams are traced so that the intersection of the plurality of laser beams traces along the weld path to form a weld pattern that is linear, curvilinear, planar or three dimensional along a joint that is inside a volume of plastic. The plastic part in which the laser beams intersect is partially absorptive to laser light at a wavelength and the laser beams have this wavelength.
    Type: Application
    Filed: April 25, 2018
    Publication date: June 18, 2020
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Patent number: 10604647
    Abstract: A composition for making a cast, thermoformable sheet or slab, comprising: a syrup comprising: about 30-40% SSI—acrylic pre-polymerized syrup by weight at 20% solids; about 30-40% MMA—methyl methacrylate by weight; about 2-3% BA—Butyl acrylate by weight; about 1-15% by weight acrylic chips; and about 1-15% by weight rigid particles with a mean diameter of about 0.5-2000 ?m. The rigid particles may preferably comprise a polymeric material such as poly allyl diglycol carbonate particles. A method for producing a thermoformed article having a textured surface comprising mixing the syrup as above; swelling the acrylic chips; degassing the syrup; heating the syrup; casting the syrup into a sheet; and thermoforming the cast sheet against a mold.
    Type: Grant
    Filed: February 12, 2018
    Date of Patent: March 31, 2020
    Assignee: Aristech Surfaces LLC
    Inventors: Mark Gatman, Scott LaFollette, Neil Caldwell, Jeff Fields
  • Publication number: 20190299310
    Abstract: Ultrasonic stack contact with an object is detected upon the determination that the frequency of the ultrasonic stack has changed from the frequency of that ultrasonic stack operating near resonance in air.
    Type: Application
    Filed: February 6, 2019
    Publication date: October 3, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190262956
    Abstract: A work piece processing device includes a tool device, a work piece holder and a servo-elastic actuator system having simultaneous precision force and position control that moves one of the tool device and the work piece holder to the other of the tool device and work piece holder. The servo-actuator system including a servo-actuator, a compliance elastic member and a weight compensation elastic member disposed in a force transmission path with the compliance elastic member and the weight compensation elastic member disposed with respect to each other so that a spring force exerted by the weight compensation elastic member is opposed to a spring force exerted by the compliance elastic member.
    Type: Application
    Filed: October 10, 2018
    Publication date: August 29, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventors: Samuel LURIE, Thomas GABRE, Scott CALDWELL, Mark URBIN
  • Publication number: 20190224779
    Abstract: A method for sensing intensity of laser light in a simultaneous laser welding system includes placing a smart part in a weld area. The smart part includes at least a laser light intensity sensor for sensing laser light directed at it. Laser light intensity is sensed by the laser light intensity sensor of the smart part which provides an output signal indicative thereof to a controller.
    Type: Application
    Filed: January 18, 2019
    Publication date: July 25, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventors: Scott CALDWELL, Christopher ALMONTE
  • Publication number: 20190224924
    Abstract: Thermoplastic welding systems to weld work pieces together are provided. The work pieces are welded together at respective thermoplastic weld interface portions of the work pieces to form a weld. Before the weld interface portions have cooled, the weld interface portions are micro-pulled away from each other a micro-distance to strengthen the weld.
    Type: Application
    Filed: January 18, 2019
    Publication date: July 25, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190224921
    Abstract: A narrow waveguide homogenizes laser light traveling from a laser light source of a laser bank through a plurality of laser delivery bundles that include at least a fiber optic bundle leg to weld a plurality of work pieces along a weld line that is narrower than the width of the fiber optic bundle leg. The narrow waveguide has a portion associated with each fiber optic bundle leg that is narrower than the fiber optic bundle leg with which that portion of the waveguide is associated. A reflective bounce plane diverts laser light of the fiber optic bundle leg that does not travel through the narrow waveguide.
    Type: Application
    Filed: January 18, 2019
    Publication date: July 25, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190176262
    Abstract: An ultrasonic system has an ultrasonic stack excited by a power supply. The ultrasonic stack has a plurality of components, including an ultrasonic converter, a booster and an ultrasonic horn. A method of controlling the ultrasonic system with the power supply includes upon replacing any of the components of the ultrasonic stack with a replacement component, inputting an amplitude parameter of the replacement component into the power supply, determining with the power supply an amplitude of an AC excitation signal at which to excite the ultrasonic converter based on amplitude parameters of the components including the amplitude parameter of each replacement component. The power supply then sets the amplitude of the AC excitation signal at this determined amplitude.
    Type: Application
    Filed: December 10, 2018
    Publication date: June 13, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventors: Thomas GABRE, Scott CALDWELL, Eugene D. POLLASTRO, Dave SULIK, Liang ZHU
  • Publication number: 20190165247
    Abstract: An ultrasonic system has a piezoelectric powered ultrasonic stack having a piezoelectric ultrasonic converter excited by an ultrasonic power supply.
    Type: Application
    Filed: July 11, 2018
    Publication date: May 30, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190152159
    Abstract: Sensors incorporated within a laser channel detect laser light upconverted by a dopant. The dopant is located after a delivery end of a laser delivery optical fiber and upconverts laser light that has traveled from a laser light source from a laser bank through one of a plurality of laser channels through to a location after the delivery end of a laser delivery optical fiber. In some embodiments, the dopant is positioned at the delivery end of the laser delivery optical fiber. In other embodiments, the dopant is positioned within a dummy part or on a surface of at least a work piece.
    Type: Application
    Filed: November 7, 2018
    Publication date: May 23, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190143610
    Abstract: A loose stack joint and/or cracked ultrasonic stack component of an ultrasonic stack of an ultrasonic device are detected by measuring a test damping coefficient with a test scan of the ultrasonic stack. The test damping coefficient is compared with a previously measured baseline damping coefficient. It is determined that the ultrasonic stack has a loose stack joint and/or a cracked ultrasonic stack component when the damping coefficient is greater than the baseline damping coefficient by more than a predetermined amount.
    Type: Application
    Filed: October 17, 2018
    Publication date: May 16, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventors: Scott CALDWELL, Tom AYARS
  • Publication number: 20190143370
    Abstract: Methods of mitigating current overload of an ultrasonic system having an ultrasonic stack under load at startup are provided. The methods include beginning an ultrasonic cycle in the ultrasonic system having the ultrasonic stack that runs a closed loop phase control through the weld cycle by ramping up the power of the ultrasonic stack under load. During ramping up of the power of the ultrasonic stack under load, a controller lowers the phase to a negative phase. After ramping up the power of the ultrasonic stack under load is complete, the controller raises the phase to 0 degrees and the ultrasonic stack is operating at steady state and with the phase at 0 degrees.
    Type: Application
    Filed: October 15, 2018
    Publication date: May 16, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190118288
    Abstract: Sensors comprising optical sensor fibers detect a laser light output from at least a laser delivery optical fiber to provide feedback of the laser light intensity detected by the optical sensor fiber. The optical sensor fibers may be integrated within a laser delivery bundle, or may be positioned between a delivery end of the laser delivery optical fiber and a plurality of work pieces to be welded. In various aspects, the feedback provided from the optical sensor fibers is used to control the laser light intensity or to alert an operator that the laser light intensity has fallen below a predetermined parameter.
    Type: Application
    Filed: September 28, 2018
    Publication date: April 25, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20190118295
    Abstract: Sensors incorporated within a laser bank detect light emitted by light sources that is directed into and travels through a delivery end of an associated laser delivery optical fiber. The light sources may be positioned between downstream of the delivery end of the associated laser delivery optical fiber and a lower tooling. In some embodiments, the light source is incorporated within a waveguide. In other embodiments, the light source is positioned within a dummy part.
    Type: Application
    Filed: September 28, 2018
    Publication date: April 25, 2019
    Applicant: Branson Ultrasonics Corporation
    Inventors: Scott CALDWELL, Christopher ALMONTE
  • Publication number: 20180290236
    Abstract: Plastic parts are welded in a laser welding system. An infrared laser source in a laser chamber is controlled by a controller using closed-loop feedback control with a corrected feedback signal that is compensated for background infrared radiation in the laser chamber. Prior to the infrared laser source being turned on, the controller senses with the optical sensor an intensity of background infrared radiation in the laser chamber. Once the laser is on, the controller senses with the optical sensor an intensity of infrared laser radiation in the laser chamber. The controller calculates the corrected feedback signal by subtracting the intensity of the background infrared radiation sensed when the infrared laser source was off from the intensity of the infrared laser radiation sensed when the infrared laser source is on.
    Type: Application
    Filed: March 2, 2018
    Publication date: October 11, 2018
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20180141157
    Abstract: A baffled optical waveguide has a body shaped to partially or wholly surround a part or parts being processed by being illuminated with light. The body has optical baffles therein that define light channels through which the light travels as it transits the baffled optical waveguide. Outlets of the light channels are adjacent an opening in the body which receives an area or areas of the parts or parts being processed. Each light channel homogenizes the light as it transits through that light channel. The optical baffles that define the light channels keep light from diverging in the baffled optical waveguide as it transits through the light channels. In an aspect, a part (or parts) is processed by illuminating it with light via the baffled optical waveguide.
    Type: Application
    Filed: November 15, 2017
    Publication date: May 24, 2018
    Applicant: Branson Ultrasonics Corporation
    Inventors: Hugh T. MCNAIR, Scott CALDWELL, Marian BLASKO
  • Publication number: 20180120148
    Abstract: A broken piezoelectric material in an ultrasonic transducer of an ultrasonic stack of an ultrasonic device is detected by measuring a test piezo coupling constant with a test scan of the ultrasonic stack. The test piezo coupling constant is compared to a previously measured baseline piezo coupling constant. The piezoelectric material is determined to be broken when the test piezo coupling constant is less than the baseline piezo coupling constant by more than a predetermined amount.
    Type: Application
    Filed: September 11, 2017
    Publication date: May 3, 2018
    Applicant: Branson Ultrasonics Corporation
    Inventor: Scott CALDWELL
  • Publication number: 20170129062
    Abstract: A work piece processing device includes a tool piece, a work piece holder and a servo-elastic actuator system having simultaneous precision force and position control that moves one of the tool piece and the work piece holder to the other of the tool piece and work piece holder.
    Type: Application
    Filed: November 4, 2016
    Publication date: May 11, 2017
    Applicant: Branson Ultrasonics Corporation
    Inventors: Scott CALDWELL, Thomas GABRE, Hugh PLUMLEE, Aare TALI