CN108080781A - 用于超声波焊接工艺的喇叭 - Google Patents

用于超声波焊接工艺的喇叭 Download PDF

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CN108080781A
CN108080781A CN201711189121.5A CN201711189121A CN108080781A CN 108080781 A CN108080781 A CN 108080781A CN 201711189121 A CN201711189121 A CN 201711189121A CN 108080781 A CN108080781 A CN 108080781A
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CN108080781B (zh
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I·A·卢梭
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GM Global Technology Operations LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
    • B29C65/082—Angular, i.e. torsional ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/26—Auxiliary equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/822—Transmission mechanisms
    • B29C66/8221—Scissor or lever mechanisms, i.e. involving a pivot point
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/863—Robotised, e.g. mounted on a robot arm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8324—Joining or pressing tools pivoting around one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Apparatuses For Generation Of Mechanical Vibrations (AREA)

Abstract

一种用于超声波焊接设备的喇叭包括具有外径表面的主体以及具有第一曲面和第二曲面的凸焊嘴。峰值曲率点由第二曲面限定。基本曲率点被限定在外径表面与第一曲面之间的交点处。内径被限定在第一曲面与第二曲面之间的交点处。

Description

用于超声波焊接工艺的喇叭
技术领域
本公开涉及超声波焊接***。
引言
此章节的陈述仅提供与本公开相关的背景信息，并且未必构成现有技术。
在超声波焊接工艺中，相邻工件紧紧地夹紧在砧座与焊接喇叭或超声波发生器之间。在特定的频率和方向的范围内通过喇叭向相邻工件施加受控的振荡或振动，从而在工件的界面处或沿着其产生显著的表面摩擦。所产生的热量使工件的相邻表面软化，从而在冷却时粘结工件。超声波焊接部分的效率、一致性、可靠性和/或耐久性在很大程度上取决于工件的物理、热力学和热机械性质以及相关焊接设备的物理和机电能力。
发明内容
一种用于超声波焊接设备的喇叭包括具有外径表面的主体以及具有第一曲面和第二曲面的凸焊嘴。峰值曲率点由第二曲面限定。基本曲率点被限定在外径表面与第一曲面之间的交点处。内径被限定在第一曲面与第二曲面之间的交点处。
一种用于连接工件的方法包括以堆叠布置设置工件并且设置机器人工具，该机器人工具在其远端处具有超声波焊接装置。超声波焊接装置包括喇叭，其具有包括外径的主体以及凸焊嘴。机器人工具的远端移动至与工件的表面相邻的第一位置，使得超声波焊接装置的喇叭在第一位置处以与垂面成第一角度接触工件。超声波焊接装置生成振动能量，其通过喇叭传播至工件。
一种用于超声波焊接设备的喇叭包括具有外径表面的主体以及具有第一径向表面和第二径向表面的凸焊嘴。第一径向表面和第二径向表面在与外径表面同心的内径处相交。
从本文所提供的描述中将明白进一步应用领域。应当理解的是，该描述和具体实例仅旨在用于说明目的，并且不旨在限制本公开的范围。
附图说明
本文所述的附图仅用于说明目的并且不旨在以任何方式限制本公开的范围。
图1是根据本公开的具有喇叭的示例性超声波焊接***的示意图；
图2是根据本公开的示例性喇叭的示意图；
图3是图2的喇叭的透视图，其描绘了根据本公开的凸焊嘴部分；
图4A是现有技术的喇叭尖的透视图；
图4B是第一示例性圆顶喇叭焊嘴的透视图；
图4C是第二示例性圆顶喇叭焊嘴的透视图；以及
图4D是第三示例性圆顶喇叭焊嘴的透视图。
具体实施方式
以下描述在本质上仅仅是示例性的并且不旨在限制本公开、应用或用途。应当理解的是，在整个附图中，对应的附图标号指示相同或对应的部分和特征。另外，诸如“顶部”、“侧面”、“后部”、“下部”和“上部”等方向是为了说明目的，且除非另有说明，否则不旨在要求具体的方向。这些方向仅作为相对于所提供的实例的参考框架提供，但在替代应用中可改变。
现在参考图1，示例性超声波焊接***10适于使用超声波焊接工艺形成焊接接头。超声波焊接***10被示为具有电源12，其用于将线路功率转换成更容易用于或有助于超声波焊接的形式。通常用于超声波焊接工艺的类型的电源(诸如电源12)可电连接至任何合适的能源(例如，约50Hz至60Hz的低频电信号)。电源12将电源功率转换成具有适合于在超声波焊接工艺中使用的预定波形特性的合适功率控制信号，例如高频、高压电信号，这取决于特定应用(例如，15kHz至70kHz，且更特别是20kHz至40kHz)。然后，高频电信号在转换器14(例如，换能器)中以超声波频率转换为机械振动。转换器14具有用于产生机械振动或振荡信号的所需机械结构。可选增压器16可包括在***10中以便放大振动的振幅。
然后，来自***的超声波振动传播通过喇叭或超声波发生器18。喇叭18可聚焦超声波振动并将振动能量传递至材料上的特定区域。换句话说，喇叭18以校准的频率和振幅振荡，由此在配对的一对工件20之间的焊接界面处生成摩擦和热量。超声波工具***10还包括工具定位***22(例如，具有终端执行器26的机械臂24)用于沿着与工件20相邻的方向移动喇叭18，以便在用于向其施加焊接压力的超声波工艺期间在预定位置处向工件20施加选定的法向力。工件20可布置在砧座或嵌座28上用于在焊接工艺期间进行支撑。然而，在一些实施例中，工件20可具有足够的固有强度以支持该工艺而不需要砧座28。
在制造环境中，工具定位***22可为具有终端执行器26的机械臂24。当工具定位***22是机械臂24时，终端执行器26可根据焊接时间表将超声波工具移动至预定的焊接位置。机械臂24和终端执行器26将超声波工具(例如，喇叭18)带至接触待焊接的工件20的位置。因为机械臂24和终端执行器26包括串联布置的多个铰接接头，所以具有固有的顺应性和定位公差。这些顺应性和定位公差可能会导致在超声波工具***10处非法向接近上面有超声波工具***起作用的工件20(例如，与法向偏离值小于10度)。另外，特别是在喇叭具有平坦的焊嘴时，非法向焊接可导致焊接降低质量和强度。
现在参考图2，示例性超声波喇叭18被描绘为具有适于将工件20固定在预定位置32处的凸焊嘴30。凸焊嘴30使得喇叭18能够产生具有一致性能、特别是一致的焊接直径和焊接强度的焊缝。凸焊嘴30的横截面的尺寸取决于在具体制造场景中可预期的偏离法向角度的量。凸焊嘴30提供制造灵活性，否则在焊接之前在没有用于位置反馈和机器人重新定位的附加视觉或机械***的情况下将不可用。另外，不需要修改焊接时间表以适应焊接强度的损失(例如，增加焊接次数)。
现在参考图3，示例性超声波喇叭18可包括凸焊嘴30。凸喇叭设计实现x-y位置公差以及接近公差的角度。每个圆顶的尺寸取决于应用所需的角度公差。在典型的制造公差内，可能存在独特的喇叭设计以覆盖整个公差窗口。在一个示例中，喇叭18可包括以焊嘴30终止的标准外径34直线设计(例如，18mm)。焊嘴30在喇叭18的下表面上可具有从外径34延伸的第一曲率半径36。焊嘴30在喇叭18的下表面上还可具有从第一曲率半径36延伸的第二曲率半径38。喇叭18的凸焊嘴30可通过与第一曲率半径36和第二曲率半径38的部分相互作用而在预定位置32处与工件20相互作用。
参考图4A，描绘了现有技术的喇叭118，其具有在拐角140处具有18mm直径和1mm全半径的平坦焊嘴130用于复合物和聚合物连接，且该喇叭提供以下结果：
参考图4B，描绘了包括具有第一曲率半径236(例如101.45mm)和第二曲率半径238(例如，46.99mm)的凸焊嘴230的示例性超声波喇叭218的第一实施例。喇叭218可用在半波、30kHz***中使用。峰值曲率点242与第二曲率半径238相关联，而基本曲率点244被限定在外径246(例如，18mm)与第一曲率半径236之间的交点处。第一曲率半径236与第二曲率半径238之间的交点限定焊嘴230的内径248(例如13.5mm)。限定峰值曲率点242至基本曲率点244的深度D1(例如，0.650mm)；限定峰值曲率点242至内径248的深度D2(例如，0.485mm)；且限定内径248至基本曲率点244的深度D3(例如，0.165mm)。如上所述的示例性喇叭218提供以下结果：
参考图4C，描绘了包括具有第一曲率半径336(例如101.45mm)和第二曲率半径338(例如，46.99mm)的凸焊嘴330的示例性超声波喇叭318的第二实施例。喇叭318可用在半波、30kHz***中使用。峰值曲率点342与第二曲率半径338相关联，而基本曲率点344被限定在外径346(例如，18mm)与第一曲率半径336之间的交点处。第一曲率半径336与第二曲率半径338之间的交点限定焊嘴330的内径348(例如8.9mm)。限定峰值曲率点342至基本曲率点344的深度D4(例如，0.518mm)；限定峰值曲率点342至内径348的深度D5(例如，0.208mm)；且限定内径348至基本曲率点344的深度D6(例如，0.310mm)。如上所述的示例性喇叭318提供以下结果：
参考图4D，描绘了包括具有第一曲率半径436(例如101.45mm)和第二曲率半径438(例如，46.99mm)的凸焊嘴430的示例性超声波喇叭418的第三实施例。喇叭418可用在半波、20kHz***中使用。峰值曲率点442与第二曲率半径438相关联，而基本曲率点444被限定在外径446(例如，18mm)与第一曲率半径436之间的交点处。第一曲率半径436与第二曲率半径438之间的交点限定焊嘴430的内径448(例如13.5mm)。限定峰值曲率点442至基本曲率点444的深度D7(例如，0.662mm)；限定峰值曲率点442至内径448的深度D8(例如，0.487mm)；且限定内径448至基本曲率点444的深度D9(例如，0.175mm)。
本文描述了本公开的实施例。本说明书在本质上仅仅是示例性的，且因此不脱离本公开的主旨的变化旨在属于本公开的范围。例如，图1中所示的示例性超声波加工***10仅表示可根据本文公开的实施例使用的超声波机械能源的一个示例。因而，应当理解的是，可采用任何合适的超声波设备来实践所公开的实施例。另外，本文提供的示例性喇叭被示为峰值曲率点与至基本曲率点相距小于1mm；然而，应当理解的是，凸圆顶尺寸取决于所需的角公差。
图式不一定按比例绘制；某些特征可以被放大或最小化以示出特定部件的细节。因此，本文公开的具体结构和功能细节并不解释为限制，而仅仅解释为用于教导本领域技术人员以各种方式采用本发明的代表性基础。如本领域一般技术人员将理解的是，参考任何一个图式说明并描述的各个特征可结合一个或多个其它图式中说明的特征以产生未明确说明或描述的实施例。所说明的特征组合提供用于各个应用的代表性实施例。然而，与本公开的教导一致的特征的各个组合和修改可期望用于特定应用或实施方案可期望，且被认为在本公开的范围内。

Claims (10)

1.一种用于超声波焊接设备的喇叭，所述喇叭包括：
具有外径表面的主体；以及
具有第一曲面和第二曲面的凸焊嘴，其中峰值曲率点由所述第二曲面限定，基本曲率点被限定在所述外径表面与所述第一曲面之间的交点处，且内径被限定在所述第一曲面与所述第二曲面之间的交点处。
2.根据权利要求1所述的喇叭，其中在所述峰值曲率点与所述基本曲率点之间限定第一深度，在所述峰值曲率点与所述内径之间限定第二深度，且在所述基本曲率点与所述内径之间限定第三深度。
3.根据权利要求2所述的喇叭，其中所述第二深度和所述第三深度在组合时等于所述第一深度。
4.根据权利要求2所述的喇叭，其中所述第一深度小于1mm。
5.根据权利要求1所述的喇叭，其中所述第一曲面限定第一圆顶形焊接表面，且所述第二曲面限定第二圆顶形焊接表面。
6.根据权利要求1所述的喇叭，其中所述内径与所述外径表面同心。
7.根据权利要求1所述的喇叭，其中所述凸焊嘴配置成将工件表面处的工件与所述第一曲面和所述第二曲面两者的至少一部分接合。
8.一种使用权利要求1的喇叭连接工件的方法，包括：
以堆叠布置设置所述工件；
设置机器人工具，所述机器人工具在其远端处具有所述超声波焊接装置，所述超声波焊接装置包括所述喇叭，所述喇叭具有包括所述外径表面的所述主体以及所述凸焊嘴；
将所述机器人工具的所述远端移动至与所述工件的表面相邻的第一位置，使得所述超声波焊接装置的所述喇叭在所述第一位置处以与垂面成第一角度接触所述工件；以及
由所述超声波焊接装置生成振动能量，其通过所述喇叭传播至所述工件。
9.根据权利要求8所述的方法，进一步包括：
将所述机器人工具的所述远端移动至与所述工件的所述表面相邻的第二位置，使得所述超声波焊接装置的所述喇叭在所述第二位置处以与垂面成第二角度接触所述工件。
10.根据权利要求9所述的方法，其中所述第一角度和所述第二角度偏离法向小于正常七度。
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