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.

Abstract: Advanced ultrasonic welding components of Applicant's U.S. Pat. No. 8,376,016 are readily incorporated into new form-fill-seal machines, but owners of existing machines utilizing heat-seal stations were unsuccessful at swapping the sealing packages. Retrofit kits to a replace heat sealing stations with an advanced ultrasonic sonotrode and anvil comprise: a housing; a linear rail fixed thereto; first and second bearing carriages being slidable upon the rail; and first and second fluidic muscles. Each of the fluidic muscles is mounted with a first end fixed to a respective housing wall, and a second end fixed to a respective bearing carriage, permitting actuation of each carriage through pressurization/depressurization of the muscles. The advanced anvil and sonotrode may be secured to respective carriages.

Abstract: The sonotrode and anvil of copending application Ser. No. 12/925,652, for advanced ultrasonic welding of work pieces, are readily incorporated into new form-fill-seal machines, but existing machines with heat-seal stations pose difficult problems for swapping of the sealing packages. Kits enabling heat station replacement, with the further improved sonotrode and anvil disclosed herein, comprise: a housing; a linear rail fixed thereto; anvil and sonotrode support members; and a parallel gripper. Each of the anvil and sonotrode support members is slidably attached to the rail(s) and are also connected to a respective piston of the gripper, permitting actuation of each through cycling of the gripper pistons.

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.

Abstract: Advanced ultrasonic welding components of Applicant's U.S. Pat. No. 8,376,016 are readily incorporated into new form-fill-seal machines, but owners of existing machines utilizing heat-seal stations were unsuccessful at swapping the sealing packages. Retrofit kits to a replace heat sealing stations with an advanced ultrasonic sonotrode and anvil comprise: a housing; a linear rail fixed thereto; first and second bearing carriages being slidable upon the rail; and first and second fluidic muscles. Each of the fluidic muscles is mounted with a first end fixed to a respective housing wall, and a second end fixed to a respective bearing carriage, permitting actuation of each carriage through pressurization/depressurization of the muscles. The advanced anvil and sonotrode may be secured to respective carriages.

Abstract: A sonotrode and anvil are adapted for ultrasonic welding of work pieces, to produce a narrower weld region that exhibits greater durability, permitting use of less material per package. The horn-to-anvil contact is through a plurality of energy directors arranged into a three-dimensional grid pattern to be capable of distributed vibration-transmissive contact. The energy directors include a series of plateau surfaces regularly spaced apart in a first direction, and in a second direction that is orthogonal to the first direction, to form the grid pattern. The energy directors of the horn are configured to interlock with the energy directors of the anvil. The rectangular-shaped plateaus are spaced apart by angled side-surfaces that form valleys. A stepped transition to a corresponding region of reduced height for the energy directors of the sonotrode and anvil may form a cosmetic seal region with a lesser integrity, in addition to the main barrier seal.

Abstract: A sonotrode and anvil are adapted for ultrasonic welding of work pieces, to produce a narrower weld region that exhibits greater durability, permitting use of less material per package. The horn-to-anvil contact is through a plurality of energy directors arranged into a three-dimensional grid pattern to be capable of distributed vibration-transmissive contact. The energy directors include a series of plateau surfaces regularly spaced apart in a first direction, and in a second direction that is orthogonal to the first direction, to form the grid pattern. The energy directors of the horn are configured to interlock with the energy directors of the anvil. The rectangular-shaped plateaus are spaced apart by angled side-surfaces that form valleys. A stepped transition to a corresponding region of reduced height for the energy directors of the sonotrode and anvil may form a cosmetic seal region with a lesser integrity, in addition to the main barrier seal.

Abstract: Advanced ultrasonic welding components of co-pending application Ser. No. 12/925,652 are readily incorporated into new form-fill-seal machines, but owners of existing machines utilizing heat-seal stations were unsuccessful at swapping the sealing packages. Retrofit kits to a replace heat sealing station with an advanced ultrasonic sonotrode and anvil comprise: a housing; a linear rail fixed thereto; first and second bearing carriages being slidable upon the rail; and first and second fluidic muscles. Each of the fluidic muscles is mounted with a first end fixed to a respective housing wall, and a second end fixed to a respective bearing carriage, permitting actuation of each carriage through pressurization and depressurization of the muscles. The advanced anvil and sonotrode may be secured to respective carriages.

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.

Abstract: The sonotrode and anvil of copending application Ser. No. 12/925,652, for advanced ultrasonic welding of work pieces, are readily incorporated into new form-fill-seal machines, but existing machines with heat-seal stations pose difficult problems for swapping of the sealing packages. Kits enabling heat station replacement, with the further improved sonotrode and anvil disclosed herein, comprise: a housing; a linear rail fixed thereto; anvil and sonotrode support members; and a parallel gripper. Each of the anvil and sonotrode support members is slidably attached to the rail(s) and are also connected to a respective piston of the gripper, permitting actuation of each through cycling of the gripper pistons.

Abstract: The sonotrode and anvil of co-pending application Ser. No. 12/925,652, for advanced ultrasonic welding of work pieces, are readily incorporated into new form-fill-seal machines, but existing machines with heat-seal stations pose difficult problems for swapping of the sealing packages. Kits enabling heat station replacement, with the further improved sonotrode and anvil disclosed herein, comprise: a housing; a linear rail fixed thereto; anvil and sonotrode support members; and a parallel gripper. Each of the anvil and sonotrode support members is slidably attached to the rail(s) and are also connected to a respective piston of the gripper, permitting actuation of each through cycling of the gripper pistons.

Abstract: Advanced ultrasonic welding components of co-pending application Ser. No. 12/925,652 are readily incorporated into new form-fill-seal machines, but owners of existing machines utilizing heat-seal stations were unsuccessful at swapping the sealing packages. Retrofit kits to a replace heat sealing station with an advanced ultrasonic sonotrode and anvil comprise: a housing; a linear rail fixed thereto; first and second bearing carriages being slidable upon the rail; and first and second fluidic muscles. Each of the fluidic muscles is mounted with a first end fixed to a respective housing wall, and a second end fixed to a respective bearing carriage, permitting actuation of each carriage through pressurization and depressurization of the muscles. The advanced anvil and sonotrode may be secured to respective carriages.

Abstract: A sonotrode and anvil are adapted for ultrasonic welding of work pieces, to produce a narrower weld region that exhibits greater durability, permitting use of less material per package. The horn-to-anvil contact is through a plurality of energy directors arranged into a three-dimensional grid pattern to be capable of distributed vibration-transmissive contact. The energy directors include a series of plateau surfaces regularly spaced apart in a first direction, and in a second direction that is orthogonal to the first direction, to form the grid pattern. The energy directors of the horn are configured to interlock with the energy directors of the anvil. The rectangular-shaped plateaus are spaced apart by angled side-surfaces that form valleys. A stepped transition to a corresponding region of reduced height for the energy directors of the sonotrode and anvil may form a cosmetic seal region with a lesser integrity, in addition to the main barrier seal.

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.

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.

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.

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.

Abstract: A sonotrode and anvil are adapted for ultrasonic welding of work pieces, to produce a narrower weld region that exhibits greater durability, permitting use of less material per package. The horn-to-anvil contact is through a plurality of energy directors arranged into a three-dimensional grid pattern to be capable of distributed vibration-transmissive contact. The energy directors include a series of plateau surfaces regularly spaced apart in a first direction, and in a second direction that is orthogonal to the first direction, to form the grid pattern. The energy directors of the horn are configured to interlock with the energy directors of the anvil. The rectangular-shaped plateaus are spaced apart by angled side-surfaces that form valleys. A stepped transition to a corresponding region of reduced height for the energy directors of the sonotrode and anvil may form a cosmetic seal region with a lesser integrity, in addition to the main barrier seal.