Ultrasonic welding head and ultrasonic welding equipment
By designing the helical tooth structure and wear-resistant materials of the ultrasonic welding head, the problems of overflow and scorching during the welding of copper and aluminum plates were solved, achieving a high-efficiency and high-strength welding effect, which is suitable for welding aluminum plates.
Patent Information
- Application Number
- CN202423315642.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-31
- Publication Date
- 2026-01-30
- Estimated Expiration
- 2034-12-31
AI Technical Summary
Existing ultrasonic welding heads are prone to problems such as overflow and scorching when welding copper and aluminum plates, resulting in insufficient welding efficiency and strength.
Design an ultrasonic welding head with a truncated square pyramidal welding tooth structure. The tooth arrangement direction forms a first angle of 10° to 80° with the edge of the welding head. The tooth structure is densely distributed and made of wear-resistant material.
It improves welding efficiency and strength, reduces overflow, and achieves higher welding quality, making it suitable for applications with high requirements for surface quality and mechanical strength.
Smart Images
Figure CN223848317U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to welding technical field especially relates to a kind of ultrasonic welding horn and ultrasonic welding equipment. BACKGROUND
[0002] With the continuous progress of science and technology, the welding between different materials also puts forward new requirements, such as the welding of copper-aluminum plate, ultrasonic welding technology just meets these requirements. Ultrasonic welding refers to the use of a high-frequency mechanical vibration, through the welding tool head to transmit high-frequency vibration to the surface of the workpiece to be welded, the interface metal under the joint action of friction and ultrasonic softening produces plastic flow and diffusion, so that the connection area gradually increases to form a reliable connection. Ultrasonic welding converts electric current into high-frequency electric energy through ultrasonic generator, and the converted high-frequency electric energy is converted into mechanical motion of the same frequency through transducer, and then the mechanical motion is transmitted to the horn through a set of amplitude-changing lever device. The horn transmits the received vibration energy to the joint of the workpiece to be welded. In this area, the vibration energy is converted into heat energy through friction, and the welded material is melted. Compared with resistance welding and laser welding, ultrasonic welding is more suitable for materials with high conductivity and thermal conductivity, and has good adaptability to special-shaped materials and multi-layer materials.
[0003] However, the ultrasonic welding horn for welding copper-aluminum plate is currently in the form of a pyramid, that is, the welding teeth of the welding end face of the horn are in the form of a quadrangular pyramid, and the teeth of the horn are arranged in parallel or perpendicular to the edge of the horn. The conical teeth arranged in this rectangular manner may cause overflow and burning during the welding of copper-aluminum plate. The above-mentioned welding tooth arrangement design has relatively weak material flow control ability, which is prone to overflow. INVENTION CONTENTS
[0004] Based on the above problems, the purpose of the utility model is to provide an ultrasonic welding horn and ultrasonic welding equipment, which can concentrate energy, has high welding efficiency, less overflow during welding, and high welding strength.
[0005] To achieve the above-mentioned purpose, the following technical solutions are provided:
[0006] In a first aspect, the utility model provides an ultrasonic welding horn, which comprises a horn connecting part, a horn power storage part and a horn emitting part. The horn connecting part is used to connect with the body of the ultrasonic welding equipment. The horn emitting part is connected with the horn connecting part through the horn power storage part. The horn emitting part is provided with a plurality of welding tooth structures in the form of a truncated square pyramid. The arrangement direction of the welding tooth structure is set at a first included angle with the edge of the horn emitting part. The value of the first included angle ranges from 10° to 80°.
[0007] As an optional solution of the ultrasonic welding horn provided by the utility model, the cross section of the welding tooth structure is in the form of an isosceles trapezoid.
[0008] As an optional scheme of the ultrasonic welding horn provided by the utility model, the included angle between the two opposite bevels of the welding tooth structure is a second included angle, and the second included angle ranges from 30° to 120°.
[0009] As an optional scheme of the ultrasonic welding horn provided by the utility model, the top surface of the welding tooth structure is square, rectangular or rhombic.
[0010] As an optional scheme of the ultrasonic welding horn provided by the utility model, the length of the side of the top surface of the welding tooth structure ranges from 0.1 mm to 0.5 mm.
[0011] As an optional scheme of the ultrasonic welding horn provided by the utility model, the distance between the top surface and the bottom surface of the welding tooth structure ranges from 0.5 mm to 2.0 mm, and / or the interval between two adjacent welding tooth structures ranges from 0 to 0.5 mm.
[0012] As an optional scheme of the ultrasonic welding horn provided by the utility model, the welding tooth structures are densely distributed.
[0013] As an optional scheme of the ultrasonic welding horn provided by the utility model, the edge of the horn emitting part is provided with a chamfer.
[0014] As an optional scheme of the ultrasonic welding horn provided by the utility model, the ultrasonic welding horn is made of wear-resistant material.
[0015] In the second aspect, the utility model further provides an ultrasonic welding device, which comprises an ultrasonic welding device body and the above-mentioned ultrasonic welding horn.
[0016] The utility model has the advantages of:
[0017] The ultrasonic welding horn and the ultrasonic welding equipment provided by the utility model can realize dense distribution of the plurality of truncated square cone shaped welding tooth structures of the horn emitting part, the arrangement direction of the welding tooth structures is arranged at a first included angle with the edge of the horn emitting part, the value range of the first included angle is 10-80°, that is, the welding tooth structures adopt bevel tooth design, energy is concentrated, welding efficiency is high, material overflow is small during the welding process, and welding strength is high. BRIEF DESCRIPTION OF DRAWINGS
[0018] In order to more clearly illustrate the technical solutions in the embodiments of the utility model, the drawings needed to be used in the description of the embodiments of the utility model will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the utility model, and other drawings can be obtained according of the contents of the embodiments of the utility model and the drawings by those skilled in the art without any creative labor.
[0019] Figure 1 It is the structure schematic view of the ultrasonic welding horn provided by the utility model specific embodiment;
[0020] Figure 2 It is the local structure schematic view of the horn emitting part of the ultrasonic welding horn provided by the utility model specific embodiment;
[0021] Figure 3 It is the structure schematic view of the ultrasonic welding horn provided by the utility model specific embodiment when welding aluminum plate and copper plate;
[0022] Figure 4It is the cross-sectional view schematic diagram of the welding tooth structure of the ultrasonic welding horn provided by the embodiment of the utility model.
[0023] In the drawing:
[0024] 1, horn connecting part; 2, horn force storage part; 3, horn emitting part;
[0025] 31, welding tooth structure;
[0026] 100, aluminum plate; 200, copper plate. EMBODIMENT
[0027] In order to make the technical problems solved by the utility model, the technical scheme adopted and the technical effects reached more clear, the technical scheme of the embodiment of the utility model will be further described in detail below in combination with the drawings. Obviously, the described embodiment is only a part of the embodiment of the utility model, not all the embodiments. Based on the embodiment in the utility model, all other embodiments obtained by the person skilled in the art without making creative labor belong to the protection scope of the utility model.
[0028] In the description of the utility model, it needs to be explained that the orientation or position relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like is the orientation or position relationship based on the drawing shown, and is only for the convenience of describing the utility model and simplifying the description, and is not to indicate or imply that the device or element indicated must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the utility model. In addition, the terms "first", "second" are only for the purpose of description, and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions.
[0029] In the description of the utility model, it needs to be explained that, unless otherwise explicitly specified and limited, the terms "mounting", "connecting", "connection" should be understood broadly, for example, it can be fixed connection, can also be detachable connection; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be the communication inside two elements. For the person skilled in the art, the specific meaning of the above terms in the utility model can be understood according to the specific circumstances.
[0030] As Figures 1 to 4As shown, the embodiment provides an ultrasonic welding horn, which ensures the uniformity of the welding mark, ensures the connection strength and reliability of the welding point, and has less overflow after welding. The ultrasonic welding horn comprises a horn connecting part 1, a horn power storage part 2 and a horn emitting part 3. The horn connecting part 1 is used to connect with the body of the ultrasonic welding equipment. The horn emitting part 3 is connected with the horn connecting part 1 through the horn power storage part 2. The horn emitting part 3 is provided with a plurality of densely distributed and truncated square pyramid shaped tooth structures 31. It can be understood that the truncated square pyramid refers to another pyramid obtained by cutting the pyramid with a plane parallel to the base surface of the pyramid. The structure is simple and has high stability. The arrangement direction (such as Figure 1 P direction) of the tooth structure 31 is arranged at a first included angle α with the edge of the horn emitting part 3 extending along the Y direction. The value of the first included angle α is 10° to 80°. It is easy to form a uniform lateral force structure to uniformly apply force to the tooth surface of the material in all directions. The crystallization of the workpiece due to plastic deformation is more uniform, and the overflow (single direction material accumulation) caused by stress concentration in the vibration direction is reduced. Figure 1 The Y direction and the X direction are perpendicular in the embodiment. When the end of the horn emitting part 3 is rectangular, the X direction can be the length direction of the rectangle, and the Y direction can be the width direction of the rectangle.
[0031] The plurality of truncated square pyramid shaped tooth structures 31 of the horn emitting part 3 can be densely distributed. The arrangement direction of the tooth structure 31 is arranged at a first included angle with the edge of the horn emitting part 3, and the value of the first included angle is 10° to 80°. That is, the tooth structure 31 adopts an inclined tooth design, which can concentrate energy, has high welding efficiency, has less overflow during the welding process, and has high welding strength. The vibration direction of the horn is usually as Figure 1 Y direction, so the tooth arrangement direction P direction and the horn vibration direction Y direction are arranged at a first included angle α. The inclined tooth design makes the tooth in the movement direction of the horn a sharp tooth, which can more effectively make the tooth of the horn penetrate deeper, thereby concentrating energy on the welding area and improving the welding efficiency. The inclined tooth design can better control the flow of the material in the horizontal direction and reduce the overflow during the welding process.
[0032] Compared to existing pyramid-shaped welding heads with rectangular arrangements, the pyramid-shaped beveled tooth welding head of this embodiment requires a smaller welding depth to achieve the same welding strength. Furthermore, the flow of molten copper and aluminum material before reaching ideal welding conditions is less, resulting in less overflow. The beveled tooth design helps to evenly distribute energy in the welding area, reducing localized overheating and improving weld quality. It is suitable for metal materials requiring uniform melting. The beveled tooth design reduces the direct impact of the welding head on the material surface, preventing scratches or damage, making it suitable for applications with high surface quality requirements. When welding thinner materials, the toothed top surface reduces localized high-pressure points, preventing excessive deformation or damage to the material at these points. The beveled tooth design promotes microscopic plastic deformation of the material at the welding interface, enhancing the bonding strength of the weld joint. This is particularly important for welding aluminum plate 100, as it requires high mechanical strength. It also helps to expel gas from the welding area, reducing porosity and improving the density and strength of the weld joint.
[0033] Optionally, the cross-section of the welding tooth structure 31 is an isosceles trapezoid. The welding tooth structure 31 with an isosceles trapezoidal cross-section can adapt to welding copper plates 200 and aluminum plates 100 of different thicknesses, ensuring good welding results on materials of different thicknesses.
[0034] In some embodiments, such as Figure 4 As shown, the included angle between the two opposite hypotenuses on the welding tooth structure 31 is the second included angle β, which ranges from 30° to 120°. This range of angle β ensures the weld joint has sufficient strength, preventing breakage due to intense welding friction, and also preventing insufficient gripping force due to a flat surface. Furthermore, because of the second included angle β, the ultrasonic waves propagate from bottom to top. As the area decreases, most of the transverse clutter is dissipated along the propagation path, leaving mainly the longitudinal waves beneficial to ultrasonic welding. The longitudinal waves have more concentrated energy and generate less ineffective heat during welding. When the included angle of the isosceles trapezoidal hypotenuses (i.e., the second included angle β) of the ultrasonic welding head is 30°-60°, it is suitable for thinner materials, providing good energy concentration and uniform distribution. When the included angle of the isosceles trapezoidal hypotenuses of the ultrasonic welding head is 60°-90°, it is suitable for medium-thickness materials, balancing the requirements of energy concentration and uniform distribution. When the isosceles trapezoidal hypotenuse angle of the ultrasonic welding head is 90°-120°, it is suitable for thicker materials, providing a larger contact area and better pressure distribution. Using different angles on copper plates (200mm) and aluminum plates (100mm) of varying thicknesses results in a more uniform distribution of ultrasonic energy on the welding surface, preventing excessively high local temperatures at the weld point and reducing the possibility of material scorching or deformation.
[0035] Meanwhile, the design of the bevel can more effectively concentrate ultrasonic energy to the welding area, improving the energy transmission efficiency. This is particularly important for aluminum plates 100 with small acoustic impedance, as they are more sensitive to ultrasonic energy absorption and transmission. It also reduces energy loss at the contact surface between the welding head and the material, ensuring that more energy is used for the welding process. Due to the bevel angle, the energy concentration at the contact point is higher, which helps to reach the required temperature in a shorter time, improving welding efficiency.
[0036] Alternatively, the top surface of the welding tooth structure 31 is square, and in other embodiments, the top surface of the welding tooth structure 31 can also be other shapes, such as rectangular or rhombus, etc., to be suitable for more application scenarios. The square design of the top surface of the welding tooth structure 31 is beneficial for uniform energy transmission during welding, thereby reducing material burning, deformation, and overflow. The square top surface of the welding tooth structure 31 is beneficial for increasing the gripping force of the welding head on the workpiece during welding, avoiding slipping of the workpiece during welding, and causing unstable welding. It also avoids piercing the welded workpiece with a too sharp top surface, while also maximizing the concentration of welding energy and improving the transmission efficiency of ultrasonic energy.
[0037] In some embodiments, the length of the side of the top surface of the welding tooth structure 31 is 0.1 mm to 0.5 mm. For example, when welding copper plates 200 and aluminum plates 100 with a thickness of less than 2 mm, the length of the side of the square top surface of the tooth is between 0.2 mm and 0.5 mm, which is more appropriate, because the energy required for welding thinner materials is low, and increasing the contact area can provide more energy while reducing energy loss, thereby achieving better welding results. When welding copper plates 200 and aluminum plates 100 with a thickness of greater than or equal to 2 mm, the length of the side of the square top surface of the tooth is between 0 and 0.2 mm, which is more appropriate, because it is more difficult for the welding head to penetrate thicker materials during welding, and reducing the tooth top surface allows the welding head to penetrate deeper, while allowing more energy to be transmitted, thereby achieving better welding results.
[0038] Alternatively, the distance between the top surface and the bottom surface of the welding tooth structure 31 is 0.5 mm to 2.0 mm. For thinner copper plates 200 and aluminum plates 100 (e.g., less than 2 mm thick), using a shallower tooth depth (typically between 0.5 mm and 1.2 mm) can ensure that energy is concentrated and uniformly transmitted to the welding area, avoiding overheating or burning of the material. For thicker copper plates 200 and aluminum plates 100 (e.g., greater than or equal to 2 mm thick), using a deeper tooth depth (typically between 1.2 mm and 2 mm) can ensure that energy can penetrate to the inside of the material, achieving sufficient melting and bonding.
[0039] In some embodiments, the spacing between two adjacent solder tooth structures 31 is 0-0.5mm. The spacing forms a groove between two adjacent solder tooth structures 31, and the solder material is extruded into the groove during ultrasonic welding, forming a solder joint. When the extrusion deformation is too large, the solder joint is prone to large deformation. The groove can drain the extruded material, preventing the material from being extruded outward and causing excessive deformation, thereby greatly reducing the deformation of the product after welding relative to the deformation before welding, and achieving more stable welding results. The above spacing allows the copper-aluminum material to have a large flow space, reducing material overflow during welding and maintaining the cleanliness of the welding area, which is suitable for applications that require high cleanliness of the welding area.
[0040] Optionally, the edge of the welding head emitting portion 3 is provided with a chamfer, which is more conducive to reducing the overflow at the edge. Correspondingly, some solder tooth structures 31 near the edge are also provided with a chamfer with a corresponding angle or arc, to avoid the formation of a relatively sharp and protruding stress concentration area.
[0041] In some embodiments, the ultrasonic welding horn is made of wear-resistant materials. Commonly used wear-resistant materials for ultrasonic welding horns include titanium alloys and alloy steels. Titanium alloys are widely used in ultrasonic welding horns as high-quality materials, and have the characteristics of low density and high strength, with outstanding specific strength among metals. Titanium alloy horns can withstand high stress under high-frequency vibration without being easily damaged, and have good acoustic properties and corrosion resistance, making them suitable for various working environments. Alloy steels have high hardness, high wear resistance, and good compressive strength, making them suitable for welding workpieces with high hardness. Some high-quality alloy steels can achieve excellent mechanical properties after heat treatment, and can withstand high welding pressure and impact force. However, the acoustic properties of alloy steels are generally not as good as those of titanium alloys, and the shape and size of the horn need to be optimized to improve energy transfer efficiency.
[0042] The embodiment also provides an ultrasonic welding device, which includes an ultrasonic welding device body and the above-described ultrasonic welding horn. The plurality of solder tooth structures 31 in the horn emitting portion 3 are densely distributed in the shape of a truncated square pyramid, and the arrangement direction of the solder tooth structures 31 forms a first included angle with the edge of the horn emitting portion 3, with a value range of 10°-80°. That is, the solder tooth structures 31 adopt an inclined tooth design, which can concentrate energy, has high welding efficiency, produces less overflow during welding, and has high welding strength. The inclined tooth design makes the teeth in the movement direction of the horn into sharp teeth, which can more effectively penetrate the teeth of the horn into a deeper position, thereby concentrating energy on the welding area and improving welding efficiency. The inclined tooth design can better control the flow of material in the horizontal direction and reduce overflow during welding.
[0043] Compared with the rectangular arranged pyramid-shaped welding head, the pyramid-shaped bevel tooth welding head of the embodiment needs smaller welding depth to achieve the same welding strength, and the molten copper-aluminum material has smaller flow before reaching the ideal welding condition, thereby having less overflow. The bevel tooth design helps to uniformly distribute energy in the welding area, reduces local overheating, and improves welding quality. It is suitable for metal materials that need to be uniformly melted. The bevel tooth design can reduce the direct impact of the welding head on the material surface, prevent the material surface from being scratched or damaged, and is suitable for application scenarios with high requirements for surface quality. When welding thin materials, the tooth top surface can reduce local high-pressure points to avoid excessive deformation or damage of the material at these points. The bevel tooth design can promote micro-plastic deformation of the material at the welding interface, and enhance the bonding force of the welded joint. This is particularly important for the welding of aluminum plate 100, as aluminum plate 100 needs to have high mechanical strength. At the same time, it helps to remove gas in the welding area, reduces the formation of pores, and improves the density and strength of the welded joint.
[0044] It should be noted that the above are only preferred embodiments of the present application and the technical principles applied. Those skilled in the art will understand that the present application is not limited to the specific embodiments herein, and those skilled in the art can make various obvious changes, readjustments and substitutions without departing from the scope of the present application. Therefore, although the present application has been described in more detail through the above embodiments, the present application is not limited to the above embodiments, and can include more other equivalent embodiments without departing from the concept of the present application, and the scope of the present application is determined by the scope of the appended claims.
Claims
1. An ultrasonic welding horn characterized by, The welding head comprises a welding head connecting part (1), a welding head force storage part (2) and a welding head emitting part (3), the welding head connecting part (1) is used for connecting with the body of the ultrasonic welding device, the welding head emitting part (3) is connected with the welding head connecting part (1) through the welding head force storage part (2), the welding head emitting part (3) is provided with a plurality of welding tooth structures (31) in the shape of a truncated square pyramid, the arrangement direction of the welding tooth structures (31) is arranged at a first included angle with the edge of the welding head emitting part (3), and the value range of the first included angle is 10°-80°.
2. The ultrasonic welding horn of claim 1, wherein, The cross section of the welding tooth structure (31) is isosceles trapezoidal.
3. The ultrasonic welding horn of claim 2, wherein, The included angle between the two opposite inclined edges of the welding tooth structure (31) is a second included angle, and the value range of the second included angle is 30°-120°.
4. The ultrasonic welding horn of claim 1, wherein, The top surface of the welding tooth structure (31) is square, rectangular or rhombic.
5. The ultrasonic welding horn of claim 4, wherein, The side length of the top surface of the welding tooth structure (31) is 0.1mm-0.5mm.
6. The ultrasonic welding horn of claim 1, wherein, The distance between the top surface and the bottom surface of the welding tooth structure (31) is 0.5mm-2.0mm; and / or, the spacing between two adjacent welding tooth structures (31) is 0-0.5mm.
7. The ultrasonic welding horn of claim 1, wherein, The plurality of welding tooth structures (31) are densely distributed.
8. The ultrasonic welding horn of claim 1, wherein, The edge of the welding head emitting part (3) is provided with a chamfer.
9. The ultrasonic welding horn of any of claims 1-8, wherein, The ultrasonic welding head is prepared from wear-resistant material.
10. Ultrasonic welding apparatus characterized in that, The ultrasonic welding device comprises a body and the ultrasonic welding head according to any one of claims 1-9.