Patent ID: 8042721

Claim:
An ultrasonic device comprising: a primary coupler; a mounting sleeve housing a portion of the primary coupler; an exponential horn formed in part by the primary coupler and in part by the mounting sleeve, with the mounting sleeve formed separately from the primary coupler and secured to the primary coupler such that the primary coupler and the mounting sleeve vibrate together as a substantially unitary member, and wherein the part of the exponential horn formed by the mounting sleeve has a greater diameter than the part of the exponential horn formed by the primary coupler, and wherein the exponential horn defines an outer surface that reduces in size along its length from a maximum diameter at a rearward end of the horn to a minimum diameter adjacent a tip of the horn; and a flange located on the mounting sleeve for supporting the mounting, sleeve at a node of minimum vibratory motion such that vibratory energy losses are minimized, and wherein the mounting sleeve contacts the primary coupler at least from a first position on the exponential horn to a second position of the primary coupler where the flange is located.