Abstract: A large surface area ultrasonic block horn includes one or more shaped elements having a node at a mid-point of the shaped element that is narrower than opposed ends of the shaped element.

Abstract: A large surface area ultrasonic block horn includes one or more shaped elements having a node at a mid-point of the shaped element that is narrower than opposed ends of the shaped element.

Abstract: A method of ultrasonic welding aluminum parts together includes placing the aluminum parts in an ultrasonic welding apparatus and contacting at least one of the aluminum parts with a horn tip of a weld horn of the ultrasonic welding apparatus. A weld amplitude is profiled during a weld cycle of the ultrasonic welding apparatus by producing a high weld amplitude above 55 ?m at the horn tip of the weld horn during an initial period of a weld cycle and producing a low weld amplitude below 55 ?m at the horn tip after the initial period.

Abstract: An ultrasonic rotary horn has tapered input sections for the conversion of axial acoustic energy into radial acoustic energy. The preferred rotary horn includes a first half having a first radial weld section and a first axial input section for receiving a first axial acoustic energy. The rotary horn further includes a second half coupled to the first half. The second half has a second radial weld section and a second axial input section for receiving a second axial acoustic energy. Each half has a coned section defined by an inner tapered surface and an outer tapered surface such that the halves convert a portion of the first and second axial acoustic energy into radial acoustic energy. Each inner tapered surface forms an inner angle with respect to an axis of the horn and each outer tapered surface forms an outer angle with respect to the axis.

Abstract: An ultrasonic rotary horn has tapered input sections for the conversion of axial acoustic energy into radial acoustic energy. The preferred rotary horn includes a first half having a first radial weld section and a first axial input section for receiving a first axial acoustic energy. The rotary horn further includes a second half coupled to the first half. The second half has a second radial weld section and a second axial input section for receiving a second axial acoustic energy. Each half has a coned section defined by an inner tapered surface and an outer tapered surface such that the halves convert a portion of the first and second axial acoustic energy into radial acoustic energy. Each inner tapered surface forms an inner angle with respect to an axis of the horn and each outer tapered surface forms an outer angle with respect to the axis.

Abstract: An electroacoustic converter is disclosed for converting electrical energy into mechanical vibrations at a predetermined frequency. The converter is supplied with alternating electrical power from a power supply. The converter has a metal front driver mass, a metal back driver mass, a front ceramic stack, a back ceramic stack, a spacer between said front and back ceramic stacks, and a fastener extending axially of the converter coupling the front and back drivers masses to clamp the ceramic stacks and the spacer between the front and back drivers. The front and back ceramic stacks are of a suitable piezoelectric ceramic material such that when energized with alternating electrical power from the power supply the piezoelectric material renders the converter resonant at the predetermined frequency. The spacer, back driver, and front driver masses are provided with fins to radiate heat from the converter. The converter exhibits substantially even temperatures and a vibrational node within the spacer.