Abstract: A copper or aluminum tube is cut and sealed in an ultrasonic tube sealer. A section of the tube is placed laterally in a V-shaped recess of a center member of a forming tool of an anvil of the ultrasonic tube sealer. The anvil and a horn tip are brought together with the center member received in a channel of a forming tool of the horn tip to cut the tube with the cut tube having cut ends on opposed sides of the center member. At least one of the cut ends is pinched together between the forming tool of the anvil and the forming tool of the ultrasonic horn tip and the ultrasonic horn is ultrasonically vibrated to ultrasonically weld the at least one cut end together to seal that cut end.

Abstract: Tooling for an ultrasonic tube sealer includes an ultrasonic horn tip and an anvil. The ultrasonic horn tip and the anvil each have at least one forming tool. The forming tools have a configuration that form an end of a tube when it is sealed by the ultrasonic tube sealer to be rounded.

Abstract: An ultrasonic horn tip for an ultrasonic horn of an ultrasonic tube sealer has a body with a plurality of sides. At least one of the sides has a pair of spaced apart weld tools configured to contact a portion of a tube being sealed in at least two places along the tube that are spaced from each other when the pair of weld tools contact the tube. An anvil for an ultrasonic tube sealer includes a body having a pair of spaced apart weld pads configured to contact a portion of a tube being sealed in at two places along the tube that are spaced from each other when the anvil contact the tube. A tooling kit for an ultrasonic tube sealer includes the foregoing ultrasonic horn tip and anvil.

Abstract: Tooling for an ultrasonic tube sealer includes an ultrasonic horn tip and an anvil. The ultrasonic horn tip and the anvil each have at least one forming tool. The forming tools have a configuration that form an end of a tube when it is sealed by the ultrasonic tube sealer to be rounded.

Abstract: Disks stuck together in a stack are separated by placing the disks on a shaft of a vibratory apparatus and vibrating the shaft to vibrate the disks by contact of the disks with the vibrating shaft to separate them and also constrain the disks with the shaft as the disks are vibrated.

Abstract: An ultrasonic collet horn for an ultrasonic welder has a body and a collet over which a replaceable horn tip is receivable. The collet has a plurality of axial slits therein that divide the collet into sections and a tapered axially extending bore that tapers outwardly as it extends axially outwardly. The body has a threaded bore that is threadably engageable with a threaded inner section of a collet lock. The sections of the collet are forced outwardly against an inner wall of the horn tip when the horn tip is received on the collet and the collet lock tightened into the threaded bore to secure the horn tip on the collet.

Abstract: Multi-stranded wires are clamped between an ultrasonic welding tip and an opposing anvil. The multi-stranded wires are made of a material that is more malleable than copper, or of a material that has a malleability that is substantially the same or greater than the malleability of aluminum. The plurality of multi-stranded wires can be clamped between opposing side surfaces to further form the wire bundle. Ultrasonic energy is applied to a first side of the wire bundle adjacent the ultrasonic welding tip. After termination of ultrasonic energy to the first side, the wire bundle is rotated 180 degrees relative to the anvil and ultrasonic energy is applied to a second side of the wire bundle, wherein the second side is oppositely disposed relative to the first side.

Abstract: An ultrasonic collet horn for an ultrasonic welder has a body and a collet over which a replaceable horn tip is receivable. The collet has a plurality of axial slits therein that divide the collet into sections and a tapered axially extending bore that tapers outwardly as it extends axially outwardly. The body has a threaded bore that is threadably engageable with a threaded inner section of a collet lock. The sections of the collet are forced outwardly against an inner wall of the horn tip when the horn tip is received on the collet and the collet lock tightened into the threaded bore to secure the horn tip on the collet.

Abstract: Disks stuck together in a stack are separated by placing the disks on a shaft of a vibratory apparatus and vibrating the shaft to vibrate the disks by contact of the disks with the vibrating shaft to separate them and also constrain the disks with the shaft as the disks are vibrated.

Abstract: Parts stuck together in a stack are separated by placing the parts in a vibratory apparatus and vibrating the stack of parts with a vibratory head of the vibratory apparatus to separate them and also constrain the parts with the vibratory head as the parts are vibrated.

Abstract: Parts stuck together in a stack are separated by placing the parts in a vibratory apparatus and vibrating the stack of parts with a vibratory head of the vibratory apparatus to separate them and also constrain the parts with the vibratory head as the parts are vibrated.

Abstract: An ergonomic horn for use in an ultrasonic welder having a base structure defining a first longitudinal axis, where the base structuring is connectable to the ultrasonic welder, and a tip mounting head defining a second longitudinal axis. The second longitudinal axis is angled relative to the first longitudinal axis to permit an ergonomic positioning of the item to be welded. The tip mounting head is operable to support a removable ultrasonic welding tip member. The ergonomic horn further having a reduced thickness neck portion interconnecting the base structure and the tip mounting head, such that the base structure, tip mounting head, and reduced thickness neck portion together transmit ultrasonic energy in the range of approximately 10 kHz to approximately 60 kHz for ultrasonic welding.

Abstract: An ergonomic horn for use in an ultrasonic welder having a base structure defining a first longitudinal axis, where the base structuring is connectable to the ultrasonic welder, and a tip mounting head defining a second longitudinal axis. The second longitudinal axis is angled relative to the first longitudinal axis to permit an ergonomic positioning of the item to be welded. The tip mounting head is operable to support a removable ultrasonic welding tip member. The ergonomic horn further having a reduced thickness neck portion interconnecting the base structure and the tip mounting head, such that the base structure, tip mounting head, and reduced thickness neck portion together transmit ultrasonic energy in the range of approximately 10 kHz to approximately 60 kHz for ultrasonic welding.

Abstract: An apparatus and method for ultrasonically welding wires includes an ultrasonic horn tip and associated structure for allowing adjustment to accommodate different diameters of wires to be welded while maintaining a tight grip around the wires during the welding process to avoid spreading or splaying of the wires. The tip is rotable to provide several alternative and interchangeable work surfaces on a standard-shaped readily machineable cross section, thereby allowing for a longer total worklife and a reduced cost of manufacture.

Abstract: The invention relates to an apparatus and method for ultrasonically welding a conductor wire to an electrical terminal. The terminal has a channel portion for receiving the conductor wire. The electrical terminal with the wire therein is confined adjacent the welding tip whereby movement of the welding tip into the channel portion presses the conductor wire against the electrical terminal and welds it thereto.

Abstract: Apparatus is provided for ultrasonic welding of wires which include a welding tip of a standard shaped readily machineable cross section with no concave surfaces. The welding tip is rotatable about an ultrasonic horn to present several alternative available worksurfaces. The worksurface in use defines a wall of the compression chamber into which wires to be welded are inserted. An anvil, a support, and a gathering tool each define an additional surface of the compression chamber. The position of each of these elements is adjustable thereby allowing for adjustment in two dimensions of the cross section of the compression chamber. This allows for the welding of various sizes or numbers of wires.

Abstract: Apparatus for ultrasonic welding of wires including a hand-held housing with an ultrasonic wave generator, a welding tip connected to said generator, an anvil for clamping the wires to be welded to said welding tip, and a tool for gathering wires disposed between said anvil and welding tips to prevent the wires from splaying during weldment.