Patent attributes
A system and method are provided which enable the joining of two materials via ultrasonic welding, including materials normally considered incompatible in traditional ultrasonic welding techniques. The system permits ultrasonic welding of a first material to a second material, the second material including material types normally considered incompatible with the first material and includes an abrader for altering the surface of the material/s to be joined. A first pressure device is operative to vary the position of the abrader and thereby vary the abrasion applied to the materials. An ultrasonic source provides acoustic energy to a weld interface between the materials. A second pressure device is operative to vary the force applied to the interface between the materials while a sensor senses the weld interface temperature. A controller dynamically adjusts the acoustic energy of the ultrasonic source, the second pressure device, and at least one of the first pressure device and a temperature varying device during junction formation. The temperature varying device is operative to modify the temperature of the material/s being welded before abrasion and/or proximate the weld interface location. In this manner, the system enables a smooth, continuous junction to form at a predetermined rate.
