Patent ID: 8651163

Claim:
Ultrasonic welding tools for joining two or more components, comprising: a horn, including: at least one work surface having a plurality of protrusions formed thereon, the protrusions being arranged in a first matrix, each protrusion having a base portion fixed to the work surface, a lower portion projecting and tapering from the base portion, and an upper domed portion projecting from the lower portion and converging to a rounded apex; and an anvil, including: one or more work surfaces, each anvil work surface having a plurality of protrusions formed thereon, the protrusions being arranged in a second matrix, each protrusion having a basal portion and an upper tapering portion sloping from the basal portion to a pointed apex, the apex of each anvil protrusion being aligned with a point between horn protrusions, and the apex of each horn protrusion being aligned with a point between anvil protrusions.