Ultrasonic Joining Anvil with Segmented Projections
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Solution Overview
Problem
Conventional ultrasonic joining apparatuses face issues with increased anvil size, leading to localized vibration interference and reduced lifespan, resulting in higher manufacturing costs and lower yield rates when producing larger adult diapers.
Innovation Solution
The ultrasonic joining apparatus features a rotating drum with a line-shaped projection and protrusions on its surface, including cut portions that extend in the opposite direction of the protrusions, which reduces vibration interference and allows for a larger anvil size without compromising the joining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the anvil size is increased to accommodate larger adult diapers, then the joining capability for larger sizes is improved, but vibration interference accumulates locally and damages the anvil more quickly
Solution Approach 1:
The anvil is divided into multiple independent projection units, each with its own cut portions. This segmentation allows vibration interference to be localized to specific regions rather than accumulating across the entire anvil surface, preventing widespread damage while maintaining the ability to join large adult diaper components.
Solution Approach 2:
Different regions of the anvil have locally optimized structures with cut portions positioned to address specific vibration patterns. This local quality adjustment ensures that each area of the enlarged anvil is designed to handle the vibration characteristics specific to its location, maintaining reliability across the entire large-scale anvil surface.
2Adaptability or versatility
If the anvil size is increased for adult diapers, then the manufacturing capability for larger products is improved, but manufacturing costs increase due to more frequent anvil replacement
Solution Approach 1:
By segmenting the anvil into multiple projection units with cut portions, the overall anvil structure becomes more resilient to vibration damage. This reduces the frequency of replacement needed, lowering manufacturing costs while maintaining the capability to produce adult-sized diapers.
3Productivity
If the anvil size is increased, then the production capacity for larger diapers is improved, but yield rate decreases due to anvil damage
Solution Approach 1:
The segmented anvil structure with cut portions in each projection unit prevents vibration-induced damage from compromising the entire anvil. This maintains high yield rates by ensuring consistent joining quality across all production areas, even when producing large adult diapers at high capacity.
Solution Approach 2:
Local optimization of each projection unit with strategically positioned cut portions ensures that vibration interference is managed effectively across the entire anvil surface. This maintains reliable joining quality and high yield rates throughout the production process for adult diapers.
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 design enhances the stability of the ultrasonic joining process, reduces damage accumulation, and lowers manufacturing costs by preventing premature anvil replacement, while maintaining high-quality joint formation for larger adult diapers.
Implementation Method 1
an ultrasonic horn configured to output ultrasonic vibrations
Implementation Method 2
the web is melted by being heated from the inside thereof
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An anvil 200 includes a base 210 and projections 220 and 230. The base 210 is installed at an attachment position 112a on an outer peripheral surface 112 of a rotating drum 110. The projection 220 protrudes from a front surface 210a of the base 210 in a normal direction H of the rotating drum 110 and is formed in a line shape extending in the cross direction CD along the front surface 210a of the base 210. On the front surface 210a of the base 210, one end 220a in the cross direction CD of the projection 220 is provided forward of the other end 220b in a rotation direction R. In the projection 220, a cut portion 260 is formed to extend in a direction opposite to the protrusion direction of each protrusion 240. The cut portion 260 extends from the front surface of the projection 220, protruding from the front surface 210a of the base 210, to the vicinity of the middle of the projection 220.