US 2025/0187102 A1 · ULTRASONIC HORN WITH FLAT ULTRASONIC BOOSTER FOR INCREASED STIFFNESS

Abstract

An ultrasonic welding system having an ultrasonic horn with a flat ultrasonic booster to provide increased stiffness to the ultrasonic horn (sonotrode) and allowing for wider welding surface applications while minimizing deflections of the horn under force. The flat booster has a small footprint but provides high stiffness to the horn. The horn and booster can be a unitary piece and can be manufactured, for example, by machining a solid plate of metal into the horn with integrated booster. Optional internal compliant tabs can be attached to side plates to enhance stiffness along a vertical direction (orthogonal to a direction of the back and forth movement of the part-interfacing surface(s) of the horn), while allowing a scrubbing back and forth motion along the ultrasonic-energy-imparting surface(s) of the horn. An optional cut-and-seal feature on the horn or anvil or both is also disclosed.

Claims22

Dependent claims

An ultrasonic welding system having an ultrasonic stack assembly, the system comprising:

an ultrasonic stack assembly including an ultrasonic horn and a first transducer arranged to impart a first ultrasonic energy into the ultrasonic horn, the ultrasonic horn having a first part-interfacing surface configured to contact a part to be joined, the ultrasonic horn having a major surface adjacent to the first part-interfacing surface and an ultrasonic booster having a generally flat shape and a major surface that is generally coplanar with the major surface of the ultrasonic horn;
one or more controllers operatively coupled to the ultrasonic stack assembly, the one or more controllers operatively being configured to:
apply the first ultrasonic energy through the ultrasonic horn via the first transducer to cause the first part-interfacing surface to move back and forth along its length as the first ultrasonic energy is applied by the first transducer to the horn.

Dependencies are inferred from the claim text.

Ultrasonic horn with flat ultrasonic booster for increased stiffness

Life of this patent

Ultrasonic horn with flat ultrasonic booster for increased stiffness

Life of this patent

Abstract

Claims22