Apparatus and method for producing aggregated or agglomerated materials

Abstract

The invention relates to a device for producing aggregate material, wherein the material comprises two material web parts and a wire positioned between the material web parts, and the two material web parts are connected to each other at two connection surfaces, wherein the wire is arranged between the two connection surfaces so that the wire is connected to the material web parts, wherein the device comprises a sonotrode having a first sealing surface and a mating tool having a second sealing surface, wherein the mating tool is a cylinder having a lateral surface and a cylinder axis, and the second sealing surface is arranged on the lateral surface, wherein the sonotrode and the mating tool are arranged in a processing position relative to each other so that the material web parts and the wire can be guided through a gap formed by the first sealing surface and the second sealing surface in a feed direction tangential to the lateral surface of the mating tool. In order to overcome or at least alleviate the above-mentioned disadvantages, the invention proposes that the sonotrode comprises a groove for receiving the wire, the groove being oriented in the feed direction and extending over the entire first sealing surface.

Description

Background Art

[0001] The present invention relates to an apparatus and a method for producing an aggregated or aggregated material. The aggregated or aggregated material comprises at least two material web portions and at least one thread positioned between the material web portions. The two material web portions are connected to each other at at least two connection surfaces, and the thread is arranged between the two material web portions and between the two connection surfaces, with the result that the thread is fixed between the material web portions so that there is a form-locking connection between the thread and the material web portions in a first direction and in a second direction oriented perpendicular to the first direction.

[0002] Relative mobility between the wire and the web portion of material may be provided in a third direction, the third direction being oriented perpendicular to the first and second directions.

[0003] The two material web portions can be realized by two material webs connected via a connecting surface.The material web can also be folded so that a first material web portion of the material web lies opposite a second material web portion and the wire is arranged between the first material web portion and the second material web portion.

[0004] The apparatus further comprises a sonotrode having a first sealing surface and a counter tool having a second sealing surface. The sonotrode is designed to be excited by ultrasonic vibrations so that contact between the first sealing surface vibrating by the ultrasonic vibrations and the material web leads to a welding process and forms a connection surface by welding the material web parts together.

[0005] The mating tool is a cylinder having a lateral surface and a first cylindrical axis. The second sealing surface is arranged on the lateral surface, and the mating tool can rotate about the cylindrical axis, wherein the ultrasonic welding electrode and the mating tool are arranged in a processing position relative to each other so that the material web portion and the wire can be guided through the gap formed by the first sealing surface and the second sealing surface in a feeding direction tangential to the lateral surface of the mating tool. The movement of the material web portion usually occurs at a speed corresponding to the rotation speed of the lateral surface of the mating tool. At least one wire arranged between the material web portions is frequently placed under tensile stress during the generation of the connection surface, thereby reducing its outer periphery and increasing its length. Once the tensile stress is released after the connection surface is generated, the outer periphery expands again.

[0006] Such a tool is known, for example, from US Pat. No. 10,259,165 B2.

[0007] In this case, a complex structured roller is used as a pairing tool. On the lateral surface of this pairing tool there are ribs, the surface of which in turn comprises notches, which are arranged transversely to the orientation of the ribs. For this tool, screwing the wire into the device involves considerable effort. The production of the engraved pairing tool is also very complex. The complex engraved pairing tool roller must be replaced when the wire is replaced by a wire of a different material or by a wire of the same material but of a different thickness, when the combination of materials for the material web and the wire is changed, and when the tension holding the wire in the tool is changed during processing. Summary of the invention

[0008] Based on the described prior art, it is therefore an object of the present invention to overcome or at least alleviate the described disadvantages.

[0009] According to the invention, this object is achieved in that the sonotrode comprises at least one groove for at least partially receiving at least one wire, the groove being oriented in the feeding direction and preferably extending over the entire first sealing surface. In order to allow the wire to move in a direction relative to the material web portion, it is necessary that the wire is not welded to said material web portion. Thus, the wire is guided in the groove, while the sealing surface portion delimiting the groove creates a connecting surface, wherein the material web portion is guided and processed between the first sealing surface and the second sealing surface. The material web portion is also partially positioned in the groove.

[0010] Advantages are achieved even if the wire is only partially received in the groove, however, it is preferred that the wire is completely received in the groove during the ultrasonic treatment.

[0011] In a further preferred embodiment, it is provided that the sonotrode comprises a plurality of grooves oriented in the feed direction for at least partially receiving the at least one wire, wherein the grooves preferably have a spacing of between 0.1 and 100 mm and are particularly preferably spaced apart from one another by a spacing of between 0.5 mm and 2.5 mm. In a preferred embodiment, more than 15 or even more than 50 grooves are provided.

[0012] Very thin wires can also be used. If the sonotrode is also intended to be suitable for producing aggregate material with very thin wires, the spacing between the grooves can be chosen even smaller. For example, the spacing can be less than 0.2 mm and optimally between 0.01 mm and 0.15 mm.

[0013] It has been shown that when a plurality of wires are connected to the material web portion in the manner described, the aggregated material is more likely to aggregate. Therefore, the sonotrode comprises a plurality of grooves, wherein each groove is arranged to receive at least one wire during processing. The wires should not be spaced too far apart. It is also possible to provide significantly more grooves than wires to be processed.

[0014] In another preferred embodiment, it is provided that at least one groove has a depth of between 0.02 and 1 mm. The depth of the groove must be dimensioned so that the wire used is at least partially engaged in the groove. In order to reduce the wire diameter, it may be necessary to apply tensile stress to the wire during processing. It has been found that in some cases, the mentioned groove depths achieve the best results.

[0015] In a further preferred embodiment, it is provided that at least one groove has a width between 0.02 and 1 mm.

[0016] In another preferred embodiment, the spacing between adjacent grooves is smaller than the width of the grooves.

[0017] It is also advantageous if at least one groove has a semicircular cross section, a U-shaped cross section or a V-shaped cross section.

[0018] In the case of a U-shaped cross section, it is advantageous if the flanks of the groove are inclined outwards. Flank angles between 0° and 30° or better between 0° and 20° are particularly preferred.

[0019] In another preferred embodiment, provision is made that the first sealing surface is substantially flat.For example, a fixed sonotrode can be used, which moves away from the second sealing surface, for guiding the material web portion and the wire, if necessary.

[0020] However, the first sealing surface can also include a substantially flat welding section and an inlet section arranged adjacent to the welding section, wherein the inlet section is convexly curved, wherein the radius of curvature of the convexly curved inlet section is preferably greater than 1 mm, particularly preferably greater than 5 mm, and optimally between 6 mm and 15 mm. The groove can be provided in both the welding section and the inlet section. In this case, the at least one wire should be fed so that it rests against the inlet section and the welding section simultaneously. This allows the at least one wire to be securely held in the groove without the risk of the wire leaving the groove during processing.

[0021] The sonotrode can alternatively also be a cylinder having a lateral surface and a second cylinder axis, wherein the first sealing surface is arranged on the lateral surface and is rotatable about the second cylinder axis, wherein the at least one groove preferably extends in a circular manner around the lateral surface of the sonotrode.

[0022] In other words, in this embodiment both the sonotrode and the counter tool are roller-shaped and roll on each other, wherein the material web portion and the at least one wire are guided between the two lateral surfaces.

[0023] In a further preferred embodiment, provision is made that the counter tool comprises at least one rib which has at least one portion which is not oriented in the circumferential direction.

[0024] The ribs are used to create the connection. They produce a weld seam which is interrupted at the location where the groove lies on the sonotrode, since at this location no welding forces are transferred to the material web.

[0025] For example, the ribs may be serrated or wavy.

[0026] The at least one rib can also be linear, whereby the rib does not have to be oriented parallel to the first cylinder axis.

[0027] The special shape of the ribs results in better force distribution.

[0028] In a further preferred embodiment, provision is made that the second sealing surface comprises no groove for partially receiving at least one wire, in order to ensure that the wire is fully received in the groove of the first sealing surface.

[0029] In an alternative embodiment, it is provided that the second sealing surface comprises at least one groove, which is oriented in the feed direction and preferably completely surrounds the lateral surface of the second tool for partially receiving at least one wire, wherein, in the processing position, at least one groove in the first sealing surface is arranged opposite to at least one groove in the second sealing surface, so that the at least one wire can be received simultaneously in at least one groove in the first sealing surface and in at least one groove in the second sealing surface.

[0030] These measures also allow the material web section to be connected to wires with larger diameters.

[0031] In a particularly preferred embodiment, the sonotrode at least partially comprises a coating, and the at least one groove is provided in the coating. The coating may, for example, comprise a hard metal and particularly preferably comprises tungsten carbide. Since the groove is provided in the coating, when the wear of the sonotrode caused by the at least one wire exceeds an acceptable level, only the coating can be replaced, while the sonotrode itself can be used further. The same applies if the arrangement and geometry of the grooves need to be replaced for any reason. The at least one groove can be introduced into the coating, for example, by erosion or grinding.

[0032] The present invention also relates to a method for manufacturing an aggregated or aggregated material, wherein the material comprises two material web portions and at least one wire, wherein the material web portions are connected to each other at at least two connecting surfaces and the wire is positioned between the material web portions and between the connecting surfaces such that a form-locked connection exists between the wire and the material web portions in a first direction and a second direction, wherein the first direction and the second direction are oriented perpendicular to each other.

[0033] According to the invention, it is now provided that a device of the above-mentioned type is used and two material web parts together with at least one wire are guided through the gap in the feed direction, while the sonotrode is set to ultrasonic vibrations, whereby the wire is guided through the at least one groove.

[0034] Elastic wires may be used. At least one of the elastic wires is then placed under tensile stress during the treatment. Thus, the diameter of the unloaded elastic wire may be greater than the diameter of the groove. Placing the elastic wire under tensile stress reduces the diameter of the elastic wire to the extent that the wire fits into the provided groove. After treatment, the tensile stress may be released again, increasing the wire diameter again, with the result that the wire is clamped between the material web portions. Although it is still possible to move the material web portions relative to the wire, it is necessary to overcome the corresponding frictional forces, and the wire may be placed under tensile stress so that there is little relative movement between the wire and the material web during normal use of the material.

[0035] It is also possible to use a sonotrode that includes a greater number of grooves than the number of wires positioned between the material web portions and between the connecting surfaces. Then it is also not clearly predetermined which wire is received in which groove. Instead, each wire itself is placed in the groove that is closest to its location. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Further advantages, options and possible applications will become apparent from the following description of the preferred embodiments and the related drawings.

[0037] The accompanying drawings show:

[0038] Figure 1 A side view of a first embodiment of the device according to the invention,

[0039] Figure 2 Figure 1 A plan view of a first sealing surface of a sonotrode of an embodiment,

[0040] Figure 3 Figure 1 A stereogram of a sonotrode.

[0041] Figure 4 yes Figure 1 A perspective view of a pairing tool of an embodiment,

[0042] Figure 5a-5c Partial cross-sectional views of groove profiles of different embodiments,

[0043] Figure 6a-8a Schematic diagram of rib arrangement of different embodiments,

[0044] Figure 6b-8b When using Figure 6a-8aSchematic diagram of the arrangement of the connecting surfaces when the ribs are arranged.

[0045] Fig. 9 A perspective view of a second embodiment of a sonotrode according to the present invention,

[0046] Figure 9a Fig. 9 The enlarged details,

[0047] Fig.10 Fig. 9 Side view of the ultrasonic welding electrode,

[0048] Fig.11 Fig. 9 a partial view of a plan view of the sealing surface of the sonotrode, and

[0049] Fig.12 Pass through Fig. 9 A partial cross-sectional view of the sealing surface of a sonotrode. DETAILED DESCRIPTION

[0050] The device 1 comprises a sonotrode 5 and a counter tool 9. The counter tool 9 is cylindrical and can rotate about a cylinder axis so that the lateral surface of the cylindrical roller 9 can rotate in a direction u.

[0051] The counter tool has a sealing surface on its side surface. The sonotrode 5 also has a sealing surface, which is arranged so that a first sealing surface of the sonotrode 5 faces a second sealing surface of the counter tool 9. A gap remains between the two sealing surfaces, through which the two material web parts 3, 4 pass, and the wire or a group of wires 2 arranged between the two material web parts 3, 4 moves in the feeding direction v. Since the sonotrode 5 is subjected to ultrasonic vibrations, the welding process takes place in the gap between the sonotrode 5 and the counter tool 9, and the two material web parts 3, 4 are welded together.

[0052] The sonotrode 5 has a holder 6 , the purpose of which is to hold the sonotrode in a manner that is as vibration-decoupled as possible.

[0053] Figure 2 A plan view of a first sealing surface 7 of a sonotrode 5 is shown. It can be seen that the sealing surface 7 is substantially flat and rectangular. However, this does not necessarily have to be the case. A series of grooves 8 are introduced into the sealing surface 7. These grooves are arranged so that they are oriented in the direction of the feed direction v.

[0054] Figure 3 A perspective view of a sonotrode 5 is shown with a sealing surface 7. A V-shaped groove 8 can be seen, which is introduced into the sealing surface 7.

[0055] The groove 8 is dimensioned such that the wire 2 can be at least partially received in the groove 8. Since the welding process taking place between the two sealing surfaces depends on a corresponding contact between the sealing surfaces and the material web, no welding is required in the region of the groove 8. As a result, the wire or wires 2 between the material web portions can be moved in the longitudinal direction, i.e. in the direction in which the groove 8 is oriented relative to the material web portions, in order to gather the material formed by the two material web portions.

[0056] Island portions 7' are generated between adjacent grooves 8, so that the first sealing surface 7 of the sonotrode 5 consists of a plurality of adjacent island portions 7'. Each island portion 7' ​​creates a connection surface between two material web portions when it encounters a corresponding counterpart element on the sealing surface of the counterpart tool during the welding process.

[0057] Figure 4 A perspective partial view of a mating tool 9 is shown. The mating tool 9 is roller-shaped, i.e. it has a cylindrical lateral surface. The lateral surface forms the second sealing surface 10. A plurality of bars 11 are arranged on the second sealing surface 10, which extend transversely to the circumferential direction of the sealing surface 10 over the entire width of the sealing surface 10. These bars 11 serve as mating elements for the island 7'.

[0058] The bars 11 are arranged at a small angle to the cylinder axis. As a result, the force applied by the sonotrode 5 to the material web portions 3, 4 is more uniform.

[0059] Welding of the two material web portions 3, 4 occurs whenever the island 7' comes into position opposite the rib 11 or a section of the rib 11. The remaining space between the island 7' and the rib 11 is small, so that as a result of the ultrasonic vibrations of the sonotrode 5, the two material web portions 3, 4 are pressed against each other and welded together.

[0060] Figure 5a to Figure 5c Three different embodiments of sonotrode are shown. Each figure shows only a partial cross-sectional view, in which the shape of the groove 8, 8', 8" is shown. Figure 5a A V-shaped groove 8 can be seen in FIG. Figure 5b As shown, the grooves 8, 8', 8" can also be U-shaped. The U-shape has been marked with the reference numeral 8'. The U-shape consists of a U-shaped base and two U-shaped flanks, which are not arranged at right angles to the U-shaped base, but are inclined outwards at a flank angle between 0° and 30° to facilitate the reception of the wire 2.

[0061] Alternatively, if Figure 5c As shown, the groove can also be configured as a semicircular or semi-elliptical groove 8".

[0062] Figure 6aThe ultrasonic welding electrode 5 with the groove 8' is schematically shown in a partial cross section. The counter tool 9 is opposite to the ultrasonic welding electrode 5. The ribs provided on the counter tool 9 are Figure 6a The zigzag rib 11' is shown in FIG. Whenever the island 7' of the ultrasonic welding electrode 5 located between the grooves 8' is in a position opposite to the rib 11', the two material web parts 3, 4 are welded together. The corresponding welding result is Figure 6b The corresponding connecting surface 12 follows the contour of the rib 11 ′, which is however interrupted whenever the sonotrode has a corresponding recess 8 ′.

[0063] The purpose of the interruption is to receive the wire 2 .

[0064] Figure 7a Another alternative arrangement of the ribs on the counter tool 9 is shown. The ribs 11" are parallel to the cylinder axis, so that Figure 7b The arrangement of the connecting surface 12 is shown in FIG.

[0065] at last, Figure 8a Another configuration of the ribs 11"' is shown, in which the ribs 11"' are wavy. This has the result that Figure 8b As shown, the corresponding connecting surface 12 also follows the wave structure. Both the sonotrode 5 and the counter tool 9 can be produced in a simple manner.

[0066] Figure 9-12 A view showing a second embodiment of the present invention is shown.

[0067] Fig. 9 A perspective view of a sonotrode 13 is shown. The sonotrode 13 has a wedge-shaped end which tapers in the direction of the sealing surface 14. Figure 3 In contrast to the first embodiment shown, the sealing surface 14 here comprises more grooves 16, such as in Figure 9a The number of grooves is so large that not every groove accommodates a wire. The sonotrode can therefore also be used to produce materials with different numbers of wires and different wire spacings.

[0068] Fig.10 1 shows a side view of the ultrasonic welding electrode 13. The sealing surface 14 has an almost semicircular cross section. However, in practice, as in Fig.11 As can be seen in the detailed plan view of , the sealing surface 14 comprises a flat welding section 15. This welding section 15 is adjoined by an inlet section 17 and an outlet section 18, which are convexly curved, in particular with a radius of curvature of 7.5 mm.

[0069] A plurality of grooves are arranged parallel to each other in the sealing surface 14. The groove cross section is Fig.12. The grooves themselves are U-shaped so that the flanks of adjacent grooves include a flank angle α of 14°. The spacing a between adjacent grooves is less than the width b of the grooves. The grooves extend above the welding section 15 and into the inlet section 17 and the outlet section 18. Due to the convex curvature of the inlet section 17 and the outlet section 18, the groove depth in the inlet section 17 and the outlet section gradually decreases as the grooves move further away from the welding section.

[0070] Reference numerals list

[0071] 1 Equipment

[0072] 2 Wire

[0073] 3 Material web part

[0074] 4 Material web part

[0075] 5 Ultrasonic welding electrode

[0076] 6 Bracket

[0077] 7 First sealing surface

[0078] 7' Island

[0079] 8, 8', 8” groove

[0080] 9 Pairing Tools

[0081] 10 Second sealing surface

[0082] 11, 11', 11", 11"' bars / ribs

[0083] 12 Connecting Surfaces

[0084] 13 Ultrasonic welding electrode

[0085] 14 First sealing surface

[0086] 15 Sealing section

[0087] 16 grooves

[0088] 17 Entrance section

[0089] 18 Exit Section

Claims

1. An apparatus for producing aggregated or aggregateable materials, wherein: The material comprises at least two material web portions and at least one wire, the at least one wire being positioned between the material web portions, wherein the two material web portions are connected to one another at at least two connecting surfaces, wherein the wire is arranged between the two connecting surfaces such that the wire is connected to the material web portions such that a form-locking connection exists between the wire and the material web portions in a first direction and in a second direction, wherein the two directions are oriented perpendicular to one another, wherein the device comprises a sonotrode having a first sealing surface and a mating tool having a second sealing surface, wherein the counter tool is a cylinder having a lateral surface and a first cylinder axis, the second sealing surface being arranged on the lateral surface and being rotatable about the cylinder axis, wherein the sonotrode and the counter tool are arranged in a processing position relative to each other such that the material web portion and the wire can be guided through a gap formed by the first sealing surface and the second sealing surface in a feed direction tangential to the lateral surface of the counter tool, It is characterized in that The sonotrode comprises at least one groove, the at least one groove being oriented in the feeding direction, and the second sealing surface does not comprise a groove for partially receiving the at least one wire.

2. The device according to claim 1, characterized in that The at least one groove extends across the first sealing surface for at least partially receiving the at least one wire.

3. The device according to claim 1, characterized in that The sonotrode comprises a plurality of grooves oriented in the feeding direction for at least partially receiving the at least one wire.

4. The device according to claim 3, characterized in that The sonotrode comprises more than 15 grooves.

5. The device according to claim 4, characterized in that The sonotrode comprises more than 50 grooves.

6. The device according to claim 3, characterized in that The grooves are spaced less than 0.2 mm apart from each other.

7. The device according to claim 6, characterized in that The grooves are spaced apart from each other by between 0.01 mm and 0.15 mm.

8. The device according to claim 1, characterized in that The at least one groove has a depth between 0.02 and 1 mm.

9. The device according to claim 8, characterized in that The at least one groove has a depth between 0.1 and 0.5 mm.

10. The device according to claim 1, characterized in that The at least one groove has a width between 0.02 and 1 mm.

11. The device according to claim 10, characterized in that The at least one groove has a width between 0.1 and 0.4 mm.

12. The device according to claim 11, characterized in that The spacing between adjacent grooves is smaller than the width of the grooves.

13. The device according to claim 1, characterized in that The at least one groove has a semicircular cross section, a U-shaped cross section, or a V-shaped cross section.

14. The device according to claim 1, characterized in that The first sealing surface includes a substantially flat welding section and an inlet section disposed adjacent to the welding section, wherein the inlet section is convexly curved.

15. The device according to claim 14, characterized in that The radius of curvature of the convexly curved inlet section is greater than 1 mm.

16. The device according to claim 15, characterized in that The radius of curvature of the convexly curved inlet section is greater than 5 mm.

17. The device according to claim 16, characterized in that The radius of curvature of the convexly curved inlet section is between 6 mm and 15 mm.

18. The device according to any one of claims 14 to 17, characterized in that The groove is provided in both the welding section and the inlet section.

19. The device according to claim 1, characterized in that The counter tool comprises at least one rib having at least one section which is not oriented in the circumferential direction.

20. The device according to claim 19, characterized in that The at least one rib extends across the entire width of the second sealing surface.

21. The device according to claim 19 or 20, characterized in that The at least one rib is shaped in a sawtooth or wavy or linear manner, so that the rib is not oriented parallel to the first cylindrical axis.

22. The device according to claim 1, characterized in that The sonotrode at least partially comprises a coating, and the at least one groove is provided in the coating.

23. The device according to claim 22, characterized in that The coating comprises a hard metal.

24. The device according to claim 23, characterized in that The coating includes tungsten carbide.

25. A method for producing an aggregated or agglomerated material, wherein: The material comprises two material web portions and at least one wire, wherein the material web portions are connected to one another at at least two connecting surfaces and the wire is positioned between the material web portions and between the connecting surfaces such that a form-locking connection exists between the wire and the material web portions in a first direction and a second direction, while a relative movement between the wire and the material web is possible in a third direction, wherein the first direction, the second direction and the third direction are oriented perpendicularly to one another, It is characterized in that The apparatus according to any one of claims 1 to 24 is used and the two material web portions are guided together with the at least one wire through the gap in a feed direction, while the sonotrode is set in ultrasonic vibration, wherein the wire is guided through the at least one groove.

26. The method according to claim 25, characterized in that At least one elastic thread is used and during processing the at least one elastic thread is placed under tensile stress.

27. The method according to claim 25 or 26, characterized in that A sonotrode is used that includes a greater number of grooves than the number of wires positioned between the material web portions and between the connecting surfaces.

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