Floating Bracket Presenter for Ultrasonic Welding Alignment
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Solution Overview
Problem
The existing bracket presenters for ultrasonic welding processes are complex and costly due to the need for multiple machined parts, and they lack efficient mechanisms for accommodating slight variations in tolerances between sensor brackets and substrates during the welding process.
Innovation Solution
A one-piece bracket presenter with nested tapered features and integrated springs allows for lateral floating and positive location of the sensor bracket, enabling efficient ultrasonic welding by reducing the number of parts and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple machined parts are used in the bracket presenter, then the alignment and tolerance accommodation capability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple separate machined parts into a single monolithic bracket presenter component. This integration maintains the alignment and tolerance accommodation functions while eliminating the complexity of assembling and machining multiple separate parts, directly resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The monolithic bracket presenter is designed to perform multiple functions simultaneously: it provides structural support, enables lateral floating movement through integrated features, and accommodates tolerance variations. This multi-functionality in a single component addresses both the precision requirements and reduces part count
2Adaptability or versatility
If the bracket presenter allows lateral floating movement, then the tolerance variation accommodation is improved, but the control over bracket position during welding may be compromised
Solution Approach 1:
The bracket presenter incorporates dynamic characteristics by allowing controlled lateral floating movement through integrated features. This enables the structure to adapt to tolerance variations while maintaining sufficient positional control during the welding process, resolving the contradiction between adaptability and precision
3Adaptability or versatility
If traditional bracket presenters are used, then the tolerance accommodation is improved, but the manufacturing cost and time increase
Solution Approach 1:
By merging multiple functional features into a single monolithic component, the patent eliminates the time and cost associated with machining and assembling multiple separate parts, while maintaining the tolerance accommodation capability through integrated design features
Solution Approach 2:
The invention changes the manufacturing approach from traditional multi-part machining to monolithic fabrication, altering the production parameters to reduce manufacturing time and cost while preserving the functional requirements for tolerance accommodation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective and simplified manufacturing process while allowing for precise alignment and floating of the sensor bracket, enhancing the efficiency of the ultrasonic welding process by reducing assembly complexity and accommodating tolerance variations.
Implementation Method 1
a spring between the first and second bracket portions
Implementation Method 2
The sonotrode 20 is operatively secured to an ultrasonic converter 16, which includes piezoelectric or other elements that vibrate (e.g., add up to 50 kHZ, for example) in response to a signal from a generator 22
Implementation Method 3
an ultrasonic converter 16, which includes piezoelectric or other elements that vibrate
Data Source
AI summary
A bracket presenter for an ultrasonic welder includes a one-piece first bracket portion and a one-piece second bracket portion mounted relative to one another. First and second tapered features are respectively provided by the first and second bracket portions and are nested relative to one another. The first and second tapered features engage in an extended position and are spaced from one another in a compressed position to provide a clearance enabling the first and second bracket portions to float lateral relative to one another. A spring biases the first and second bracket portions apart.