# US 2014/0190638 A1 · Sonotrode and Anvil Energy Director Grids for Narrow/Complex Ultrasonic Welds of Improved Durability

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- Number: US 2014/0190638 A1
- Document ID: US20140190638A1
- Status: Published application
- Kind: A1
- Application number: 13/736,199
- Filed: 2013-01-08
- Published: 2014-07-10
- Earliest claimed: 2013-01-08
- Assignees: Rinco Ultrasonics AG
- Applicants: Rinco Ultrasonics Inc.
- Inventors: Gordon Hull
- Web page: https://patentgrep.com/patent/US20140190638A1

## CPC

- B23K 20/106: {Features related to sonotrodes}
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/244: {said joint lines being non-straight, e.g. forming non-closed contours}
- B29C 66/43: {Joining a relatively small portion of the surface of said articles (B29C66/45 takes precedence)}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/81427: {comprising a single ridge, e.g. for making a weakening line; comprising a single tooth}
- B29C 66/81431: {comprising a single cavity, e.g. a groove}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/8167: {Quick change joining tools or surfaces}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B29C 66/83221: {cooperating reciprocating tools, each tool reciprocating along one axis}
- B29C 66/847: {Drilling standard machine type}
- B65B 51/225: {by ultrasonic welding}
- B29C 65/7451: {the severing tool and the welding tool being movable with respect to one-another}
- B29C 66/3022: {said melt initiators being integral with at least one of the parts to be joined}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/8242: {Pneumatic or hydraulic drives (using fluid pressure directly acting on the parts to be joined B29C66/8266)}
- B29C 66/849: {Packaging machines}
- B29C 66/9513: {characterised by specific vibration frequency values or ranges}
- B29C 66/9516: {by controlling their vibration amplitude}
- B29C 66/9517: {characterised by specific vibration amplitude values or ranges}
- B29L 2031/7128: {Bags, sacks, sachets (tea bags B29L2031/7122; medical bags B29L2031/7148)}
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B65B: MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING (bundling and pressing devices for cigars A24C1/44; devices for tensioning and securing binders adapted to be supported by the article or articles to be bound B25B25/00; applying closure members to bottles, jars or similar containers B67B1/00-B67B6/00; concurrent cleaning, filling and closing of bottles B67C7/00; emptying bottles, jars, cans, casks, barrels or similar containers B67C9/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A specially designed sonotrode and anvil are adapted to be used in combination for ultrasonic welding of work pieces, to produce a narrower weld region, but one exhibiting greater durability, thereby permitting use of less packaging material. The contact surfaces comprise a surface of the anvil having a plurality of energy directors, where the plurality of energy directors are arranged into a three-dimensional grid pattern to be capable of distributed vibration-transmissive contact. The energy directors may comprise a series of plateau surfaces being regularly spaced apart from each other in a first direction, and in a second direction that is orthogonal to the first direction, to form the grid pattern. The rectangular-shaped plateaus may be spaced apart by valleys. Engagement of the energy directors of the anvil with the corresponding surface of the sonotrode may cause minor elastic deformation of work pieces positioned therebetween prior to ultrasonic welding.

## Claims

### Claim at position 1

1-37. (canceled)

### Claim 38

A horn and anvil combination, said horn and anvil combination being particularly adapted for use in ultrasonic welding of thin work pieces, for improved integrity in the packaging of solids and liquids with narrow welds to reduce per-package material usage and costs:
said horn comprising:
a plurality of energy directors, said plurality of energy directors being spaced in a first direction and in a second direction to form a pattern, each of said plurality of energy directors comprising a rectangular-shaped plateau surface with each side of said rectangular-shaped plateau surfaces configured to transition into an angled side surface to create a first, a second, a third, and a fourth angled side surface for each said plateau surface; each of said angled side surfaces of each said plateau surface being connected with another side surface of an adjacent plateau surface, except at an outer periphery of said horn;
said anvil comprising:
a plurality of energy directors being spaced in a first direction and in a second direction to form a pattern, each of said plurality of energy directors comprising a rectangular-shaped plateau surface with each side of said rectangular-shaped plateau surfaces configured to transition into an angled side surface to create a first, a second, a third, and a fourth angled side surface for each said plateau surface; each of said angled side surfaces of each said plateau surface being connected with another side surface of an adjacent plateau surface, except at an outer periphery of said anvil;
and
wherein said energy directors of said horn and said energy directors of said anvil are configured for alignment to ultrasonically weld the thin work pieces, whereby said side surfaces of said horn plateaus interlock with said side surfaces of said anvil plateaus in a pattern, in both said first direction and said second direction, to provide improved weld integrity permitting substantially narrower welds to reduce per-package material usage and costs.

### Claim 39 (depends on 38)

The horn and anvil combination according to claim 38 wherein said interlocking energy directors of said horn and said anvil are configured to increase a total surface area of contact between said horn and said anvil, and are thereby configured to transmit vibrations and to cause minor elastic deformation of said thin work pieces to produce said improved integrity in the packaging of solids and liquids.

### Claim 40 (depends on 38)

The horn and anvil combination according to claim 38 wherein said energy directors of said horn and said energy directors of said anvil are configured to sonically weld thin plastic film work pieces.

### Claim 41 (depends on 38)

The horn and anvil combination according to claim 38 wherein said angled side surfaces for each said plateau surface is at an angle of 45 degrees to said plateau surface.

### Claim 42 (depends on 38)

The horn and anvil combination according to claim 38 further comprising a peripheral flange being positioned proximate to a mid-plane of said horn to be configured to provide support for said horn for said alignment.

### Claim 43 (depends on 38)

The horn and anvil combination according to claim 38 wherein each of said angled side surfaces of each said plateau surface are connected with another side surface of said adjacent plateau surface to form a trough line therebetween.

### Claim 44 (depends on 38)

The horn and anvil combination according to claim 38 wherein each of said angled side surfaces of each said plateau surface are connected with another side surface of said adjacent plateau surface with radiused surface therebetween.

### Claim 45 (depends on 38)

The horn and anvil combination according to claim 38 wherein each said rectangular-shaped plateau surfaces are oriented to have each said side be at a 45 degree angle to a weld-line.

### Claim 46 (depends on 38)

The horn and anvil combination according to claim 38,
wherein said second direction on said horn is orthogonal to said first direction on said horn, with said plurality of energy directors of said horn being regularly spaced in said first horn direction and regularly spaced in said second horn direction to form a grid pattern thereon; and
wherein said second direction on said anvil is orthogonal to said first direction on said anvil, with said plurality of energy directors of said anvil being regularly spaced in said first anvil direction and regularly spaced in said second anvil direction to form a grid pattern thereon.

### Claim 47 (depends on 38)

The horn and anvil combination according to claim 38 wherein each said rectangular-shaped plateau surface is generally flat.

### Claim 48

A sonotrode and anvil combination, said sonotrode and anvil combination being configured for use on a form-fill-seal machine to ultrasonically weld thin work pieces:
said sonotrode comprising:
a plurality of energy directors, said plurality of energy directors being spaced in a first direction and spaced in a second direction, each of said plurality of energy directors comprising a rectangular-shaped plateau surface with each side of said rectangular-shaped plateau surfaces configured to transition into an angled side surface to create a first, a second, a third, and a fourth angled side surface for each said plateau surface; each of said angled side surfaces of each said plateau surface being connected with another side surface of an adjacent plateau surface, except at an outer periphery of said sonotrode;
said anvil comprising:
a plurality of energy directors being spaced in a first direction and spaced in a second direction, each of said plurality of energy directors comprising a rectangular-shaped plateau surface with each side of said rectangular-shaped plateau surfaces configured to transition into an angled side surface to create a first, a second, a third, and a fourth angled side surface for each said plateau surface; each of said angled side surfaces of each said plateau surface being connected with another side surface of an adjacent plateau surface, except at an outer periphery of said anvil;
and
wherein said energy directors of said sonotrode and said energy directors of said anvil are configured for alignment to ultrasonically weld the thin work pieces, whereby said side surfaces of said sonotrode plateaus interlock with said side surfaces of said anvil plateaus in a pattern in both said first direction and said second direction.

### Claim 49 (depends on 48)

The sonotrode and anvil combination according to claim 48,
wherein said second direction on said sonotrode is orthogonal to said first direction on said sonotrode, with said plurality of energy directors of said sonotrode being regularly spaced in said first sonotrode direction and regularly spaced in said second sonotrode direction to form a grid pattern thereon; and
wherein said second direction on said anvil is orthogonal to said first direction on said anvil, with said plurality of energy directors of said anvil being regularly spaced in said first anvil direction and regularly spaced in said second anvil direction to form a grid pattern thereon.

### Claim 50 (depends on 49)

The horn and anvil combination according to claim 49 wherein each said rectangular-shaped plateau surface is generally flat.

### Claim 51 (depends on 50)

The sonotrode and anvil combination according to claim 50 wherein said angled side surfaces for each said plateau surface is at an angle of 45 degrees to said plateau surface.

### Claim 53 (depends on 52)

The sonotrode and anvil combination according to claim 52 wherein said interlocking energy directors of said sonotrode and said anvil are configured to increase a total surface area of contact between said sonotrode and said anvil, and are thereby configured to transmit vibrations and to cause elastic deformation of the thin work pieces to produce the improved integrity in the packaging of solids and liquids.

### Claim 54 (depends on 53)

The sonotrode and anvil combination according to claim 53 wherein each said rectangular-shaped plateau surfaces are oriented to have each said side be at a 45 degree angle to a weld-line.

### Claim 55 (depends on 54)

The sonotrode and anvil combination according to claim 54 wherein each of said angled side surfaces of each said plateau surface are connected with another side surface of said adjacent plateau surface to form a trough line therebetween.

### Claim 56 (depends on 54)

The sonotrode and anvil combination according to claim 54 wherein each of said angled side surfaces of each said plateau surface are connected with another side surface of said adjacent plateau surface with a radiused surface therebetween.

### Claim 57 (depends on 50)

The sonotrode and anvil combination according to claim 50 further comprising a peripheral flange being positioned proximate to a mid-plane of said sonotrode to be configured to provide support for said sonotrode for said alignment.