Method and apparatus for ultrasonic welding thermoplastic components

Abstract

According to an aspect of the present disclosure, an ultrasonic welding tool having a longitudinal axis is provided that includes an ultrasonic tool, a tapered step horn, an ultrasonic transducer, and a plurality of helical grooves. The ultrasonic tool (UT) has a diameter, a UT length extending between a UT first end and a distal tool tip, and a UT exterior surface that extends around a UT circumference of the ultrasonic tool. The tapered step horn (SH) has an SH length that extends between an SH first end and an SH second end, a major diameter disposed at the SH first end, a minor diameter disposed at the SH second end, a middle diameter between the SH first end and the SH second end, and an SH exterior surface that extends around an SH circumference of the step horn. The SH second end of the step horn is connected to the UT first end of the ultrasonic tool. The ultrasonic transducer is in communication with the step horn and the ultrasonic tool. The ultrasonic transducer is controllable to ultrasonically vibrate the step horn and the ultrasonic tool. The ultrasonic tool, the step horn, and the ultrasonic transducer are disposed along the longitudinal axis. The plurality of helical grooves may be disposed in the UT exterior surface spaced apart from one another around the UT circumference, or in the SH exterior surface spaced apart from one another around the SH circumference, or both. The ultrasonic vibration caused by the ultrasonic transducer produces a composite ultrasonic vibration of the ultrasonic tool that includes a longitudinal component and a torsional component.

Dependencies are inferred from the claim text.