Anvil Roll Ridge Design for Ultrasonic Bonding Particle Interference
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Solution Overview
Problem
The existing method for manufacturing absorbent articles using ultrasonic bonding often results in granular particles getting caught between the anvil and horn protrusions, leading to bonding failures and potential damage to the equipment.
Innovation Solution
A device with an anvil roll featuring protruding portions and a ridge with a lower height than the protrusions, along with suction and discharge holes, is used to prevent granular particles from being caught between the anvil and horn during ultrasonic welding by creating a space for them to escape into, ensuring proper bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic bonding is used to bond base sheets together, then adhesive is not needed and bonding efficiency is improved, but granular particles may get caught between the anvil and horn causing bonding failure and equipment damage
Solution Approach 1:
The patent applies preliminary action by creating a protective structure (protruding portion with groove) on the anvil before the bonding process occurs. This pre-configured structure proactively prevents granular particles from entering the bonding interface between the anvil and horn, eliminating the need for reactive measures after particle contamination occurs. The groove is预先 designed to intercept and contain particles before they can cause bonding failure or equipment damage.
Solution Approach 2:
The groove on the protruding portion of the anvil acts as an intermediary structure between the granular particles and the bonding interface. Instead of allowing particles to directly interfere with the ultrasonic bonding process, the groove serves as a mediator that captures and isolates particles, preventing them from reaching the critical bonding zone between the base sheets and the horn.
2Manufacturing precision
If granular particles are placed on base sheets in a predetermined pattern, then absorbent article functionality is improved, but particles may interfere with the ultrasonic bonding process
Solution Approach 1:
The patent applies local quality by creating a localized protective feature (groove) at the specific location where particle interference is most problematic - on the protruding portion of the anvil at the bonding interface. This localized structure provides particle containment exactly where needed, while leaving the rest of the base sheet and bonding process unaffected, thus maintaining particle placement precision while preventing interference.
Solution Approach 2:
The protruding portion with the groove effectively segments the bonding area from the particle placement area. The groove creates a physical barrier that divides the space, allowing particles to be contained in specific zones on the base sheet while preventing them from migrating to the bonding interface, thus enabling both precise particle placement and successful bonding.
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 solution effectively prevents granular particles from getting caught, ensuring a strong bonded state and reducing the risk of equipment damage, thereby improving the manufacturing process for absorbent articles like feminine sanitary products and diapers.
Implementation Method 1
the anvil roll defines: at least one suction hole for drawing a first air, through the non-woven fabric sheets, together with the granular particles and the non-woven fabric sheets, so as to carry the non-woven fabric sheets
Implementation Method 2
a horn for ultrasonically vibrating so that the two non-woven fabric sheets are bonded together between the horn and the plurality of protruding portions
Data Source
AI summary
A device including: a plurality of protruding portions of an anvil roll; an ultrasonically vibrating horn; a suction hole for drawing granular particles together with non-woven fabric sheets so as to carry the non-woven fabric sheets and to prevent the granular particles from being placed on the non-woven fabric sheets over the protruding portions; and a ridge extending along an outer circumference of the suction hole with a protruding height lower than a protruding height of the protruding portions.