Rotary ultrasonic bonder or processor capable of high speed intermittent processing

An ultrasonic processing apparatus, comprising:

• a rotatable, ultrasonic horn member having a first axial side and a second axial side;
• a first, rotatable axle member which is operatively joined to said first axial side of said horn member;
• a first isolation member which is operatively joined to said first axle member, said first isolation member capable of bending under a horn-life range of sonic frequencies to provide an operative component of motion along a radial direction of said first isolation member and an operative component of motion along an axial direction of said first isolation member;
• a first coupler which connects between said first isolation member and a first, fixedly mounted rotational bearing, said first coupler operatively secured to said first isolation member;
• a second, rotatable axle member which is operatively joined to said second axial side of said horn member;
• a second isolation member which is operatively joined to said second axle member, said first isolation member capable of bending under a horn-life range of sonic frequencies to provide an operative component of motion along a radial direction of said second isolation member and an operative component of motion along an axial direction of said second isolation member;
• a second coupler which connects between said second isolation member and a second, fixedly mounted rotational bearing, said second coupler operatively secured to said second isolation member;
• a rotatable anvil member which is cooperatively positioned to provide a selected horn-anvil gap between said anvil member and said horn member;
• an ultrasonic exciter which is connected to said horn member and can provide an operative amount of ultrasonic energy;
• an actuator which is configured to selectively adjust said horn-anvil gap;
• an automated drive which is operatively connected to said actuator to automatically modify said horn-anvil gap;
• a force sensor which is configured to detect a gap force at said horn-anvil gap;
• and
• an electronic processor which is configured to employ an output from said force sensor to monitor said intermittent gap force, and provide a drive signal to said automated drive to thereby adjust said horn-anvil gap to operatively maintain a target, intermittent gap force value.

An ultrasonic processing apparatus, comprising:

• a rotatable, ultrasonic horn member having a first axial side and a second axial side;
• a first, rotatable axle member which is operatively joined to said first axial side of said horn member, said first axle member capable of providing a first node plane;
• a first isolation member which is operatively joined to said first axle member, and has a location that is operatively proximate said first node plane of the first axle member, said first isolation member capable of bending under a horn-life range of sonic frequencies to provide an operative component of motion along a radial direction of said first isolation member and an operative component of motion along an axial direction of said first isolation member;
• a first coupler which connects between said first isolation member and a first, fixedly mounted rotational bearing, said first coupler operatively secured to said first isolation member;
• a second, rotatable axle member which is operatively joined to said second axial side of said horn member, said second axle member capable of providing a second node plane;
• a second isolation member which is operatively joined to said second axle member and has a location that is operatively proximate said second node plane of the second axle member, said first isolation member capable of bending under a horn-life range of sonic frequencies to provide an operative component of motion along a radial direction of said second isolation member and an operative component of motion along an axial direction of said second isolation member;
• a second coupler which connects between said second isolation member and a second, fixedly mounted rotational bearing, said second coupler operatively secured to said second isolation member;
• a rotatable anvil member which is cooperatively positioned to provide a selected horn-anvil gap between said anvil member and said horn member, said anvil member located in a horizontally offset and vertically overlapping arrangement relative to said horn member;
• an ultrasonic exciter which is connected to said horn member and can provide an operative amount of ultrasonic energy at a frequency within the range of about 15-60 KHz;
• an actuator which is configured to selectively adjust said horn-anvil gap;
• an automated drive which is operatively connected to said actuator to automatically modify said horn-anvil gap;
• a force sensor which is configured to detect a gap force at said horn-anvil gap;
• and
• an electronic processor which is configured to employ an output from said force sensor to monitor said intermittent gap force, and provide a drive signal to said automated drive to thereby adjust said horn-anvil gap to operatively maintain a target, intermittent gap force value.

An ultrasonic processing method, comprising:

• a rotating of an ultrasonic horn member having a first axial side and a second axial side;
• said first axial side of said horn member having been operatively joined to a first, rotatable axle member;
• said first axle member having been operatively joined to a first isolation member, said first isolation member capable of bending under a horn-life range of sonic frequencies to provide an operative component of motion along a radial direction of said first isolation member and an operative component of motion along an axial direction of said first isolation member;
• a first coupler having been connected between said first isolation member and a first, fixedly mounted rotational bearing, said first coupler operatively secured to said first isolation member;
• a rotatable anvil member having been cooperatively positioned to provide a selected horn-anvil gap between said anvil member and said horn member;
• an operative amount of ultrasonic energy having been provided to said horn member;
• an actuator which having been configured to selectively adjust said horn-anvil gap;
• an automated drive having been operatively connected to said actuator to automatically modify said horn-anvil gap;
• an intermittent gap force having been detected at said horn-anvil gap;
• and
• said intermittent gap force having been monitored to provide a drive signal to said automated drive to thereby adjust said horn-anvil gap to operatively maintain a target, intermittent gap force value.