Dukane Ias, LLC

Dukane Corporation

Charles Leroy Leonard

Leo Klinstein

Matthew James Dittrich

Paul J Golko

Petr Vasko

Robert Edward Aldaz

Joseph Re

John Putnam Hays, Iv

William E Jurkowski

David K Johansen

Andrew Germaine

Iv John Putnam Hays

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.

Automated ultrasonic press systems and methods for welding physically variant components

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.

Systems and methods using multiple synchronized ultrasonic transducers to finish a part

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.

Ultrasonic welding systems and methods using dual, synchronized horns on opposite sides of parts to be joined

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.

Multipoint controllers for power delivery to multiple probes in ultrasonic welding systems

Ultrasonic transducer coupling adapters, ultrasonic transducer assemblies with an adapter, and methods for making and for using ultrasonic transducer adapter components are disclosed. An ultrasonic transducer assembly is disclosed for generating and transmitting ultrasonic energy to a work piece (e.g., non-resonant structures). The assembly includes piezoelectric actuators that generate ultrasonic vibrations in response to high-frequency electrical signals. A feedback system monitors and regulates voltages applied to the piezoelectric actuators. The assembly also includes an adapter that is connected to the piezoelectric actuators (e.g., via a front mass) and is configured to distribute the ultrasonic vibrations from the actuators to the work piece. The adapter reduces or substantially eliminates transmission back to the piezoelectric actuators of erratic strain generated by the work piece in response to these ultrasonic vibrations. The adapter helps to ensure that the ultrasonic transducer assembly vibrates with a simple axial motion when the work piece vibrates erratically.

Adapter for ultrasonic transducer assembly

An ultrasonic generator comprising an input module for receiving a power signal. An output module for outputting an ultrasonic signal is also included in the generator. A motherboard is coupled to both the input module and the output module. The motherboard includes a digital controller adapted to control the input module and the output module.

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St. Charles, IL, United States of America

Charles Leroy Leonard