Ultrasonic welding tool and welding system for activated carbon filter cartridges

Abstract

The utility model discloses an active carbon filter element ultrasonic welding frock and welding system, active carbon filter element includes PP nylon net, spun -bond non -woven fabric and is located between the active carbon bag of both, and welding frock includes base, clamping groove and auxiliary pressure disc, and the surface of base top end is equipped with the cavity, and the clamping groove is located in the cavity, and the upper surface of clamping groove and the upper surface of cavity constitute the stepped welding contact surface together, and the auxiliary pressure disc is located in the surface of base top end and is located the cavity outer periphery, and the concave area of cavity and clamping groove forms the first containing area for containing active carbon filter element together, and the concave area of auxiliary pressure disc and cavity forms the second containing area for containing nylon net and spun -bond non -woven fabric together. Through above -mentioned mode, the utility model realizes the close fusion of PP nylon net, spun -bond non -woven fabric and active carbon filter element, promotes filter core leakproofness and prevents active carbon particle leakage, avoids carbon powder from being shaken out due to vibration, guarantees product appearance no black powder pollution, and significantly improves the yield.

Description

Technical Field

[0001] This utility model relates to the field of activated carbon packaging tooling technology, and in particular to an ultrasonic welding tooling and welding system for activated carbon filter elements. Background Technology

[0002] Activated carbon is a commonly used adsorption and filtration medium, and the stability of its performance and the reliability of its encapsulation are crucial. To prevent leakage of activated carbon particles, granular activated carbon is usually encapsulated in a space consisting of a plastic frame and filter material (such as PP nylon mesh or spunbond nonwoven fabric).

[0003] Currently, the mainstream sealing method is ultrasonic welding, which has the advantages of high efficiency and good sealing performance. However, existing ultrasonic welding methods have some problems in practical applications.

[0004] When the ultrasonic welding head acts directly on the surface of the filter material, it generates high-frequency vibrations. These vibrations are transmitted directly to the activated carbon particles, causing them to bounce, break, and leak from the fiber gaps of the spunbond nonwoven fabric. This not only reduces filtration performance but also causes black carbon powder to adhere to the filter screen surface, resulting in product appearance contamination.

[0005] Furthermore, welding pressure is typically increased to ensure a tight seal. However, this can exacerbate the problem of toner leakage. Conversely, reducing welding pressure, while decreasing toner leakage, can lead to weak welds, resulting in incomplete welds or leaks.

[0006] Therefore, there is an urgent need for a new welding fixture solution that can achieve a firm seal while fundamentally isolating or reducing the direct impact of vibration on activated carbon, thereby solving the problems existing in the current ultrasonic welding method. Utility Model Content

[0007] The main technical problem solved by this utility model is to provide an ultrasonic welding fixture and welding system for activated carbon filter elements. By optimizing the welding method through the fixture structure, the welding energy is concentrated at the joint through the stepped welding contact surface, realizing the tight fusion of PP nylon mesh, spunbond nonwoven fabric and activated carbon filter element, improving the filter element's sealing performance, effectively preventing the leakage of activated carbon particles, avoiding the carbon powder being shaken out due to vibration, ensuring that the product appearance is free of black powder contamination, and significantly improving the yield rate.

[0008] To solve the above-mentioned technical problems, the present invention provides an ultrasonic welding fixture for activated carbon filter elements. The activated carbon filter element includes a PP nylon mesh, a spunbond nonwoven fabric, and an activated carbon pack disposed between the two. The welding fixture includes a base, a slot, and an auxiliary pressure plate. The base is mounted on the chassis of an ultrasonic welding equipment. A cavity is provided on the top surface of the base. The slot is detachably embedded in the cavity. The upper surface of the slot and the upper surface of the cavity together form a stepped welding contact surface. The auxiliary pressure plate is disposed on the top surface of the base and located on the outer periphery of the cavity. The concave areas of the cavity and the slot together form a first receiving area for accommodating the activated carbon filter element; the concave areas of the auxiliary pressure plate and the cavity together form a second receiving area for accommodating the nylon mesh and spunbond nonwoven fabric; the welding port of the ultrasonic welding equipment is positioned at the location of the stepped welding contact surface for welding.

[0009] In a preferred embodiment of this utility model, the card slot and the auxiliary pressure plate are made of nylon.

[0010] In a preferred embodiment of the present invention, the cavity has an exhaust hole at its center bottom, which communicates with the outside.

[0011] In a preferred embodiment of the present invention, a first positioning hole is provided around the center of the cavity, and a second positioning hole adapted to the first positioning hole is provided on the slot.

[0012] In a preferred embodiment of the present invention, there are four first positioning holes and four second positioning holes, which are evenly distributed along the circumferential direction of the center of the cavity.

[0013] In a preferred embodiment of the present invention, the top of the base is provided with a third positioning hole, and the auxiliary pressure plate is provided with a fourth positioning hole that matches the third positioning hole.

[0014] In a preferred embodiment of the present invention, there are four third positioning holes and four fourth positioning holes, which are evenly distributed along the outer circumference of the cavity.

[0015] In a preferred embodiment of this utility model, the cavity depth is 5-10mm, the slot depth is 4-8mm, and the auxiliary pressure plate depth is 5-10mm.

[0016] In a preferred embodiment of this utility model, the stepped welding contact surface has a height difference formed by the upper surface of the cavity being higher than the upper surface of the slot, and this height difference is adapted to the thickness of the connection between the PP nylon mesh, spunbond nonwoven fabric and activated carbon filter element.

[0017] To solve the above-mentioned technical problems, the present invention provides an ultrasonic welding system, including the ultrasonic welding fixture for activated carbon filter elements.

[0018] The beneficial effects of this utility model are: Precise alignment is achieved through the precise cooperation of the base, slot and auxiliary pressure plate, ensuring that the ultrasonic welding head can always act on the preset welding trajectory, avoiding insufficient welding strength or incomplete welding due to positioning deviation. The stepped welding contact surface design concentrates high-frequency vibration energy at the connection between the PP nylon mesh, spunbond nonwoven fabric and filter frame to form a uniform and firm sealing interface, which improves the overall sealing performance of the filter element, avoids the risk of activated carbon particle leakage, prevents carbon powder leakage from contaminating the product appearance, and ensures the product yield rate. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein: Figure 1 This is a structural schematic diagram of a preferred embodiment of the base of this utility model; Figure 2 This is a schematic diagram of a preferred embodiment of the card slot of this utility model; Figure 3 This is a schematic diagram of a preferred embodiment of the auxiliary pressure plate of this utility model; Figure 4 This is a schematic diagram of a preferred embodiment of the present invention, in which the card slot is embedded in the base cavity; Figure 5 This is a schematic diagram of a preferred embodiment of the ultrasonic welding fixture for activated carbon filter elements of this utility model; The components in the attached diagram are labeled as follows: 1. Base; 11. Third positioning hole; 2. Slot; 21. Second positioning hole; 3. Auxiliary pressure plate; 31. Fourth positioning hole; 4. Cavity; 41. First positioning hole; 5. Exhaust hole; 6. Stepped welding contact surface; 7. First receiving area; 8. Second receiving area. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0022] Please see Figures 1 to 2 This utility model relates to an ultrasonic welding fixture for activated carbon filter elements, which aims to solve the problem of poor sealing and easy leakage due to vibration during the assembly of traditional activated carbon filter elements, and realizes efficient and highly sealed welding assembly of filter elements.

[0023] The ultrasonic welding fixture for activated carbon filter elements includes an activated carbon filter element and a welding fixture for encapsulating the activated carbon filter element. The welding fixture includes a base, a slot, and an auxiliary pressure plate. The activated carbon filter element includes a PP nylon mesh, a spunbond nonwoven fabric, and an activated carbon pack disposed between the two. The three are tightly connected by ultrasonic welding.

[0024] Specifically, the first component is the base 1, which is configured to be mounted on the chassis of the ultrasonic welding equipment. The top surface of the base 1 has a cavity 4, the shape of which is adapted to the shape of the activated carbon filter element to ensure that the filter element can be accurately placed and kept stable. The depth of the cavity 4 is preferably 5-10mm to ensure that the activated carbon filter element is fully accommodated within the cavity 4.

[0025] Furthermore, a vent 5 is provided at the bottom center of the cavity 4, which communicates with the outside. The vent 5 effectively discharges air from the enclosed space formed between the activated carbon filter element, the cavity 4, and the slot 2 during the ultrasonic welding process, preventing the filter element from bulging or deforming, ensuring a tight fit between the filter element and the tooling components, ensuring welding sealing, and improving welding quality.

[0026] In addition, there are four first positioning holes 41 around the center of the cavity 4, which are evenly distributed around the center of the cavity. The first positioning holes 41 are set to provide a reference for the installation of the slot and to prevent the slot 2 from shifting during the welding process.

[0027] Secondly, there is the slot 2, which is detachably embedded in the cavity 4 of the base. This detachable design allows for replacement according to the size of different activated carbon filter elements, increasing the applicability of the tooling. The slot 2's shape matches the cavity 4, and the upper surface of the slot 2 and the upper surface of the cavity 4 together form a stepped welding contact surface 6. The upper surface of the cavity 4 is higher than the upper surface of the slot 2, creating a height difference. This height difference is adapted to the thickness of the connection between the PP nylon mesh, spunbond nonwoven fabric, and activated carbon filter element, allowing the welding port to accurately act on the part to be welded, ensuring welding strength and sealing.

[0028] Furthermore, the slot 2 is provided with four second positioning holes 21 that are adapted to the first positioning hole 41, and their positions correspond one-to-one with the first positioning hole 41. During assembly, the positioning pin passes through the first positioning hole 41 and the second positioning hole 21 to achieve precise positioning of the slot 2 and the base 1, preventing the slot from rotating or shifting during welding.

[0029] In addition, the depth of the slot 2 is 4-8mm, which is reasonably matched with the depth of the cavity 4. The concave areas of the two together form the first receiving area 7, which is used to receive the activated carbon filter element.

[0030] Furthermore, there is the auxiliary pressure plate 3, which is located on the top surface of the base 1 and on the outer periphery of the cavity 4. Its main function is to position and press the PP nylon mesh and spunbond nonwoven fabric, ensuring that the connection between the two and the activated carbon filter element remains flat during the welding process. The auxiliary pressure plate 3 has a depth of 5-10mm, which coordinates with the depth of the cavity 4. The auxiliary pressure plate 3 and the concave area of ​​the cavity 4 together form the second receiving area 8, which is used to receive the nylon mesh and spunbond nonwoven fabric.

[0031] Furthermore, the top of the base 1 is provided with a third positioning hole 11, and the auxiliary pressure plate 3 is provided with a fourth positioning hole 31 that matches the third positioning hole 11. There are four third positioning holes 11 and four positioning holes 31, which are evenly distributed along the outer circumference of the cavity 4. By passing a positioning pin through the third positioning hole 11 and the fourth positioning hole 31, the auxiliary pressure plate 3 and the base 1 are precisely positioned.

[0032] In addition, the slot 2 and the auxiliary pressure plate 3 are made of nylon, which can ensure sufficient strength and wear resistance, avoid adhesion to PP nylon mesh and spunbond nonwoven fabric during the welding process, and ensure the appearance quality of the filter element after welding.

[0033] The aforementioned welding fixtures ensure that the activated carbon filter element is encapsulated with uniform and firm sealing weld marks, ensuring good welding sealing performance. At the same time, the side wall of the slot can isolate the high-frequency vibration of ultrasonic waves, preventing them from being directly transmitted to the activated carbon area, avoiding the carbon powder being "shaken out" due to violent vibration, thus ensuring that the product appearance is free of black powder contamination and significantly improving the yield rate.

[0034] The working process of this novel ultrasonic welding fixture for activated carbon filter elements is as follows: First, install the base 1 on the chassis of the ultrasonic welding equipment. According to the specifications of the activated carbon filter element to be welded, select the appropriate slot 2 and embed the slot 2 into the cavity 4 of the base 1 through the positioning pin to ensure that the stepped welding contact surface 6 formed by the upper surface of the slot 2 and the upper surface of the cavity 4 meets the requirements. Then, place the activated carbon pack in the concave area of ​​the slot 2 and ensure that it is centered. Next, cover the surface of the activated carbon pack with spunbond nonwoven fabric and PP nylon mesh, so that it is fully unfolded and attached to the upper surface of the slot 2, and align the connection between the PP nylon mesh and the spunbond nonwoven fabric and the activated carbon pack with the stepped welding contact surface 6. Then, the auxiliary pressure plate 3 is installed on the top of the base 1 using the positioning pins to press and fix the PP nylon mesh and spunbond nonwoven fabric. Start the ultrasonic welding equipment and position the welding port at the location of the stepped welding contact surface 6. The ultrasonic welding equipment generates high-frequency vibration and transmits the vibration energy through the welding port to the stepped welding contact surface. Under the action of vibration energy, the molecules at the connection between the PP nylon mesh, spunbond nonwoven fabric and activated carbon filter element rub against each other to generate heat. When the temperature reaches the melting point of the PP nylon mesh and spunbond nonwoven fabric, the two melt together, completing the welding seal.

[0035] This utility model also relates to an ultrasonic welding system, including the ultrasonic welding fixture for activated carbon filter elements, which realizes automation, high precision and high efficiency in the packaging of activated carbon filter elements.

[0036] The beneficial effects of this utility model of ultrasonic welding fixture and welding system for activated carbon filter elements are: Precise positioning: Precise positioning is achieved through the positioning cooperation between the base, the slot, and the auxiliary pressure plate, ensuring that the welding port can always act on the part to be welded, avoiding insufficient welding strength or incomplete welding due to positioning deviation; Reliable sealing: The stepped welding contact surface concentrates the welding energy at the joint, achieving a tight fusion of the PP nylon mesh, spunbond nonwoven fabric and activated carbon filter element, improving the filter element's sealing performance and effectively preventing activated carbon particle leakage; at the same time, it avoids the carbon powder being shaken out due to vibration, ensuring that the product appearance is free of black powder contamination and significantly improving the yield rate.

[0037] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made using the content of this utility model specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. An ultrasonic welding fixture for activated carbon filter elements, characterized in that, The activated carbon filter element includes a PP nylon mesh, a spunbond nonwoven fabric, and an activated carbon pack disposed between the two. The welding fixture includes: A base configured to be mounted on the chassis of an ultrasonic welding equipment, wherein a cavity is provided on the top surface of the base; The slot is detachably embedded in the cavity, and the upper surface of the slot and the upper surface of the cavity together form a stepped welding contact surface; An auxiliary pressure plate is located on the top surface of the base and on the outer periphery of the cavity. The concave areas of the cavity and the slot together form a first receiving area for accommodating the activated carbon filter element; the concave areas of the auxiliary pressure plate and the cavity together form a second receiving area for accommodating the nylon mesh and spunbond nonwoven fabric; the welding port of the ultrasonic welding equipment is positioned at the location of the stepped welding contact surface for welding.

2. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The card slot and auxiliary pressure plate are made of nylon.

3. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The cavity has an exhaust port at its center bottom, which is connected to the outside.

4. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The cavity is provided with a first positioning hole around its center, and the slot is provided with a second positioning hole that matches the first positioning hole.

5. The ultrasonic welding fixture for activated carbon filter elements according to claim 4, characterized in that, The number of the first positioning hole and the second positioning hole are both 4, and they are evenly distributed along the central circumference of the cavity.

6. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The base has a third positioning hole at its top, and the auxiliary pressure plate has a fourth positioning hole that matches the third positioning hole.

7. The ultrasonic welding fixture for activated carbon filter elements according to claim 6, characterized in that, The number of the third and fourth positioning holes is four, and they are evenly distributed along the outer circumference of the cavity.

8. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The cavity depth is 5-10mm, the slot depth is 4-8mm, and the auxiliary pressure plate depth is 5-10mm.

9. The ultrasonic welding fixture for activated carbon filter elements according to claim 1, characterized in that, The stepped welding contact surface has a height difference formed by the upper surface of the cavity being higher than the upper surface of the slot, and this height difference is adapted to the thickness of the connection between the PP nylon mesh, spunbond nonwoven fabric and activated carbon filter element.

10. An ultrasonic welding system, characterized in that, Including the ultrasonic welding fixture for activated carbon filter elements as described in any one of claims 1-9.

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