Abstract: An ultrasonic horn includes a generally cylindrical input section having an energy input end, a generally cylindrical output section having an energy output end, and a throat section disposed between the input section and the output section, the throat section being defined by a side wall having a continuous curve and having a diameter tapering down from a diameter generally equal to a diameter of the input section on a side connected to the input section, and tapering down from a diameter generally equal to a diameter of the output section on a side connected to the output section, to a minimum throat diameter. The minimum throat diameter is smaller than the diameter of the output section and the diameter of the output section is smaller than the diameter of the input section. The side wall of the throat section has a constant radius of curvature.

Abstract: An ultrasonic block horn includes a generally cylindrical block of material having a first generally circular planar end surface, a second generally circular planar end surface and a generally circular circumferential side surface extending between the first and second generally planar end surfaces. A first plurality of through holes are formed in the generally cylindrical block of material, each of the first plurality of through holes extending from a first opening in the circumferential side surface to a second opening in the circumferential side surface, and each of the first plurality of through holes being generally parallel with, and spaced apart from, each other of the first plurality of through holes.

Abstract: A sealing tool includes an anvil and a horn, at least one of which includes a sealing surface having a gusset sealing section and a zipper sealing section, each configured differently than the other. The gusset sealing section includes a plurality of sealing beads including a gusset section barrier sealing bead having a first height and a protective sealing bead having a second height, the second height being smaller than the first height. The zipper sealing section includes a zipper section barrier sealing bead extending and a tapered section adjacent to the zipper section sealing bead, the tapered section tapering from a larger height adjacent to the zipper section sealing bead to a smaller height as a distance away from the zipper section sealing bead increases.

Abstract: An ultrasonic sealing device, including a horn having a sealing surface, an anvil having a sealing surface, at least one of the horn and the anvil being moveable to engage the respective sealing surfaces, the sealing surfaces of the horn and the anvil including a plurality of protrusions and a recess between each of the protrusions, each of the protrusions having a distal surface and sloped sidewalls with curved edges therebetween and each of the recesses including a recess surface with curved edges, wherein, upon engagement of the sealing surface of the horn with the sealing surface of the anvil, the distal surfaces of each of the protrusions on each of the sealing surfaces engage corresponding ones of the recess surfaces of each of the recesses on each of the sealing surfaces and define gaps between the sidewalls of each adjacent protrusion.

Abstract: An ultrasonic sealing device, including a horn having a sealing surface, an anvil having a sealing surface, at least one of the horn and the anvil being moveable to engage the respective sealing surfaces, the sealing surfaces of the horn and the anvil including a plurality of protrusions and a recess between each of the protrusions, each of the protrusions having a flat distal surface and sloped sidewalls with curved edges therebetween and each of the recesses including a flat recess surface with curved edges, wherein, upon engagement of the sealing surface of the horn with the sealing surface of the anvil, the flat distal surfaces of each of the protrusions on each of the sealing surfaces engage corresponding ones of the flat recess surfaces of each of the recesses on each of the sealing surfaces and define gaps between the sloped sidewalls of each adjacent protrusion.

Abstract: An ultrasonic welding device including a sonotrode having a central weld region adjacent to an anvil, a first converter providing mechanical vibrations to a proximal end of the sonotrode, a second converter providing mechanical vibrations to a distal end of the sonotrode in a direction opposite to the first converter, a power supply delivering electrical energy to each of the first and second converters, and the mechanical vibrations received by the sonotrode from the first converter being in phase with the mechanical vibrations received from the second converter.

Abstract: An ultrasonic sealing tool including an anvil with a sealing surface, a horn with a sealing surface facing the sealing surface of the anvil, the sealing surface of the anvil including a plurality of beads including a first bead having a first height and at least one second bead having a second height, the second height being less than the first height, the ultrasonic sealing tool delivering ultrasonic vibrations via at least one of the anvil and the horn to create a closure seal in a work piece positioned between the anvil and the horn, the closure seal including a first seal created by the first bead and at least one second seal created by the at least one second bead, the first seal having a weld depth greater than a weld depth of the at least one second seal.

Abstract: A method for testing the integrity of a stack during ultrasonic welding, includes the steps of: (i) ultrasonically welding two or more work pieces with a stack, the stack including a convertor and a horn; (ii) measuring a frequency profile based on a vibration of the horn during the welding step; and (iii) comparing the measured frequency profile to a standard frequency profile to obtain an error rate, the error rate being indicative of a difference between the measured frequency profile and the standard frequency profile. A system employing the aforementioned method is also provided.

Abstract: An ultrasonic tool having a sonotrode having a single weld region and two nodal regions formed on either side of the weld region. Two rigid mount boosters are each coupled to either side of the weld region. One transducer is coupled to one of the rigid mount boosters. Two ultrasonic stack mounting rings are each configured to be coupled to a housing assembly at a non-nodal region and coupled to one of the rigid mount boosters at a nodal region.

Abstract: A multi-element ultrasonic atomizer and method for atomizing liquids is described, having a power generator, a converter, an ultrasonic horn coupled to the converter, and at least two atomizing probes coupled to the ultrasound horn, each atomizing probe including at least one liquid passage extending longitudinally along the atomizing probe and terminating at an atomizing tip at a distal end of the atomizing probe. The atomizing probes are made to vibrate at same frequency. A liquid is delivered to an atomizing surface through the liquid passage and through an opening at the atomizing tip.

Abstract: A safety device for a press having a head for applying force, a single fixed pressure source for actuating a low force pressure driven actuator and a high force pressure driven actuator for the head, wherein the operation of the head is limited to only with the low force actuator until the head is in a safe position, when the head is determined to be in a safe position the high force actuator's use is permitted.

Abstract: A system and method for terminating a wire having an aluminum conductor includes a terminal having a conductor receiving area adapted to receive the aluminum conductor, and a welding buffer sized and shaped to fit within the conductor receiving area of the terminal with the aluminum conductor disposed between the welding buffer and the terminal. The terminal, the welding buffer and the aluminum conductor are ultrasonically welded together to form an integrated unit, such that the welding buffer forms a part of a finished terminated wire assembly.

Abstract: A system for ultrasonic sample preparation includes a sample container having a wall defining an outer surface and an inner volume for containing a sample material, a converter which converts AC electricity to mechanical vibrations in the ultrasonic range, and an ultrasonic probe in contact with the outer surface of the sample container. The ultrasonic probe is in communication with the converter and transmits the mechanical vibrations in the ultrasonic range to the wall of the sample container and thereby to the inner volume, thereby mixing the sample material.

Abstract: A system for ultrasonic assisted electrical discharge machining of a component part having a longitudinal axis, a half wavelength resonant frequency along the longitudinal axis and an attachment portion, is provided. The system includes an ultrasonic horn having a longitudinal axis, a half wavelength resonant frequency along the longitudinal axis and an attachment portion. The half wavelength resonant frequency of the ultrasonic horn is the same as the half wavelength resonant frequency of the component part. Additionally, one of the attachment portion of the component part and the attachment portion of the ultrasonic horn is a male part and the other one of the attachment portion of the component part and the attachment portion of the ultrasonic horn is a female part sized and shaped to mate and engage one another when the component part and the ultrasonic horn are at generally the same temperature.

Abstract: An ultrasonic welding assembly is disclosed. The assembly includes an ultrasonic welder having nodal horn support for improving transmission of transducer energy to the weld comprising an acoustical tool having a horn; a weld tip on the end of said horn; and at least two nodal mounts which are in contact with and axially and radially support said horn. The horn self-aligns in housing by sitting a housing-key within a keyway in the horn. The weld tip self aligns by sitting the keyed tip in a keyway of the horn.

Abstract: A system for performing an ultrasonic staking operation in order to join a first part having a post protruding therefrom and a second part having a hole through which the post is passed includes a horn having an end vibrating at a frequency in the ultrasonic range and a motion system operatively connected to the horn, the motion system being capable of selectively moving the horn toward and away from the parts. The motion system moves the horn, with the end of the horn in contact with the post, toward the parts at a first speed such that the ultrasonic vibrations of horn cause melting of the post, and once a determination is made that the end of the horn has contacted a surface of the second part, the motion system moves the horn toward the parts at a second speed, the second speed being slower than the first speed.

Abstract: A flow cell for the ultrasonic treatment of a liquid includes a housing with a wall at least partially defining a flow chamber therein. The housing includes a first liquid passage and a second liquid passage for flowing the liquid into and out of the flow chamber. An ultrasonic horn extends into the flow chamber for imparting ultrasonic energy to liquid in the flow chamber, the ultrasonic horn having an outer surface and an end surface, and having a recess formed in the end surface. A tubular member having a first end in fluid communication with a second end, is arranged such that the first end is in fluid communication with the second liquid passage, and the second end extends into the recess in the ultrasonic horn.

Abstract: These and other objects of the present invention are achieved by provision of a flow through ultrasonic system for facilitating the flow of flow-resistant materials. The system includes a supply of material and an ultrasonic horn having at least one passage extending therethrough. An isolating tube which is compatible with the material is provided passing through the at least one passage in the ultrasonic horn, the isolating tube in communication the supply of material and completely isolating the ultrasonic horn from the material. A converter imparts ultrasonic energy to the ultrasonic horn, and in turn to the isolating tube so as to inhibit the material from attaching to and clogging the isolating tube.

Abstract: A fabric having a backing layer with a lower surface, at least a portion of the backing layer adjacent the lower surface being formed from a thermoplastic material, is provided. At least the lower surface of the backing layer is heated in order to soften the lower surface of the backing layer, and a die having a surface in which are formed a plurality of recesses is forced into the softened lower surface of the backing layer in order to create a plurality of raised areas protruding from the lower surface of the backing layer. The fabric is placed on the substrate so that the raised areas protruding from the lower surface of the backing layer are in intimate pressurized contact with the substrate at an interface thereof, and a vibration or orbital welding process is performed thereon to achieve a bond therebetween.

Abstract: A method and apparatus for determining the resonance frequency for a vibration welder are described. The vibration frequencies at a predetermined vibration level and on both sides of the resonance frequency are derived and are then used to determine and operate the vibration welder at the resonance frequency. In one embodiment the vibration frequency of the vibration welder is swept up from one side of the resonance point and the vibration amplitude is monitored and a first frequency at a particular vibration amplitude is determined. The same sweeping is done from the other side of the resonance point and a second frequency determined for the same vibration amplitude reference level but on the other side of the resonance frequency. The two measured frequencies are then combined to yield the resonance frequency which can then be used to operate the vibration welder.