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Bi-material ultrasonic horn with integral isolation memberRelated Patent Categories: Metal Fusion Bonding, Means To Apply Vibratory Solid-state Bonding Energy (e.g., Ultrasonic, Etc.) To WorkBi-material ultrasonic horn with integral isolation member description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070125829, Bi-material ultrasonic horn with integral isolation member. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF INVENTION [0001] This invention relates to an ultrasonic horn for use in manufacturing operations such as bonding, perforation, and cutting. More specifically the invention relates to an ultrasonic horn that includes an integral isolation member. [0002] Ultrasonic horns are used to distribute ultrasonic energy in a variety of industrial processes. One example involves bonding of two thermoplastic sheets of material together in the manufacture of personal care products such as diapers. [0003] Ultrasonic horn systems can have a number of distinct components, which can be connected in a stack. In one arrangement, these components may include a power excitation device known as a converter (or driver assembly), amplitude modification devices known as boosters, and an ultrasonically energized tool known as an ultrasonic horn, at least a portion of which imparts ultrasonic energy to a work piece. In addition, the ultrasonic horn can include isolation members that can be configured for mounting the horn at a work (i.e., bonding) location. [0004] Generally, horns have been manufactured by machining a final horn shape from forged bar stock, such as titanium bar stock. Alternatively, horns can be manufactured by way of machining the horn from a hot isostatically pressed preform for improved performance. [0005] Unfortunately, in certain circumstances, such horns may not always be completely satisfactory. For example, even in the case of hot isostatic pressing, machining the horn from the base piece of material can result in a certain amount of potentially costly material that must be machined into the desired shape. Moreover, since the ultrasonic horn is typically manufactured from a material that can transport or transmit ultrasonic energy in a highly efficient manner, isolation members that are also of that same material may not function completely as desired. In particular, the isolation member in such circumstances may be more susceptible to higher noise transmission and potentially undesirably heating of the mounting element that it is joined to (e.g., a bearing). [0006] Thus there is a need for an ultrasonic horn that is provided by a material that efficiently transports ultrasonic energy but yet includes an isolation member that is at least partially of a different material, suitably a material that is less efficient at transporting ultrasonic energy. In addition, there is a need for an ultrasonic horn that can be provided by a method that results in an effective ultrasonic horn but with reduced material waste. SUMMARY OF THE INVENTION [0007] In one aspect, the present invention is directed to an ultrasonic horn for transporting ultrasonic energy to an operating location defining a radial direction and an axial direction. The ultrasonic horn includes a horn member and an energy transfer surface disposed on the horn member. The ultrasonic horn also includes an axle member joined to the horn member where the axle member is provided by a first material. The ultrasonic horn further includes an isolation member integrally joined to the axle member and adapted for mounting the ultrasonic horn at a work location where at least a portion of the isolation member is provided by a second material. [0008] In another aspect, the present invention is directed to an ultrasonic horn for transporting ultrasonic energy to an operating location defining a radial direction and an axial direction. The ultrasonic horn includes a horn member, an energy transfer surface disposed on the horn member and an axle member joined to the horn member. The ultrasonic horn also includes an isolation member integrally joined to the axle member and adapted for mounting the ultrasonic horn at a work location. In addition, the axle member can be configured to transport ultrasonic energy at least 200% more efficiently than at least a portion of the isolation member. [0009] In yet another aspect, the present invention is directed to an ultrasonic horn for transporting ultrasonic energy to an operating location defining a radial direction and an axial direction. The ultrasonic horn includes a horn member, an energy transfer surface disposed on the horn member, and an axle member joined to the horn member. The ultrasonic horn also includes an isolation member integrally joined to the axle member adapted for mounting the ultrasonic horn at a work location wherein at least a portion of the isolation member is acoustically decoupled from the axle member. [0010] In still yet another aspect, the present invention is directed to a method for manufacturing an ultrasonic horn. The method includes forming metal powder into a horn body perform within a preform mold and hot isostatically pressing the horn body preform to consolidate the metal powder to form a compressed horn preform shape. The compressed horn preform shape can have a uniform isotropic microstructure characterized by randomly isotropic directional grain alignment wherein at least a portion of the ultrasonic horn is provided by the preform mold. [0011] The above-mentioned and other aspects of the present invention will become more apparent, and the invention itself will be better understood by reference to the drawings and the following description of the drawings. BRIEF DESCRIPTION OF THE FIGURES [0012] FIG. 1 representatively illustrates a side view of a representative ultrasonic horn system including an ultrasonic horn of the present invention; [0013] FIG. 2 representatively illustrates a cross-section through the ultrasonic horn system of FIG. 1; [0014] FIG. 3 representatively illustrates a perspective view of another ultrasonic horn of the present invention; [0015] FIG. 4 representatively illustrates a side view of a cross-section through a mounted configuration of the ultrasonic horn of FIG. 3; and [0016] FIG. 5 representatively illustrates a cross-section of a hot isostatic press casing that can be used in connection with making the ultrasonic horn illustrated in FIG. 1. DEFINITIONS [0017] "Attach" and its derivatives refer to the joining, adhering, connecting or the like, of two elements. Two elements will be considered to be attached together when they are attached directly to one another or indirectly to one another, such as when each is directly attached to intermediate elements, or when they are integrally or non-integrally attached to each other. [0018] The terms "Bond" and "Weld" and their derivatives may be used interchangeably, and refer to the substantially permanent joining of at least one layer of a material with another layer of a like or different material. The nature of the materials to be bonded is not known to be critical. However, the present invention is particularly useful in the bonding of two or more layers of materials, such as woven fabrics, nonwoven fabrics, and films. [0019] The terms "disposed on," "disposed along," "disposed with," or "disposed toward" and variations thereof are intended to mean that one element can be integral with another element, or that one element can be a separate structure bonded to or placed with or placed near another element. [0020] The term "Fabric" is used broadly in the present disclosure to mean a sheet or web of a woven or nonwoven fibrous material. The fabric or film layer may be continuous, as in a roll, or may be discontinuous. Continue reading about Bi-material ultrasonic horn with integral isolation member... Full patent description for Bi-material ultrasonic horn with integral isolation member Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Bi-material ultrasonic horn with integral isolation member patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. 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