Patent ID: 7771551

Claim:
A system for ultrasonic welding a first material to a second material, the second material including material types considered incompatible with the first material in ultrasonic welding techniques, the system comprising: an abrader for altering a surface of at least one of the first material and the second material; a first pressure device for varying the position of the abrader and thereby varying an amount of abrasion applied to the at least one of the first material and the second material; an ultrasonic source for providing acoustic energy to an interface between the first material and the second material; a second pressure device for varying the force applied to the interface between the first material and the second material; a sensor for determining an interface temperature of the interface between the first material and the second material; a first temperature varying device for altering the temperature of at least one of the first material and the second material; and a controller for dynamically adjusting the acoustic energy of the ultrasonic source, the second pressure device, and at least one of the first pressure device and the temperature varying device during junction formation at the interface to enable a smooth, continuous junction to form at a predetermined rate.