System for enhancing sonotrode performance in ultrasonic additive manufacturing applications
An ultrasonic welding assembly, comprising a sonotrode, wherein the sonotrode further includes at least one welding region and at least one node adjacent to the welding region; a mount for supporting the sonotrode, wherein the mount further includes a force application region; at least one ultrasonic transducer connected to the sonotrode for transmitting acoustic vibrations to the at least one welding region; at least one roller connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis; a device for maintaining axial alignment of the sonotrode relative to a target welding area; and a low-friction bearing in contact with the at least one node for the application of force thereto, wherein the at least one low-friction bearing is connected to the mount.
1. An ultrasonic welding assembly, comprising:
(a) a sonotrode, wherein the sonotrode further includes at least one welding region and at least one node adjacent to the welding region;
(b) a mount for supporting the sonotrode, wherein the mount further includes a force application region;
(c) at least one ultrasonic transducer connected to the sonotrode for transmitting acoustic vibrations to the at least one welding region;
(d) at least one roller connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis;
(e) a device connected to the roller for maintaining axial alignment of the sonotrode relative to a target welding area; and
(f) at least one low-friction bearing in contact with the at least one node for the application of force thereto, wherein the at least one low-friction bearing is connected to the mount.
2. The assembly of claim 1 , further including a diaphragm spring disposed between the ultrasonic transducer and the sonotrode for permitting rotation of the sonotrode about its axis.
3. The assembly of claim 1 , wherein the device for maintaining axial alignment of the sonotrode relative to a target welding area includes at least one linear guide.
4. The assembly of claim 3 , wherein the at least one roller further includes a roller bearing.
5. The assembly of claim 4 , further comprising a support ring, wherein the support ring encircles the roller bearing, and wherein the support ring is connected to the mount.
6. The assembly of claim 5 , further comprising a biasing member mounted between the support ring and the linear guide.
7. The assembly of claim 1 , wherein the mount further includes a mounting plate having a force application region on the upper surface thereof.
8. An ultrasonic welding system, comprising:
(a) a sonotrode, wherein the sonotrode further includes a welding region and at least one node adjacent to the welding region on either side thereof;
(b) a mount for supporting the sonotrode, wherein the mount further includes a force application region;
(c) at least two ultrasonic transducers connected to the sonotrode on opposite sides of the welding region for transmitting acoustic vibrations to the welding region;
(d) at least two rollers connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis;
(e) a device connected to each roller for maintaining axial alignment of the sonotrode relative to a target welding area; and
(f) a low-friction bearing in contact with each node for the application of force thereto, wherein each low-friction bearing is connected to the mount.
9. The system of claim 8 , further including a diaphragm spring disposed between each ultrasonic transducer and the sonotrode for permitting rotation of the sonotrode about its axis.
10. The system of claim 8 , wherein the device connected to each roller for maintaining axial alignment of the sonotrode relative to a target welding area includes at least one linear guide.
11. The system of claim 10 , wherein each roller further includes a roller bearing.
12. The system of claim 11 , further comprising support rings encircling each roller bearing, and wherein each support ring is connected to the mount.
13. The system of claim 12 , further comprising a biasing member mounted between each support ring and each linear guide.
14. The system of claim 8 , wherein the mount further includes a mounting plate having a force application region on the upper surface thereof.
15. An ultrasonic welding system for use in ultrasonic additive manufacturing, comprising:
(a) a sonotrode, wherein the sonotrode further includes a welding region and at least one node adjacent to the welding region on either side thereof;
(b) a mount for supporting the sonotrode, wherein the mount further includes a force application region;
(c) at least two ultrasonic transducers connected to the sonotrode on opposite sides of the welding region for transmitting acoustic vibrations to the welding region;
(d) at least two rollers connected to the sonotrode in a flexible manner for permitting rotation of the sonotrode about its axis;
(e) a device connected to each roller for maintaining axial alignment of the sonotrode relative to a target welding area, wherein the device includes at least one linear guide; and
(f) a low-friction bearing in contact with each node for the application of force thereto, wherein each low-friction bearing is connected to the mount.
16. The system of claim 15 , further including a diaphragm spring disposed between each ultrasonic transducer and the sonotrode for permitting rotation of the sonotrode about its axis.
17. The system of claim 15 , wherein each roller further includes a roller bearing.
18. The system of claim 17 , further comprising support rings encircling each roller bearing, and wherein each support ring is connected to the mount.
19. The assembly of claim 18 , further comprising a biasing member mounted between each support ring and each linear guide.
20. The assembly of claim 15 , wherein the mount further includes a mounting plate having a force application region on the upper surface thereof.