Ultrasonic horn assembly with fused stack components
First Claim
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1. An ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the horn assembly comprising:
- a first stack component having at least one transfer face, wherein the first stack component is metal and is selected from the group consisting of an ultrasonic horn, an ultrasonic energy booster, and an ultrasonic energy converter;
a second stack component having at least one transfer fate adapted to engage the transfer face of the first stack component at an interface for transmitting ultrasonic energy from one of the first and second stack components to the other, wherein the second stack component is metal and is selected from the group consisting of an ultrasonic horn, an ultrasonic energy booster, and an ultrasonic energy converter, and wherein the first and second stack components are not the same component; and
a fusion zone at the interface integrally connecting the first and second stack components together, wherein the fusion zone comprises metallic fusion of the first stack component to the second stack component.
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Abstract
An ultrasonic horn assembly for applying ultrasonic energy at an operating location which assembly includes a metallic fusion zone at an interface between adjacent horn assembly components. A method of manufacturing an ultrasonic horn assembly including forming this metallic fusion zone.
367 Citations
27 Claims
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1. An ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the horn assembly comprising:
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a first stack component having at least one transfer face, wherein the first stack component is metal and is selected from the group consisting of an ultrasonic horn, an ultrasonic energy booster, and an ultrasonic energy converter;
a second stack component having at least one transfer fate adapted to engage the transfer face of the first stack component at an interface for transmitting ultrasonic energy from one of the first and second stack components to the other, wherein the second stack component is metal and is selected from the group consisting of an ultrasonic horn, an ultrasonic energy booster, and an ultrasonic energy converter, and wherein the first and second stack components are not the same component; and
a fusion zone at the interface integrally connecting the first and second stack components together, wherein the fusion zone comprises metallic fusion of the first stack component to the second stack component. - View Dependent Claims (3, 7, 8, 9)
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2. An ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the horn assembly comprising
a first stack component having at least one transfer face, wherein the first stack component is metal; -
a second stack component distinct from the first stack component, the second stack component having at least one transfer face adapted to engage the transfer face of the first stack component at an interface for transmitting ultrasonic energy from one of the first and second stack components to the other, wherein the second stack component is metal;
a fusion zone at the interface integrally connecting the first and second stack components together, wherein the fusion zone comprises metallic fusion of the first stack component to the second stack component; and
a connector adapted to connect the first and second stack components together with their transfer faces in engagement, the connector extending through the fusion zone.
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4. An ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the horn assembly comprising
a first stack component having at least one transfer face, wherein the first stack component is metal; -
a second stack component distinct from the first stack component, the second stack component having at least one transfer face adapted to engage the transfer face of the first stack component at an interface for transmitting ultrasonic energy from one of the first and second stack components to the other, wherein the second stack component is metal;
a fusion zone at the interface integrally connecting the first and second stack components together, wherein the fusion zone comprises metallic fusion of the first stack component to the second stack component; and
wherein the first stack component is an ultrasonic horn and the second stack component in an ultrasonic energy booster. - View Dependent Claims (5, 6, 27)
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10. An ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the horn assembly comprising:
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a first stack component selected from the group consisting of an ultrasonic energy booster and an ultrasonic energy converter, wherein the first stack component is metal;
an isolation ring shell for mounting the first component to a mounting housing and supporting the stack component in suspension, wherein the isolation ring shell is distinct from the first stack component and is connected to the first stack component at an interface; and
a fusion zone at the interface integrally connecting the isolation ring shell and the first stack component together, wherein the fusion zone comprises metallic fusion of the isolation ring shell to the first stack component. - View Dependent Claims (11, 12, 13, 14, 15)
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16. A method for manufacturing an ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the method comprising:
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engaging a transfer face of a first stack component with a transfer face of a second stack component to define an interface between the stack components, wherein the first and second stack components are metal and are selected from the group consisting of an ultrasonic horn, an ultrasonic energy booster, and an ultrasonic energy converter, and wherein the first and second stack components are not the same component; and
metallurgically fusing the transfer face of the first stack component with the transfer face of a second stack component to form a fusion zone at the interface between the stack components. - View Dependent Claims (17, 18, 19)
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20. A method for manufacturing an ultrasonic horn assemble for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the method comprising:
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engaging a transfer face of a first stack component with a transfer face of a second stack component to define an interface between the stack components; and
metallurguically fusing the transfer face of the first stack component with the transfer face of a second stack component to form a fusion zone at the interface between the stack components, wherein the metallurgically fusing comprises hot isostatic pressing. - View Dependent Claims (21, 22, 23, 24)
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25. A method for manufacturing an ultrasonic horn assembly for transporting ultrasonic energy to an operating location to apply the ultrasonic energy to at least one article at the operating location, the method comprising:
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fitting an isolation ring shell onto a component of the ultrasonic horn assembly, which isolation ring shell is adapted for mounting the ultrasonic horn assembly component to a mounting housing and supporting the component in suspension, such that a surface of the isolation ring shell engages a surface of the component at an interface, wherein the ultrasonic horn assembly component is metal and is selected from the group consisting of an ultrasonic energy booster and an ultrasonic energy converter; and
metallurgically fusing the isolation ring shell to the component to form a fusion zone at the interface. - View Dependent Claims (26)
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Specification