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    Vibration welding system with thin film sensor
    1.
    发明授权
    Vibration welding system with thin film sensor 有权
    具有薄膜传感器的振动焊接系统

    公开(公告)号：US08672211B2

    公开(公告)日：2014-03-18

    申请号：US13474891

    申请日：2012-05-18

    申请人： Wayne W. Cai ,  Jeffrey A. Abell ,  Xiaochun Li ,  Hang Li ,  Hongseok Choi ,  Jingzhou Zhao

    发明人： Wayne W. Cai ,  Jeffrey A. Abell ,  Xiaochun Li ,  Hang Li ,  Hongseok Choi ,  Jingzhou Zhao

    IPC分类号： B23K31/02 ,  B23K20/10 ,  B29C65/08

    CPC分类号： B23K20/10 ,  B23K20/106 ,  B29C65/08 ,  B29C66/1122 ,  B29C66/45 ,  B29C66/91212 ,  B29C66/9512 ,  B29C66/9513 ,  B29C66/9516

    摘要： A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

    摘要翻译： 振动焊接系统包括砧座，焊接喇叭，薄膜传感器和过程控制器。 砧座和喇叭包括在焊接过程中接触工件的工作表面。 传感器测量工作表面的控制值。 测量的控制值被发送到控制器，控制器部分地使用测量的控制值来控制系统。 薄膜传感器可以包括多个热电堆和热电偶，其共同测量工作表面处的温度和热通量。 一种方法包括：向焊接设备提供邻近焊接设备的工作表面的槽，将薄膜传感器插入槽中，并使用传感器来测量工作表面上的控制值。 然后，过程控制器部分地使用测量的控制值来控制振动焊接系统。

    VIBRATION WELDING SYSTEM WITH THIN FILM SENSOR
    2.
    发明申请
    VIBRATION WELDING SYSTEM WITH THIN FILM SENSOR 有权
    具有薄膜传感器的振动焊接系统

    公开(公告)号：US20130306216A1

    公开(公告)日：2013-11-21

    申请号：US13474891

    申请日：2012-05-18

    申请人： Wayne W. Cai ,  Jeffrey A. Abell ,  Xiaochun Li ,  Hang Li ,  Hongseok Choi ,  Jingzhou Zhao

    发明人： Wayne W. Cai ,  Jeffrey A. Abell ,  Xiaochun Li ,  Hang Li ,  Hongseok Choi ,  Jingzhou Zhao

    IPC分类号： B32B37/06 ,  B23K20/10 ,  B32B41/00

    CPC分类号： B23K20/10 ,  B23K20/106 ,  B29C65/08 ,  B29C66/1122 ,  B29C66/45 ,  B29C66/91212 ,  B29C66/9512 ,  B29C66/9513 ,  B29C66/9516

    摘要： A vibration welding system includes an anvil, a welding horn, a thin film sensor, and a process controller. The anvil and horn include working surfaces that contact a work piece during the welding process. The sensor measures a control value at the working surface. The measured control value is transmitted to the controller, which controls the system in part using the measured control value. The thin film sensor may include a plurality of thermopiles and thermocouples which collectively measure temperature and heat flux at the working surface. A method includes providing a welder device with a slot adjacent to a working surface of the welder device, inserting the thin film sensor into the slot, and using the sensor to measure a control value at the working surface. A process controller then controls the vibration welding system in part using the measured control value.

    摘要翻译： 振动焊接系统包括砧座，焊接喇叭，薄膜传感器和过程控制器。 砧座和喇叭包括在焊接过程中接触工件的工作表面。 传感器测量工作表面的控制值。 测量的控制值被发送到控制器，控制器部分地使用测量的控制值来控制系统。 薄膜传感器可以包括多个热电堆和热电偶，其共同测量工作表面处的温度和热通量。 一种方法包括：向焊接设备提供邻近焊接设备的工作表面的槽，将薄膜传感器插入槽中，并使用传感器来测量工作表面上的控制值。 然后，过程控制器部分地使用测量的控制值来控制振动焊接系统。

    Beam welding of a multi-sheet work stack having a reduced thickness feature
    5.
    发明授权
    Beam welding of a multi-sheet work stack having a reduced thickness feature 有权
    具有减小的厚度特征的多片工作堆叠的束焊接

    公开(公告)号：US08535395B2

    公开(公告)日：2013-09-17

    申请号：US13069639

    申请日：2011-03-23

    申请人： Wayne W. Cai ,  Thomas B. Stoughton ,  David Yang ,  Xiang Zhao

    发明人： Wayne W. Cai ,  Thomas B. Stoughton ,  David Yang ,  Xiang Zhao

    IPC分类号： B23K26/20 ,  B23K15/00 ,  H01M4/00 ,  H01M2/20 ,  H01M2/30

    CPC分类号： B23K15/0006 ,  B23K26/244 ,  H01M2/206 ,  H01M10/052 ,  H01M2220/20 ,  Y02E60/122 ,  Y10T29/49108

    摘要： A method for beam welding a multi-sheet work stack includes providing a reduced thickness feature in a first sheet, positioning the first sheet adjacent to a second sheet to define a first welding interface, and positioning a third sheet adjacent to the second sheet to define a second welding interface. A laser or electron beam is directed through the first sheet at the feature to form a fusion weld at one of the welding interfaces. A second beam may be directed onto the other interface to form a second fusion weld. Providing a reduced thickness feature in the first sheet may include forming the feature with the beam and mechanically pre-forming the feature. One of the interfaces may be pre-heated using the beam, and the beam may be split using a beam splitter to form multiple beams. A welded assembly formed via the method is also disclosed.

    摘要翻译： 一种用于对多片工作堆叠进行束焊的方法，包括在第一片材中提供减小的厚度特征，将第一片材邻近第二片材定位以限定第一焊接界面，以及将邻近第二片材定位的第三片材定义 第二焊接界面。 激光或电子束在特征处被引导通过第一片，以在焊接界面之一形成熔焊。 可以将第二光束引导到另一个界面上以形成第二熔焊。 在第一片材中提供减小的厚度特征可以包括用梁形成特征并机械预成形该特征。 其中一个界面可以使用光束预热，并且可以使用分束器将光束分离以形成多个光束。 还公开了一种通过该方法形成的焊接组件。

    Multi-mode ultrasonic welding control and optimization
    6.
    发明授权
    Multi-mode ultrasonic welding control and optimization 有权
    多模超声波焊接控制和优化

    公开(公告)号：US08450644B2

    公开(公告)日：2013-05-28

    申请号：US13039979

    申请日：2011-03-03

    申请人： Jason C. H. Tang ,  Wayne W. Cai

    发明人： Jason C. H. Tang ,  Wayne W. Cai

    IPC分类号： B23K9/12 ,  B23K15/00 ,  B23K11/10 ,  B23K31/02 ,  B23K20/08 ,  B23K1/06

    CPC分类号： B23K20/10

    摘要： A system and method for providing multi-mode control of an ultrasonic welding system. In one embodiment, the control modes include the energy of the weld, the time of the welding process and the compression displacement of the parts being welded during the welding process. The method includes providing thresholds for each of the modes, and terminating the welding process after the threshold for each mode has been reached, the threshold for more than one mode has been reached or the threshold for one of the modes has been reached. The welding control can be either open-loop or closed-loop, where the open-loop process provides the mode thresholds and once one or more of those thresholds is reached the welding process is terminated. The closed-loop control provides feedback of the weld energy and/or the compression displacement so that the weld power and/or weld pressure can be increased or decreased accordingly.

    摘要翻译： 一种用于提供超声波焊接系统的多模式控制的系统和方法。 在一个实施例中，控制模式包括在焊接过程中焊接的能量，焊接过程的时间和被焊接部件的压缩位移。 该方法包括为每个模式提供阈值，并且在已经达到每个模式的阈值之后终止焊接过程，已达到多于一个模式的阈值或已达到其中一个模式的阈值。 焊接控制可以是开环或闭环，其中开环过程提供模式阈值，并且一旦达到这些阈值中的一个或多个，则焊接过程终止。 闭环控制提供焊接能量和/或压缩位移的反馈，使得可以相应地增加或减小焊接功率和/或焊接压力。

    SINGLE-SIDED MAGNETIC FIXTURING SYSTEMS
    7.
    发明申请
    SINGLE-SIDED MAGNETIC FIXTURING SYSTEMS 审中-公开
    单面磁悬浮系统

    公开(公告)号：US20090283946A1

    公开(公告)日：2009-11-19

    申请号：US12123236

    申请日：2008-05-19

    申请人： Wayne W. Cai ,  Chi-Hung Shen

    发明人： Wayne W. Cai ,  Chi-Hung Shen

    IPC分类号： B25B11/00

    CPC分类号： B25B11/002

    摘要： A combination useful for providing a clamping force to a workpiece during a manufacturing operation so as to maintain a workpiece in a stationary position includes a workpiece having a first side and a second side, a magnet disposed about a portion of the first side of the workpiece, and a pressure pad disposed about a portion of the second side of the workpiece. The pressure pad may include one or more of permanently magnetic materials and ferromagnetic materials, and disposed in sufficient proximity with respect to the magnet to enable the pressure pad to be attracted by the magnet, thus providing a clamping force on the workpiece.

    摘要翻译： 用于在制造操作期间向工件提供夹紧力以将工件保持在静止位置的组合的组合包括具有第一侧和第二侧的工件，围绕工件的第一侧的一部分设置的磁体 以及设置在工件的第二侧的一部分周围的压力垫。 压力垫可以包括永久磁性材料和铁磁材料中的一种或多种，​​并且相对于磁体足够接近地设置，以使得压力垫能够被磁体吸引，从而在工件上提供夹紧力。

    Method and apparatus to minimize adhesive induced distortion
    8.
    发明申请
    Method and apparatus to minimize adhesive induced distortion 审中-公开
    减少粘合剂诱导失真的方法和装置

    公开(公告)号：US20080149256A1

    公开(公告)日：2008-06-26

    申请号：US11960902

    申请日：2007-12-20

    申请人： Pei-Chung Wang ,  Wayne W. Cai

    发明人： Pei-Chung Wang ,  Wayne W. Cai

    IPC分类号： B32B37/00

    CPC分类号： F16B11/006 ,  B21J15/025 ,  B21J15/36 ,  B32B37/12 ,  B32B2309/02 ,  B32B2309/04 ,  B32B2311/24 ,  F16B5/04 ,  F16B19/086

    摘要： A method to minimize adhesive induced distortion between heat cured adhesively bonded sheet materials, includes applying a layer of heat curable adhesive between the two sheets; installing a self-piercing rivet or clinching the sheets to connect the sheets; and heating the sheets to cure the adhesive so that the adhesive and the rivet or clinching connection counterbalance the stresses tending to distort the sheets. The heating to cure the adhesive can occur prior to or after the connecting of the sheets by the rivet or clinching. If the sheets are of dissimilar metals having different coefficients of expansion, then the self-piercing rivet is installed or the clinching is performed from the direction to first enter the sheet having the lower coefficient of thermal expansion. If the sheets are of similar metals of different thickness, then the self-piercing rivet is installed or the clinching is performed from the direction to first enter the thicker of the sheets.

    摘要翻译： 一种使热固化粘合片材之间的粘合剂引起的变形最小化的方法包括在两片之间施加一层热固化性粘合剂; 安装自穿铆钉或夹紧纸张以连接纸张; 并加热片材以固化粘合剂，使得粘合剂和铆钉或夹紧连接抵消倾向于使片材变形的应力。 用于固化粘合剂的加热可以在通过铆钉或铆钉连接片材之前或之后发生。 如果片材是具有不同膨胀系数的异种金属，则安装自穿孔铆钉，或者从首先进入具有较低热膨胀系数的片材的方向进行铆接。 如果片材具有不同厚度的类似金属，则安装自穿孔铆钉或从首先进入厚度较薄的方向进行铆钉。

    Thermally-insulated vibration welding tool
    9.
    发明授权
    Thermally-insulated vibration welding tool 有权
    绝热振动焊接工具

    公开(公告)号：US08444039B2

    公开(公告)日：2013-05-21

    申请号：US12971875

    申请日：2010-12-17

    申请人： Wayne W. Cai ,  Paul F. Spacher ,  Edgar M. Storm, Jr. ,  Xingcheng Xiao ,  Susan M. Smyth

    发明人： Wayne W. Cai ,  Paul F. Spacher ,  Edgar M. Storm, Jr. ,  Xingcheng Xiao ,  Susan M. Smyth

    IPC分类号： B23K20/00 ,  B23K20/10

    CPC分类号： B23K20/10 ,  B29C65/08 ,  B29C66/81433 ,  B29C66/8167 ,  B29C66/81821

    摘要： A welding assembly for forming a weld along a welding interface of a work piece(s) using vibrations includes a welding tool and a thermal barrier. The thermal barrier is at least a chemical and/or mechanical insulating layer positioned adjacent to the welding tool, which minimizes the rate of dissipation of heat generated by the vibrations at or along the welding interface. The welding assembly may also include a wear-resistant layer adjacent to the thermal barrier, which protects the thermal barrier from damage or wear. The welding tool is a portion an anvil assembly and/or a sonotrode assembly. A method of insulating a welding tool includes applying or connecting a thermal barrier to a surface of the welding tool, and minimizing the rate of dissipation of heat generated by the vibrations at or along the welding interface using the thermal barrier, which includes an insulating layer.

    摘要翻译： 用于使用振动沿着工件的焊接界面形成焊缝的焊接组件包括焊接工具和热障。 热障是至少与焊接工具相邻定位的化学和/或机械绝缘层，其最小化由焊接界面处或沿着焊接界面的振动产生的热耗散速率。 焊接组件还可以包括邻近热障的耐磨层，其保护热障免受损坏或磨损。 焊接工具是砧座组件和/或超声波组件的一部分。 绝缘焊接工具的方法包括将热障施加或连接到焊接工具的表面，并且使用热障将最小化由焊接界面处或沿着焊接界面的振动产生的热的散失速率降低，其包括绝缘层 。

    PASSIVELY DAMPED VIBRATION WELDING SYSTEM AND METHOD
    10.
    发明申请
    PASSIVELY DAMPED VIBRATION WELDING SYSTEM AND METHOD 有权
    经常性阻尼振动焊接系统及方法

    公开(公告)号：US20130081753A1

    公开(公告)日：2013-04-04

    申请号：US13438200

    申请日：2012-04-03

    申请人： Chin-An Tan ,  Bongsu Kang ,  Wayne W. Cai ,  Tao Wu

    发明人： Chin-An Tan ,  Bongsu Kang ,  Wayne W. Cai ,  Tao Wu

    IPC分类号： B29C65/04

    CPC分类号： B23K20/10

    摘要： A vibration welding system includes a controller, welding horn, an anvil, and a passive damping mechanism (PDM). The controller generates an input signal having a calibrated frequency. The horn vibrates in a desirable first direction at the calibrated frequency in response to the input signal to form a weld in a work piece. The PDM is positioned with respect to the system, and substantially damps or attenuates vibration in an undesirable second direction. A method includes connecting the PDM having calibrated properties and a natural frequency to an anvil of an ultrasonic welding system. Then, an input signal is generated using a weld controller. The method includes vibrating a welding horn in a desirable direction in response to the input signal, and passively damping vibration in an undesirable direction using the PDM.

    摘要翻译： 振动焊接系统包括控制器，焊接喇叭，砧座和被动阻尼机构（PDM）。 控制器产生具有校准频率的输入信号。 响应于输入信号，喇叭以校准频率以期望的第一方向振动，以在工件中形成焊缝。 PDM相对于系统定位，并且基本上阻止或衰减在不期望的第二方向上的振动。 一种方法包括将具有校准特性和固有频率的PDM连接到超声波焊接系统的砧座上。 然后，使用焊接控制器产生输入信号。 该方法包括响应于输入信号在期望的方向上振动焊接喇叭，并且使用PDM在不期望的方向上被动地阻尼振动。