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

A non-transitory computer-readable medium for ultrasonic staking a first part having a fastening portion that includes a flap-prone structure which resonates at frequencies of 40 kHz or less to a second part having an opening corresponding to the fastening portion, the computer-readable medium comprising instructions that, when executed by a processor, cause the processor to perform a method comprising:

• aligning the fastening portion that includes the flap-prone structure with the corresponding opening in the second part;
• inserting a head of the fastening portion that includes the flap-prone structure through the corresponding opening;
• and
• causing a horn of an ultrasonic staking stack to
• (i) contact the head,
• (ii) apply ultrasonic energy oscillating at a frequency between 45 kHz and 75 kHz without resonance disaster of the fastening portion that includes the flap-prone structure, and
• (iii) move along an axis of the fastening portion as the head melts to form a stake,
• wherein the stake comprises a melt-form that joins the first part and the second part to each other, and
• wherein the fastening portion that includes the flap-prone structure has a geometry or a size disposed to flapping at frequencies 40 kHz or less.

A system for ultrasonic staking a first part having a fastening portion that includes a flap-prone structure which resonates at frequencies of 40 kHz or less to a second part having an opening corresponding to the fastening portion, the system comprising:

• a horn configured to apply ultrasonic energy at a predetermined frequency;
• and
• a controller configured to operate the horn, including to
• (i) position the horn to contact a head of the fastening portion that includes the flap-prone structure,
• (ii) apply ultrasonic energy oscillating to the horn at a frequency between 45 kHz and 75 kHz without resonance disaster of the fastening portion that includes the flap-prone structure, and
• (iii) move the horn along an axis of the fastening portion as the head melts to form a stake,
• wherein the stake comprises a melt-form that joins the first part and the second part to each other, and
• wherein the fastening portion that includes the flap-prone structure has a geometry or a size disposed to flapping at frequencies of 40 kHz or less.