Ultrasonic horn with flat ultrasonic booster for increased stiffness

Abstract

To provide an ultrasonic welding system having an ultrasonic horn with a flat ultrasonic booster to have an increased stiffness to the ultrasonic horn and allowing for a wider welding surface application while minimizing deflections of the horn under force.SOLUTION: There is provided an ultrasonic welding system having an ultrasonic stack assembly. The system is configured in that: the flat boosters 108a and 108b have a small footprint but provide high stiffness to a horn 102; the horn and boosters can be an 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 a stiffness along a vertical direction while allowing a scrubbing back and forth motion along an ultrasonic-energy-imparting surface of the horn; and an optional cut-and-seal feature on the horn or an anvil or both is also provided.SELECTED DRAWING: Figure 1B

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