Patent Description:
Modern vehicles increasingly use sensors to detect objects around them, such as ultrasonic parking sensors. It is common for front and rear bumper facias to include numerous sensors mounted to the bumper fascia <NUM> by a sensor bracket <NUM>, which holds the sensor (<FIG>). As shown in <FIG>, one type of typical sensor bracket <NUM> includes a face <NUM> from which a sensor holder <NUM> extends. The sensor holder <NUM> receives a generally cylindrically shaped sensor in a snap fit relationship. The face <NUM> of the sensor bracket <NUM> has a contour matching an inner face or B-side of the bumper fascia <NUM>. This face <NUM> is commonly ultrasonically welded to the bumper fascia <NUM>.

Referring to <FIG>, an example ultrasonic welder is shown. The welder <NUM> is used in the example to join the face <NUM> of the sensor bracket <NUM> to a substrate <NUM>, such as a bumper fascia. A workpiece <NUM> is typically supported in a fixture or jig <NUM> during the ultrasonic welding process. The sensor holder <NUM> typically includes a passage should line up with a hole <NUM> in the workpiece <NUM> to center and expose a face of the sensor once fully assembled.

During installation of the sensor bracket <NUM> onto the bumper facia <NUM>, a sonotrode <NUM> selectively engages the face <NUM> to impart a vibration on the face sufficient to generate heat and melt the face <NUM> to the substrate <NUM>. In the example, the sonotrode <NUM> has one or more "points" <NUM> terminating in a geometry such as a PIP <NUM>. The sonotrode <NUM> is operatively secured to an ultrasonic converter <NUM>, which includes piezoelectric or other elements that vibrate (e.g., add up to <NUM>, for example) in response to a signal from a generator <NUM> that is commanded by a controller <NUM>. The sonotrode <NUM> may be designed to be used at other frequencies, if desired. A booster may be mounted between the converter <NUM> and the sonotrode to tune the frequency provided by the converter <NUM> to the sonotrode <NUM>.

During operation, a motion device advances the sonotrode <NUM> to engage the face <NUM> with the PIP <NUM> and maintaining contact pressure during the welding process. The motion device, for example, a pneumatic cylinder <NUM>, may be regulated by a valve <NUM> that selectively controls the flow of compressed air from an air source <NUM> to the cylinder <NUM> in response to a command from the controller <NUM>. Cooling air can be provided to the sonotrode <NUM> via an air line <NUM>.

The welder <NUM> can be configured in a different manner than described, for example, the motion device may be provided by a servomotor and/or robot. The sensor bracket <NUM> must be held in a desired orientation with respect to the substrate during the ultrasonic welding process. In one example, a sensor bracket <NUM> is loaded onto a bracket presenter <NUM>, for example of the type illustrated in <FIG>. The bracket presenter <NUM> has a first plate <NUM> that is mounted to a motion device, such as a pair of cylinders <NUM>. These cylinders <NUM> may be used to advance and retract the bracket presenter <NUM>, and thus the sensor bracket <NUM>, during the ultrasonic welding process.

It is desirable to allow slight movement between the sensor bracket <NUM> and the substrates <NUM> as the sensor bracket <NUM> mates with the substrate <NUM> to accommodate slight variations in tolerances between the parts. To this end, the bracket presenter <NUM> includes a second plate <NUM> that floats with respect to the first plate <NUM>. In one example, fasteners, pins, and/or springs may be used to loosely locate the first and second brackets <NUM>, <NUM> with respect to one another while preventing significant rotation or displacement between the first and second plates <NUM>, <NUM>. For example, as shown in <FIG> (broken view) and <FIG> (in phantom), a shoulder bolt <NUM> fixed relative to the first plate is received within a clearance hole <NUM> provided in the second plate <NUM>. This arrangement accommodates horizontal float during engagement of the sensor bracket and the workpiece <NUM>. But, undesirably, the plates are also permitted to floated when fully separated. A spring-loaded "pogo stick" <NUM> is provided between the first and second plates <NUM>, <NUM> to enable the first plate, and thus the sensor bracket, to self-center with respect to the hole <NUM> in the workpiece.

A main body <NUM> extends from the second plate <NUM> in a direction opposite the first plate <NUM>. The main body includes mounts <NUM>, which engage locating features <NUM>, such as apertures and/or slots in the sensor bracket <NUM>. The various components illustrated in <FIG> are provided by numerous discrete parts that must be machined to size and assembled with respect to one another, adding great cost and complexity to the bracket presenter <NUM>.

<CIT> describes a device having a base unit provided with a robot that supports a demountable processing tool. The base unit is designed for operating the demountable processing tool, and a work piece retainer is designed as a demountable work piece retainer, and different work pieces are processed on the work piece retainer in the base unit. The work piece retainer is inserted into the base unit, and comprises positioning segments that position the work pieces.

<CIT> describes a sonotrode for an ultrasound welding system for welding work pieces, comprising a pressure element which has a contact surface. The pressure element can be applied to carry out the welding process with said contact surface on one of the work pieces to be welded to each other, wherein the contact surface has an annular design. A centering pin axially projecting over the contact surface is arranged inside the annular contact surface. Also described is a method for welding a connection element, in particular an adapter for a PDC sensor, to a component, in particular an exterior add-on part of a motor vehicle.

<CIT> describes an apparatus for use in applying a fitment to packaging material comprising an applicator including an anvil comprising a body and a receiver mounted on the body and arranged to receive the fitment. The apparatus further comprises a counter-member, e.g. an ultrasonic horn, between which and the receiver the fitment is sandwiched, and thereby the fitment is pressed against the receiver. The receiver is loosely mounted on the body so as to be self-aligning relative to the counter-member when the fitment is pressed against the receiver. A resilient biasing device encircling the receiver is arranged to urge the receiver towards the counter-member, and a detent on the receiver is arranged to limit movement of the receiver towards the counter-member relative to the body.

<CIT> describes a device for attaching a mouth plug which can be applied to both inside mounting type and outside mounting type, each of which is mounted within the edge of a window hole for a pour port formed in a paper container body and which prevents cracks from being produced in a barrier film. The device for mounting a mouth plug comprises a horn to convert ultrasonic waves to longitudinal vibrations and a fixed anvil opposed to the horn. An approximately circular groove is formed at the center of the anvil, and a vibration absorbing body is provided at the center of the groove. A retracting anvil is provided in the groove around the body through a vertically movable holder.

In one exemplary embodiment, a bracket presenter for an ultrasonic welder, the bracket presenter includes a one-piece first bracket portion and a one-piece second bracket portion that is mounted relative to one another. First and second tapered features are respectively provided by the first and second bracket portions. The first and second tapered features are nested relative to one another and engage in an extended position and are spaced from one another in a compressed position to provide a clearance that enables the first and second bracket portions to float lateral relative to one another. The first and second brackets are closer to one another in the compressed position than when in the extended position.

In a further embodiment of the above, the second bracket portion has a central body with mounts that are configured to support a sensor bracket in a desired orientation. The first and second bracket portions respectively include first and second plates. The bracket presenter further includes a set of first posts that extend from one of the first and second plates. Each of the first posts have a generally first conical shape and increase in diameter from the one of the first and second plates. A set of first tapered walls extend from another of the first and second plates. Each of the first tapered walls provide a first generally conical pocket that receives a corresponding one of the first posts. The bracket presenter further includes at least one spring that is arranged between the first and second plates. The first and second plates define a first height in an extended position. The first and second plates define a second height that is less than the first height in a compressed position in which the at least one spring is compressed. The first posts and their respective first tapered walls have a clearance between them in the compressed position and are in engagement with one another in the extended position. The first posts and first tapered walls provide the first and second tapered features.

In a further embodiment of the above, the one-piece first and second bracket portions and their respective first and second tapered features are each formed of 3D-printed layers.

In a further embodiment of the above, the second bracket portion has a central body that extends from the second plate on a side opposite the set of the first post or the set of first tapered walls. The central body is configured to receive a sensor bracket.

In a further embodiment of the above, the bracket presenter includes a second post that extends from the other one of the first and second plates. The second post has a second conical shape that increases in diameter from the other of the first and second plates. A second tapered wall extends from the one of the first and second plates to provide a second generally conical pocket that receives the second post.

In a further embodiment of the above, the set of first posts are provided on the first plate, and the second post is provided on the second plate.

In a further embodiment of the above, the at least one spring includes a pair of springs. One of the pair of springs circumscribes a corresponding one of the first posts.

In a further embodiment of the above, at least one of the first and second plates includes the springs integral with the corresponding one of the one-piece first and second bracket portions.

In a further embodiment of the above, a spacer is provided between at least several coils of the at least one spring to generate a preload that ensures engagement between the first posts and their respective first pockets in the extended position.

In another exemplary embodiment, a method of securing a sensor bracket to a substrate, the method includes mounting a sensor bracket to a bracket presenter that has first and second bracket portions that are movable relative to one another and with a spring that is arranged between the first and second bracket portions. The method further includes advancing the sensor bracket toward a substrate and engaging a hole in a substrate with an end of the second bracket. The method further includes moving the first and second bracket portions toward one another and compressing the spring to allow the second bracket portion to float relative to the first bracket portion. The moving step includes decoupling first and second tapered surfaces that are respectively provided by the first and second bracket portions. The method further includes locating the sensor bracket relative to the hole with the end. The method further includes seating the sensor bracket against the substrate, ultrasonically welding the sensor bracket to the substrate, and retracting and separating the bracket presenter from the sensor bracket.

In another exemplary embodiment, a method of manufacturing a bracket presenter, the method includes printing a first bracket portion with a first tapered feature, printing a second bracket portion with second tapered feature that is configured to selectively cooperate with the first tapered feature between extended and compressed bracket presenter positions, and providing a spring between the first and second bracket portions.

In a further embodiment of the above, the spring provides the step which includes printing the spring between the first and second bracket portions.

In a further embodiment of the above, the spring circumscribes the first and second tapered features.

In a further embodiment of the above, the spring printing step is performed during at least one of the first and second bracket portions printing steps such that the spring is integrally formed with the at least one of the first and second bracket portions.

In a further embodiment of the above, the method includes the step of inserting a space into the spring subsequent to the printing steps.

The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

Referring to <FIG>, an example bracket presenter <NUM> includes first and second bracket portions <NUM>, <NUM> and/or one or more springs <NUM> that are formed simultaneously during a 3D-printing process using, for example, a polymer such as a fiber reinforced nylon. The bracket presenter <NUM> may also be formed from other materials, if desired. Multiple 3D-printed layers are laid down to form the first and second bracket portions <NUM>, <NUM> to provide one-piece, integral structures that are unitary and are able to move relative to one another, but also include capture features that limit their travel relative to one another during the ultrasonic welding process described above. By "unity" it is meant that the first and second bracket portions are retained with respect to one another without the need for further assembly. This structural relationship avoids the many separately machined and secured parts of the prior art, while providing additional advantages not found in traditional bracket presenters.

The bracket presenter <NUM> is manufactured by printing the first bracket portion <NUM> with a first tapered feature (e.g., first posts <NUM>). At the same time, the second bracket portion <NUM> is printed with a second tapered feature (e.g., tapered walls <NUM>) that are configured to selectively cooperate with the first tapered feature between extended and compressed bracket presenter positions (H1, H2). It should be understood that the tapered features need not be provided by conical surfaces, rather that the points of engagement and disengagement between the first and second tapered features be of different sizes to permit coupling and decoupling of the first and second bracket portions <NUM>, <NUM> from one another. The first bracket portion <NUM> may be the fixed part and the second bracket portion <NUM> may be the floating part, or vice versa.

In one example, a spring <NUM> is printed about, or circumscribing, each of the first and second tapered features to provide a compact design. The spring(s) <NUM> can be printed while the first and second bracket portions <NUM>, <NUM> are printed such that the spring(s) <NUM> is integrally formed with the at least one of the first and second bracket portions <NUM>, <NUM>. It is desirable for the first and second tapered features to engage one another when the first and second bracket portions <NUM>, <NUM> are in the extended position (H1). This enables the bracket presenter <NUM> to be positively positioned for automated loading of the sensor bracket <NUM> onto the presenter. If the spring <NUM> is printed between the first and second bracket portions <NUM>, <NUM>, then then there will be no preload on the spring <NUM> and the first and second tapered features will not be in full engagement. So, a spacer <NUM> (<FIG> and <FIG>) is inserted between coils in the spring <NUM> subsequent to printing.

The bracket presenter <NUM> has the one-piece first bracket portion <NUM> and a one-piece second bracket portion <NUM> mounted relative to one another in one disclosed example. The second bracket portion <NUM>, which is the floating part in the example, has a central body <NUM> with mounts <NUM> configured to support the sensor bracket <NUM> in a desired orientation, as best shown in <FIG>. The first and second bracket portions <NUM>, <NUM> respectively including first and second plates, with the first plate secured to the sonic welder, and second plate supports the central body <NUM>.

The central body <NUM> has a tapered end <NUM> that enables the second bracket portion <NUM>, and thus the carried sensor bracket <NUM>, with respect to the substrate <NUM> as the tapered end <NUM> is inserted into the hole, the bracket presenter <NUM> is compressed and the second bracket portion <NUM> begins to float, as explained in more detail below.

A set of first posts <NUM> extend from one of the first and second plates, in the example, the second plate, to provide the first tapered features. Each of the first posts <NUM> has a generally first conical shape and increasing in diameter from the second plate in the example. A set of first tapered walls <NUM> extend from the other of the first and second plates, here, the first plate, to provide the second tapered features. Each of the first tapered walls <NUM> provide a first generally conical pocket that receives a corresponding one of the first posts <NUM> in a nested relationship. These complementary tapered surfaces provide a positive location when engaged with one another in the extended position H1. The first posts <NUM> and their respective first tapered walls <NUM> have a clearance <NUM> (<FIG>) between them in the compressed position H2, which enables floating of the second bracket portion <NUM> in all directions in plane perpendicular to the direction of compression as well as some wobble of the second bracket portion <NUM>.

At least one spring <NUM> is arranged between the first and second plates. In the example, the spring <NUM> is printed along with the first and second bracket portions <NUM>, <NUM>. One or both ends may be integrally formed with (i.e., joined do as part of the printing process) the first and second bracket portions <NUM>, <NUM>. Alternatively, the spring <NUM> may be printed uncoupled to either of the first and second bracket portions <NUM>, <NUM>. In the example, a spring <NUM> circumscribes each first post <NUM>/first tapered wall <NUM> pairing. The spacer <NUM> can be located with respect to a recess <NUM> in one of the plates, as shown in <FIG>. In this example, the spacer <NUM> is U- or C-shaped to accommodate the first post <NUM> during insertion of the spacer <NUM> into the recess <NUM>.

A second post <NUM> extending from the other one of the first and second plates, in the example, to provide further stability and robustness. The second post has a second conical shape increasing in diameter from the first plate in the example. A second tapered wall <NUM> is provided on the opposite plate to provide a second generally conical pocket that receives the second post.

Some or all of the first and second posts <NUM>, <NUM> may have an end that acts as a stop to limit the relative travel between the first and second bracket portions <NUM>, <NUM> from the extended position H1 to the compressed position H2. The tapered features act as stops when engaged to limit travel when fully extended. Although three pairs of complementary structures are shown (one pair first post <NUM> and wall <NUM>, another first post <NUM> and wall <NUM>, and a second post <NUM> and wall <NUM>) that provide the mating first and second tapered features, a bracket presenter may be used that only has one pair. Such a simplified configuration may be used where the sensor bracket <NUM> does not need to be positively located at the extended position. That is, one, two, three or more pairs of complementary structures may be used depending upon the application.

In operation, the sensor bracket <NUM> is secured to a substrate <NUM> with the sensor bracket <NUM> mounted to the bracket presenter <NUM>. The first and second bracket portions <NUM>, <NUM> are movable relative to one another with the springs <NUM> arranged therebetween. The sensor bracket <NUM> is advanced toward the substrate <NUM>, and the hole <NUM> in the substrate <NUM> is engaged with the tapered end <NUM>. The first and second bracket portions <NUM>, <NUM> move toward one another and compress the springs <NUM>, which creates clearances <NUM>, to allow the second bracket portion <NUM> to float relative to the first bracket portion <NUM>. This movement decouples the tapered surfaces between the first and second bracket portions, i.e., the first and second posts <NUM>, <NUM> with respect to their first and second tapered walls <NUM>, <NUM>.

As a result, the sensor bracket <NUM> is located relative to the hole <NUM> with the tapered end <NUM> so that the sensor bracket <NUM> can be seated against the substrate <NUM>. At this point, the sensor bracket <NUM> can be ultrasonically welded to the substrate <NUM> in the desired position, and the bracket presenter subsequently retracted.

The disclosed bracket presented provides a unique configuration that enables lateral floating of the first and second bracket portions <NUM>, <NUM> during sensor bracket positioning, but also positive locating of the bracket presenter for automated loading of the sensor bracket onto the presenter. The design of the bracket presenter no only permits one-piece construction of each of the first and second bracket portions <NUM>, <NUM>, but in such a manner that the portions and even the springs can be formed simultaneously further reducing presenter manufacturing time.

It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.

Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations.

Claim 1:
A bracket presenter (<NUM>) for an ultrasonic welder (<NUM>), the bracket presenter (<NUM>) comprising:
a one-piece first bracket portion (<NUM>) and a one-piece second bracket portion (<NUM>) mounted relative to one another, first and second tapered features respectively provided by the first and second bracket portions (<NUM>, <NUM>), the first and second tapered features nested relative to one another and engaging in an extended position and spaced from one another in a compressed position to provide a clearance (<NUM>) enabling the first and second bracket portions (<NUM>, <NUM>) to float lateral relative to one another, the first and second brackets closer to one another in the compressed position than when in the extended position.