A method is described for welding a splice by way of an ultrasonic welding device, the ultrasonic welding device having a sonotrode for generating ultrasonic vibrations, an anvil, a first lateral element, a second lateral element and a compaction chamber, the height of which is adjustable by varying a distance between the sonotrode and the anvil and the width of which is adjustable by varying a distance between the first lateral element and the second lateral element.

A welding device may include a frame, a welding assembly, a fastening bracket, a protective pressure plate, a first drive mechanism, and a second drive mechanism; the welding assembly may include a first welding head and a second welding head that are arranged opposite each other, and the first welding head may be fastened on the frame; the fastening bracket may be movably provided on the frame, and the second welding head may be fastened on the fastening bracket; the protective pressure plate may be fastened on the fastening bracket or the second welding head; and the first drive mechanism may be drivingly connected to the fastening bracket and configured to drive the fastening bracket so that the second welding head may reach a position of a welding point and the protective pressure plate may press against a to-be-welded member.

An ultrasonic welding system is provided. The ultrasonic welding system includes a support structure for supporting a workpiece. The ultrasonic welding system also includes a weld head assembly including an ultrasonic converter carrying a sonotrode. The ultrasonic welding system also includes a z-axis motion system carrying the weld head assembly. The z-axis motion system includes (i) a z-axis forcer for moving the weld head assembly along a z-axis of the ultrasonic welding system, and (ii) a z-axis overtravel mechanism disposed between the z-axis forcer and the weld head assembly.

A sonotrode includes multiple layers of a material melted to one another to form a structure. The structure provides a base that has an attachment feature that is configured to operatively secure to an ultrasonic converter. The structure includes a shaft that extends from the base to a terminal end that provides a working surface that is configured to selectively engage a workpiece.

Described is a ultrasonic welding of laminates, more particular to the use of ultrasonic energy to create stable perforations in a laminate, in particular a laminate that includes a silicone gel. Specifically, a perforation element is provided, that is optionally part of array of perforation elements, which perforation element or array of perforation elements is advantageously used in an ultrasonic welding device and in a process for continuously introducing perforations into a laminate.

A capillary guide device 40 includes: a guide body portion 41 capable of being in contact with a capillary 8 held in a hole 7h; and a drive portion 42 which arranges the guide body portion 41 at a position capable of being in contact with the capillary 8 by moving the guide body portion 41 along an X-axis direction. The drive portion 42 includes: a table 46 connected to the guide body portion 41; a drive shaft 47b extending in the X-axis direction and exhibiting a frictional resistance force with the table 46; and an ultrasonic element 47a fixed to an end of the drive shaft 47b and supplying an ultrasonic wave to the drive shaft 47b.

A capillary guide device (40) includes: a guide body portion (41) capable of being in contact with a capillary (8) held in a hole (7h); and a drive portion (42) which arranges the guide body portion (41) at a position capable of being in contact with the capillary (8) by moving the guide body portion (41) along an X-axis direction. The drive portion (42) includes: a table (46) connected to the guide body portion (41); a drive shaft (47b) extending in the X-axis direction and exhibiting a frictional resistance force with the table (46); and an ultrasonic element (47a) fixed to an end of the drive shaft (47b) and supplying an ultrasonic wave to the drive shaft (47b).

An ultrasonic welding assembly comprising a sonotrode having a first body portion, a first nodal region, a welding region, a second nodal region, and a second body portion; a transducer rotationally connected to the second body portion for transmitting acoustic vibrations to the welding region; a roller device connected to the transducer and sonotrode for permitting axial rotation of the transducer and sonotrode; a support device flexibly connected to the roller device for maintaining axial alignment of the transducer and sonotrode relative to a target welding area; a mount for supporting the sonotrode; and four frictionless bearings positioned around the nodal regions of the sonotrode, wherein the frictionless bearings are attached to the mount.

A method performed during a run-in-hole process for a casing section includes applying pressure to a cable against an outer portion of the casing section. Additionally, the method includes ultrasonic welding the cable to the outer portion of the casing section while the pressure is applied to the cable against the outer portion of the casing section.

An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.