Ultrasonic rigid horn assembly

Claim 1

An ultra-sonic tool system for industrial processing with acoustic energy, said system comprising an elongated, straight, rigid, unitary tool holder of rigid material having a longitudinal axis and a length of an integral number of half-wave lengths at the operating frequency, the transverse dimensions being so proportioned to the length thereof as to minimize undesired modes of transmission other than along the tool holder length, said tool holder having only two ends shaped to provide finished flat sonic energy input and output areas, the tool holder providing a common transmission path for all sonic energy from the input to the output thereof, threaded means at the input end for coupling at least one source of sonic energy thereto; at least two, elongated, rigid tool members laterally spaced from each other rigidly secured directly to a sonic output area of the tool holder, each tool member having at one end a sonic input area conforming to a sonic tool holder output area in the secured positions of the tool holder and tool members, each tool member having a sonic energy working output tip at its other end, the tool holder output area being great enough to accommodate a plurality of laterally offset, secured tool members arranged to create a desired pattern of work areas, each tool member having a length of an integral number of half-wave lengths; whereby said tool holder material may be selected on a basis of acoustic properties, cost, and ease of machining and the tool member material may be selected on a basis of acoustic properties and toughness for working life, said tool holder and tool members being each resonant to the acOustic energy so that efficient transmissions of sonic energy to the work areas result, each tool member being susceptible to individual design with regard to tool member contours, amplitude of sonic energy at a work area and physical length of a tool member; the machining problem of the tool holder being distinct from any problem of machining a tool member, said tool system being sufficiently rigid so that it may be pressed against work without accessories for guiding tool members.