Patent Publication Number: US-2013240152-A1

Title: Hollow tip welding tool

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application having attorney docket number NIKE.162501, entitled “HOLLOW TIP WELDING TOOL” is related by subject matter to U.S. patent application Ser. No. 13/299,908, filed Nov. 18, 2011, having attorney docket number NIKE.162500, and entitled “MULTI-FUNCTIONAL MANUFACTURING TOOL.” Further, this application is also related by subject matter to U.S. patent application Ser. No. 13/299,934, filed Nov. 18, 2011, having attorney docket number NIKE.162096, and entitled “MANUFACTURING VACUUM TOOL.” The entireties of the aforementioned applications are incorporated by reference herein. 
    
    
     BACKGROUND 
     Traditionally, parts used in manufacturing a product are picked up and placed in a position for manufacturing by human hand or robotic means. However, current robotic means have not provided a level of control, dexterity, and effectiveness to be cost-effectively implemented in some manufacturing systems. 
     Automated manufacturing systems that implement a variety of processes have traditionally relied on discrete mechanisms to implement each of the different processes. However, having automation machinery dedicated to a primarily-discrete task may be inefficient from a production perspective and from a cost perspective. 
     SUMMARY 
     Aspects of the present invention relate to systems, methods and apparatus for an ultrasonic welding vacuum tool. The ultrasonic welding vacuum tool is comprised of a converter for converting electrical input into an ultrasonic mechanical vibration. The ultrasonic welding vacuum tool is further comprised of a horn coupled to the converter for transferring the ultrasonic mechanical vibration to a part-contacting distal end of the horn, the horn comprised of a vacuum channel. The vacuum channel extending from an exterior surface of the horn through an interior portion of the horn to the part-contacting distal end of the horn. 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Illustrative embodiments of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein: 
         FIG. 1  depicts an exemplary ultrasonic welding vacuum tool, in accordance with aspects of the present invention; 
         FIG. 2  depicts another exemplary aspect of the pick-up tool having an integrated vacuum generator, in accordance with aspects of the present invention; 
         FIG. 3  depicts a perspective view of a pick-up tool mounted within a coupler, in accordance with aspects of the present invention; 
         FIG. 4  depicts an internal view of the pick-up tool along cutline  4 - 4  of  FIG. 1 , in accordance with aspects of the present invention; 
         FIG. 5  depicts an internal view of the pick-up tool along cutline  5 - 5  of  FIG. 2 , in accordance with aspects of the present invention; 
         FIG. 6  depicts an internal view of an exemplary pick-up tool utilizing an alternative internal vacuum mechanism, in accordance with aspects of the present invention; 
         FIG. 7  depicts an exemplary horn having a coanda effect internal vacuum generator, in accordance with aspects of the present invention; 
         FIG. 8  depicts an exemplary horn coupled with an exemplary horn tip, in accordance with aspects of the present invention; and 
         FIGS. 9-17  depict exemplary aperture patterns, in accordance with aspects of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  depicts an exemplary ultrasonic welding vacuum tool  100 , in accordance with aspects of the present invention. The ultrasonic welding vacuum tool  100  may also be referred to as a pick-up tool  100  herein. An ultrasonic welder, in general, is comprised of a stack. The stack is comprised of a converter  102  and a horn  104 . The converter  102  converts an electrical signal into a mechanical vibration, such as an ultrasonic vibration (the converter  102  may also be referred to as a transducer, such as a piezoelectric transducer). The horn  104 , traditionally, transfers the mechanical vibration produced by the converter  102  to a manufacturing part to be welded (the horn may also be referenced to as a sonotrode). Additional components of an ultrasonic welder stack may traditionally include a booster (not shown). The booster modifies amplitude of vibration produced by the converter  102  to be transmitted by the horn  104 . In an exemplary aspect, the booster is useable to couple the ultrasonic welder stack to a moveable member, such as a press manufacturing or a computer-numerically-controlled robot. 
     An ultrasonic welder may further be comprised of an electronic ultrasonic generator (may also be referred to as a power supply) and a controller. The electronic ultrasonic generator may be useable for delivering a high-powered alternating current signal with a frequency matching a resonance frequency of the stack (e.g., horn, converter, and booster). The controller controls the delivery of the ultrasonic energy from the ultrasonic welder to one or more parts. 
     While the converter  102  is depicted herein as a cylindrical in shape, it is contemplated that other formations are applicable. The converter  102  of  FIG. 1  has a first end  130  and a second end  132 . 
     The horn  104  is generally depicted as having a circular cross-section within  FIG. 1 ; however, it is contemplated that additional cross-sectional geometries may be implemented. For example, to provide one or more mechanical vibration traits, the cross-sectional shape may be altered. In particular, it is contemplated that a variety of curved geometries utilizing one or more diameters may be implemented. Further, it is contemplated that one or more non-curved geometries (e.g., rectangular, triangular, star-like, and the like) may also be implemented in exemplary aspects. 
     The horn  104  may be constructed from a rigid or semi-rigid material, such as a metallic material and/or a polymer-based material. In an exemplary embodiment, the horn  104  is constructed from aluminum, copper, steel, brass, titanium, and/or the like. Further, it is contemplated that the horn  104  may be constructed from a nylon, polyethylene, polycarbonates, polypropylene, polyvinyl, and/or other thermo-formed or thermo-set plastics. The horn tip  106  may also be constructed/formed from one or more similar materials. 
     The horn  104  has a proximal end  120  and a distal end  122 . The distal end  122 , in some aspects is also a part-contacting distal end  121 . However, in other aspects, the horn  104  is further comprised of the horn tip  106 . When a horn tip  106  is coupled (either permanently coupled or removeably coupled) to the horn  104 , the horn distal end  122  may provide a coupling location for the horn tip  106  as opposed to serving as the part-contacting distal end  121 . 
     The horn tip  106  may be positioned at a distal portion of the pick-up tool  100 . In an exemplary aspect, it is contemplated that the horn tip  106  is removeably coupled to the horn  104  such that different horn tips may be utilized depending on one or more variables (e.g., desired vacuum force, desired ultrasonic welding surface area, to-be-welded part material, and the like). For example, it is contemplated that the horn tip  106  may couple to the horn  104  utilizing a threading mechanism, a compression fit, an adhesive, a mechanical connector, and the like. As a result, depending on the desired characteristics of the pick-up tool  100 , the horn tip  106  may be changed/altered. 
     In use, it is contemplated that the pick-up tool  100  is functional for exerting a vacuum force on a part to be welded such that the pick-up tool  100  can either maintain the part in a particular location/orientation and/or to reposition the part. For example, during the construction of a shoe upper, one or more pieces of malleable materials (e.g., leather, nylon, foam, mesh) may be picked up and positioned on top of another material (or portion of material) to be secured at that location/orientation. The parts may then be secured utilizing a variety of techniques, including ultrasonic welding. Therefore, the ability to pick a part up, place the part, maintain the part, and also secure the part utilizing a common tool is desired in an aspect of the present invention. 
     To exert the vacuum force useable for moving, maintain, and/or placing a part, it is contemplated that the horn  104  itself acts as a conduit for the vacuum force. Therefore, it is contemplated that the horn  104  transfers ultrasonic vibrations and also provides a means for exerting a vacuum force on the material. To exert the vacuum force, it is contemplated that a vacuum force is generated within the horn  104  and/or a vacuum force is generated external (e.g., by way of a mechanical vacuum pump, by way of a venturi effect vacuum pump, by way of a coanda effect vacuum pump) to the horn  104  and transferred to the horn  104  by way of one or more means (e.g., channels, tubing, and other conduits). 
     As will be discussed in more detail hereinafter, it is contemplated that a venturi effect vacuum pump is integrated within at least a portion of an internal volume of the horn  104 . Further, it is contemplated that a coanda effect vacuum pump is integrated within at least a portion of the internal volume of the horn  104 . 
       FIG. 1  depicts the pick-up tool  100  capable of generating a vacuum force at the part-contacting distal end  121  utilizing an external vacuum source that is coupled (either removeably or permanently) to the horn  104  by way of a vacuum source port  111 . For example, it is contemplated that a remote vacuum pump (e.g., an electrically operated pump, a pressurized air pump) is flexibly coupled to the pick-up tool  100  by way of a length of flexible tubing (not shown). The flexible tubing is functional to maintain a portion of the vacuum force generated by the remote vacuum pump such that the vacuum force is introduced to an internal channel within the horn  104  (to be discussed with respect to  FIG. 4  hereinafter). The vacuum force passes through the horn  104 , by way of the internal channel, to the part-contacting distal end  121  at a vacuum inlet  110 . As a result of this transfer of the vacuum force, the pick-up tool  100  is functional for exerting the vacuum force on a part proximate to a point at which the pick-up tool  100  is also capable of ultrasonically welding the part. Further, it is contemplated that a smaller footprint may be recognized by integrating the pickup portion and the welding portion of the pick-up tool  100 . 
     The vacuum pick-up tool  100  of  FIG. 1  depicts a cutline  4 - 4  that depicts an internal cut view of the pick-up tool  100  of  FIG. 1  in  FIG. 4 , to be discussed hereinafter. 
       FIG. 2  depicts another exemplary aspect of the pick-up tool  100  having an integrated vacuum generator, in accordance with aspects of the present invention. As will be discussed in greater detail with respect to  FIG. 5  hereinafter, the pick-up tool  100  may be comprised of a vacuum generator  128  (not shown in  FIG. 2 ). The vacuum generator  128  may be any type of vacuum generator. In particular, it is contemplated that a venturi effect vacuum generator is utilized. Further, it is contemplated that a coanda effect vacuum generator is utilized. Either the venturi or the coanda effect vacuum generator may be implemented with the basic configuration depicted at  FIG. 2 . 
     The internal generation of a vacuum force may provide advantages such as greater durability (e.g., fewer remote parts), great control (e.g., fewer variables to the generated vacuum force as realized at the vacuum inlet  110 ), smaller footprint (e.g., less space utilized by a remote device), and the like. However, both internal generation of vacuum force and external generation of vacuum force may be desired in various aspects. 
     The pick-up tool  100  of  FIG. 2  receives pressurized air at an air-supply inlet  108 . The pressurized air is used to generate a vacuum force internally. The vacuum force that is generated internally draws in ambient air by way of the vacuum inlet  110 . As a result of a pressure gradient (i.e., lower pressure on an internal side of the vacuum inlet  110  and a higher relative pressure (e.g., ambient air pressure) on an external side of the vacuum inlet  110 ), a vacuum force is experienced by a part proximate the vacuum inlet  110 . This vacuum force allows the pick-up tool  100  to manipulate the part (e.g., orientation, location, position). 
     The pressurized air and air that is introduced by way of the vacuum inlet  110  are passed from an interior volume of the horn  104  by way of an exhaust port  112 . While the pick-up tool  100  of  FIG. 2  depicts the air-supply inlet  108  and the exhaust port  112  offset, it is contemplated that a relative orientation between the two may be altered (e.g., parallel and similarly positioned). 
       FIG. 2  depicts the horn tip  106  having a proximal end  134  and a distal end  136 . In an exemplary aspect, the horn distal end  136  is also the part-contacting distal end  121 , discussed previously. 
     The vacuum pick-up tool  100  of  FIG. 2  depicts a cutline  5 - 5  that represents an internal cut view of the pick-up tool  100  of  FIG. 2  in  FIG. 5 , to be discussed hereinafter. 
       FIG. 3  depicts a perspective view of a pick-up tool  100  mounted within a coupler  200 , in accordance with aspects of the present invention. The coupler  200 , in an exemplary aspect, allows for the pick-up tool  100  to be removeably attached to a moveable member. For example, as previously discussed, it is contemplated that the pick-up tool  100  is connected to a CNC robot. The CNC robot serves as a moveable member for positioning the pick-up tool  100  for manipulating and welding one or more parts. 
       FIG. 4  depicts an internal view of the pick-up tool  100  along cutline  4 - 4  of  FIG. 1 , in accordance with aspects of the present invention.  FIG. 4  illustrates a vacuum channel  116  passing through an interior volume  124  of the horn  104 . For example, in a traditional horn, the interior volume  124  may be continuously solid to effectively transfer mechanical vibration from the converter  102  to a to-be-welded part. However, a solid horn is incapable of providing an internal vacuum channel  116 , as illustrated in  FIG. 4 . 
     As previously discussed with respect to  FIG. 1 , the pick-up tool  100  in this aspect relies on an external vacuum generator. Therefore, a vacuum force is introduced to the horn  104  by way of the vacuum source port  111 . The vacuum force is then transferred through the interior volume of the horn  104  by way of the vacuum channel  116 . The vacuum channel continues to extend towards the horn distal end  122 . The horn distal end  122  is proximate the horn tip  106  proximal end  134 . 
     The horn tip  106  includes an aperture  140  that transfers the vacuum force to a defined area at the horn tip  106  distal end  136 . In an exemplary aspect, as illustrated in  FIG. 4 , the aperture  140  is a single circular aperture; however, it is contemplated that additional configurations of the aperture  140  may be utilized (e.g.,  FIGS. 9-17 ). In this example, the horn tip  106  distal end  136  also forms at least a portion of the part-contacting distal end  121 . 
     While a particular aspect of the vacuum source port  111  and the vacuum channel  116  are depicted in  FIG. 4 , additional orientations, configurations, sizes, dimensions, and the like are also contemplated. For example, the vacuum channel  116  may extend only within the horn tip  106 , such that both the vacuum source portion  111  and the aperture  140  are maintained within the horn tip  106 . 
       FIG. 5  depicts an internal view of the pick-up tool  100  along cutline  5 - 5  of  FIG. 2 , in accordance with aspects of the present invention. The pick-up tool  100  of  FIG. 5  depicts an internal venturi-effect vacuum pump. While a particular configuration is illustrated, it is contemplated that additional configurations may be implemented. 
     Internal generation of a vacuum force, in this example, leverages incoming pressurized air to generate a vacuum force. For example, pressurized air is introduced to the interior of the horn  104  by way of the air-supply inlet  108 . The pressurized air passes from the air-supply inlet  108  to a vacuum generator  128  through an air-supply channel  114 . The exemplary vacuum generator  128  of  FIG. 5  relies on a venturi effect to generate a vacuum force; however, it is also contemplated that a coanda effect may also be utilized in alternative configurations. 
     Within the horn  104 , the vacuum force is transferred from the interior of the horn  104  to the vacuum inlet  110  by way of a vacuum channel  116 . Further, air from the air supply and air pulled in through the vacuum inlet  110  are expelled from the interior of the horn  104  at an exhaust port  112  by way of an exhaust channel  118 . 
       FIG. 6  depicts an internal view of an exemplary pick-up tool  100  utilizing an alternative internal vacuum mechanism, in accordance with aspects of the present invention. In this example, the internal generation of a vacuum force may be accomplished with a cartridge insert  129 . For example, a vacuum generator may be produced that is functional for being inserted into a horn  104  to generate a desired amount of vacuum force. For example, manufacturing limitations may limit, in some examples, an amount of internal formation of channels and components within the horn  104 . As such, it may be desired, in an exemplary aspect, to allow for a cartridge insert that contains the applicable portions needed for the generation of a vacuum force internally of the horn  104  without requiring the complexity of integrally forming the portions within the horn  104 . As such, it is contemplated that the horn  104  may be configured to receive a cartridge that is capable of generating a vacuum force that is conveyed internally through the horn  104 . 
     In this example, while the cartridge insert  129  is a discrete component from the horn  104 , the cartridge insert  129  is considered a portion of the horn  104  when used in combination. As such, components internal to the cartridge insert  129  are therefore internal to the horn  104 . 
       FIG. 7  depicts an exemplary horn  104  having a coanda effect internal vacuum generator  128 , in accordance with aspects of the present invention. Similar to a venturi vacuum generator discussed with respect to  FIG. 5 , a coanda effect vacuum pump generates a vacuum force utilizing a supply of pressurized air. The pressurized air is received at the horn  104  at the air-supply inlet  108 . The pressurized air is then transferred to the vacuum generator  128  by way of the air-supply channel  114 . A vacuum channel  116  transfers air pulled into the vacuum inlet  110  to the vacuum generator  128 . The exhaust channel  118  transfers the pressurized air (now at a lower pressure) and any air introduced into the interior of the horn  104  by way of the vacuum inlet  110  to the exhaust port  112 . 
       FIG. 8  depicts an exemplary horn  104  coupled with an exemplary horn tip  106 , in accordance with aspects of the present invention. In particular, the horn tip  106  is exploded in view from the horn  104  to provide a prospective view of the vacuum channel  116  extending to the aperture  140 . Further, exemplary threading is depicted as a means for detachably coupling the horn tip  106  and the horn  104 .  FIG. 8  includes a cutline  9 - 9  which is used to depict a parallel plane in the following  FIGS. 9-17 . 
       FIGS. 9-17  depict exemplary aperture combinations extending through the distal end  136  of the horn tip  106 , in accordance with aspects of the present invention. For example, a circular aperture  142  (e.g., as seen in  FIG. 9 ), a non-circular aperture (e.g., as seen in  FIG. 17 ), and/or combinations of various apertures (e.g., as seen in  FIG. 16 ) are depicted by  FIGS. 9-17 . It is contemplated that the depicted structures are exemplary in nature and not limiting as to aspects contemplated herein. For example, one or more structures depicted may be combined/modified with one or more other structures depicted in  FIGS. 9-17 . 
     Exemplary aspects of the present invention incorporate a non-porous center portion  146  in the distal end  136  of the horn tip  106 . For example, it is contemplated that the non-porous center portion  146  (e.g., as seen in  FIGS. 10-12 ) is an effective portion of the horn tip  106  for transferring a sufficient portion of the mechanical vibrations from the pick-up tool  100  to a to-be-welded part. In an exemplary aspect, the non-portion center portion  146  does not include an aperture and therefore provides a continuous portion of an exterior surface  138  of the distal end  136  for the horn tip  106  to contact a weldable part. 
     However, it is contemplated that any portion of the exterior surface  138  of the distal end  136  may be effective for contacting the weldable part by the pick-up tool  100 . Additionally, other geometries are contemplated herein. For example, it is contemplated that a horn tip  106  may be comprised of more or fewer apertures  140 . Further, different geometries (e.g., circle, rectangular, triangular, and the like) may be utilized. Different sizes (in combination or consistently) may be utilized for the various apertures  140 . Further, various combinations of sizes, geometries, and or orientations of the apertures  140  is also contemplated herein. 
     Exemplary aspects are provided herein for illustrative purposes. Additional extensions/aspects are also contemplated in connection with aspects of the present invention. For example, a number, size, orientation, and/or form of components, portions, and/or attributes are contemplated within the scope of aspects of the present invention.