METHOD FOR LOW INITIAL WELD SPEED IN ULTRASONIC WELDING

An improved ultrasonic method. The ultrasonic stack is moved at a low, constant (or slowly varying) speed at the initiation of the welding operation, with this speed being maintained until the predetermined condition is satisfied. In some applications, this produces a higher quality weld, such as in applications involving plastic material that softens very quickly once ultrasonic energy is imparted to the workpieces being welded, which causes the force between the workpieces to decrease rapidly. Advancing the ultrasonic stack at a low speed or slow acceleration can avoid scuffing or marking of the surface of the workpiece in contact with the ultrasonic horn, decrease audible noise produced during the welding process, and improve the consistency of weld quality in such applications compared to conventional techniques.