IP Library › Granted Patent US 12703004
Granted Patent B2
US 12703004 · App. 17/960,113 · Granted Aug 11, 2026

Converter for an ultrasonic welding device having increased arc resistance

Inventors: Scott Caldwell (New Milford, CT); John Maneca (Waterbury, CT); Eugene D. Pollastro (Bethel, CT)
Assignee: Branson Ultrasonics Corporation
B06B1/0611H04R17/00H04R31/006
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Quick Facts
Patent No.
US 12703004
App. No.
17/960,113
Granted
Aug 11, 2026
Kind
B2
Abstract

A converter for an ultrasonic welder includes a stack of piezoelectric disks alternately stacked with metal conductor disks in between. A pair of driver plates are disposed on opposite ends of the stack of piezoelectric disks. The piezoelectric disks include an outer perimeter surface that extends radially outward beyond the metal conductor disks. The outer perimeter surface of the piezoelectric disks can include an undulating surface.

Claims (27)

1 . A converter for an ultrasonic welder, comprising:

a stack of piezoelectric disks alternately stacked with metal conductor disks in between;

a pair of driver plates disposed on opposite ends of the stack of piezoelectric disks;

wherein the stack of piezoelectric disks include an undulating outer perimeter surface in a stacking direction of the piezoelectric disks.

2 . The converter according to claim 1 , wherein the undulating outer perimeter surface of the piezoelectric disks are rounded.

3 . The converter according to claim 1 , wherein the undulating outer perimeter surface of the piezoelectric disks undulate radially outward.

4 . The converter according to claim 1 , wherein the undulating outer perimeter surface of the piezoelectric disks undulate radially inward.

5 . The converter according to claim 1 , wherein the undulating outer perimeter surface is coated with an insulating coating.

6 . The converter according to claim 1 , wherein each of the stack of piezoelectric disks include an aperture therethrough with an undulating inner perimeter surface in the stacking direction.

7 . The converter according to claim 6 , wherein the undulating inner perimeter surface is coated with an insulating coating.

8 . A converter for an ultrasonic welder, comprising:

at least one piezoelectric disk;

a pair of driver plates disposed on opposite ends of the at least one piezoelectric disk;

wherein the at least one piezoelectric disk includes an outer perimeter surface with an arc length that is greater than a thickness of the at least one piezoelectric disk.

9 . The converter according to claim 8 , wherein at least one piezoelectric disk includes an aperture therethrough with an inner perimeter surface with an arc length that is greater than thickness of the at least one piezoelectric disk.

10 . The converter according to claim 9 , wherein the inner perimeter surface is coated with an insulating coating.

11 . The converter according to claim 9 , wherein the inner perimeter surface of the aperture in the at least one piezoelectric disk has an undulating surface in the stacking direction.

12 . The converter according to claim 8 , wherein the outer perimeter surface of the at least one piezoelectric disk has an undulating surface in a stacking direction of the at least one piezoelectric disk and the pair of driver plates.

13 . The converter according to claim 8 , wherein the outer perimeter surface is coated with an insulating coating.

14 . A method of assembling a converter for an ultrasonic welder comprises:

placing at least one piezoelectric disk between a first driver plate and a second driver plate and all within a jig, the at least one piezoelectric disk having at least one hole;

applying a liquid insulating coating inside the at least one hole of the at least one piezoelectric disk while the at least one piezoelectric disk and the first driver plate and the second driver plate are held secure by the jig; and

inserting a bolt through a hole in the first driver plate, the hole in the at least one piezoelectric disk and tightening the bolt into a threaded hole in the second driver plate to create an assembled converter, wherein the at least one piezoelectric disk has an outer perimeter surface with an arc length between the metal conductor disks that is greater than a thickness of the at least one piezoelectric disk.

15 . The method according to claim 14 , further comprising applying a liquid insulating coating to an exterior surface of the assembled converter.

16 . The method according to claim 14 , wherein the outer perimeter surface of the at least one piezoelectric disk has an undulating surface in a stacking direction of the at least one piezoelectric disk, the first driver plate and the second driver plate.

17 . The method according to claim 14 , wherein the hole in the at least one piezoelectric disk has an inner perimeter surface with an arc length that is greater than a thickness of the at least one piezoelectric disk.

18 . The method according to claim 17 , wherein the inner perimeter surface of the hole in the at least one piezoelectric disk has an undulating surface in a stacking direction of the at least one piezoelectric disk, the first driver plate and the second driver plate.