Ultrasonic Welding Anvil Parallel Lever Mechanism
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Solution Overview
Problem
Ultrasonic welding devices face challenges in maintaining mobility between the anvil and ultrasonic hammer to ensure well-sealed weld seams and minimize wear, which affects the consistency and longevity of the welds.
Innovation Solution
The anvil is mounted on a parallel lever with pivotable axes, allowing it to adapt to the ultrasonic hammer in two dimensions, and is biased and damped to ensure consistent contact pressure, while being attached to a pivotable holder for precise alignment and movement, reducing abrasion and bouncing during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the anvil and ultrasonic hammer are designed to be movable to clamp material, then welding capability is improved, but wear and inconsistency increase
Solution Approach 1:
The anvil is mounted on a parallel lever mechanism that allows dynamic adjustment of the anvil's position and orientation. The parallel lever comprises two levers pivoting about parallel axes, enabling the anvil to adapt to the ultrasonic hammer's position in two dimensions while maintaining parallel surfaces, thus resolving the contradiction between mobility for welding and stability for consistent contact
Solution Approach 2:
The biasing means (spring element) continuously adjusts the contact pressure parameter between the anvil and ultrasonic hammer, compensating for wear and position variations. This ensures consistent welding pressure over time, addressing the reliability issue while maintaining welding capability
2Manufacturing precision
If the anvil is mounted on a parallel lever with pivotable axes, then contact consistency is improved, but device complexity increases
Solution Approach 1:
The parallel lever mechanism uses simple pivoting levers with parallel axes to achieve automatic alignment between the anvil and ultrasonic hammer. This dynamic alignment mechanism maintains surface parallelism in all positions without requiring complex active control systems, thus improving contact consistency while limiting the increase in device complexity
Solution Approach 2:
The parallel lever mechanism is self-aligning through its geometric design. The two levers pivoting about parallel axes automatically maintain the anvil surface parallel to the ultrasonic hammer surface throughout the range of motion, eliminating the need for external alignment systems or complex control mechanisms
3Manufacturing precision
If the anvil adapts to ultrasonic hammer position in two dimensions, then weld quality is improved, but device complexity increases
Solution Approach 1:
The anvil is mounted on a holder that can pivot about an axis perpendicular to the parallel lever axes, providing two-dimensional adaptation capability. This allows the anvil to follow the ultrasonic hammer's position variations in both lateral and vertical directions, ensuring consistent contact and weld quality without requiring complex multi-axis positioning systems
Solution Approach 2:
The parallel lever mechanism provides adaptation in one dimension (lateral movement through lever pivoting), while the pivotable holder adds adaptation in a second dimension (angular adjustment). This two-dimensional adaptation approach improves weld quality by ensuring contact consistency without the complexity of three-dimensional active positioning systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures consistent and well-sealed welds with reduced wear, allowing for efficient and high-quality ultrasonic welding with minimal device degradation, even at high speeds and for multiple welds, enhancing production throughput.
Implementation Method 1
the anvil is mounted on a parallel lever which has two levers which can be pivoted about axes and are aligned parallel to one another
Implementation Method 2
the anvil is further preferably biased towards an ultrasonic hammer by biasing means
Implementation Method 3
the anvil is preferably coupled to a damping means which dampens movement of the anvil
Implementation Method 4
welded closed by applying ultrasound emitted by the ultrasonic hammer
Data Source
Figure 1
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AI summary
The invention relates to an anvil (1) for ultrasonic welding with a bearing of the anvil (1) on a parallel lever (2). The invention further relates to a device for ultrasonic welding with at least one ultrasonic hammer (16) and the aforementioned anvil (1).