Abstract: An ultrasonic weld/seal-cut system having an ultrasonic cutting horn with a flat ultrasonic booster to provide increased stiffness to the ultrasonic cutting horn (sonotrode) and allowing for wider cutting applications while minimizing deflections of the cutting horn under force. The flat booster has a small footprint but provides high stiffness to the cutting horn. The cutting horn and booster can be a unitary piece and can be manufactured, for example, by machining a solid plate of metal into the cutting horn with integrated booster.

Abstract: An ultrasonic weld/seal-cut system having an ultrasonic cut stack assembly, including an ultrasonic cutting horn with a transducer arranged to impart an ultrasonic energy to the ultrasonic cutting horn (sonotrode) and allow for wider cutting applications while minimizing deflections of the cutting horn under force. The cutting horn has a cutting feature configured to contact a part to be cut and a major surface adjacent to the cutting feature and a booster. The booster can have a generally flat shape and a major surface that is generally coplanar with the major surface of the ultrasonic cutting horn. One or more controllers can be operatively coupled to the ultrasonic cut stack assembly and configured to apply ultrasonic energy through the ultrasonic cut horn via the transducer to cause the cutting feature to move back and forth along its length as the ultrasonic energy is applied by the transducer to the cutting horn.

Abstract: An ultrasonic weld/seal-cut system having an ultrasonic cutting horn with a flat ultrasonic booster to provide increased stiffness to the ultrasonic cutting horn (sonotrode) and allowing for wider cutting applications while minimizing deflections of the cutting horn under force. The flat booster has a small footprint but provides high stiffness to the cutting horn. The cutting horn and booster can be a unitary piece and can be manufactured, for example, by machining a solid plate of metal into the cutting horn with integrated booster.

Abstract: An ultrasonic welding system having an ultrasonic horn with a flat ultrasonic booster to provide increased stiffness to the ultrasonic horn (sonotrode) and allowing for wider welding surface applications while minimizing deflections of the horn under force. The flat booster has a small footprint but provides high stiffness to the horn. The horn and booster can be a unitary piece and can be manufactured, for example, by machining a solid plate of metal into the horn with integrated booster. Optional internal compliant tabs can be attached to side plates to enhance stiffness along a vertical direction (orthogonal to a direction of the back and forth movement of the part-interfacing surface(s) of the horn), while allowing a scrubbing back and forth motion along the ultrasonic-energy-imparting surface(s) of the horn. An optional cut-and-seal feature on the horn or anvil or both is also disclosed.

Abstract: Ultrasonic transducer coupling adapters, ultrasonic transducer assemblies with an adapter, and methods for making and for using ultrasonic transducer adapter components are disclosed. An ultrasonic transducer assembly is disclosed for generating and transmitting ultrasonic energy to a work piece (e.g., non-resonant structures). The assembly includes piezoelectric actuators that generate ultrasonic vibrations in response to high-frequency electrical signals. A feedback system monitors and regulates voltages applied to the piezoelectric actuators. The assembly also includes an adapter that is connected to the piezoelectric actuators (e.g., via a front mass) and is configured to distribute the ultrasonic vibrations from the actuators to the work piece. The adapter reduces or substantially eliminates transmission back to the piezoelectric actuators of erratic strain generated by the work piece in response to these ultrasonic vibrations.

Abstract: Ultrasonic transducer coupling adapters, ultrasonic transducer assemblies with an adapter, and methods for making and for using ultrasonic transducer adapter components are disclosed. An ultrasonic transducer assembly is disclosed for generating and transmitting ultrasonic energy to a work piece (e.g., non-resonant structures). The assembly includes piezoelectric actuators that generate ultrasonic vibrations in response to high-frequency electrical signals. A feedback system monitors and regulates voltages applied to the piezoelectric actuators. The assembly also includes an adapter that is connected to the piezoelectric actuators (e.g., via a front mass) and is configured to distribute the ultrasonic vibrations from the actuators to the work piece. The adapter reduces or substantially eliminates transmission back to the piezoelectric actuators of erratic strain generated by the work piece in response to these ultrasonic vibrations.