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: 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 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: 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: 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 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 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: An energy controller is described for a vibration welder wherein the energy imparted into work-pieces being vibration welded is derived and compared with an energy set point to control the vibration welding operation. After a vibration welding operation has encountered the energy set point the welding operation is stopped and the quality of a weld derived from a comparison with another parameter associated with the vibration welding. The other parameter can be the amount of movement of one of the work-pieces during vibration welding or the time involved to inject the energy into the work-pieces to achieve the vibration weld.

Abstract: An energy controller is described for a vibration welder wherein the energy imparted into work-pieces being vibration welded is derived and compared with an energy set point to control the vibration welding operation. After a vibration welding operation has encountered the energy set point the welding operation is stopped and the quality of a weld derived from a comparison with another parameter associated with the vibration welding. The other parameter can be the amount of movement of one of the work-pieces during vibration welding or the time involved to inject the energy into the work-pieces to achieve the vibration weld.

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.

Abstract: A control for an ultrasonic surgical instrument is described wherein a transducer having an elongate tip is vibrated to perform surgery. The amplitude of the vibrations by the tip are controlled and the power delivered to the tip can be set so that the operator of the instrument can in effect render the instrument sensitive to different tissues to avoid damage thereto and enhance the safety of the patient.