Dukane Ias, LLC

Dukane Corporation

Dukan Ias, LLC

Leo Klinstein

Paul J Golko

William E Jurkowski

Petr Vasko

Robert Edward Aldaz

Charles Leroy Leonard

Matthew James Dittrich

Alexander Savitski

Joseph Re

Andrew Germaine

Eugene Palatnik

Grzegorz Zdzislaw Bugaj

Jiri Vizek

John Putnam Hays, Iv

Hardik Shailesh Pathak

Kenneth Andrew Holt

Arnost Benda

David K Johansen

Justin Marshall Lafferty

Miranda Bair Marcus

Raymond M LaFlamme

Iv John Putnam Hays

An apparatus having a first treatment module and a second treatment module, at least one of which includes a welding device for treating one or more workpieces. The apparatus has a controller arranged to: receive a real-time amplitude signal of ultrasonic vibration of at least one of the first treatment module and the second treatment module during a treatment cycle; segment the amplitude signal into a plurality of amplitude segments for the treatment cycle; monitor an amplitude value of each of the plurality of amplitude segments during the treatment cycle; operate a plurality of closed-loop control algorithms to determine a plurality of amplitude adjustment values, each of the plurality of amplitude adjustment values corresponding to a respective one of the plurality of amplitude segments; and apply each amplitude adjustment value to the corresponding respective one of the plurality of amplitude segments during the subsequent treatment cycle in real-time.

Apparatus and a method for bonding webs of non-woven plastic material

An ultrasonic weld/seal-cut system having an ultrasonic cut stack assembly, including an ultrasonic cutting horn with a transducer arranged to impart an ultrasonic energy to the ultrasonic cutting horn (sonotrode) and allow for wider cutting applications while minimizing deflections of the cutting horn under force. The cutting horn has a cutting feature configured to contact a part to be cut and a major surface adjacent to the cutting feature and a booster. The booster can have a generally flat shape and a major surface that is generally coplanar with the major surface of the ultrasonic cutting horn. One or more controllers can be operatively coupled to the ultrasonic cut stack assembly and configured to apply ultrasonic energy through the ultrasonic cut horn via the transducer to cause the cutting feature to move back and forth along its length as the ultrasonic energy is applied by the transducer to the cutting horn. The cutting horn and booster can be a unitary piece, and can be produced by machining a solid plate of metal into the cutting horn with integrated the booster.

High stiffness booster for ultrasonic welding apparatus with a cutting blade integrated into the horn

A method and an apparatus for ultrasonic staking a first part having a fastening portion to a second part having an opening corresponding to the fastening portion. The method comprises aligning the fastening portion of the first part with the corresponding opening in the second part, inserting a head of the fastening portion through the corresponding opening, and causing a horn of an ultrasonic staking stack to contact the head, apply ultrasonic energy oscillating at a frequency between 45 kHz and 75 kHz, and move along an axis of the fastening portion as the head melts to form a stake. The stake can include a melt-form that joins the first part and the second part to each other, and the fastening portion can have a geometry or a size disposed to flapping.

Apparatus and a method for targeted ultrasonic melt-forming or staking

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

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.

Systems and methods using an ultrasonic transducer and scrubbing horn motion to seal a part

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.

Methods for determining a melt layer thickness associated with a predetermined weld strength based on a correlation therebetween

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.

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. A collapse distance of a weld formed at the interface portion is less than the thickness of the first part, to avoid read-through effects on the exposed surface of the second part.

Servo-driven ultrasonic welding system and method for welding to a thin part without read-through

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

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.

Laser welding system and method using cooling mask to control the width of the weld

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.

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Glenview, IL, United States of America

Leo Klinstein