An ultrasonic systems and methods for sealing complex interfaces or for metal forming. Complex interfaces, such as a Gable top, have multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. An example system includes two ultrasonic horns arranged opposite a gap between which the interface is provided. The frequency and phase of the ultrasonic energy are synchronized as the energy is applied simultaneously while the interface is pressed between a jaw and the energy is applied to both sides of the interface. Another example system includes two ultrasonic transducers synchronized in frequency and phase and used to vibrate a horn mechanically to facilitate a sealing or welding interface or to assist in a metal-forming process.

An ultrasonic welding system. The system includes an ultrasonic transducer assembly having a horn and a first transducer and a second transducer arranged to impart ultrasonic energy into the horn. The horn has a first part-interfacing surface and a second part-interfacing surface opposite the first part-interfacing surface. An actuator assembly is operatively coupled to the ultrasonic transducer assembly and configured to cause rotation of the horn. A controller is configured to: cause the actuator assembly to rotate the horn so that the first part-interfacing surface applies the ultrasonic energy to a first part along an entire length of the first part-interface surface while a first ultrasonic energy is applied through the horn via the first transducer to cause the first part-interfacing surface to vibrate back and forth along its entire length as the first ultrasonic energy is applied by the first transducer to the horn.

In a welded film laminate 1, a second protective layer 14 of a first film substrate 2 and a third protective layer 22 of a second film substrate 3 are welded and fixed to each other by an adhesive layer melted out from at least one of a first adhesive layer 11 to a fourth adhesive layer 27 via a first melted penetration portion 6a of the second protective layer 14 and/or a second melted penetration portion 6b of the third protective layer 22. A welding fixed portion 6c is surrounded in a plan view by a first welded portion 33 in which the first adhesive layer 11 and a second adhesive layer 15 of the first film substrate 2 are welded to each other and/or a second welded portion 35 in which a third adhesive layer 23 and the fourth adhesive layer 27 of the second film substrate 3 are welded to each other.

A bag contains polysilicon, has been welded and includes at least one weld seam and a polyethylene film having: a thickness of 150-900 μm; a stiffness at a flexural modulus F.sub.max of 300-2000 mN and F.sub.t of 100-1300 mN; a fracture force F determined by dynamic penetration testing of 200-1500 N; a fracture energy Ws of 2-30 J; a penetration energy W.sub.tot of 2.2-30 J; a film tensile stress at 15% longitudinal and transverse elongation of 9-50 MPa; an Elmendorf longitudinal film tear resistance of 10-60 cN; an Elmendorf transverse film tear resistance of 18-60 cN; a longitudinal film elongation at break of 300-2000%; a transverse film elongation at break of 450-3000%; and a weld seam strength of 25-150 N/15 mm. A method includes filling a bag with polysilicon, and welding by pulse sealing with contact pressure greater than 0.01 N/mm.sup.2 to obtain a 25-150 N/15 mm weld seam strength.

A moveable seam welding machine, system, and method of use is provided. The seam welding machine includes at least one sensor that generates at least one data point having geolocation coordinates incorporated or integrally formed therewith. The data point typically relates to the integrity or quality of the welded seam created by the machine. The sensor generates data points which may be evaluated in alarm logic for abnormalities or anomalies. The geolocation coordinates inherent or integral to the data point may be plotted or registered overtop satellite imagery. The coordinates of the anomalies or the registered image, or both, can be provided to the workman or operator so he/she may manually inspect the geolocation at where the abnormal or anomaly data point was generated by the sensor to spot check the welded seam by hand.

A moveable seam welding machine, system, and method of use is provided. The seam welding machine includes at least one sensor that generates at least one data point having geolocation coordinates incorporated or integrally formed therewith. The data point typically relates to the integrity or quality of the welded seam created by the machine. The sensor generates data points which may be evaluated in alarm logic for abnormalities or anomalies. The geolocation coordinates inherent or integral to the data point may be plotted or registered overtop satellite imagery. The coordinates of the anomalies or the registered image, or both, can be provided to the workman or operator so he/she may manually inspect the geolocation at where the abnormal or anomaly data point was generated by the sensor to spot check the welded seam by hand.

A simplified method for making an impermeable joining on three-layer or bi-layer fabric materials, either with or without a complex construction on a joining side thereof, and being preliminarily joined by a stitching or ultrasound joining arrangement, wherein the method comprises only two method steps, a first joining step of joining two fabric material panels and a second impermeabilizing step carried out by cauterizing and sealing a strip element, and being performed by a single machine in a single operation thereof.

A system using a pressure differential to clamp welding heads on opposite sides of a joint of a thermoplastic composite structure to be welded. The heads are positioned over the joint opposite each other. Each head includes a housing defining a chamber having a lower pressure such that the pressure differential forces the head against the side. Each head includes a contour plate located in the space and against the joint, and at least one of the heads includes a heater located in the space and heating the contour plate to a welding temperature. The system may also include a first arm coupled with one of the heads and moving it along the joint so as to remain aligned with the other head, and a second arm coupled with the other head and moving it along the joint while the system welds the joint in successive overlapping sections.

An ultrasonic welding system. The system includes an ultrasonic transducer assembly having a horn and a first transducer and a second transducer arranged to impart ultrasonic energy into the horn. The horn has a first part-interfacing surface and a second part-interfacing surface opposite the first part-interfacing surface. An actuator assembly is operatively coupled to the ultrasonic transducer assembly and configured to cause rotation of the horn. A controller is configured to: cause the actuator assembly to rotate the horn so that the first part-interfacing surface applies the ultrasonic energy to a first part along an entire length of the first part-interface surface while a first ultrasonic energy is applied through the horn via the first transducer to cause the first part-interfacing surface to vibrate back and forth along its entire length as the first ultrasonic energy is applied by the first transducer to the horn.

Molded pulp containers with fused junctions and methods of making of same are provided. The present invention provides a pulp container, comprising a molded pulp body, wherein the body comprising a bottom and at least one side wall forming a wherein the at least one side wall comprising a upper rim, a neck, wherein the neck comprising a upper closure part and a lower rim, a fused junction, wherein a part of the upper rim of the at least one sidewall of the body and a part of the lower rim of the neck are aligned and fused together. The fused junction may be formed by ultrasonic welding.