An ultrasonic welding assembly comprising a horn, an anvil and an anvil cover.
The horn comprises a generally T-shaped flattening surface and a rail projecting
forward of the flattening surface. The rail is shaped to serve as a dam for flowing
thermoplastic zipper material during stomping of slider end stops. The horn further
comprises a plurality of vertical energy directors designed to direct ultrasonic
energy into the mass of zipper material and deflect flowing zipper material toward
the dam. The horn further comprises first and second recesses located on opposite
sides of a stem of the T-shaped flattening surface. The anvil cover overlies opposing
portions of the anvil and comprises a T-shaped cutout. The T-shaped flattening
surface of the horn fits in the T-shaped cutout of the anvil cover. The resulting
zipper has slider end stops located at opposing ends. Each end stop comprises flattened
zipper material having a plurality of spaced indentations, the indentations being
formed by the energy directors during stomping. The zipper can be pre-heated prior
to ultrasonic stomping. A flange of the zipper can be cooled by fluid during ultrasonic
stomping of the zipper parts.