A cover layer is joined to an object by a pressing force and mechanical vibration. The cover layer has a cover layer contact surface, and the object has an object contact surface, and the cover layer contact surface and the object contact surface face each other. At least one of the cover layer and the object include a joining material. The cover layer contact surface is brought into contact with the object contact surface, and a sonotrode presses the cover layer against the object and applies mechanical vibration to an outer surface of the cover layer for a time sufficient for activating the joining material. Cover layer and object are conveyed relative to the sonotrode in a continuous manner in a conveying direction throughout the steps of arranging, of bringing into contact, of pressing and of applying vibration.

A method of altering a portion of a substrate may include providing a first device and a second device with a nip therebetween. The second device may comprise a stationary or rotating source of vibration energy. When conveyed through the nip, the substrate may be exposed to the vibration energy and the portion thereof may be altered. Thermal energy may be applied to the portion of the substrate upstream of the nip to raise a temperature of the portion of the substrate to a temperature below a melting temperature thereof. A substrate spreader may contact the substrate upstream of the nip to mitigate fold over or wrinkles in the substrate. When the first device is a rotating anvil and the second device comprises a rotating source of vibration energy, the surface velocities thereof may be variable and may be the same or different.

A method and apparatus for making bags or pouches is disclosed. An ultrasonic sealer may be used to form the seals. Sealing patterns may be used to provide a desired strength profile.

A method and apparatus for making bags or pouches is disclosed. An ultrasonic sealer may be used to form the seals. Sealing patterns may be used to provide a desired strength profile.

An ultrasonic system and method for sealing a complex interface, such as a Gable top, having multiple and a variety of layers across the interface, or an oval or round spout having a complex geometry. The 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. Only one application of the frequency- and phase-synchronized ultrasonic energy is required to hermetically seal all the layers of the interface together.

An ultrasonic processing method and an ultrasonic processing device may include a controlling/regulating module, preferably a digital controlling/regulating module, which is integrated into a signal processing of the ultrasonic generator so that a plurality of generator data with respect to the ultrasonic generator are processible in the ultrasonic generator. At this, a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via a gap regulator in the controlling/regulating module to specify a position reference value POS.sub.soll of the sonotrode relative to the roll for adjustment of the power reference value P.sub.soll of the ultrasonic generator, and/or a power actual value P.sub.ist is compared with a power reference value P.sub.soll of the ultrasonic generator via an amplitude regulator in the controlling/regulating module to specify an amplitude reference value A.sub.soll to the ultrasonic generator for adjustment of the power reference value P.sub.soll.

Aspects relate to systems, methods, and apparatus for a manufacturing tool. The manufacturing tool is comprised of a vacuum tool and an ultrasonic welder as a unified manufacturing tool. The manufacturing tool may be used to pick and position a manufacturing part that is then welded with the associated ultrasonic welder.

An ultrasonic bonding tool is used on a horn side or anvil side of an ultrasonic joining device in which two synthetic resin sheets that include a polyethylene layer, a polypropylene layer and a ceramic heat-resistant layer are superposed and joined together so that the heat-resistant layers face each other. The ultrasonic bonding tool includes a plurality of protrusions shaped as quadrangular pyramids having a flat top surface. Each of the protrusions has an apex angle formed by two mutually opposite side surfaces that is within a range of 110-130. When two separators of a battery cell are joined together using the ultrasonic bonding device with the ultrasonic bonding tool, a force with which the separators adhere to the protrusions is weak. In this way, the separators do not adhere to the horn during ultrasonic bonding of the synthetic resin sheets.

Aspects relate to systems, methods, and apparatus for a manufacturing tool. The manufacturing tool is comprised of a vacuum tool and an ultrasonic welder as a unified manufacturing tool. The manufacturing tool may be used to pick and position a manufacturing part that is then welded with the associated ultrasonic welder.

An ultrasonic bonding tool is used on a horn side or anvil side of an ultrasonic joining device in which two synthetic resin sheets that include a polyethylene layer, a polypropylene layer and a ceramic heat-resistant layer are superposed and joined together so that the heat-resistant layers face each other. The ultrasonic bonding tool includes a plurality of protrusions shaped as quadrangular pyramids having a flat top surface. Each of the protrusions has an apex angle formed by two mutually opposite side surfaces that is within a range of 110-130. When two separators of a battery cell are joined together using the ultrasonic bonding device with the ultrasonic bonding tool, a force with which the separators adhere to the protrusions is weak. In this way, the separators do not adhere to the horn during ultrasonic bonding of the synthetic resin sheets.