Ultrasonic consolidation of materials

A system for consolidating materials, comprising:

• (a) at least one ultrasonic transducer configured to provide ultrasonic energy to a sonotrode, wherein the at least one ultrasonic transducer is mounted in an articulated housing configured to provide the sonotrode with compressive force and varying angles of contact relative to placement of the materials to be consolidated, wherein the sonotrode is configured to direct ultrasonic energy into materials to be consolidated, and wherein the materials to be consolidated have both a glass transition temperature and a melting temperature;
• (b) a multi-layered, non-rigid consolidating material configured to ensure bonding of the materials to be consolidated, wherein the consolidating material has a thickness that decreases with increasing thickness of the materials to be consolidated, wherein the multi-layered, non-rigid consolidating material is in proximity to the sonotrode, wherein the multi-layered, non-rigid consolidating material and sonotrode define a region therebetween for receiving the materials to be consolidated, and wherein the multi-layered, non-rigid consolidating material has a glass transition temperature that is higher than the glass transition temperature of the materials to be consolidated and a melting temperature that is higher than the melting temperature of the materials to be consolidated;
• and
• (c) an incoming material anvil positioned on one side of the sonotrode and an outgoing material anvil positioned on the opposite side of the sonotrode, wherein the anvils are configured to provide additional compressive force on the materials being consolidated, and wherein the anvils are configured to either cool or heat the materials being consolidated.

A method for consolidating materials, comprising:

• (a) configuring a sonotrode to direct ultrasonic energy into materials to be consolidated and exert compressive force on the materials to be consolidated, wherein the materials to be consolidated have both a glass transition temperature and a melting temperature;
• (b) placing a non-rigid consolidating material with a plurality of layers in proximity to the sonotrode, wherein the non-rigid consolidating material and sonotrode define a region therebetween for receiving the materials to be consolidated, wherein the non-rigid consolidating material has a glass transition temperature that is higher than the glass transition temperature of the materials to be consolidated and a melting temperature that is higher than the melting temperature of the materials to be consolidated, wherein the non-rigid consolidating material contacts at least one of the materials to be consolidated without bonding thereto, and wherein the non-rigid consolidating material is configured to ensure bonding of the materials to be consolidated;
• and
• (c) joining the materials to be consolidated by activating the sonotrode and moving the sonotrode across the materials under compressive force and at predetermined angles.