System for enhancing sonotrode performance in ultrasonic additive manufacturing applications

1. An ultrasonic welding assembly, comprising:

(a) a sonotrode, wherein the sonotrode further includes a single welding region and two nodal regions formed on either side of the welding region;

(b) a mounting plate for supporting the sonotrode, wherein the mounting place further includes a force application region on the upper surface thereof;

(c) at least one ultrasonic transducer connected to the sonotrode;

(d) at least one diaphragm spring disposed between the ultrasonic transducer and the sonotrode;

(e) at least one roller bearing connected to the diaphragm spring;

(f) at least two linear guides connected to the roller bearing, wherein the at least two linear guides are connected to the mounting plate and support the roller bearing and the sonotrode in a flexible manner; and

(g) first and second low-friction linear bearings in contact with nodal regions on either side of the welding region of the sonotrode for the application of force thereto, wherein the first and second linear bearings are connected to the mounting plate.

2. The assembly of claim 1 , further comprising a brush mount unit connected to the ultrasonic transducer, wherein the brush mount unit is also connected to the mounting plate.

3. The assembly of claim 1 , further comprising a spring clamp plate connected to one side of the diaphragm spring and a diaphragm spring mount connected to the other side of the diaphragm spring.

4. The assembly of claim 1 , further comprising a retaining ring mounted between the roller bearing and the ultrasonic transducer.

5. The assembly of claim 1 , further comprising a support ring, wherein the support ring encircles the roller bearing, and wherein the support ring is connected to the mounting plate.

6. The assembly of claim 5 , further comprising a biasing member mounted between the support ring and each linear guide.

7. The assembly of claim 1 , further including a bearing support housing disposed between each linear bearing and the mounting plate and connected to the mounting plate.

8. An ultrasonic welding device, comprising

(a) a sonotrode, wherein the sonotrode further includes a single welding region and two nodal regions formed on either side of the welding region;

(b) a mounting plate for supporting the sonotrode, wherein the mounting place further includes a force application region on the upper surface thereof;

(c) two ultrasonic transducers connected to the sonotrode, one on each side thereof;

(d) at least one diaphragm spring disposed between each ultrasonic transducer and the sonotrode;

(e) at least one roller bearing connected to each diaphragm spring;

(f) at least two linear guides connected to each roller bearing, wherein the at least two linear guides are connected to the mounting plate and support each roller bearing and the sonotrode in a flexible manner; and

(g) first and second low-friction linear bearings in contact with nodal regions on either side of the welding region of the sonotrode for the application of force thereto, wherein the first and second linear bearings are connected to the mounting plate.

9. The device of claim 8 , further comprising a brush mount unit connected to each ultrasonic transducer, wherein each brush mount unit is also connected to the mounting plate.

10. The device of claim 8 , further comprising a spring clamp plate connected to one side of each diaphragm spring and a diaphragm spring mount connected to the other side of each diaphragm spring.

11. The device of claim 8 , further comprising a retaining ring mounted between each roller bearing and each ultrasonic transducer.

12. The device of claim 8 , further comprising a support ring, wherein the support ring encircles the roller bearing, and wherein the support ring is connected to the mounting plate.

13. The device of claim 12 , further comprising a biasing member mounted between the support ring and each linear guide.

14. The device of claim 8 , further including a bearing support housing disposed between each linear bearing and the mounting plate.

15. An ultrasonic welding device for use in ultrasonic additive manufacturing, comprising

(a) a sonotrode, wherein the sonotrode further includes a single welding region and two nodal regions formed on either side of the welding region;

(b) a mounting plate for supporting the sonotrode, wherein the mounting place further includes a force application region on the upper surface thereof;

(c) two ultrasonic transducers connected to the sonotrode, one on each side thereof;

(d) at least one diaphragm spring disposed between each ultrasonic transducer and the sonotrode;

(e) at least one roller bearing connected to each diaphragm spring;

(f) at least two linear guides connected to each roller bearing, wherein the at least two linear guides are connected to the mounting plate and support each roller bearing and the sonotrode in a flexible manner;

(g) first and second linear bearings in contact with nodal regions on either side of the welding region of the sonotrode for the application of downward force thereto, wherein the first and second linear bearings are connected to the mounting plate; and

(h) a brush mount unit connected to each ultrasonic transducer, wherein each brush mount unit is also connected to the mounting plate.

16. The device of claim 15 , further comprising a brush mount unit connected to each ultrasonic transducer, wherein each brush mount unit is also connected to the mounting plate.

17. The device of claim 15 , further comprising a spring clamp plate connected to one side of each diaphragm spring and a diaphragm spring mount connected to the other side of each diaphragm spring.

18. The device of claim 15 , further comprising a retaining ring mounted between each roller bearing and each ultrasonic transducer.

19. The device of claim 15 , further comprising a support ring, wherein the support ring encircles the roller bearing, and wherein the support ring is connected to the mounting plate.

20. The device of claim 19 , further comprising a biasing member mounted between the support ring and each linear guide.