Patent ID: 8056792

Claim:
An ultrasonic welder comprising: an electro-acoustic converter converting an electrical signal into a mechanical vibratory motion; a diaphragm operably coupled to said electro-acoustic converter for transmitting said mechanical vibratory motion; a half-wave horn operably coupled to said diaphragm to receive said mechanical vibratory motion and transmit said mechanical vibratory motion to a removable tip member, said horn having: a base structure including a first longitudinal axis, said base structure being coupled to said diaphragm, said base structure having a reduced thickness neck portion at a distal end of said base structure, said reduced thickness neck portion being contoured with a radius extending about said base structure and coaxial with said first longitudinal axis; a tip mounting head including a second longitudinal axis, said tip mounting head being mounted directly to said base structure adjacent said reduced thickness neck portion, said second longitudinal axis being inclined relative to said first longitudinal axis, said tip mounting head supporting said removable tip member; and a scallop portion consisting of a single plane extending along at least a portion of said base structure and said reduced thickness neck portion and interrupting said base structure and said reduced neck portion thereby resulting in an asymmetrical shape of said reduced thickness neck portion, said base structure, tip mounting head, and reduced thickness neck portion together transmit said mechanical vibratory motion at a frequency in the range of approximately 10 kHz to approximately 60 kHz.