Method and apparatus to form a workpiece employing vibration welding

Abstract

A workpiece is described, and includes a substrate, a cable, and a cover piece. A portion of the cable is joined to the substrate employing a vibration welding tool, and the cover piece is interposed between the portion of the cable and the vibration welding tool during the joining.

1 . A workpiece, comprising:
 a substrate, a cable, and a cover piece;   wherein a portion of the cable is joined to the substrate by a vibration welding tool; and   wherein the cover piece is interposed between the portion of the cable and the vibration welding tool during the joining.   
     
     
         2 . The workpiece of  claim 1 , wherein the cable comprises a single strand formed from a high tensile strength steel. 
     
     
         3 . The workpiece of  claim 1 , wherein the cable comprises a single strand formed from a shape-memory alloy. 
     
     
         4 . The workpiece of  claim 1 , wherein the cable comprises multiple strands, wherein each strand is formed from a shape-memory alloy. 
     
     
         5 . The workpiece of  claim 1 , wherein the substrate and the cover piece are fabricated from aluminum. 
     
     
         6 . The workpiece of  claim 1 , wherein the substrate and the cover piece are fabricated from copper. 
     
     
         7 . The workpiece of  claim 1 , wherein the substrate is fabricated from a thermoplastic polymer. 
     
     
         8 . The workpiece of  claim 1 , wherein the cover piece comprises a sheet element. 
     
     
         9 . The workpiece of  claim 1 , wherein the cover piece comprises a tubular sheath having a hollow portion, and wherein the portion of the cable is inserted into the hollow portion of the tubular sheath. 
     
     
         10 . The workpiece of  claim 1 , wherein the substrate includes a channel on surface thereof, and wherein the portion of the cable in the channel is inserted into the channel. 
     
     
         11 . The workpiece of  claim 1 , wherein the portion of the cable joined to the substrate includes a hook portion. 
     
     
         12 . The workpiece of  claim 1 , wherein the portion of the cable is joined to the substrate in a lap arrangement. 
     
     
         13 . A workpiece, comprising:
 an end portion of a first cable, an end portion of a second cable, and a cover piece, wherein the cover piece is employed to join the end portion of the first cable and the end portion of the second cable;   wherein a vibration welding tool is employed to join the end portion of the first cable and the end portion of the second cable with the cover piece; and   wherein the cover piece is interposed between the vibration welding tool and the end portions of the first and second cables during the joining.   
     
     
         14 . The workpiece of  claim 13 , wherein the first cable and the second cable each comprise a single strand formed from a high tensile strength steel. 
     
     
         15 . The workpiece of  claim 13 , wherein the first cable and the second cable each comprise a single strand formed from steel having a high Young's modulus. 
     
     
         16 . The workpiece of  claim 13 , wherein the first cable and the second cable each comprise a single strand formed from a shape-memory alloy. 
     
     
         17 . The workpiece of  claim 13 , wherein the cover piece comprises a tubular sheath is fabricated from aluminum. 
     
     
         18 . The workpiece of  claim 13 , wherein the cover piece comprises a thin, flexible foil element that is wrapped around the end portions of the first and second cable elements multiple times. 
     
     
         19 . A method for joining a shape-memory alloy (SMA) cable to a substrate employing a vibration welding system, the method comprising,
 positioning a portion of the cable onto a surface of the substrate;   interposing an aluminum cover piece overtop of the portion of the cable;   placing the substrate, the portion of the cable and the cover piece onto an anvil of the vibration welding system such that the cover piece is interposed between the cable and a sonotrode of the vibration welding system; and   applying, via the sonotrode of the vibration welding system, vibration energy onto the cover piece, the portion of the cable and the substrate;   wherein applying the vibration energy mechanically joins the substrate, the cable and the cover piece.   
     
     
         20 . The method of  claim 19 , further comprising:
 forming a channel on the surface of the substrate; and   positioning the portion of the cable in the channel formed on the surface of the substrate.