American Technology Corporation

Michael J Patrikios

Guillermo Coto

Curtis L Welter

Rodney H Hawkins

James A Markus

Betty Link

Mark W Dearth

An ultrasonic welder is provided which automatically recognizes and reliably welds varying weld zone sizes of material The welder comprises a base, a transducer, a tip, an anvil, a gathering tool, and an actuator for moving both the anvil and gathering tool to define a weld zone. An encoder reads movement of the actuator and a microprocessor determines weld zone size to control the transducer for maximizing weld efficiency. Preferably, a horn is mounted between the transducer and tip and the horn is dynamically mounted along an axis of the transducer to transmit the maximum amount of ultrasonic energy to the weld. In another aspect, the invention relates to a method of operating an ultrasonic welder to automatically recognize and reliably weld varying weld zone sizes.

Automated, energy efficient ultrasonic welder

An ultrasonic welder is provided which comprises a base, a transducer, a tip, an anvil, a gathering tool, and an actuator for moving both the anvil and gathering tool. The anvil has angled sidewalls to improve weld efficiency.

Ultrasonic welder including anvil with angled sidewalls

An ultrasonic welder is provided which automatically recognizes and reliably welds varying weld zone sizes of material. The welder comprises a base, a transducer, a tip, an anvil, a gathering tool, and an actuator for moving both the anvil and gathering tool to define a weld zone. An encoder reads movement of the actuator and a microprocessor determines weld zone size to control the transducer for maximizing weld efficiency. Preferably, a horn is mounted between the transducer and tip and the horn is dynamically mounted along an axis of the transducer to transmit the maximum amount of ultrasonic energy to the weld.

Ultrasonic welder with dynamic nodal horn support

An apparatus and method for ultrasonically welding wires includes an ultrasonic horn tip and associated structure for allowing adjustment to accommodate different diameters of wires to be welded while maintaining a tight grip around the wires during the welding process to avoid spreading or splaying of the wires. The tip is rotable to provide several alternative and interchangeable work surfaces on a standard-shaped readily machineable cross section, thereby allowing for a longer total worklife and a reduced cost of manufacture.

Apparatus and method for ultrasonic welding of wires

An ultrasonic welding apparatus adapted to simultaneously weld individual wire ends to individual contacts on a wire connector is disclosed. The apparatus includes an ultrasonic horn having a welding tip attached at one end. An anvil selectively and separately supports the wire ends on the individual wire contacts. A comb is engaged with the anvil for selectively maintaining separation between the adjacent wire ends and the adjacent contacts during ultrasonic welding and for dislodging the wire connector after the wire ends have been welded thereto.

Method and apparatus of ultrasonic gang welding

The invention relates to an apparatus and method for ultrasonically welding a conductor wire to an electrical terminal. The terminal has a channel portion for receiving the conductor wire. The electrical terminal with the wire therein is confined adjacent the welding tip whereby movement of the welding tip into the channel portion presses the conductor wire against the electrical terminal and welds it thereto.

Ultrasonically welding a conductor wire to an electrical terminal

Apparatus is provided for ultrasonic welding of wires which include a welding tip of a standard shaped readily machineable cross section with no concave surfaces. The welding tip is rotatable about an ultrasonic horn to present several alternative available worksurfaces. The worksurface in use defines a wall of the compression chamber into which wires to be welded are inserted. An anvil, a support, and a gathering tool each define an additional surface of the compression chamber. The position of each of these elements is adjustable thereby allowing for adjustment in two dimensions of the cross section of the compression chamber. This allows for the welding of various sizes or numbers of wires.

Apparatus for ultrasonic welding of wires

Apparatus for ultrasonic welding of wires including a hand-held housing with an ultrasonic wave generator, a welding tip connected to said generator, an anvil for clamping the wires to be welded to said welding tip, and a tool for gathering wires disposed between said anvil and welding tips to prevent the wires from splaying during weldment.

Portable gun for ultrasonically welding wires

Apparatus for the automated feeding, placement and ultrasonic welding of a metal disc, such as a copper heatsink, to a recipient workpiece. A metal disc is automatically fed through the broader end of a chamfered bore cut in a weld location mask. The metal disc is gravity-fed to the narrower end of the bore as the weld location mask is automatically positioned over a recipient workpiece. An ultrasonic welding tip is inserted through the bore to hold the metal disc against the recipient workpiece. Welding of the disc to the recipient workpiece is accomplished by ultrasonically vibrating the tip.

Ultrasonic weld location mask and method of use

Apparatus for ultrasonically welding a wire to a wire terminal. A stationary anvil forms the lower horizontal wall of a work chamber into which a wire workpiece is inserted. The vertical walls of the work channel are formed by the walls of a slot in a relatively movable horizontal support plate cantilevered from a base. The slot in the support plate fits about the anvil. The horizontal support plate is oscillatable to swing vertically thereby adjusting the size of the work channel. A terminal is seated on the support plate and covers the chamber. An ultrasonic welding tip contacts the terminal and forces down the support plate so as to maintain very tight spot contact between the wire on the anvil and the terminal, against the flexure of the cantilevered arm. Welding of the wire to the terminal is effected by the ultrasonic vibration of the welding tip against the terminal. As the wire is tightly confined in the work channel, no spreading or splaying will occur while the wire is in a plastic-like state, and the spot weld precisely locates the wire end on the terminal.

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Stratford, CT, United States of America

Michael J Patrikios