Segmented dies for use with ultrasonics

Abstract

A forming die that includes a body, wherein the body of the forming die includes at least one opening created therein; at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.

1 . A forming die, comprising:
 (a) a body, wherein the body of the forming die comprises: a cavity circumscribed by the body and at least one opening in the body;   (b) at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die and be adjacent to the cavity, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and   (c) optionally, at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.   
     
     
         2 . The forming die of  claim 1 , further comprising at least one source of ultrasonic vibrations in communication with the die segment for directing ultrasonic vibrations into the die segment. 
     
     
         3 . The forming die of  claim 2 , wherein the at least one source of ultrasonic vibrations is either embedded within the die segment or external to the die segment. 
     
     
         4 . The forming die of  claim 1 , further comprising at least one vibration-isolating device positioned between each die segment and the body of the forming die, wherein the at least one vibration isolating device prevents ultrasonic vibrations from the die segment from entering the body of the forming die. 
     
     
         5 . The forming die of  claim 4 , wherein the at least one vibration-isolating device is a low friction pad. 
     
     
         6 . The forming die of  claim 1 , further comprising a die segment adapting fixture, wherein the adapting fixture is mounted within the body of the forming die, wherein the die segment is mounted within the adapting fixture, and wherein the at least one vibration isolating device is mounted between the die segment and the adapting fixture. 
     
     
         7 . The forming die of  claim 1 , wherein the at least one geometric feature includes a cylindrical bore, and wherein the cylindrical bore is oriented transversely, side-to-side, within the die segment. 
     
     
         8 . The forming die of  claim 1 , wherein the at least one geometric feature includes a cylindrical bore, wherein the cylindrical bore is oriented vertically within the die segment. 
     
     
         9 . The forming die of  claim 1 , wherein the at least one geometric feature includes a square cutout, and wherein the square cutout is oriented vertically within the die segment. 
     
     
         10 . The forming die of  claim 1 , wherein the at least one geometric feature includes a rectangular cutout, and wherein the rectangular cutout is oriented transversely, side-to-side, within the die segment at a predetermined angle. 
     
     
         11 . The forming die of  claim 1 , wherein the at least one die segment has a length, a height, and a width, and wherein the at least one geometric feature formed within the die segment permits the width of the die segment to be increased from an acoustic quarter-wavelength to a predetermined multiple thereof. 
     
     
         12 . A forming die, comprising:
 (a) a body, wherein the body of the forming die comprises: a cavity circumscribed by the body and at least one opening in the body;   (b) at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die and be adjacent to the cavity, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations;   (c) at least one source of ultrasonic vibrations in communication with the at least one die segment for directing ultrasonic vibrations into the at least one die segment, wherein the at least one source of ultrasonic vibrations is either embedded within the at least one die segment or external to the at least one die segment; and   (d) optionally, at least one geometric feature formed within the at least one die segment, wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner.   
     
     
         13 . The forming die of  claim 12 , further comprising at least one vibration-isolating device positioned between the die segment and the body of the forming die, wherein the at least one vibration isolating device prevents ultrasonic vibrations from the die segment from entering the body of the forming die, and wherein the at least one vibration-isolating device is a low friction pad. 
     
     
         14 . The forming die of  claim 12 , further comprising a die segment adapting fixture, wherein the adapting fixture is mounted within the body of the forming die, wherein the die segment is mounted within the adapting fixture, and wherein the at least one vibration isolating device is mounted between the die segment and the adapting fixture. 
     
     
         15 . The forming die of  claim 12 , wherein the at least one geometric feature includes a cylindrical bore, and wherein the cylindrical bore is oriented either transversely, side-to-side, within the die segment or vertically within the die segment. 
     
     
         16 . The forming die of  claim 12 , wherein the at least one geometric feature includes a square cutout, and wherein the square cutout is oriented vertically within the die segment. 
     
     
         17 . The forming die of  claim 12 , wherein the at least one geometric feature includes a rectangular cutout, and wherein the rectangular cutout is oriented transversely, side-to-side, within the die segment at a predetermined angle. 
     
     
         18 . The forming die of  claim 12 , wherein the at least one die segment has a length, a height, and a width, and wherein the at least one geometric feature formed within the die segment permits the width of the die segment to be increased from an acoustic quarter-wavelength to a predetermined multiple thereof. 
     
     
         19 . A forming die for use in automotive applications, comprising:
 (a) a body, wherein the body of the forming die comprises: a cavity circumscribed by the body and at least one opening in the body;   (b) at least one die segment, wherein the at least one die segment is adapted to be inserted into the at least one opening in the body of the forming die and be adjacent to the cavity, and wherein the at least one die segment is further adapted to receive ultrasonic vibrations; and   (c) optionally, at least one geometric feature formed within the at least one die segment,
 (i) wherein the at least one geometric feature affects the ultrasonic vibrations in a predetermined manner, and 
 (ii) wherein the at least one geometric feature includes a cylindrical bore that is oriented transversely, side-to-side, within the at least one die segment; a cylindrical bore that is oriented vertically within the at least one die segment; a square cutout that is oriented vertically within the at least one die segment; a rectangular cutout that is oriented transversely, side-to-side, within the at least one die segment at a predetermined angle; or combinations thereof. 
   
     
     
         20 . The forming die of  claim 19 , wherein the at least one die segment has a length, a height, and a width, and wherein the at least one geometric feature formed within the die segment permits the width of the die segment to be increased from an acoustic quarter-wavelength to a predetermined multiple thereof.